REPAIR MANUAL. W 390 MS torque converter a

Transcription

1 REPAIR MANUAL W 390 MS a

2 Subject to technical changes Copyright by ZF This documentation is protected by copyright. Any reproduction and dissemination in whatever form also in adapted, paraphrased or extracted form in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law. Printed in Germany ZF Friedrichshafen AG, MC-C / Edition: a

3 Table of contents Page Preface... 4 Important information... 5 Instructions for repairs... 6 Tightening torques... 8 Consumables... 0 Adjustment data... Cross-section... Special tools... 3 Removing and installing Removing Installing Measuring end float Measuring installation dimension Dismantling and assembling Dismantling Dismantling stator Assembling stator Dismantling circuit cover Assembling circuit cover Measuring end float of axial bearing (take measurement for checking purposes) Assembling Checking for seal integrity a 3

4 Preface This repair manual is intended for skilled personnel trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products. This manual deals with the standard ZF product in accordance with the state of development on the date of issue. However, due to continuing development of the product, repair work might require work practices and test or adjustment data not contained in this manual. We recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training centers. Service points equipped by ZF Friedrichshafen AG all over the world offer you:. Continually trained personnel. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications All work performed at these service points is carried out conscientiously and with utmost care. ZF FRIEDRICHSHAFEN AG Commercial Vehicle /Special Transmissions Division Service Plant Tel.: / Fax: / Internet: Warranty: Repair work carried out at ZF service points is subject to the contractual conditions prevailing in the individual case. Damage resulting from work performed by non-zf personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used a 4

5 Important information SAFETY NOTICE Companies repairing ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations. Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained. The following safety instructions appear in this manual: Refers to special processes, techniques, data, use of auxiliary equipment, etc. CAUTION This is used when incorrect, unprofessional working practices could damage the product.! DANGER This is used when lack of care could lead to personal injury or death. GENERAL INFORMATION Read this manual carefully before starting any tests or repair work. CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration). Always follow the working steps as described in the text. After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly.! THREATS TO THE ENVIRONMENT! Lubricants and cleaning agents must not be allowed to enter the soil, ground water or sewage system. Ask your local environment agency for safety information on the relevant products and adhere to their requirements. Collect used oil in a suitably large container. Dispose of used oil, dirty filters, lubricants and cleaning agents in accordance with environmental protection guidelines. When working with lubricants and cleaning agents always refer to the manufacturer s instructions. CAUTION The transmission must NOT be hung by the input shaft NOR by the output flange a 5

6 Instructions for repairs In case of doubt always turn to the relevant department within ZF After-Sales Services for advice. All work on transmissions is to be performed expertly and under clean conditions. Use specified tools to dismantle and assemble transmissions. After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening. Pay particular attention to the projections and recesses of housings and covers when cleaning. Parts joined with Loctite are easier to separate if warmed with a fan heater. GASKETS, LOCKING PLATES Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates). SHAFT SEALS Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition. CLEANING PARTS Remove remains of old gaskets on all seal-faces. Carefully remove burrs or similar patches of roughness using an oil-stone. Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check for perfect passage. Carefully cover opened transmissions to prevent foreign matter from entering. REWORKING Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling. If rework is needed on distance washers, shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality. REUSING PARTS Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used. Replace parts which are damaged or have suffered from excessive wear. TRANSMISSION ASSEMBLY Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measurement. During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual a 6

7 Instructions for repairs BEARINGS If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet). Temperature should be at approx. 85 C and must not exceed 0 C. Each mounted bearing must be oiled with operating oil. SEALING If a specific sealing agent* is to be used for sealing, comply with the manufacturer s directions for use. Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores, wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent enters the oil feeds when the surfaces are sealed. SHAFT SEALS a) Apply a light coat of sealing agent* on outer edge of shaft seals with steel surround. b) Never apply sealing agent to shaft seals with rubber surround, but apply a thin coat of Vaseline 840 to the outer edge or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g. Pril, Coin, Palmolive). c) Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b). d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards. X e) Fill the gap between the sealing lips so it is 60 % filled with grease (e.g. produced by Aral such as Aralub HL or by DEA such as Spectron FO 0). f) If possible, heat shaft seal bores to between 40 and 50 C (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan. RETAINING AGENTS Retaining agents* may only be used in places as specified in the parts list. Always comply with manufacturer s directions for use when using retaining agents (e.g. Loctite). During assembly, comply with all adjustment data, checking data and tightening torques. TRANSMISSION OIL After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point and on the internet under After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques. * refer to expendable material a 7

