LuK Repair Solution for manual transmissions. Disassembly and assembly Special tool/failure diagnosis PSA MA

Size: px

Start display at page:

Download "LuK Repair Solution for manual transmissions. Disassembly and assembly Special tool/failure diagnosis PSA MA"

Tabitha Wells
5 years ago
Views:

1 LuK Repair Solution for manual transmissions Disassembly and assembly Special tool/failure diagnosis PSA MA

2 The content of this brochure shall not be legally binding and is for information purposes only. To the extent legally permissible, Schaeffler Automotive Aftermarket GmbH & Co. KG assumes no liability out of or in connection with this brochure. Copyright Schaeffler Automotive Aftermarket GmbH & Co. KG April 2017 All rights reserved. Any copying, distribution, reproduction, making publicly available or other publication of this brochure in whole or in extracts without the prior written consent of Schaeffler Automotive Aftermarket GmbH & Co. KG is prohibited.

Schaeffler in the Automotive Aftermarket more innovation, more quality and more service. Schaeffler in the Automotive Aftermarket four strong brands.

With our four strong brands LuK, INA, FAG, and Ruville, we are a reliable global partner offering repair solutions for passenger cars, light and heavy commercial vehicles as well as tractors.

Innovation, technical expertise, and the highest material and manufacturing quality make us not only one of the leading development partners for vehicle manufacturers, but also a pioneering provider

Our comprehensive portfolio includes products and repair solutions for clutches and clutch release systems, engine and transmission applications, and chassis applications.

3 Schaeffler in the Automotive Aftermarket more innovation, more quality and more service. Schaeffler in the Automotive Aftermarket four strong brands. Whenever a vehicle needs to go to the garage, our products and repair solutions are usually first choice to fix them. With our four strong brands LuK, INA, FAG, and Ruville, we are a reliable global partner offering repair solutions for passenger cars, light and heavy commercial vehicles as well as tractors. Whether for the transmission, engine, or chassis all products are based on a comprehensive systems approach. Innovation, technical expertise, and the highest material and manufacturing quality make us not only one of the leading development partners for vehicle manufacturers, but also a pioneering provider of value-retaining spare parts and complete repair solutions always in original equipment quality. Our comprehensive portfolio includes products and repair solutions for clutches and clutch release systems, engine and transmission applications, and chassis applications. All components are optimally tuned to work together perfectly, and allow fast and professional parts replacement. Schaeffler REPXPERT the service brand for garage professionals. Under the REPXPERT brand we offer a comprehensive package of services for the products and repair solutions of the LuK, INA, FAG, and Ruville brands. Looking for specific information or damage diagnosis? Are you in need of particular tools to make your everyday garage routine easier? Whether online portal, service hotline, installation instructions and videos, training seminars, or events all technical services are provided in just one place. Then simply register for free in just a few clicks at: For over 50 years, Schaeffler has offered everything needed for transmission repair. With its LuK RepSet family (LuK RepSet, LuK RepSet Pro, LuK RepSet DMF, and LuK RepSet 2CT) Schaeffler supports garages with professional clutch repair. The portfolio includes the entire hydraulic release system and the dual-mass flywheel.

Repair Manual for the PSA MA gearbox 1 Drain the

Remove the gearbox from the vehicle in accordance with

Once you have drained the gearbox, screw the plug back

Unscrew the screws (1) for the guide sleeve.

4 Repair Manual for the PSA MA gearbox 1 Drain the transmission fluid (arrow). Remove the gearbox from the vehicle in accordance with the vehicle manufacturer s requirements. Once you have drained the gearbox, screw the plug back onto the opening at 33 Nm. Unscrew the screws (1) for the guide sleeve. Completely remove the guide sleeve, incl. the O-ring on the input shaft. 2 3 Remove the switch for the reversing lights (1) and the speedometer drive (2). 4

5 4 Unscrew the screws on the gearbox cover for the fifth gear (1). Completely remove the gearbox cover for the fifth gear. 5 Push out the bearing pin from the fifth gear shift fork (arrow). 6 Remove the retaining ring (1) and the supporting ring (2) from the fifth gear synchronizer unit. 5

