5HP18 Repair Manual

REPAIR–MANUAL

5 H P - 18

ZF GETRIEBE GETRIEBE GMBH SA SA A RBRÜ CKEN CKEN

Impressum: Verantwortlich Verantwortlich für d en Inh alt Abteilung Abteilung MKTD, MKTD, ZF Getriebe GmbH, Saarbrücken Druck: HAG ER PAPPRINT GmbH, St. St. Ingbert Ingbert Gedruckt in der BRD Published Published by ZF Getriebe GmbH, Saarbrücken, Department-MKTD Printed in Germany by HAGE R PAPPRINT GmbH, St. St. Ingbert Ingbert..

CONTENTS Preliminary information 1. 1.1 1.2 1.3 1.4

1.5 1.6 1.7 1.8 2. 2.1 2.2 2.3

2.4

2.5 2.5 2.6 3. 3.1 3.2

3.3 3.4 3.5

3.6 3.7

Page 1

G e ne ne ra ral re ma marks D r a win g o f t r a n sm issio n Po we r flo w sch e m a t ic O il flo w ch a r t s A d ju st m e n t wo r k 1.4.1 R e le a se cle a r a n ce a t clu t ch F ( sn a p r in g) 1.4.2 R e le a se cle a r a n ce a t b r a k e G ( sn a p r in g) 1.4.3 R e le a se cle a r a n ce a t b r a k e D ( sn a p r in g) 1.4.4 C le a r a n ce a t o u t p u t sid e ( wa sh e r ) 1.4.5 R e le a se cle a r a n ce a t clu t ch E ( sn a p r in g) 1.4.6 R e le a se cle a r a n ce a t clu t ch A ( sn a p r in g) 1.4. 1.4.7 7 Release clearance at brak e C 1 ( sn a p r in g) 1.4.8 Tr a n sm issio n a xia le cle a r a n ce ( wa sh e r ) 1.4. 1.4.9 9 Release clearan ce at br ake C 2 ( t wo wa sh e r s) Tigh t e n in g t o r q u e s Tr o u b le sh o o t in g ( fa u lt s, ca u se s a n d r e m e d ie s) C h e ck in g t h e t r a n sm issio n Sp e cia l t o o ls

2 2 3 4 5/1 5/1 5/2 5/3 5/4 5/6 5/7 5/8 5/9 5/11 6 7/1 8 9

D is ismantling D ism a n t lin g a cco r d in g t o a sse m b ly gr o u p s O u t p u t sid e P la n e t a r y ge a r s, co m p le t e 2.3.1 P la n e t a r y ge a r se t I I I 2.3.2 C lu t ch F 2.3.3 B r a k e D G wit h 1st ge a r fr e e wh e e l I n p u t sid e 2.4.1 C lu t ch E 2.4.2 C lu t ch A 2.4.3 C lu t ch B a n d 3r d ge a r fr e e wh e e l 2.4.4 2.4.4 Brake Br ake C 2 O il supply unit with with brak e C 1 H o u sin g wit h sh ift a n d p a r k in g p a wl

10 10 16 18 18 20 21 24 25 26 27 30 31 32

Assemb Assemblin ling acc accor ordi ding ng to ass assemb embly ly group oups H o u sin g wit h sh ift a n d p a r k in g p a wl P la n e t a r y ge a r se t , co m p le t e 3.2.1 P la n e t a r y ge a r se t I I I 3.2.2 C lu t ch F 3.2.3 B r a k e D G wit h 1st ge a r fr e e wh e e l O u t p u t sid e P l a n e t a r y g e a r se t s I a n d I I I n p u t sid e 3.5.1 C lu t ch E 3.5.2 C lu t ch A 3.5.3 C lu t ch B a n d 3r d ge a r fr e e wh e e l 3.5.4 3.5.4 Brak e C 2 Oil suppl upply unit unit wi with brake brake C 1 Se le ct o r u n it , o il su m p a n d co n ve r t e r

35 35 39 39 41 43 48 51 56 56 58 61 66 68 75

PRELIMINARY INFORMATION This manu al contains precise det ails of how to r epair t he complete tra nsmission. A l dismant ling and assembly work is described in th e correct or der. The phot ographs have bee n selected t o cover various types of transmission and ma y ther efore differ from th e vehicle on which you are work ing. The compon ent list pr ecisely defines which version of the tra nsmission you are working on, and this is also reflected in the par ts list. If any major modifications have to be taken into account when repairs are carried out, you will be n otified b y Technical Bu lletin. D epending on the natur e of the fault, it may be possible to limit the repair to the actual compone nts and are as of the t ransmission that h ave failed. In th is connection, please note: - A lways ren ew the pistons if ther e is a fault on clutch F or br ake G. Never re-use seals, for exam ple 0-rings and sha ft sealing rings. - If the tr ansmission has been run for a considerable distance ( > 50.000 km), renew all lined an d stee l discs. - If clutch dam age has occurr ed th e converter, oil cooler lines and the oil cooler itself must be t horo ughly flushed o ut with a suitable cleaning agent. The following conditions must be satisfied: - The n ecessary special tools must be available The complet e set is listed in Section 1.8 of this manu al. - A suitable tr ansmission te st rig should be available. R efer to the Technical Bulletins for t he r elevant te st values. NOTE:

In th is manu al the contr ol unit is tre ate d as a single element; it shoult always be exchanged as a complete un it and n ot d ismant led except by suitably tra ined per sonnel possessing full knowledge of its design. Warning:

The tra nsmission should only be delivered with the oil content stat ed in the r elevant compone nt list (on microfiche).

1

1. General information

1.1 D rawing of tra nsmission

2

1.2 Power flow

For a full description, refer to seperate documentation. 3

1.4

A djustme nt work

1.4.1

Release clearance at clutch F (snap ring)

91 084

Insert snap ring 77.010/180. (Selected th ickness = 1.9 mm) . Place dial gauge and bar in p osition. E xtend dial gauge pointer unt il it touches the end disc, and set dial gauge to ”O ”.

91 085 R aise the complete d isc set a nd r ead off play at the dial gauge. It should be: – with 4 lined discs = 1,30 to 1,60 mm – with 5 lined discs = 1,65 to 1,95 mm

91 086 If a different r eading is obta ined, select a th icker o r thinn er snap r ing.

5/1

1.4.2 Re lease clearance at brake G (snap ring)

91 088

Insert complete d isc set G. Starting with spring d isc 73.040, insert steel discs 73.050 and lined discs 73.060 alternately. Place fina l disc 73.070 in po sition and insert snap r ing 73.080. (Selecte d th ickness = 2.1 mm.) Place dial gauge with bar in position. E xtend th e dial gauge pointer as far as the final disc and set th e dial gauge to ”O ”.

91 089 R aise the complete disc set and rea d off play at the dial gauge. It should be: – with 3 pa irs of discs = 0.95 to 1.25 mm – with 4 pa irs of discs = 1.30 to 1.60 mm

91 090 If a differen t rea ding is obtained, select a th icker o r thinn er snap ring.

5/2

1.4.3 Re lease clearance at brake D (snap ring)

91091

Insert complete set. Starting with spring disc 73.010/160, insert steel discs 73.010/170 and line d discs 73.010/180 alter nate ly. Place final disc 73.010/190 in po sition and insert snap ring 73.010/200. (Selected t hickness = 3.0 mm) Place dial gauge with bar in position. E xtend the dial gauge pointer as far as the final disc and set th e dial gauge to ”O”.

91092 R aise the complete disc set and read off play at t he dial gauge. It should be: – with 5 pa irs of discs = 1.75 to 2.26 min – with 6 pa irs of discs = 2.09 to 2.74 mm

91093 If a different r eading is obta ined, select a th icker o r th inner snap r ing.

5/3

1.4.4 Clearance at output side (washer)

91 111

Support the d ial gauge bar a t appr ox. 140 mm inter vals with a ppro x. 20 mm thick gauge blocks. Set the dial gauge to ”O” on a gauge plate.

91 112 Place th e out put side on a suitable unde rlay or clamp into a vise. Warning! Do not place on the ou tput flange.

To avoid incorr ect readings, move the out put flange towards the ou tpu t side so that play is eliminated.

91 113 Determine distance A : Measure between t he machined face on the extension and the hub of the o utput flange.

Example: distance A = 2.50 mm

5/4

distance B: B: Determine distance U sing sing a depth gauge, gauge, measure bet ween machined faces on tra nsmissi nsmission on ho using and pa rking pawl gear.