8 Tightening torques Tightening torques for nuts and bolts, extract from ZFN 48 This standard applies to bolts acc. to DIN 9, DIN 93, DIN 933, DIN 960, DIN 96 as well as ISO 476, ISO 404, ISO 407, ISO 8765, ISO 8676, and to nuts acc. to DIN 934 as well as ISO 403, ISO This Standard contains data on tightening torques (M A ) for bolts and nuts in strength categories 8.8, 0.9 and.9, and nuts in strength categories 8, 0 and. Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chromeplated and oiled. Tighten screws with a calibrated torque spanner or wrench. Irregular tightening torques are listed separately in the Repair Manual. Regular screw thread Fine screw thread Size Tightening torque Size Tightening torque (Nm) for (Nm) for Bolt Bolt Nut 8 0 Nut 8 0 M M8x M M9x M M0x M M0x M Mx M Mx M M4x M M6x M M8x M M8x M M0x M Mx M M4x M M4x M M7x M7x M30x M30x Edition: August 99/ checked a 8

9 Tightening torques Screw plugs DIN 908, 90 and 7604 The screw plug tightening torques M A were determined according to DIN 7604 for screwing into steel, grey cast and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. The values for the tightening torque M A apply analogously for screw plugs according to DIN 908 and DIN 90, as the thread geometries are almost identical. General rule: Screw/bolt class 5, ZFN 48- Screw/bolt material: steel acc. to DIN Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled. Union screws DIN 7643 The tightening torques M A were determined for screwing into steel, grey cast and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. General rule: screw/bolt class 5, ZFN 48- Material: 9SMnPb8K acc. to DIN 65 Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled. Screw plugs (DIN 908, 90, 7604) Dimensions Tightening torque in Nm screwed into steel/gray cast Al alloy M8x 0* 0* M0x 5 / 30* 5 / 0* Mx M4x M6x M8x M0x Mx.5 60 / 80* 50 / 65* M4x M6x.5 80 / 05* 70 / 90* M7x M30x.5 00 / 30* 90 / 30* M30x M33x 0 0 M36x M38x M4x M4x 45 5 M45x M45x M48x M48x M5x M60x M64x * DIN 7604 Form C Union screws (DIN 7643) Pipe Thread Tightening outer torque diameter in Nm 4-5 M8x M0x Mx M4x M6x M8x Mx.5 60 M6x M30x M38x.5 40 Edition: October a 9

10 Consumables Description Name Approx. Application Comments ZF item number quantity Grease For example General assembly aid Spectron FO 0 Grease Techn. Vaseline 840 General assembly aid : Inquire as to size of containers before placing any orders a 0

11 Adjustment data Description Dimension Measurement device Comments 0. Torque converter installation dimension (depending on version) 8.5 ± 0.5 mm Depth gauge Installation dimension measured from mounting face on to mounting face on transmission housing. Installation dimension can be adjusted using one or more spacer rings on the stator hollow shaft. 0. Torque converter end float between face end of converter internal sprang race and spacer ring on stator hollow shaft 0.3 to 0.4 mm Depth gauge End float can be adjusted using shim on face end of turbine shaft. OTK Clutch disc clearance of lock-up clutch 0.6 to. mm Feeler gauge Clutch disc clearance is measured between end disc and inner clutch disc 04. End float of axial bearing in 0 to. mm GO gauge and depth gauge Only take check measurement 05. Maximum pressure for testing seal integrity of bar Forcing device X , pneumatic unit X and water tank Torque converter test is carried out under water using air 06. Tightening torque of 36 hex bolts (M0x) on 65 Nm Torque wrench 07. Tightening torque of M6 cylindrical screw in turbine shaft 80 to 90 Nm Torque wrench and retaining fixture X Use counter holder X to lock 08. Tightening torque of M 33x screw plug in 90 to 0 Nm Torque wrench Fit new Cu seal. Use counter holder X to lock in place 09. Tightening torque of 4 cylindrical screws (M0x30) on circuit cover 69 Nm Torque wrench a

