GROUP 4 DISASSEMBLY AND ASSEMBLY

1. TRANSMISSION
1) DISASSEMBLY
Solenoid valves, inductive sensor, screw
plugs and nozzles (orifices)
(1) Loosen cylindrical screws, remove bracket
and pull solenoid valves off the holes.
※ Mark solenoid valves (different versions).
1 = Y1 (control valve)
2 = YPB (parking brake - rear axle)
3 = YDL (differential lock - rear axle)
4 = Y3 (control valve)
5 = Y2 (control valve)
6 = Y5 (control valve)
7 = Y4 (control valve)
8 = Y6 (control valve)
9 = YWD (front wheel drive)

HB108TM007

※ Version with inductive sensor (option).

(2) Loosen inductive sensor (1).
※ Remove O-ring.

HB108TM008

(3) Pull output flange (1) off the output shaft.

※ Remove all screw plugs and nozzles
(orifices).

HB108TM009

3-25
2) DISASSEMBLY OF ENGINE CONNECTION, MAIN PRESSURE VALVE AND CONVERTER
SAFETY VALVE
(1) Engine connection
① Loosen hexagon screws (1) and
separate flexplate (2) from converter
(3).

HB108TM010

② Pull off converter (1) by hand.

HB108TM011

③ Loosen bolted connection between

converter bellhousing/housing (1) and
transmission pump/housing (2).

HB108TM012

④ Loosen screw plug "measuring point 63"

(1).
※ Remove O-ring.

HB108TM013

3-26
⑤ Separate converter bellhousing from
the mounting face of the transmission
housing by means of slight hits with a
plastic hammer.

HB108TM014

⑥ Remove converter bellhousing by means

of assembly lever.
※ Difficult disassembly due to fixing by
cylindrical pins.

HB108TM015

⑦ If required, remove both cylindrical pins

(1).
⑧ Remove filter (2).

※ Transmission pump cannot be separated

from the housing until the 4 cylindrical
screws of the housing inner side have
been loosened.
Fit adjusting screws to ensure that the
transmission pump is centered at the HB108TM016

housing after the 4 cylindrical screws

have been loosened.
(S) Adjusting screws (M10) 5870 204 007

3-27
(2) Main pressure valve and conver ter
safety valve
① Loosen screw plug (1) and remove main
pressure valve (control pressure valve) :
Main pressure valve consists of:
1 = Screw plug
2 = O-ring
3 = Piston
4 = Spacer ring HB108TM017

5 = Compression spring

※ Functional check of converter safety

valve (1).
Use a screwdriver to check the movability
of the ball in the valve.
※ If the valve is o.k., it does not need to be
removed.
※ Valve assy is installed in the housing-not
visible.
HB108TM018

3) REMOVAL OF CLUTCHES, CENTRAL SHAFT AND DISASSEMBLY OF TRANSMISSION

PUMP
(1) Removal of clutches
① Force out cylindrical pins (1).
Loosen bolted connection (2) of housing
front and rear part.

HB108TM019

3-28
② Separate housing front par t from
transmission housing rear part by means
of lifting device (approx. 1 cm).
③ Use the plastic hammer to reset the
output shaft (1) of the front wheel drive to
its initial position, thus separating the
screen sheet (2) from the shaft of the
clutch.
(S) Eye bolts assortment 5870 204 002

HB108TM020

④ Remove screen sheet (1) and separate

transmission housing front part by means
of lifting device.

HB108TM021

3-29
⑤ Designation of clutches:
KV = Forward clutch (directional clutch)
KR = Reverse clutch (directional clutch)
K1 = K1 clutch (gear clutch)
K2 = K2 clutch (gear clutch)
K3 = K3 clutch (gear clutch)
K4 = K4 clutch (directional clutch)
VA = Front wheel drive clutch

HB108TM022

⑥ Remove K4 clutch.

HB108TM023

⑦ Slightly lift clutch (K2) and remove

clutch (K1).

HB108TM024

⑧ Lift KV and KR clutch off the bearing

outer rings jointly and then remove them
one after the other.

HB108TM025

3-30
⑨ Jointly remove VA, K2 and K3 clutch
together with screen sheet (1).
⑩ Use the lifting device to jointly lift VA and
K3 clutch together with K2 clutch, and
then remove the components one after
the other.
(S) Eyebolts 5870 204 080

HB108TM026

⑪ Snap out retaining ring (1) and remove

central shaft (2).

HB108TM027

⑫ Snap out rectangular ring (1).

⑬ Press ball bearing (2) off the central shaft
(3).

HB108TM028

3-31
⑭ Remove O-rings (1).
⑮ Remove all bearing outer rings (2)
from the housing rear part.
※ If the tapered roller bearings of clutches
are not replaced, it is imperative to
ensure the previous pairing (bearing
outer ring / bearing inner ring).
※ Bearing outer ring and bearing inner ring
must be marked. HB108TM029

16 Loosen the cylindrical screws (1) and

remove suction tube (2) .
17 Remove all bearing outer rings (3) from
the housing front part.
※ If the tapered roller bearings of clutches
and input are not replaced, it is
imperative to ensure the previous pairing
(bearing outer ring / bearing inner ring).
※ Bearing outer ring and bearing inner ring HB108TM030

must be marked.

(2) Disassembly of transmission pump

① Loosen cylindrical screws (3 and 4) and
remove transmission pump.
Pay attention so that the transmission
pump does not drop.

HB108TM031

② Remove transmission pump (1).

HB108TM032

3-32
 ③ Remove O-ring (1).
④ Loosen cylindrical screws (2).

HB108TM033

※ Check transmission pump:

In case of wear marks in the pump
housing, stator hollow shaft or on the
inner and outer rotor, the complete
transmission pump must be replaced.
1 = Stator hollow shaft
2 = Inner rotor
3 = Outer rotor
4 = Pump housing HB108TM034

⑤ Remove shaft seal ring (1) from the

pump housing (2).

HB108TM035

4) DISASSEMBLY CLUTCHES
(1) KR clutch / input
① Snap out rectangular ring (1).

HB108TM036

3-33
② Pull off bearing inner ring with inner
disk carrier (1).

HB108TM037

③ Remove bearing inner ring (1), axial

bearing assy (2) and inner disk carrier
(3).

HB108TM038

④ Remove needle cage (1).

HB108TM039

⑤ Remove axial bearing assy (1).

HB108TM040

3-34
⑥ Remove snap ring (1).

HB108TM041

⑦ Remove end plate (1), disk package (2)

and plate assy with cup springs (3) from
the disk carrier.

HB108TM042

⑧ Remove retaining ring (1) at axial

bearing contact.

HB108TM043

⑨ Preload compression spring and remove

snap ring (1).
(S) Assembly aid 5870 345 114

HB108TM044

3-35
⑩ Remove spring cup (1) and compression
spring (2).

HB108TM045

⑪ By means of compressed air (see arrow),

press piston (1) off the shaft/disk carrier
and remove it.

HB108TM046

⑫ Remove both O-rings (1 and 2).