91114

Example: distan ce B = 3.80 3.80 mm

91115 D eter mine washer washer th ickness ickness ”S” by the following following form form ula: S = distance B – distance distance A – play

acc. acc. to gauge cleara cleara nce acc. acc. par ts list list Play acc. to gau ge = 0.15 0.15 to 0.35 0.35 mm introduction date:01.91 Example: S = 3.80 mm-2.50 mm-0.15 to 0.35 mm S = 0.95 mm to 1.15 mm

5/5

1.4.5 Re lease clearance clearance at clutch E ( snap ring) ring)

91131

Insert In sert sna p ring 71.130 71.130.. (Selected t hickness = 1.5 1.5 mm). Place dial gauge with with ba r in po sition. sition. E xtend the dial gauge gauge pointer as far as the final final disc and set t he dial gauge gauge to ”O ”.

91132 R aise the complete disc set and rea d off play at the dial gauge. gauge. It should be: – with with 4 pairs of d iscs iscs = 1. 12 to 2.11 2.11 mm – with with 5 pairs of d iscs iscs = 1. 50 to 2.50 2.50 mm

91 133 133 If a different different r eading is obt ained, select select a th icker icker o r thinne r snap ring.

5/6

1.4.6 1.4.6 Re lease clearance clearance at clutch A (snap ring)

85 271 271

Insert In sert snap ring 70.010/ 70.010/23 230. 0. (Selecte d th ickness = 1.4 1.4 mm.) mm .) Place dial gauge gauge with bar in position. E xtend the dial gauge gauge pointer as far far as the final disc disc and set th e dial gauge gauge to ”O ”.

85 272 272 R aise the complete disc set and read off play at t he dial gauge. It should be: – with 4 pa irs of d iscs = 1.30 to 1.60 mm – with 5 pa irs of d iscs = 1.65 to 1.95 mm

85 273 273 If a different different r eading is obta ined, select select a th icker icker o r th inner snap r ing. ing.

5/7

1.4.7 Re lease clearance at brake C 1 snap ring)

91 155

Insert sna p ring 10.130. (Selected th ickness = 1,5 mm) . Place dial gauge with bar in position. E xtend th e dial gauge pointer as far as the final disc and set th e dial gauge to ”O ”.

91 156 Ra ise th e complete disc set and r ead off play at the dial gauge. It should be: – with 3 pa irs of discs = 0.95 to 1.25mm – with 4 pa irs of discs = 1.30 to 1.60mm

91 157 If a differen t rea ding is obtained, select a th icker o r thinn er snap ring.

5/8

1.4.8 Transmission axiale clearance (washer)

91158

Requirements:

A ngle disc 10.190, need le ro ller thr ust be aring 10.200 and shim washer 10.210 (selecte d t hickness = 2.0 mm) are attached to the intermediate plate with grea se.

91159 Clamp assembly fixture 5 X 46 000 563 on to the stator shaft and align the rectan gular-section r ings on cent ering fixtur e 5 X 46 000 312.

91160 Insert the oil supply unit, at th e same, time tur ning in both d irections unt il the diap hragm spring of brak e C is touching the housing. (Test by applying pressure: spring conta ct should be felt.) See also adjacent picture. Warning!

This is a difficult assembly oper ation and must be carried out with great care.

5/9

91 161 A tta ch the oil supply unit with two machine screws on op posite sides. (Wr ench size = TX -27). (Tighten ing torque = 10 Nm).

91 162 Clamp t he sleeve of measurin device 5 P 01 001 415 by its 3 retaining bolts to the stator shaft, so that no play is present . Push measuring device 5 P 01 001 415 over the input shaft splines and secure with t he locking screw so that it can not t ilt.

91 163 Pull the handle to det ermine end play (take the m easurement more than once). D esired end play value = 0.10 – 0.30 mm. If this value is not re ached, insert a thicker or thinner washer 10.210, than check end play again. U nscrew and lift out th e oil supply unit.

5/10

1.4.9 Re lease clearance at brake C2 (two washers) Requirements:

1.The fully assembled piston 75.030 and wash er 75.034 and shim washer 75.040, must b e installed. 2. Cover 75.050 must be inserted and secured with snap r ing 75.060. Example: Shim washer 75.040 = 3.25 mm thick; washer 75.034 = 3.25 mm thick

91 173 Since the r elease cleara nce must be determined under load, it is essential t o use m easuring device 5P 01 002 028. Set the dial gauge to ”O ” in the off-load position.

91 174 Tension th e m easuring device by moving the e ccentr ic lever round . The release cleara nce can the n be determined and r ead off at the dial gauge. (E xample: measure release cleara nce = 1.80 mm) D esired rele ase clearance – 1.35 to 1.70 mm

5/11

If the r elease cleara nce is too large, insert a thicker shim washer 75.040 and a th inner washer 75.034. If it is too small, the opposite procedure applies. Important: Select washers as shown in t he adjacent table.

Paired washers Shim washer

Washer

Pos. 75.040

Pos. 75.034

(mm)

(mm) 1,50

5,00

1,75

4,75

2,00

4,50

2,25

4,25

2,50

4,00

2,75

3,75

3,00

3,50

3,25

3,25

3,50

3,00

3,75

2,75

4,00

2,50

4,25

2,25

91 175 Example: Install a 3,50 mm t hick shim washer 75.040 with a 3,00 mm thick washer 75.034.

5/12

1.5 Tightening to rques

Item

Wrench size

See page

Tightening torque

– Screw plug (transmission housing)

5 mm A llen screw

35/ 73

15 Nm

– Machine screw (detent spring)

TO R X-TX 27

36

10 Nm

– Screw plug (pawl pin)

6 min A llen screw

38

32 Nm

– Machine screw (guide plate)

TO R X-TX 27

38

10 Nm

– Machine screw (complete planetary gear set)

TO R X-TX 50

49

See directive

– Slotted nut (output side)

Socket wrench 5 X 46 000 541

49

120 Nm

– Machine screw (output side)

13 mm across flats

49

23 Nm

– Csk.screw (intermediate plate, pump)

TORX-TX 30

68

10 Nm

– Machine screw (oil supply unit)

TO R X-TX 27

5/10 an d 71

10 Nm

– H ex nut (wiring harness)

32 mm across flatsF

74

20 Nm

– Machine screw (selector unit)

TO R X-TX 27

75

8 Nm

– Machine screw (filter)

TO R X-TX 27

76

8 Nm

– Screw plug (oil sump) M 10 x 1

5 mm A llen screw

76

15 Nm

– Screw plug (oil sump) M 30 x 1,5

17 mm A llen screws

76

100 Nm

– Collar nut (oil sump)

30 mm across flats

76

– H ex bolt (oil sump)

10 mm across flats

77

Pre-assembly:20 Nm Final assembly: 100 Nm 6 Nm

6

Troubleshooting 5 HP 18 EH automatic transmission and electronic-hydraulic selector unit Introduction The troubleshooting table which follows is intended as an aid to diagnosing malfunct ions in the ZF 5 HP 18 E H au tomatic transmission and taking the correct remdial action. The malfunctions have been stated in the same way as the customer would generally describe them. H owever, the same fault can often be described in different ways;the person accepting the custome r' s instructions should be ar t his in mind when de ciding which fault may have occurred. If leaks are complained of,it is best to dete rmine the precise leakage point before attempting any sealing work. This can be d one with a suitable crack testing agent such as Met-L-Chek This product is available as a spray from t rade outlets. A fter it has been a pplied and a short test run undertaken , the leakage point can be accurately located.

Warning:

For all trou bleshooting work on th e auto matic transmission, it is assumed that bo th the mechanical and electrical periphera ls (tra nsmitted signals, cables and lines) are in good working order. In te rms of the vehicle's control circuits, the a utoma tic transmission is a passive element and will also carry out incorre ct comma nds (information) from t he per iphery. It is wrong to assume that such comma nds represent faults in the aut omat ic tran smission. Note s on trou bleshooting in periphe ral equipment are included .

