ZF TRANSMATIC Service Manual

¨

WSK 400 for 16 S 151, 16 S 221 WSK 440 for 16 S 251 4130 751 103a

Subject to alterations in design

Copyright by ZF These repair instructions are protected by copyright. Any reproduction and dissemination in whatever form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.

Printed in Germany

Edition: 02.00

4130 751 103a

WSK 400/440

Contents Page

Preface .......................................................................................................................................................

Important information ................................................................................................................................

Instructions for carrying out repairs ...........................................................................................................

Tightening torques .....................................................................................................................................

Consumables ..............................................................................................................................................

Adjustment data .........................................................................................................................................

Spring table ................................................................................................................................................

Special tools ...............................................................................................................................................

4 5 6 8 10 11 16 17

1

Disassembly and assembly of WSK / engine ........................................................................................... 1-1

2

Transmission mounting ........................................................................................................................... 2-1

3

Central wiring harness – WSK 400/440 ................................................................................................. 3-1

4

Oil reservoir – WSK 400/440 ................................................................................................................... 4-1

5

Clutch cylinder WSK 400/440 ................................................................................................................ 5-1

6

WSK / transmission WSK 400/440 ......................................................................................................... 6-1

7

Selector clutch – WSK 400/440 ............................................................................................................... 7-1

Converter – WSK 400/440 .......................................................................................................................

Converter installation depth “C” ................................................................................................................

Axial play of tapered roller bearing “G” ....................................................................................................

Inductive sensor distance (“n engine”) .......................................................................................................

8.1 Dismantling and assembling converter (WSK 440) ...................................................................................

8

8-1 8-2 8-3 8-4 8-5

9

Turbine shaft – WSK 400/440 ................................................................................................................. 9-1

10

Oil filter – WSK 400/440 ......................................................................................................................... 10-1

11

Control unit – WSK 400/440 ................................................................................................................... 11-1

12

Retarder – WSK 400/440 ......................................................................................................................... 12-1

13 13.1 13.2 13.3 13.4 13.5

Converter housing – WSK 400/440 .........................................................................................................

Oil feed flange ...........................................................................................................................................

Gear pump and wiring harness ...................................................................................................................

Converter housing ......................................................................................................................................

Screw connection M10 WSK 400 ..............................................................................................................

Screw connection M12 WSK 440 ..............................................................................................................

14

Pressures and measuring points for WSK 400 and WSK 440 ............................................................... 14-1

15

After-Sales Service function test for WSK system ................................................................................. 15-1

13-1 13-1 13-2 13-4 13-5 13-6

Preface This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products.

This manual deals with the standard ZF product in accordance with the state of development on the date of issue.

However, due to continuing development of the product, repair work might require work practices and test or adjustment data not contained in this manual.

We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out conscientiously and with utmost care.

Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case.

ZF FRIEDRICHSHAFEN AG C.V./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726

4

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used.

Important information SAFETY NOTICE

GENERAL INFORMATION

Companies repairing ZF units are responsible for their own work safety.

Read this manual carefully before starting any tests or repair work.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to.

Before starting work, mechanics must familiarize themselves with these regulations.

Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.

The following safety instructions appear in this manual:

NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc.

CAUTION This is used when incorrect, unprofessional working practices could damage the product. ! DANGER This is used when lack of care could lead to personal injury or death.

CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures.

Pictures, drawings and components are not to scale.

Conclusions about size and weight should not be drawn (even within a complete illustration).

Always follow the working steps as described in the text.

After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly. ! THREATS TO THE ENVIRONMENT !

Lubricants and cleaning agents must not be allowed to enter the soil, ground water or sewage system.

• Ask your local environment agency for safety information on the relevant products and adhere to their requirements.

• Collect used oil in a suitably large container.

• Dispose of used oil, dirty filters, lubricants and cleaning agents in accordance with environmental protection guidelines.

• When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.

CAUTION The transmission must NOT be hung by the input shaft NOR by the output flange.

5

Instructions for repairs In case of doubt always turn to the relevant department within ZF After-Sales Services for advice.

All work on transmissions is to be performed expertly and under clean conditions.

Use specified tools to dismantle and assemble transmissions.

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening.

Pay particular attention to the projections and recesses of housings and covers when cleaning.

Parts joined with Loctite are easier to separate if warmed with a fan heater.

GASKETS, LOCKING PLATES Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).

SHAFT SEALS Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.

RE WO RK I NG CLEANING PARTS Remove remains of old gaskets on all seal-faces.

Carefully remove burrs or similar patches of roughness using an oil-stone.

Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check for perfect passage.

Carefully cover opened transmissions to prevent foreign matter from entering.

Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling.

If rework is needed on distance washers, shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality.

TRANSMISSION ASSEMBLY REUSING PARTS Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used.

Replace parts which are damaged or have suffered from excessive wear.

6

Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measurement.

During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.

Instructions for repairs BEARI N GS If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet).

Temperature should be at ca. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil.

S E ALI NG If a specific sealing agent* is to be used for sealing, comply with the manufacturer’s directions for use.

Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the surfaces are sealed.

d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.

X

e) Fill the gap between the sealing lips so it is 60% filled with grease (e.g. produced

by Aral such as Aralub HL2 or by DEA such as Spectron FO 20). f) If possible, heat shaft seal bores to between 40 and 50 °C (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.

RETAINING AGENTS Retaining agents* may only be used in places as specified in the parts list.

Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite).

During assembly, comply with all adjustment data, checking data and tightening torques.

SHAFT SEALS a) Apply a light coat of sealing agent* on outer edge of shaft seals with “steel surround”.

TRANSMISSION OIL b) Never apply sealing agent to shaft seals with “rubber surround”, but apply a thin coat of Vaseline 8420 to the outer edge or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g.

Pril, Coin, Palmolive). c) Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b).

After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.

* refer to expendable material

7

Tightening torques Tightening torques for nuts and bolts, extract from ZFN 148 This standard applies to bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934.

This Standard contains data on tightening torques (MA) for bolts and nuts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12.

Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chrome-plated and oiled.

Tighten screws with a calibrated torque spanner.

NOTE Irregular tightening torques are listed separately in the Repair Manual.

Regular screw thread

Fine screw thread

Size

Size

Bolt Nut M 4 M 5 M 6

Tightening torque MA (Nm) for 8.8 10.9 8 10 2.8 5.5 9.5

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

Bolt Nut

12.9 12

4.1 8.1 14

4.8 9.5 16.5

M 8x1 M 9x1 M 10 x 1

24 36 52

36 53 76

43 62 89

M 7 M 8 M 10

15 23 46

23 34 68

28 40 79

M 10 x 1.25 M 12 x 1.25 M 12 x 1.5

49 87 83

72 125 122

84 150 145

M 12 M 14 M 16

79 125 195

115 185 280

135 215 330

M 14 x 1.5 M 16 x 1.5 M 18 x 1.5

135 205 310

200 300 440

235 360 520

M 18 M 20 M 22

280 390 530

390 560 750

460 650 880

M 18 x 2 M 20 x 1.5 M 22 x 1.5

290 430 580

420 620 820

490 720 960

M 24 M 27 M 30

670 1000 1350

960 1400 1900

1100 1650 2250

M 24 x 1.5 M 24 x 2 M 27 x 1.5

760 730 1100

1100 1050 1600

1250 1200 1850

M 27 x 2 M 30 x 1.5 M 30 x 2

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991 / checked 1997 8

Tightening torques Screw plugs DIN 908, 910 and 7604

Union screws DIN 7643

The screw plug tightening torques MA were determined according to DIN 7604 for screwing into steel, grey cast and aluminum alloys.

The values are based on experience and are intended as reference values for the fitter.

The values for the tightening torque MA apply analogously for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.

General rule: Screw/bolt class 5, ZFN 148-1 Screw/bolt material: steel acc. to DIN 7604. Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.

The tightening torques MA were determined for screwing into steel, grey cast and aluminum alloys.

The values are based on experience and are intended as reference values for the fitter.

General rule: screw/bolt class 5, ZFN 148-1 Material: 9SMnPb28K acc. to DIN 1651 Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled.

