Instructions forrepairs
In case of doubt always turn to the relevant department within ZFAfter-Sales Services foradvice. All work on transmissions is to be performed expertly and underclean 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.
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.
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.
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.
REWORKING
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
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 layerin the measurement.
During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.
BEARINGS
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.
SEALING
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.
SHAFT SEALS
a)Apply a light coat of sealing agent* on outer edge of shaft seals with “steel surround”.
b) Neverapply 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).
d)Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards.
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.
TRANSMISSION OIL
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
Tightening torques
Tightening torques fornuts 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.
Regularscrew threadFine screw thread
SizeTightening torqueSizeTightening torque MA (Nm) forMA (Nm) for Bolt8.810.912.9Bolt8.8 10.912.9 Nut81012Nut81012 M 42.84.14.8M 8 x 1243643 M 55.58.19.5M 9 x 1365362 M 69.51416.5M 10 x 1527689
M 7152328M 10 x 1.25497284 M 8233440M 12 x 1.2587125150 M 10466879M 12 x 1.583122145
M 1279115135M 14 x 1.5135200235 M 14125185215M 16 x 1.5205300360
M 16195280330M 18 x 1.5310 440520
M 18280390460M 18 x 2290 420490 M 20 390560650M 20 x 1.5430620 720 M 22530750880M 22 x 1.5580820960
M 246709601100M 24 x 1.576011001250
M 27100014001650M 24 x 273010501200
M 30135019002250M 27 x 1.5110016001850
M 27 x 2105015001800 M 30 x 1.5155022002550 M 30 x 2150021002500
Edition: August 1991 / checked 1997
Screw plugs DIN 908, 910 and 7604
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 forthe 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.
Screw plugs (DIN 908, 910, 7604)
DimensionsTightening torque screwed into steel/gray castAl alloy
M 8 x 12010
M 10 x 125 / 30*15 / 20*
M 12 x 1.535 25
M 14 x 1.53525
M 16 x 1.54030
M 18 x 1.55035
M 20 x 1.555 45
M 22 x 1.560 / 80*50 / 65*
M 24 x 1.57060
M 26 x 1.580 / 105*70 / 90*
M 27 x 28070
M 30 x 1.5100 / 130*90 / 130*
M 30 x 29585
M 33 x 2120110
M 36 x 1.5130115
M 38 x 1.5140120
M 42 x 1.5150130
M 42 x 2145125
M 45 x 1.5160140
M 45 x 2150130
M 48 x 1.5170145
M 48 x 2160135
M 52 x 1.5180150
M 60 x 2195165
M 64 x 2205175
* DIN 7604 Form C
Union screws DIN 7643
Tightening torques
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 forthe 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)
PipeThreadTightening outertorqueMA diameterinNm 4-5M8x120-25
6M10x125-35
8M12x1.530-40
10M14x1.535-40
12M16x1.545
15M18x1.550
18M22x1.560
22M26x1.590
28M30x1.5130
35M38x1.5140
Status: October 1995
ConsumablesWSK
DescriptionNameApprox.ApplicationRemarks
ZF ref.noquantity
Jointing compound
0666 690 017Loctite no. 24130 mm3 M3x22 cyl. screw / wiring harnessChapter 13
Sealing compound
0666 790 017WEVO L 10020 gOil feed flangeChapter 13 Gear pumpChapter 13
Grease
0671 190 050Olista Longtime 3EB7 gSeparating clutchChapter 7
Grease
0671 195 016Molycote BR2 plus4 gRelease deviceChapter 7
GreaseFor example:
0750 199 001Aralub HL250 g- Split ring / converterChapter 8
5 g- Needle sleeve / turbine shaftChapter 9
2 g- Shaft seal / retarder housingChapter 12
2 g- Shaft seal / converter housingChapter 13
Graphite greaseConverter centring journalChapter 1
NOTE: Inquire about the size of bundles that can be delivered before placing any orders!
