RepAnleitungVoithDIWA3 E

Repair Manual
DIWA Transmissions
D 851.3E / D 863.3E
D 854.3E / D 864.3E
Voith. Repair Manual DIWA.3E

55.6704.13 / 2003-01
© by Voith Turbo 2002
Copyright
This document is protected by copyright.

All rights reserved. All types of copying and
distributing, including partially and for other
purposes than those agreed - especially
that of further commercial or private use -
are forbidden and will be prosecuted.
© 2002
Changes
The version of the documentation is noted on the cover sheet.
When revising the document, the number of version is increased of 1.
Changes are listed in the following table:
Version Date Changes
55.6704.12 02-12 Included page describing changes.
55.6704.13 03-01 Output flange Bolted connection 3x M10x50-10.9 :

tightening torque changed from 67 Nm to 72 Nm.
Important Notes
You are responsible for familiarizing yourself with the warning notes and precautionary meas-
ures described in these instructions.
However, these instructions only contain the most important information. It is not
possible to include all conceivable faults and hazardous circumstances.
Therefore, everybody who performs repairs or maintenance work must very carefully make sure
that his own personal safety and the safety of other persons is not endangered.
This document describes the transmission as originally delivered.
Subject to change due to technical progress.
Symbol
DANGER!
This symbol warns of an immidiate threat to the life and health of persons.
Ignoring the instruction may result in severe injury or may even be fatal.
NOTE:
This symbol stands for information about the proper use of the Diwa transmission.
It does not imply any imminent danger.
ENVIRONMENT
This symbol warns of possible damage to the environment caused by operation, mainte-
nance, or repair of the transmission.
Voith. Repair Manual DIWA.3E I

Notes on Safety at Work and Product Safety
Only genuine Voith parts may be used!
The instructions in the repair manual are based on the assumption that the design and function
of the DIWA transmission are known. Pertinent explanations are found in the ”Technical Manual
55.6357. ..“.
To ensure perfect operation of the transmission it is essential that the oil filter and oil is changed
after at least 5,000 km, when the transmission was overhauled or a service exchange unit was
installed.
During general overhauls of the transmission, the ball, roller and needle bearings of the
transmission must be checked and all sealing elements, hoses, inner friction discs and other
wear parts replaced.
Immerse inner friction discs in oil before installation.
Check TB inner discs and all outer discs for wear. Replace if overheated and/or deformed.
Very dirty transmissions must be cleaned prior to disassembly to keep out foreign objects (chips,
sand, etc.).
All parts including the heat exchanger must be cleaned and blown out carefully after disassem-
bly.
Cleanliness must be ensured when the transmission is assembled.
When replacing larger components, make sure they are carefully attached to the hoists and se-
cured.
Storage and useful life of heat exchanger hoses:

Even if stored properly and under permissible stress, hoses and hose lines are subject to natural
ageing. This also limits their useful lives.
DIN 20066 recommends: the useful life of a hose line, including its storage time, should not ex-
ceed 6 years.
Check running faces of piston rings for grooves and polish out light scores, if required.
Expand inside piston rings before installation.
Generally install piston rings with the groove toward the oil side.
Grease all sliding faces of piston rings and O-rings.
Oil or grease sliding surfaces of shaft seals.
Do not open circlips more than necessary when installing.
Do not remove or install inductive pick-ups using a slugging wrench.
NOTE: When removing the transmission from the vehicle, observe the instructions of the
vehicle’s manufacturer. This handbook does not contain instructions on removal of the
transmissions from the vehicle.
If the transmission is removed after an longer operating time (approx. 400,000 km or more),
check of Hydrodamp, chapter 3.2.
Rework, modifications and design improvements that should be taken into account in transmis-
sion overhauls are described in the ”Service Bulletins“.
Work must be carried out properly to prevent damage to parts and tools.
Voith recommends always replacing all the parts printed in bold-italics.

All the other parts must be examined individually and replaced when necessary.
II Voith. Reparaturanleitung DIWA.3E

Malfunctions
In case of malfunctions, the NOTEs and instructions in the brochures ”Diagnostic Manual
55.6264. ..“ and ”Fault Finding 55.6303. ..“ should be consulted first.
Towing
NOTE: Please pay attention to the following in order to avoid damage to the DIWA trans-
mission during towing.
Shift transmission to neutral and disconnect the electrical connector at the transmission
or electronic control unit.
If the transmission is damaged, remove the cardan shaft or stub shaft of the rear axle.If
transmission damage is not present, the vehicle may also be towed with the cardan shaft
installed, however, at most for a distance of 10 km. Allowed maximum speed: 30 km/h.
If the transmission has an angle drive, the cardan shaft or stub shaft must be removed in
any case.
Special issues must be observed for railroad vehicles, e.g. that the reversing axle gearbox
is shifted to neutral.
Observe instructions by the vehicle manufacturer.
NOTE: If a transmission is stored after repair without a test run, corrosion protection will
be required.
All transmission parts must be treated with ATF during assembly.
See also Voith’s List of Lubricants 55.6335..., 55.6336... .
Consequences of coolant or oil loss, treatment of used oil
DANGER! If oil leaks because the piping, seals or O-rings are not properly installed or
have become leaky over time, accidents may occur.
Disposal of used oil
ENVIRONMENT: Do not pollute the environment with oil or coolant!

Used oil must be disposed of in accordance with applicable laws. Do not contaminate
earth or sewers.
Who is allowed to repair
Only trained automobile mechanics or workers with similar skills.
Persons who already attended a Voith repair training course for DIWA transmission.
Untrained staff may only work on the DIWA transmission in the presence of an experiencer per-
son.
Voith. Repair Manual DIWA.3E III

IV Voith. Repair Manual DIWA.3E
Differences between 3 and 4-Speed
Transmissions
Externally, the two variants can be distinguished by an intermediate housing between

cover and body on the input drive side.
Most parts of the transmission variants are identical.

Where this is not so the difference is marked by symbols in the illustrations and text.
See illustrations for 3-speed and 4-speed version.
D 851.3 / D 863.3: 3-speed transmissions
3-speed
D 854.3 / D 864.3: 4-speed transmissions
4-speed
Voith. Repair Manual DIWA.3E V

VI Voith. Repair Manual DIWA.3E
Contents
Page
Important Notes ....................................................................................................................I
Differences between 3 and 4-Speed Transmissions ....................................................... V
Contents ..............................................................................................................................1
1 Tools ..............................................................................................................................3
1.1 Standard Tools .................................................................................................... 3
1.2 Special Tools .................................................................................................... 4-7
1.3 Auxiliary Tools ............................................................................................... 8-10
2 Transmission Removal ..............................................................................................11
3 Removal of Torsional Vibration Damper ..................................................................12

3.1 Hydrodamp .........................................................................................................12
3.2 Check of Hydrodamp Hub for Wear....................................................................13
4 Removal of Electronic Control Unit .........................................................................15
5 Removal of Assemblies from Transmission..........................................................17

5.1 Heat Exchanger .................................................................................................17
5.2 Valve Blocks ................................................................................................. 18-19
5.3 Cable Harness ....................................................................................................20
5.4 Output Drive........................................................................................................21
5.5 Turbine Gear, Stator and Turbine Wheel...................................................... 22-23
5.6 Input Drive ..........................................................................................................24
5.7 Suction Strainer ..................................................................................................25
5.8 Gear Pump .........................................................................................................25
5.9 Converter Drain Valve ........................................................................................26
5.10 Working Pressure Valve .....................................................................................26
5.11 Oil Filter ..............................................................................................................27
5.12 Impeller Brake............................................................................................... 28-30
6 Dismantling and Assembly of Subassemlies...........................................................31

6.1 Disassembly of Input Differential .................................................................. 31-40
6.2 Disassembly of Planet Gear Carriers .................................................................41
6.3 Assembly of Planet Gear Carriers ......................................................................41
6.4 Assembly of Input Differential ....................................................................... 42-54
6.5 Disassembly of Impeller Brake ..................................................................... 55-57
6.6 Assembly of Impeller Brake .......................................................................... 58-61
6.7 Disassembly of Stator and Turbine Wheel .........................................................62
6.8 Assembly of Stator and Turbine Wheel ....................................................... 63-64
6.9 Disassembly of Turbine Gear ....................................................................... 65-66
6.10 Assembly of Turbine Gear ..................................................................................67
6.11 Disassembly of Output Drive and Reverse Gear.......................................... 68-69
6.12 Disassembly and Assembly of Working Pressure Valve ....................................70
6.13 Disassembly of Gear Pump with Inductive Pick-up N1.......................................71
6.14 Assembly of Gear Pump with Inductive Pick-up N1 ..........................................72
6.15 Disassembly and Assembly of Converter Drain Valve .......................................73
6.16 Disassembly and Assembly of Valve Blocks ............................................... 74-76
Voith. Repair Manual DIWA.3E 1

Page
7 Installation of Assemblies in Transmission ............................................................ 77

7.1 Impeller Brake............................................................................................... 77-80
7.2 Working Pressure Valve .................................................................................... 81
7.3 Converter Drain Valve........................................................................................ 81
7.4 Oil Filter.............................................................................................................. 82
7.5 Valve Plate......................................................................................................... 83
7.6 Gear Pump......................................................................................................... 83
7.7 Suction Strainer ................................................................................................. 84
7.8 Input Drive.......................................................................................................... 85
7.9 Stator and Turbine Wheel .................................................................................. 86
7.10 Turbine Gear................................................................................................. 87-88
7.11 Reverse Gear in Output Drive............................................................................ 89
7.12 Measurement and Adjustment of Disc Clearance for Reverse Gear ................. 90
7.13 Output Drive ................................................................................................. 91-93
7.14 Inductive Pick-Ups ............................................................................................. 94
7.15 Cable Harness ................................................................................................... 94
7.16 Valve Blocks ................................................................................................. 95-96
7.17 Installation Examples for Heat Exchanger ......................................................... 97
8 Installation of Transmission in the Vehicle ............................................................. 98

8.1 Bolt Hydrodamp to Engine Flywheel.................................................................. 98
8.2 Installing the Transmission ................................................................................ 99
9 Checks ...................................................................................................................... 100

9.1. Check of Working Pressure and Converter Pressure .............................. 100-101
9.2 Further Checks ............................................................................................... 101
10 Transmission Weights............................................................................................. 103
11 Tightening Torques.................................................................................................. 105
2 Voith. Repair Manual DIWA.3E

1 Tools
1.1 Standard Tools

Bit holder
Voith part no. 02.0112.04
Screwdriver bit
B-K 5x11 Voith part no. 02.0111.86
K-5 long Voith part no. 02.0078.20
Torque wrench 0 - 150 Nm
Forcing bolt 2x M6 Voith part no. 50.0677.10

Circlip pliers for inner circlips

Pliers J1 Circlip 8 - 25 mm dia.
J2 19 - 60 mm dia.
J3 40 - 100 mm dia.
Circlip pliers for outer circlips

Pliers A1 Circlip 10 - 25 mm dia.
A2 19 - 60 mm dia.
A3 40 - 100 mm dia.