Union screws (DIN7643)

Screw plugs (DIN 908, 910, 7604) Dimensions

M 8x1 M 10 x 1 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 26 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M 33 x 2 M 36 x 1.5 M 38 x 1.5 M 42 x 1.5 M 42 x 2 M 45 x 1.5 M 45 x 2 M 48 x 1.5 M 48 x 2 M 52 x 1.5 M 60 x 2 M 64 x 2

Tightening torque screwed into steel/gray cast Al alloy 20 25 / 30* 35 35 40 50 55 60 / 80* 70 80 / 105* 80 100 / 130* 95 120 130 140 150 145 160 150 170 160 180 195 205

10 15 / 20* 25 25 30 35 45 50 / 65* 60 70 / 90* 70 90 / 130* 85 110 115 120 130 125 140 130 145 135 150 165 175

Pipe outer diameter

Thread

Tightening torque MA in Nm

4-5

M8x1

20 - 25

6

M 10 x 1

25 - 35

8

M 12 x 1.5

30 - 40

10

M 14 x 1.5

35 - 40

12

M 16 x 1.5

45

15

M 18 x 1.5

50

18

M 22 x 1.5

60

22

M 26 x 1.5

90

28

M 30 x 1.5

130

35

M 38 x 1.5

140

* DIN 7604 Form C

Status: October 1995 9

Consumables

Description ZF ref. no

WSK 400/440

Approx. quantity

Application

Remarks

Jointing compound 0666 690 017 Loctite no. 241

30 mm3

M3x22 cyl. screw / wiring harness

Chapter 13

Sealing compound 0666 790 017

WEVO L 100

20 g

Oil feed flange Gear pump

Chapter 13 Chapter 13

Grease 0671 190 050

Olista Longtime 3EB

7g

Separating clutch

Chapter 7

Grease 0671 195 016

Molycote BR2 plus

4g

Release device

Chapter 7

Grease 0750 199 001

For example: Aralub HL2

- Split ring / converter - Needle sleeve / turbine shaft - Shaft seal / retarder housing - Shaft seal / converter housing

Chapter 8 Chapter 9 Chapter 12 Chapter 13

Converter centring journal

Chapter 1

Graphite grease

Name

50 g 5g 2g 2g

NOTE: Inquire about the size of bundles that can be delivered before placing any orders !

10

WSK 400/440

Adjustment data

Description

Dimension

Measurement device

Remarks

01.

Setting converter installation dimension

WSK 400 80.7 mm ± 0.20 mm WSK 440 81.6 mm ± 0.20 mm

Depth gauge

Adjust using appropriate adjusting disc and/or shim (7) at the oil feed flange

02.

Distance of “n engine” inductive sensor

0.80 mm ± 0.20 mm

Depth gauge and 1P01 137 833

Adjust using appropriate washer

03.

Axial play of tapered roller bearing

0.05 - 0.15 mm

Depth gauge

Adjust using appropriate washer (6) on turbine shaft

04.

Tightening torque M12x1.5 at adapter ring / converter

83 Nm

Torque wrench

05.

Tightening torque of anti-fatigue bolt on converter

190 Nm

Torque wrench

06.

Tightening torque M3x22 on wiring harness

1.3 Nm

Torque wrench

07.

Tightening torque M10x16 on wiring harness

46 Nm

Torque wrench

08.

Tightening torque at inductive sensor / “n engine” converter

40 Nm

Torque wrench

Use correct size of washer

09.

Tightening torque of M12x1.5 screw plug at control unit

35 Nm

Torque wrench

Use new sealing ring

11

Adjustment data

WSK 400/440

Description

Dimension

Measurement device

10.

Tightening torque M6x40 at valve housing

9.5 Nm

Torque wrench

11.

Tightening torque M5x12 at solenoid valve

5.5 Nm

Torque wrench

12.

Tightening torque M6x18 M6x12 at cover / control unit

Torque wrench 14 Nm 10 Nm

13.

Tightening torque M8x25, M8x35 M8x40, M8x60 at control unit housing

23 Nm

Torque wrench

14.

Tightening torque M10x55 at pressure plate

46 Nm

Torque wrench

15.

Tightening torque M10x16 at spacer plate

46 Nm

Torque wrench

16.

Tightening torque of M24x1.5 screw plug on oil reservoir

60 Nm

Torque wrench

17.

Tightening torque M10x60 at oil reservoir

46 Nm

Torque wrench

18.

Tightening torque M8x28 at piping

23 Nm

Torque wrench

12

Remarks

Use new sealing ring

WSK 400/440

Description

Adjustment data

Dimension

Measurement device

Remarks

19.

Tightening torque of 45 Nm hollow screw on retarder housing

Torque wrench

Use new sealing rings

20.

Tightening torque WSK 440 WSK 400 Cylindrical screws M12x115 M10x115 M12x110 M10x110 Dowel pins M12x175 M10x175 Nuts M12 M10 M12 (2x) ------Hex bolts M8x80, M8x50 on retarder housing

Torque wrench

As of 1999, M10 cylindrical screws and M10 dowel pins and M10 nuts are replaced

by M12 versions in the WSK 400 + Ecosplite III transmissions (refer to WSK 440)

WSK 440

WSK 400

100 Nm 43 Nm

48 Nm 46 Nm

18 Nm

14,5 Nm

90 Nm 43 Nm

48 Nm -------

23 Nm

23 Nm

21.

Tightening torque M8x35 on plug

23 Nm

Torque wrench

22.

Tightening torque M8x22 on connecting piece

23 Nm

Torque wrench

23.

Tightening torque of temperature sensor

30 Nm

Torque wrench

24.

Tightening torque Hex bolts M8x25, M8x28 M8x35, M8x45 cylindrical screw M8x22 dowel pin M8x25 nut M8 on retarder housing

Use new sealing ring

Torque wrench 23 Nm

23 Nm 10 Nm 23 Nm

13

Adjustment data

WSK 400/440

Description

Dimension

Measurement device

25.

Tightening torque M10x55 on gear pump

46 Nm

Torque wrench

26.

Tightening torque of vent / converter housing

10 Nm

Torque wrench

27.

Tightening torque of screw plugs M24x1.5 M26x1.5 on converter housing

28.

Tightening torque M10x40 on oil feed flange

29.

Tightening torque of dowel pins M8SK6, M8x16 nuts M8 at strainer insert / filter

Torque wrench

Remarks

Use new sealing rings

50 Nm 65 Nm

46 Nm

Torque wrench

Torque wrench 10 Nm 23 Nm

30.

Tightening torque of slotted nut in clutch housing

120 Nm

Torque wrench

Use new locking plate

31.

Tightening torque of inductive sensor / “n turbine” connection plate

30 Nm

Torque wrench

Use new o-ring/round.

Distance is specified.

32.

Temperature of outer bearing race / oil feed flange

Approx. 100 °C

Temperature probe

14

WSK 400/440

Adjustment data

Description

Dimension

Measurement device

Remarks

33.

Tightening torque of screw plug M39x2 on converter

140 Nm

Torque wrench

Only for WSK 400, depending on version.

Use new sealing ring.

34.

Installation depth of WSK /engine

83.25 ± 0.8 mm

Depth gauge

Shim

35.

Thickness of diaphragms (engine / WSK)

WSK 400 2.4 ± 0.14 mm WSK 440 1.5 ± 0.14 mm

(2 diaphragms) (1 diaphragm)

36.

Tightening torque of hex bolt on converter housing / flywheel housing

M10 = 49 Nm or M12 = 79 Nm

Torque wrench

37.

Tightening torque of M12x1.5 hex bolt on flywheel / converter

90 Nm

Torque wrench

38.

Tightening torque of M10x45 cylindrical screw on converter cover

48 Nm

Torque wrench

WSK converter 440

39.

Tightening torque of M8x35 cylindrical screw on piston

35 Nm

Torque wrench

WSK converter 440

40.

Tightening torque of M8x18 cylindrical screw on pump

25 Nm

Torque wrench

WSK converter 440

41.

Disc clearance or piston clearance in converter cover

0.70 - 1.70 mm

Feeler gauge

WSK converter 440

15

Adjustment data

WSK 400/440

Description

Dimension

Measurement device

Remarks

42.

149.8 -0.2 mm

Depth gauge

WSK converter 400 Adjust using appropriate adjusting disc.