HB108TM047

⑬ Snap out rectangular rings (1).

HB108TM048

3-36
 ⑭ Pull tapered roller bearing (inner ring) off
the shaft.
(S) Grab sleeve 5873 001 026
(S) Basic tool 5873 001 000

HB108TM049

※ The input shaft (1) cannot be disass-

embled.
It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Ball
1B = Helical gear
1C = Disk carrier
1D = Input shaft HB108TM050

(2) KV clutch
① Snap out rectangular ring (1).

HB108TM051

② Pull off bearing inner ring with inner disk

carrier (1).

HB108TM052

3-37
③ Remove bearing inner ring (1), axial
bearing assy (2) and inner disk carrier
(3).

HB108TM053

④ Remove needle cage (1).

HB108TM054

⑤ Remove axial bearing assy (1).

HB108TM055

⑥ Remove snap ring (1).

HB108TM056

3-38
⑦ Remove end plate (1), disk package (2)
and plate assy with cup springs (3) from
the disk carrier.

HB108TM057

⑧ Remove retaining ring (1) at axial bearing

contact.

HB108TM058

⑨ Preload compression spring and remove

snap ring (1).
(S) Assembly aid 5870 345 114

HB108TM059

⑩ Remove spring cup (1) and compression

spring (2).

HB108TM060

3-39
⑪ By means of compressed air (see arrow),
press piston (1) off the shaft/disk carrier
and remove it.

HB108TM061

⑫ Remove both O-rings (1 and 2).

HB108TM062

⑬ Snap out rectangular ring (1).

HB108TM063

⑭ Pull tapered roller bearing (inner ring) off

the shaft.
(S) Grab sleeve 5873 000 029
(S) Basic tool 5873 000 001

HB108TM064

3-40
 ※ The clutch (1) cannot be disassembl-ed.
It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Retaining ring
1B = Helical gear
1C = Helical gear
1D = Disk carrier
1E = Shaft HB108TM065

(3) K1 clutch
① Snap out rectangular ring (1).

HB108TM066

② Pull off bearing inner ring with inner

disk carrier (1).

HB108TM067

③ Remove bearing inner ring (1), axial

bearing assy (2) and inner disk carrier
(3).

HB108TM068

3-41
④ Remove needle cage (1).

HB108TM069

⑤ Remove axial bearing assy (1).

HB108TM070

⑥ Remove snap ring (1).

HB108TM071

⑦ Remove end plate (1), disk package (2)

and cup springs (3) from the disk carrier.

HB108TM072

3-42
⑧ Remove retaining ring (1) at axial bearing
contact.

HB108TM073

⑨ Preload compression spring and remove

snap ring (1).
(S) Assembly aid 5870 345 114

HB108TM074

⑩ Remove spring cup (1) and

compression spring (2).

HB108TM075

⑪ By means of compressed air (see arrow),

press piston (1) off the shaft/disk carrier
and remove it.

HB108TM076

3-43
⑫ Remove both O-rings (1 and 2).

HB108TM077

⑬ Snap out rectangular ring (1).

HB108TM078

⑭ Pull tapered roller bearing (inner ring)

off the shaft.
(S) Grab sleeve 5873 011 011
(S) Basic tool 5873 001 000

HB108TM079

※ The clutch (1) cannot be disassembl-ed.

It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Helical gear
1B = Disk carrier
1C = Shaft

HB108TM080

3-44
(4) K2 clutch
① Snap out rectangular ring (1).

HB108TM081

② Pull off bearing inner ring with inner

disk carrier (1).

HB108TM082

③ Remove bearing inner ring (1), axial

bearing assy (2) and inner disk carrier
(3).

HB108TM083

④ Remove needle cage (1) and bushing

(2).

HB108TM084

3-45
⑤ Remove axial bearing assy (1).

HB108TM085

⑥ Remove snap ring (1).

HB108TM086

⑦ Remove end plate (1), disk package (2)

and cup springs (3) from the disk carrier.

HB108TM087

⑧ Remove retaining ring (1) at axial bearing

contact.

HB108TM088

3-46
⑨ Preload cup springs and remove snap
ring (1).
(S) Assembly aid 5870 345 114

HB108TM089

⑩ Remove axial washer (1) and cup

springs (2).

HB108TM090

⑪ By means of compressed air (see arrow),

press piston (1) off the shaft/disk carrier
and remove it.

HB108TM091

⑫ Remove both O-rings (1 and 2).

HB108TM092

3-47
 ⑬ Snap out rectangular rings (1).

HB108TM093

⑭ Pull tapered roller bearing (inner ring)

off the shaft.
(S) Grab sleeve 5873 001 026
(S) Basic tool 5873 001 000

HB108TM094

※ The clutch (1) cannot be disassembl-ed.

It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Ball
1B = Helical gear
1C = Shaft
1D = Disk carrier
HB108TM095

(5) K3 clutch
① Snap out rectangular ring (1).

HB108TM096

3-48
② Pull off bearing inner ring with inner
disk carrier (1).

HB108TM097

③ Remove bearing inner ring (1), axial

bearing assy (2) and inner disk carrier
(3).

HB108TM098

④ Remove needle cage (1) and bushing

(2).

HB108TM099

⑤ Remove axial bearing assy (1).

HB108TM100

3-49
⑥ Remove snap ring (1).

HB108TM101

⑦ Remove end plate (1), disk package (2)

and cup springs (3) from the disk carrier.

HB108TM102

⑧ Preload compression spring and remove

snap ring (1).
(S) Assembly aid 5870 345 114

HB108TM103

⑨ Remove spring cup (1) and compression

spring (2).

HB108TM104

3-50
⑩ By means of compressed air (see
arrow), press piston (1) off the shaft/
disk carrier and remove it.

HB108TM105

⑪ Remove both O-rings (1 and 2).

HB108TM106

⑫ Snap out rectangular ring (1).

HB108TM107

⑬ Pull tapered roller bearing (inner ring)

off the shaft.
(S) Grab sleeve 5873 000 029
(S) Basic tool 5873 000 001

HB108TM108

3-51
 ※ The clutch (1) cannot be disassembled.
It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Helical gear
1B = Shaft
1C = Disk carrier

HB108TM109

(6) K4 clutch
① Snap out rectangular ring (1).

HB108TM110

② Pull off bearing inner ring with inner

disk carrier (1).

HB108TM111

③ Remove bearing inner ring (1), axial

bearing assy (2) and inner disk carrier
(3).

HB108TM112

3-52
④ Remove needle cage (1).

HB108TM113

⑤ Remove axial bearing assy (1).

HB108TM114

⑥ Remove snap ring (1).

HB108TM115

⑦ Remove end plate (1), disk package (2)

and plate assy with cup springs (3) from
the disk carrier.

HB108TM116

3-53
⑧ Remove retaining ring (1) at axial bearing
contact.

HB108TM117

⑨ Preload compression spring and remove

snap ring (1).
(S) Assembly aid 5870 345 114

HB108TM118

⑩ Remove spring cup (1) and

compression spring (2).