1 Tools
1.2 Special Tools

The following special tools are required for disassembly and assembly. You can make them
yourself, or you may order them from Voith - see following sketches.
Special tool no.1

Extractor for input cover
Manufactured from
M16x100 DIN 933
Welded
30x30
Special tool no. 2

Forcing bolt M10
M10x350
Hardened
Special tool no. 3

Tool for removal and installation of spring
clips.

1 Tools
Special tool no. 4

Screwdriver with socket wrench
Lock washer B 8 DIN 127
Special tool no. 5

for removing the plugs from solenoids.
M4x10 DIN 912-10.9
Length approx. 150

1 Tools
Special tool no. 6

for removing the plugs from the cable harness,
Pliers DIN 5254-A40-gl
inductive pick-up N1, and temperature sensor.
10
14 Pliers DIN 5254-A40-gl
15 5 R
8 2.
2.5 5
20°
16
Ø2.5
15
5 Hard-soldered
13.1+0.1
Special tool no. 7

for installing plugs on inductive pick-ups.
Screwdriver DIN 5265-C-A0.5x3
Point removed
Hard-soldered
5.5
10
7
8
3
2.5
9.5
13
1.5
Ø 3.2
R
3
Special tool no. 8

for installing plugs on cable harness,
inductive pick-up N1, and temperature sensor.
Pliers DIN 5256-C40-gl
4
1x45° Ø 2.5°
1x45°
5X45°
5
10
17
9 14.5 Hard-soldered
13.2 18.5
17

1 Tools
Special tool no. 9

for installing the shaft seal of the output drive cover.
Special tool no. 10

for installing the shaft seal of the input drive cover.

1 Tools
1.3 Auxiliary Tools

These tools are not available from Voith.
Auxiliary tool no. 1 Auxiliary tool no. 2

Sleeve for mounting the Sleeve for mounting the EK disc carrier
input shaft bearing bearing
Ø 60 Ø 73
100
100
90
90
Ø 52 Ø 62

Sleeve for mounting the turbine gear clutch Disc for forcing off the ring gear of input dif-
and pump brake bearings ferential
Ø 84,5
Ø 60
Ø 41
130
120
10
16
Ø 76

1 Tools

for installing the inner ring and ball bearing. for installing the needle bushings
on the turbine shaft. in the gear pump.
5 8
5
2 x 30°
Ø 21,9
Ø 27,9
Ø 68,5
Ø 40
Ø 60
Ø 80
R 1,5
25
2 x 45° 2 x 30°
41
54
Auxiliary tool no. 7

for installing the needle bushing
in the gear pump housing.
1
Ø 27,9
Ø 34
Ø 60
15 16

2 Transmission Removal
NOTE: The transmission should not
be removed when hot, as the clutch
housing centring is under increased
pressure due to expansion.
DANGER! Apply the parking brake,

secure vehicle against rolling. Other-
wise, there is a danger of accidents.
Press neutral button of push-button

switch.
Turn off engine:
Turn off ignition to prevent damage to
the electronics during further work.
After that, disconnect the cable from the
transmission housing (1/3).
Disconnect tachometer cable from the
adapter (1/4).
Drain off coolant and dispose of it in an
1 environmentally acceptable manner.
Open drain plugs (1/6) and (1/7) and
drain off transmission oil (approx. 26 lit-
res). Dispose of the oil in an environmen-
tally acceptable manner.
DANGER! Hot coolant and/or oil may

cause scalding!
Suspend the transmission from a crane

via suspension lugs.
DANGER! Screw in eyebolts comple-

tely. Otherwise, they might break.
The rope must have a sufficient car-
rying capacity. Transmission can
weigh up to 450 kg!
NOTE: If a lifting device is used, tie

the transmission to it.
All mechanical and electrical connec-

tions to the transmission, such as bolts
(1/2) and cardan shaft (1/5), as well as
coolant pipes and electrical cables must
be removed.
NOTE: In order to prevent damage to

the Hydrodamp, move the transmissi-
on out for about 8 cm parallel to the
engine until the pinion shaft (1/1) is
free, then lower it.
When removing the transmission, a

small quantity of oil (up to 30 ml are per-
missible) may escape from the inside of
the Hydrodamp seal.

3 Removal of Torsional Vibration Damper
3.1 Hydrodamp
Handling
NOTE: The Hydrodamp has been manufactured to close inside tolerances. External dam-
age may result in failure of the damper.
Important note for handling, storage and replacement: Do not lay down the Hydrodamp on
its hub.
For transportation, storage up to installation and sending back, the Hydrodamp must re-
main in its original Voith packing.
In case of defects, the Hydrodamp must be replaced complete.
If oil traces are visible in the hub area, check the oil level.
Oil level check
DANGER! Danger of scalding - do not

remove the Hydrodamp while it is hot.
With the damper temperature lower than

50 °C (122 °F), turn the Hydrodamp - or
1 hold it with a vice - so that the inspection
holes (2/1 and 2/2) are located vertically
one above the other.
Wait for about three minutes, then remove
the upper screw plug (2/1).
2 Turn Hydrodamp clockwise about the hub
axis by approx. 40° - 45°.
If oil flows out while doing so, close bore-
hole (2/1) again with a screw plug M10x1
and a new copper seal 10.5x16x2,
VGN 3019 (special size, not DIN) using
2 Loctite type 243 - tightening torque:
18 Nm.
If no oil comes out, the oil level must have
dropped below the minimum permissible
quantity. Leaks may be a possible cause.
Replace the Hydrodamp.
To facilitate removal:
Remove 2 opposite bolts M10 from the ou-
ter pitch circle of Hydrodamp (3/2) and re-
place them by studs (3/1, length 100 mm).
Remove remaining 10 bolts from the outer
pitch circle but do not remove the short
hex. bolts of the damper.
Then force off the damper by means of
forcing bolts (special tool no. 2).
If the intermediate ring, if installed, comes
loose from the flywheel centring socket,
push the ring back.
3

3 Removal of Torsional Vibration Damper
3.2 Check of Hydrodamp Hub for Wear

Check the circumferential backlash bet-
ween drive shaft and hub of the Hydrod-
amp.
Install Hydrodamp on a new shaft.

If the circumferential backlash at the
pitch circle dia. (approx. 410 mm) is gre-
ater than 2 mm, then replace the Hydro-
damp completely

4 Removal of Electronic Control Unit
For cable 1 and 2: open clamping lever
(5/1) and pull off flat pin connector (5/2).
Unscrew 4 fastening nuts M6 (5/3).

1
2
3
Cable 1
Cable 2
5

5 Removal of Assemblies from Transmis-
sion
5.1 Heat Exchanger Removal

DANGER! Danger of scalding - there
may still be hot oil in the heat ex-
changer.
The heat exchanger is installed at va-

rious points of the transmission or in a
separate location.
Example:
standard variant.
Heat exchanger attached to the output

drive side at the bottom.
1 For removing the heat exchanger, first

2 disconnect hoses (7/1, 7/2) and then the
heat exchanger (7/3) itself. Screw off
mounting plate, if any.

5 Removal of Assemblies from Transmission
5.2 Removal of Valve Blocks

For one and two-piece covers.
one-piece two-piece
One-piece:
Unscrew 12 hex. bolts M8 (8/1) of control
unit cover (8/2) and remove it.
2 1 Remove gasket underneath.
8
3-speed
Remove cable guard (9/1).
Pull plugs (10/4) off the solenoids using

special tool no. 5 (see fig. 12).
1
2 NOTE: Do not pull the cables.
3 Undo 12 socket-head bolts M8 (10/2) of
4 valve blocks (10/1, 10/5) and remove the
blocks.
Remove connecting pipe (10/3).
2
5
10

4-speed
Remove cable guard (11/1).
11
Pull plugs (12/4) off the solenoids using

Special tool no. 5 special tool no. 5.
1 NOTE: Do not pull the cables.

2
Undo 12 socket-head bolts M8 (12/2) of
3 valve blocks (12/1, 12/5) and remove the
blocks.
4 Remove connecting pipe (12/3).
2
1 5
12

5.3 Removal of Cable Harness
Special tool no. 6 Disconnect earth cable (13/1).

Open connection for inductive pick-up
N1 and temperature sensor using spe-
cial tool no. 6.
13
Open union nuts (14/3, 14/5, 14/6) and

1 2 3 4 56 7 undo 3 socket-head bolts M6 of multi-pin
socket (14/7).
Screw off cap (14/1) and pull off the con-
tacts from the inductive pick-up N2.
Screw out male union (14/2).
Undo 3 socket-head bolts M8 of cap
(14/4).
Pull contacts off inductive pick-up N3.
Remove cable harness from the trans-
mission.
14
Unscrew inductive pick-ups N2 (15/1)

1 2 3 and N3 (15/2).
Pull 4 tubes (16/3) out of the transmissi-
on by using a screw M12.
15

5.4 Removal of Output Drive

Set up the transmission with the output
2 3 shaft at the top.
DANGER! Secure the transmission

against toppling.
If the transmission has an angle drive on

1 4 the output side, remove it - see special
Repair Manual for angle drives.
5 Unscrew lubricating pipe (16/1).