16

Converter monitoring depth

WSK 400/440

Spring table

Installation point

Transmission

Safety valve

WSK 400 0732 042 511

17.5

2.50

20.1

96.3

WSK 440 0732 042 692

17.0

2.80

20.1

85.0

0732 040 769

12.5

1.25

11.45

42.3

0732 042 444

16.5

2.50

19.5

89.9

WSK 400 0732 040 972

14.5

2.50

24.6

126.0

WSK 440 0742 042 691

17.0

3.00

24.5

113.4

0732 041 246

48.5

2.80

18.45

250

WSK 400 0732 041 217 with NMV

17.5

1.60

15.4

87.4

Lock-up clutch shift valve

Order no.

No. of windings

Wire diam. in mm

Spring diam. Untensioned in mm length in mm

WSK 400 WSK 440

Lock-up clutch pressure valve

WSK 400 WSK 440

Converter back pressure valve

Housing

WSK 400 WSK 440

NMV shift valve / safety valve

17

Special tools

Fig. no.

Special tools

WSK 400/440

Order no.

Application

Qty.

Chapter 13

1X56 091 173

1

Adapter for shaft seal in converter housing

1

Chapter 7

1X56 104 910

2

Clamping bar for pressure plate / clutch

2

Chapter 12 Chapter 13

1X56 112 761

3

Adapter for outer bearing race /oil feed flange and shaft seal / retarder housing on output side

1

Chapter 9

1X56 119 917

4

Adapter for needle sleeves and shaft seal in turbine shaft

1

Chapter 6 Chapter 7 Chapter 9

1X56 136 242

5

18

Lifting tool for WSK housing parts

Remarks

1

WSK 400/440

Fig. no.

Special tools

Special tools

Order no.

Application

Qty.

Chapter 7

1X56 136 914

6

Centring punch for clutch disc

1

Chapter 8

1X56 137 539

7

Lifting device for converter

1

8

1

9

1

Chapter 8

1X56 138 107

10

Gripper for adapter 1X56 138 224

WSK 400

Chapter 8

1P01 137 833 Measuring device for adjusting “n engine� inductive sensor

WSK 440 WSK 400

Chapter 8

1X56 136 577 Lifting device for converter in conjunction with M39x2screw plug

Remarks

1

WSK 440

19

Special tools

Fig. no.

Special tools

WSK 400/440

Order no.

Application

Qty.

Chapter 8

1X56 138 151

11

Clutch fixation for release fork (exchange of converter with attached torque converter clutch)

1

Chapter 7

1X56 138 159

12

Downhold device for installation and removal of release device on pressure plate

1

Chapter 5 Chapter 6

1X56 138 116

13

Fixing plate for changing the clutch release cylinder or for supplies without the release cylinder

1

Chapter 8

1X56 138 217

14

Ring used for several purposes on the converter

1

20

Adapter used for several purposes on the converter

WSK 440

Chapter 8

1X56 138 218

15

Remarks

1

WSK 440

WSK 400/440

Fig. no.

Special tools

Special tools

Order no.

Application

Qty.

Chapter 8

1X56 138 224

16

Adapter for angular ball bearing with gripper 1X56 138 107

1

Assembly fixture for complete Transmatic

WSK 440

Chapter 2 Chapter 6

1X56 139 137

17

Remarks

1

21

22

1P01 137 833

1X56 112 761

1X56 104 910

1X56 138 151

1X56 139 137

1X56 138 116

1X56 138 159

1X56 136 577

1X56 119 917

1X56 136 914

1X56 091 173

1X56 137 539

1X56 136 242

Special tools WSK 400

1X56 112 761

19

1X56 104 910

1X56 138 151

1X56 138 159

1X56 138 217

1P01 137 833

1X56 139 137

1X56 138 116

4

20x

1X56 119 917

1X56 137 539

1

1X56 091 173

1X56 136 914

5

1X56 136 242

1X56 138 218

1X56 138 224

1X56 138 107

WSK 440 Special tools

23

WSK 400/440 1

WSK /engine

WSK /engine Disassembly NOTE The diagram shows the diaphragm connection between the WSK and engine. The converter of the WSK is connected to the flywheel using 10 hex bolts located on the circumference via 2 diaphragms in the WSK 400 and 1 diaphragm in the WSK 440.

1

2

3

3

2

1

Use a mounting lever to rotate the starter crown wheel (1) until one of the retaining bolts (2) on the converter is accessible through the assembly aperture of the flywheel housing (3). Use a socket wrench to unscrew the M12x1.5 hex bolts (2) and spring washer.

Continue rotating the starter crown wheel (1) until it reaches the next hex bolt and remove all hex bolts from the converter in this manner.

Fit lifting device under WSK ensuring that the transmission is horizontal. Unfasten and remove retaining bolts (5) holding circumference of converter housing (4) with flywheel housing.

Move WSK out approx. 100 mm in the direction of the axle. The engine and WSK are only separated once the converter centring journal (6) has slipped out of the flywheel (7).

NOTE Once the transmission has been removed, take off the diaphragms (8) located on the flywheel and check that they are in perfect condition.

015063

6

8 7

4 5 015064

1-1

WSK /engine

WSK 400/440

Monitoring measurement for engine connection NOTE Take the following measurement to determine whether the diaphragms (8) have possibly been bent.

3 8 A

9

7

1

2

Use the converter installation depth on the transmission side to calculate “C” WSK 400 = 80.7 ± 0.2 mm WSK 440 = 81.6 ± 0.2 mm.

On the engine side, measure length “A” between the connecting and sealing surface of the flywheel housing (3) and the contact surface for the diaphragms on the flywheel (7). Take this measurement at two opposite points. The installation depth “A” must be 83.25 ± 0.8 mm. Deviations should be corrected by placing shims between the flywheel and diaphragms.

3

Measure the thickness of the diaphragms (8), dimension “B”.

The dimension of the diaphragms is specified: WSK 400 = 2.4 ± 0.14 mm (2 diaphragms) WSK 440 = 1.5 ± 0.14 mm (1 diaphragm)

4

Dimension “A” – dimension “C” produces the axial distance between converter (9) and flywheel (7) when installed. This dimension must not deviate from the measured dimension “B” (thickness of diaphragms) by any more than ± 1 mm (otherwise the diaphragms are bending).

5

The face runout “TS” on the flywheel housing must not exceed 0.2 mm.

1-2

B

C TS 015065

WSK 400/440

WSK /engine

Assembly 1

Before the WSK is assembled on the engine, the diaphragms (8) should be fastened onto the flywheel (7) using the clamping washer (10). The tightening torques of the hex bolts (11) required should be obtained from the vehicle manufacturer in question.

6

8 7

2

Rub grease into the centring journals (6) before installing them on the converter (9).

3

Run-in WSK in direction of axle and fit lifting device under WSK ensuring that the transmission is horizontal.

4

5

9

4

Insert retaining bolts (5) between circumference of converter housing and flywheel housing (3) and tighten ; M10 tightening torque = 49 Nm or M12 tightening torque = 79 Nm. Use a mounting lever to rotate the starter crown wheel (1) until one of the threaded bores on the converter (9) is accessible through the assembly aperture of the flywheel housing (3). Use a socket wrench to insert the M12x1.5 hex bolts (2) and spring washer and tighten; Tightening torque = 90 Nm Continue rotating the starter crown wheel (1) until it reaches the next threaded bore and screw in all hex bolts on the converter in this manner.

015066

11 3

10

2

1 5 015067

1-3

WSK 400/440 2

Transmission mounting

2.1

Draining oil from transmission

WSK /transmission

CAUTION Do not let any oil enter the soil, ground water or sewage system. Catch any overflowing oil in a suitable container and dispose of in accordance with environmental regulations.

1

Unscrew oil drain screw on transmission and catch used oil in suitable vessel.

1

NOTE • Not all the oil in the converter can be drained.

An additional approx. 7 dm3 can however be drained by unscrewing the pressure measuring stop (1) on the WSK control unit and the amount of oil left in the converter is therefore reduced to approx. 6 dm3. • Depending on version and arrangement, a certain amount of oil also remains in the heat exchange and connection lines. This can also not be drained.

009517

4 2.2

Assembly device 1X56 139 137

1

Screw assembly device (2) onto output flange (3) of transmission.