12 Cross-section M0x0 (SW 6) hex bolt with shim Compression spring with shim 3 Roller 4 Impeller 5 Stator 6 Thrust disc 7 Axial roller bearing 8 Thrust disc 9 Internal sprag race 0 Ball bearing Thrust disc Rollers 3 Thrust disc 4 Ball bearing 5 End shim 6 M0x30 cylindrical screws 7 O-ring 8 Inner clutch disc 9 Outer clutch disc 0 Inner clutch disc Outer clutch disc Plate piston 3 Inner piston ring, plate piston 4 Ball bearing 5 Thrust disc 6 Axial needle cage 7 Housing disc 8 Turbine wheel 9 Outer piston ring, plate piston 30 Cup spring 3 Circuit cover a

13 Special tools Fig. Special tools Order no. Application Qty. Comments no. X Lifting device for turbine shaft X Lifting device for X Support for stator bearing X Counter holder for unfastening and tightening screw plug in X Retaining fixture for unfastening and tightening M6 cylindrical screw in a 3

14 Special tools Fig. Special tools Order no. Application Qty. Comments no. X Pneumatic unit for seal integrity test of and clutch carrier, used in conjunction with feed bush X and forcing devicex X Forcing device for seal integrity test P Feeler gauge for measuring the clutch disc clearance a 4

15 . Removing and installing. Removing Rotate the transmission in the swivel stand so that the is facing upwards. Attach counter holder X () to and transmission housing and screw in. 3 Unscrew screw plug (). 4 Screw retaining fixture X (3) into circuit cover and tighten by hand Make sure rubber washer is fitted onto retaining device thread. In addition to the pneumatic retaining device, ZF can also use a mechanical retaining device X in conjunction with the hex insert X Connect pneumatic unit X onto retaining fixture X Turn the regulator () anti-clockwise a few times. 7 Open stopcock (). The lever must be horizontal. 8 Use the regulator () to set a pressure level of.5 bar a -

16 9 Insert / socket wrench extension () and unfasten cylindrical screw. Use a suitably long grip. The M6 cylindrical screw is tightened to 90 Nm in the turbine shaft. 0 Close stopcock. Unscrew retaining fixture X () from circuit cover. Unscrew cylindrical screw () and take out Screw lifting device X () into and tighten by hand Remove counter holder X Carefully take out of transmission. Before lifting out the completely, raise it to just above the turbine shaft. Then tilt the slightly so that the oil can drain out a -

17 6 Unscrew lifting device. 7 Turn the over and remove the shim(s) () from the or turbine shaft.! DANGER Torque converter weighs approx. 50 kg. Before removing the lifting device, secure the to prevent it from rolling away. 8 Remove spacer ring () from stator hollow shaft a -3

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19 . Installing.. Measuring end float Screw lifting device X () into so that the torque converter turbine wheel is clamped tight. Turn over. DANGER Torque converter weighs approx. 50 kg. Secure to prevent it from rolling away. 3 Measure the distance "C" between the face end of the spur gear and the turbine wheel Note down distance "C". 5 Measure the distance "B" between the face end of the spur gear and the face end of the internal sprag race Note down distance "B" a -5

20 7 Calculate the theoretical distance "D" between the face end of the internal sprag race and the plane face of the shim as follows. C B = D Note down distance "D". D C B 8 Check rectangular ring () for damage. Replace if necessary Align rectangular ring centrally. Rectangular ring has hooked ends. 0 Slide spacer ring () onto stator hollow shaft so that there is no end float. Screw lifting device X into turbine shaft Tighten lifting device by hand until there is no end float on the turbine shaft. 3 Place depth gauge in recess of lifting device on end face of turbine shaft. 4 Measure distance "A" between face end of turbine shaft and spacer ring () on stator hollow shaft. A 5 Note down distance "A". 6 Unscrew lifting device from turbine shaft a -6