7/1

Troubleshooting – 5 HP 18 EH automatic transmission Malfunction

Possible cause

Remedial action

1. Position P

1.1 Park position does not en gage reliably

– shift cable between selector lever – and tra nsmission is incorrectly – adjusted

– adjust correctly

– too much friction in parking – interlock mechan ism

– renew parking – interlock – components – (connecting – rod,pawl)

1.2 Park position does not stay engaged (slips out )

– shift cable between selector lever – and tra nsmission is incorrectly – adjusted,


1.3 E ngine cannot be started

– position switch incorrectly – adjusted


– position switch defective

– renew position – switch

– incorrect position switch

– fit correct – position switch

– selector lever not correctly adjusted – position switch defect ive

– adjust corre ctly – renew position – switch

– shift cable between selector lever – and tra nsmission is incorrectly – adjusted


– clutch B damaged beyond repair

– fit an exchange – transmission

– Brake D damaged – beyond repair (in this case, no – bra king effect in position 2, 1st gear)


– brake G damaged beyond repair


– see troubleshooting on hydraulic – selector unit, item 1.1

–

– engine idle speed – > 1500 min

– adjust to – correct idle – speed –

1.4 E ngine starts althou gh lever is in park position

2. Position R

2.1 R everse gear not available

2.2 Violent jerk when shifting from P – R or N – R

– see troubleshooting on – hydraulic selector u nit, item 1.2

7/2

Troubleshoo ting – 5 HP 18 EH automatic transmission Malfunction

2.3 R eversing light does not come on (vehicle' s e lectrics in work ing orde r)

Possible cause

Remedial action

– position lever incorrectly adjusted – position switch defective

– adjust correctl – renew position – switch

3.1 E ngine cannot be started

– position lever incorrectly adjusted – position switch defective

– adjust correctly – renew position – switch

3.2 Vehicle moves (creeps) forward

– clutch A defective (discs fused – together)


– shift cable between select or lever – and tra nsmission is incorre ctly – adjusted

– adjust correct ly

4.1 E ngin e st alls wh en shifting from N to D

– co nve rt er locku p clu tch e ngaged a ll – the time

– se e t ro ub le – shooting on – hydraulic – selector u nit, – item 3.3

4.2 No power transmitted

– clutch A damaged beyond repair


– fault in shift cable between – selector lever and tra nsmission

– check setting – and ad just if – necessary

– defective lst gear freewheel


– engine idle speed > 1500 min

– adjust to correct – idle speed


–

3. Position N

4. Position D

4.3 Violent jerk when shifting from N – D

7/3


Possible cause

Remedial action

4.4

No shift action (whether warm or cold) Items 4.4.1 – 4.4.8

– see troubleshooting on hydraulic – selector unit, items 2.4 – 2.4.8

–

4.1

No shift action from 1 – 2

– brakes Cl and C2 defective


– inadequate oil supply to brakes – C1 and C2


4.4.2 No shift action from 2 – 1

– see troubleshooting on hydraulic – selector unit, item 2.4.2

–


– clutch F defective


– inadequate oil supply to – clutch F



– see troubleshooting on hydraulic – selector unit, item 2.4.4

–


– clutch E defective


– inadequate oil supply to clutch E


– brake band C2 defective; in this – case 1 – 2 shift also no t working – correctly


– inadequate oil supply to br ake C2

- fit an exchange – transmission

– no preload at brake band C2 – (spring broke n; in this cas 1 – 2 – shift a lso n ot working correctly)

– adjust the – brake band

4.4.6 No shift action No braking effect fro m 4 –3

7/4


Possible cause

Remedial action


– see item 4.4.5

–


– clutch A defective; in this case – lst to 4th gears also out of action


4.5

Vehicle moves away in 2nd gear

– see troubleshooting on – hydraulic selector unit, item 2.5

–

4.6

Vehicle moves away in 3rd gear


–

4.7

Vehicle moves away 4th gear


–

4.8

Shift transition off-load to o violent


–

4.9

Shift transitions at full load t oo violent


–

– discs damaged


– see troubleshooting on – hydraulic selector u nit, – item 2.10

–

4.10 Shift tra nsitions at full load or kick-down tak e too long

7/5


Possible cause

Remedial action

4.11 No downshifts when kick-down is operate d

– see notes on troubleshooting for – peripherals, item 1

–

4.12 E ngine speed rises steeply during 2 – 3/ 3 - 2 shifts

– low friction at discs

– fit an exchange – transmission –

4.13 E ngine speed rises steeply dur ing 4 – 5/ 5 - 4 shifts

– low fiction at discs


– see troubleshooting on hydraulic – selector u nit, item 2.12F

–

4.14 E ngine speed rises steeply dur ing 2 - 1 shifts



– 1st gear freewheel not operating – correctly


4.15 E ngine speed rises steeply during 4 - 3 shifts



– 3rd gear freewheel not oper ating – correctly


– see troubleshooting on hydraulic – selector un it, item 2.11

5.

Position 4

5.1

See items 4.4 – 4.4.6

–

–

5.2

No engine bra king effect, no ma nual 5 - 4 downshift possible

– clutch A damaged


– see troubleshooting on hydraulic – selector un it, item 2.4.8 and not es – on tro ubleshooting for per ipherals, – item 2

–

7/6

Troubleshooting – 5 HP 18 EH automatic transmission Malfunction

Possible cause

Remedial action

6. Position 3

6.1 See items 4.4 – 4.4.4

–

–

6.2 No engine braking effect, no manual 4 – 3 downshift possible

– see troubleshooting on hydraulic – selector unit, item 2.4.6 and notes – on trou bleshooting for periph erals, – item 2

– –

7.1 See items 4.4 – 4.4.2

–

–

7.2 No engine bra king effect, no ma nual 3 - 2 downshift possible

– see troubleshooting on hydraulic – selector unit, item 2.4.4 and notes – on trou bleshooting for – peripherals, item 2

– –

7.3 No 1st gear, no br aking effect

– brake D defective

–

– see troubleshooting on hydraulic – selector u nit, item 2.4.2

–

– converter defective

– fit an exchange – converter


–

7.

8.

Po sitio n 2

Converter lockup clutch (WK)

8.1 Shifts too violent

7/7


8.2 Converter does not lock up

Possible cause

Remedial action



– see troubleshooting on hydraulic – selector unit, items 3.2 and 3.4

–




–

9.1 No drive either forward or in reverse,loud noises

– pump impeller driver forced off


9.2 G enerally poor shift quality


–

– oil level too low

– add oil to – correct level

– selector unit leaking

– fit an exchange – selector unit – fit an exchang – oil filter

8.3 E ngine stalls when vehicle is halt ed with a gear selected (converte r lock-up clutch do es not open)

9.

General

10. Noise

10.1 Noise in all positions (suction noise)

– oil filter blocked – m issin g o r da ma ge d O -r in g se als a t – oil filter

– r ene w O -r in g – seals

11. Le aks

– leaking usit rings

– renew usit rings

11.1 O il dripping from converter bell housing

– leaking shaft sealing ring

– renew shaft – sealing ring

– leakig O -ring

– renew O -ring

7/8


Possible cause

Remedial action

11.2 Leakage between transmission housing and oil sump

– damaged oil sump gasket

– renew gasket

– loose screw at oil sump

– take up stack at – screws – (tightening – torque 6 Nm)

11.3 Leakage at output side

– shaft sealing ring at flange leaking


– O -ring in transmission extension – leaking

– renew O -ring

11.4 Leakage at selector shaft

– shaft sealing ring leaking


11.5 Loss of oil at transmission socket

– nut loose

– retighten nut – (tightening – torque 20 Nm)

– O -ring leaking

– renew O -ring

11.6 Leakage at screw plug of measuring union for P H –P Mo d and clutches A,E,C2

– bolts loose

– retighten bolts – (tightening – torque 15 Nm) – renew sealing – rings

11.7 Leakage at screw plug for parking interlock pin

– loose bolt

– sealing ring leaking

– sealing ring damaged

– retighten bolt – (tightening – torque 32 Nm) – renew sealing – ring

7/9

Troubleshoo ting – 5 HP 18 EH automatic transmission NOTES

7/10

Troubleshooting – 5 HP 18 E 11 electronic-hydraulic selector unit Malfunction 1.

Remedial action

Position R

1.1 No dr ive in reverse

1.2 Violent jerk when selecting position R

2.

Possible cause

Position D

– signal line fr om MV3 shor t t o ear th – (ground)

– eliminat e fault; – if necessar y – ren ew wiring – harness

– piston in reverse gear interlock valve – not in rest position

– eliminate fault; – if necessar y – fit an e xchange – hydraulic – selector unit

– damping function of brake D not – working correctly

– check damping – function

– modulation pressure too high

– check function – of modulation – valve;if – necessary rene w – housing

– break in electric line to pressure – regulator

– eliminate fault; – if necessary – rene w wiring – harness

– defective pressure regulator

– fit an exchange – pressure – regulator – (complete – housing)

– see notes on troubleshooting for – peripherals, items 3 and 4

–

– damper A blocked

– check function – of damper A

– solenoid valve 5 signal line: shor t – to earth (ground)

– eleminate fault; – if necessary, – rene w wiring – harness

– damping function of clutch A not – working correctly

– check damping – function

– break in electric line to pressure – regulator


2.1 No forward drive

2.2 Violent jerk when position D is selected

7/11

Troubleshoo ting – 5 HP 18 E 11 electronic-hydraulic selector unit Malfunction

2.3 Violent jerks with all shifts

Possible cause

Remedial action


– fit an exchange – pressure – regulator – (complete – housing)

– modulation valve malfunctioning

– check – modulation – valve;if – necessary – renew complete – housing

– see notes on troubleshooting for – periphe rals, items 3 and 4

–


– check – modulation – valve;if – necessary – renew complete – housing

– bre ak in electric line to pressure – regulator

– eliminate fault; – if necessar y – ren ew wiring – harness


– fit an exchange – pressure – regulator – (complete – housing) –

– see notes on troubleshooting for – per ipherals, items 3 and 4 2.4 No shift action (whether warm or cold) items 2.4.1 – 2.4.8