CAUTION Do not attach lifting tackle directly onto converter (see arrow). Attach rope and chain (4) as shown in diagram. ! DANGER The weight of the complete transmission is approx.

600 kg. It is essential that appropriate lifting tackle is used. Do not stand in the hazardous area.

2

Place complete transmission in vertical position.

3

The WSK can only be removed from above when in this position (refer to chapter 6).

3

2

014920

2-1

WSK 400/440 3

Central wiring

Central wiring

d

Disassembly NOTE Label central wiring (1) according to its connectors before dismantling.

1

1

Disconnect all connectors and remove central wiring.

e

Assembly 1

Assemble central wiring (1) according to its connectors.

015212

2

Tightening torque (2) = 2 Nm. 2

a

c

b 015213

d

f 015214

3-1

Central wiring

WSK 400/440

e

f

3

1

b d

2 a c

011901

1 2 3

Central wiring M4x10 hex bolts Cable clamp

a) b) c)

ZVK connection to chassis 19-pin “n turbine� inductive sensor 3-pin ZVK connection to internal WSK 10-pin (nEng/WK) T sensor to electronics unit 2-pin (oil temp. of ret. feedback) N switch for transmission 2-pin Clutch switch on servo cylinder 2-pin

d) e) f)

3-2

WSK 400/440

Oil reservoir

6

3 8

4

8

1

2 7

4

8

5 8

1 8 8 1 011902

4

Oil reservoir for WSK oil supply Disassembly

CAUTION – RESIDUAL OIL Do not let any oil enter the soil, ground water or sewage system. Catch any overflowing oil in a suitable container and dispose of in accordance with environmental regulations.

Assembly 1

Insert greased new O-rings (8) in pipes.

2

Insert return pipe (5) and intake pipe (4) in oil reservoir (3).

3

Attach oil reservoir with new gasket (6) on transmission.

1

Loosen hex bolts (1 and 2).

2

Remove oil reservoir (3) with intake pipes (4) and return pipe (5).

4

Insert hex bolts (2) and tighten ; Tightening torque = 46 Nm

3

Remove gasket (6).

5

Screw pipes onto WSK with hex bolts (1); Tightening torque = 23 Nm

4

Remove pipes from oil reservoir and take off O-rings (8).

6

Screw in oil drain plug (7) with new sealing ring and tighten ; Tightening torque = 60 Nm

5

Loosen and remove oil drain plug (7).

4-1

WSK 400/440

Clutch cylinder

1

5

2

1 * 4 5 3

013464

5

Clutch cylinder Disassembly

1

Loosen screws (1) and remove clutch cylinder (2) with gasket (4).

Assembly 1

NOTE No gasket with first version. Remove sealing compound.

2

NOTE Apply some sealing compound (Silastic 732 RTV) to the groove on the clutch housing (optional) (before 03.99).

Use a suitable sealing material to seal the clutch housing at the opening and closing points.

Remove sealing cap (3).

CAUTION When changing the clutch cylinder or transporting the transmission without the clutch cylinder, fixing plate 1X56 138 116 must be used. The release device must not be incorrectly rotated.

NOTE Sealing cap (3), gasket (4) and hose ventilation (5) are only fitted in the fordable version.

Insert clutch cylinder (2) with new gasket (4 in fordable version) in transmission.

2

Insert hex bolts (1) and tighten crosswise: Tightening torque = 23 Nm

3

When working with the fordable version, insert Vaseline with sealing cap (3) and check that connection of hose ventilation (5) can be accessed.

5-1

WSK 400/440 6

WSK /transmission

WSK /transmission Disassembly

2

NOTE Place complete Transmatic in vertical position (refer to Chapter 2).

1

Loosen and remove hex bolts (1) between WSK and transmission.

1

2

Attach lifting equipment 1X56 136 242 to WSK and lift it slowly.

! DANGER Do not lift WSK when aligning release device – danger of crushing !

CAUTION The release fork (a) is still engaged. Rotate release device (b) in transmission by 90° and lift WSK carefully (see arrows).

3

011904

b a

Remove metal gasket (2) from transmission.

NOTE When depositing WSK, ensure it is adequately supported to prevent screws from being damaged.

011905

011906

6-1

WSK /transmission

WSK 400/440

Assembly 1

Place metal gasket (2) on transmission.

2

Use lifting equipment 1X56 136 242 to lift WSK over transmission and then lower slowly.

b a

! DANGER Do not lower WSK when aligning release device – danger of crushing.

CAUTION Ensure that the driver of the release device (b) is at 90° to the release fork (a) (see arrows).

011905

3

4

5

Lower WSK slowly to the unit and bring release device into position. The spot-faced surface (C) must face the release cylinder.

Attach fixing plate 1X56 138 116 or fix clutch release cylinder (refer to Chapter 5.1 and 5.2).

b

C

Insert and tighten hex nuts (1); WSK 400 - M10 tightening torque = 48 Nm WSK 440 - M12 tightening torque = 90 Nm M12 tightening torque = 43 Nm (2x) NOTE Tighten 2 hex nuts with a torque of 43 Nm. (For position, refer to screw connection WSK 440 in Chapter 13.5) 015071

2

1

011904

6-2

WSK 400/440

WSK /transmission

1

3

*

2 013411

“n turbine� inductive sensor Disassembly 1

Pull and remove cable connection (1) from inductive sensor (2).

2

Loosen slotted nut (3) and remove together with locking plate. Remove cable connection (1) from clutch housing.

3

Loosen inductive sensor (2) and remove from connection plate.

Assembly 1

Screw in and tighten inductive sensor (2) together with new O-ring ; Tightening torque = 30 Nm

2

Insert and tighten cable connection (1) and slotted nut (3) with new locking plate in clutch housing ; Tightening torque = 120 Nm.

3

Connect cable connection and inductive sensor.

* depending on parts list

6-3

WSK 400/440 7

Selector clutch

Selector clutch Disassembly NOTE Ensure that selector clutch cannot be misaligned.

1

Since the plate springs have been pretensioned, insert 4 spacers (see arrow) in pressure plate (1) before disassembling the clutch to ensure that the pressure plate can be refitted at a later date.

Loosen and remove screws (2).

1 011908

NOTE Make your own spacers.

We recommend the following dimensions: 4x8x55 mm 2

Lift up pressure plate and place to one side.

3

To remove release device, use brace 1X56 138 159 and compress spring elements (3).

4

Remove tension ring (4). Release and remove brace.

5

Remove tension ring (4) and ring (5) from the pressure plate.

6

Remove plate spring (6), disc (7) and release device (8) from pressure plate.

7

WSK 400 Remove clutch disc (9) and torsion damper.

WSK 440 Remove clutch disc (9a) without torsion damper.

3

4 011933

WSK 400 1

9

11

6 7

8 2

10 4 5

9a

NOTE Ensure spacer plate (11) cannot rotate.

8

Loosen and remove screws (10).

9

Remove spacer plate (11).

WSK 440 013412

7-1

Selector clutch

WSK 400/440

Assembly 1

Insert spacer plate (11).

2

Insert and tighten hex bolts (10); tightening torque = 46 Nm.

3

Use centring punch 1X56 136 914 to place clutch disk (9 or 9a) on spacer plate.

WSK 400

11

Place release device (8) on brace 1X56 138 159.

Place disc (7) and plate spring (6) on top.

5

Place pressure plate (1) on brace. Place ring (5) on tension ring (4) on top.

6

Mount brace and compress spring elements (3).

7

Engage tension ring (4), release and remove brace.

8 2

10 9a

WSK 440 013412

NOTE Rub grease (Olista Longtime 3EB : 7g) into keygroove of clutch disc (9 or 9a).

8

6 7

4 5

NOTE Evenly pack O-ring (12) of thrust bush of release device with grease (Molykote BR2 plus).

4

1

9

12

Place completed pressure plate (1) on spacer plate (11).

NOTE Ensure pressure plate cannot rotate.

9 10

015072

Insert hex bolts (2) and tighten down crosswise; Tightening torque = 46 Nm

3

Remove 4 spacers.

! DANGER The WSK must be rotated before the converter can be installed.You MUST attach clamping bar 1X56 104 910 to selector clutch because it is not attached to anything in the WSK (see Chapter 8).

