4149 751 606a · 2002-09-24 · Tightening torques W 390 MS torque converter 4149 751 606a 8...

W 390 MS torque converter

4149 751 606a

REPAIR MANUAL

Subject to technical changes

Copyright by ZF

This documentation is protected by copyright. Any reproduction and dissemination in whatever form –also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronicreproduction or as a storage in data-processing equipmentor data networks without approval by the holder of thecopyright is prohibited and will be prosecuted under civiland criminal law.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2002-06

Edition: 2002-06

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Page

Preface ................................................................................................................................................................ 4

Important information ........................................................................................................................................... 5

Instructions for repairs .......................................................................................................................................... 6

Tightening torques................................................................................................................................................. 8

Consumables ......................................................................................................................................................... 10

Adjustment data..................................................................................................................................................... 11

Cross-section ......................................................................................................................................................... 12

Special tools ......................................................................................................................................................... 13

1 Removing and installing torque converter .................................................................................................. 1-1

1.1 Removing torque converter ......................................................................................................................... 1-1

1.2 Installing torque converter .......................................................................................................................... 1-5

1.2.1 Measuring torque converter end float ......................................................................................................... 1-5

1.2.2 Measuring torque converter installation dimension .................................................................................... 1-9

2 Dismantling and assembling torque converter ............................................................................................ 2-1

2.1 Dismantling torque converter ..................................................................................................................... 2-1

2.1.1 Dismantling stator....................................................................................................................................... 2-3

2.1.2 Assembling stator........................................................................................................................................ 2-5

2.1.3 Dismantling circuit cover ............................................................................................................................ 2-7

2.1.4 Assembling circuit cover............................................................................................................................. 2-9

2.1.5 Measuring end float of axial bearing (take measurement for checking purposes) ...................................... 2-13

2.2 Assembling torque converter ...................................................................................................................... 2-15

3 Checking torque converter for seal integrity .............................................................................................. 3-1

Table of contentsW 390 MS torque converter

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ZF FRIEDRICHSHAFEN AGCommercial Vehicle /Special Transmissions DivisionService Plant 2Tel.: 00 49 / 75 41 77-0Fax: 00 49 / 75 41 77-5726Internet: www.zf.com

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

This manual deals with the standard ZF product inaccordance with the state of development on the dateof issue.

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

We recommend that work done on your ZF product iscarried out only by skilled mechanics who have hadtheir practical and theoretical knowledge updated on aregular basis at our After-Sales Service training centers.

Service points equipped by ZF Friedrichshafen AG allover 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 outconscientiously and with utmost care.

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

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional mannerand any consequential costs are excluded from the con-tractual liability agreement. Exclusion of liability alsoapplies if genuine ZF spares are not used.

PrefaceW 390 MS torque converter

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SAFETY NOTICE

Companies repairing ZF units are responsible for theirown work safety.

To avoid injury to personnel and damage to pro-ducts, all safety regulations and legal requirementswhich apply to repair and maintenance work mustbe adhered to.Before starting work, mechanics must familiarizethemselves with these regulations.

Personnel required to carry out repairs on ZF productsmust receive appropriate training in advance. It is theresponsibility of each company to ensure that theirrepair staff is properly trained.

The following safety instructions appear in this manual:

NOTERefers to special processes, techniques, data, use ofauxiliary equipment, etc.

CAUTIONThis is used when incorrect, unprofessional workingpractices could damage the product.

DANGERThis is used when lack of care could lead to personal injury or death.

GENERAL INFORMATION

Read this manual carefully before starting any tests orrepair work.

CAUTIONPictures, drawings and components do not alwaysrepresent the original object, but are used to illustrateworking procedures.Pictures, drawings and components are not to scale.Conclusions about size and weight should not bedrawn (even within a complete illustration).Always follow the working steps as described in thetext.

After completion of repair work and testing, skilled staffmust satisfy themselves that the product is functioningcorrectly.

THREATS TO THE ENVIRONMENT !Lubricants and cleaning agents must not be allowedto 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 withenvironmental protection guidelines.

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

CAUTIONThe transmission must NOT be hung by the inputshaft NOR by the output flange.