Remove 3 hex. bolts M10 (16/2) of out-
put flange (16/3) and lift off with washer,
adjusting discs and O-ring.
Unscrew 26 nuts M8 (16/4) of oil pan

16 (16/5) and remove with gasket.
NOTE: Oil may still run out.
Unscrew 12 hex. bolts M10 (17/2) of out-

put cover (17/1) and lift off uniformly.
DANGER! If the RG planet carrier re-

maines in the output cover it may
1 drop out when lifting the cover.
17
Remove ring gear R (18/1),

inner and outer discs R (18/2), and key
(18/3).
1
2 NOTE: Mark the position of the ring
gear so that the same side will be
3 seated during reinstallation.
18

5.5 Removal of Turbine Gear, Stator and Turbine Wheel

Special variant:
Remove blocking oscillator (19/1).
19
Disconnect hose line (20/2) and male

1 union (20/1).
20
Remove RG-TB disc carrier (21/1) from
the transmission.
21
Special tool no. 2 Remove turbine gear (22/1) using spe-

cial tool no. 2.
NOTE: The planet gear carrier shaft

may jam.
22

Remove TB friction discs (23/2) and

panet gear carrier shaft (23/1).
23
Undo 4 socket-head bolts M8 (24/5) of

abutment ring (24/4).
1 Remove abutment ring with brass disc
and disc springs, large disc spring (24/3),
and brake piston (24/2).
2 Undo 12 socket-head bolts M8 (24/1),
then press off and remove the stator to-
3 gether with the turbine wheel and shaft
4 using special tool no. 2.
Set the transmission on its output side.

24
NOTE: Provisionally fix the oil pan to
the housing with two nuts to protect
the pipes.

5.6 Removal of Input Drive
3-speed
Input drive cover "B" (25/1):

Undo 12 socket-head bolts M10.
Force off cover using special tool no. 2.
Remove cover together with input diffe-
1 rential (25/2).
2 Input drive cover "A":

Undo 12 socket-head bolts M10 of the
connecting flange.
Remove the flange.
25 Undo 2 socket-head bolts M10.
rential.
4-speed
Input drive cover "B" or "D" (26/1):

Undo 12 socket-head bolts M10.
1 rential (26/2).
Remove adaptor housing (26/3).

2
Input drive cover "A" or "C":
Undo 12 socket-head bolts M10 of the
3 connecting flange.
Remove the flange.
26 Undo 2 socket-head bolts M10.
rential.
Remove adaptor housing (26/3).

5.7 Removal of Suction Strainer

Undo 2 hex. head bolts M10 (27/1) and
remove the strainer (27/2).
27
5.8 Removal of Gear Pump

To facilitate removal of the gear pump,
unscrew 3 hex. bolts M8 (28/1) and re-
move the flange (28/2).
2
1
28
Pull out the plug-in tube (29/1).
29
NOTE: Remove all pipes.
Unscrew 4 hex. bolts M10 (30/1).
1 Remove gear pump (30/2).

Pull off plug from inductive pick-up N1.
2
30

5.9 Removal of Converter Drain Valve

Unscrew 5 socket-head bolts M6 (31/1).

Remove converter drain valve (31/2).
3 Unscrew drain plug for converter oil
1 (31/3).
2
2
31
5.10 Removal of Working Pressure Valve

Screw 4 hex. head bolts M8 (32/1) and

3 hex. head bolts M10 (32/2) out of valve
plate (32/3).
Pull valve plate out of plug-in tubes.

3 Remove plug-in tubes.
2 Remove working pressure valve.
1
32

5.11 Removal of Oil Filter

Unscrew cover (33/1).
33
Remove filter element (34/2).
34
Unscrew 5 hex. head bolts (35/1).
Remove oil filter housing (34/1).
35

5.12 Removal of Impeller Brake
3-speed
Unscrew socket-head bolt M10 (36/2),

remove and unrivet gear (36/1),
press grooved ball bearing and abutment
ring (36/3) out of the gear.
NOTE: The gear can also be replaced

complete.
1
2 Remove all pipes and pipe with cable.
3
36
Unscrew 11 hex. head bolts M10 (37/1).

Force off impeller brake (37/2) using spe-
cial tool no. 2 (figure 39) and remove.
1
2
37

4-speed
Unscrew socket-head bolt M10 (38/3),

remove and unrivet gear (38/2),
press grooved ball bearing and abutment
ring (38/4) out of the gear.
1
NOTE: The gear can also be replaced
complete.
2
3 Remove all pipes and pipe with cable.
4
Unscrew 11 hex. head bolts M10 (38/1).
38
Special tool no. 2

Remove impeller brake (39/1) using spe-
cial tool no. 2.
39

6 Dismantling and Assembly of Sub-As-
semblies
6.1 Disassembly of Input Differential
3-speed
Special tool no. 2 Remove circlip (40/1).
Pull off input cover from input differential

Special tool no. 1
by means of special tools no. 1 and 2.
40
Unscrew 12 hex. head bolts (41/2),

remove input shaft (41/1).
Unscrew 12 hex. head bolts (41/3).

1
2
3
41
Remove circlip (42/3),

uniformly force off EK disc carrier (42/2)
1 by means of two bolts M10 (42/1).
42

6 Dismantling and Assembly of Sub-Assemblies
Remove EK discs (43/1),

planet gear carrier (43/2) with
1 ring gear (43/3) from disc carrier.
43
Tap off DK disc carrier (44/1) using a

plastic hammer.
44
Lift out DK discs (45/1).
45
Push off 12 spring clips (46/1) using spe-

Special tool no 3 1 cial tool no. 3.
DANGER! The springs are under ten-

sion. They may spring off and cause
injuries.
Remove springs,
spring cups,
bars and
outer discs.
46

Remove pistons (47/1 and 47/2) from the

EK-DK piston carrier and remove piston
rings.
3 1 Remove 4 O-rings (47/3).
47
NOTE: Check oil strainers (48/1) in

EK-/DK piston carrier for damage. Re-
place if necessary.
48
Force ring gear (49/1) off planet gear car-

rier (49/2) using auxiliary tool no. 4 and
Special tool no. 2 special tools no. 1 and 2.
NOTE: Spacer ring (49/3) will come off

too.
Special tool no. 1
3 Auxiliary tool no. 4
2
49

Remove circlip (50/1) and

grooved ball bearing (50/2) from ring ge-
ar.
1
2
50
Remove snap ring (51/1),

1 supporting disc and driver (51/2) from
ring gear.
2
51
If bush (52/1) of DK disc carrier is dama-

ged due to wear of piston rings or gear,
unscrew 6 socket-head bolts M8 (52/2)
and press out bush.
1
The bore of the bush can be re-ground to
2 a dimension of 85.120 mm, the permis-
sible roughness is 1.6 microns.
To re-insert the bush, heat up the disc

52 carrier to 120 °C (248 °F).
NOTE: Lube hole of bush must be in

line with lube hole of DK disc carrier.
After the DK disc carrier has cooled

down, install inner gear (53/1) and secu-
re with 6 hex. bolts M8x45-10.9 -
1
34 Nm.
53

4-speed
Special tool no. 2 Remove circlip (54/1).
Pull off input cover with special tools no.

Special tool no. 1
1 and 2.
54

Lift off input shaft (55/1).

1
2
3
55
Remove circlip (56/3).

Uniformly force off EK disc carrier (56/2)
1 by means of two bolts M12 (56/1).
2 Lift off EK discs.
56

Lift off ring gear (57/2) with auxiliary tool

Special tool no. 2 no. 4 and special tools no. 1 and no. 2.
NOTE: Spacer ring (57/1) will come off

Special tool no. 1 too.
Lift off complete EK-DK piston carrier

(57/3).
1
2
57
Lift off complete planet gear carrier

(58/1) together with DK discs (58/2).
58
Lift off input cover disc (59/1).
59

NOTE: SK disc carrier is spring-loa-

ded.
1
Uniformly unscrew hex. bolts M10 (61/1).
Lift off SK disc carrier (60/2).
2
60
Lift off all SK discs (61/1),

springs and spring sockets (61/2).
1
2
61
Take out piston (62/1) and remove piston

rings.
Remove 6 O-rings (62/2).
62

Remove snap ring (63/1) from groove of

SK planet gear carrier.
If sealing bush (63/2) of SK disc carrier is

1 damaged due to wear of piston rings or
gear, unscrew 6 socket-head bolts (63/3)
and press out bush.
2
The bore of the bush can be re-ground to
3 a dimension of 85.120 mm, the permis-
sible roughness is 1.6 microns.
To re-insert the bush, heat up the disc

carrier to 120 °C (248 °F). Install bush
and secure with 6 socket-head bolts
M8x25-10.9 - 34 Nm
63
NOTE: Lube hole of bush must be in
line with lube hole of SK disc carrier.
Force off SK planet gear carrier (64/2)

Special tool no. 2 from disc carrier (64/1) by means of auxi-
liary tool no. 3 and special tools no. 1 and
no. 2.
Special tool no. 1
2
64

Using special tool no. 3,

Special tool no. 3 1 push off 12 spring clips (65/1).

injuries.
Remove springs,
spring sockets,
rods, and
guide plates.
65
Pull pistons (66/1, 66/2) out of EK/DK

piston carrier and remove piston rings.
Remove 4 O-rings (66/3).
3 1
66
NOTE: Check cylindrical sieves (67/1)

on the EK/DK side and at the SK pis-
ton carrier for damage and replace, if
necessary.
67

Remove circlip (68/1) and

grooved ball bearing (68/2) from suppor-
ting disc.
1
2
68
Remove snap ring (69/1),

1 supporting disc and driver (69/2) from
ring gear.
69

6.2 Disassembly of Planet Gear Carriers

NOTE: The procedure described here
is basically the same for all types of
planet gear carriers.
Check all parts for wear and replace, if

necessary.
1 Remove dowel pin (70/2),

axle (70/1),
2 planet gear (70/4),
spacer rings (70/3).
4
3
70
6.3 Assembly of Planet Gear Carriers

NOTE: There are different bearing de-
signs depending on the type of diffe-
rential. The type of differential can be
seen from the nameplate.
The distinguishing features are:
Differential 3: 2 needle roller cages

1 Differential 4: needle roller cage, ring,
2 needle roller cage
This also applies to the SK planet gear
3 carrier.
Planet gear carrier of turbine gear:

71
2 needle roller cages
Planet gear carrier of reverse gear:

2 needle roller cages
Insert oiled needle roller cages into

planet gear (71/3).
Assemble planet gear with spacer ring
(71/2) on both sides.
Press axle into the correct position and
secure with dowel pin (71/1).