7 Place the puller on the disc between the idler gear for the

Lift out the synchronizer package and the idler gear for the

When pulling, pay attention that the gear shift fork (1) is

This prevents the entire synchronizer package (rollers,

8 Remove the retaining rings from the output shaft (1) and

6 7 Place the puller on the disc between the idler gear for the fifth gear and the engaging gears. Lift out the synchronizer package and the idler gear for the fifth gear from the output shaft. When pulling, pay attention that the gear shift fork (1) is also lifted. This prevents the entire synchronizer package (rollers, springs, and locking pieces) from coming apart. 8 Remove the retaining rings from the output shaft (1) and drive shaft (2), as well as the spring washer (3). 9 Pull off fifth gear. 10 Remove the screws (1) from the bearing retaining rings. Pull out the bearing retaining rings in the direction of the arrows shown. Clean the threads of the screws for the bearing retaining rings with a thread tap to remove any remaining thread-locking adhesive. 6

7 11 Remove the screws from the gearbox housing. Label the position of the housing s screws. 12 Lift up the gearbox housing (arrow). Caution: Do not cause damage to the sealing faces. 13 Pull out the shaft for the reverse sliding gear (1). Remove the reverse sliding gear (2). Put the gearbox in the neutral position first. 14 Pull out the bearing pin (1) from the reverse gear shift fork. Press down on the gear shift fork (arrow) to relieve the bearing pin of pressure. 7

8 15 Remove the gear shift fork for the reverse gear. Remove the mounting screw (1) from the mounting plate behind the locking key. Put the transmission in second gear (pull out the front gear lever and turn it counterclockwise). Push out the mounting pin (2) from the shift finger in the direction of the arrow shown. Put the mounting pin (2) off to the side Pull out the gear shift lever (1). Remove the spring (2). Remove the locking key. 18 8

19 Lift the complete drive and output shafts, incl.

housing. 20 Remove the screws from the mounting plate.

fork, incl. spring. Lift out the differential (3).

lever (2) in the direction of the arrow shown.

9 19 Lift the complete drive and output shafts, incl. the bearings, gear shift forks, and shift rods, off the housing. 20 Remove the screws from the mounting plate. Lift off the mounting plate from the gearbox housing. 21 Remove the magnet (1) and clean it. Remove the locking finger (2) from the reverse gear shift fork, incl. spring. Lift out the differential (3). 22 Push out the mounting pin (1) from the gear selector lever (2) in the direction of the arrow shown. Remove the gear selector (2) and gear selector lever shaft (3). Put the mounting pin (1) off to the side. 9

10 23 Replace the shaft O-ring (1) in the opening of the gear selector lever shaft. Grease the shaft O-ring before installing. 24 Insert the gear selector lever shaft (3) and install the gear selector lever (2). Connect the gear selector lever (2) to the gear selector lever shaft (3) with the mounting pin (1). Grease the gear selector lever shaft before installing. 25 Remove the flanged shaft O-ring on the engine side. 26 Replace the bearing cup for the differential on the engine side. 10

11 27 Mount the flanged shaft O-ring on the engine side. Clean the sealing face before installing the new O-ring. 28 Remove the flanged shaft seal on the gearbox side. Replace the bearing cup for the differential on the gearbox side. 29 Mount the flanged shaft O-ring on the gearbox side. Clean the sealing face before installing the new O-ring

12 31 Lift off the speedometer worm gear. 32 Pull off the two differential bearings. 33 Press-mount the new differential bearings. 34 Mount the speedometer worm gear. 12

13 35 Pull off the drive shaft bearing on the engine side. Caution: Keep parts from falling down. 36 Pull off the drive shaft bearing on the gearbox side. Caution: Keep parts from falling down. 37 Press-mount the new drive shaft bearing on the engine side. Press using the appropriate sleeve on the inner ring. 38 Press-mount the new drive shaft bearing, with the groove (1) positioned at the top, on the gearbox side. Press using the appropriate sleeve on the inner ring. 13

39 Pull off the output shaft bearing on the gearbox side.

40 Lift the disc (1), idler gear for the fourth gear (2), synchronizer ring for

synchronizer ring for the third gear (5) off the output shaft.

Lift the idler gear for the third gear (7) off of the output shaft.