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In case of doubt always turn to the relevant depart-ment within ZF After-Sales Services for advice.All work on transmissions is to be performed expertlyand under clean conditions.Use specified tools to dismantle and assemble trans-missions.

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent beforeopening.Pay particular attention to the projections and recessesof 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. Care-fully remove burrs or similar patches of roughness usingan oil-stone.

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

Carefully cover opened transmissions to prevent foreignmatter from entering.

REUSING PARTS

Parts such as ball or roller bearings, multi-discs, thrustwashers 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 fromexcessive wear.

GASKETS, LOCKING PLATES

Parts which cannot be removed without being damagedmust always be replaced with new parts (e.g. gasketsand locking plates).

SHAFT SEALS

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

REWORKING

Rework may be carried out on seal contact surfacesusing plunge-cut grinding only, never use an emerycloth. 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 reworkedareas contain no face runout and have the same surfacequality.

TRANSMISSION ASSEMBLY

Find a clean site to assemble the transmission. Gasketsare installed without the use of sealing compound orgrease. When measuring silicon-coated gaskets, takecare not to include the silicon layer in the measure-ment.During assembly, comply with all adjustment data,checking data and tightening torques in the Repair Manual.

Instructions for repairsW 390 MS torque converter

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BEARINGS

If bearings are mounted in heated condition, they are tobe heated evenly (e.g. heating cabinet).Temperature should be at approx. 85 °C and must notexceed 120 °C. Each mounted bearing must be oiledwith 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 andspread evenly. Do not allow sealing to enter oil ductsand bores. On oil-carrying ducts and bores, wipe off thesealing agent on the surfaces to be sealed near aperturesto ensure that no sealing agent enters the oil feeds whenthe surfaces are sealed.

SHAFT SEALS

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

b) Never apply sealing agent to shaft seals with “rubber surround”, but apply a thin coat of Vaseline8420 to the outer edge or wet with a lubricant, e.g. awater-soluble, concentrated washing-up liquid (e.g.Pril, Coin, Palmolive).

c) Shaft seals with steel and rubber surrounds should betreated on the outer edge of the rubber surround asdescribed above in section b).

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

e) Fill the gap between the sealinglips so it is 60 % filled with grease (e.g. produced by Aral such as Aralub HL2 or by DEA such asSpectron FO 20).

f) If possible, heat shaft seal bores to between 40 and50 °C (makes fitting easier). Press the seal shaft withmounting or faceplate onto the relevant installationdepth plan.

RETAINING AGENTS

Retaining agents* may only be used in places as specified in the parts list.Always comply with manufacturer’s directions for usewhen 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 trans-mission oil. For the procedure and approved oils, referto the transmission operating manual and List of Lubri-cants TE-ML (refer to identification plate) which areavailable from any ZF After-Sales Service Point and onthe internet under www.zf.com. After filling the transmission with oil, tighten the screwplugs at the oil filling point and the oil overflow to thespecified torques.

* refer to expendable material

X

Instructions for repairsW 390 MS torque converter

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Tightening torquesW 390 MS torque converter

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Tightening torques for nuts and bolts, extract fromZFN 148

This standard applies to bolts acc. to DIN 912, DIN 931,DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO4014, ISO 4017, ISO 8765, ISO 8676, and to nuts acc. toDIN 934 as well as ISO 4032, ISO 8673.

This Standard contains data on tightening torques (MA)for bolts and nuts in strength categories 8.8, 10.9 and12.9, and nuts in strength categories 8, 10 and 12.

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

Tighten screws with a calibrated torque spanner orwrench.

NOTEIrregular tightening torques are listed separately in theRepair Manual.

Edition: August 1991/ checked 1997

Regular screw thread Fine screw thread

Size Tightening torque Size Tightening torque(Nm) for (Nm) for

Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9Nut 8 10 12 Nut 8 10 12

M4 2.8 4.1 4.8 M8x1 24 36 43M5 5.5 8.1 9.5 M9x1 36 53 62M6 9.5 14 16.5 M10x1 52 76 89

M7 15 23 28 M10x1.25 49 72 84M8 23 34 40 M12x1.25 87 125 150M10 46 68 79 M12x1.5 83 120 145

M12 79 115 135 M14x1.5 135 200 235M14 125 185 215 M16x1.5 205 300 360M16 195 280 330 M18x1.5 310 440 520