6.4 Assembly of Input Differential
3-speed
Insert piston rings into EK and DK pis-

Oil pressure side tons (72/1 and 72/2) with the groove fa-
3 cing the oil pressure side.
1
Grease sliding surfaces in EK/DK piston
carrier (72/3).
Install both pistons (72/1 and 72/2) in the
piston carrier.
Make sure they are in the correct positi-
on.
2 NOTE! In principle these instructions

apply to the installation of all piston
72 rings.
Slightly expand inner piston rings be-
fore insertion.
Pay attention to possible damage to
sliding surfaces. Remachine, if neces-
sary.
Position outer friction disc (73/1) and se-

1 Special tool no. 3 cure it at two opposing points as follows:
spring sockets (73/4),
helical springs (73/5),
rods (73/3) with spring clips (73/2).
2
DANGER! Clips may come loose if
they are incorrectly installed.
Hold rods and guide plate and turn piston

carrier around.
Place the other guide plate (73/1),

install spring sockets and springs.
5 4 3
Support rods (73/3), e. g. with a hammer.
73
Using special tool no. 3, compress
springs (73/5) and fit clips (73/2).
Align the two guide plates.
Install remaining rods, spring sockets,

helical springs, and spring clips.

Install driver and supporting disc (74/2) in

1 ring gear.
Secure with snap ring B190 (74/1).
2
74
Press grooved ball bearing (75/2) into

supporting disc and secure with circlip
95x3 (75/1).
1
2
75
Install ring gear (76/2) on planet gear

1 2 3 carrier (76/3) and press grooved ball
bearing onto planet gear carrier using
suitable auxiliary tool no. 2.
Glue spacer ring (76/1) onto planet gear

carrier neck using Loctite 270.
76

Transmission D 851.3E (see namepla-

te).
Install and align 6 EK discs on the ring
gear as follows (fig. 77):
inner disc,
outer disc 3.5 mm thick,
inner disc,
inner disc,
outer disc 2.0 mm thick.

te).
Install and align 8 EK discs on the ring
77 gear as follows (fig. 77):
inner disc,
inner disc,
inner disc,
inner disc,
Install EK disc carrier (78/3) and

1 2 3 grooved ball bearing 16012 DIN 625
(78/1),
using auxiliary tool no. 2.
Insert circlip (78/2).
Turn the assembly around.
78
Install complete EK/DK piston carrier

(79/2).
Install 4 O-rings 9x2 (79/1) in the piston

carrier with grease.
79


1 2 te).
Install and align 6 DK discs (80/1) in the
EK-DK piston carrier as follows:
inner disc,
inner disc,
inner disc,
80
te).
Install and align 8 DK discs (80/1) in the
EK-DK piston carrier as follows:
inner disc,
inner disc,
inner disc,
inner disc,
Install DK disc carrier (80/2) on the as-

sembly, align it with the dowel pin, and
fasten.
Turn the assembly around
Secure EK disc carrier with 12 hex. head

1 bolts M10x150-10.9 and washers B10.5
(81/1) - 55Nm.
2
81
1 2 Check for proper operation:

Block off one of the holes (82/1 or 82/2)
and blow compressed air into the oppo-
site one.
The pistons must move and compress
the appropriate clutch packs.
NOTE: Air must escape from two relief

bores (81/2) opposite each other.
82

Measuring the input shaft (fig. 83)

Measure tooth profile of the shaft at the
wear points by means of balls or rollers
of dia. 4 mm. If the dimension is less than
53.85 mm, replace the input shaft.
83
Put input shaft (84/1) on the input diffe-

rential and secure with 12 hex. bolts
1 M12x30-10.9 and spring washers B12
(84/2) - 115 Nm.
3 Fit O-ring 45x2 (84/3) into the groove of
2 the input shaft.
84
Install complete input drive cover (85/1)

(with grooved ball bearing 6210C3, cir-
Auxiliary tool no. 1 clip 90x3, and shaft seal A60x78x10) on
the input shaft using auxiliary tool no.1.
NOTE: Visible surface of oiled shaft

seal (87/2) should be 2 mm lower than
1 the upper edge of the input cover.
85
Grease bush (86/1) on outside and in-

1 2 3 side and install it. Install circlip 50x2
(86/3).
86

4-speed
Insert piston rings into SK piston (87/2)

Oil pressure side of SK piston carrier (87/1) with grooves
towards the oil pressure side.
Grease sliding surfaces in piston carrier

and insert piston.
NOTE: This procedure applies to all

piston rings to be inserted.
Expand inner piston rings slightly be-
fore insertion.
Look for any possible damage to sli-
87
ding surfaces of pistons and rectify, if
necessary.
Install 6 O-rings 9x2 (87/3) with grease

in piston carrier.
Install snap ring B180 (88/2) on SK disc

carrier (88/3).
Inspect grooved ball bearing (88/1) and
install it.
1
2
3
88
Install SK planet gear carrier (89/1) on

the grooved ball bearing.
1
NOTE: Do not jam snap ring (89/2).
DANGER! The planet gear carrier may

fall out of the grooved ball bearing
when the assembly is turned around.
89

Insert snap ring B180 (90/1) into the

groove of the SK planet gear carrier.
90

te).
Install and align 6 SK discs in the SK
piston carrier as follows (fig. 91):
inner disc,
inner disc,
inner disc.

te).
91
Install and align 8 SK discs in the SK
inner disc,
inner disc,
inner disc,
inner disc.
Install 4 rods (92/1) with helical springs

1.6x8x65 (92/3),
spring cups (92/2) and
guide plate (92/4),
at two points opposite each other.
1
2
3
92

Install SK piston carrier (93/1) on guide

plate.
NOTE: Pay attention to the location of

the dowel.
93
Install remaining springs and spring

cups.
Fix them with rods (fig. 94).
Press SK piston carrier (95/1) down.
94
Uniformly bolt piston carrier (95/1) and

1 disc carrier (95/2) together using
12 hex. head bolts M10x30 - 8.8 and
washers B 10.5 (95/3) - 46 Nm.
Remove rods.

injuries.
NOTE: Make sure the friction discs

are working smoothly and the SK pis-
3 2
ton is correctly seated.
95
DANGER of blocking!

Place EK/DK planet gear carrier with

mounted ring gear (96/1) onto the as-
sembly.
1
te).
Install and align 6 DK discs in the SK
inner disc,
inner disc,
96
inner disc.

te).
Install and align 8 DK discs in the SK
outer disc 2.0 mm thick
inner disc,
inner disc,
inner disc,
inner disc.
Oil pressure side

3
1 Insert piston rings into EK and DK pis-
tons (97/1 and 97/2) with the groove to-
ward the oil pressure side.
Grease sliding surfaces in EK/DK piston
carrier (97/3).
Install both pistons (97/1 and 97/2) in the
piston carrier.
Make sure they are correctly positioned.
2
97
Grease 4 O-rings 9x2 (98/1) and install

them in the piston carrier.
98

3 2 Rod (99/1)
Lock washer(99/2)
Serrated cup washer (99/3)
6 Compression spring (99/4)
Spring sockets (99/5)
Compression spring (99/4)
Spring clip (99/6)
4 5 4 1 NOTE: Lock washer is secured by ser-

99 rated cup washer.
Place guide plate (100/1) onto EK/DK

piston carrier and assemble in the follo-
wing order:
Rods (100/5) - chamfer on O-ring side,
spring sockets (100/2),
5 springs 1.6x8x65 (100/3), and
4 1 serrated cup washers (100/4).
3
Turn the EK-DK piston carrier around,
2 holding the rods.
100
Special tool no. 3

Install outer disc (101/1) and then as-
semble as follows:
Spring sockets (101/2),
helical springs (101/3),
1 spring clips (101/4).
4 2 Support rods (e. g. by putting a hammer

underneath).
Using special tool no.3, compress helical
3 springs (101/3) and install spring clips
(101/4).
Align both outer discs.

101
Install remaining rods, spring sockets,
helical springs, and spring clips.
DANGER! Clips may come loose if in-

correctly installed.

Install EK/DK piston carrier (102/2) with

guide pin suiting the SK piston carrier
(102/3).
Install ring gear (102/1) with auxiliary tool
1 no. 2.
102
Install spacer ring (103/1) with Loctite

270.
1
te).
Install and align 6 EK discs in the EK/DK
inner disc,
inner disc,
103
inner disc,

te).
Install and align 8 EK discs in the EK/DK
inner disc,
inner disc,
inner disc,
inner disc,
1
2 Install EK disc carrier (104/1) and deep
groove ball bearing 16012 DIN 625
(104/2) with auxiliary tool no. 2.
3 Bolt disc carrier to EK/DK piston carrier
(104/3) using 12 hex. bolts M10x150-
10.9 and washers B10.5
- 55 Nm.
104

Tilt input differential through 90°.
DANGER! Prevent differential from

rolling away.
1 Knock onto the bearing again until the

planet gear carrier abuts.
Use auxiliary tool no. 2.
Reinstall circlip 60x3 (105/1).
Set the input differential up again.

