Order No.

: 5871 172 002 E

ZF – ERGOPOWER
4 WG-310 (4)

ZF Passau GmbH
Donaustr. 25 – 71
D - 94034 Passau Edition: 2002/10
 REPAIR INSTRUCTIONS

ZF – ERGOPOWER

4 WG-310 (4)

NOTE:
The described repair instructions are based on the design level of the
ZF - Unit at the time of preparation of the Repair Manual.
Technical development of the product as well as extensions concerning the
design possibilities may require differing steps, which can be carried out by qualified
Specialists without greater difficulties with the help of the Perspective Illustrations
in the corresponding Spare Parts Lists.

For information about the Description, Installation Instructions, Operation and

Maintenance, refer to the corresponding operating instructions.

The present Disassembly and Reassembly Manual is losing its legal obligation with
the publication of a new successional Edition.
The ZF Passau GmbH is in this connection not responsible for the
positive knowledge at the User of the Manual.

ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau

Abt.: ASTDM / Section : ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous reserve de modifications techniques!
1. Auflage / 1. Edition
2. Auflage / 2. Edition: 2007/01
TABLE OF CONTENTS Chapt./Page

Preface .............................................................................................................................. 0/1

General ....................................................................................................................... 0/2 ... 0/3
Designation of the Legal Units ........................................................................... 0/4
Conversion Table for Dimensional Units........................................................................ 0/5
Torque Limits for Screws ................................................................................... 0/6

SPECIAL TOOLS
W/1 ... W/10
LIST OF TOOLS
ILLUSTRATED TABLES WB/1 ... WB/17

1. ELECTRO-HYDRAULIC CONTROL UNIT 1/1 ... 1/11

WITH PROPORTIONAL VALVES

1.1 DISASSEMBLY 1/2 ... 1/4

1.2 REASSEMBLY 1/5 ... 1/11

2. TRANSMISSION 2/1 ... 2/121

2.1 DISASSEMBLY 2/1 ... 2/27

2.1.1. Converter Drive 2/1 ... 2/3

2.1.2 Input Shaft – Pump/Power Take-Off 2/4 ... 2/6
2.1.2.1 Version with 2nd/3rd and 4th Power Take-Off 2/4 ... 2/5
2.1.2.2 Version only with 1st Power Take-Off 2/6

2.1.3 Transmission Pump 2/7 ... 2/8

2.1.4 Power Take-Off 2/9 ... 2/10

2.1.4.1 Version with 3rd and 4th Power Take-Off 2/9 ... 2/10

2.1.5 Layshaft 2/10 ... 2/11

2.1.6 Inductive and Speed Transmitter 2/11

2.1.7 Output 2/12

2.1.7.1 Standard Version 2/12
2.1.7.2 Version with Parking Brake 2/12
Type: FSG 110 (Knott)
 Chapt./Page
TABLE OF CONTENTS
2.1.8 Removal of Clutches and Layshaft 2/13 ... 2/15

2.1.9 Removal of the 2nd Power Take-Off 2/14 ... 2/17

2.1.10 Dismantling of the Multi-Disc Clutch K4/K3 2/18 ... 2/21

2.1.11 Dismantling of the Multi-Disc Clutch KR/K2 2/21 ... 2/24

2.1.12 Dismantling of the Multi-Disc Clutch KV/K1 2/24 ... 2/27

2.2 REASSEMBLY 2.28 ... 2/121

2.2.1 Power Take-Off 2/28 ... 2/35

2.2.1.1 2nd Power Take-Off 2/29 ... 2/30
2.2.1.2 3rd/4th Power Take-Off 2/31 ... 2/35

2.2.2 Assembly of the Multi-Disc Clutch K4/K3 2/36 ... 2/47

2.2.2.1 Disc Components – K4 2/39
2.2.2.2 Disc Components – K3 2/43

2.2.3 Assembly of the Multi-Disc Clutch KR/K2 2/48 ... 2/59

2.2.3.1 Disc Components - KR 2/51
2.2.3.2 Disc Components – K2 2/55

2.2.4 Assembly of the Multi-Disc Clutch KV/K1 2/60 ... 2/72

2.2.4.1 Disc Components - KV 2/63
2.2.4.2 Disc Components – K1 2/67

2.2.5 Installation of Layshaft Gear, Multi-Disc Clutches and Output Gear 2/72 ... 2/76

2.2.6 Preassembly and Mounting of the Housing Cover 2/76 ... 2/86

2.2.7 Output 2/87 .. 2/95

2.2.7.1 Installation of the Output Shaft 2/87 .. 2/89
2.2.7.2 Output Flange-Standard Version (without Parking Brake) 2/90 ... 2/92
2.2.7.3 Output Flange-Version with Parking Brake Type: FSG 110 (Knott) 2/93 ... 2/94
2.2.7.4 Output Flange (Converter Side) 2/95

2.2.8 Installation of the Idler Shaft 2/96 ... 2/97

2.2.9 Transmission Pump 2/98 ... 2/106

2.2.9.1 Version combined with 2nd/3rd or 4th Power Take-Off 2/98 ... 2/102
2.2.9.2 Version combined only with the 1st Power Take-Off 2/103 ... 2/106

2.2.10 Input-Converter Bell 2/107 ... 2/114

2.2.11 Coarse Filter 2/114

2.2.12 Inductive and Speed Transmitters 2/115 ... 2/119

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PREFACE

This documentation has been developed for skilled staff trained by the ZF Passau GmbH for the repair and
maintenance works on ZF-units.

Documented is a ZF-serial product representing the design state at the time of the edition.

However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.

The service stations established world-wide by the ZF Friedrichshafen AG are offering to you:

1. Continuously trained staff

2. Prescribed facilities, e.g. special tools

3. Genuine ZF-spare parts meeting the latest state of development

Here, all operations are carried out for you with utmost care and reliability.

Repairs carried out by ZF-service stations are covered by an adequate warranty within the scope of
the applicable contractual conditions.

Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.

ZF Passau GmbH

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GENERAL

The Service Manual covers all works required for the dismantling and the pertaining installation.

When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been
removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing
races, and similar, use suitable pulling devices.

Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:

REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!

CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
The use of Molykote is prohibited.
Lined plates must not be washed. They must be cleaned with a leather cloth.

DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.

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Structure of the Repair Manual

The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.

Important information on industrial safety

Generally, the persons repairing ZF-units are responsible on their own for the industrial safety.

The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.

The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.

The following safety references are used in the present Repair Manual:

) Serves as reference to special working procedures, methods,

information, the use of auxiliaries etc..

CAUTION Is used, if a deviating and improper working procedure can

damage the product.

Is used, if lacking care can lead to personal injury or danger to

DANGER life.

___________________________________________________

REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE

CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description.

REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again.

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BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Densité lineaire en kg/m; Densité superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit New old Conversion Note
Unité Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Masse
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours

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VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION

25,40 mm = 1 in ( inch)

1 kg ( Kilogramm ) = 2,205 lb ( pounds )

9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)

1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5,560 lb / in ( pound per inch )

1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per square inch lbf/in2 )

=
0,070 bar ( 0,071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0,264 Gallon ( Imp. )
=
4,456 Liter 1 Gallon ( Imp. )
=
1 Liter 0,220 Gallon ( US )
=
3,785 Liter 1 Gallon ( US )
=
1609,344 m 1 Mile ( Landmeile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273,15 Kelvin

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TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148

Friction value: μ tot.= 0.12 for screws and nuts without after-treatment, as well as phosphatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following list:

Metric ISO-Standard thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100

Metric ISO-Fine thread DIN 13, Page 13

Abmessung 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300

0/6
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2. TRANSMISSION

2.1 DISASSEMBLY

Fasten the complete transmission to the assembly truck.

(S) Assembly truck 5870 350 000

(S) Holding fixture 5870 350 071

Figure 1

Remove the plug (arrow) and drain the oil.

Then remove the oil cylinder.

Figure 2

Remove all oil pipes, the complete gear shift system and
the duct plate.

Figure 3

2.1.1 Converter Drive

By means of the lifting tackle separate the torque converter from

the transmission.

(S) Eyebolts assortment 5870 204 002

(S) Lifting chain 5870 281 047

Figure 4

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Loosen the bolt connection and by means of the forcing screws

(3x) separate the cover from the converter bell.

(S) Forcing screws 5870 204 005

Figure 5

By means of the extractor pull the oil supply flange out of the
converter bell.

(S) Extractor 5870 000 089

Figure 6

Remove the converter safety valve (arrow 1), if required.

1
) Converter safety valve is fixed by means of slotted pin
(arrow 2)!

2
Figure 7

Loosen the bolt connection (M8 and M12) and by means of lift-
ing tackle and pry bar set separate the converter bell from the
transmission housing.

(S) Eyebolts assortment 5870 204 002

(S) Pry bar set 5870 345 036
(S) Lifting chain 5870 281 047

Figure 8

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Remove the rectangular ring (arrow).

Figure 9

Press the input shaft out of the spur gear bearing. Remove the
released bearing inner ring and the spur gear.

Figure 10

Press off the bearing inner ring from the spur gear.

Figure 11

Remove the converter pressure back-up valve.

Figure 12

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Remove the inductive transmitter.

9 = n – Engine
9

Figure 13

2.1.2 Input Shaft – Pump/Power Take-Off

2.1.2.1 Version with 2nd/3rd and 4th Power Take-Off

) Version with only the 1st power take-off is described from

page 2/6!

Pull the complete input shaft out of the transmission housing and
pump respectively.

Figure 14

Snap-out the rectangular ring (arrow).

Figure 15

Separate the spur gear from the shaft and snap out the retaining
ring (arrow).

Figure 16

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Pull off the bearing inner ring from the spur gear.

(S) Gripping insert 5873 001 020

(S) Basic tool 5873 001 000

Figure 17

Fasten the shaft in the vice.

Loosen the cap screw and remove the clamping plate.

) Use protective jaws!

Figure 18

Pull off the bearing inner ring and driver from the shaft.

) Support the puller on the face-input shaft!

Pay attention to released shim!

(S) Three-armed puller 5870 971 002

Figure 19

Separate the bearing inner ring from the driver.

) Pay attention to the released shim!

If necessary snap out the V-rings (3x).