4 011933

011908

7-2

WSK 400/440 8

Converter

Converter Disassembly NOTE (WSK removed from transmission) If only the converter needs to be changed, then you must ensure that the selector clutch is secured by means of the clamping bar 1X56 104 910.

This is the only means by which oil can be stopped from running over the clutch disc.

Use a depth gauge to measure the distance between the faces of several threaded journals at converter and the connecting face of the converter housing.

Note down dimensions “C�.

WSK 400 = 80.7 mm WSK 440 = 81.6 mm

011910

NOTE (WSK attached to transmission) When changing converter, use clutch fixation 1X56 138 151 to stop release fork. Use this to press and hold release device to input.

1

Release and remove retaining ring (1).

2

Remove washer (2) with O-ring (3).

C

NOTE As an aid, insert hex bolt and pull off using mounting lever.

3

Remove O-ring (3) from washer.

NOTE WSK 400 may have a M39x2 screw plug and seal ring rather than a washer (2).

4

011911

Loosen and remove tension bolt (4).

NOTE Use mounting lever to ensure converter cannot rotate.

5

Use lifting device 1X56 137 539 or 1X56 136 577 to engage retaining ring and remove converter (5) from converter housing.

6

Remove shims (6 and 7) from turbine shaft and oil feed flange.

7

5

6

1

2

3 4

011912

8-1

Converter Installation

WSK 400/440

WSK 400

WSK 440 a

NOTE Only use converter after turbine shaft is inserted and the selector clutch has been mounted.

Adjust converter installation depth “C” (by placing shims on oil feed flange) 1

Screw in lifting device 1X56 136 539 (8) until there is no axial play on sealing washer (10) in converter; Tightening torque = 25 Nm.

5

10

10

b

9

8

NOTE When working with the WSK 400 (version with M39x2 screw plug), use lifting device 1X56 136 577 (9).

2

Use depth gauge to measure the distance between the face of the threaded journal and the face of the converter gear and note down as dimension “a”.

3

Use depth gauge to measure the distance between face of converter gear and inner bearing race of converter ball bearing and note down as dimension “b”.

4

a–b=D Note down dimension “D” for additional measuring procedure.

5

013417

d

c

Using strip, measure distance between converter housing and converter bearing when firmly in contact with the oil feed flange and note down as dimension “c”.

6

Measure distance between strip and contact face of converter housing and note down as dimension “d”.

7

c–d=F Note down dimension “F”.

8

D–F=C Dimension “C” (converter installation depth) must be: WSK 400 = 80.7 mm ± 0.2 mm WSK 440 = 81.6 mm ± 0.2 mm.

Divergences must be rectified using the appropriate shim (7).

011913

011914

77

011915

8-2

WSK 400/440 Adjustment of axial play of the tapered roller bearing “G” (shim on turbine shaft) 9

10

11

WSK 400

WSK 440

Use depth gauge to measure distance between the face of the converter gear and the sealing washer in the converter. Note down as dimension “e”.

5

e–b=G Note down dimension “G”.

e G

Use a crane to life turbine shaft (11) or fit appropriate device under shaft for measurement. Rotate the converter housing to ensure that the tapered roller bearing is free of clearance. Use depth gauge to measure distance between face of turbine shaft and point of contact between converter bearing and oil feed flange with shim (7) on top.

Note down as dimension “H”.

12

G – H + (axial play of 0.05 to 0.15 mm) = S Correct variances with appropriate grade of shim (6).

13

Grease correct shim and place on centre of turbine shaft.

14

Carefully push converter onto spline of turbine shaft and lower until firmly home.

15

If converter cannot be inserted completely, then it is located on spline of oil feed flange. If this occurs, raise crane hook until there is slight slack in wires. Pull central wire with both hands to raise the converter slightly, rotate and then release.

Repeat until converter slides onto spline of oil feed flange.

16

Converter

013416

b

011916

11 H

7

011917

Carefully lower converter to next point of contact.

Here, the converter can be located on the gear pump impeller. Rotate converter slightly again until teeth mesh.

CAUTION Never use a hammer to insert converter.

6

011918

8-3

Converter 17

WSK 400/440

Remove lifting device 1X56 136 539 or 1X56 136 577 from converter.

NOTE The converter is only firmly in place once the anti-fatigue bolt is tightened.

18

Ensure converter cannot rotate. Screw in and tighten anti-fatigue bolt (4); Tightening torque = 190 Nm

19

Use some grease to insert new O-ring (3) into disc (2) and insert into converter.

20

1

2

3 4

Insert retaining ring (1) in converter.

NOTE WSK 400 may have a M39x2 screw plug rather than a washer (2) (use new seal ring).

Tightening torque = 140 Nm

011919

a Adjusting “n engine” inductive sensor 21

Push retaining ring forwards into measuring device 1P01 137 833 and insert in bore until it reaches the tooth tip of the converter gear.

Measure and note down dimension “a” on measuring device.

22

Measure distance between contact face and point of contact with inductive sensor. Note down as dimension “b”.

23

Example: a–b=T 35.5 mm – 35.1 mm = 0.4 mm If there is a permissible distance of 0.8 ± 0.2 mm, a washer with a thickness of 0.4 mm can be inserted.

24

Screw in and tighten “n engine” inductive sensor with selected washer; Tightening torque = 40 Nm

1P01 137 833

T b

NOTE Use remachined socket (SW = 24) to screw in inductive sensor (see Chapter 13.2).

25

Connect plug from cable harness with inductive sensor.

011920

8-4

WSK 440

Converter

3 5

4 11

6 7 7

6

8

R 9 1

10

R

2

015075

8.1

Dismantling and assembling converter (WSK 440) 2

Carefully lift off and put down converter cover.

Remove lifting device and rotate converter cover.

NOTE The circumference of the converter cover and pump are marked with an “R” (= residual imbalance). These marks must be set at opposing 180° positions.

3

Take off O-ring (3), unfasten and remove cylindrical screws (4).

4

Take off pressure ring (5), remove inner discs (6) and outer discs (7).

Insert lifting device 1X56 137 539 in converter cover (1) and unfasten cylindrical screws (2).

If necessary, mark converter cover and pump.

5

Use compressed air to press off and remove piston (8) through oil bore.

6

Take O-rings (9 and 10) off piston.

7

Remove grooved ball bearing (11) from converter cover.

8.1.1 Converter cover Disassembly and dismantling

1

CAUTION Keep converter cover horizontal so that the turbine gear does not misalign with the inner discs in the converter cover.

NOTE The grooved ball bearing (11) may also sit on the turbine gear.

Index: a

8-5

Converter

WSK 440

3 5 6

4 11

7 6

7 8 9 1

10

2

015159

Assembling converter cover 1

Insert grooved ball bearing (11) into contact point in converter cover (1).

2

Use grease to insert new O-rings (9 and 10) in piston (8) and insert pistons into contact point in converter cover.

3

Insert outer (7) and inner discs (6). Insert in turn, starting with an outer disc, then an inner disc.

4

Attach pressure ring (5) and screw in and tighten cylindrical screws (4); Tightening torque = 35 Nm.

5

Use feeler gauge to check disc clearance or piston clearance.

Clearance = 0.7 – 1.7 mm

8-6

6

Use grease to fit new O-ring (3) on converter cover.

NOTE Instructions for installation of the converter cover can be found in Chapter 8.1.5

Index: a

WSK 440

Converter

3

5

4 2 1

015076

Assembling turbine gear

8.1.2 Dismantling turbine gear 1

Remove sealing washer (1) and O-ring (2) from turbine gear (3).

2

Take O-ring off washer.

3

Snap piston ring (4) off turbine gear and take off.

4

Take axial bearing (5) off stator and check for wear.

1

Snap piston ring (4) into turbine gear (3).

2

Use grease to insert new O-ring (2) in sealing washer (1) and press the complete sealing washer into contact point into the turbine gear.

3

Insert axial bearing (5) in turbine gear.

NOTE The instructions for turbine gear installation can be found in Chapter 8.1.5.

Index: a

8-7

Converter

WSK 440

9 1

8

5 6 7 2 4 3

015077

8.1.3 Dismantling stator CAUTION When removing the free-wheel inner race, ensure that parts cannot spring out.

1

Place stator (1) on ring 1X56 138 217 (diameter 131 mm) and use adapter 1X56 138 218 (diameter 84 mm) to drive out free-wheel inner race (2) with grooved ball bearing (3) and thrust washer (4).