105
Input shaft measurement (fig. 106)

Measure splined profile of the shaft at the
wear points by means of balls or rollers
of dia. 4 mm. If the dimension is less than
53.85 mm, replace the input shaft.
106
Place input shaft (107/1) onto the input

1 differential and secure with 12 hex. bolts
M12x30-10.9 and spring washers B12
3
2 (107/2) - 115 Nm.
Insert O-ring 45x2 (107/3).
107

Auxiliary tool no. 1 Install complete input cover (108/1) (with

ball bearing 6210C3, circlip 90x3 and
shaft seal A60x78x10) on the input shaft
1 by means of auxiliary tool no. 1.
NOTE: Visible surface of oiled shaft

seal (109/2) should be 2 mm lower
than the upper edge of the input co-
ver.
108
1 2 3 Grease inside and outside of bush

(109/1). Install the bush and fit circlip
50x2 (109/3).
109

6.5 Disassembly of Impeller Brake

Remove circlip (110/1),
lift off guide ring (110/2),
2 pump impeller (110/3), and
1 3 sheet metal disc (110/4).
4 Uniformly unscrew and remove 3 socket-
5 head bolts M8 (110/5).
NOTE: Disc carrier is spring-loaded.
110
Lift the following parts off one after the

other from the piston carrier:
thrust plate (111/1),
7 PB discs (111/2),
6 1 springs (111/3),
2 spring sockets (111/4),
3 guide plate (111/5),
sealing ring (111/6),
5 4
Inner PB disc carrier (111/7).
111
Pull PB piston (112/1) out of the piston

carrier using 2 bolts M8.
Unscrew 6 socket-head bolts M8 (112/2)
and uninstall carrier by means of a plas-
tic hammer or a press.
1
2
112

3-speed
Lift piston ring carrier (113/2) off impeller

shaft (113/4).
2
1 NOTE: To remove the rectangular-
section rings (113/3), press one end in
and unhook.
3 2 bores are provided for removal of
4 the cylindrical roller bearings.
Clean all parts thoroughly and inspect
them for wear. Replace if necessary.
113
Remove double ring (114/1),

ring (114/2), and
sealing bush (114/3) from
the impeller shaft.
1 2 3
114

4-speed
Lift piston ring carrier (115/2) off impeller

2 shaft (115/4).
1
NOTE: To remove the rectangular-
section rings (115/3), press one end in
3 and unhook.
4 2 bores are provided for removal of
the cylindrical roller bearing.
Clean all parts thoroughly and inspect
them for wear. Replace if necessary.
115
Remove double ring (116/1),

ring (116/2), and
rectangular-section ring (116/3) from
the impeller shaft.
NOTE: If Teflon bush (116/4) is dama-

4 3 2 1 ged, remove it using a suitable tool.
116

6.6 Assembly of Impeller Brake
3-speed
Insert sealing bush (117/3),

ring (117/2), and
double ring (117/1) into impeller shaft.
1 2 3
117
Install rectangular-section rings

(118/3) in piston ring carrier (118/2).
Then slide piston ring carrier over impel-

2 ler shaft (118/4) while slightly compres-
1 sing the rectangular-section rings.
Install circlip (118/1).

3
4
118
4 3 2 1 Inspect grooved ball bearing (119/1).

Replace it if necessary.
Stick gasket (119/4) on piston ring carri-

er (119/3) by applying a little grease at
some points.
Install PB piston carrier (119/2) on piston

ring carrier (119/3).
NOTE: Make sure when assembling

that the bore holes (119/5) are on the
5 same side.
119

4-speed
Install rectangular-section rings (120/

3),
bush (120/2), and
double ring (120/1).
NOTE: If Teflon bush (120/4) was re-

4 3 2 1 moved, press in a new one until it is
flush.
120
Insert rectangular-section rings

(121/3) into piston ring carrier (121/2).
Then slide the piston ring carrier over im-

2 peller shaft (121/4) while slightly com-
1 pressing the rectangular-section rings.
Install circlip (121/1).

3
4
121
4 3 2 1
Inspect deep groove ball bearing
(122/1) and replace it, if necessary.
Stick gasket (122/4) to piston ring carrier

(122/3).
Install PB piston carrier (122/2) on piston

ring carrier (122/3).
NOTE: Make sure when assembling

that bore holes (122/5) are on the
same side.
5
122

2 Tighten 6 socket-head bolts M8x20-10.9

with washers B8 (123/1) in a criss-cross
manner - 33 Nm.
3 NOTE: Grease sliding surfaces of pis-

ton rings.
Insert piston rings (123/2) into PB pis-

ton (123/3) with the groove toward the
pressure side and install in PB piston
carrier (123/4).
1 4
123
Insert the following parts into the piston

carrier:
inner PB disc carrier (124/7),
7 O-ring (124/6) (greased and centred),
6 1 guide plate (124/5),
2 10 spring sockets (124/4),
3 10 helical springs (124/3),
1 inner disc (124/2),
5 4
2 outer discs (124/2),
1 inner disc (124/2),
thrust plate (124/1).
124
NOTE: Align outer discs with guide
plate.
Place PB disc carrier (125/1) on piston

carrier.
1
3 NOTE: Pay attention to the bore hole
of locating pin (125/3) and the spring
2 seats when assembling.
Secure disc carrier with 3 socket-head

bolts M8x20-10.9 (125/2) - 33 Nm.
NOTE: Make sure when tightening

125 that the guide tongues can be introdu-
ced into the friction discs without jam-
ming.

Install the following parts one after the

other:
2 Install sheet metal disc (126/4),
1 3 pump impeller (126/3),
guide ring (126/2), and
4 circlip (126/1).
NOTE: Do not open circlip more than

necessary when installing.
126
Measure end play of pump impeller:

If it exceeds 0.1 mm, compensate by fit-
ting a suitable shim (127/1).
1
NOTE: Place shim (127/1) underneath
impeller (126/3).
127
Function check:
Close hole (128/1) manually and apply
compressed air max. 2bar to PB piston
via hole (128/2).
1
2
128

6.7 Disassembly of Stator and Turbine Wheel

Remove 2 snap rings and circlip (129/1)
from turbine wheel (129/2).
1 Lift off turbine wheel and (129/3) from

2 turbine shaft.
3
129
NOTE: Do not remove core ring (130/

1).
Replace stator complete in case of da-
1 mage.
130
1 2 3 4 5 6 Press turbine shaft (131/1) out of

deep groove ball bearing (131/3) and
inner ring (131/2).
Remove
double ring (131/6),
ring (131/5), and
packing bush (131/4) from shaft.
131

6.8 Assembly of Stator and Turbine Wheel

Check that stator bush (132/1) and do-
wel pin (132/2) are firmly seated.
2
The inner diameter must not be greater
1 than 68.200.
132
If the stator bush (133/1) needs to be re-

placed, see Service Bulletin No. 156.
1
133

1 2 3 4 Install sealing bush (134/2),

ring (134/3), and
double ring (134/4)
in turbine shaft (134/1).
134
1 2 3 4 Press deep groove ball bearing with in-

stalled double ring and inner ring (135/3)
onto turbine shaft using auxiliary tool
no. 5.
Place distance washer (135/1) on ball
bearing.
135
Place stator (136/4) and turbine wheel

(136/1) onto turbine shaft and secure by
1 means of circlip A58x2 and two snap
rings B73 (136/2).
136

6.9 Disassembly of Turbine Gear

Screw out 6 hex. bolts M8 (137/1).
Remove double ring (137/2).
1
2
137
Press inner gear (138/1) off planet gear

Special tool no. 2 carrier using special tool no. 2.
Remove T ring gear (138/2).
138
Remove spacing plate (139/1),

circlip (139/2), and
ring (139/3).
3
2
139

Uniformly force off retaining ring (140/2)

and ball bearing (140/1) from planet gear
carrier by means of 2 forcing bolts M8.
NOTE: Forcing bolts must not press

1 onto an axle.
3
140
Inspect deep groove ball bearing

(141/1),
replace if necessary, and install with Loc-
tite 270.
1 NOTE: Dismantling and assembly of

the T planet gear carrier is described
in chapters 6.2 and 6.3.
141

6.10 Assembly of Turbine Gear

Place retaining ring (142/1) onto planet
gear carrier (142/6) with the recess at
the top.
3 4 Install grooved ball bearing with circlip
2 (142/2) onto the planet gear carrier using
5
1 auxiliary tool no. 5.
6
Install spacer ring (142/5),
circlip A80x2,5 (142/4), and
spacing plate (142/3).
142
Install inner gear (143/1) on ring gear

(143/2).
Install double ring (143/3), replace if ne-
cessary.
1
2
3
143
Install inner gear with ring gear on the

planet gear carrier and secure it using 6
hex. head bolts M8x16-8.8 and spring
washers B8 (144/1) - 23 Nm.
1
NOTE: With transmission models R2

the inner gear and ring gear are two
pieces (see rating plate).
144

6.11 Disassembly of Output Drive and Reverse Gear

Force the R planet gear carrier (145/1)
Special tool no. 2
off the output cover (145/2) by means of
special tool no. 2.
145
Remove 6 socket-head bolts (146/1).

Force off abutment ring (146/2) by
means of 2 forcing bolts M8.
Remove disc spring (146/3), brake pis-
1 ton (146/4), and shim behind.
2
3
146
Remove abutment ring (147/1),

1 ring (147/2),
gear rim (147/3), and
2 speedometer drive gear (147/4)
3 from output cover (147/5).
4
5
147

Remove hex. screw (148/3) and

speedometer flange (148/2).
Remove shaft seal (148/1).
1
NOTE: The reverse gear and output
drive are reassembled only after
measurement of the reverse gear disc
play.
3
148
Disassemble, inspect, and reassemble

R planet gear carrier (149/1) as descri-
bed in chapters 6.2 and 6.3.
1
Change rectangular-section rings
2 (149/2).
149

6.12 Dismantling and Assembly of Working Pressure Valve

Dismantle working pressure valve.
NOTE: Do not remove grub screw and

hex. nut (150/6) for working pressure.
Bracket (150/4) and cover (150/12) are
spring-loaded.
Check pistons/spools and bores for da-

mage and replace if necessary.
NOTE: Pay attention to the installation

position and ease of motion of the
spools and pistons.

other:
150 (150/1) housing,
(150/2) washer,
(150/3) piston,
(150/4) bracket,
(150/5) 3 socket-head bolts CV84
6x20 - 14 Nm,
(150/7) 1 helical spring 3.2x21.0x101
(150/8) 1 helical spring
2.0x15.5x76.5,
(150/9) selector piston,
(150/10) spool,
(150/11) piston with circlip,
(150/12) cover,
(150/13) 4 hex. bolts M6x45 - 8.8
- 9 Nm
4 spring washers B6
Location of spools/pistons and springs

(figure 151).
151

other:
(152/1) valve plate,
(152/2) cover,
M6x20 - 14 Nm,
(152/4) piston,
(152/5) helical spring
3.0x20.0x31.6,
(152/6) cover,
M6x20 - 14 Nm.
152

6.13 Disassembly of Gear Pump with Inductive Pick-up N1

Remove the following parts one after the
other:
(153/12) inductive pick-up,
(153/1) 7 hex. bolts M8,
(153/2) 2 straight pins,
(153/3) cover,
(153/15) gearwheel,
(153/16) gearwheel,
(153/14) needle bush
(153/18) driver,
(153/17) intermediate plate,
(153/5) gearwheel,
(153/6) hex. nut,
(153/7) washer,
(153/8) drive gearwheel out of the
153 (154/4) housing by using a
copper punch,
(153/9) remove cylindrical gear,
(153/10, /11) press out needle bushes
(153/13) and axle.