Figure 20

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2.1.2.2 Version only with the 1st Power Take-Off

Loosen the cap screw.

Figure 21

Remove the cap screw and clamping plate.

Figure 22

Press the input shaft out of the bearing.

) Pay attention to released input shaft as well as shims!

(S) Extractor 5870 000 065

Figure 23

Snap out the rectangular ring (arrow 1) and remove both shims
1 (arrow 2).
2

Figure 24

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2.1.3 Transmission Pump

Loosen the cap and hexagon screws (depending on the version)

respectively and separate the pump flange from the housing.

Figure 25

Loosen the cap screws (4x / M8). Position the extractor on the
transmission pump and fasten it by means of screws (M8x65) to
the transmission pump.
Then pull out the pump from the housing bore.

) Extracting is supported by slightly tapping onto the trans-

mission housing!

(S) Extractor 5870 000 089

Figure 26

Remove the bearing outer ring (Fig. 27)

Version with 2nd/3rd and 4th power take-off.

Pull out the bearing outer ring from the bore.

(S) Internal extractor 5870 300 017

(S) Counter-support 5870 300 009

Figure 27

Remove the ball bearing and the driver (Fig. 28 ... 29)
Version only with 1st power take-off.

Snap out the retaining ring.

Figure 28

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Press out the driver with ball bearing from the bearing bore.
Then separate the ball bearing from the driver.

Figure 29

Loosen the cap screws, take off the pump cover and remove the
rotor set.

If marks due to running-in are found on the pump housing

or housing cover, the complete pump is to be replaced!

Then assemble the rotor set with the chamfer on the tooth tip
showing downwards and install the housing cover again.

Tightening torque (M8/8.8) ................ MA = 23 Nm

Tightening torque (M6/8.8) ................ MA = 9.5 Nm

Figure 30

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2.1.4 Power Take-Off

2.1.4.1 Version with 3rd/and 4th Power Take-Off

) Removal of the 2nd power take-off is described from page

2/16!

Remove the screw-in sleeve (arrow).

Figure 31

Sealing cap is to be drilled centrically and thread M8 to be cut.

By means of the striker expel the sealing cap from the housing
bore.

Figure 32

By means of the striker expel the pin from the housing bore (Fig.
33) and remove the complete spur gear (Fig. 34).

) Pay attention to released shim(s)!

(S) Striker 5870 650 001

Figure 33

Figure 34

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Loosen the hexagon screws and remove the cover.

Figure 35

Remove the pump flange on the rear side and snap out the retain-
ing ring.

) Pay attention to released shim(s)!

(S) Clamping pliers 5870 900 021

Figure 36

Expel the driver from the bearing bore and remove the released
single components.

(S) Plastic hammer 5870 280 004

Figure 37

2.1.5 Layshaft

Remove the sealing cover and loosen the hexagon screw.

Figure 38

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Expel the idler shaft by means of the striker from the housing
bore and layshaft bearing respectively.

(S) Striker 5870 650 014

Figure 39

2.1.6 Removal of Inductive and Speed transmitter

(Fig. 40 ... 41)

5 14 = n – Turbine
14 5 = n – internal speed input
13 = n – Output (Speed transmitter)

Figure 40

13

Figure 41

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2.1.7 Output

2.1.7.1 Standard Version

Converter side:
Remove the lock plate. Loosen hexagon screws and take off the
output flange.
Rotate the housing by 180° and remove the output flange on the
housing rearside.

Figure 42

2.1.7.2 Version with Parking Brake

Type: FSG 110 (Knott)

Transmission rearside:
For working on the brake system observe the instructions
and specifications of the brake manufacturer!

Unscrew the screw cap!

Figure 43

Loosen the counternut and unscrew the adjusting screw in coun-

terclockwise direction until the brake disc is released.

Figure 44

Loosen the cap screws and separate the complete brake from the
transmission housing.

Remove the lock plate. Loosen the hexagon screws and separate
the output flange/brake disc from the output shaft.

(S) Socket spanner 5870 656 047

Figure 45

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2.1.8 Removal of the Clutches and Layshaft

Loosen the hexagon screws and expel the bearing cover KV/K1
by means of the striker from the housing bore.
Remove the bearing cover KR/K2 (arrow) analogously.

) Mark the installation location of the bearing cover!

(S) Threaded insert 5870 204 069

(S) Striker 5870 650 014

Figure 46

Pull out the bearing cover K4/K3 by means of the forcing screws
from the housing bore.

(S) Forcing screws 5870 204 005

Figure 47

Separate the bearing inner ring from bearing cover K4/K3.

(S) Three-armed puller 5870 971 003

Figure 48

Loosen the bolt connection.

Separate the housing cover from the housing by equally tighten-

ing both forcing screws (arrow 1 and 2) as well as the threaded
2 1 spindle (arrow 3).

3 (S) Internal hex. spanner, size 8 5870 290 003

(S) Forcing screws 5870 204 005
(S) Lifting tackle 5870 281 061

Figure 49

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Expel the output shaft from the output gear.

Figure 50

Loosen the hexagon screws and remove the oil baffle.

Lift the output gear out of the transmission housing (Figure).

(S) Stop washer 5870 100 054

(S) Eyebolts assortment 5870 204 002

Figure 51

Remove the bearing inner ring from the output gear.

(S) Three-armed puller 5870 971 003

Figure 52

Take the roller bearing out of the housing bore and remove the
oil baffle (arrow).

Figure 53

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Remove the multi-disc clutches

) For removal of the single clutches observe the following se-

quence:
K4/K3 Ÿ KR/K2 Ÿ KV/K1.
For removal of clutch K4/K3, lift the clutch KR/K2 slightly
and move it in direction of the arrow, see figure!

(S) Eyebolts assortment 5870 204 002

Figure 54

Opposite figure shows the clutches when removed.

K3 K2 K1

K4 KR
KV

Figure 55

Remove the layshaft gear.

Figure 56

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2.1.9 Removal of the 2nd Power Take-Off

Snap out the retaining ring and remove the shims.

Figure 57

Lift the output shaft by means of the pry bar set until the bearing
outer ring is released.

(S) Pry bar set 5870 345 036

Figure 58

Take the output shaft out of the housing.

Figure 59

Pull the bearing outer ring out of the housing bore.

(S) Internal extractor 5870 300 007

(S) Counter-support 5870 300 003

Figure 60

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Pull off the bearing inner ring from the shaft (Fig. 61).

Press off the opposite bearing inner ring from the shaft.

) Shaft and gear cannot be separated (shrink fit)!

(S) Gripping insert 5873 001 027

(S) Back-off insert 5870 026 100

Figure 61

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2.1.10 Dismantling of the Multi-Disc Clutch K3/K4

By means of clamping ring (S) fasten the clutch to the assembly

truck.

(S) Clamping ring 5870 654 033

Figure 62

Pull off the roller bearing from the disc carrier.

(S) Three-armed puller 5870 971 002

Figure 63

Separate spur gear K3 from the disc carrier.

Figure 64

Pull off the bearing inner ring from the disc carrier.

(S) Rapid grip 5873 012 012

(S) Basic tool 5873 002 001

Figure 65

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Squeeze out the snap ring.

Remove the end shim and disc set K3.

Figure 66

Rotate disc carrier by 90°.

Loosen the slotted nut.

(S) Slotted nut wrench 5870 401 118
(S) Slotted nut wrench 5870 401 115

Figure 67

Rotate disc carrier by 90°.

Pull off the taper roller bearing.

(S) Gripping insert 5873 011 012

(S) Basic tool 5873 001 000

Figure 68

Pull off the spur gear K4 from the disc carrier.

(S) Three-armed puller 5870 971 003

Figure 69

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Remove the ring.

Figure 70

Pull off the taper roller bearing.

(S) Three-armed puller 5870 971 002

Figure 71

Squeeze out the snap ring.

Remove the end shim and the disc set K4.

Figure 72

Preload the compression spring by means of fixture (S).

Squeeze out the snap ring and the released single components.

Remove the opposite single components (K3 side) analogously.

(S) Pressure piece 5870 345 072

Figure 73

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Separate both pistons by means of compressed air from the disc

carrier.

Figure 74

2.1.11 Dismantling of the Multi-Disc Clutch KR/K2

Fasten the clutch by means of clamping ring (arrow) on the as-

sembly truck.

(S) Clamping ring 5870 654 033

Figure 75

Rotate disc carrier by 90°.

Loosen the slotted nut.

(S) Slotted nut wrench 5870 401 099

Figure 76

Pull off the taper roller bearing from the disc carrier.

(S) Gripping insert 5873 012 018

(S) Basic tool 5873 002 001

Figure 77

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Press off the spur gear K2 from the disc carrier.

Pay attention to released disc carrier!

Figure 78

Fasten the disc carrier by means of clamping ring (S).

Pull off the taper roller bearing from the disc carrier.

(S) Clamping ring 5870 654 033

(S) Gripping insert 5873 012 019
(S) Basic tool 5873 002 001

Figure 79

Squeeze out the snap ring.

Remove the end shim and disc set K2.

Figure 80

Rotate disc carrier by 90°.

Loosen the slotted nut.

(S) Slotted nut wrench 5870 401 099

Figure 81

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Pull off the taper roller bearing from the disc carrier.

(S) Gripping insert 5873 002 044

(S) Basic tool 5873 002 001

Figure 82

Fasten spur gear KR by means of clamping ring (arrow) and pull

it from the disc carrier.

) Collar of the clamping ring must show upwards (to the spur
gear)!

(S) Three-armed puller 5870 971 003

(S) Clamping ring 5870 654 045

Figure 83

Remove the ring.

Figure 84

Squeeze out the snap ring.

Remove end shim and disc set KR.

Figure 85

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Pull off the taper roller bearing from the disc carrier.

(S) Gripping insert 5873 012 013

(S) Basic tool 5873 002 001

Remove both pistons (like described in Fig. 73 and 74).

Figure 86

2.1.12 Dismantling of the Multi-Disc Clutch KV/K1

Fasten clutch by means of clamping ring to the assembly truck.

Loosen the slotted nut (Fig. 87).