M18 280 390 460 M18x2 290 420 490M20 390 560 650 M20x1.5 430 620 720M22 530 750 880 M22x1.5 580 820 960

M24 670 960 1100 M24x1.5 760 1100 1250M27 1000 1400 1650 M24x2 730 1050 1200M30 1350 1900 2250 M27x1.5 1100 1600 1850

M27x2 1050 1500 1800M30x1.5 1550 2200 2550M30x2 1500 2100 2500

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Screw plugs DIN 908, 910 and 7604

The screw plug tightening torques MA were determinedaccording to DIN 7604 for screwing into steel, grey castand 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 analo-gously 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 manu-factured (without surface protection) andlightly oiled or galvanized, chromated andlightly oiled.

Union screws DIN 7643

The tightening torques MA were determined for screwing into steel, grey cast and aluminum alloys.The values are based on experience and are intendedas reference values for the fitter.General rule: screw/bolt class 5, ZFN 148-1

Material: 9SMnPb28K acc. to DIN 1651Surface condition: as manufactured(without surface protection) and lightlyoiled or galvanized, chromated and lightly oiled.

Screw plugs (DIN 908, 910, 7604)

Dimensions Tightening torquein Nm screwed into

steel/gray cast Al alloy

M8x1 20* 10*M10x 1 25 / 30* 15 / 20*M12x1.5 35 25M14x1.5 35 25M16x1.5 40 30M18x1.5 50 35M20x1.5 55 45M22x1.5 60 / 80* 50 / 65*M24x1.5 70 60M26x1.5 80 / 105* 70 / 90*M27x2 80 70M30x1.5 100 / 130* 90 / 130*M30x2 95 85M33x2 120 110M36x1.5 130 115M38x1.5 140 120M42x1.5 150 130M42x2 145 125M45x1.5 160 140M45x2 150 130M48x1.5 170 145M48x2 160 135M52x1.5 180 150M60x2 195 165M64x2 205 175

* DIN 7604 Form C

Union screws (DIN 7643)

Pipe Thread Tighteningouter torque

diameter in Nm

4 - 5 M8x1 20 - 25

6 M10x1 25 - 35

8 M12x1.5 30 - 40

10 M14x1.5 35 - 40

12 M16x1.5 45

15 M18x1.5 50

18 M22x1.5 60

22 M26x1.5 90

28 M30x1.5 130

35 M38x1.5 140

Edition: October 1995

Description Name Approx. Application CommentsZF item number quantity

Grease For example General assembly aid0750 199 001 Spectron FO 20

Grease Techn. Vaseline 8420 General assembly aid0671 190 016

NOTE: Inquire as to size of containers before placing any orders.

ConsumablesW 390 MS torque converter

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Description Dimension Measurement device Comments

Depth gauge

Depth gauge

Feeler gauge

GO gauge and depthgauge

Forcing device 1X56 137 129,pneumatic unit 1X56 137 130 andwater tank

Torque wrench

Torque wrench andretaining fixture 1X56 137 158

Torque wrench

Torque wrench

01. Torque converter installation dimension (depending on version)

02. Torque converter end float between face end of converter internal sprang race and spacerring on stator hollow shaft

03. Clutch disc clearance of torque converter lock-up clutch

04. End float of axial bearingin torque converter

05. Maximum pressure fortesting seal integrity oftorque converter

06. Tightening torque of 36 hex bolts (M10x22) on torque converter

07. Tightening torque of M16 cylindrical screw inturbine shaft

08. Tightening torque of M 33x2 screw plug intorque converter

09. Tightening torque of 24cylindrical screws(M10x30) on circuit cover

81.25 ± 0.5 mm

0.3 to 0.4 mm

0.6 to 1.2 mm

0 to 1.1 mm

2.5 +0.5 bar

65 Nm

180 to 190 Nm

190 to 210 Nm

69 Nm

Installation dimension measured from mountingface on torque converter tomounting face on trans-mission housing. Installation dimension canbe adjusted using one ormore spacer rings on the stator hollow shaft.

End float can be adjustedusing shim on face end ofturbine shaft.