6.14 Assembly of Gear Pump with Inductive Pick-up N1

If a new pin (154/13) is installed in hou-
sing (154/4) the housing must be heated
to 120° C.
Press needle bush (154/19) into hou-

sing (155/4) using auxiliary tool no. 6.
Press needle bush (154/10) into cover

(154/3) using auxiliary tool no. 7.
Press needle bush (154/11) into gear

wheel (154/5) using auxiliary tool no. 6.
NOTE: One side of the needle bearing

is lettered. It must be up when the be-
154 aring is pressed in.

other:
(154/9) cylindrical gear,
(154/8) gear shaft,
(154/7) washer,
(154/6) insert hex. nut BM16x1.5 with
Loctite 270
- 100 Nm,
(154/5) gearwheel,
(154/17) intermediate plate,
(154/18) driver,
(154/16) gearwheel,
(154/15) gearwheel,
(154/14) needle bush
(154/3) cover,
(154/2) 2 straight pins 10x40,
(154/1) 7 hex. bolts M8x40 - 8.8
- 23 Nm,
(154/12) inductive pick-up - 30 Nm.
NOTE: The cover, intermediate plate

and housing are marked with the
same number and must not be con-
fused.

6.15 Dismantling and Assembly of Converter Drain Valve

Dismantle converter drain valve.
Check spools/pistions and bores for

wear, replace if necessary.
NOTE: Pay attention to the installati-

on position and ease of motion of the
spools and pistons.
Tighten all bolts to 10 Nm.
155 Install the following parts one after the

other:
(155/1) housing,
(155/2) plate,
(155/13) 2 socket-head bolts M6x50
- 8.8,
(155/3) spool,
(155/4) cover,
- 8.8,
(155/7) 2 spools,
(155/8) 2 helical springs
0.9x10.5x31,
(155/9) piston,
(155/10) cover
- 8.8,
(155/17) 1 piston,
(155/8) 1 helical spring
0.9x10.5x31,
(155/16) cover,
- 8.8,
(155/5) piston,
(155/6) cover,
- 8.8.
Location of spools, pistons, and springs

(fig. 156).
156

6.16 Dismantling and Assembly of Valve Blocks
3-speed
Dismantle valve block.
NOTE: Screw WP screw plug M10

(157/23) with sealing washer (157/24)
out of housing (157/20). Otherwise the
spool (157/26) cannot be removed.

spools.

157 other:
(157/31) 4 solenoids (connection at the
top),
-CV84 - 5 Nm,
(157/26) spool,
(157/25) helical spring 1.7x13x12.7
(157/29) 3 spool,
(157/28) 3 control pin,
(157/27) 3 helical spring 1.3x12.5x19,
(157/22) cover,
(157/21) 5 hex. bolts M6x12-8.8
- 9Nm,
(157/24) sealing washer,
(157/23) screw plug WP
158 M10x1 - 15 Nm.

4-speed
NOTE: Screw WP screw plug M10

(160/23) with sealing washer (160/24)
out of housing (160/20). Otherwise the
spool (160/26) cannot be removed.

spools.

other:
159 (159/31) 5 solenoids (Anschluß nach
oben,
-CV84 - 5 Nm,
(159/26) spool,
(159/25) helical spring 1.7x13x12.7
(159/29) 4 spool,
(159/28) 4 control pin,
(159/27) 4 helical spring 1.3x12.5x19,
(159/22) cover,
(159/21) 5 hex. bolts M6x12-8.8
- 9 Nm,
(159/24) sealing washer,
(159/23) screw plug WP
M10x1 - 15 Nm.
160

3-speed 4-speed
NOTE: Screw TB, RG, and WR screw

plugs M10 (161/2) with sealing was-
hers (161/3) out of housing (161/1).
Otherwise the spools (161/13 and 15)
cannot be removed.
161

spools.

other:
(161/19) solenoids (connection at the
top),
(161/18) 8 socket-head bolts

M5x12 CV84 - 5Nm,
(161/10) insert
(note installation position),
(161/8) O-rings,
(161/9) ball,
(161/7) valve body,
(161/6) circlip,
(161/17) spool,
(161/12) control pin,
(161/11) helical spring 1.3x12.5x19,
(161/13) spool,
(161/12) control pin,
(161/11) helical spring 1.3x12.5x19,
(161/15) 2 spool,
(161/14) 2 helical spring 1.7x13.0x12,7,
162
(161/5) cover,
(161/4) 4 hex. bolts M6x12-8.8
- 9Nm,
(161/3) sealing washers A10x13.5,
(161/2) TB, RG and WR screw plugs
M10x1 - 15 Nm.

7 Installation of Assemblies in Transmis-
sion
3-speed
Install insert (163/1),
washer (163/2),
3 screw plug (163/3) in transmission hous-
ing (fig. 164).
2
NOTE: Tighten screw plug (164/3)
1. at least until it is flush with the hou-
1 sing,
163 2. tightening torque 30 Nm.
164
7.1 Installation of Impeller Brake

Place transmission housing on output
side.
Expand O-ring 275x2.65 (165/1) a little,

grease it and place it in the housing groo-
ve.
165

7 Installation of Assemblies in Transmission
Install impeller brake assembly (166/1)

by means of special tool no. 2 (fig. 173).
Align impeller brake with centring pin.
1 Tighten 10 hex. bolts M10x65 - 8.8 - and

10 spring washers B1 (166/2) - 46 Nm.
3 Position (166/3) remains open.

2
166
NOTE: Install greased O-rings 12x2

7 8 9 and 29.2x3 to plug-in tubes before in-
stalling the tubes.
1 Install plug-in tubes (167/7 to 167/9).
Fix pipes in this order:

pipe with cable (167/1),
2 pipes (167/2, /3, /5, /6),
6 pipe (167/4) with banjo bolt M14x1.5x32
5 - 38 Nm.
3
NOTE: Install all banjo bolts with cop-
per seals on both sides.
4
167
Fix pipe with cable (168/2) using hex.

bolt M8x10 (168/1) - 15 Nm.
1
2
168
Install deep groove ball bearing in ge-

arwheel (169/3), place discs on both si-
des and rivet.
Install abutment ring (169/1),
tighten socket-head bolt M10x30 - 10.9
and spring washer B10x18 (169/2)
- 67Nm.
1
2
3
169

4-speed
Install insert (170/1),

washer (170/2),
3 screw plug (170/3) in transmission hous-
ing (fig. 171).
2
NOTE: Tighten screw plug (170/3)
1. at least until it is flush with the hou-
1
sing,
170 2. tightening torque 30 Nm.
171
Place transmission housing on output si-

de.
Expand O-ring 275x2.65 (172/1) a little,

grease it and place it in the housing groo-
ve.
1
172
Special tool no. 2 Install impeller brake assembly (173/1)

by means of special tool no. 2.
Align impeller brake with centring pin.
173

Tighten 10 hex. bolts M10x65 - 8.8 - and

10 spring washers B10 (174/1) - 46 Nm.
Position (174/2) remains open.
2
1
174
NOTE: Place greased O-rings 12x2 or

8 9 10 11 29.2x3 on plug-in tubes before inser-
ting the tubes.
1 Install plug in tubes (175/9 to 175/11)

with the thread upward.
Install pipes in this order:

7 2 pipe with cable (175/1),
6 pipes (175/2, /3, /5, /6),
5 3 tighten 1 hexagon bolt M10x65 - 8.8 with
spring washer B10 (175/7) to 46 Nm,
4
pipe (175/4) with banjo bolt M14x1.5x32
- 38 Nm,
175 pipe (175/8) with banjo bolt M16x1.5x28
- 42 Nm.
NOTE: Install all banjo bolts with cop-

1 per seals on both sides.
2
Fix pipe with cable (176/2) by means of
hex. bolt M8x10 (176/1) - 15 Nm.
176
Install deep groove ball bearing in ge-

arwheel (177/3), place discs on both si-
des and rivet.
Install abutment ring (177/1),
tighten socket-head bolt M10x30 - 10.9
and spring washer A10x18 (177/2)
- 67Nm.
1
2
3
177

7.2 Installation of Working Pressure Valve

NOTE: Pipe (178/3) is only present
from transmission no. 825 408.
Refer to fig. 189 for a better overview

5 of the piping.
4 Install the following one after the other:

Working pressure valve (178/1),
3 plug-in tube (178/2).
2 Connect pipes (178/3, /4, /5) to working
pressure valve by means of banjo bolts.
1
178
7.3 Installation of Converter Drain Valve
6 7 Proceed in the following order:

Secure converter drain valve (179/1) us-
ing 5 socket-head bolts M6x40 - 10.9
(179/4) - 14 Nm.
Connect pipes (179/2, /3, /5, /8, /9, /10,/

11) to converter drain valve by means of
banjo bolts.
5 Fix pipe (179/7) to the transmission using

4 hex. bolt M8x10 - 8.8 (179/6) - 23 Nm.
3
1 11 10 9 8
179

7.4 Installation of Oil Filter

Screw in two auxiliary bolts (180/1) for lo-
cating the gasket.
1 Place gasket (180/2) on top of oil filter
housing (180/3).
2
180
Install filter housing (181/1) in the trans-

mission.
Install flange and gasket (182/1) and se-

1 cure with 3 hex. head bolts M8x65-8.8
(182/3).
Remove auxiliary bolts (180/1).
Fit 2 hex. head bolts M8x65-8.8 (182/2).