HB108TM119

⑪ By means of compressed air (see arrow),

press piston (1) off the shaft/disk carrier
and remove it.

HB108TM120

3-54
⑫ Remove both O-rings (1 and 2).

HB108TM121

⑬ Snap out rectangular ring (1).

HB108TM122

⑭ Pull tapered roller bearing (inner ring)

off the shaft.
(S) Grab sleeve 5873 011 011
(S) Basic tool 5873 001 000

HB108TM123

※ The clutch (1) cannot be disassembled.

It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Retaining ring
1B = Helical gear
1C = Disk carrier
1D = Shaft
HB108TM124

3-55
(7) Front wheel drive (VA)
① Snap out rectangular ring (1).

HB108TM125

② Pull tapered roller bearing (inner ring) off

the shaft.
(S) Grab sleeve 5873 000 029
(S) Basic tool 5873 000 001

HB108TM126

③ Remove running disk (1).

HB108TM127

④ Pull off inner disk carrier (1).

HB108TM128

3-56
⑤ Remove snap ring (1).

HB108TM129

⑥ Remove end plate (1) and disk package

(2) from the disk carrier.

HB108TM130

⑦ Preload cup springs and remove snap

ring (1).
(S) Assembly aid 5870 506 128

HB108TM131

⑧ Remove washer (1) and cup springs (2).

HB108TM132

3-57
⑨ By means of compressed air (see arrow),
press piston (1) off the shaft/disk carrier
and remove it.

HB108TM133

⑩ Pull tapered roller bearing (inner ring) off

the shaft.
(S) Grab sleeve 5873 001 026
(S) Basic tool 5873 001 000

HB108TM134

※ The clutch (1) cannot be disassembled.

It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Shaft
1B = Disk carrier

HB108TM135

3-58
5) REASSEMBLY OF CLUTCHES
(1) KR clutch / input
※ The input shaft (1) is supplied by the
spare parts service only as a complete
assy which consists of:
1A = Ball
1B = Helical gear
1C = Disk carrier
1D = Input shaft
HB108TM136

Η Heat up bearing inner ring (approx. 120˚C).

HB108TM137

② Mount bearing inner ring (1) until contact

is obtained.
Fit rectangular rings 50×2.5 (2).
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM138

③ Insert both O-rings (1 and 2) into the

piston grooves and oil them.
1 = 40×3
2 = 104.5×3

HB108TM139

3-59
④ Insert piston (1) into the disk carrier.
※ Pay attention to the installation position,
see figure.

HB108TM140

⑤ Use a hand-operated press to place

piston into the disk carrier by means of
the assembly aid.
(S) Assembly aid 5870 345 114

HB108TM141

⑥ Mount compression spring (1) and spring

cup (2).

HB108TM142

⑦ By means of the assembly aid, preload

compression spring under a hand-
operated press until the retaining ring
40×1.75 (1) can be snapped in.
(S) Assembly aid 5870 345 114

HB108TM143

3-60
⑧ Mount plate assy with cup springs (1),
with the open side showing towards the
piston.
※ Installation position of plate see also the
next figure ⑨.

HB108TM144

⑨ Fit plate (1) according to sketch (see

arrow).
Legend:
1 = Plate assy with cup springs
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Input shaft assy
HB108TM145

⑩ Install outer and inner disks alternately

into the disk carrier (3) as shown in the
night figure, starting with an outer disk
and ending with an inner disk.
Legend:
1 = Outer disks (10 pcs)
2 = Inner disks (10 pcs)
3 = Input shaft assy
HB108TM146

⑪ Mount end plate (1) with the flat side

showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.

HB108TM147

3-61
⑫ Equally press on end plate with F
(approx 1.8 kg to 2.0 kg) and set dial
indicator to "zero".

HB108TM148

⑬ Then press end plate against the snap

ring (upwards) and read the disk
clearance.
※ Disk clearance: 2.0 to 2.3 mm
※ In case of deviations, the disk clearance
must be corrected with an appropriate
snap ring (optional thickness = 2.0 ~ 3.5
mm / available in steps of 0.25 mm)
HB108TM149

⑭ Snap retaining ring 40×1.75 (1) into the

groove.
※ Contact for axial bearing - see figure ⑮.

HB108TM150

⑮ Mount running disk 40×60×3.5 (1),

axial needle cage 40×60×3 (2) and
axial washer 40×60×1 (3) and oil them.
※ Mount running disk (1), with the chamfer
showing towards the retaining ring.

HB108TM151

3-62
16 Mount needle cage 40×45×17 (1) and
oil it.

HB108TM152

17 Mount inner disk carrier until contact is

obtained.
18 Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).

HB108TM153

19 Mount axial washer 40×60×1 (1), axial

needle cage 40×60×3 (2) and running
disk (3) 40×60×3.5 and oil them.
※ Mount running disk (3), with the chamfer
showing towards the tapered roller
bearing.

HB108TM154

20 Heat up bearing inner ring (approx. 120˚C).

HB108TM155

3-63
 21 Mount bearing inner ring (1) until contact
is obtained.
22 Fit rectangular ring 30×2 (2).

Wear protective gloves.

※ Adjust bearing inner ring after cooling-
down.

HB108TM156

※ Check closing and opening of the clutch

by means of compressed air at the hole
(see arrow).
Closing and opening of the clutch must
be clearly audible.

HB108TM157

(2) KV clutch
※ The clutch (1) is supplied by the spare
parts service only as a complete assy
which consists of:
1A = Retaining ring
1B = Helical gear
1C = Helical gear
1D = Disk carrier
1E = Shaft HB108TM158

① Heat up bearing inner ring (approx. 120˚C).

HB108TM159

3-64
② Mount bearing inner ring (1) until contact
is obtained.
③ Fit rectangular ring 30×2 (2).
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM160

④ Insert both O-rings (1 and 2) into the

piston grooves and oil them.
1 = 40×3
2 = 104.5×3

HB108TM161

⑤ Insert piston (1) into the disk carrier.

※ Pay a t t e n t i o n t o t h e i n s t a l l a t i o n
position, see figure.

HB108TM162

⑥ Use a hand-operated press to place

piston into the disk carrier by means of
the assembly aid.
(S) Assembly aid 5870 345 114

HB108TM163

3-65
⑦ Mount compression spring (1) and spring
cup (2).

HB108TM164

⑧ By means of the assembly aid, preload

compression spring under a hand-
operated press until the retaining ring
40×1.75 (1) can be snapped in.
(S) Assembly aid 5870 345 114

HB108TM165

⑨ Mount plate assy with cup springs (1),

with the open side showing towards the
piston.
※ Installation position of plate see also
figure ⑩.

HB108TM166

⑩ Fit plate (1) according to sketch (see

arrow).
Legend:
1 = Plate assy with cup springs
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Input shaft assy
HB108TM167

3-66
⑪ Install outer and inner disks alternately
into the disk carrier (3) as shown in
figure, starting with an outer disk and
ending with an inner disk.
Legend:
1 = Outer disks (10 pcs)
2 = Inner disks (10 pcs)
3 = Clutch assy
HB108TM168

⑫ Mount end plate (1) with the flat side

showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.