OTK 0730 005 591

Clutch disc clearance is measured between end discand inner clutch disc

Only take check measurement

Torque converter test is carried out under waterusing air

Use counter holder 1X56 137 658 to lock torque converter

Fit new Cu seal. Use counterholder 1X56 137 658 to locktorque converter in place

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Adjustment dataW 390 MS torque converter

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Cross-sectionW 390 MStorque converter

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1 M10x20 (SW 16) hex bolt with shim

2 Compression spring with shim

3 Roller

4 Impeller

5 Stator

6 Thrust disc

7 Axial roller bearing

8 Thrust disc

9 Internal sprag race

10 Ball bearing

11 Thrust disc

12 Rollers

13 Thrust disc

14 Ball bearing

15 End shim

16 M10x30 cylindrical screws

17 O-ring

18 Inner clutch disc

19 Outer clutch disc

20 Inner clutch disc

21 Outer clutch disc

22 Plate piston

23 Inner piston ring, plate piston

24 Ball bearing

25 Thrust disc

26 Axial needle cage

27 Housing disc

28 Turbine wheel

29 Outer piston ring, plate piston

30 Cup spring

31 Circuit cover

018009

1 2 3 4 6 7 8 9 10 12 15 1611 13 14 17

31 30 29 28 27 26 25 23 22 21 20 19 1824

5

Fig. Special tools Order no. Application Qty. Commentsno.

1X56 137 213

Lifting devicefor turbine shaft

1

1

1X56 136 862

Lifting devicefor torque converter

1

2

1X56 137 152

Supportfor stator bearing

1

3

1X56 137 658

Counter holderfor unfastening and tightening screwplug in torque converter

1

4

1X56 137 158

Retaining fixturefor unfastening and tightening M16cylindrical screw in torque converter

1

5

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Special toolsW 390 MS torque converter

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Fig. Special tools Order no. Application Qty. Commentsno.

1X56 137 130

Pneumatic unitfor seal integrity test of torque con-verter and clutch carrier, used in con-junction with feed bush 1X56 137128 and forcing device1X56 137 129

1

6

1X56 137 129

Forcing devicefor torque converter seal integrity test

1

7

1P46 173 831

Feeler gaugefor measuring the clutch disc clear-ance

1

8

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Special toolsW 390 MS torque converter

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1. Removing and installing torque converter

1.1 Removing torque converter

1 Rotate the transmission in the swivel stand sothat the torque converter is facing upwards.

2 Attach counter holder 1X56 137 658 (1) totorque converter and transmission housing andscrew in.

3 Unscrew screw plug (2).

4 Screw retaining fixture 1X56 137 158 (3) intotorque converter circuit cover and tighten byhand.

NOTEMake sure rubber washer is fitted onto retaining device thread.

NOTEIn addition to the pneumatic retaining device,ZF can also use a mechanical retaining device1X56 136 864 in conjunction with the hexinsert 1X56 136 863.

5 Connect pneumatic unit 1X56 137 130 ontoretaining fixture 1X56 137 158.

6 Turn the regulator (1) anti-clockwise a fewtimes.

7 Open stopcock (2). The lever must be horizontal.

8 Use the regulator (1) to set a pressure level of1.5 bar.

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9 Insert 1/2” socket wrench extension (1) andunfasten cylindrical screw.

NOTEUse a suitably long grip. The M16 cylindricalscrew is tightened to 190 Nm in the turbineshaft.

10 Close stopcock.

11 Unscrew retaining fixture 1X56 137 158 (2)from torque converter circuit cover.

12 Unscrew cylindrical screw (1) and take outtorque converter.

13 Screw lifting device 1X56 136 862 (1) intotorque converter and tighten by hand.

14 Remove counter holder 1X56 137 658.

15 Carefully take torque converter out of trans-mission.

NOTEBefore lifting out the torque converter completely, raise it to just above the turbineshaft. Then tilt the torque converter slightly sothat the oil can drain out.

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16 Unscrew lifting device.

17 Turn the torque converter over and remove theshim(s) (1) from the torque converter or turbineshaft.

DANGERTorque converter weighs approx. 50 kg. Beforeremoving the lifting device, secure the torque con-verter to prevent it from rolling away.