NOTE When driving out the free-wheel inner race, the cylindrical rollers (5) are also removed. The spring caps (6) and the cylindrical springs (7) may also be loosened during this process.

2

Take thrust washer (8) off stator.

3

Use a suitable plastic mandrel to drive off grooved ball bearing (9).

8-8

Index: a

WSK 440

Converter

1

5 3

9 4

6

8 7 2

Input

Output 015073

Assembling stator 1

Use ring 1X56 138 217 (diameter 130 mm) and adapter 1X56 138 218 to press grooved ball bearing (3) into contact point into stator.

6

Fit thrust washer (8) and use adapter 1X56 138 218 (diameter 84 mm) to drive freewheel inner race firmly home.

2

Insert thrust washer (4) in stator (1).

7

Place stator (1) and grooved ball bearing (3) on ring 1X56 138 217 (diameter 130 mm).

3

Use grease to insert all cylindrical springs (7) and spring caps (6) in free-wheel inner race (2).

8

Use adapter 1X56 138 218 to press grooved ball bearing (9) firmly home in stator.

9

Check free-wheel: Free-wheel must lock in the direction shown above when the inner race is retained (see arrow).

4

5

Place free-wheel inner race in correct position on stator and use adapter 1X56 138 218 (diameter 84 mm) to drive in approx. 1/2 of the width of the bearing.

Insert cylindrical rollers (5) by sliding back the spring caps.

NOTE The instructions for stator attachment can be found in Chapter 8.1.5.

NOTE To simplify the assembly of the cylindrical rollers, firstly insert 4 cylindrical rollers at angles of 90°.

Index: a

8-9

Converter

WSK 440

2 3

5 4

67 1

015078

Assembling pump

8.1.4 Dismantling pump 1

Take spacer (1) off pump (2) and rotate pump.

1

Use grease to insert new O-ring (5) in pump hub (4).

2

Unfasten cylindrical screws (3) and take off with washers.

2

Insert pump hub in accordance with the mark made on the pump (2).

NOTE Mark position of pump hub (4) in relation to pump (2).

3

NOTE To simplify the installation, use suitable cylindrical pins.

Remove pump hub (4) from pump (2).

3

4

Take off O-ring (5) and use mounting lever to remove angular ball bearing (6).

Insert cylindrical screws (3) with washers and tighten; Tightening torque = 25 Nm. NOTE For installation of the angular ball bearing (6), the spacer (1) and attachment of pump, refer to Chapter 8.1.5.

8-10

Index: a

WSK 440

Converter

8.1.5 Measuring and completing converter 1

2

Place turbine gear (1) and axial bearing (2) on thrust piece (diameter 40 mm).

4

5

Place stator (3) in correct position on axial bearing.

3

Place spacer (4) and angular ball bearing (5) on stator.

4

Use depth gauge to measure from angular ball bearing inner race to sealing washer (8).

Monitoring length (9) = 149.8 – 0.2 mm

3 9 2 1

5

8

Take all parts off again.

015081

6

Place turbine gear (1) on converter cover above the inner disc spline of the converter cover (6).

7

Place axial bearing (2) on turbine gear and attach stator (3) in correct position. Blade outlet side faces the turbine gear.

8

Place spacer (4) on stator.

9

Use adapter 1X56 138 224 to press angular ball bearing (5) firmly into pump hub. The wide side of the inner bearing race faces the input.

7

3

R

1

4

5

2

6

R

10

Attach pump (7) in accordance with marking (“R” at 180° to the converter cover).

11

Screw in 4 cylindrical screws at an angle of 90°, tighten by hand and invert the complete converter.

12

Insert the remaining cylindrical screws and tighten ; Tightening torque = 48 Nm.

13

Insert lifting device 1X56 136 539 and again check monitoring length of 149.8 – 0.2 mm (as described under point 4).

015079

015080

Index: a

8-11

WSK 400/440 9

Turbine shaft

Turbine shaft 1

Disassembly

4 3

NOTE Turbine shaft can be taken off after disassembling the selector clutch and removing the converter.

1

Use lifting device 1X56 136 242 to lift converter housing with retarder over turbine shaft (1).

2

2

Remove piston rings (2) from turbine shaft.

3

Use conventional two-armed extractor to grip needle sleeve (3) from below and remove from turbine shaft with shaft seal (4).

011921

Assembly 1

Use adapter 1X56 119 917 to press greased needle sleeve (3) into contact point of turbine shaft (1).

2

Use adapter 1X56 119 917 to insert shaft ring (4) into contact point.

3

Insert piston rings (2) in turbine shaft.

4

Insert turbine shaft in housing.

9-1

WSK 400/440 10

Oil filter

Oil filter Disassembly

1

Loosen hex bolts (1). Remove with washers and pan (2).

2

Loosen hex bolts (3). Remove with leaf spring (4) and washer (5).

3

Remove filter (6) with bush (7) and gasket (8).

4

If necessary, remove dowel pin (9).

6 Assembly 1

2

3

Screw in and tighten dowel pin (9); Tightening torque = 10 Nm. Insert bush (7). Put on gasket (8) and insert filter (6).

7

2

9

4 8 5

1

NOTE Replace filter. The plate cover (a) of filter must face outwards.

3

4

011922

Insert washer (5), leaf spring (4). Tighten with hex bolt (3); Tightening torque = 23 Nm.

c

Put on pan (2). a NOTE Attach pan in such a way that its deeper side (b) is over the intake aperture (c).

5

Put on hex bolts (1) with washers and tighten ; Tightening torque = 23 Nm.

005599

b

009516

10-1

WSK 400/440 without NMV

Control unit 25

26 63

24

6

5 27 7

23 2 21 1 24 4

13 90 12 10

8

25 3

7

14

15 64

16 19

18

17

22

23

37 9

11

40 20

21

011923

11

Control unit

11.1 WSK without NMV Removal and disassembly 1

NOTE Cover is spring loaded. Carefully loosen screws and press cover against control housing until all screws have been removed.

Loosen hex bolts (1, 2, 3 and 4) and remove with control unit.

6

Pressure spring (13) with ball (14); Pressure spring (15) with piston (16); Remove pressure spring (17), bush (18) with piston (19) and bush (20) with pressure spring (21) and piston (22) from control unit housing.

7

If necessary, loosen 2 screw plugs (23) and remove with sealing rings.

NOTE When removing control unit, loosen solenoid valve cable.

2

3

Loosen hex bolts (5) and remove “WK� solenoid valve (6) with valve housing (27).

Loosen cylindrical screws (24), remove with spring clips and flat plug (25). Pull solenoid valve out of housing (27) and remove O-rings (26).

4

Remove gasket (7) and cover sheet (8) from control unit housing.

5

Loosen hex bolts (9 and 10), remove cover (11) with gasket (12).

Item no.

90 64 37 40 63

Designation Safety valve Lock-up clutch shift valve Lock-up clutch pressure valve Converter back pressure valve Preselector valve

11-1

Control unit

WSK 400/440 without NMV

25

26

24

5

6

27 7

23 2 21 1 24 4

7

14

13

15

011924

8

25 3

16

12 10

17

9

11

18

19 22

20

23

21 011923

Assembly and installation 1

Screw in and tighten 2 screw plugs (23) together with new gaskets ; Tightening torque = 35 Nm.

2

Insert pressure spring (13) with ball (14); pressure spring (15) with piston (16); pressure spring (17), bush (18) with piston (19) and bush (20) with pressure spring (21) and piston (22) in correct positions in control unit housing.

3

Put on new gasket (12) with cover (11).

4

Insert and tighten hex bolts (9 and 10) ; M6x12 tightening torque (9) = 10 Nm; M6x18 tightening torque (10) = 14 Nm.

5

Put on new gaskets (7) with cover plate (8).

6

Insert greased O-rings (26) in solenoid valve.

Place solenoid valve in correct position on axial support in housing (27).

11-2

7

Fix solenoid valve and flat plug (25) to valve housing (27) with cylindrical screws (24); Tightening torque = 5.5 Nm.