(S) Clamping ring 5870 654 033
(S) Slotted nut wrench 5870 401 118
(S) Slotted nut wrench 5870 401 099

Figure 87

Pull off the taper roller bearing from the disc carrier.

(S) Gripping insert 5873 001 023

(S) Basic tool 5873 001 000

Figure 88

Remove the shim.

Figure 89

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Pull off spur gear K1 from the disc carrier.

(S) Three-armed puller 5870 971 003

Figure 90

Opposite figure shows the spur gear bearing K1.

1 Bearing (1) can only be obtained as complete part.

If it is necessary to remove the clutch-pack-sided ball bearing

(arrow or Fig. 93 and 94), the complete bearing (1) has to be
removed!

Figure 91

Take off the bush.

Figure 92

Pull off the ball bearing from the disc carrier (Fig. 93 and 94).

) Pay attention to released balls!

Figure 93

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Figure 94

Squeeze out the snap ring.

Remove end shim and disc set K1.

Figure 95

Rotate disc carrier by 90°.

Loosen the slotted nut.

(S) Slotted nut wrench 5870 401 118
(S) Slotted nut wrench 5870 401 115

Figure 96

Pull off the taper roller bearing from the disc carrier.

(S) Gripping insert 5873 001 034

(S) Basic tool 5873 001 000

Figure 97

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Pull off spur gear KV from the disc carrier.

(S) Three-armed puller 5870 971 003

Figure 98

Remove the ring.

Figure 99

Pull off the taper roller bearing from the disc carrier (Figure
100).

Squeeze out the snap ring.

Remove end shim and disc set KV.

Remove both pistons (like described in Fig. 73 and 74).

(S) Gripping insert 5873 001 034

(S) Basic tool 5873 001 000

Figure 100

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)
2.2 REASSEMBLY
1 2 2.2.1 Power Take-Off

3 The following assembly description refers to several power

takes-off (depending on the version)!

Figure 101 and 102 show the installation survey with arrange-
ment of the single power takes-off.
K1

KV

1 = 1st power take-off (standard version)

K2

KR

K3
2 = 2nd power take-off
Assembly, see page 2/29 and 2/30
K4

3 = 3rd and 4th power take-off

Assembly, see page 2/31 to 2/35

4 =

Figure 101

Figure 102

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2.2.1.1 2nd Power Take-Off

Undercool the shaft (ca. - 80° C), heat the gear (approx. + 120°
C) and install or press it until contact.

Figure 103

Press the bearing inner ring until contact.

Press the opposite bearing inner ring until contact.

Figure 104

Insert the bearing outer ring (arrow) into the housing bore until
contact.

Figure 105

Position the preassembled power take-off shaft in the housing

and insert the bearing outer ring until contact.

Figure 106

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Axial play – power take-off bearing max. 0.10 mm, to be

adjusted by means of shim(s) and retaining ring.

Figure 107

Rotate the transmission housing by 180°.

Insert the sealing disc (arrow) with the concave side showing
downwards into the housing bore until contact.

) Wet contact face with Loctite (Type No. 262)!

Do not damage the centric orifice bore ∅ 0.80 mm when

installing the sealing disc!

Figure 108

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2.2.1.2 3rd/4th Power Take-Off

2

1 To Figure 109:
3
1 = Ball bearing
6 2 = Spur gear
3 = Driver
4
4 = Ball bearing
5 = Pump flange
7 6 = Cover
5 7 = Intermediate gear
8 = Shim
9 = Pin
11 9 10 = Sealing cover
11 = Orifice

10
8

Figure 109

Insert the ball bearing (1) into the housing bore until contact.

Figure 110

Position spur gear (2).

) Pay attention to the installation position, see sketch 109!

Figure 111

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Heat the ball bearing (inner ring) and bore of the gear respec-
tively.

(S) Hot-air blower 230V 5870 221 500

(S) Hot-air blower 115V 5870 221 501

Figure 112

Align the spur gear centrally and insert the driver (3) until con-
tact.

) Pay attention to the installation position, also see sketch page

2/31!

Figure 113

Install the ball bearing (4) by means of fixture until contact.

) Pay attention to perfect contact of the ball bearing!

(S) Fixture 5870 000 083

Figure 114

Adjust the axial play of power take-off bearing = 0.2 ... 0.3
mm (Figure 115 ... 116)

Fasten ball bearing by means of shim s = 1.80 mm (empirical

value) and retaining ring.

(S) Clamping pliers 5870 900 021

Figure 115

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Check the axial play by means of feeler gauge!

) If different from the required axial play = 0.2 ... 0.3 mm this is to
be corrected with the corresponding shim!

(S) Feeler gauge 5870 200 112

Figure 116

Place the O-Ring (arrow) in the annular groove of the pump

flange (5) and grease it.

Figure 117

Fasten the pump flange (5) by means of hexagon screws.

Tightening torque (M14/8.8) ............ MA = 125 Nm

Figure 118

Converter side:

Place the O-Ring (arrow) with assembly grease in the recess of

the housing bore.

Figure 119

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Fasten the cover (6) with hexagon screws.

Tightening torque (M14/8.8) ............ MA = 125 Nm

Provide the orifice (arrow) with a new sealing ring (CU) and
install it.

Figure 120

Preassemble the intermediate gear (7) according to Figure 121.

) Exact locating of the single components to be ensured by

pressing!

Figure 121

Put in the bearing inner rings and position the intermediate gear
(7), see arrow!

Figure 122

Adjust the axial play-intermediate gear bearing max. 0.1 mm

(Figure 123 ... 124)

Determine the gap size by means of feeler gauge (arrow).

Dim. I e.g. ....................................... 1.25 mm

Example

Dim. I (gap size) .............................. 1.25 mm

Axial play (0 .... 0.1 mm) e.g. ........ - 0.05 mm
Figure 123 resulting shim e.g. s = 1.20 mm

(S) Feeler gauge 5870 200 112

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Install the corresponding shim (8) e.g. s = 1.20 mm (arrow).

) Install shim on the converter side!

Figure 124

Align the single components centrically.

Undercool the pin (9) and install it until contact.

Figure 125

Flush-mount the sealing cover (10) with the concave side show-
1 ing upwards (arrow 1).

) Wet contact face of the sealing cover with Loctite (Type No.
262)!

2 Provide orifice (11) with a new O-Ring and install it

(arrow 2).

Figure 126

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2.2.2 Assembly of the Multi-Disc Clutch K4/K3

The following sketch shows the clutch sectioning

1
3
2
K4 K3

5 4 4 5

Figure 127

To Figure 127:

1 = Disc carrier (assy)

2 = Spur gear K4
3 = Spur gear K3
K4 = Multi-disc clutch K4
K3 = Multi-disc clutch K3
4 = Piston
5 = Compression spring
6 = Plug 2x (König)
7 = Plug 1x (König)

) Observe the installation position of the single components for the following assembly!

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Lift the disc carrier with the K4-side showing downwards into
the clamping ring (S) and fasten it.
Rotate disc carrier by 180°.
(S) Clamping ring 5870 654 033

To install new disc carriers the finished bores have to be

sealed with plugs (König)!
Installation position, see arrow, Figure 128 and 129!

(S) Hand inserting tool 5870 320 014

Figure 128 (S) Ratchet spanner 5870 320 018

Figure 129

Flush-mount the drain valve (arrow) with the chamfer showing

downwards.

(S) Inserting tool 5870 320 019

Figure 130

Put both O-Rings scroll-free into the annular grooves of the

piston, see arrows!

Figure 131

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Oil the O-Rings and the piston contact surface.

Install K3 piston equally until contact.

) Observe the installation position of the piston, see figure!

Figure 132

Install spacer and compression spring.

Figure 133

Place guide ring, with the chamfer (arrow) showing upwards,

over the compression spring and install the snap ring.

Figure 134 Lift the disc carrier out of the clamping ring.
Preload the compression spring by means of fixture (S) and
engage the snap ring into the annular groove of the disc carrier
(arrow), see Fig. 135!

(S) Fixture 5870 345 072

or
(S) Clamping fixture 5870 654 036

Install the drain valve, piston and compression spring on the

opposite side (Clutch K4) analogously ( Fig. 130 ...135)!

Then lift the disc carrier with the K4-side showing downwards
into the clamping ring and fasten it.
Rotate disc carrier by 180°.
Figure 135

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2.2.2.1 Disc Components K4

) Below sketch or table shows the standard version as to the installation position of the single components!
Obligatory is the respective spare parts list!

K4 K3

3 4 3 2 1

7 6 5

Figure 136

Pos. Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 Coated on one side
4 Outer clutch disc 5 2.5 Coated on both sides
5 Inner clutch disc 3 3.5
6 Inner clutch disc 1 4.0
7 Inner clutch disc 2 2.5 ... 4.0 optional
8 Snap ring 1 2.10 ... 3.10 optional
9 End shim 1
Number of friction surfaces: 12
Disc clearance: 2.2 ... 2.4 mm

) Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively!
The respective clutch side can be seen on the length of the disc carrier, see sketch!
K4 = Dimension X (short disc carrier side)
K3 = Dimension Y (long disc carrier side)

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Check disc clearance K4 = 2.2 ... 2.4 mm (Fig. 137 ... 139)

) In order to ensure a perfect measuring result, the disc set is

first of all to be installed without oil!

Install disc set according to sketch or table (Page 2/39).

Figure 137

Install the end shim and fasten it by means of the snap ring.

Figure 138

Press on end shim with approx. 100 N (10 kg) and set dial
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance on the dial indicator.

) If the required disc clearance differs, it has to be corrected

with the adequate inner clutch disc or/and snap ring, see
table / Pos. 7 and Pos. 8!

Upon setting of disc clearance, remove the disc set, oil the clutch
discs to ZF List of Lubricants TE-ML 03 and reinstall them.

Figure 139
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057

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Preassemble and install spur gear K4 (Fig. 140 ... 144):

4 1 Opposite figure shows the single components of spur gear K4.

2
3
1 2 1
2
=
=
Bearing inner ring
Bearing outer ring
3 = Ring
4 = Spur gear

Locate both bearing outer rings (2) until contact.

Figure 140

Heat the bearing inner ring and install it until contact.

Figure 141

Install the ring (3).

Figure 142

Assemble the spur gear until all inner clutch discs are located.