– see notes on troubleshooting for – per ipherals, items 1 to 4

–


– Short circuit or break in line to – out put-side speed sensor

– eliminate fault; – if necessar y, – ren ew wiring – harness

– o ut pu t-sid e spe ed se nsor d efe ct ive

– r en ew sp ee d – sensor

– solenoid valve 1 signal line: shor t – to earth (ground)

– eliminate fault; – if necessary, – rene w wiring – harness

– shift valve 1 sticking in off position

– free shift valve

– damper C2 or clutch valve C1 – blocked

– free damper or – clutch valve

– shift valve 3 blocked in off position

– free the valve 7/12

Troubleshooting – 5 HP 18 E 11 electronic-hydraulic selector unit Malfunction





Possible cause

Remedial action

– line break at solenoid valve I – (signal or po sitive line)


– shift valve 1 sticking in extended – position

– fr ee shift valve

– solenoid valve I has a mechanical – defect (no vent ing action)

– fit a new – solenoid valve 1

– solenoid valve 2 signal line: short – to earth (ground)



– free the valve

– traction valve 2 – 3 blocked in – rest position

– free the valve

– damper F blocked

– free the damper

– solenoid valve 2 has a mechanical – defect (no vent ing action)



–

– line break at solenoid valve 2 – (signal or positive line)

– eleminate – fault;if – necessary – rene w wiring – harness

– shift valve 2 sticking in rest position

– free the valve

– traction valve 2 – 3 blocked in – extended position

– free the valve






– free the valve

– damper E sticking

– free the damper


–

7/13





Possible cause

Remedial action

– line break at solenoid valve 3 – (signal or po sitive line)



– free the valve

– line break at solenoid valve I – (signal or po sitive line)


– eliminate – fault;if – necessary – rene w wiring – harness – free the valve

– damper C2 blocked

– free the damper


–




– free the valve



7/14


2.5 Vehicle moves away in 2nd gear

2.6 Vehicle moves away in 3rd gear

Possible cause

– line break at solenoid valve 1 – (signal or positive line); in this 5th – gear also unobt ainable



– free the valve


–

– line break at solenoid valve 1 + 2 – (signal or po sitive line)

– eliminate fault; – if necessary – rene w wiring – harness – free the valves

– shift valves 1 + 2 sticking in rest – position

2.7 Vehicle moves away in 4th gear

2.8 O ff-load shift tra nsitions too violent

Remedial action


–

– line break at all positive lines – (no electric power reaching – transmission)

– eliminate – fault;if – necessary – rene w wiring – harness

– sh ift va lves 1, 2 + 3 st ick in g in r est – position

– fr ee t he valves


– check – modulation – valve function

– br eak in line to pr essure regulat or

– check wir ing – harness,renew – if necessary

– pr essur e r egulat or m alfun ct ion in g – (th e ad justing screw setting may be – incorrect)

– r en ew p re ssur e – regulator – (complete – housing)

– damper malfunction

– check damper – function –


7/15


2.9 Full-load shift tra nsitions too violent

2.10 Full-load and kick-down shift transitions take too long

Possible cause


– check – modulation – valve function

– break in line t o pressur e r egulator

– check wiring – harness,renew – if necessar y

– p re ssur e r egula to r m alfu nct io ning – (th e adjusting screw setting may – be incorr ect)

– r en ew p re ssu re – regulator – (complete – housing)

– damper malfunction

– check damper – function


–

– pressure reducing valve 1 or 2 – malfunctioning

– check function – of pressure – reducing valve


– check funct ion – of modu lation – valve – renew pressure – regulator – (complete – housing)


2.11 E ngine speed rises steeply dur ing 2 – 3/ 3 – 2 shifts (overlap control)

Remedial action


–



– solenoid valve 4 defective – traction-coasting valve 1 stiff

– renew solenoid – valve – free the valve

– gate for damper G blocked

– clean the gate

– damper F stiff

– free the damper

– traction valve 2 – 3 stiff

– free the valve


– free the valve

7/16

Troubleshoo ting – 5 HP 18 E 11 electronic-hydraulic selector unit Malfunction

2.12 E ngine speed rises steeply during 4 – 5/5 – 4 shifts (overlap control)

Possible cause

Remedial action



– solenoid valve 5 defective

– renew solenoid – valve

– traction-coasting valve 2 stiff

– free the valve

– damper C2 malfunctioning

– check damper – function


– free the valve


– free the valve

– damper A stiff

– free the damper

2.13 Engine speed rises steeply dur ing 1 – 2/ 2 – 1 shifts (freewheel control)

– see automatic transmission – tro ubleshooting, item 4.14

–

2.14 Engine speed rises steeply dur ing 3 – 4/ 4 – 3 shifts (freewheel control)

– see automatic transmission – tro ubleshooting, item 4.15

–

– converter lockup valve – malfunctioning

– check function – of valve

3.

Converter lockup clutch (WK)

3.1 Shift transitions too violent

7/17


3.2 No converter lock-up

Possible cause

Remedial action

– line break at solenoid valve 6 – (signal or po sitive line)


– solenoid valve 6 defective

– renew solenoid – valve

– short to earth (ground) at – solenoid valve 6 signal line


– lo ck -u p valve st ick in g in ext en de d

– fr ee t he valve – position


– fit a new – solenoid valve

– temperature sensor malfunctioning

– renew the – wiring har ness

4.1 No lubricating oil pressure

– lubricating pressure valve – malfunctioning (clogged with dirt )

– check – lubricating – pressure valve

4.2 No converter pressure

– converter pressure valve – malfunctioning (clogged with dirt )

– check converter – pre ssure valve

4.3 No main pressure

– main pressure valve malfunctioning – (clogged with dirt )

– check main – pre ssure valve

4.4 G enerally poor shift q uality

– defective temperature sensor

– renew wiring – harness

3.3 E ngine stalls when veh icle is halted in gear (lock-up clutch does not open)

3.4 Shift speed incorrect

4.

General

7/18

Troubleshooting – 5 HP 18 EH electronic-hydraulic selector unit NOTES

7/19

Troubleshoo ting – 5 HP 18 E 11 – peripherals Malfunction 1)

Kick-down ( KD ) switch

a)

Short to earth (ground)

b)

Line break (ope n circuit)

c) Swit ch d efe ct ive

Possible cause

Remedial action

– larger than half load (only KD – circuits)

– eliminate fault; – if necessar y – renew

– smaller than half-load (normal – shift points) – (th e fault is stored in t he fault – memory with no external – identification)

– kick-down – switch or – vehicle wiring – harness

– no KD shifts, only part/full-load – shifts

– eliminate fault; – if necessary – renew vehicle – wiring har ness

– p ossib ly un de fin ed shift s ( ,,hu nt ing”)

– renew the switch

2)

Position switch (selector lever)

a)

Break in signal line for D, 4,3 or 2

– no shifts, vehicle remains in – selected gear


b)

No positive power supply (fuse blown)

– no shifts, vehicle remains in select ed – gear

– renew the fuse

C)

Short-circuit bet ween signal lines D, 4,3 or 2

– ,,Manual shift” signal to E G S. No – upshift because of shor t-circuited – line e.g. selector lever at D, short – circuit to position 4, shift 4 - 5 is – prevented

– eliminate fault; – if necessary – ren ew vehicle – wiring har ness – or selector – lever switch

3)

Potentiometer at accelerator pedal (E ML) or throttle butterfly

a)

A ccelerator pedal setting too slack

– incorrect shift points

– correct setting – of accelerat or – pedal 7/20

Troubleshooting – 5 HP 18 E 11 – peripherals Malfunction

Possible cause

Remedial action

b)

A ccelerator pedal preload too high

– incorrect shift points

– correct setting – of accelerat or – pedal

c)

Potentiometer defective

– possibly undefined shifts (,,hunting”)

– renew – potentiometer

4)

Program switch

a)

Break in S progra m signal line or short-circuit to positive side

– S program not available

– eliminate fault; – if necessar y – ren ew vehicle – wiring har ness

b)

S program signal line: short to earth (ground)

– only S program available – (,,S” displayed)


c)

Break in W program signal line or short-circuit to po sitive side

– W program not available


d)

W program signal line : short to earth (ground)

– only W (winter) program available – (,,W” displayed)


7/21

Troubleshooting – 5 HP 18 EH – peripherals NOTES

7/22

1.7. Checking the transmission

The following points must be checked: Oil level correct

Comp ly with t he vehicle man ufacturer ' s instructions. Oil level too low

The engine will overspeed when t he vehicle is corn ered , ther e will be valve chatt er as a result of air inclusions and genera l malfunctioning of the tr ansmission. Oil level too high

R isk of severe splash losses and foam ing, severe rise in tem pera tur e if driven fast. O il lost through breather. Correct engine settings

Cor rect idle speed (comply with vehicle manufactur er' s instructions).