HB108TM169

⑬ Equally press on end plate with F

(approx. 1.8 kg to 2.0 kg) and set dial
indicator to "zero".

HB108TM170

⑭ Then press end plate against the snap

ring (upwards) and read the disk
clearance.
※ Disk clearance: 2.0 to 2.3 mm
※ In case of deviations, the disk clearance
must be corrected with an appropriate
snap ring (optional thickness = 2.0 ~ 3.5
mm / available in steps of 0.25 mm)
HB108TM171

3-67
⑮ Snap retaining ring 40×1.75 (1) into the
groove.
※ Contact for axial bearing - see the next
figure 16 .

HB108TM172

16 Mount running disk 40×60×3.5 (1),

axial needle cage 40×60×3 (2) and
axial washer 40×60×1 (3) and oil them.
※ Mount running disk (1), with the chamfer
showing towards the retaining ring.

HB108TM173

17 Mount needle cage 40×45×17 (1) and

oil it.

HB108TM174

18 Mount inner disk carrier until contact is

obtained.
19 Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).

HB108TM175

3-68
20 Mount axial washer 40×60×1 (1), axial
needle cage 40×60×3 (2) and running
disk (3) 40×60×3.5 and oil them.
※ Mount running disk (3), with the chamfer
showing towards the tapered roller
bearing.

HB108TM176

21 Heat up bearing inner ring (approx. 120˚C).

HB108TM177

22 Mount bearing inner ring (1) until contact

is obtained.
23 Fit rectangular ring 30×2 (2).

Wear protective gloves.

※ Adjust bearing inner ring after cooling-
down.

HB108TM178

※ Check closing and opening of the clutch

by means of compressed air at the hole
(see arrow).
Closing and opening of the clutch must
be clearly audible.

HB108TM179

3-69
(3) K1 clutch
※ The clutch (1) is supplied by the spare
parts service only as a complete assy
which consists of:
1A = Helical gear
1B = Disk carrier
1C = Shaft

HB108TM180

① Heat up bearing inner ring (approx. 120˚C).

HB108TM181

② Mount bearing inner ring (1) until contact

is obtained.
③ Fit rectangular ring 30×2 (2).
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM182

④ Insert both O-rings (1 and 2) into the

piston grooves and oil them.
1 = 40×3
2 = 104.5×3

HB108TM183

3-70
⑤ Insert piston (1) into the disk carrier.
※ Pay attention to the installation position,
see figure.

HB108TM184

⑥ Use a hand-operated press to place

piston into the disk carrier by means of
the assembly aid.
(S) Assembly aid 5870 345 114

HB108TM185

⑦ Mount compression spring (1) and spring

cup (2).

HB108TM186

⑧ By means of the assembly aid, preload

compression spring under a hand-
operated press until the retaining ring
40×1.75 (1) can be snapped in.
(S) Assembly aid 5870 345 114

HB108TM187

3-71
⑨ Mount cup spring 112×75×2.55 (1)
with the convex side showing towards the
piston.
※ Installation position of cup spring see
also the next figure ⑩.

HB108TM188

⑩ Install cup spring (1) according to the

sketch.
Legend:
1 = Cup spring 112×75×2.55 (convex
side towards the piston)
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Clutch assy HB108TM189

⑪ Install outer and inner disks alternately

into the disk carrier (3) as shown in
figure, starting with an outer disk and
ending with an inner disk.
Legend:
1 = Outer disks (10 pcs)
2 = Inner disks (10 pcs)
3 = Clutch assy
HB108TM190

⑫ Mount end plate (1) with the flat side

showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.

HB108TM191

3-72
⑬ Equally press on end plate with F
(approx. 1.8 kg to 2.0 kg) and set dial
indicator to "zero".

HB108TM192

⑭ Then press end plate against the snap

ring (upwards) and read the disk
clearance.
※ Disk clearance : 2.0 to 2.3 mm
※ In case of deviations, the disk clearance
must be corrected with an appropriate
snap ring (optional thickness = 2.0 ~ 3.5
mm / available in steps of 0.25 mm)
HB108TM193

⑮ Snap retaining ring 40×1.75 (1) into the

groove.
※ Contact for axial bearing - see the next
figure 16.

HB108TM194

16 Mount running disk 40×60×3.5 (1),

axial needle cage 40×60×3 (2) and
axial washer 40×60×1 (3) and oil them.
※ Mount running disk (1), with the chamfer
showing towards the retaining ring.

HB108TM195

3-73
17 Mount needle cage 40×45×17 (1) and
oil it.

HB108TM196

18 Mount inner disk carrier until contact is

obtained.
19 Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).

HB108TM197

20 Mount axial washer 40×60×1 (1), axial

needle cage 40×60×3 (2) and running
disk (3) 40×60×3.5 and oil them.
※ Mount running disk (3), with the chamfer
showing towards the tapered roller
bearing.

HB108TM198

21 Heat up bearing inner ring (approx. 120˚C).

HB108TM199

3-74
 22 Mount bearing inner ring (1) until contact
is obtained.
23 Fit rectangular ring 30×2 (2).

Wear protective gloves.

※ Adjust bearing inner ring after cooling-
down.

HB108TM200

※ Check closing and opening of the clutch

by means of compressed air at the hole
(see arrow).
Closing and opening of the clutch must
be clearly audible.

HB108TM201

(4) K2 clutch
※ The clutch (1) is supplied by the spare
parts service only as a complete assy
which consists of:
1A = Ball
1B = Shaft
1C = Helical gear
1D = Disk carrier
HB108TM202

① Heat up bearing inner ring (approx. 120˚C).

HB108TM203

3-75
② Mount bearing inner ring (1) until contact
is obtained.
③ Fit rectangular rings 50×2.5 (2).
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM204

④ Insert both O-rings (1 and 2) into the

piston grooves and oil them.
1 = 40×3
2 = 115×3

HB108TM205

⑤ Insert piston (1) into the disk carrier.

※ Pay attention to the installation position,
see figure.

HB108TM206

⑥ Use a hand-operated press to place

piston into the disk carrier by means of
the assembly aid.
(S) Assembly aid 5870 345 114

HB108TM207

3-76
⑦ Mount cup spring package (1) and axial
washer (2).
※ Installation position of cup springs see
the next figure ⑧.

HB108TM208

⑧ Fit cup springs according to the sketch.

Legend:
1 = Clutch
2 = Piston with O-rings
3 = Cup springs (7 pcs)
4 = Axial washer (40×60×1)
5 = Retaining ring (40×1.75)

HB108TM209

⑨ By means of the assembly aid, preload

cup springs under a hand-operated
press until the retaining ring 40×1.75 (1)
can be snapped in.
(S) Assembly aid 5870 345 114

HB108TM210

⑩ Mount cup spring 122.7×87×2.55 (1)

with the convex side showing towards the
piston.
※ Installation position of cup spring see
also the next figure ⑪.