18 Remove spacer ring (2) from stator hollowshaft.

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1.2 Installing torque converter

1.2.1 Measuring torque converter end float

1 Screw lifting device 1X56 136 862 (1) intotorque converter so that the torque converter turbine wheel is clamped tight.

2 Turn torque converter over.

DANGERTorque converter weighs approx. 50 kg. Securetorque converter to prevent it from rolling away.

3 Measure the distance "C" between the face endof the spur gear and the turbine wheel.

4 Note down distance "C".

5 Measure the distance "B" between the face endof the spur gear and the face end of the internalsprag race.

6 Note down distance "B".

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7 Calculate the theoretical distance "D" betweenthe face end of the internal sprag race and theplane face of the shim as follows.

C – B = DNote down distance "D".

8 Check rectangular ring (1) for damage. Replaceif necessary.

9 Align rectangular ring centrally.

NOTERectangular ring has hooked ends.

10 Slide spacer ring (2) onto stator hollow shaft sothat there is no end float.

11 Screw lifting device 1X56 137 213 into turbineshaft.

12 Tighten lifting device by hand until there is noend float on the turbine shaft.

13 Place depth gauge in recess of lifting device onend face of turbine shaft.

14 Measure distance "A" between face end of turbine shaft and spacer ring (1) on stator hollow shaft.

15 Note down distance "A".

16 Unscrew lifting device from turbine shaft.

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17 Calculate thickness "S" of shim (1).D – A = EDistance "E" plus the specified torque converter end float (distance "G")(* 0.3 to 0.4 mm) gives the required thickness "S" of the shim (1) to be fitted.E + 0.3 to 0.4 mm = S

Calculation example:

C = 174.7 mm D = 119.50 mm– B = 55.2 mm – A = 118.30 mm

D = 119.5 mm E = 1.20 mm* + G = 0.35 mm

S = 1.55 mm

CAUTIONDistance "G" must be added and not subtractedotherwise the bearings will be damaged.

Shims (OTK) 0730 005 591 are available inthicknesses ranging from 2.6 mm to 1.0 mm, in 0.1 to 0.3 mm steps.

NOTEThicker shims mean greater end float.

18 Thinly coat shim (1) with grease and affix.

19 Centre the shim.

20 Centre rectangular ring (2).

21 Thinly coat race of seal (arrow) with oil.

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22 Screw lifting fixture 1X56 136 862 into torqueconverter.

23 Carefully lower torque converter so that it iscentred on the turbine shaft. Fit the torque converter so that there is no end float.

24 Loosen lifting device 1X56 136 862 byunscrewing a few turns.

CAUTIONTake care not to damage the seal. Ensure the shimis correctly positioned on the turbine shaft.

NOTEThe turbine shaft and stator hollow shaft splinesmust mesh inside the torque converter. Rotatethe torque converter slightly if necessary. Thegear on the torque converter must also meshwith the input gear of the primary shaft.

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1.2.2 Measuring torque converter installationdimension

1 Make sure the torque converter is fitted correctly and without any end float.

2 Measure installation distance "F" betweentorque converter mounting face and transmission mounting face.

3 Measure the distance at several points aroundthe circumference and calculate the averagevalue.

NOTEInstallation dimension "F" must be X ± 0.5 mm.Ecomat transmissions can be equipped with dif-ferent types of torque converter. Distance "F"(torque converter installation dimension) mustbe one of the following installation dimensions, depending on torque converter version.

Distance "F" = 81.25 mm

If installation dimension "F" is between X + 0.5mm and X – 0.5 mm, then the setting is correct.

4 If the installation dimension is less than X – 0.5 mm, fit a second spacer ring on the stator hollow shaft.

5 If the distance is more than X + 0.5 mm,remove the spacer ring.

NOTEThe spacer ring is 1 mm thick.

CAUTIONIf the distance "F" is changed by adding/removinga spacer ring on the stator hollow shaft, the shimon the turbine shaft must also be changed accord-ingly. Otherwise the bearings will be damaged.

6 Unscrew lifting device 1X56 136 862 fromtorque converter.

7 Screw M16 cylindrical screw (1) into turbineshaft.

8 Re-check the installation dimension.

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9 Attach counter holder 1X56 137 658 to trans-mission housing and bolt it to torque converter.