Figure 143

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Heat the bearing inner ring (spur gear bearing) and locate it until
contact.

Use safety gloves!

Figure 144

Heat the bearing inner ring (clutch bearing) and install it until
contact.

Use safety gloves!

Figure 145

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2.2.2.2 Clutch Components K3

) Below sketch or table shows the standard version as to the installation position of the single components!
Obligatory is the respective spare parts list!

K4 K3

1 2 3 4 3

5 6

Figure 146

Pos. Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 coated on one side
4 Outer clutch disc 8 2.5 coated on both sides
5 Inner clutch disc 7 3.0
6 Inner clutch disc 2 2.5 ... 4.0 optional
7 Snap ring 1 2.10 ... 3.10 optional
8 End shim 1
Number of friction surfaces: 18
Disc clearance: 2.6 ... 2.8 mm

) Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively!
The respective clutch side can be seen on the length of the disc carrier, see sketch!
K3 = Dimension Y (long disc carrier side)
K4 = Dimension X (short disc carrier side)

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Check disc clearance K3 = 2.6 ... 2.8 mm (Fig. 147 ... 149)

) In order to ensure a perfect measuring result, the disc set is

first of all to be installed without oil!

Install disc set according to sketch or table (Page 2/43).

Figure 147

Install the end shim and fasten it by means of the snap ring.

Figure 148 Press on end shim with approx. 100 N (10 kg) and set dial
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance on the dial indicator.

)
If the required disc clearance differs, it has to be corrected
with the adequate inner clutch disc or/and snap ring, see
table / Pos. 6 and Pos. 7!

Upon setting of disc clearance, remove the disc set, oil the clutch
discs to ZF List of Lubricants TE-ML 03 and reinstall them.

(S) Magnetic stand 5870 200 055

Figure 149 (S) Dial indicator 5870 200 057

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Heat the bearing inner ring and install it until contact.

Use safety gloves!

Figure 150

Lift the disc carrier out of the clamping ring (S).

To ensure the exact locating of the single components, preload

the bearing with 100 000 N (10 t) (Fig. 151)

Support on the lower as well as upper bearing inner ring!

Use pressure pieces (S)!

(S) Pressure piece 5870 506 096

Figure 151

Lift the disc carrier with the K4-side showing downwards into
the clamping ring (S) and fasten it.
Rotate disc carrier by 90°.

Install the slotted nut.

) Observe installation position of the slotted nut! Collar

∅ 60 mm) must show to the bearing inner ring, also see
(∅
sketch/page 2/36! Oil the thread!
Tightening torque ....................... MA = 550 Nm
(S) Clamping ring 5870 654 033
(S) Slotted nut wrench 5870 401 118
Figure 152
(S) Slotted nut wrench 5870 401 115

Install the bearing outer ring into spur gear K3 until contact.

Figure 153

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Assemble the spur gear until all inner clutch discs are located.

Figure 154

Heat the roller bearing and locate it until contact.

Use safety gloves!

Figure 155

Install the bearing inner ring.

Figure 156

Check function of the clutches K3 and K4 by means of com-

pressed air.

) Closing or opening of the clutches is clearly audible when the

single parts have been installed adequately!

Figure 157

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Snap-in and lock the rectangular rings (3x, see arrows).

Figure 158

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2.2.3 Assembly of the Multi-Disc Clutch KR/K2

The following sketch shows the clutch sectioning!

2 1 3

KR K2

5 4 4 5

Figure 159

To Figure 159:

1 = Disc carrier
2 = Spur gear KR
3 = Spur gear K2
KR = Multi-disc clutch KR
K2 = Multi-disc clutch K2
4 = Piston
5 = Compression spring
6 = Plug 2x (König)
7 = Plug 1x (König)

) Observe the installation position of the single components for the following assembly!

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Lift the disc carrier with the KR-side showing downwards into
the clamping ring (S) and fasten it.

Then rotate disc carrier by 180°.

To install new disc carriers the finished bores have to be

sealed with plugs (König)!
Installation position, see arrow, Figure 160 ... 161!

(S) Clamping ring 5870 654 033

(S) Hand mounting tool 5870 320 014
(S) Ratchet 5870 320 018
Figure 160

Figure 161

Flush-mount the drain valve (arrow) with the chamfer showing

downwards.

(S) Inserting tool 5870 320 019

Figure 162

Put both O-Rings scroll-free into the annular grooves of the

piston, see arrows!

Figure 163

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Oil the O-Rings and the piston contact surfaces.

Install K2 piston equally until contact.

) Observe the installation position of the piston, see figure!

Figure 164

Install spacer and compression spring.

Figure 165

Place guide ring, with the chamfer (arrow) showing upwards,

over the compression spring and install the snap ring.

Figure 166
Lift the disc carrier out of the clamping ring (S).

Preload the compression spring by means of fixture (S) and

engage the snap ring into the annular groove of the disc carrier
(arrow), see Fig. 167!

Install the drain valve, piston and compression spring on the

opposite side (Clutch KR) analogously (like Fig. 162 ... 167)!

Then lift the disc carrier with the KR-side showing downwards
into the clamping ring (S) and fasten it.
Rotate disc carrier by 180°.

(S) Pressure piece 5870 345 072

Figure 167 or
(S) Clamping fixture 5870 654 036

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2.2.3.1 Disc Components KR

) Below sketch or table shows the standard version as to the installation position of the single components!
Obligatory is the respective spare parts list!

KR K2

Figure 168

Pos. Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 coated on one side
4 Outer clutch disc 11 3.35 coated on both sides
5 Inner clutch disc 5 2.5
6 Inner clutch disc 5 3.0
7 Inner clutch disc 2 2.5 ... 4.0 optional
8 Snap ring 1 2.10 ... 3.1 optional
9 End shim 1
Number of friction surfaces: 24
Disc clearance: 2.8 ... 3.0 mm

) Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively!
The respective clutch side can be seen on the length of the disc carrier, see sketch!
KR = Dimension Y (long disc carrier side)
K2 = Dimension X (short disc carrier side)

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Check disc clearance KR = 2.8 ... 3.0 mm (Fig. 169 ... 171)

) In order to ensure a perfect measuring result, the disc set is

first of all to be installed without oil!

Install disc set according to sketch or table (Page 2/51).

Figure 169

Install the end shim and fasten it by means of the snap ring.

Figure 170

Press on end shim with approx. 100 N (10 kg) and set dial
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance on the dial indicator.

) If the required disc clearance differs, it has to be corrected

with the adequate inner clutch disc or/and snap ring, see
table / Pos. 7 and Pos. 8!

Upon setting of disc clearance, remove disc set, oil clutch discs
to ZF List of Lubricants TE-ML 03 and reinstall them.

Figure 171
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057

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Preassemble and install spur gear KR (Fig. 172 ... 176)

Opposite figure shows the single components of spur gear KR.

1 = Bearing inner ring (75 x 37 mm)

2 = Ring
3 = Spur gear
4 = Bearing inner ring (75 x 41 mm)

1 2 3 4
Figure 172

Heat the bearing inner ring (75 x 37 mm) and install it until con-
tact.

Use safety gloves!

Figure 173

Assemble the spur gear until all inner clutch discs are located.

Figure 174

Install the ring.

Figure 175

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Heat the bearing inner ring (75 x 41) and locate it until contact.

Use safety gloves!

Figure 176

Heat the bearing inner ring (clutch bearing) and locate it until
contact.

Use safety gloves!

Figure 177

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2.2.3.2 Disc Components K2

) Below sketch or table shows the standard version as to the installation position of the single components!
Obligatory is the respective spare parts list!

KR K2

Figure 178

Pos. Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 coated on one side
4 Outer clutch disc 8 2.5 coated on both sides
5 Inner clutch disc 7 3,0
6 Inner clutch disc 2 2.5 ... 4.0 optional
7 Snap ring 1 2.10 ... 3.10 optional
8 End shim 1
Number of friction surfaces: 18
Disc clearance: 2.6 ... 2,8 mm

Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively!

) The respective clutch side can be seen on the length of the disc carrier, see sketch!
K2 = Dimension X (short disc carrier side)
KR = Dimension Y (long disc carrier side)

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Check disc clearance K2 = 2.6 ... 2.8 mm (Fig. 179 ... 181)

) In order to ensure a perfect measuring result, the disc set is

first of all to be installed without oil!

Install disc set according to sketch or table (Page 2/55).

Figure 179

Install the end shim and fasten it by means of the snap ring.

Figure 180

Press on end shim with approx. 100 N (10 kg) and set dial
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance on the dial indicator.

) If the required disc clearance differs, it has to be corrected

with the adequate inner clutch disc or/and snap ring, see
table / Pos. 6 and Pos. 7!

Upon setting of disc clearance, remove the disc set, oil the clutch
discs to ZF List of Lubricants TE-ML 03 and reinstall them.

Figure 181
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057

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Preassemble and install spur gear K2 (Fig. 182 ... 186):

1
Undercool gear 1 (approx. – 80° C) and heat gear 2 (approx.
2 120° C).
Engage the snap ring (arrow), preload it and join both compo-
nents by means of hydr. press until the snap ring engages into the
annular groove of gear 2.

Figure 182

Opposite figure shows the single components of the spur gear

bearing.

1 = Bearing inner ring

2 = Spur gear assy
1 3 = Bearing inner ring

3
2
Figure 183

Heat the bearing inner ring and install it until contact.

Use safety gloves!

Figure 184

Assemble the spur gear until all inner clutch discs are located.

Figure 185

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Heat the bearing inner ring (spur gear bearing) and install it until
contact.

Use safety gloves!

Figure 186

Heat the bearing inner ring (clutch bearing) and locate it until
contact.

Use safety gloves!

Figure 187

Lift the disc carrier out of the clamping ring (S).

To ensure the exact locating of the single components, preload

the bearing with 100 000 N (10 t) (Fig. 188).

Support on the lower as well as upper bearing inner ring!

Use pressure pieces (S)!

(S) Pressure pieces 5870 506 096

Figure 188

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Lift the disc carrier into the clamping ring (S) and fasten it.
Rotate disc carrier by 90°.
K2-side:
Install the slotted nut.