2
NOTE: Tighten all hex. head bolts to
- 23 Nm.
Install plug-in pipe (181/2).

181
2
3
2
182
Insert filter element into filter housing.
Secure cover (183/1) SW36 - 25 Nm .
183

7.5 Installation of Valve Plate

Proceed in the following order:
Press valve plate (184/4) onto plug-in tu-
bes.
Bolt to working pressure valve using 3
hex. head bolts (184/3) M10x65 - 8.8
- 46 Nm,
4
and 4 hex. head bolts (184/2) M8x60 -
3 8.8 - 23 Nm.
2 Tighten drain plug (184/1) for converter
oil - 50 Nm.
1
NOTE: Tighten all banjo bolts and

screw plugs.
184
7.6 Installation of Gear Pump

Connect inductive pick-up N1.
10
1 Install gear pump (185/1), fasten with 2
9 2 hex. bolts M10x45-8.8 and spring was-
hers B10 (185/2).
2 3 Fasten strap (185/4) by means of 1 hex.
4 head bolt M10x45 - 8.8 and spring was-
her B10 (185/3).
Install pipe (185/10) with O-ring and se-
5 cure it by means of 1 hex. head bolt
6 M10x45 - 8.8 and spring washer B10
7 (185/9).
8 Fasten pipe (185/5) and temperature
185 sensor (185/6) to plate (185/7) using 2
hex. head bolts M10x20 - 8.8 (185/8).
NOTE: Tighten all hex. head bolts to

- 46 Nm.
1 Insert plug-in tube (186/1) for gear pump.
186
Secure flange with gasket (187/2) using
3 hex. head bolts M8x30 - 8.8 and spring
washers B8 (187/1) - 23 Nm.
2
1
187

7.7 Installation of Suction Strainer

Bolt on suction strainer (188/2) using
2 hex. bolts M10x20 - 8.8 with
spring washers B10 (188/1) - 46 Nm.
188
Fig. 189: Overview of piping
189

7.8 Installation of Input Drive
3-speed
NOTE: Slightly roughen contact areas

1 of gaskets on Transmission housing
and adaptor housing.
Place gasket onto the transmission hou-

sing.
Constantly turning the shaft (190/1), lo-
2 wer the input differential (190/2) and
align it with the dowel pin.
Secure input cover "A" by means of

190 2 socket-head bolts M10x25 - 46 Nm.
Screw tight connection flange with

12 hex. bolts M10x50 - 8.8 with
spring washers B10 - 46 Nm.
Secure input cover "B" (fig. 190) by

means of 13 hex. bolts M10x50 - 8.8 and
13 spring washers B10 - 46 Nm.
4-speed
Place gasket onto the transmission hou-

1 sing.
Align adaptor housing (191/3) with dowel
pin and place on the transmission hou-
sing.
Place gasket onto intermediate housing.
Constantly turning the shaft (191/1), lo-
2 wer the input differential (191/2) and
align it with the dowel pin.
3 NOTE: Make sure the gears of the dri-
veline engage properly.
191
Secure input cover "A" by means of
2 socket-head bolts M10x100 - 46 Nm.
Screw tight connection flange with
12 hex. bolts M10x130 - 8.8 with lock
washers A10 - 46 Nm.
Secure input cover "B" by means of

13 hex. bolts M10x130 - 8.8 and
13 spring washers B10 - 46 Nm.

7.9 Installation of Stator and Turbine Wheel

Install stator with turbine wheel and turbi-
ne shaft (192/1) in the transmission hou-
sing using special tool no. 2.
1
NOTE: The projection on the stator
must be aligned with the groove in the
housing.
Special tool no. 2

192
Insert throttle with O-ring 12x2 into the

hole in the transmission housing (valve
block side).
Secure the stator using 12 socket-head

bolts M10x35 and washers B10.5
1 (193/1) - 50 Nm.
2
3 Install piston rings in T brake piston
(193/2) with the groove on the pressure
4
side.
5 Install piston.
6 Install disc spring (193/3) and abutment
ring (193/4).
Screw in 4 socket-head bolts (193/6)
M8x30 -10.9 with Loctite 242 - 33 Nm.
193 Install 2 disc springs and 1 brass disc
(193/5) in abutment ring.
NOTE: Insert disc springs in X confi-

guration.
Insert planet gear carrier shaft (194/1)

with double ring (194/2) and introduce
into the gearing by turning
1
194

7.10 Installation of Turbine Gear

Install turbine gear (195/1) in the trans-
Special tool no. 2
mission housing by means of special tool
no. 2.
195
Alternately install 4 TB outer discs with

marks and 3 inner discs (196/1) and align
them.
Start with an outer disc.
1
Mark in outer
disc
196
Install RG-TB disc carriers (197/1) with

abutment ring (197/2) with the keyway
facing the key.
1 NOTE: Avoid canting of the disc carri-

er.
The disc carrier must be seated on the
2 stator.
197

Install male union (198/1) with hose

1 (198/3).
2 Connect hose to converter drain valve
via banjo bolt and sealing washer
A10x16 (198/2).
3
198
Install two O-rings 12x3 (199/1) and key

1
(199/2).
Special tool no. 2
Install R ring gear (199/3) in disc carrier.
Install R planet gear carrier (199/4) using

special tool no. 2.
2
3
4
199
Install 6 outer and 5 inner R discs

(200/1).
Start with an outer one.
200
Special variant:
Install blocking oscillator (201/1)
- 27 Nm.
201

7.11 Installation of Reverse Gear in Output Drive

Press oiled shaft seal (202/1) into output
1 2 cover (202/2) using special tool no. 10.
2 mm
NOTE: Shaft seal should be recessed

2 mm below upper edge of output co-
ver.
202
Install complete speedometer flange

with new O-ring (203/1) in output cover.
Secure with socket-head bolt M6x20 -
8.8 and spring washer B6 (203/2) - 9 Nm.
2
203
Install the following parts in output cover

1 (205/5) one after the other:
speedometer drive gear (205/4) - paying
2 attention to orientation,
3 gear rim (205/3),
ring (205/2),
4 abutment ring (205/1).
5
NOTE: Inspect abutment ring (205/1)
for wear and replace it, if necessary.
204

7.12 Measurement and Adjustment of Disc Clearance for

Reverse Gear
NOTE: Insert brake piston without
piston rings into output cover.
Discs and piston must be in contact
during measurement see figure (205/1
and /2).
Do not compress the discs.
Measure dimension "A" and dimension

"B".
NOTE: Dimension B must not be

smaller than 0.1 mm.
Example: A = 5.5 mm
B = 1.0 mm
Dimension "A" minus dimension "B" is

the measured disc clearance.
Example: 5.5 - 1.0 = 4.5 mm disc clea-

rance.
205
Determine shim thickness:
Available sizes are 0.5 mm, 1.0 mm, and
1.5 mm.
Example: 4.5 mm clearance (measured)

minus 1.5 mm shim
equals 3.0 mm clearance (adjusted)
NOTE: The target clearance is 2.7 -

3.2 mm.
Remove brake piston from output cover.

Install piston rings with groove (206/1
und /3) toward the pressure side and
piston rings without groove (206/2) in the
brake piston.
Install brake piston in output cover.
206

7.13 Installation of Output Drive

Inspect deep groove ball bearing 6215
(207/1), replace if necessary.
1
207
Install disc spring (208/1) and ring

(208/2) in the output cover.
Secure by means of 6 socket-head bolts
M8x30 - 10.9 and 6 spring washers A8
1 (208/3) - 33 Nm.
4
208
NOTE: Slightly roughen contact areas

of gasket on Transmission housing.
1 Place gasket (209/1) on transmission

housing.
209
Install output cover (210/1) by means of

special tool no. 2.
Special tool no. 2
210

NOTE: Care must be taken not to cant

the speedometer drive gear, gear rim,
and ring or damage the shaft seal (fig.
211) when lowering the output cover.
211
Special tool no. 2 Locate output cover and gasket using

special tool no. 2.
Install output flange (212/1).

Knock onto the output flange with a plas-
1 tic hammer until the cover is properly
seated on the transmission housing.
Fasten output cover:

11 hex. bolts M10x65 - 8.8,
212
1 hex. bolt M10x110 - 8.8 and
spring washer B10 - 46 Nm.
Place disc (213/1) on shaft.

Tighten 2 bolts (213/2) M10x50 - 10.9 to
1 - 67 Nm.
Measure spacing between shaft and
2 flange.
The spacing must be 0.5 ± 0.1 mm

(fig. 214).
213
If required, adjust by means of shims

(215/2).
Remove disc and bolts (213/1 and /2).
0.5 ± 0.1 mm clearance adjusted by

shims, with the bolts tightened.
214

Install O-ring 48x4.5 (215/1) and shim(s)

(215/2) of calculated thickness.
215
Install disc (216/1),

tighten 3 hex. bolts M10x50 - 10.9 and
lock washers A10 (216/2) - 72 Nm.
1
2
216
1 2 Plug screw M14x1.5 with sealing ring

A14x2 (217/1) into oil pan (217/2)
- 38 Nm.
3 Bolt oil pan with gasket ,

Use 26 nuts M8 and
washers B8.4 (217/3) - 25 Nm.
4 Install screw plug M26x1.5 with sealing

ring A26x34 (217/4) - 100 Nm.
217

7.14 Installation of Inductive Pick-Ups

Tighten inductive pick-ups N2 (218/1)
1 2 and N3 (218/2) to - 30 Nm.
218
7.15 Installation of Cable Harness

Install cable harness (fig. 219) as de-
scribed below.
NOTE: Do not squeeze cables.
Fasten cable harness with gasket

(220/3) using 3 socket-head bolts
M6x40 CV84 and spring washers B6
(220/4).
219
Fit connection for inductive pick-up N2

6 5 4 3 2 1 (220/5).
Connect inductive pick-up N2 using
special tool no. 7.
Tighten cap with sealing ring (220/6)
- 50 Nm.
Connect inductive pick-up N3 using spe-

cial tool no. 7.
Bolt on cap with gasket (220/3) using 3
socket-head bolts M8x30 CV84 with
spring washers B8 (220/4) - 25 Nm.
220
NOTE: Tighten all bolts and fittings.
Fasten earth cable (221/2) using hex.