HB108TM211

3-77
⑪ Install cup spring (1) according to the
sketch.
Legend:
1 = Cup spring 122.7×87×2.55 (convex
side showing towards the piston)
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Clutch assy HB108TM212

⑫ Install outer and inner disks alternately

into the disk carrier (3) as shown in
figure, starting with an outer disk and
ending with an inner disk.
Legend:
1 = Outer disks (13 pcs)
2 = Inner disks (13 pcs)
3 = Clutch assy
HB108TM213

⑬ Mount end plate (1) with the flat side

showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.

HB108TM214

⑭ Equally press on end plate with F

(approx. 1.8 kg to 2.0 kg) and set dial
indicator to "zero".

HB108TM215

3-78
⑮ Then press end plate against the snap
ring (upwards) and read the disk
clearance.
※ Disk clearance : 2.2 to 2.5 mm
※ In case of deviations, the disk clearance
must be corrected with an appropriate
snap ring (optional thickness = 2.0 ~ 3.5
mm / available in steps of 0.25 mm)
HB108TM216

16 Snap retaining ring 40×1.75 (1) into the

groove.
※ Contact for axial bearing - see figure 17 .

HB108TM217

17 Mount running disk 40×60×3.5 (1),

axial needle cage 40×60×3 (2) and
axial washer 40×60×1 (3) and oil them.
※ Mount running disk (1), with the chamfer
showing towards the retaining ring.

HB108TM218

18 Mount needle cage 40×45×17 (1) and

bushing (2) and oil them.

HB108TM219

3-79
19 Mount inner disk carrier until contact is
obtained.
20 Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).

HB108TM220

21 Mount axial washer 40×60×1 (1), axial

needle cage 40×60×3 (2) and running
disk (3) 40×60×3.5 and oil them.
※ Mount running disk (3), with the chamfer
showing towards the tapered roller
bearing.

HB108TM221

22 Heat up bearing inner ring (approx. 120˚C).

HB108TM222

23 Mount bearing inner ring (1) until contact

is obtained.
24 Fit rectangular ring 30×2 (2).

Wear protective gloves.

※ Adjust bearing inner ring after cooling-
down.

HB108TM223

3-80
 ※ Check closing and opening of the clutch
by means of compressed air at the hole
(see arrow).
Closing and opening of the clutch must
be clearly audible.

HB108TM224

(5) K3 clutch
※ The clutch (1) is supplied by the spare
parts service only as a complete assy
which consists of:
1A = Helical gear
1B = Disk carrier
1C = Shaft

HB108TM225

① Heat up bearing inner ring (approx. 120˚C).

HB108TM226

② Mount bearing inner ring (1) until contact

is obtained.
③ Fit rectangular rings 30×2 (2).
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM227

3-81
④ Insert both O-rings (1 and 2) into the
piston grooves and oil them.
1 = 40×3
2 = 104.5×3

HB108TM228

⑤ Insert piston (1) into the disk carrier.

※ Pay attention to the installation position,
see figure.

HB108TM229

⑥ Use a hand-operated press to place

piston into the disk carrier by means of
the assembly aid.
(S) Assembly aid 5870 345 114

HB108TM230

⑦ Mount compression spring (1) and spring

cup (2).

HB108TM231

3-82
⑧ By means of the assembly aid, preload
compression spring under a hand-
operated press until the retaining ring
40×1.75 (1) can be snapped in.
(S) Assembly aid 5870 345 114

HB108TM232

⑨ Mount cup spring 112×75×2.55 (1)

with the convex side showing towards the
piston.
※ Installation position of cup spring see
also the next figure ⑩.

HB108TM233

⑩ Install cup spring (1) according to the

sketch.
Legend:
1 = Cup spring 112×75×2.55 (convex
side showing towards the piston)
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Clutch assy HB108TM234

⑪ Install outer and inner disks alternately

into the disk carrier (3) as shown in
figure, starting with an outer disk and
ending with an inner disk.
Legend:
1 = Outer disks (9 pcs)
2 = Inner disks (9 pcs)
3 = Clutch assy
HB108TM235

3-83
⑫ Mount end plate (1) with the flat side
showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.

HB108TM236

⑬ Equally press on end plate with F

(approx. 1.8 kg to 2.0 kg) and set dial
indicator to "zero".

HB108TM237

⑭ Then press end plate against the snap

ring (upwards) and read the disk
clearance.
※ Disk clearance : 1.8 to 2.1 mm
※ In case of deviations, the disk clearance
must be corrected with an appropriate
snap ring (optional thickness = 2.0 ~ 3.5
mm / available in steps of 0.25 mm)
HB108TM238

⑮ Mount running disk 35×52×3.5 (1),

axial needle cage 35×52×2 (2) and
axial washer 35×52×1 (3) and oil them.
※ Mount running disk (1), with the chamfer
showing towards the retaining ring.

HB108TM239

3-84
16 Mount needle cage 35×42×18 (1) and
bushing (2) and oil them.

HB108TM240

17 Mount inner disk carrier until contact is

obtained.
18 Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).

HB108TM241

19 Mount axial washer 35×52×1 (1), axial

needle cage 35×52×2 (2) and running
disk (3) 35×52×3.5 and oil them.
※ Mount running disk (3), with the chamfer
showing towards the tapered roller
bearing.

HB108TM242

20 Heat up bearing inner ring (approx. 120˚C).

HB108TM243

3-85
 21 Mount bearing inner ring (1) until contact
is obtained.
22 Fit rectangular ring 30×2 (2).

Wear protective gloves.

※ Adjust bearing inner ring after cooling-
down.

HB108TM244

※ Check closing and opening of the clutch

by means of compressed air at the hole
(see arrow).
Closing and opening of the clutch must
be clearly audible.

HB108TM245

(6) K4 clutch
※ The clutch (1) is supplied by the spare
parts service only as a complete assy
which consists of:
1A = Retaining ring
1B = Helical gear
1C = Disk carrier
1D = Shaft
HB108TM246

① Heat up bearing inner ring (approx. 120˚C).

HB108TM247

3-86
② Mount bearing inner ring (1) until contact
is obtained.
③ Fit rectangular rings 30×2 (2).
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM248

④ Insert both O-rings (1 and 2) into the

piston grooves and oil them.
1 = 40×3
2 = 104.5×3

HB108TM249

⑤ Insert piston (1) into the disk carrier.

※ Pay attention to the installation position,
see figure.

HB108TM250

⑥ Use a hand-operated press to place

piston into the disk carrier by means of
the assembly aid.
(S) Assembly aid 5870 345 114

HB108TM251

3-87
⑦ Mount compression spring (1) and spring
cup (2).

HB108TM252

⑧ By means of the assembly aid, preload

compression spring under a hand-
operated press until the retaining ring
40×1.75 (1) can be snapped in.
(S) Assembly aid 5870 345 114

HB108TM253

⑨ Mount plate assy with cup springs (1),

with the open side showing towards the
piston.
※ Installation position of plate see also the
next figure ⑩.