) Observe installation position of the slotted nut! Chamfer

must
show to the bearing inner ring, also see sketch/page 2/48!
Oil the thread!
Tightening torque ..................... MA = 800 Nm

Figure 189 (S) Clamping ring 5870 654 033

(S) Slotted nut wrench 5870 401 099

KR-side:
Install the slotted nut

) Observe installation position of the slotted nut! Collar

∅ 76 mm) must show to the bearing inner ring, also see
(∅
sketch/page 2/48!
Oil the thread!
Tightening torque ..................... MA = 800 Nm

(S) Slotted nut wrench 5870 401 099

Figure 190

Check function of the clutches K3 and K4 by means of com-

pressed air (Fig. 191).

) Closing or opening of the clutches is clearly audible when the

single parts have been installed adequately!

Snap-in and lock the rectangular rings (3x, see arrows).

Figure 191

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2.2.4 Assembly of the Multi-Disc Clutch KV/K1

The following sketch shows the clutch sectioning

2 1

KV K1
7

5 4 4 5

Figure 192

To Figure 192:

1 = Disc carrier
2 = Spur gear KV
3 = Spur gear K1
KV = Multi-disc clutch KV
K1 = Multi-disc clutch K1
4 = Piston
5 = Compression spring
6 = Plug 2x (König)
7 = Plug 1x (König)

) Observe the installation position of the single components for the following assembly!

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Lift the disc carrier with the KV-side showing downwards into
the clamping ring (S) and fasten it.

Then rotate disc carrier by 180°.

To install new disc carriers the finished bores have to be

sealed with plugs (König)!
Installation position, see arrow, Figure 193 ... 194!

(S) Hand mounting tool 5870 320 014

(S) Ratchet spanner 5870 320 018

Figure 193

Figure 194

Flush-mount the drain valve (arrow) with the chamfer showing

downwards.

(S) Inserting tool 5870 320 019

Figure 195

Put both O-Rings scroll-free into the annular grooves of the

piston, see arrows!

Figure 196

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Oil the O-Rings and the piston contact surfaces.

Install K1 piston equally until contact.

) Observe the installation position of the piston, see figure!

Figure 197

Install spacer and compression spring.

Figure 198

Place guide ring, with the chamfer (arrow) showing upwards,

over the compression spring and install the snap ring.

Figure 199

Lift the disc carrier out of the clamping ring.

Preload the compression spring by means of fixture (S) and
engage the snap ring into the annular groove of the disc carrier
(arrow), see Fig. 200!
Install the drain valve, piston and compression spring on the
opposite side (Clutch KV) analogously.
Then lift the disc carrier with the KV-side showing downwards
into the clamping ring (S) and fasten it.
Rotate disc carrier by 180°.
(S) Pressure piece 5870 345 072
Figure 200
or
(S) Clamping fixture 5870 654 036

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2.2.4.1 Disc Components KV

) Below sketch or table shows the standard version as to the installation position of the single components!
Obligatory is the respective spare parts list!

KV K1
Y X
3 4 3 2 1

7 5 6 5

Figure 201

Pos. Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 coated on one side
4 Outer clutch disc 11 2.5 coated on both sides
5 Inner clutch disc 9 3,5
6 Inner clutch disc 1 4,0
7 Inner clutch disc 2 2.5 ... 4.0 optional
8 Snap ring 1 2.10 ... 3,10 optional
9 End shim 1
Number of friction surfaces: 24
Disc clearance: 2.8 ... 3,0 mm

)
Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively!
The respective clutch side can be seen on the length and ∅ of the disc carrier respectively, see sketch!
KV = Dimension Y (long disc carrier side and large ∅ respectively)
K1 = Dimension X (short disc carrier side and small ∅ respectively)

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Check disc clearance KV = 2.8 ... 3.0 mm (Fig. 202 ... 204)

) In order to ensure a perfect measuring result, the disc set is

first of all to be installed without oil!

Install disc set according to sketch or table (Page 2/63).

Figure 202

Install the end shim and fasten it by means of the snap ring.

Figure 203

Press on end shim with approx. 100 N (10 kg) and set dial
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance on the dial indicator.

)
If the required disc clearance differs, it has to be corrected
with the adequate inner clutch disc or/and snap ring, see
table / Pos. 7 and Pos. 8!

Upon setting of disc clearance, remove the disc set, oil the clutch
discs to ZF List of Lubricants TE-ML 03 and reinstall them.

Figure 204
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057

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Preassemble and install spur gear KV (Fig. 205 ... 209)

Opposite figure shows the single components of spur gear KV.

1 = Bearing inner ring

2 = Bearing outer ring
3 = Ring
4 = Spur gear

2 1
4 Install both bearing outer rings (2) until contact.

1 2 3
Figure 205

Heat the bearing inner ring and install it until contact.

Use safety gloves!

Figure 206

Install the ring.

Figure 207

Assemble the spur gear until all inner clutch discs are located.

Figure 208

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Heat the bearing inner ring (spur gear bearing) and locate it until
contact.

Use safety gloves!

Figure 209

Heat the bearing inner ring (clutch bearing) and locate it until
contact.

Use safety gloves!

Rotate disc carrier by 180°.

Figure 210

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2.2.4.2 Disc Components K1

) Below sketch or table shows the standard version as to the installation position of the single components!
Obligatory is the respective spare parts list!

KV K1
Y X

1 2 3 4 3

5 6

Figure 211

Pos. Description Quantity s (mm) Remarks

1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 coated on one side
4 Outer clutch disc 8 2.5 coated on both sides
5 Inner clutch disc 7 2,5
6 Inner clutch disc 2 2.5 ... 4.0 optional
7 Snap ring 1 2.1 ... 2.5 optional
8 End shim 1
Number of friction surfaces: 18
Disc clearance: 2.6 ... 2.8 mm

Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively!

) The respective clutch side can be seen on the length and ∅ of the disc carrier respectively, see sketch!
K1 = Dimension X (short disc carrier side and small ∅ respectively)
KV = Dimension Y (long disc carrier side and large ∅ respectively)

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Check disc clearance K1 = 2.6 ... 2.8 mm (Fig. 212 ... 214)

) In order to ensure a perfect measuring result, the disc set is

first of all to be installed without oil!

Install disc set according to sketch or table (Page 2/67).

Figure 212

Install the end shim and fasten it by means of the snap ring.

Figure 213

Press on end shim with approx. 100 N (10 kg) and set dial
indicator to „Zero“.
Then press end shim against snap ring (upwards) and read disc
clearance on the dial indicator.

) If the required disc clearance differs, it has to be corrected

with the adequate inner clutch disc or/and snap ring, see
table / Pos. 6 and Pos. 7!

Upon setting of disc clearance, remove disc set, oil clutch discs
to ZF List of Lubricants TE-ML 03 and reinstall them.

Figure 214
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057

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Preassemble and install spur gear K1 (Fig. 215 ... 222):

1 Opposite figure shows the single components of spur gear K1.

1 = Ball bearing (assy)

2 = Snap ring
3 = Spur gear

2 3 ) Prior to installation of the single components, align the disc

set by means of the spur gear radially and center it, see Fig.
216!

Figure 215

Figure 216

Install the snap ring.

Figure 217

Install the bush with collar (arrow) on face end showing to the
snap ring.

Figure 218

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Press in the ball bearing until contact.

) Install the ball bearing with the lubricating groove (arrow)

showing downwards!
Put the press-in tool only to the bearing outer ring!

Figure 219

Heat the second ball bearing and install it until contact.

) Lubricating groove (arrow), must show upwards!

Use safety gloves!

Figure 220

Assemble the bush.

Figure 221

Heat the spur gear to approx. 120° C and assemble it until all
inner clutch discs are located.

Use safety gloves!

Figure 222

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Install shim s = 1,20 mm.

Figure 223

Heat the bearing inner ring and install it until contact.

Use safety gloves!

Figure 224

Lift the disc carrier out of the clamping ring (S).

To ensure the exact locating of the single components, preload
the bearing with 100 000 N (10 t) (Fig. 225).

Support on the lower as well as upper bearing inner ring!

Use pressure pieces (S)!

(S) Pressure pieces 5870 506 096

Figure 225
Lift the disc carrier into the clamping ring (S).
Rotate disc carrier by 90°.
Install the slotted nut.

) Observe installation position of the slotted nut! Collar

∅ 60 mm) must show to the taper roller bearing, also see
(∅
sketch/page 2/60!
Oil the thread!
Tightening torque ....................MA = 550 Nm
(S) Slotted nut wrench 5870 401 118
(S) Slotted nut wrench 5870 401 099

Install the opposite slotted nut (KV-side) analogously.

Figure 226
(S) Slotted nut wrench 5870 401 118
(S) Slotted nut wrench 5870 401 115

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Check function of the clutches KV and K1 by means of com-

pressed air.

) Closing or opening of the clutches is clearly audible when the

single parts have been installed adequately!

Figure 227

Snap-in and lock the rectangular rings (3x, see arrows).

Figure 228

1 2.2.5 Installation of Layshaft Gear, Multi-Disc Clutches and

3 Output Gear
2
1 Opposite figure shows the single components of the layshaft gear
bearing.

1 = Bearing inner ring (2x)

2 = Ring
3 = Layshaft gear

Figure 229

Position layshaft gear (assy) in the housing.

) Only when the clutches are installed, the idler shaft can be
mounted!

Figure 230

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Insert the bearing outer rings KV/K1, KR/K2 and K3/K4 into the
housing bores until contact, see arrows.

Figure 231

Position clutch KV/K1 by means of lifting tackle.

(S) Eyebolts assortment 5870 204 002

Figure 232

Position clutch KR/K2.

(S) Eyebolts assortment 5870 204 002

Figure 233

Check the installation position of the layshaft gear (arrow) once

again and correct it, if required.

Figure 234

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Fasten the spur gear K3 by means of fixture and eyebolt (arrow)

axially.

) Spur gear fixing prevents the clutch discs from dislocating

when the clutch is lifted in!

(S) Assembly fixture 5870 345 033

(S) Eyebolt 5870 204 066

Figure 235

Lift the clutch KR/K2 slightly, move it in direction of the arrow

and position clutch K3/K4.

Then remove the fixture (Fig. 235) again.

Figure 236

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Insert the bearing outer ring into the housing bore until contact.