D rive taken up forwards and in rese rve

Selector linkage or cables corr ectly adjusted ( comply with vehicle manu facturer' s instructions). Shift quality

See troubleshoot ing tab le

Noise

See troubleshoot ing tab le Fault memory

If activated , comply with vehicle man ufacturer ' s instructions.

8

1.8 Special tools 5 HP 18

Pic. No.

Item

82183

O rder No. / purpose

R emarks

5 P 01 001 415

identical with

– E nd play measuring device

4 H P 22

1

91186

5 P 01 002 028 – Brake band ad justment me asuring device

2

84258

5 X 46 000 167 – A ssembly aid

3

identical with 4 HP 14 4 HP 18 Q 4 HP 22

9/1


Pic. No.

Item

85 417


R emarks

5 X 46 000 221

identical

– Assembly fixture for

with

- diaphragm spring, clutch B

4 H P 18 Q

4

88 258

5 X 46 000 312 – Centering device

with

– for C 1 lined discs

4 H P 18 FL

5

91 187

5 X 46 000 541 – Socked wrench for slotted nut

6

9/2

identical


Pic. No.

Item

91 188


R emarks

5 X 46 000 542 – Retainer for o utput flange

7

91 189

5 X 46 000 545 – Lifter for tower

8

91 190

5 X 46 000 563 – Remo val fixture for

9

– complete o il supp ly unit

9/3


Pic. No.

Item

91 191


5 X 46 000 574 – Assembly fixture for – piston C 2 brake band

10

91 192

5 X 46 000 576 – Assembly device for – snap ring D-G/F

11

91 193

5 X 46 000 577 – Counter- holder for

12

9/4

– 1st gear freewhee l

R emarks


Pic. No.

Item

91194


R emarks

5 X 46 000 620 – Assembly clamp

13

78 085

5 X 46 000 680 – Assembly sleeve for pu mp – shaft sealing ring

14

91195

5 X 46 000 685 – Driver for selector shaft

15

– clamp sleeve

9/5


Pic. No.

Item

91196


5 X 46 000 737 – Pressing-in to ol for – selector shaft sealing ring

16

91197

5 X 46 000 760 – Pressing-in to ol for – ball thrust bearing, – tran smission extension

17

91198

5 X 46 000 761 – Pre ssing-in for

18

9/6

– shaft sealing ring, – tran smission extension

R emarks


Pic. No.

Item

91 199


R emarks

5 X 46 000 763 – Workbench holder for – assembly clamp

19

84 260

5 X 46 000 863 – Assembly device for – diaphr agm spring, clutch E

20

84 258

5 X 56 000 021 – Pump testing sleeve

21

identical with 3 HP 22 4 HP 22

9/7


Pic. No.

Item

76 050


5 X 56 000 072 – Mounting for tower

R emarks

identical with 3 HP 22 4 HP 22

22

76 046

23

9/8

5 X 56 000 090

identical

– H andles for pulling

with

– out converter

3 H P 22 4 HP 22

2. Dismantling

91 001

2.1 D ismantling the transmission according to assembly groups

Place the complet e tr ansmission in assembly clamp 5 X 46 000 620, remove the converter retaining hoop and pull out t he converte r by screwing in the two h and les 5 X 56 000 090. Warning: O il will escape

Avoid da mage to converter bearings and shaft sealing ring.

91 002 Take o ut th e bolts holding the oil sump and det ach the sump with its gasket . (Wr ench size = 10 mm) Note: D ifferent patt erns of oil sump may be fitted. The dipstick connection has been deleted.

91 003 R emove the oil strainer by taking out the 3 machine screws. (Torx socket wrench insert = TX 27)

10

91 004 D etach the socket for the wiring harn ess and pre ss it inwards. (Wr ench size = 32 mm) Take o ut all the bo lts with the lar ger head, and lift off the complete control unit, including the cover plate. (Wrench size = Torx socket wrench insert TX 27)

91 005 Turn t he tr ansmission th rou gh 90 degrees an d un screw th e oil supply unit (consisting of pump, interm ediate plate and brake C 1; to do this, remove the 9 machine screws with th eir usit rings. (Wrench size = Torx TX 27)

91 006 Clamp assemb ly fixture 5 X 46 000 563 on to t he stator shaft. Screw down the spindle on the fixtur e to re lease and lift off the complete unit.

11

91 007 Warning: do not turn the t ransmission any further.

Re move the angled disc, needle roller thrust bearing and shim washer. Note that the a ngled disc may stick to the intermediate plate.

91 008 R emove the inpu t side with clutches A, B and E. At the input shaft, take out the complete unit consisting of clutch A , clutch B with 2nd gear free wheel and clutch E .While doing so, hold the brake b and firmly to pr event it from tilting.

91 009 Take out t he brake b and opposite the brake plates.When removing, make sure that the brake ban d is not bent outwards;to prevent this, use ret aining clip (a lso indicates ”top” ). Important: Make sure that the brak e band is not t urne d over accident ally when it is installed a gain.

12

91010 Take out the interme diate shaft complete with 2 thrust washers and 1 axial (AX ) nee dle roller cage. Warning: It is quite po ssible when remo ving axial bearings that the washer s will rem ain sticking to the o pposing runn ing face.

It is always desirable to keep the bear ings completely assembled.

91011 R emove the sun wheel shaft complete with th rust bearing, one thr ust washer and o ne an gled disc.

91012 R emove case with thrust bearing,o ne washer and o ne an gled disc.

13

91 013 Lift off the sun whee l.

91 014 A fter this the complete planet spider, the thrust bearing,on e washer and one an gled disc can be rem oved.

91 015 Pull out the shaft complete with the h ollow gear.

14

91016 R emove the spider case. Take out the t hrust washer, need le roller cage and angled disc.

91017 To remo ve the complete planetary gear set, first take out the 3 machin e screws. (W ren ch size = Torx TX-50)

91018 Insert lifter 5 X 46 000 545 into the planet wheel carrier of the tower and pr ess the t ensioner down to locate it centrally.

15

91019 Lift out the complete tower and insert it into moun ting 5 X 56 000 072. R emove the shim washer.

91020 Turn t he tr ansmission thro ugh 90 degrees and take out the 7 hex bolts. The output side cannot be pulled off until these bolts have been removed. (Wr ench size = 13 mm)

91021 2.2 Output side

Place the o utput side on r etainer 5 X 46 000 542. Clamp t he r etainer into t he vise. Warning: D ifferen t patt erns are possible.

Pull the O -ring off the extension.

16

91 022 R elease the slotted nut with a suitable chisel, and unscrew it with slotte d nu t wrench 5 X 46 000 541. A fter this, the out put flange can be pulled off.

91 023 R emove the snap r ing with suitable pliers. A fter this, press out the b all bear ing in an man drel pr ess. Warning:

The two inner be aring races must not be accidentally mixed u p.

91 024 D rive out the shaft sealing ring with a suitably shaped p unch.

17

2.3

Planetary gears, complete

91 025

2.3.1 Plane tary gear set III

Before planetary gear set III can be taken off, the complete planetary gear assembly (tower) m ust be subdivided into the component s brake D-G, clutch F and planetar y gear set III.

91 026 Re move the angled disc, needle roller thrust bear ing and thrust washer. Lift off the hollow gear carrier.

91 027 The hollow gear can be separat ed from its carr ier by rem oving the snap ring.

18

91028 Turn the planet carrier round and re move the angled disc, needle roller thrust bear ing and thrust washer.

91029 Take ou t the snap ring and lift off the parking pawl gear. R emove the thrust washer, angled disc and ne edle roller thrust bearing.

91030 Take off the sun wheel.U nderneath it are an angled disc, a need le roller thr ust bearing and anot her an gled disc.

19

2.3.2 Clutch F

91 031

Take out the snap ring and re move the complete d isc cluster of clutch F.

91 032 U sing assemb ly device 5 X 46 000 576, press the diaphr agm spring down in the mandr el press and remove the split ring. R emove the diaphragm spring.

91 033 A pply a compressed air jet to one of the oil feed bo res, block off two open oil feed bor es with the fingertips and force out p iston F by building up th e ne cessary air pressure. Warning:

Set the piston down in such a way that the sealing lip is not d amaged or folded over.

20

2.3.3 Brake D G with 1st gear freewheel

91 034

E ngage the t hree cylindrical alignmen t pins of coun ter-holder 5 X 46 000 577 in the freewheel of the carrier. Turn t he complete unit round .

91 035 Take out the snap ring and re move the comp lete disc cluster for b rake G. R emove t he 2 r ectangular-section r ings.

91 036 U se the hoo p of assembly fixture 5 X 46 000 576 to press down diaphragm spring G in the ma ndrel press, and take o ut the snap ring with suitable p liers.