HB108TM254

⑩ Fit plate (1) according to sketch (see

arrow).
Legend:
1 = Plate assy with cup springs
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Input shaft assy
HB108TM255

3-88
⑪ Install outer and inner disks alternately
into the disk carrier (3) as shown in
figure, starting with an outer disk and
ending with an inner disk.
Legend:
1 = Outer disks (7 pcs)
2 = Inner disks (7 pcs)
3 = Clutch assy
HB108TM256

⑫ Mount end plate (1) with the flat side

showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.

HB108TM257

⑬ Equally press on end plate with F

(approx. 1.8 kg to 2.0 kg) and set dial
indicator to "zero".

HB108TM258

⑭ Then press end plate against the snap

ring (upwards) and read the disk
clearance.
※ Disk clearance : 1.4 to 1.7 mm
※ In case of deviations, the disk clearance
must be corrected with an appropriate
snap ring (optional thickness = 2.0 ~ 3.5
mm / available in steps of 0.25 mm)
HB108TM259

3-89
⑮ Snap retaining ring 40×1.75 (1) into the
groove.
※ Contact for axial bearing - see the next
figure 16.

HB108TM260

16 Mount running disk 40×60×3.5 (1),

axial needle cage 40×60×3 (2) and
axial washer 40×60×1 (3) and oil them.
※ Mount running disk (1) with the chamfer
showing towards the retaining ring.

HB108TM261

17 Mount needle cage 40×45×17 (1) and

oil it.

HB108TM262

18 Mount inner disk carrier until contact is

obtained.
19 Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).

HB108TM263

3-90
20 Mount axial washer 40×60×1 (1), axial
needle cage 40×60×3 (2) and running
disk (3) 40×60×3.5 and oil them.
※ Mount running disk (3), with the chamfer
showing towards the tapered roller
bearing.

HB108TM264

21 Heat up bearing inner ring (approx. 120˚C).

HB108TM265

22 Mount bearing inner ring (1) until contact

is obtained.
23 Fit rectangular ring 30×2 (2).

Wear protective gloves.

※ Adjust bearing inner ring after cooling-
down.

HB108TM266

※ Check closing and opening of the clutch

by means of compressed air at the hole
(see arrow).
Closing and opening of the clutch must
be clearly audible.

HB108TM267

3-91
(7) Front wheel drive (VA)
※ The clutch (1) is supplied by the spare
parts service only as a complete assy
which consists of:
1A = Shaft
1B = Disk carrier

HB108TM268

① Heat up bearing inner ring (approx. 120˚C).

HB108TM269

② Mount bearing inner ring (1) until contact

is obtained.
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM270

③ Insert piston (1) into the disk carrier.

※ Oil both sealing lips.
※ Pay attention to the installation position,
see figure.

HB108TM271

3-92
④ Use a hand-operated press to place
piston into the disk carrier by means of
the assembly aid.
(S) Assembly aid 5870 345 114

HB108TM272

⑤ Mount cup spring package (1) and

washer (2).
※ Installation position of cup springs see
the next figure ⑥.

HB108TM273

⑥ Fit cup springs according to the sketch.

Legend:
1 = Clutch
2 = Piston
3 = Cup springs (7 pcs)
4 = Washer
5 = Retaining ring (50×2)

HB108TM274

⑦ By means of the assembly aid, preload

cup springs under a handoperated press
until the retaining ring 50×2 (1) can be
snapped in.
(S) Assembly aid 5870 506 128

HB108TM275

3-93
⑧ Install outer and inner disks alternately
into the disk carrier (3) as shown in
figure, starting with an outer disk and
ending with an inner disk.
Legend:
1 = Outer disks (12 pcs)
2 = Inner disks (12 pcs)
3 = Clutch assy
HB108TM276

⑨ Mount end plate (1) with the flat side

showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.

HB108TM277

⑩ Equally press on end plate with F

(approx. 1.8 kg to 2.0 kg) and set dial
indicator to "zero".

HB108TM278

⑪ Then press end plate against the snap

ring (upwards) and read the disk
clearance.
Disk clearance : 2.3 to 2.8 mm
※ In case of deviations, the disk clearance
must be corrected with an appropriate
snap ring (optional thickness = 2.0 ~ 4.0
mm / available in steps of 0.25 mm)
HB108TM279

3-94
⑫ Mount inner disk carrier until contact is
obtained.
Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).

HB108TM280

⑬ Mount running disk 40×60×3.5 (1).

HB108TM281

⑭ Heat up bearing inner ring (approx.

120°C).

HB108TM282

⑮ Mount bearing inner ring (1) until contact

is obtained.
Fit rectangular ring 30×2 (2).
Wear protective gloves.
※ Adjust bearing inner ring after cooling-
down.

HB108TM283

3-95
※ Check closing and opening of the clutch
by means of compressed air at the hole
(see arrow).
Closing and opening of the clutch must
be clearly audible.

HB108TM284

3-96
6) REINSTALLATION AND REASSEMBLY OF TRANSMISSION PUMP, OIL SUCTION TUBE
AND OIL FILLER TUBE, CONTROL PRESSURE AND CONVERTER SAFETY VALVE,
COARSE FILTER AND CLUTCHES

(1) Reassembly of transmission pump

※ In case of wear marks in the pump
housing, stator hollow shaft, inner rotor,
outer rotor and on the sliding bearing, the
pump assy must be replaced.
Legend:
1 = Stator hollow shaft
2 = Inner rotor
3 = Outer rotor HB108TM285

4 = Pump housing with sliding bearing

② With the sealing lip showing downwards,

carefully insert the shaft seal 55×75×8
(1) into the pump housing (2) until
contact is obtained.
※ Fill space between sealing lip and dust
lip with grease.
※ Outer diameter :
·If rubber-coated : wet with spirit
·If made of metal : apply sealing agent HB108TM286

loctite No. 574.

(S) Driver tool 5870 048 219

③ Fit outer rotor (1) and inner rotor (2).

※ The driver pins of the inner rotor (see
arrows) are to be fitted in upward
direction.

HB108TM287

3-97
 ④ Fit stator hollow shaft (1).

HB108TM288

⑤ Fix stator hollow shaft radially with two

cylindrical screws (1).
※ Do not tighten the cylindrical screws –
just turn them in until contact is obtained
and then turn them back by approx. 1/2
rotation.
Place O-ring (2) 135×3 into the annular
groove and grease it.
HB108TM289

(2) Oil suction tube and oil filter tube

① Mount O-ring 30×3 (1) onto the suction
tube (2) and grease it.

HB108TM290

② Fix suction tube (1) with cylindrical

screws M8×16 (2).
·Tightening torque M8/8.8×16 ;
2.35 kgf·m (17.0 lbf·ft)
※ When reusing the cylindrical screws
these must be secured with loctite #243.
※ New cylindrical screws are already
provided with adhesive (microcapsule).
The microcapsule bursts when the screw HB108TM291

is turned in, wets screw and nut thread

and hardens.

3-98
 ③ Insert tube (1) into the transmission
housing by means of driver tool (S).
(S) Driver tool 5870 048 309
※ Use the driver tool to obtain the correct
offset.
※ Apply loctite #574 onto the surface (A).