10 Screw retaining fixture 1X56 137 158 intotorque converter circuit cover and tighten byhand.

NOTEEnsure rubber washer is fitted onto retaining device thread.

11 Connect pneumatic unit 1X56 137 130 ontoretaining fixture 1X56 137 158.

12 Turn regulator (1) anti-clockwise a few times.

13 Open stopcock. Move the lever (2) into horizontal position.

14 Use regulator (1) to set a pressure level of 1.5bar.

15 Insert 1/2" socket range extension and tightenhexagon socket head screw;tightening torque: 180 - 190 Nm

16 Close stopcock.

17 Remove retaining fixture 1X56 137 158 (3)from torque converter circuit cover.

18 Fit new copper seal on screw plug (1).

19 Tighten M33x2 screw plug;tightening torque: 190 - 210 Nm

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2 Dismantling and assembling torque converter

2.1 Dismantling torque converter

1 Place torque converter on planks so thatimpeller faces upwards.

2 Unscrew all M10x22 (SW 16) hex bolts andwashers (1) leaving only one hex bolt on eachopposite side.

3 Turn torque converter over so that impellerfaces downwards or circuit cover facesupwards.

4 Remove two remaining hex bolts on oppositesides.

5 Attach hoisting rope to lifting device 1X56 136 862 (2) and lift circuit cover (3) offimpeller using hoist.

DANGERTurbine wheel may remain in circuit cover and fallout. Therefore, only lift the circuit cover as high asnecessary and immediately lay it down close by.

6 Take off turbine wheel (1).

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7 Take housing disc (1), axial needle cage (2) andthrust disc (3) off stator (4).

CAUTIONDo not mix the bearing assemblies when installing.The thrust and housing discs must not be mixed upwith any other bearing modules. Clearly mark allparts.

8 Take stator (4) out of impeller (5).

9 Take out thrust disc (6), roller bearing (7) andthrust disc (8).

CAUTIONThe thrust and housing discs must not be mixed upwith any other bearing modules. Clearly mark allparts.

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2.1.1 Dismantling stator

1 Place stator (1) on support with collar (2)facing downwards.

2 Place suitable pressure piece (1) on internalsprag race.

3 Press internal sprag race out of stator.

4 Remove roller (1) from internal sprag race (2).

5 Take off thrust disc (3) from internal sprag race.

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6 Press internal sprag race (1) out of ball bearing(2).

DANGERDo not clean bearings using compressed air.Bearing races could come loose and damage thebearing due to lack of lubrication.

7 Place stator (1) on press using suitable support(2).

8 Use suitable pressure piece (3) to press ballbearing out of stator.

CAUTIONThe diameter of the pressure piece must match theoutside diameter of the bearing.

9 Remove ball bearing (1) and thrust disc (2)from stator.

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2.1.2 Assembling stator

1 Insert stator on suitable support in press withcollar (2) facing upwards.

2 Insert thrust disc in stator.

3 Use special tool 1X56 137 152 (1) to press ballbearing (3) in as far as it will go.

4 Insert support 1X56 137 152 (3) into press withhollow facing upwards.

5 Turn stator over (collar (2) facing upwards) andplace on support 1X56 137 152.

6 Insert internal sprag race (1) into stator with thelonger collar facing downwards and press in.

NOTEUsing support 1X56 137 152 ensures that theinternal sprag race is fitted in the correct position.

7 Insert rollers (1) in stator.

NOTEAfter insertion, moderately oil the rollers androtate the stator several times.

8 Insert thrust disc (2) in stator.

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9 Insert support 1X56 137 152 in press and placestator on support complete with ball bearing.

10 Place second support 1X56 137 152 (1) on ballbearing (2).

11 Press ball bearing into stator until firmly home.

NOTEEnsure that the hollows on both supports 1X56 137 152 are facing the stator. Using thesupports ensures that the bearing is fitted in thecorrect position.

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2.1.3 Dismantling circuit cover

1 Unscrew 24 M10 cylindrical screws (1) fromcircuit cover.

2 Remove O-ring (2).

3 Remove end disc (3).

4 Remove inner and outer clutch discs (4) fromcircuit cover.

NOTECompression springs with discs (5) can befound on the last outer clutch disc.