Figure 237

Heat the bearing inner ring and install it until contact.

Use safety gloves!

) Observe installation position – collar (arrow) shows to the

spur gear! Install the bearing inner ring after cooling down
subsequently (press)!

Figure 238

Position the oil baffle.

Figure 239

Install the output gear by means of lifting tackle.

(S) Stop washer 5870 100 054

(S) Eyebolts assortment 5870 204 002

Figure 240

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Position upper oil baffle and fasten both plates by means of

hexagon screws (4x).

) Install washers!
Secure hexagon screws with Loctite (Type No. 243)!

Tightening torque (M8/8.8) ....................MA = 23 Nm

1.

Figure 241 2.2.6 Preassembly and Mounting of the Housing Cover

Note to Fig. 242 and 243:

Depending on the transmission version, differences as re-
gards the single components and their installation position
are possible!
Obligatory is the respective spare parts list!

) Install the sealing cover (arrow).

Wet the sealing surface with Loctite (Type No. 262)!

Figure 242

Insert the O-Ring into the annular groove of the cover and fasten
the cover by means of hexagon screws.

) Wet the thread of the hexagon screws with Loctite (Type No.
574)! Observe the installation position of the cover, see Fig-
ure!

Tightening torque (M8/8.8) .................... MA = 23 Nm

Figure 243

Wet the mounting face with sealing compound (Loctite, Type

No. 574).
By means of the lifting tackle place the housing cover on the
transmission housing until contact.

(S) Lifting tackle 5870 281 055

Figure 244

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Install both cylindrical pins (arrow 1 and 2) and the slotted pin
2 (arrow 3).

Then fasten the housing cover by means of hexagon and cap

screws.

Tightening torque M10/8.8) ................. MA = 46 Nm

3 1

Figure 245

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Adjust the bearing preload of clutch K4/K3 = 0.0 ... 0.05 mm

1 (Fig. 248 ... 250)

) For installation of a new bearing cover, both finished bores

have to be sealed by means of a plug (König)!
Finished bores are located opposite (180°) to each other, also
2 see arrow/Fig. 246 and 247!
To Figure 246 and 247:
1 = Bearing cover-K4/K3
(S) 2 = Plug (König)
(S) = Special tool
Figure 246 (S) Hand mounting tool 5870 320 014
(S) Ratchet spanner 5870 320 018

(S)

Figure 247

Housing dimension:
Press on equally the bearing inner ring and determine Dim. I,
from the mounting face to the bearing inner ring.
Dim. I e.g. ........................................... 43.65 mm

) Take several measuring points and determine the mean

value!
Then remove the bearing inner ring again.

(S) Measuring shaft 5870 200 022

(S) Digital depth gauge 5870 200 072
Figure 248

Cover dimension:

Determine Dim. II, from the mounting face until contact/bearing

inner ring.

Dim. II e.g. ......................................... 42.12 mm

(S) Straightedge 5870 200 022

(S) Gauge blocks 5870 200 067
(S) Digital depth gauge 5870 200 072

Figure 249

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Example:

Dim. I ................................................. 43.65 mm

Dim. II ................................................ - 42.12 mm
Difference .......................................... = 1.53 mm
Bearing preload ....................... e.g. + 0.02 mm
Resulting shim(s) s = 1.55 mm

Put on the shim.

Figure 250

Heat the bearing inner ring and place it until contact.

Use safety gloves!

)
Install the bearing inner ring after cooling down subse-
quently (press)!

Figure 251

Grease the rectangular rings (3x, arrows) and centrally align

them.

Figure 252

Install the O-Ring (arrow) and grease it.

Heat the inner diameter of the bearing cover (bearing seat).

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501

Figure 253

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Install two adjusting screws.

Assemble the bearing cover and tighten it equally until contact
by means of hexagon screws.

Tightening torque M10/8.8) ................. MA = 46 Nm

) Observe the radial installation position!

(S) Adjusting screws 5870 204 007

Figure 254

Check the function of both clutches by means of compressed air!

) In case of a decisive pressure loss, the possible cause might be

the breakage of one or several rectangular rings (see arrow,
Figure 252)!
Replace the rectangular rings, if required!

Figure 255

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Adjust the bearing preload of clutch KR/K2 = 0.0 ... 0.05 mm

1 (Fig. 258 ... 262):

) For installation of a new bearing cover, both finished bores

have to be sealed by means of a plug (König)!
Finished bores are located opposite (180°) to each other, also
2 see arrow/Fig. 256 and 257!

To Figure 256 and 257:

(S) 1 = Bearing cover-KR/K2

2 = Plug (König)
Figure 256 (S) = Special tool

(S) Hand mounting tool 5870 320 014

1 (S) Ratchet spanner 5870 300 018

(S)
Figure 257

Install both studs (arrows).

) Wet the thread with Loctite (Type No. 243)!

Tightening torque (M10) ................. MA = 13 Nm

Figure 258

Install the bearing outer ring until contact.

) Pay attention to exact contact!

Figure 259

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Housing dimension:

Determine Dim. I, from the bearing outer ring to the mounting

face.

Dim. I e.g. ............................................ 16.13 mm

Figure 260

Cover dimension:

Determine Dim. II, from the contact/bearing outer ring to the

mounting face.

Dim. II e.g. ........................................... 17.75 mm

(S) Digital depth gauge 5870 200 072

Figure 261

Example:

Dim. II ................................................. 17.75 mm

Dim. I ................................................... - 16.13 mm
Difference ............................................ = 1.62 mm
Bearing preload ..............................e.g. + 0.03 mm
resulting shim(s) s = 1.65 mm

Fix the shim with assembly grease into the cover.

Install the O-Ring (arrow).

Figure 262

Grease the rectangular rings (arrows) and centrally align them.

Figure 263

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Pull the bearing cover equally until contact.

Tightening torque M10/8.8) ................. MA = 46 Nm

Figure 264

Check the function of both clutches by means of compressed air!

) In case of a decisive pressure loss, the possible cause might be

the breakage of one or several rectangular rings (see Figure
263)!
Replace the rectangular rings, if required!

Figure 265

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Adjust the bearing preload of clutch KV/K1 = 0.0 ... 0.05 mm

1 (Fig. 267 ... 270)

) For installation of a new bearing cover, both finished bores

have to be sealed by means of a plug (König)!
Installation position, see arrows / Fig. 266 !
2
To Figure 266:

(S) 1 = Bearing cover-KV/K1

2 = Plug (König)
Figure 266 (S) = Special tool

(S) Hand mounting tool 5870 320 014

(S) Ratchet spanner 5870 300 018

Put the bearing outer ring over the bearing inner ring.

Housing dimension:
Press on equally the bearing outer ring and determine Dim. I,
from the mounting face to the bearing outer ring.

Dim. I e.g. ....................................... 52.67 mm

) Take several measuring points and determine the mean

value!

Figure 267

Put the ring with the chamfer showing downwards into the bear-
ing cover.

Figure 268

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Cover dimension:

Determine Dim. II, from the mounting face to the ring.

Dim. II e.g. .......................................... 50.75 mm

(S) Digital depth gauge 5870 200 072

(S) Gauge blocks 5870 200 067

Figure 269

Example:

Dim. I ................................................. 52.67 mm

Dim. II................................................... - 50.75 mm
Difference ........................................e.g. 1.92 mm
Bearing preload ............................... + 0.03 mm
resulting shim(s) s = 1.95 mm

Put in the shim.

Figure 270

Install the bearing outer ring until contact.

Assemble the O-Ring (arrow).

Figure 271

Grease the rectangular rings (arrows) and centrally align them.

Figure 272

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Heat the bearing bore.

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501

Figure 273

Install two adjusting screws.

Place the bearing cover until contact and fasten it by means of

hexagon screws.

) Observe the radial installation position, see figure!

(S) Adjusting screws 5870 204 007

Figure 274

Check the function of both clutches by means of compressed air!

) In case of a decisive pressure loss, the possible cause might be

the breakage of one or several rectangular rings (see arrow,
Figure 272)!
Replace the rectangular ring(s), if required!

Figure 275

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2.2.7 Output

2.2.7.1 Installation of the Output Shaft

Heat the inner diameter of the output gear.

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501

Figure 276

Assemble the output shaft with the long gearing showing down-
wards until contact.

Figure 277

Rotate the transmission housing into the vertical position (90°).

By means of the mounting tool the output shaft has preliminarily

to be fixed axially (Fig. 278 and 279) at the converter side.

(S) Mounting tool 5870 048 265

Then rotate the transmission housing back again (90°).

Figure 278

Figure 279

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Adjust the axial play of the output bearing = 0.3 ... 0.5 mm
(Fig. 280 ... 282)

Determine Dim. I, from plane face/housing to end face/

output shaft.

Dim. I e.g. ......................................... 66.90 mm

(S) Digital depth gauge 5870 200 072

Figure 280

Measure Dim. II, from plane face/housing to contact face/ball

bearing.

Dim. II e.g. ...................................... 64.20 mm

Example :

Dim. I ............................................................ 66.90 mm

Dim. II............................................................ - 64.20 mm
Difference ........................................................ = 2.70 mm
required axial play (0.3 ... 0.5 mm) e.g. - 0.40 mm
Figure 281 resulting shim e.g. s = 2.30 mm

Install the shim.

Figure 282

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Install the ball bearing (Fig. 283) and pull it until contact by
means of the output flange (Fig. 284).

Then remove the output flange again.

Figure 283

Figure 284

Fasten the ball bearing by means of retaining ring.

(S) Clamping pliers 5870 900 021

Figure 285
Remove the converter-side mounting tool again.

Install the shaft seal, (arrow) with the sealing lip showing to the
oil sump.

)
Using of the specified mounting tool (S), results in the exact
installation position (without retaining ring = 20 mm)!
Grease the sealing lip!

(S) Mounting tool 5870 048 265

Depending on the version different shaft seals can be used:

Outer diameter rubber-coated – wet it with spirit!
Outer diameter metallic – wet it with sealing compound
Figure 286 (Loctite, Type No. 574)!

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2.2.7.2 Output Flange – Standard Version

(without Parking Brake)
Version with parking brake is described from
page 2/93!

Press on the screen sheet (arrow) until contact.