21 7 Calculate thickness "S" of shim (). D A = E Distance "E" plus the specified torque converter end float (distance "G") (* 0.3 to 0.4 mm) gives the required thickness "S" of the shim () to be fitted. E to 0.4 mm = S Calculation example: C = 74.7 mm D = 9.50 mm B = 55. mm A = 8.30 mm D = 9.5 mm E =.0 mm * + G = 0.35 mm S =.55 mm CAUTION Distance "G" must be added and not subtracted otherwise the bearings will be damaged. Shims (OTK) are available in thicknesses ranging from.6 mm to.0 mm, in 0. to 0.3 mm steps. Thicker shims mean greater end float. 8 Thinly coat shim () with grease and affix. 9 Centre the shim. 0 Centre rectangular ring (). Thinly coat race of seal (arrow) with oil a -7

22 Screw lifting fixture X into torque converter. 3 Carefully lower so that it is centred on the turbine shaft. Fit the torque converter so that there is no end float. 4 Loosen lifting device X by unscrewing a few turns CAUTION Take care not to damage the seal. Ensure the shim is correctly positioned on the turbine shaft. The turbine shaft and stator hollow shaft splines must mesh inside the. Rotate the slightly if necessary. The gear on the must also mesh with the input gear of the primary shaft a -8

23 .. Measuring installation dimension Make sure the is fitted correctly and without any end float. Measure installation distance "F" between mounting face and transmission mounting face. 3 Measure the distance at several points around the circumference and calculate the average value. Installation dimension "F" must be X ± 0.5 mm. Ecomat transmissions can be equipped with different types of. Distance "F" ( installation dimension) must be one of the following installation dimensions, depending on version. Distance "F" = 8.5 mm If installation dimension "F" is between X mm and X 0.5 mm, then the setting is correct. 4 If the installation dimension is less than X 0.5 mm, fit a second spacer ring on the stator hollow shaft. 5 If the distance is more than X mm, remove the spacer ring. The spacer ring is mm thick. CAUTION If the distance "F" is changed by adding/removing a spacer ring on the stator hollow shaft, the shim on the turbine shaft must also be changed accordingly. Otherwise the bearings will be damaged. 6 Unscrew lifting device X from. 7 Screw M6 cylindrical screw () into turbine shaft. 8 Re-check the installation dimension. F a -9

24 9 Attach counter holder X to transmission housing and bolt it to. 0 Screw retaining fixture X into circuit cover and tighten by hand. Ensure rubber washer is fitted onto retaining device thread. Connect pneumatic unit X onto retaining fixture X Turn regulator () anti-clockwise a few times. 3 Open stopcock. Move the lever () into horizontal position Use regulator () to set a pressure level of.5 bar. 5 Insert /" socket range extension and tighten hexagon socket head screw; tightening torque: Nm 3 6 Close stopcock. 7 Remove retaining fixture X (3) from circuit cover. 8 Fit new copper seal on screw plug (). 9 Tighten M33x screw plug; tightening torque: 90-0 Nm a -0

25 Dismantling and assembling torque converter. Dismantling Place on planks so that impeller faces upwards. Unscrew all M0x (SW 6) hex bolts and washers () leaving only one hex bolt on each opposite side. 3 Turn over so that impeller faces downwards or circuit cover faces upwards. 4 Remove two remaining hex bolts on opposite sides. 5 Attach hoisting rope to lifting device X () and lift circuit cover (3) off impeller using hoist.! DANGER Turbine wheel may remain in circuit cover and fall out. Therefore, only lift the circuit cover as high as necessary and immediately lay it down close by Take off turbine wheel () a -

26 7 Take housing disc (), axial needle cage () and thrust disc (3) off stator (4). CAUTION Do not mix the bearing assemblies when installing. The thrust and housing discs must not be mixed up with any other bearing modules. Clearly mark all parts. 8 Take stator (4) out of impeller (5) Take out thrust disc (6), roller bearing (7) and thrust disc (8). CAUTION The thrust and housing discs must not be mixed up with any other bearing modules. Clearly mark all parts a -

27 .. Dismantling stator Place stator () on support with collar () facing downwards. Place suitable pressure piece () on internal sprag race. 3 Press internal sprag race out of stator Remove roller () from internal sprag race (). 5 Take off thrust disc (3) from internal sprag race a -3

28 6 Press internal sprag race () out of ball bearing ().! DANGER Do not clean bearings using compressed air. Bearing races could come loose and damage the bearing due to lack of lubrication. 7 Place stator () on press using suitable support (). 8 Use suitable pressure piece (3) to press ball bearing out of stator CAUTION The diameter of the pressure piece must match the outside diameter of the bearing. 9 Remove ball bearing () and thrust disc () from stator a -4