HB108TM292

(3) Coarse filter

① Insert filter (1).

HB108TM293

(4) Reinstallation of converter safety valve

① Insert valve (1) with drift (S) into the
housing until contact is obtained.
(S) Drift 5870 705 012

HB108TM294

(5) Reassembly of main pressure valve

(control pressure)
① Insert main pressure valve (1).
Main pressure valve consists of:
2 = Piston
3 = Spacer ring (2 pcs)
recommended value 5 mm
4 = Compression spring
※ The main pressure 16+3 bar is HB108TM295

determined by means of the spacer

rings.
※ Gradation of available spacer rings see
spare parts list.

3-99
 ② Fit screw plug M22×1.5 (1) with O-ring
19×2.
·Tightening torque :
5.1 kgf·m (36.9 lbf·ft)

HB108TM296

(6) Reinstallation of transmission pump

① Fit two adjusting screws (S) and position
converter bellhousing (1) equally until
contact is obtained.
※ Pay attention to the hole pattern.
※ Wet mounting face with loctite #574.
(S) Adjusting screws (M10)5870 204 007
HB108TM297

② Force the cylindrical pins 12×24 (1) into

the holes (blind holes) until contact is
obtained.

HB108TM298

③ Fix conver ter bellhousing (1) with

cylindrical screws M10×30 (2).
·Tightening torque (M10/8.8×30) ;
4.69 kgf·m (33.9 lbf·ft)

HB108TM299

3-100
④ Fit two adjusting screws (S) and mount
preassembled pump (1).
※ Pay attention to the hole pattern.
(S) Adjusting screws (M8) 5870 204 011

HB108TM300

⑤ Position transmission pump with 3

cylindrical screws (1) M8×60 (3×120°
offset position) equally until contact is
obtained.
※ Do not damage (shear off) the O-ring.
⑥ Fix transmission pump with cylindrical
screws M8x60 (1).
·Tightening torque (M8/8.8×60) ;
HB108TM301
2.35 kgf·m (17.0 lbf·ft)

⑦ Fix pump with cylindrical screws (1 and 2).

1 = M8×16
2 = M8×35
·Tightening torque (M8/8.8×16) ;
2.35 kgf·m (17.0 lbf·ft)
·Tightening torque (M8/8.8×35) ;
2.35 kgf·m (17.0 lbf·ft)
※ New cylindrical screws are to be fitted on
a general basis. HB108TM302

※ These cylindrical screws are already

provided with adhesive (microcapsule).
The microcapsule bursts when the screw
is turned in, wets screw and nut thread
and hardens.

3-101
(7) Reinstallation of clutches
① Insert all bearing outer rings (1) into the
bearing holes of both housing parts (see
figures).
※ Place bearing outer rings into the bearing
holes using assembly grease.

HB108TM303

※ If the tapered roller bearings of clutches

and input are not replaced, it is
imperative to ensure the previous pairing
(bearing inner ring/bearing outer ring) -
see figures TM029, 030 at page 3-32.

HB108TM304

Reinstallation of K2, K3 and front

wheel drive
② Align and grease rectangular rings
50×2.5 (4) and rectangular rings 30×2
(6), as well as those of the front wheel
drive.
③ Hold K3 clutch (5) and front wheel drive
(1) by means of the lifting device, position
K2 clutch (2) and screen sheet (3) at K3
clutch (5), and then jointly insert the
assembly.
(S) Eyebolts 5870 204 080
※ Bolts (8) of the screen sheet must be
fixed into the pilot holes (7).

HB108TM306

3-102
 Reinstallation of K1
④ Align and grease rectangular ring 30×2
(2).
⑤ Position K1 clutch (1).

HB108TM307

Reinstallation of KV and KR
⑥ Align and grease rectangular rings 50×2
(4) and rectangular ring 30×2 (3).
⑦ Jointly position KV clutch (1) and KR
clutch (2).

HB108TM308

Reinstallation of K4
⑧ Align and grease rectangular ring 30×2
(1).
⑨ Position K4 clutch (2).

HB108TM309

3-103
⑩ Place O-rings (5 and 6) into the hole and
grease them. Align and grease
rectangular rings (1, 2, 3, 4, 8 and 9).
1 = Rectangular ring 30×2 (KV clutch)
2 = Rectangular ring 30×2 (K4 clutch)
3 = Rectangular ring 35×2 (KR clutch)
4 = Rectangular ring 30×2 (K1 clutch)
5 = O-ring 15×2
6 = O-ring 21.89×2.62 HB108TM311

7 = ......................... (front wheel drives)

8 = Rectangular ring 30×2 (K2 clutch)
9 = Rectangular ring 30×2 (K3 clutch)

⑪ Use the lifting device to carefully bring

the transmission housing front part into
contact position.
※ Bolts (1) of the screen sheet must be
fixed into the pilot holes.
※ Wet mounting face with loctite # 574.

HB108TM312

⑫ Hand-tighten the transmission housings

crosswise with 2 cylindrical screws (1).
⑬ Fit cylindrical pins 12×24 (2) centrically
to the mounting face.

HB108TM313

3-104
⑭ Fix transmission housing front and rear
part by means of cylindrical screws (1
and 2).
⑮ Fit bracket (3).
Cylindrical screw (1) M10×30 (14 EA)
Cylindrical screw (2) M10×50 (10 EA)
·Tightening torque M10/8.8×30 ;
4.69 kgf·m (33.9 lbf·ft)
HB108TM314
·Tightening torque M10/8.8×50 ;
4.69 kgf·m (33.9 lbf·ft)

3-105
7) REASSEMBLY OF REAR AXLE OUTPUT FLANGE AND SCREW PLUG AT MEASURING
POINT "63" AFTER THE CONVERTER, AND SEALING OF VERSION WITH AND WITHOUT
FRONT WHEEL DRIVE

(1) Reassembly of rear axle output flange

Η Use driver tool (S) to fit the shaft seal
60×90×8 (1) until contact position, with
the sealing lip showing towards the oil
sump (see figure below).
(S) Driver tool 5870 048 200
※ Fill space between sealing lip and dust
lip with grease.
HB108TM315

※ Wet rubber-coated outer diameter with

spirit.
※ Use the driver tool to obtain the correct
offset.

※ Installation situation - rear axle output

1 = Shaft seal 60×90×8
2 = Screen sheet
3 = Closing cover
4 = Output flange
5 = K2 clutch shaft
6 = Transmission housing

HB108TM316

② Press closing cover (3) into the flange (4)

until contact is obtained (see figure
above).
※ Apply loctite #518 to the closing cover.
※ Use suitable pressure piece; closing
cover must not be deformed.

HB108TM317

3-106
 ③ Press screen sheet (2) onto the flange
(4) until contact is obtained.
※ Use suitable pressure piece; screen
sheet must not be deformed.

HB108TM318

④ Mount output flange (4) until contact

position.