) Observe the installation position, see figure 288!

(S) Pressing bush 5870 506 138

Figure 287

1 To Figure 288:

1 = Screen sheet
2 = Output flange
2

Figure 288

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Adjust gap size X = 0.3 ... 0.8 mm

(Fig. 289 ... 292):

1
To Figure 289:

X = Gap size
1 = Shim
2 = O-Ring

Figure 289

Install the output flange until contact.

Measure Dim. I, from the plane face of the output flange to the
end face of the output shaft.

Dim. I e.g. .......................................... 37.00 mm

(S) Digital depth gauge 5870 200 072

Figure 290 Measure Dim. II, from the plane face to the collar of the output
flange.

Dim. II z. B. .......................................... 36.00 mm

Example :

Dim. I ................................................. 37.00 mm

Dim. II ................................................... - 36.00 mm
Difference ............................................ = 1.00 mm
Gap size X (0.3 ... 0.8 mm).... . e.g. - 0.50 mm
resulting shim s = 0.50 mm

Figure 291

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Place the O-Ring (arrow) into the space between output flange
and shaft (see also Fig. 289) and put on the shim.

Figure 292

Put on the washer and fasten the output flange by means of

hexagon screws.

Tightening torque M10/8.8) ................. MA = 46 Nm

Figure 293

Fasten the hexagon screws by means of the lock plate.

(S) Mounting tool 5870 057 009

(S) Handle 5870 260 002

Figure 294

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2.2.7.3 Output Flange – Version with Parking Brake

Type: FSG 110 (Knott)

Press on the screen sheet (arrow) until contact.

) The installation position of the screen sheet is identical with

the output flange – standard version, see Fig. 288, page 2/90!

(S) Pressing bush 5870 506 138

Figure 295

Install the output flange-brake disk until contact.

) Adjusting of the gap size as well as fixing of the output flange

is identical with the standard version, see page 2/91 and 2/92!

Figure 296

Mount the brake (Fig. 297 ... 301)

For working on the brake system, the instructions and speci-

fications of the brake manufacturer are mandatory!

Remove the screw cap and loosen the locking nut (wrench size
30).
Unscrew the adjusting screw in counterclockwise direction until
>13 a Dim. > 13.0 mm (brake disc shim) results (Fig. 297).

Figure 297

Position the brake and fasten it with cap screws.

Tightening torque M14/8.8) ................. MA = 125 Nm

(S) Socket spanner 5870 656 047

Figure 298

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Adjust the nominal clearance = 2.0 mm (Fig. 299 ... 301)

Make the pressure connection and apply the required release

pressure = 150 bar to the brake (cup spring set preloaded). Fas-
ten the adjusting screw in clockwise direction until both brake
lining carriers contact the brake disc (turning of the adjusting
screw is then not possible or admissible any more without a
higher application of force).

Then turn back the adjusting screw by 4/5 turns in counter-

clockwise direction. 4/5 turns is equal to a nominal clearance of
2.0 mm!
Figure 299

Keep the adjusting screw positioned and fix it by means of a

lock nut.

(S) HP-Pump 5870 287 007

(S) Mini-measuring hub 5870 950 102

Figure 300

Put new O-Ring into the screw cap and grease it.
Install the screw cap.

Figure 301

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2.2.7.4 Output Flange (Converter Side)

Install the shaft seal (arrow) with the sealing lip showing to the
oil sump.

) Using of the specified mounting tool (S), results in the exact

installation position (with retaining ring = 7.0 mm)!
Grease the sealing lip!
(S) Mounting tool 5870 048 265
Depending on the version different shaft seals can be used:
Outer diameter rubber-coated – wet it with spirit!
Outer diameter metallic – wet it with sealing compound
Figure 302 (Loctite, Type No. 574)!

Press the screen sheet (arrow) over the collar of the output flange
until contact.

) Observe the installation position, see figure 304 !

(S) Pressing bush 5870 506 138

Figure 303

To Figure 304:
1
1 = Screen sheet
2 = Output flange

Figure 304

Install the output flange until contact.

) Setting of the gap size as well as fixing of the output flange is

identical with the installation of the output flange at the
transmission rearside, see page 2/91 and 2/92!

Figure 305

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2.2.8 Installation of the Idler shaft

Align the layshaft gear and the single components centrically.

Heat the layshaft gearing (Fig. 306).

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501

Figure 306

Install the adjusting screw.

(S) Adjusting screws 5870 204 007

Figure 307

Install the idler shaft until contact.

Figure 308

Remove the adjusting screw and fasten the axle by means of

hexagon screw.

) Wet the thread of the hexagon screw with Loctite (Type No.
243)!

Tightening torque (M10/8.8) ................. MA = 46 Nm

Figure 309

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Insert the sealing covers (arrow), with the concave side showing
downwards, flush to the housing surface.

) Wet contact face with Loctite (Type No. 262)!

Figure 310

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2.2.9 Transmission Pump

2.2.9.1 Version combined with

2nd/3rd or 4th Power Take-Off

) Version combined only with the 1st Power Take-off is de-

scribed from page 2/103.

Press the needle sleeve (arrow), with the reinforced coating to-
wards the press-in tool until contact.

(S) Mounting tool 5870 058 041

(S) Handle 5870 260 002

Figure 311

Locate the bearing outer ring until contact.

Figure 312

Install the O-Ring (arrow) and grease it.

Figure 313

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Heat the housing bore.

(S) Preheating bush 5870 801 006

(S) Hot-air blower 230 V 5870 221 500
(S) Hot-air blower 115 V 5870 221 501

Figure 314

Install two adjusting screws and assemble the pump until contact.

Observe the radial installation position!

) (S) Adjusting screws 5870 204 021

Figure 315

Put the O-Ring (arrow) into the annular groove of the pump
flange.

) Depending on the transmission version, differences as re-

gards the version and fastening of the pump flange are possi-
ble!
Obligatory is the respective spare parts list!

Figure 316

Fasten the pump flange and pump respectively by means of cap

screws.

) Wet thread of both cap screws (position, see arrows) with

Loctite, Type No. 574 (through holes)!

Tightening torque (M12/8.8) ................. MA = 79 Nm

Figure 317

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Rotate the transmission housing by 180°.

Snap the V-Rings (3x) into the recess of the driver (internal gear-
ing).
Install the key (arrow).

Figure 318

Install shim s = 2.0 mm and locate the bearing inner ring until
contact.

Figure 319

Install shim s = 2.0 mm.

Figure 320

Install the driver by means of clamping plate until contact and

fasten it by means of cap screw.

Tightening torque M10/8.8, DIN 6912) ............MA = 32 Nm

) Wet thread of the cap screw with Loctite (Type No. 243)!

Figure 321

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Press the bearing inner ring until contact.

Figure 322

Snap in the retaining ring (arrow) and install the input gear.

(S) Set of external pliers 5870 900 015

Figure 323

Snap-in and lock the rectangular ring (arrow).

Figure 324

Install the preassembled input shaft until contact.

) Pay attention to align the key to the keyway!

Figure 325

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Adjust the axial play of the input shaft bearing

= 0.0 ... 0.05 mm (Fig. 326 ... 328):

Put on the gasket.

Put on the bearing outer ring, press it on equally and determine
Dim. I, from the mounting face (gasket) to the bearing outer ring.
Dim. I e.g. .......................................... 128.50 mm

Take several measuring points and determine the mean

) value!

Figure 326

Measure Dim. II, from the mounting face/converter bell to the

mounting face/bearing outer ring.

Dim. II e.g. ........................................ 127.46 mm

(S) Straightedge 5870 200 022

(S) Gauge blocks 5870 200 080
(S) Digital depth gauge 5870 200 072

Figure 327

Example :

Dim. I ................................................. 128.50 mm

Dim. II ................................................. - 127.46 mm
Difference ........................................... = 1.04 mm
Axial play .......................................... - 0.04 mm
resulting shim(s) s = 1.00 mm

Put in the shim and locate the bearing inner ring until contact.

Figure 328

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2.2.9.2 Version combined only with

the 1st Power Take-Off

Press the needle sleeve (arrow), with the reinforced coating to-
wards the press-in tool until contact.

(S) Mounting tool 5870 058 041

(S) Handle 5870 260 002

Figure 329

Snap the V-Rings (3x) into the recess of the driver (internal gear-
ing).
Install the key (arrow).

Figure 330

Press the ball bearing over the collar of the driver until contact.

Figure 331

Install the ball bearing and driver respectively and press it until
contact.

) Pay attention to align the key to the keyway!

Figure 332

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Fasten the ball bearing by means of retaining ring.

(S) Set of internal pliers 5870 900 013

Figure 333

Install the O-Ring (arrow) and grease it.

Figure 334

Heat the housing bore.

(S) Preheating bush 5870 801 006

(S) Hot-air blower 230 V 5870 221 500
(S) Hot-air blower 115 V 5870 221 501

Figure 335

Install two adjusting screws and assemble the pump until contact.

Observe the radial installation position!

) (S) Adjusting screws 5870 204 021

Figure 336

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Put the O-Ring (arrow) into the annular groove of the pump
flange.

) Depending on the transmission version, differences as re-

gards the version and fastening of the pump flange are possi-
ble!
Obligatory is the respective spare parts list!

Figure 337

Fasten the pump flange and the pump respectively by means of

hexagon screws.

) Wet thread of both hexagon screws (position, see arrows)

with Loctite, Type No. 574 (through holes)!

Tightening torque M12/8.8) ................. MA = 79 Nm

Then rotate the transmission housing by 90° .

Figure 338

Snap-in and lock the rectangular ring (arrow).

Figure 339

Install both shims (each 2.0 mm thick).

) Use assembly grease!

Figure 340

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Heat the bevel bearing inner ring.

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501

Figure 341

Install the input shaft until contact.

Figure 342

Fasten the input shaft by means of clamping plate and cap screw
(arrow).

Tightening torque (M10/8.8, DIN 6912) ..........MA = 32 Nm

) Wet thread of the cap screw with Loctite (Type No. 243)!

Figure 343

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2.2.10 Input – Converter Bell

To install a new converter bell the finished bores (3x) have to

be sealed with plugs (König)!
Installation position, see arrow, Figure 344!