29 .. Assembling stator Insert stator on suitable support in press with collar () facing upwards. Insert thrust disc in stator. 3 Use special tool X () to press ball bearing (3) in as far as it will go. 3 4 Insert support X (3) into press with hollow facing upwards Turn stator over (collar () facing upwards) and place on support X Insert internal sprag race () into stator with the longer collar facing downwards and press in. Using support X ensures that the internal sprag race is fitted in the correct position Insert rollers () in stator. After insertion, moderately oil the rollers and rotate the stator several times. 8 Insert thrust disc () in stator a -5

30 9 Insert support X in press and place stator on support complete with ball bearing. 0 Place second support X () on ball bearing (). Press ball bearing into stator until firmly home. Ensure that the hollows on both supports X are facing the stator. Using the supports ensures that the bearing is fitted in the correct position a -6

31 ..3 Dismantling circuit cover Unscrew 4 M0 cylindrical screws () from circuit cover. Remove O-ring (). 3 Remove end disc (3). 4 Remove inner and outer clutch discs (4) from circuit cover. Compression springs with discs (5) can be found on the last outer clutch disc. 5 Remove compression springs, discs (5) and last outer clutch disc. 6 Take out twelve rollers (6) Take out cup spring () a -7

32 8 Force the ball bearing () off the turbine wheel using two assembly levers. 9 Gently strike circuit cover with plastic hammer to remove plate piston (). 0 Use appropriate tool ( mm thickness) to grasp inner rectangular ring () and carefully take out plate piston.! DANGER Grooved edge of plate piston may have sharp edges. Wear protective gloves. At the same time slide both sides of outer rectangular ring () in direction indicated by arrows. Grasp protruding part of rectangular ring and take out of annular groove a -8

33 ..4 Assembling circuit cover Thoroughly clean all components and dry using compressed air. Only use lint-free cloths to wipe off the rectangular rings. Check rectangular rings for damage and replace if necessary. Coat inner rectangular ring () and outer rectangular ring () with Vaseline and insert them into the plate piston. Stretch the inner rectangular ring a little before installing so that it sits firmly in the base of groove. 3 If removed, use plastic hammer to drive in ball bearing (5). CAUTION Insert plate piston (3) in circuit cover without tilting it. Ensure that the rectangular rings are firmly seated in the base of the groove all the way around. 4 Tap around the edge of the plate piston with a plastic hammer. Make sure that the plate piston is correctly positioned. 5 Place cup spring (4) onto plate piston with camber facing downwards. 6 Insert twelve rollers (6) into holes around the edge Use a straight edge to check that the outer and inner clutch discs are flat and not distorted or perform a visual check. Check the discs against the end disc or a flat surface. CAUTION Replace any discs that are dished or corrugated. Maximum permitted wear is 0.3 mm. Replace lined discs that have damaged or blackened linings. Replace inner clutch discs that have damaged tooth flanks. Maximum permitted wear per tooth flank is 0. mm a -9

34 8 Insert first outer clutch disc () so that the holes slide over the rollers. 9 Place four discs and four springs () over the rollers and onto the outer clutch disc at 90 intervals. 0 Insert first inner clutch disc (3). Insert second outer clutch disc (4) offset at an angle to the first outer clutch disc. Insert second inner clutch disc (5) in circuit cover Insert outer clutch disc (4) so that the tooth spaces for the springs (arrow) and bores are above the remaining rollers. Outer clutch disc (4) must not rest on the springs Insert two M0 threaded pins () at angle. 4 Line up the holes on the end disc () with the holes in the circuit cover. Fit end disc over threaded pins and onto springs in circuit cover a -0

35 5 Screw in 4 M0x30 cylindrical screws (). Tightening torque: 69 Nm Before tightening the hex bolts, tap the plate piston fully home with a plastic hammer. 6 Use a feeler gauge () to measure the play between the last inner clutch disc and the end disc (3) and note down as distance "A". 3 7 Disc play (distance "A") must be between 0.6 mm and. mm If the disc play is less than 0.6 mm or more than. mm, fit new outer clutch discs as necessary. Then re-measure distance "A". A 8 Turn over turbine wheel and drive spacer disc () into turbine wheel as far as it will go (if previously removed). 9 Strike spacer disc at four points around the edge to secure it. Install spacer disc with holes facing upwards Insert rectangular ring () in annular groove and hook in the open ends of the ring.! DANGER Rectangular ring has sharp edges. Wear protective gloves a -