8

Screw complete “WK� solenoid valve (6) with hex bolts (5) to control housing ; Tightening torque = 9.5 Nm. NOTE Before installing control unit, measure and install inductive sensor (refer to Chapter 8).

9

Insert solenoid valve cable and attach control unit to WSK by means of 2 cylindrical pins.

10

Screw in and tighten hex bolts (1, 2, 3 and 4); Tightening torque = 23 Nm.

WSK 400 with NMV

Control unit

63 25 3

26

24

5 27

6

7 1

8

2 30 12

11

90 33

32

31

28 9

7

29

15

16

64

17

19

18

23

37 37 10

38

36

20

40

34

21

22

35

39 015074

11.2 WSK with NMV Removal and disassembly 1

NOTE Cover is spring loaded. Carefully loosen screws and press cover against control housing until all screws have been removed.

Loosen hex bolts (1 and 2) and remove with control unit.

NOTE When removing control unit, loosen solenoid valve cable.

2

Loosen hex bolts (5) and remove “WK� solenoid valve (6) with valve housing (27).

3

Loosen cylindrical screws (24), remove with spring clips and flat plug (25). Pull solenoid valve out of housing (27) and remove O-rings (26).

4

Loosen retaining screw (3), remove gaskets (7) and cover sheet (8) from control unit housing.

5

Loosen hex bolts (9, 10 and 37), remove cover (11) with gasket (12). Loosen hex bolts (38 and 39), remove cover (34) and gasket (35).

6

Gear shift piston (33), pistons (32, 31 and 30) with pressure spring (29); Bush (28), pressure spring (15) with piston (16); Remove pressure spring (17), bush (18) with piston (19) and bush (20) with pressure spring (21) and piston (22) from control unit housing.

7

If necessary, loosen 2 screw plugs (23) and take off with sealing ring.

Item no.

90 64 37 40 63

Designation NMV gear shift valve + safety valve Lock-up clutch selector valve Lock-up clutch pressure valve Converter back pressure valve Preselector valve

11-3

Control unit

WSK 400 with NMV

25 3

26

24

5 27

6

7 1

8

2 011924

30 12

11

33

32

7

29

31

28

15

16

9 17 37 10

36

19

18

23

38 20 34

21

22

35

39 015074

Assembly and installation 1

Screw in and tighten 2 screw plugs (23) together with new gaskets ; Tightening torque = 35 Nm.

6

Install greased O-rings (26) in solenoid valve.

Place solenoid valve in correct position on axial support in housing (27).

2

Insert gear shift piston (33), pistons (32, 31 and 30) with pressure spring (29); bush (28), pressure spring (15) with piston (16); pressure spring (17), bush (18) with piston (19) and bush (20) with pressure spring (21) and piston (22) in correct position in control unit housing.

7

Fix solenoid valve and flat plug (25) to valve housing (27) with cylindrical screws (24); Tightening torque = 5.5 Nm.

8

Screw complete “WK� solenoid valve (6) with hex bolts (5) to control unit housing ; Tightening torque = 9.5 Nm.

3

4

5

11-4

Put on new gasket (12 and 35) with cover (11 and 34).

Insert and tighten hex bolts (9, 10, 37, 38 and 39) ; M6x12 tightening torque (9, 38) = 10 Nm ; M6x18 tightening torque (10, 39) = 14 Nm ; M6x35 tightening torque (37) = 9.5 Nm. Put on new gaskets (7) and cover plate (8).

Insert and tighten retaining screw (3); M8x16 tightening torque = 45 Nm.

NOTE Before installing control unit, measure and install inductive sensor (refer to Chapter 8).

9

Insert solenoid valve cable and attach control unit by means of 2 cylindrical pins.

10

Screw in and tighten hex bolts (1, 2, 3 and 4); Tightening torque = 23 Nm.

WSK 400/440

Retarder

18

14

4

15

10

20

19

14 5

21 16

13 11

11

7

2

12

17

5 9

6

5

1 6

22 5

5 23

5 5 8

22

5 5a 5

3 5 5a

35

5 011925

12

Retarder Removal and disassembly

1

Loosen screws and hex bolts and remove with washers and/or spring washers; Hex bolts M8x 25 (1) M8x 35 (2) M8x 50 (3) M8x 80 (4) Cylindrical screws WSK 440: M12x115 (5) M12x110 (5a) WSK 400: M10x115 (5) M10x110 (5a) Hex nuts M8 (6) NOTE Hex bolts (1 and 2) and hex nuts (6) are located on input end of retarder housing.

2

Remove retarder housing (7) on output side and remove shaft seal (8).

3

Loosen temperature sensors (9 and 10) and remove with sealing ring.

4

Loosen hex bolts (11), take off connecting pieces (12 and 13) and remove O-rings (14).

CAUTION Connecting piece (16) is spring-loaded.

Loosen screws carefully.

5

Loosen hex bolts (15) with spring washers, carefully take off connecting piece (16) and gasket (17).

6

Remove piston (18) with grooved rings (19) and slide valve (20) with pressure spring (21) from bore.

7

Remove grooved rings (19) from piston.

8

Loosen union screws (22). Remove pressure line (23) with sealing rings.

9

If necessary, remove cylindrical pins (35).

12-1

Retarder

WSK 400/440

25 26

27

31 24

29

26 30

28

32

34

33 011926

10

Remove gasket (24).

11

Remove rotor (25). Remove piston rings (26) and washer (27) with pins (28).

12

Remove inner bearing race (29) from oil feed flange.

13

Loosen cylindrical screws (30) and take off with stator (31).

14

Loosen and remove hex bolts (32 and 33).

15

Remove retarder housing (34) at input side from converter housing.

12-2

WSK 400/440

Retarder

25 26

31

27

24

29

26 30

28

32

34

33 011927

Assembly and installation 1

Slightly grease input side of retarder housing (34) at oil feed flange and put on converter housing.

6

Insert piston rings (26) in rotor and place rotor in housing.

NOTE For ease of installation, screw in 2 guide pins (see arrows).

7

Fit new gasket (24).

2

Insert and tighten hex bolts (32 and 33) with spring washers ; Tightening torque = 23 Nm.

3

Place stator (31) in correct position in output side of retarder housing. Insert and tighten cylindrical screws (30) with washers ; Tightening torque = 23 Nm.

4

Put inner bearing race (29) on oil feed flange.

5

Fit washer (27) with clamping pins (28) on rotor (25).

12-3

Retarder

WSK 400/440

18

14

4

10

20

19 15

13 11 14

5

21 16

11

7

2

12

17

5 9

6

5

1 6

22 5

5 23

5 5 8

22

5 5 5a

3 5a 5

35 5 011925

8

Fit pressure line (23) with hollow screws (22) and new sealing rings to retarder housing at output side ; Tightening torque = 45 Nm.

9

Place grooved rings (19) on piston (18).

10

Insert spring (21), slide valve (20) and piston (18) in housing.

11

Secure new gasket (17) with connecting piece (16) at housing with hex bolts (15) and spring washers ; Tightening torque = 23 Nm.

12

13

Insert new greased O-rings (14) in connecting pieces (12 and 13) and secure to housing with hex bolts (11); Tightening torque = 23 Nm. Screw in and tighten temperature sensors (9 and 10) with new sealing rings ; Tightening torque = 30 Nm.

CAUTION Temperature sensor (9 – electronic unit) is marked in white;

12-4

Temperature sensor (10 – indicating device) is marked in black.

Never confuse them.

14

Drive shaft seal (8) into housing with adapter 1X56 112 761 until flush.

15

Align retarder housing (7) at output side with input side of retarder housing and place on top.

Drive cylinder pins (35) home.

16

Insert and tighten: Hex bolts :

Cylindrical screws WSK 440: WSK 400: Hex nuts :

M8x M8x M8x M8x

25 (1) 35 (2) 50 (3) 80 (4)

= = = =

23 Nm 23 Nm 23 Nm 23 Nm

M12x115 (5) = 100 Nm M10x115 (5) = 49 Nm M10x110 (5a)= 46 Nm M8 (6) = 23 Nm

NOTE In WSK 440, M12x110 2 cylindrical screws (5a) are tightened at tightening torque = 43Nm.

WSK 400/440 13

Converter housing

Converter housing

1

13.1 Oil feed flange Disassembly 1

Remove gasket (1).