(S) Lever riveting tongs 5870 320 016

Figure 344

Locate the bearing outer ring into the housing bore until contact
and install the bearing inner ring, see arrow!

Figure 345

Install the spur gear (arrow) with the long collar showing up-
wards and position it.

Figure 346

Heat the spur gear bore (arrow).

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501

Figure 347

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Install the input shaft until contact.

Figure 348

Heat the bearing inner ring and install it until contact.

Use safety gloves!

Figure 349

Install the bearing outer ring until contact.

Figure 350

Snap in the rectangular ring (arrow) into the annular groove of

the input shaft and lock it.
Then grease the rectangular ring and centrally align it.

Figure 351

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Install the converter safety valve (arrow 1) and fasten it by

means of slotted pin (arrow 2).
1
) Flush-mount slotted pin to recess!

Put the O-Ring (arrow 3) into the annular groove.

3 2
Figure 352

Press the needle bearing (arrow), with the reinforced coating

towards the press-in tool into the bore of the bearing cover until
contact.

(S) Mounting tool 5870 058 051

(S) Handle 5870 260 002

Figure 353

Flush-mount the shaft seal (arrow) with the sealing lip showing
(downwards) to the oil sump.

) Wet the outer diameter with spirit!

Grease the sealing lip!

(S) Mounting tool 5870 048 030

Figure 354

)
Make the following steps (Figure 355...358) in direct time
sequence to secure the precise contact of the oil supply
flange !

Heat the housing bore.

(S) Preheating bush 5870 801 006

(S) Hot-air blower 5870 221 500
(S) Hot-air blower 5870 221 501

Figure 355

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Install two adjusting screws and put in the oil supply flange until
contact.

) Observe the radial installation position!

(S) Adjusting screws 5870 204 007

Figure 356

Place the O-Ring (arrow) with assembly grease into the annular
groove of the bearing cover.

Figure 357

Put on the bearing cover and fasten it by means of hexagon

screws.

Tightening torque (M10/8.8) ................. MA = 46 Nm

Figure 358

Install the single components according to the opposite figure.

1 = Screw plug .............. MA = 150 Nm

2 = Screw plug .............. MA = 25 Nm
1 2 3 = Temperature sensor ... MA = 25 Nm
and screw plug respectively (depending on
the version) ............ MA= 35 Nm

) Always install new O-Rings!

3
Figure 359

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Converter pressure back-up valve (Fig. 360 ... 361):

Install the slotted pin (6 x 50 mm) until contact.

Figure 360

Assemble piston and compression spring.

Provide screw plug with a new O-Ring and install it.

Tightening torque (M36x1.5) ................. MA = 130 Nm

Figure 361

Fasten the gasket and cover plate by means of hexagon screws

(install the washers).

Tightening torque (M6/8.8) ................. MA = 9.5 Nm

Figure 362

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Install two adjusting screws and put on the gasket (arrow 1).
Put the O-Ring (arrow 2) into the annular groove.
1 (S) Adjusting screws 5870 204 021

Figure 363

Install the converter bell by means of lifting tackle until contact.

) Slight rotary motions of the input shaft facilitate the installa-

tion (protect teeth from damage)!
Observe the radial installation position!

(S) Lifting tackle 5870 281 047

(S) Eyebolts assortment 5870 204 002

Figure 364

Fasten the converter bell by means of hexagon screws.

Tightening torque (M8/10.9) ................. MA = 34 Nm

Tightening torque (M12/10.9) ................. MA = 115 Nm

Figure 365

Fasten flexible plates (3x) by means of hexagon screws (install

the washers).

) Wet thread of the hexagon screws with Loctite (Type No.

243) !

Tightening torque (M10/8.8) ................. MA = 46 Nm

Figure 366

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Install the rectangular ring (arrow) into the annular groove and
lock it.
Then grease the rectangular ring and centrally align it.

Figure 367

Assemble converter by means of lifting tackle until contact (Fig-

ure 368).

) At a control dimension < 43 mm, the exact installation posi-

tion of the converter is ensured, see Fig. 369!

(S) Eyebolts assortment 5870 204 002

(S) Lifting chain 5870 281 047

Figure 368

Figure 369

Until installation of the transmission, fix the converter axi-

ally, see Fig. 370!

Figure 370

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2.2.11 Coarse Filter

Install filter (assy) into the housing bore.

)
Oil the sealing (arrow)!

Figure 371

Fasten the cover by means of hexagon screws (install the wash-

ers).

) Install the new O-Ring (arrow)!

Tightening torque (M8/8.8) ................. MA = 23 Nm

Figure 372

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2.2.12 Inductive and Speed Transmitters

14 Following sketches show the installation position of

the single inductive and speed transmitters.

5 = Inductive transmitter n – Turbine

14 = Inductive transmitter n – Engine
9 = Inductive transmitter n – int. speed input
13 = Speed transmitter n – Output

Note: Depending on the version, the installation

position of the speed transmitter 13 is
different, see arrows Figure 374!
5

Figure 373

K1

KV

K2

KR K3 13
K4

Figure 374

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)
The following figures describe the installation and setting
respectively of the inductive transmitter n – Engine (14)!
Installation of the inductive transmitter n – Turbine (5) and
n – internal speed input (9) is to be made analogously!

Observe the different setting dimensions „X“ :

"S"
"A"
I

Inductive transmitter n – Engine (14) ..... X = 0.5 + 0.3 mm

Inductive transmitter n – Turbine (5) . .. X = 0.5 + 0.3 mm
X

Induct. transmitter n – int. speed input (9) X = 0.3 ± 0.1 mm

Figure 375

Adjust Dim. „X" by means of shim ring(s) (Fig. 376 ... 381)

Measure Dim. I on the inductive transmitter, from contact face to

screw-in face.

Dim. I e.g. ........................................... 30.00 mm

Figure 376

Turn in the counting disc radially until one tooth tip is centrally
to the inductive transmitter bore.

Turn the plug gauge until contact.

Locate anvil at the tooth tip and lock it by means of threaded pin
(Fig. 377 and 378).

(S) Plug gauge 5870 200 104

Figure 377

(S) Plug gauge 5870 200 104

II

Figure 378

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Turn out the plug gauge and determine Dim. II (also see Fig.
378).

Dim II e.g. ............................................ 30.10 mm

Figure 379

Example „A1“:
Dim. II ............................................... 30.10 mm
Dim. X (0.5 + 0.3 mm) .......................... - 0.60 mm
results in installation dimension A = 29.50 mm

Example „A2“:
Dim. I ............................................... 30.00 mm
Installation dimension A ........ ............ - 29.50 mm
results in shim ring(s) s = 0.50 mm

Install the adequate shim ring(s) and wet the thread (arrow) with
Loctite (Type No. 574).

Figure 380

Install the inductive transmitter n – Engine (14), see arrow!

Tightening torque ................. MA = 30 Nm

Set and install the inductive transmitter n – Turbine (5) and

n-internal speed input (9) analogously!

) Observe the different setting dimensions!

Installation position of the single inductive transmitters, also
see page 2/115!

Figure 381

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X Install speed transmitter n – Output/Speedo (13)

(Fig. 382 ... 387):
2
13
To Figure 382:
1
1 = Housing
2 = Spur gear K3
3
3 = Disc carrier
13 = Speed transmitter (Hall sensor)
X = Setting dimension „X“ = 1.0 + 0.5 mm

Figure 382

Opposite figure shows the speed transmitter (Hall sensor).

Figure 383

Determine Dim. I, from the housing face to spur gear K3.

Dim. I e.g. ......................................... 39.70 mm

(S) Digital depth gauge 5870 200 072

Figure 384

Measure Dim. II, from the contact face to the mounting face.

Dim. II e.g. ........................................ 40.00 mm

(S) Digital depth gauge 5870 200 072

Figure 385

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Example „B1“:
Dim. I ............................................... 39.70 mm
Dim. X (1.0 + 0.5 mm) ........................ - 1.20 mm
results in installation dimension = 38.50 mm

Example „B2“:
Dim. II ............................................... 40.00 mm
Installation dimension ...................... - 38.50 mm
results in shim(s) s = 1.50 mm

Install shims (3x, s = 0.50 mm) and grease the O-Ring (arrow).
Figure 386

Fasten the speed transmitter by means of cap screw.

Tightening torque (M8/8.8) ................. MA = 23 Nm

) Installation position of the speed transmitter, also see

page 2/115!

Figure 387

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Note:
Following figures describe the installation of various periph-
eral components.
Depending on the transmission version, differences as re-
2 gards the single components and their installation position
1 are possible!
Obligatory is the respective spare parts list!
Provide screw plug (arrow 1) with a new O-Ring and install it.
Tightening torque (M42x2) ................. MA = 145 Nm

Insert the sealing covers (arrow 2), with the concave side show-
ing downwards, flush to the housing recess
Figure 388

) Wet contact face with Loctite (Type No. 262)!

Preassemble the angle piece acc. to Figure 389

1 To Figure 389:
3 1 = Angle piece
4 2 = O-Ring
6 3 = Slotted nut
4 = Threaded bush
5 = O-Ring
6 = Snap ring
2
5
) Install the slotted nut with the chamfer (arrow) showing to
the angle piece!
By locking of the slotted nut the angle piece is fixed radially
Figure 389 (after mounting of the pressure line)!

Install the preassembled angle piece, see arrow !

Figure 390

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Flush-mount cup (arrow) to the housing face and install the

breather.

Tightening torque (breather) ......... MA = 12 Nm

) Wet the sealing surface of the cup with Loctite (Type No.
262)!

Figure 391

Provide both screw plugs (arrow 1 and 2) with a new O-Ring and
1 install them.

2 Tightening torque (M30x1.5) ................. MA = 100 Nm

Tightening torque (M42x2) .................... MA = 145 Nm

3
Provide the adapter (arrow 3) with a new O-Ring and install it.

Figure 392

Install both fixing plates (arrows).

Figure 393

Provide screw plug with a new O-Ring and install it.

Tightening torque (M26x1.5) ................. MA = 80 Nm

) Installation of the hydr. control unit is described in

Chapter 1!

Prior to putting into operation of the transmission, make an

oil filling acc. to operating instructions 5872 188 002 !

Figure 394

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