1 head bolt M8x10 and lock washer S8
(221/1) - 15 Nm.
2
3 Connect connection (221/3) for inductive
pick-up N1 and temperature sensor
using special tool no. 8.
221

7.16 Installation of Valve Blocks
3-speed
Assemble as follows:
Fix valve block (222/6) using 6 socket-
head bolts M8x50 (222/2).
1 Connect plugs (222/5) to solenoids.
2
3 NOTE: Plugs (222/5) for valve block
(222/6) are marked with black rubber
4
rings or black spiral wrap.
5
Install connecting pipe (222/3) with
2 O-rings 12x2.
6 Fasten valve block (222/1) using 6 so-
cket-head bolts M8x50 (222/2).
Connect plugs (222/4) to solenoids.
222
NOTE: Do not squeeze the cables.
Tighten 12 socket-head bolts M8x50 of

valve blocks to 20 Nm.
Install cable guard (223/1).
223
Install control unit cover with gasket

(224/1).
Tighten 12 hex. bolts M8x30 - 8.8,
spring washers B8, and
washers B8.4 (224/2) - 23 Nm.
1
2
224

4-speed
Assemble as follows:
1 Fix valve block (225/6) using 6 socket-
head bolts M8x50 (225/2).
2 Connect plugs (225/5) to solenoids.
3
NOTE: Plugs (225/5) for valve block
4 (225/6) are marked with black rubber
5 rings or black spiral wrap.
2 Install connecting pipe (225/3) with

6 O-rings 12x2.
Fasten valve block (225/1) using 6 so-
cket-head bolts M8x50 (226/2).
Connect plugs (225/4) to solenoids.
225
NOTE: Do not squeeze the cables.
Tighten 12 socket-head bolts M8x50 of

valve blocks to 20 Nm.
Install cable guard (226/1).
226
Install control unit cover with gasket

(227/1).
Tighten 12 hex. bolts M8x30 - 8.8,
spring washers B8 and
washers B8.4 (227/2) - 23 Nm .
1
2
227

Install lube oil pipe (228/1), tighten to

25 Nm.
Insert dipstick (228/2).
2
228
7.17 Installation Examples for Heat Exchanger

Standard position
Fasten 2 hose lines (230/1) - 100 Nm.
1
NOTE: Grease friction surfaces of fit-
tings.
grease
229
NOTE: Different designs are possible.

See also Spare Parts Catalogue No.
55.6603. ..

8 Installation of Transmission in the
Vehicle
8.1 Bolt Hydrodamp to Engine Flywheel

Coat splines of Hydrodamp with molyb-
denum disulfide (paste or spray).
Bolt Hydrodamp to engine flywheel.
230
12 Mounting the Hydrodamp on engine fly-

11 1 wheel:
1. Suspend Hydrodamp from two as-

10 2 sembly pins in positions 2 and 10 (on
b outer reference diameter, s. fig. 231)
and slide it into the centring.
9 3 2. Tighten two bolts in a criss-cross
manner.
a 3. Screw out assembly pins and replace
them by bolts.
8
4 4. Tighten all 12 bolts M10-8.8 in a criss-
cross manner - 46 Nm.
7 5 If centring is via locating pins at positions
6 a and b (fig. 231), assembly is performed
231 in an analogous way.

8 Installation of Transmission in the Vehicle
8.2 Installing the transmission

NOTE! Prior to installing the transmission, it is absolutly necessary to treat the transmis-
sion input shaft with molybdenum disulfide (paste or spray).
Make sure not to cant the input shaft when introducing it into the hub as this may damage
the Hydrodamp!
Mount the transmission (232/2) and

cardan shaft (232/5) .
NOTE: Observe the tightening tor-

ques and installation regulations spe-
cified by the vehicle manufacturer.
Connect cooling water pipes and tacho-

meter (232/3 and /4).
Fill in coolant and oil.

Oil volume: approx. 26 litres.
For transmissions with angle drive, the

additional oil volume is indicated in the
Repair Manual for the angle drive.
232
If the heat exchanger was drained, too,
fill in about 2 l more.
NOTE: Always use the dipstick to ve-

rify that the oil level is correct!
The approved brands of oil are listed
in the Lists of Lubricants 55.6335. ..
and 55.6336. ...

9 Checks
9.1 Check of Working Pressure and Coverter Pressure

Measure working pressure and conver-
ter pressure after every repair.
1 2
Test point for working pressure
(233/1):
The set point for working pressure is al-
ways pA = 8.5 bar.
Tolerance: ± 0.2 bar.
Only measure the pressure at an oil tem-

perature of 80-90 °C (194 °F) immediate-
ly after shifting to 2nd gear, engine speed
approx. 1,500 rev/min.
Target value at idling speed:

pA ≥ 3.5 bar
233
Test point for converter pressure
(233/2):
With an oil temperature toil of about 80-
90 °C, a forward gear engaged, the par-
king brake applied, and the engine idling
(500 ± 50 rev/min), the converter pressu-
re must be at least pW ≥ 2 bar.
DANGER! Install or uninstall pressure

gauge or measuring cover only with
the engine stopped.
Otherwise hot oil may result in scal-
ding.
If a measuring cover (fig. 234) is used,

the working pressure must be available
at the measuring points for the clutches
DK, EK, PB, WP, and SK.
234

9 Checks
The working pressure can be set at the

1 grub screw of the working pressure valve
through the oil filler neck (235/1).
If the required working pressure is not re-

ached, check piping and other compon-
ents for leaks.
235
9.2 Further Checks

DANGER! All important transmission functions must be tested with the diagnostic pro-
gram DIWAGNOSIS before driving the vehicle for the first time, as assembly errors can
lead to transmission damage, or under some circumstances can cause an accident. Refer
to "Diagnostic Manual" 55.6264. .. and, if necessary, "Fault Finding" 55.6303. ...
NOTE: Adaptation should be reset prior to a test ride by using DIWAGNOSIS.

Before and after the test drive, check the transmission for oil leaks.
Recommendation: If oil is dirty (caused by parts not being cleaned in a professional man-
ner), the oil and oil filter should be changed.
Voith recommends to change oil and oil filter at the latest 5,000km after a repair.

10 Transmission Weights
3-speed
D 851.3E D 863.3E
Transmission without oil 275 kg 280 kg

Transmission with oil 300 kg 305 kg
Heat exchanger 25 kg 25 kg
4-speed
D 854.3E D 864.3E
Transmission without oil 310 kg 315 kg

Transmission with oil 335 kg 340 kg
Heat exchanger 25 kg 25 kg

11 Tightening Torques
Tightening torques for hex. bolts and socket-head bolts.
Size Strength Tightening torque in Nm
M4 8.8 3
M4 10.9 4
M5 8.8 5
M5 10.9 8
M6 8.8 9
M6 10.9 14
M8 8.8 23
M8 10.9 33
M 10 8.8 46
M 10 10.9 72
M 10x1 8.8 51
M 10x1 10.9 75
M 12 8.8 78
M 12 10.9 115
NOTE: Observe special cases.
Designation Size Tightening torque in Nm
Valve block M8x50 20 Nm
Input differential M10x150 55 Nm
Stator M10x35 50 Nm
Output flange M10x50-10.9 72 Nm

Tightening torques for screw plugs and banjo bolts with copper seals.
Tightening torque in Nm
Size Sealing Steel / Al Installation Designation

washer oiled dry
M 10x1.5 10x13.5 13 X Banjo bolt
M 10x1 10x13.5 15 X Screw plug
M 12x1.5 12x15.5 20 X Screw plug
M 14x1.5 14x18 38 X Screw plug
M 18x1.5 18x22 45 X Screw plug
M 26x1.5* 26x34 100 X Screw plug
NOTE: For sizes marked * the sealing washer and bolt must be oiled slightly.
In all other cases, the washers and bolts must remain dry.

Voith Turbo GmbH & Co. KG
Commercial Vehicle Division
Alexanderstraße 2
D-89522 Heidenheim
Telephone (07321) 37-0
Telefax (07321) 37 7618

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Repair Manual

Voith. Repair Manual DIWA.3E

This document is protected by copyright.

Version Date Changes

55.6704.12 02-12 Included page describing changes.

55.6704.13 03-01 Output flange Bolted connection 3x M10x50-10.9 :

This document describes the transmission as originally delivered.

Subject to change due to technical progress.

Voith. Repair Manual DIWA.3E I

Only genuine Voith parts may be used!

Storage and useful life of heat exchanger hoses:

Voith recommends always replacing all the parts printed in bold-italics.

II Voith. Reparaturanleitung DIWA.3E

Consequences of coolant or oil loss, treatment of used oil

Disposal of used oil

ENVIRONMENT: Do not pollute the environment with oil or coolant!

Who is allowed to repair

Only trained automobile mechanics or workers with similar skills.

Voith. Repair Manual DIWA.3E III

Externally, the two variants can be distinguished by an intermediate housing between

Most parts of the transmission variants are identical.

D 851.3 / D 863.3: 3-speed transmissions

D 854.3 / D 864.3: 4-speed transmissions

Voith. Repair Manual DIWA.3E V

Important Notes ....................................................................................................................I

Differences between 3 and 4-Speed Transmissions ....................................................... V

2 Transmission Removal ..............................................................................................11

3 Removal of Torsional Vibration Damper ..................................................................12

4 Removal of Electronic Control Unit .........................................................................15

5 Removal of Assemblies from Transmission..........................................................17

6 Dismantling and Assembly of Subassemlies...........................................................31

Voith. Repair Manual DIWA.3E 1

7 Installation of Assemblies in Transmission ............................................................ 77

8 Installation of Transmission in the Vehicle ............................................................. 98

9 Checks ...................................................................................................................... 100

10 Transmission Weights............................................................................................. 103

11 Tightening Torques.................................................................................................. 105

2 Voith. Repair Manual DIWA.3E

1.1 Standard Tools

Torque wrench 0 - 150 Nm

Forcing bolt 2x M6 Voith part no. 50.0677.10

Circlip pliers for inner circlips

Circlip pliers for outer circlips

Voith. Repair Manual DIWA.3E 3

1.2 Special Tools

Special tool no.1

Special tool no. 2

Special tool no. 3

4 Voith. Repair Manual DIWA.3E

Special tool no. 4

Lock washer B 8 DIN 127

Special tool no. 5

M4x10 DIN 912-10.9

Length approx. 150

Voith. Repair Manual DIWA.3E 5

Special tool no. 6

Special tool no. 7

Special tool no. 8

Pliers DIN 5256-C40-gl

6 Voith. Repair Manual DIWA.3E

Special tool no. 9

Special tool no. 10

Voith. Repair Manual DIWA.3E 7

1.3 Auxiliary Tools