5 Remove compression springs, discs (5) and lastouter clutch disc.

6 Take out twelve rollers (6).

7 Take out cup spring (1).

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8 Force the ball bearing (1) off the turbine wheelusing two assembly levers.

9 Gently strike circuit cover with plastic hammer to remove plate piston (2).

10 Use appropriate tool (0.5 - 0.75 mm thickness)to grasp inner rectangular ring (2) and carefullytake out plate piston.

DANGERGrooved edge of plate piston may have sharp edges.Wear protective gloves.

11 At the same time slide both sides of outer rec-tangular ring (1) in direction indicated byarrows. Grasp protruding part of rectangularring and take out of annular groove.

!

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2.1.4 Assembling circuit cover

NOTEThoroughly clean all components and dry usingcompressed air. Only use lint-free cloths towipe off the rectangular rings.

1 Check rectangular rings for damage and replaceif necessary.

2 Coat inner rectangular ring (2) and outer rectan-gular ring (1) with Vaseline and insert them intothe plate piston.

NOTEStretch the inner rectangular ring a little beforeinstalling so that it sits firmly in the base ofgroove.

3 If removed, use plastic hammer to drive in ballbearing (5).

CAUTIONInsert plate piston (3) in circuit cover without tilt-ing it. Ensure that the rectangular rings are firmlyseated in the base of the groove all the way around.

4 Tap around the edge of the plate piston with aplastic hammer. Make sure that the plate pistonis correctly positioned.

5 Place cup spring (4) onto plate piston with camber facing downwards.

6 Insert twelve rollers (6) into holes around theedge.

7 Use a straight edge to check that the outer andinner clutch discs are flat and not distorted orperform a visual check. Check the discs againstthe end disc or a flat surface.

CAUTIONReplace any discs that are dished or corrugated.Maximum permitted wear is 0.3 mm. Replace lineddiscs that have damaged or blackened linings.Replace inner clutch discs that have damaged toothflanks. Maximum permitted wear per tooth flankis 0.2 mm.

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8 Insert first outer clutch disc (1) so that the holesslide over the rollers.

9 Place four discs and four springs (2) over therollers and onto the outer clutch disc at 90°intervals.

10 Insert first inner clutch disc (3).

11 Insert second outer clutch disc (4) offset at anangle to the first outer clutch disc.

12 Insert second inner clutch disc (5) in circuitcover.

NOTEInsert outer clutch disc (4) so that the toothspaces for the springs (arrow) and bores areabove the remaining rollers. Outer clutch disc(4) must not rest on the springs.

13 Insert two M10 threaded pins (1) at angle.

14 Line up the holes on the end disc (2) with theholes in the circuit cover. Fit end disc overthreaded pins and onto springs in circuit cover.

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15 Screw in 24 M10x30 cylindrical screws (1).Tightening torque: 69 Nm

NOTEBefore tightening the hex bolts, tap the platepiston fully home with a plastic hammer.

16 Use a feeler gauge (2) to measure the playbetween the last inner clutch disc and the enddisc (3) and note down as distance "A".

17 Disc play (distance "A") must be between 0.6 mm and 1.2 mm.

NOTEIf the disc play is less than 0.6 mm or more than1.2 mm, fit new outer clutch discs as necessary.Then re-measure distance "A".

18 Turn over turbine wheel and drive spacer disc(1) into turbine wheel as far as it will go (if pre-viously removed).

19 Strike spacer disc at four points around the edgeto secure it.

NOTEInstall spacer disc with holes facing upwards.

20 Insert rectangular ring (2) in annular grooveand hook in the open ends of the ring.

DANGERRectangular ring has sharp edges.Wear protectivegloves.

!

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21 Align inner clutch discs. The discs must covereach other.

22 Insert turbine wheel (1) in circuit cover.

CAUTIONEnsure that the teeth on the turbine wheel mesh inthe gaps on the inner clutch discs. Rotate the tur-bine wheel back and forth until it engages. Ensurethat the turbine wheel is fully engaged and insertedas far as it will go. If necessary, tap edges of innerteeth with plastic hammer. Take care not to damageinner clutch discs.

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2.1.5 Measuring axial bearing end float.Take measurement as check

NOTEProduction tolerances give the specified axialplay. There are no provisions for adjusting theaxial play using shims. Measuring is for check-ing purposes only.