21

91 037 Take out the t hrust washer and the diaph ragm spring.

91 038 A pply a compressed air jet to the oil feed bor e and press out piston G by means of the air pr essure. Warning:

Set the piston down so that t he sealing lip is not d amaged or folded over.

91 039 Lift cylinder D G away from comp lete carrier (freewheel).

22

91040 Take ou t the snap ring for brake D and remove the complete disc cluster, the diaph ragm spring and th e reta ining washer.

91041 A pply a compressed air jet to the oil feed bor e and force out piston D by air pressure.

91042 D isengage the thr ee cylindrical pins of the counter-holder and remove it.

23

91 043 Pull both O -rings off the carrier and press out the freewheel.

91 044 2.4 Input side

Re move the 3rd gear freewheel.

91 045 Pull clutch B away from clutch A.

24

91046 R emove 2 angled discs and o ne nee dle roller thrust bearing.C lutch A can then be separated from clutch E.

91047 2.4.1 Clutch E

Take out the snap r ing and r emove the complete clutch E disc cluster.

84097 U se assemb ly fixtur e 5 X 46 000 863 to pr ess diaphr agm spring E do wn completely in the mand rel pre ss. Take ou t the split ret aining ring and r emove the diaphragm spring.

25

91048 U se compressed air to force out piston E, by applying a compressed air jet to t he oil feed bore. Remove the O -ring;the rectan gular-section r ings normally remain on th e input shaft. Note:

The plastic rings have chamfer ed bu tt ends.

85143 2.4.2 Clutch A

R emove the snap ring from cylinder A and take out the complete disc cluster including the spring disc.

84092 U sing the hoop fro m special tool 5 X 46 000 167, pre ss down the ret aining disc in the ma ndr el press and lever out t he snap ring with suitable pliers and with the a id of a screwdriver.

26

84 093 A pply a compressed air jet to one of the oil feed bore s, block off two open oil feed b ores with the fingertips and force out piston A b y building up the necessary air pressure.

84 094 R emove the r etaining disc and the diaphragm spring beneath it by striking lightly on t he work bench.

91 049 2.4.3 Clutch B and 3rd gear free whee l

Take o ut th e clutch B snap ring and remo ve the complet e disc cluster.

27

91 050 050 U sing special too l 5 X 46 000 221, 221, press the diaphr agm spring down in the mandrel press and take ou t the split split ret aining ring.

85 136 136 Take ou t the d iaphra gm spring. spring.

85 137 137 A pply a compr compr essed air jet jet to the oil feed feed bore and force out piston B by building up the a ir pressure.

28

85138 Press the intermediate ring out of the piston.

91051 The 3rd gear freewheel can can be strippe d down for cleaning cleaning pur poses. poses. First First pr ess the inne r race of the freewheel out o f the cage. cage.

91052 Separat e the two cover cover discs from the outer race together with with the freewheel cage. cage.

29

2.4.4 Brake C 2

91 053 053

Take o ut t he 3 screw screw plugs. plugs. Bolt on assembly fixtu fixture re 5 X 46 000 000 574. 574. Press Pr ess the bra ke band control cover cover down and take out the snap ring, ring, using using a suitable screwdriver. screwdriver. (A llen key size size = 5 mm)

91 054 054 Take o ut t he cover, shim shim washer and complete piston piston . R emove the pin of the brake band fastener from the housing. housing.

91 055 055 The complete piston can be stripped down for cleaning after th e lock washer washer has been pulled off. off.

30

2.5 Oil supply unit with brake C 1

91 056

Re move the snap ring from the groove and ta ke out t he complete set of discs for brak e C with th e diaphr agm spring.

91 057 Force out piston C with a compre ssed air jet applied to the oil feed bor e.

91 058 Take o ut t he 7 machine screws unde r the piston and a lso the two additional machine screws. Separate t he pu mp from the intermediate p late. (Wrench size = Torx TX 30) Note:

The re ctangular-section r ings and the locating pin nor mally rem ain on th e intermediate plate.

31

91 059 Pull off the O -ring. The pump can be stripped down by taking out the pump gear and pump h ollow gear. Lever out the shaft sealing ring with a suitable screwdriver b lade; there is a corrugated washer un der this ring.

91 060 2.6 Ho using with shift and parking interlock

Using a suitable mandrel, drive the clamping sleeve out o f the det ent disc and p ull out th e selector shaft.

91 061 The det ent disc with conne cting rod can now be removed. Lever out the shaft sealing ring with a screwdriver.

32

91062 The deten t spring nor mally rem ains in the tra nsmission h ousing. If it is to be taken out, slacken off the t wo machine screws. Warning:

O lder versions have a loose locating pin. (Wrench size = Torx TX 27)

91063 Take out the four machine screws and remo ve the guide plate. (Wrench size = Torx TX 27)

91064 R emove th e screw plug with its sealing ring and p ress the p in out of th e housing from the inside. (A llen k ey size = 6 mm)

33

91 065 The pawl and its tor sion spring can now be removed.

91 066 When cleaning the tra nsmission housing you are recommended to take out all the screw plugs. (A llen key size = 5 mm) The straight pin and the breather can remain in the hou sing.

34

3. A sse mbling 3.1 Transmission housing with shift and parking pawl

91067 Insert two of t he 5 screw plugs 01.060, M 10 x 1, with n ew O -rings into tr ansmission ho using 01.010 on ea ch side. Leave the holes designated C 2, PM and PH in the tr ansmission housing open for later assembly stages. (A llen ke y size = 5 mm) (Tighte ning torque = 15 Nm) Install straight p in 01.020 and bre athe r 01.040, and th e two plastic plugs 01.090.

35

91068 U sing pre ssing-in too l 5 X 46 000 737, drive a ne w shaft sealing rin g 06.010 into t he tr ansmission ho using.

91069 U sing a plastic-headed ha mmer , drive roller 06.040 into det ent spring 06.030.

91070 Secure the det ent spring with 2 machine screws 06.050 in a po sition in which th e spring does not scrape on the transmission h ousing.O lder versions: the locating pin must be installed separat ely. (Wr ench size = Torx insert TX 27) (Tighten ing torque = 10 Nm)

36

91 071 A tta ch connecting rod 06.080 to dete nt disc 06.070, and tu rn to secure.

91 072 Insert dete nt disc with conne cting rod into tr ansmission ho using and p ush in selector shaft 06.060.

91 073 U sing special tool 5 X 46 000 685 or a suitable punch, drive a new locking pin 06.090 into a p osition in which t he o pen side of t he locking pin faces toward s the ou tput side.

37

91 074 Place pa wl 24.020 with t orsion spring 24.030 in th e tr ansmission housing and secure it by pr essing in pin 24.010. A fter this, seal the hole with screw plug 24.070, with a ne w sealing ring. (A llen key size = 6 mm) (Tighten ing torque = 32 Nm)

91 075 Press down the pawl.The connecting rod must be pressed to the rear b y tur ning the det ent disc. Secure guide plate 24.040 with 4 ma chine screws 24.050. (Wrench size = Torx TX 27) (Tighten ing torque = 10 Nm)

38

3.2 Planetary gear set, complete 3.2.1 Planetary gear set III

91076 Place thr ust washer 42.080, need le roller t hrust bear ing 42.070 and angled d isc 42.060 in parking inter lock gear 42.090.

39

91 077 Install the sun wh eel 42.050 and place angled d isc 42.040, need le r oller thr ust be aring 42.030 and angled disc 42.020 over t he sun whe el hub.

91 078 Planet carrier 42.010 can n ow be installed, and secured with snap ring 42.100. Make sure t hat t he thrust bear ings remain centered. Place the complete unit o n mount ing 5 X 56 000 072.

91 079 Place ho llow gear carrier 42.150 in hollow gear 42.140 and secure with snap ring 42.160. Place thr ust washer 42.170, need le roller t hrust bear ing 42.180 and angled d isc 42.190 on h ollow gear u nit.

40

91 080 Place thru st washer 42.110, need le roller t hrust b earing 42.120 and an gled disc 42.130 on the planet carrier and install the comp lete ho llow gear unit on it.

3.2.2 Clutch F

41

91 081 A pply a light coat of grea se (Vaseline) to th e inside and outside of the sealing lips on piston F 77.010/120, and press into cylinder F 77.010/110. Warning:

The piston must not be tilted or the sealing lips folded o ver.

91 082 Inser t diaphr agm spr ing 77.010/130. Press it down in the man dre l press with assembly fixture 5 X 46 000 576, and the split re taining ring 77.010/140.

91 083 Insert th e complet disc cluster, starting with spr ing disc 77.010/150.A fter this, insert steel disccs 77.010/160 and lined discs 77.010/170 alter nat ely. Secure the uppe r steel disc with snap ring 77.010/180. Important: carry out adjusting procedure (see it em 1.4.1, Page 5/1).