36 Align inner clutch discs. The discs must cover each other. Insert turbine wheel () in circuit cover. CAUTION Ensure that the teeth on the turbine wheel mesh in the gaps on the inner clutch discs. Rotate the turbine wheel back and forth until it engages. Ensure that the turbine wheel is fully engaged and inserted as far as it will go. If necessary, tap edges of inner teeth with plastic hammer. Take care not to damage inner clutch discs a -

37 ..5 Measuring axial bearing end float. Take measurement as check Production tolerances give the specified axial play. There are no provisions for adjusting the axial play using shims. Measuring is for checking purposes only. Insert the axial disc (3) in the impeller (4). Insert the axial roller bearing (). 3 Insert the axial disc () Insert the stator (5) in the impeller with the longer collar of the freewheel inner ring facing downwards. 5 Fit the axial disc (3) on the shorter collar of the freewheel inner ring (4) on the stator. 6 Fit the axial needle cage (). 7 Fit the housing disc () Place the measuring plates (3) on the mating face of the impeller. 9 Fit the measuring strip (). 3 0 Place the depth gauge on the measuring strip and measure the distance "A" between the measuring strip and the impeller mating face (). Note down distance "A". The measuring strip must not lie on the stator a -3

38 Move the depth gauge to the middle. Measure the distance "B" between the measuring strip and the front face of the housing disc (). 3 Note down distance "B" and subtract distance "A" from it. B - A = Distance "C" 4 Mount the measuring setup on the circuit cover mating face Do not insert an O-ring in the circuit cover for the purpose of measuring. 5 Use the depth gauge to determine the distance "D" between the measuring strip and the mating face of the circuit cover (). 6 Note down distance "D". 7 Determine the distance "E" between the measuring strip and the point of contact with the shim (). 8 Note down distance "E" and subtract it from distance "D" D - E = Distance "F" Subtract distance "F" from distance "C". C - F = Distance "G" Distance "G" = axial play of the axial bearing Specified axial play of the axial bearing = 0.0 to. mm Distance "G" must be within the specified axial play of 0.0 to. mm a -4

39 . Assembling Insert housing disc () in the turbine wheel with chamfered side facing turbine wheel. Insert axial needle cage () and thrust disc (3) in turbine wheel. 3 3 Insert stator () in turbine wheel with short collar of internal sprag race facing the turbine wheel. Coat all bearings with oil before installation. 4 Place thrust disc () on long collar of internal sprag race with chamfered side facing stator. 5 Fit roller bearing (3). 6 Fit thrust disc (4) Insert O-ring (). 8 Screw two M0 threaded pins () opposite one another in circuit cover flange a -5

40 9 Place impeller () on circuit cover. 0 Screw in two of the M0x hex bolts (SW 6) with washers. Unscrew M0 threaded pins (). Screw in remaining M0x hex bolts. 3 Tighten M0x hex bolts (SW6), Tightening torque: 65 Nm Check end float of internal sprag race (). 5 Use both hands to grasp inside of internal sprag race and move in axial direction. End float must be palpable a -6

41 3 Checking seal integrity of Insert forcing device X () into at spur gear end Screw lock nut () onto forcing device.! DANGER Torque converter weighs approx. 50 kg. 3 Lower into basin using lifting gear so that forcing device is underwater Connect pneumatic unit X to forcing device. CAUTION The water in the basin must contain part antifreeze to 0 parts water. Water temperature = 0 C a 3-

42 5 Turn regulator () anti-clockwise 6 Open stopcock (). 7 Use regulator () to set a pressure level of.5 bar. CAUTION Torque converter must be absolutely leak-tight. 8 Close pneumatic device X and remove from forcing device X Lift out of basin using lifting gear and lay to one side on work surface Detach from lifting gear and turn over. Unscrew lock nut (). Place on circuit cover and remove forcing device X () from. Dry using compressed air. Lightly coat spur gear with oil a 3-