HB108TM319

(2) Sealing of front-wheel-drive

① Use driver tool (S) to fit the shaft seal
40×62×7 (1) until contact position, with
the sealing lip showing towards the oil
sump (see figure below).
(S) Driver tool 5870 048 310
※ Fill space between sealing lip and dust
lip with grease.
HB108TM320

※ Wet rubber-coated outer diameter with

spirit.
※ Use the driver tool to obtain the correct
offset.

Installation situation
1 = Shaft seal 40×62×7
2 = Screen sheet
3 = VA clutch shaft
4 = Transmission housing

HB108TM321

3-107
② Use the driver tool (S) to install screen
sheet (2) onto the VA clutch shaft (3) until
contact position (see figure TM321 of
previous page).
(S) Driver tool 5870 048 310

HB108TM322

(3) Reassembly of screw plug at measuring

point "63"
① Fit screw plug M14×1.5 (1) with new
O-ring 11×2 (2).
·Tightening torque ;
2.55 kgf·m (18.4 lbf·ft)
※ Refer to page 3-23 for measuring point
63.
HB108TM325

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8) REINSTALLATION OF NOZZLES (ORIFICES), SCREW PLUGS, SOLENOID VALVES,
INDUCTIVE SENSOR AND MOUNTING PROVISION FOR OIL FILLER TUBE

(1) Reinstallation of nozzles (orifices)

① Fit nozzle M10×1 ͚1.55 (1) for the
directional clutches KV, KR and K4.
·Tightening torque ;
1.02 kgf·m (7.38 lbf·ft)

HB108TM326

② Fit nozzles for the gear clutches K1, K2

and K3.
1 = Nozzle (K1) M10×1 ͚1.4
2 = Nozzle (K2) M 8 ͚1.7
3 = Nozzle (K3) M 8 ͚1.4
·Tightening torque M8, M10×1 ;
1.02 kgf·m (7.38 lbf·ft)

HB108TM327

(2) Reinstallation of screw plugs

① Install all screw plugs with O-rings.
1 = Screw plug 3/4 -16 UNF;
O-ring 16.36×2.21 (2 EA)
2 = Screw plug M10×1;
O-ring 8×1.5 (36 EA)
3 = Screw plug 9/16 -18 UNF;
O-ring 11.89×1.98 (3 EA)
HB108TM328
· Tightening torque 3/4 -16 UNF ;
2.86 kgf·m (20.7 lbf·ft)
· Tightening torque M10×1 ;
0.61 kgf·m (4.43 lbf·ft)
· Tightening torque 9/16 -18 UNF ;
1.53 kgf·m (11.1 lbf·ft)

3-109
(3) Reinstallation of solenoid valves
① Insert solenoid valves (1 and 2) into the
transmission housing and fix them by
means of bracket and cylindrical screw
M6×12 (3).
1 = Solenoid valve - parking brake - rear
axle
2 = Solenoid valve - differential lock –
rear axle HB108TM329

·Tightening torque M6/8.8 ;

0.97 kgf·m (7.01 lbf·ft)

② Insert solenoid valve Y2 (1) into the

transmission housing and fix it by means
of bracket and cylindrical screw M6×12
(2).
·Tightening torque M6/8.8 ;
0.97 kgf·m (7.01 lbf·ft)

HB108TM330

③ Insert solenoid valves Y1 (1) and Y3 (2)

into the transmission housing and fix
them by means of bracket and cylindrical
screw M6×12 (3).
·Tightening torque M6/8.8 ;
0.97 kgf·m (7.01 lbf·ft)

HB108TM331

④ Insert solenoid valve YWD (1) into the

transmission housing and fix it by means
of bracket and cylindrical screw M6×12
(2).
·Tightening torque M6/8.8 ;
0.97 kgf·m (7.01 lbf·ft)

HB108TM332

3-110
 ⑤ Insert solenoid valve Y5 (1) into the
transmission housing and fix it by means
of bracket and cylindrical screw M6×12
(2).
·Tightening torque M6/8.8 ;
0.97 kgf·m (7.01 lbf·ft)

HB108TM333

⑥ Insert solenoid valves Y6 (1) and Y4 (2)

into the transmission housing and fix
them by means of bracket and cylindrical
screw M6×12 (3).
·Tightening torque M6/8.8 ;
0.97 kgf·m (7.01 lbf·ft)

HB108TM334

(4) Reinstallation of inductive sensor (option)

① Install inductive sensor (1) with O-ring
15×2 (2).
·Tightening torque ;
3.06 kgf·m (22.1 lbf·ft)

HB108TM335

(5) Mounting provision for oil filler tube

(option)
① Fix closing cover (2) and seal (3) with
hexagon screws (1).
·Tightening torque (M8/8.8×18) ;
3.47 kgf·m (25.1 lbf·ft)

HB108TM336

3-111
9) REASSEMBLY OF PTO
(1) Press ball bearing 45×75×16 (1) onto the
pump shaft (2) until contact is obtained.
(2) Fit rectangular ring 50×2.5 (3).
(3) Grease and centrically align rectangular
ring.

HB108TM337

(4) Mount pump shaft (2) until contact is

obtained and fix it by means of retaining
ring 75×2.5 (1).

HB108TM338

10) REASSEMBLY OF ENGINE CONNECTION

(1) Mount conver ter (1) until contact is
obtained.

HB108TM339

(2) Position 1 washer/each / thickness=1.0

mm (4 EA) (1) onto the flexplate mounting
webs (4 EA).
(3) Place flexplates (2).
※ Pay attention to the installation position!
Spot- welded reinforcing disks of the
flexplate to be arranged towards the
outside - see arrows.
HB108TM340
(4) Mount washer (3) onto the hexagon screw
M10×16 (4) and fix flexplates.

3-112
 (5) Tighten hexagon screws (1).
·Tightening torque (M10/8.8×16) ;
4.69 kgf·m (33.9 lbf·ft)
※ When reusing the hexagon screws these
must be secured with loctite 243.
※ New hexagon screws are already
provided with adhesive (microcapsule).
The microcapsule bursts when the screw
is turned in , wets screw and nut thread HB108TM341

and hardens.
Fix converter axially.
Risk of injury.

11) REASSEMBLY OF FILTER AND OIL DRAIN PLUG

(1) Place O-rings 34.2×3 (1) into the holes
and grease them.

HB108TM342

(2) Attach filter head (1) with cylindrical

screws M8×30 (2).
·Tightening torque (M8/8.8×30) ;
2.35 kgf·m (17.0 lbf·ft)

HB108TM343

※ The filter (1) has to be fitted as follows:

- Slightly oil the seal
- Turn in the filter until contact with the
sealing surface is obtained, and then
tighten it by hand with approx. 1/3 to 1/2
rotation.

HB108TM344

3-113
(3) Fit oil drain plug 7/8-14 UN 2A (1).
·Tightening torque (7/8-14 UN 2A) ;
3.06 kgf·m (22.1 lbf·ft)
(4) Fix identification plate (2) by means of 4
grooved pins 3×5.

HB108TM345

※ Before putting the transmission into

operation, fill it with specified oil (SAE
15W-40).

HB108TM346

3-114