14 39 Pull off the output shaft bearing on the gearbox side. Caution: Keep parts from falling down. 40 Lift the disc (1), idler gear for the fourth gear (2), synchronizer ring for the fourth gear (3), synchronizer sleeve for the third/fourth gear (4), and synchronizer ring for the third gear (5) off the output shaft. 41 Remove the retaining ring (6). Lift the idler gear for the third gear (7) off of the output shaft. 42 Remove the retaining ring (8). Lift the idler gear for the second gear (9), synchronizer ring for the second gear (10), synchronizer unit for the first/second gear (11), and synchronizer ring for the first gear (12) off of the output shaft. 14

Press using the appropriate sleeve on the inner ring.

15 43 Remove the retaining ring (13). Lift the idler gear for the first gear (14) off of the output shaft. Remove the retaining ring (15). 44 Press off the output shaft bearing on the engine side. Caution: Keep parts from falling down. 45 Press-mount the new output shaft bearing on the engine side. Press using the appropriate sleeve on the inner ring. Caution: Do not cause damage to the oil feed restrictor (1) while pressing. 46 Install the retaining ring (15). Attach the idler gear for the first gear (14) to the output shaft. Install the retaining ring (13). 15

47 Place the synchronizer ring for the first gear (12), synchronizer unit for the first/second gear (10), and idler gear for the second gear (9) onto the output shaft. Install the retaining ring (8).

16 47 Place the synchronizer ring for the first gear (12), synchronizer unit for the first/second gear (10), and idler gear for the second gear (9) onto the output shaft. Install the retaining ring (8). Mount the synchronizer unit (11) with the groove (a) positioned at the bottom. Caution: Align the noses of the synchronizer rings (10 and 12) with the locking pieces of the synchronizer unit (11). 48 Place the idler gear for the third gear (7) onto the output shaft. Install the retaining ring (6). 49 Place the synchronizer ring for the third gear (5), synchronizer unit for the third/fourth gear (4), synchronizer ring for the fourth gear (3), idler gear for the fourth gear (2), and washer (1) onto the output shaft. Mount the synchronizer unit for the third/fourth gear (4) with the groove (b) positioned at the top. Caution: Align the noses of the synchronizer rings (3 and 5) with the locking pieces of the synchronizer unit (4). 16

50 Press-mount the new output shaft bearing on the gearbox side

Caution: When pressing, protect the oil feed restrictor (2) from

51 Clean the sealing faces on both halves of the housing.

Mount the locking finger (2) of the reverse gear shift fork, incl.

Mount the differential (3). 52 Apply sealing

Loctite 549) to the contact faces of the mounting plate (1) and the

17 50 Press-mount the new output shaft bearing on the gearbox side with the groove (1) positioned at the top. Caution: When pressing, protect the oil feed restrictor (2) from damage by using the appropriate sleeve. 51 Clean the sealing faces on both halves of the housing. Insert the magnet (1). Mount the locking finger (2) of the reverse gear shift fork, incl. spring. Mount the differential (3). 52 Apply sealing compound (e.g. Loctite 549) to the contact faces of the mounting plate (1) and the clutch housing. Insert the gear shift fork (2) through the opening in the mounting plate. Mount the mounting plate. Torque for tightening the mounting plate screws: 50 Nm Caution: Remove any remaining adhesive in the bearing seat and the wells of the gear shift fork shaft upon tightening the mounting plate screws. 17

18 53 Push the gear shift fork onto the synchronizer unit s sleeve. Insert the drive and output shafts, incl. gear shift, into the gearbox housing. 54 Combine the shift finger (1) and blocking clip (2) to create a selector locking mechanism. 55 Install the locking key (1). The finger of the locking key has to be engaged in the claws of the shift rod. 56 Place the blocking clip (1) onto the shift fork of the selector shaft (2). 18

19 57 Insert the spring (1) for the locking key. Mount the gear shift shaft (1) using the new shaft seal (2). Push the gear shift shaft so far until the pin holes (3) of the shift finger and shift shaft are aligned Couple the shift finger and shift shaft with the cotter pin. The holes in the shift finger and shift rod were drilled together. Therefore, they have to be replaced together and not separately. 60 Mount the gear shift fork (1) for the reverse gear. 19