1 Insert the axial disc (3) in the impeller (4).

2 Insert the axial roller bearing (2).

3 Insert the axial disc (1).

4 Insert the stator (5) in the impeller with thelonger collar of the freewheel inner ring facingdownwards.

5 Fit the axial disc (3) on the shorter collar of thefreewheel inner ring (4) on the stator.

6 Fit the axial needle cage (2).

7 Fit the housing disc (1).

8 Place the measuring plates (3) on the matingface of the impeller.

9 Fit the measuring strip (2).

10 Place the depth gauge on the measuring stripand measure the distance "A" between the mea-suring strip and the impeller mating face (1).Note down distance "A".

NOTEThe measuring strip must not lie on the stator.

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11 Move the depth gauge to the middle.

12 Measure the distance "B" between the measur-ing strip and the front face of the housing disc(1).

13 Note down distance "B" and subtract distance"A" from it.

B - A = Distance "C"

14 Mount the measuring setup on the circuit covermating face.

NOTEDo not insert an O-ring in the circuit cover forthe purpose of measuring.

15 Use the depth gauge to determine the distance"D" between the measuring strip and the matingface of the circuit cover (1).

16 Note down distance "D".

17 Determine the distance "E" between the mea-suring strip and the point of contact with theshim (2).

18 Note down distance "E" and subtract it fromdistance "D".

D - E = Distance "F"

Subtract distance "F" from distance "C".

C - F = Distance "G"

Distance "G" = axial play of the axial bearing

Specified axial play of the axial bearing = 0.0 to 1.1 mm

NOTEDistance "G" must be within the specified axialplay of 0.0 to 1.1 mm.

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2.2 Assembling torque converter

1 Insert housing disc (1) in the turbine wheel withchamfered side facing turbine wheel.

2 Insert axial needle cage (2) and thrust disc (3)in turbine wheel.

3 Insert stator (1) in turbine wheel with short collar of internal sprag race facing the turbinewheel.

NOTECoat all bearings with oil before installation.

4 Place thrust disc (2) on long collar of internal sprag race with chamfered side facingstator.

5 Fit roller bearing (3).

6 Fit thrust disc (4).

7 Insert O-ring (2).

8 Screw two M10 threaded pins (1) opposite oneanother in circuit cover flange.

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9 Place impeller (1) on circuit cover.

10 Screw in two of the M10x22 hex bolts(SW 16) with washers.

11 Unscrew M10 threaded pins (2).

12 Screw in remaining M10x22 hex bolts.

13 Tighten M10x22 hex bolts (SW16),Tightening torque: 65 Nm

14 Check end float of internal sprag race (1).

15 Use both hands to grasp inside of internal spragrace and move in axial direction. End float mustbe palpable.

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3 Checking seal integrity of torque converter

1 Insert forcing device 1X56 137 129 (1) intotorque converter at spur gear end.

2 Screw lock nut (2) onto forcing device.

DANGERTorque converter weighs approx. 50 kg.

3 Lower torque converter into basin using lifting gear so that forcing device is underwater.

4 Connect pneumatic unit 1X56 137 130 to forcing device.

CAUTIONThe water in the basin must contain 1 partantifreeze to 120 parts water.Water temperature = 20°C.

!

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5 Turn regulator (1) anti-clockwise

6 Open stopcock (2).

7 Use regulator (1) to set a pressure level of 2.5 bar.

CAUTIONTorque converter must be absolutely leak-tight.

8 Close pneumatic device 1X56 137 130 andremove from forcing device 1X56 137 129.

9 Lift torque converter out of basin using lifting gear and lay to one side on work surface.

10 Detach torque converter from lifting gear andturn over.

11 Unscrew lock nut (1).

12 Place torque converter on circuit cover andremove forcing device 1X56 137 129 (2) fromtorque converter.

NOTEDry torque converter using compressed air.Lightly coat spur gear with oil.

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4149 751 606a · 2002-09-24 · Tightening torques W 390 MS torque converter 4149 751 606a 8...

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Transcript of 4149 751 606a · 2002-09-24 · Tightening torques W 390 MS torque converter 4149 751 606a 8...