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DescriptionDimensionMeasurement deviceRemarks
01.Setting converter installation dimension
02.Distance of“n engine” inductive sensor
03.Axial play of tapered roller bearing
04.Tightening torque M12x1.5 at adapter ring / converter
05.Tightening torque of anti-fatigue bolt on converter
06.Tightening torque M3x22 on wiring harness
07.Tightening torque M10x16 on wiring harness
08.Tightening torque at inductive sensor / “n engine” converter
09.Tightening torque of M12x1.5 screw plug at control unit
Depth gauge
Adjust using appropriate adjusting disc and/or shim (7) at the oil feed flange
Depth gauge and 1P01
Adjust using appropriate washer
Depth gauge
Adjust using appropriate washer (6) on turbine shaft
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Use correct size of washer
Torque wrench
Use new sealing ring
Adjustment data
DescriptionDimensionMeasurement
10.Tightening torque
M6x40 at valve housing
11.Tightening torque
M5x12 at solenoid valve
12.Tightening torque
M6x18
M6x12 at cover / control unit
13.Tightening torque
M8x25, M8x35
M8x40, M8x60 at control unit housing
14.Tightening torque
M10x55 at pressure plate
15.Tightening torque
M10x16 at spacer plate
16.Tightening torque of
M24x1.5 screw plug on oil reservoir
17.Tightening torque
M10x60 at oil reservoir
18.Tightening torque
M8x28 at piping
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
DescriptionDimensionMeasurement
19.Tightening torque of hollow screw on retarder housing
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
21.Tightening torque
M8x35 on plug
22.Tightening torque
M8x22 on connecting piece
23.Tightening torque of temperature sensor
24.Tightening torque
Hex bolts
M8x25, M8x28
M8x35, M8x45
cylindrical screw
M8x22
dowel pin M8x25 nut M8 on retarder housing
Use new sealing rings
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)
Use new sealing ring
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Torque wrench
Adjustment data
DescriptionDimensionMeasurement
25.Tightening torque
M10x55 on gear pump
26.Tightening torque of vent/converter housing
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
30.Tightening torque of slotted nut in clutch housing
31.Tightening torque of inductive sensor/ “n turbine” connection plate
32.Temperature of outer bearing race/oil feed flange
Torque wrench
Torque wrench
Torque wrench
Use new sealing rings
Torque wrench
Torque wrench
Torque wrench
Use new locking plate
Torque wrench
Temperature probe
Use new o-ring/round. Distance is specified.
WSK 400/440
WSK 400/440
Adjustment data
DescriptionDimensionMeasurement deviceRemarks
33.Tightening torque of screw plug M39x2 on converter
34.Installation depth of WSK/engine
35.Thickness of diaphragms (engine/WSK)
36.Tightening torque of hex bolt on converter housing/ flywheel housing
37.Tightening torque ofM12x1.5 hex bolt on flywheel/ converter
38.Tightening torque ofM10x45 cylindrical screw on converter cover
39.Tightening torque ofM8x35 cylindrical screw on piston
40.Tightening torque ofM8x18 cylindrical screw on pump
41.Disc clearance or piston clearance in converter cover
Torque wrench
Depth gauge
Only for WSK 400, depending on version. Use new sealing ring.
Shim (2 diaphragms) (1 diaphragm)
Torque wrench
Torque wrench
Torque wrench
WSK converter 440
Torque wrench
WSK converter 440
Torque wrench
WSK converter 440
Feeler gauge
WSK converter 440
Adjustment data
DescriptionDimensionMeasurement deviceRemarks
WSK 400/440
42.Converter monitoring depth 149.8 -0.2 mm Depth gauge WSK converter 400 Adjust using appropriate adjusting disc.
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of converter with attached torque converter clutch)
1X56 138 224
Adapter for angular ball bearing with gripper 1X56 138 107
1X56 139 137
Assembly fixture for complete Transmatic 1
440
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1WSK/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.
1Use 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.
2Fit 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.
3Move 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.
Monitoring measurement for engine connection
NOTE
Take the following measurement to determine whether the diaphragms (8) have possibly been bent.
1Use 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.
2On 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.
3Measure 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)
4Dimension “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).
5The face runout “TS” on the flywheel housing must not exceed 0.2 mm.