42

3.2.3 Brake D G with 1st gear free wheel

91087 You are r ecommended to dete rmine the release clearance of br akes D and G first.To do this, fit O -rings 73.010/130 and 73.010/140 to p iston D (73.010/120). G rea se the O -rings on piston D and t he sealing lips of piston G lightly (Vaseline) and install both pistons in cylinder DG 73.010/110. Important: The pistons must make full contact, or else the rea dings will be incorre ct. If necessary, drive the m in fully with a suitable punch. Warning: carry out a djustment procedure (see items 1.4.2 and 1.4.3, Page 5/2) 43

91 094 Press carrier ( inner race of freewheel) 73.100/110 into fre ewhee l 73.100. To do this, pre vent th e freewheel from moving and turn the carrier clockwise.

91 095 Place th e complete unit on count er-holde r 5 X 46 000 577 and tur n unt il the 3 pins of the special tool engage with th e freewheel. Pull on the two O -rings 73.100/140 and a pply a light coat of grease (Vaseline) t o them .

91 096 Place diap hragm sprin g D 73.010/150 in cylinder D G a nd pr ess in retaining washer 73.090.

44

91097 Place cylinder D G o n complete carrier and pre ss on fully.

91 098 Insert diaphr agm spring G 73.030 on th e other side of cylinder D G. Place thrust washer 73.110 in position.

91099 Place snap r ing 73.120 on the cone of assembly fixture 5X46 000 576, and pre ss down slightly with the pre ssure pad. Place the cone on the hub,push the pr essure pa d (with cover) o ver it and insert the hoop of the fixture into the cylinder. Press the complete un it down in the man drel pre ss. Warning:

The serrations on the thrust washer must slide into t he splines on th e carrier as this is done.

45

91100 A pply a light coat of grease (Vaseline) to t he two r ectangular-section rings 73.130 and 73.140, and install the m on the carrier. Insert the correctly dimensioned disc cluster G, starting with spr ing disc 73.040 and continuing with ste el discs 73.050 and lined discs 73.060 alternat ely. Insert the final disc 73.070 and secure with sna p ring 73.080.

91101 Turn th e complete unit round and remove the counter-holder. Insert the correctly dimensioned disc cluster D, starting with spring disc 73.010/160. This is followed by stee l discs 73.010/170 and lined discs 73.010/180 altern ately. Insert t he final disc 73.010/190 and secure with snap ring 73.010/200.

91102 Place clutch F on planeta ry gear set II I, tur ning in both d irections until the serr ated edges of the lined discs and t he splines in th e hollow gear engage with one an othe r fully. Check through the cutouts in the cylinder: the final disc must no t be pressed up b y the lined discs. The gap at th e top must be wider than at the bott om.

46

91 103 103 U sing sing the same procedure, install install brake D G with with Ist gear freewheel on clutch F, F, and insert lifter 5 X 46 000 000 545 into the carrier carrier of th e complete planetary gear set (tower). Press down down the lever lever in the centre. centre. Note that t his will will not be po ssible ssible if bra ke D G is incorrectly mounte d on clutch clutch F. F.

91 104 104 Insert the tower into t he t ransmissi ransmission on housing, aligning aligning the 3 holes. holes. Warning:

The tr ansmission ansmission hou sing sing must rem ain vertical vert ical while while th is is being do ne.

91 105 105 Important: comply with the following fo llowing tightening tightening instructions:

1.I nsert the th ree machine screw screwss 73.200 73.200 by abo ut 2 tur ns. 2. Pre load the centre screw initially initially at 30 Nm, then at 63 Nm. 3.Tighte 3.Tighte n the t wo outer screws screws to a torque of 15 15 Nm, then 30 Nm and finally 63 63 Nm. (Wrench size size = TO R X TX 50) 50) The lifter lifter must rem ain installed; installed; tur n the t ransmission ransmission thro ugh 180 180 degrees. 47

3.3 Output side

91 106 106 Place e xtension 14.010 14.010/11 /110 0 on t he conta ct surface of pre ssing-in ssing-in device device 5 X 46 000 760. Place b all bea ring 14.010 14.010/12 /120 0 on t he pressing-in pressing-in pin of the to ol. Press it into the extension extension using using the ma ndrel press, press, and secure with snap snap ring 14.010/130. Warning:

D o not accidentally interchan ge or turn the t wo inner inner bearing races races.The .The cutouts at t he ed ge must face face each other.

48

91107 Turn t he extension roun d and install shaft sealing r ing 14.010 14.010/14 /140 0 in t he mand rel pr ess, ess, using pressingpressing-in in pin 5 X 46 000 000 761. 761. Pul Pu l on O -ring 14.100 14.100..

91108 Place out put flange flange 14.03 14.030 0 on h older 5 X 46 000 542. 542. Place ext ension o n outp ut flange. flange.

91109 U se the vise! vise!

Screw Screw slotted nut 14.0 14.040 40 on t o th e outp ut flange and tighten down with with socket wren ch 5 X 46 000 541. 541. (Tighte (Tighte ning torqu e = 120 Nm) Secure Secure t he nut with with pu nch marks at two point s on its circumferen circumferen ce.

49

91 110 Place washer 14.050 on t he p arking interlock gear in the t ran smission housing. Important:adjusting work is nee ded (see item 1.4.4, Page 5.4)

91 116 Install the ou tput side assembly and tighte n do wn with 7 hex bolt s 14.110. A t the same time, secure reta ining plate 14.120 in t he position illustra ted (Wr ench size = 13 mm) (Tighten ing torque = 23 Nm)

50

3.4 Plane tary gear sets I and II

91 117 Turn the tra nsmission t hrou gh 180 degrees and pu ll out lifter 5 X 46 000 545 at the centre han dle. Install case 32.074 on fre ewhee l.

51

91 118 Inser t sha ft 32.040/110 into hollow gear, and secure with snap r ing 32.040/130.

91 119 Insert angled disc 32.010, need le roller thr ust bea ring 32.020 and thr ust washer 32.030.

91 120 Insert the ou tput shaft with the hollow gear into th e tr ansmission housing.

52

91121 Install thr ust washer 32.050, need le roller t hrust bear ing cage 32.060 and angled d isc 32.070.

91122 Place plan et car rier 32.080 in tra nsmission housing.

91123 Place sun wheel 32.090 in p lanet carrier.

53

91 124 Place case 32.100 on sun wheel spline s.

91 125 Place thru st washer 32.110, need le roller t hrust bear ing cage 32.120 and angled disc 32.130 in t he case.

91 126 Insert sun wheel 32.140 and check for correct function. If assembly was correct, the case will turn in the oppo site direction to t he sun wheel.

54

91127 Push a ngled disc 32.170, need le ro ller thr ust bea ring cage 32.160 and thr ust washer 32.170 over t he e nd of interm ediate shaft 32.180, and install the interm ediate shaft.

91128 Place thru st washer 32.190, need le roller thr ust bea ring cage 32.200 and thr ust washer 32.210 over th e inter mediat e shaft journ al.

55

3.5 Input side 3.5.1 Clutch E

91129 Install new O -ring seals 71.060 and 71.070 on piston E 71.050, and grease lightly (with Vaseline) . Pres piston E into the complete input shaft cylinder 71.010.

56

85 260 Place the two diap hragm springs 71.080 on the piston, press down in the mand rel p ress using assembly fixtur e 5 X 46 000 863 and secur e with t he split retaining ring 71.090.

91 130 Insert the comp lete set of discs for clutch E , starting with outer disc 71.100 and con tinuing altern ately with lined disc 71.110 and the out er d isc. Install final disc 71.120 and secur e with snap ring 71.130. Warning:adjustment work is ne ede d (se e ite m 1.4.5, Page 5/6)

91 134 Install the two re ctangular-section rings 71.020 and 71.030 on the inp ut shaft. Pull on O -ring 71.040 and coat all rings with grea se (Vaseline) .

57

3.5.2 Clutch A

85 196 Install new O -ring seals 70.010/120 and 70.010/130 on piston 70.010/180, and grease lightly (with Vaseline) .

58

91135 Press piston A into cylinder A (70.010/110) and inser t diaph ragm spring 70.010/140 with t he convex side u pwards.

85267 Pull O -ring seal 70.010/160 on to retaining disc 70.010/150 and grease lightly (with Vaseline) .

85268 Insert the r etaining disc and press it down with the ho op of special tool 5 X 46 000 167. Snap ring 70.010/170 can be pressed into position by hand, or suitab le pliers used if necessary.

59

85 269 Insert the comp lete disc cluster for clutch A. starting with spring disc 70.010/190 and cont inuing alter nat ely with oute r d iscs 70.010/200 and line d discs 70.010/210.