2

Loosen cylindrical screws (2) and remove with spring washers.

3

5

6

Remove oil feed flange (3) from converter housing.

4

4

Remove piston ring (4) from oil feed flange.

5

Remove outer bearing race (5) from oil feed flange.

3

6

2 011928

Remove O-ring (6).

Assembly 1

Place greased O-ring (6) and piston ring (4) in oil feed flange (3).

! DANGER Wear gloves when handling hot components.

2

Heat oil feed flange to approx. 100 °C using hot air blower. Use adapter 1X56 112 761 to firmly press on outer bearing race (5).

3

Coat contact surface face of oil feed flange (3) with sealing compound WEVO L100 and insert, in correct position, in converter housing by means of 2 guide pins.

4

Insert and tighten cylindrical screws (2); Tightening torque = 46 Nm.

5

Fit new gasket (1) on converter housing.

13-1

Converter housing

WSK 400/440

13.2 Gear pump and wiring harness 7

Disassembly 9 1

Loosen hex bolts (1 and 2) and remove with spring washers.

8

5 1

2

Lift gear pump (3) out of converter housing.

NOTE Open pump and check parts for wear: If necessary, replace pump.

Tightening torque : Hex bolts M8 = 21 Nm, Cylindrical screw M6 = 9 Nm, Hex bolts M8 = 7 Nm.

2

6 4 3

011929

3

Remove O-ring (4) from pump.

4

Mark fixation point and then remove cable harness (5).

5

Loosen “n engine” inductive sensor (6) with remachined socket (SW 24, refer to sketch) and remove together with washer.

SW 24

¯ 18

0.5r

26

28.8 +0.1

011930

13-2

WSK 400/440

Converter housing

Assembly 1

7

Insert greased O-ring (4) in gear pump (3).

9

2

Insert gear pump into converter housing.

Insert hex bolts (1 and 2) with spring washers and tighten.

NOTE Coat sealing face suction channel (10) of gear pump with sealing compound WEVO L100 A. Always ensure that suction channel is left free.

Pull pump in direction of converter housing wall to attain sufficient tooth flank clearance. Tighten hex bolts; Tightening torque = 46 Nm.

10

8

5 1

2

6 4 3

011929

3

Install wiring harness (5) with new gaskets (7) and fix with pipe clamps; Tightening torque (8) = 46 Nm; Tightening torque (9) = 1.3 Nm. NOTE Insert cylindrical screws (9) with Loctite no. 241.

NOTE The measurement and installation of the “n engine� inductive sensor (6) are contained in Chapter 8.

13-3

Converter housing

WSK 400/440

13.3 Converter housing 4

Disassembly 1

If necessary, remove dowel pins (1) from converter housing.

2

Remove shaft seal (2) and washer (3) from converter housing.

3

Loosen ventilator (4), screw plugs (5, 6 and 7) and remove with sealing rings.

4

Remove O-ring (8) from converter housing.

8 6 1 3 2

5 7

Assembly 1

Insert greased O-ring (8).

2

Check ventilator (4) for through-flow, screw in and tighten; Tightening torque = 10 Nm. NOTE There is an optional connection for hose ventilation (4) in fordable versions.

3

Insert and tighten screw plugs (5, 6 and 7) with new sealing rings ; Tightening torque (5 und 6) = 50 Nm, Tightening torque (7) = 65 Nm.

4

Insert washer (3) in converter housing.

5

Use adapter 1X56 091 173 to press shaft seal (2) into converter housing until flush.

NOTE Sealing lip of shaft seal points towards output.

6

13-4

Screw in and tighten dowel pins (1) into converter housing ; WSK 440 M12x175 Tightening torque = 18 Nm, WSK 400 M10x175 Tightening torque = 14.5 Nm.

011931

WSK 400

Converter housing

1

2

1 2

1

1 2 2 1

1 2

2 1

1

2

2 1

1

3

1

3

1

2 013415

13.4 Screw connection M10 (WSK 400) Position

Designation

Tightening torque

1

Dowel pin M10x175

14.5 Nm

Hex nut M10

48 Nm

2

Cylindrical screw M10x115

48 Nm

3

Cylindrical screw M10x110

46 Nm

13-5

Converter housing

WSK 440

1

3

1 3 1 1 3 3 1 1 3 3 1

1

3

3 1

1

4

2

4

2

3 011932

13.5 Screw connection M12 (WSK 440 and WSK 400* as of 1999) Position

Designation

1

Dowel pin M12x175

18 Nm

Hex nut M12

90 Nm

Dowel pin M12x175

18 Nm

Hex nut M12

43 Nm

2

13-6

Tightening torque

3

Cylindrical screw M12x115

100 Nm

4

Cylindrical screw M12x110

43 Nm

* exception: “WSK NMV” version

WSK 400/440 14

Pressures and measuring points

Pressures and measuring points WSK 400 and WSK 440 PVR

14.1 Retarder PRA Retarder pretension pressure PVR Measuring point: temperature sensor at retarder output WSK 400 2.0 bar ± 0.5 / 600 rpm WSK 440 2.0 bar ± 0.5 / 600 rpm Retarder outlet pressure PRA Measuring point: PRA - pipe connection WSK 400 max. 4.5 bar ± 0.5 WSK 440 max. 4.5 bar ± 0.5

013479

14.2 Lock-up clutch Lock-up clutch closing pressure PWK Measuring point: PWK WSK 400 8.5 bar ± 0.5 WSK 440 10.5 bar ± 0.5 Converter back pressure PWA Measuring point: PWA WSK 400 3.7 to 4.3 bar WSK 440 5.5 to 6.0 bar PWA PWK

009517

14.3 NMV (only in WSK 400) Lubricating pressure (1) Measuring point: Plubr.

WSK 400 0.05 to 0.25 bar / 1500 rpm

(1) Plubr.

Shift pressure (2) Measuring point: Pshift WSK 400 10 to 11 bar / 1500 rpm

(2) Pshift 009514

14-1

After-Sales Service function test WSK system Protocol for test procedure

Tester:

Date:

Main parts list: 4130 . . . . . . . . . . . . . . . .

Product no.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converter no.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converter designation F + S: . . . . . . . . . . . . . . . . . . . . . .

1. Oil filling: Test oil: Renolin MR 10 Z / Shell S 7294

nin

nout

800

0

PWA (bar) Fill until overflow monitoring screw

Nominal 3.9 - 4.3 Actual: . . . . . .

2. Transmission function: t = approx. 40 °C Shifting and synchronizing in accordance with test instructions 1Q49 150 050, 053, 063 and 547 3. Sensor signals: nin: 1500 rpm, t = approx. 40 °C Engine: . . . . . . . VSS

Turbine: . . . . . . . VSS (min. 2 VSS)

4. Pressure and oil through-flow measurement: t = 80 °C

Number of teeth of toothed washer: . . . . . . . . teeth

Unit

nin rpm

PWA (bar)

PWK (bar)

Plubr. (bar)

NMV Pshift Plubr. (bar) (bar)

–

–

–

–

–

10±0.5 0.15±0.1

WSK

600

WSK

1 500

–

QK 1/min nominal

actual

min. 10 min. 45

5. Converter test: t = 80 °C nin: . . . . . . . rpm

nout: 0 rpm

Tin: . . . . . . . . . . . . Nm

6. WK test (filling time measurement): t = 80 °C Nominal: 1.0 – 3.5 sec.

Actual: . . . . . . . Sek.

7. Coasting free-wheel test: Findings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Retarder test: t = 80 °C nin: 600 rpm

PRet.: actual: . . . . . . . . . . . . bar

PVR: nominal = 2.0±0.2 bar

nout : nominal: 1 500 rpm

PVR: actual = . . . . . . . . . . . . bar

Tout : actual: . . . . . . . . . . . . Nm

9. Leak test: test instructions as for item 2 t = 80 – 100 °C Findings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean oil sieve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Miscellaneous: System pressures nominal: WSK 400 WSK 440 PWA = 3.7 – 4.3 bar 5.5 – 6.0 bar PWK = 8.0 – 9.0 bar 10.0 – 11.0 bar MKS-IQ MKS-IQ, 03/91 / Wesener (letzte Änderung: 98-07-27)

Test rig no.: 4130 754 104a