61 Insert the bearing pin (1) for the reverse gear shift fork.

Add the shaft of the return sliding gear (2).

that the retention ring (1) and the spring (2) for the reverse

20 61 Insert the bearing pin (1) for the reverse gear shift fork. Press down on the gear shift fork (arrow) to relieve the bearing pin of pressure. 62 Insert the reverse sliding gear (1). Add the shaft of the return sliding gear (2). Turn the shaft of the reverse sliding gear until the nose (a) fits the slot of the housing. 63 Caution: For gearboxes with a reverse gear lock, ensure that the retention ring (1) and the spring (2) for the reverse gear are in place on the shift rod for the first/second gear. 64 Apply sealing compound (e.g. Loctite S15135) evenly on the seal faces of the gearbox housing on the engine side. Mount the sealing (1) on the shift shaft. Align the clutch activator lever (2) vertically. Place the gearbox housing on top. 20

65 Insert the housing screws in the previously labeled holes.

rings with the bevel (a) positioned at the top.

Torque for tightening the screws of the bearing retention rings: 18 Nm 67 Mount the fixed gear

The protruding hub of the fixed gear must be positioned at the top when installing.

21 65 Insert the housing screws in the previously labeled holes. Torque for tightening the gearbox housing screws: 23 Nm 66 Insert the two bearing retention rings with the bevel (a) positioned at the top. Mount the screws (1) of the bearing retention rings using thread-locking adhesive. Torque for tightening the screws of the bearing retention rings: 18 Nm 67 Mount the fixed gear for the fifth gear. The protruding hub of the fixed gear must be positioned at the top when installing. 68 Install the spring washer (1) and the new retention ring (2). Press the retention ring down strongly against the force of the spring washer using the appropriate sleeve until it has snapped into place in the groove. If needed, tighten some more using a pipe wrench. 21

69 Mount the retention ring (1) onto the output shaft.

fork (2) is evenly mounted with the synchronizer unit

assembly (rollers, springs, and locking pieces) from

71 Mount the supporting ring (1) and the new

22 69 Mount the retention ring (1) onto the output shaft. 70 Mount the synchronizer unit for the fifth gear (1) together with the gear shift fork (2). Pay attention during installation that the gear shift fork (2) is evenly mounted with the synchronizer unit for the fifth gear to prevent the synchronizer assembly (rollers, springs, and locking pieces) from falling apart. 71 Mount the supporting ring (1) and the new retention ring (2) onto the output shaft. 72 Mount the gear shift fork for the fifth gear using the new clamping sleeve. 22

Caution: The three mounting screws (1) protrude into e

Before installing the ounting screws, apply sealing

23 73 Replace the seal on the cover. Clean the sealing face of the gearbox cover for the fifth gear. 74 Mount the lid for the gearbox housing and tighten the screws (1). Torque for tightening the gearbox lid screws: 22 Nm Clean the sealing faces beforehand. 75 Mount the new guide sleeve, incl. flanged shaft O-ring. Torque for tightening the guide sleeve screws: 10 Nm Caution: The three mounting screws (1) protrude into e gearbox housing. Before installing the ounting screws, apply sealing compound (e.g. Loctite 243). 76 Install the switch for the reversing lights (1). Torque for tightening the reversing lights switch: 25 Nm Replace the O-ring for the speedometer drive and then mount the speedometer drive (2). Torque for tightening the speedometer drive screw: 10 Nm 23

24 77 Remove the cap from the ventilation opening (1). Fill the empty gearbox with exactly 2.1 liters of oil through the ventilation opening. Screw the cap back onto the ventilation opening (1). The vehicle manufacturer recommends ESSO 75W80 EZL 848 or TOTAL 75W80 H

25 Notes 25

26 26 Notes

27 Notes 27

28 Optional sender details (highlighted) Optional sender details (2nd line of text) Optional sender details (3rd line of text) *optional subline with legal text / Schaeffler Automotive Aftermarket GmbH & Co. KG

PSA MA gearbox. INA GearBOX

PSA MA gearbox. INA GearBOX LuK Repair Tractor Manual Clutches PSA MA gearbox INA GearBOX Repair Manual for the PSA MA gearbox Drain the transmission fluid (arrow). Remove the gearbox from the vehicle in accordance with the vehicle