85 270 Place final disc 70.010/220 in po sition and secure with snap ring 70.010/230. Warning: adjustment work is nece ssary (see item 1.4.6, Page 5/7)

60

3.5.3 Clutch B and 3rd gear freewhe el

85 277 Pull new O -ring 72.130 on to hub or cylinder B 72.010, and grease lightly (with Vaseline) .

61

85278 Pre ss inte rmediat e ring 72.120 fully into t he cylinder with its chanifered side facing down.

85280 Pull new O -ring seals 72.050 and 72.060 on t o p iston B 72.040 and gre ase lightly (with Vaseline) . Press the piston int o the cylinder.

91136 Install the center ing ring of assembly fixtur e 5 X 46 000 221 and p lace diaph ragm spring 72.110 in position. Press down in the mand rel pre ss using fixtur e 5 X 46 000 221 and secur e with ret aining ring 72.140 by pushing th e two halves of this ring together.

62

91137 Install the complete disc cluster for clutch B, starting with out er disc 72.070 and cont inuing alter nate ly with lined disc 72.080 and a n ou ter disc. Place the fina l disc 72.090 on t op a nd secure it with sna p r ing 72.100.

91138 Pre-assemble the 3rd gear free wheel 72.030 by pressing one of th e two cover discs of the fre ewheel into the oute r race o f the freewheel initially.

91139 Insert t he freewheel cage with the shoulder d ownwards. Warning:

If installed incorr ectly (the wron g way round), the freewheel will lock in the wrong direction.

63

91 140 Place the freewheel cover disc in position and p ress it in.

91 141 Insert the inner race of the freewheel from the front , tur ning it clockwise at the same time. Important: Check for correct function: it should be possible to t urn th e inner race of the freewheel freely clockwise at t he shoulder or inte rnal splines when t he oute r race is pre vented from m oving.

91 142 Insert clutch E at the input shaft, tur ning it while inserting. Make sure that all the clutch discs are corr ectly engaged.

64

91143 Insert complete clutch A , turning it at the same time in both directions and en suring that the disc teet h engage. Warning: The clutch must slide over th e O -ring on th e input shaft. The hub of cylinder B should then be heard to strike sheet-met al cylinder E .

91144 Insert angled disc 72.160, need le roller thr ust be aring 72.170 and angled disc 72.180.

65

3.5.4 Brake C 2

91145 Press pin 75.010 into th e tr ansmission housing and insert br ake b and 75.020 using the re taining clip. R emove the clip after insertion of the brake band.

66

91 146 Insert the complete clutch B, turning it in either direction unt il the discs mesh together fully. If correctly installed, cylinder B mu st engaged in the cutou ts on the case so that only a gap of appr ox. 1 mm is still visible. Note: Final assembly of bra ke C 2 and the 3rd gear freewheel should not b e undert aken until the necessary adjustmen ts to clutch C 2 and o f transmission end play have been carried out. To d o t his, first install the oil supply unit with brak e C 1. For final assembly, see Page 73.

67

3.6 Oil supply unit with brake C 1

91 147 Inser t washe r 10.010/150 and use assembly sleeve 5 X 46 000 680 to install shaft sealing ring 10.010/160 in the pump h ousing.

68

91148 Pre-assemble pum p 10.010, making sure that the marks on the pump gear and the ho llow gear are both at t he top.

91149 U sing a plastic-faced hammer, drive the two stra ight pins 10.020/140 into interm ediate plate 10.020.

91150 Place the interm ediate plate on the pump an align it. A ttach it with 9 countersunk bolts 10.030. (Wrench size = Torx TX 30) (Tighte ning torque = 10 Nm)

69

91 151 Place the two re ctangular-section r ings 10.170 and r ectan gular-section r ing 10.180 on th e hub o f the inter mediat e plate an d engage in position. Check free movement of pump with special tool 5 X 56 000 021.

91 152 Pull O -rings 10.040 and 10.050 on to piston 10.060 and gr ease th em lightly (with Vaseline) . Press the piston into the intermediate plate.

91 153 Install the complete disc cluster for brake C' , starting with spring disc 10.080 followed by th ick outer disc 10.090. Insert diaphra gm spring 10.070 with t he raised out er r im facing you. Follow this with lined discs 10.110 and out er discs 10.100 alternately. Place t he fina l disc 10.120 on t op.

70

91 154 Secure the final disc with snap ring 10.130. Warning: adjustment work is nece ssary (see item 1.4.7, Page 5/8)

91158 U se grease (Vaseline) to a tta ch angled disc 10.190, need le roller thr ust bear ing 10.200 and washer 10.210 to the intermediate plate. Warning: adjustment work is nece ssary (see item 1.4.8, Page 5/9)

91 164 Place the 3rd gear freewheel on the hub of cylinder B.

71

91 165 Pull O-ring 10.160 on t o th e pu mp, coat with ATF (aut omat ic tra nsmission fluid) a nd u se asembly fixtur e 5 X 46 000 563 to insert the comp lete pump /intermed iate plate assembly, tur ning this in eithe r direction a s it is inserted. Warning: This is a difficult assembly oper ation which must be per formed with great care.

91 166 If correctly assembled, the complete unit mak es spring contact with th e housing. The turb ine shaft projects approx. 62 mm beyond the stator shaft.

91 167 Tighten do wn with t he 9 machine screws 10.230, using new U sit rings 10.220 on th e screws. (Wr ench size = Torx socket wrench insert TX 27) (Tighten ing torque = 10 Nm) Check e nd p lay.

72

91168 Final assembly – Page 67

Pre-assembly piston C 2 by installing the two d iaphragm springs 75.030/120 and 75.030/130 with t heir convex sides against the shoulder on piston rod 75.030/110. Slide pist on 75.030/140 over this assembly and secur e it with lock washe r 75.030/160.

91169 Pull O -ring 75.030/150 on t o th e piston and grea se lightly (Vaseline). Place the two coil springs 75.030/170 and 75.030/180 over th e piston ro d.

91170 Place washer 75.034 (previously rem oved) in the tran smission housing and insert piston C 2.

73

91 171 Pull O -ring 75.050/110 on t o cover 75.050/100 and grease (with Vaseline) . Place shim washer 75.040 (previously remo ved) in tran smission ho using and attach the cover.

91 172 Bolt assembly fixture 5X46 000 574 to t he t ransmission hou sing and use it to press the cover down. Insert snap ring 75.060 with a screwdriver. Warning:adjustment work is necessary. The thickness of the washers must be determined. (see item 1.4.9, Page 5/11)

91 176 Next, insert t he 3 screw plugs 01.060, using new sea ling rings. (A llen key size = 5 mm) (Tighten ing torque = 15 Nm)

74

3.7 Selector unit, oil stump and converter

Before installing the selector un it you are re commend ed to check all clutches/brake s for leaks. To do this, inject compr essed air at t he oil feed bor es. 91177 Place the selector un it loosely in position. Pull a n ew O -ring 27.340/112 on t o th e wiring harne ss socket and secure t he wiring har ness by tighten ing hex nut 27.340/114. O n older versions the flat chamfered face on th e socket mu st be parallel with the wall of the t ran smission ho using. U sing a screwdriver, pre vent the wiring harn ess from t urning while it is being tightened . (Wr ench size = 32 mm) (Tighten ing torque = 20 Nm) A ttach du st cap 27.340/118.

75

91178 O ffer up the selector u nit at an angle, so that th e pin of the dete nt disc can be engaged in the cutout o n the shift valve. Then lower the selctor u nit and locate it on th e pin in the tr ansmission housing.

Secure the complete selector unit with th e following machine screws: Position

Quantity Length (mm)

Tightening torque (Nm)

27.410 27.400

11 2

8 8

76

55 30

91 179 A lso secure cover plat e 27.460 with one of th e ma chine screws 27.400.

91 180 Pull two O -rings 27.430 on to t he int ake shoulder o f filter 27.420. Secure the filter with 3 m achine screws 27.440. (Wr ench size = Torx socket wrench insert TX 27) (Tighten ing torque = 8 Nm)

91 181 Insert 2 ma gnets 03.090 in the swaged recesses of oil sump 03.010. A tta ch gasket 03.050 to t he ed ge of the oil sump. If necessary, install screw p lugs 03.020 and 03.030 with ne w sealing rings and end cap 03.100 with collar nut 03.110. Various patt erns are in use (with an d withou t connection for oil dipstick). (For tightening torqu es, see Page 6.)

77

91 182 A ttach the oil sump to t he tra nsmission h ousing, using 5 ret aining angles 03.070 and 3 re taining angles 03.060. Secure with 8 he x bolts 03.080. (Wr ench size = 10 mm) (Tighten ing torque = 10 Nm)

91 183 Screw in two han dles 5 X 56 000 090 into convert er 22.020 and insert it carefully.

91 184 Turn the tra nsmission th rou gh 90 degrees.Turn t he converter in either direction until the pump dr ive journals have engaged.

78

5HP18 Repair Manual

Recommend Documents