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INSTALL FILTER
1. Mount filter (compl.).
NOTE: Grease sealing ring (Figure
294).

Figure 294
2. Fasten cover by means of hex. head
screws (mount plain washers).
NOTE: Install new O-rings (Figure
295).
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(16.96 ft lbs).

Figure 295
3. Equip screw plug (1, Figure 296) with new
O-ring and instal it. Mount gasket and
fasten cover plate by means of hex. head
screws (2).
NOTE: Torque limit 6.12 kg•m (44.25 ft
lbs).
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(16.96 ft lbs).

Figure 296
HYDRAULIC PUMP
1. Press needle sleeve in, with reinforced
shell facing press-in tool until contact is
obtained.

Figure 297

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2. Insert outer bearing race until contact is

obtained.

Figure 298
3. Cool pump to about 80°C (176°F). Clean
area of suction and pressure port (1,
Figure 299) again and wet it with Loctite
#262. Assemble and oil O-ring (2).

Figure 299
4. Install two adjusting screws and install
pump until contact is obtained.
NOTE: Pay attention to radial
installation position.

Figure 300
5. Install O-ring (Figure 301) and fasten
pump flange, resp. pump by means of hex.
head screws.
NOTE: Torque limit (M12/8.8) 8.06
kg•m (58.27 ft lbs).

Figure 301

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6. Insert O-ring (Figure 302) into annular

groove of pump flange (power take off) and
oil it. Mount two adjusting screws and
fasten flange by means of hex. head
screws.
NOTE: Torque limit (M14/8.8) 12.75
kg•m (92.20 ft lbs).

Figure 302
DRIVE SHAFT (POWER TAKE-OFF PUMP)
1. Install V-rings (3x) into recess of driver
(internal gearing). Mount fitting key (Figure
303).

Figure 303
2. Adjust gap = 0.50 mm (0.0197 in.) (driver-
drive shaft) Figure 304 thru Figure 308.

Figure 304
3. Assemble disk s = 1.90 mm (0.0748 in.)
and place inner bearing race against
shoulder.

Figure 305

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A. Determine Dimension I from inner

bearing race to end face/driver.
NOTE: Dimension I e.g. 9.60 mm
(0.3780 in.).

Figure 306
B. Determine Dimension II (A - B).
NOTE: Dimension II e.g. 10.60 mm.

Figure 307
EXAMPLE H:

Dimension II 10.60 mm (0.4173 in.)

Dimension I - 9.60 mm (0.3780 in.)
Difference 1.00 mm (0.0394 in.)
Required Gap + 0.50 mm (0.0197 in.)
Gives Shim (S) = 1.50 mm (0.0591 in.)

4. Assemble shim e.g s = 1.50 mm (0.0591

in.) and position driver, resp. inner bearing
race against shoulder.

Figure 308

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5. Attach driver by means of clamping disk

and socket head screw.
NOTE: Insert socket head screw with
Loctite #242.
NOTE: Torque limit (M10/8.8 DIN 6912)
3.26 kg•m (23.60 ft lbs).

Figure 309
6. Press inner bearing race upon collar of
drive gear power take off.

Figure 310
7. Install snap ring (Figure 311) and
assemble drive gear.

Figure 311
8. Install and engage rectangular ring (Figure
312).

Figure 312

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9. Install pre-assembled drive shaft until

contact is obtained.
NOTE: Pay attention to overlapping of
fitting key/fitting key groove.

Figure 313
10. Adjust axial play of drive shaft bearing =
0.0 - 0.05 mm (0.0000 - 0.0020 in.) Figure
314 thru Figure 316).
11. Mount gasket. Mount outer bearing race,
press it uniformly on and determine
Dimension I from mounting face (gasket)
to outer bearing race.
NOTE: Dimension I e.g. 129.55 mm
(5.1004 in.).
NOTE: Apply several measuring points
and determine average.
Figure 314
12. Measure Dimension II from mounting face/
converter bell to contact face/outer bearing
race.
NOTE: Dimension II e.g. 127.43 mm
(5.0169 in.).

Figure 315
NOTE: Shims are available in 0.05 mm
(0.0020 in.) graduation.
13. Insert shim e.g. s = 2.10 mm (0.0827 in.)
and position outer bearing race against
shoulder.

Figure 316

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INPUT - CONVERTER
1. Insert outer bearing race into housing bore
until contact is obtained and install bearing
race, see Figure 317.

Figure 317
2. Install spur gear (Figure 318) starting from
side, with long collar showing, and position
it.

Figure 318
3. Insert both roll pins (Ø 2.50 mm (0.0984
in.) and Ø 1.50 mm (0.0591 in.)) flush-
mounted into bore (Figure 319) of drive
shaft.

Figure 319
4. Cool down drive shaft and install it until
contact is obtained.

Figure 320

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5. Heat inner bearing race and assemble it

until contact is obtained.

Figure 321
6. Place outer bearing race against shoulder.
NOTE: Spur gear bearing must have
free play.

Figure 322
7. Adjust bearing preload of drive gear
bearing 0.00 - 0.07 mm (0.0000 - 0.0028
in.).
8. (Figure 323, EXAMPLE K:
A. Measure Dimension I from mounting
face to outer bearing race.
NOTE: Dimension I e.g. 62.10 mm
(2.4449 in.).

Figure 323
B. Mount gasket (Figure 324) and
determine Dimension II from
mounting face to contact face of
outer bearing race.
NOTE: Dimension II e.g. 60.85 mm
(2.3957 in.).

Figure 324

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EXAMPLE K:

Dimension I 62.10 mm (2.4449 in.)

Dimension II - 60.85 mm (2.3957 in.)
Difference = 1.25 mm (0.0492 in.)
Bearing Preload (0.07 - + 0.05 mm (0.0020 in.)
0.90 mm (0.0028 -
0.0354 in.)) e.g
Gives Shim = 1.30 mm (0.0512 in.)

NOTE: Reassemble of shim, see Figure 328.

9. Insert needle bearing until contact is
obtained Insert shaft seal flush mounted,
with sealing lip showing downward.
NOTE: Wet outer diameter of shaft seal
with sealing compound Loctite
#574. Grease sealing lip.

Figure 325
10. Install two adjusting screws and mount
gasket. Install converter safety valve,
composed of disk, compression spring and
ball (1, Figure 326).
11. Install rectangular ring into annular groove
of drive shaft and engage it (2, Figure
326). Now, grease rectangular ring and
align it centrically.

Figure 326

IMPORTANT
Carry out following steps (Figure 327
thru Figure 330) immediately within
short chronological order.

12. Cool down oil feed flange about - 80°C

(176°F) Clean area of suction and
pressure port (Figure 327) again and wet it
with Loctite #241.
Figure 327

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13. Make shim e.g. s = 1.30 mm (0.0512 in.)

(See EXAMPLE K.). adhere with grease in
bearing bore.

Figure 328
14. Install oil feed flange until contact is
obtained.
NOTE: Pay attention to radial
installation position.

Figure 329
15. Mount gasket (Figure 330) and install
bearing cover.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (33.93 ft lbs).
NOTE: Pay attention to radial
installation position.

Figure 330
16. Insert roll pin until contact is obtained.

Figure 331

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17. Install converter pressure valve. Install

temperature sensor (1, Figure 332) and
screw plug (2).
NOTE: Install new O-ring each time.

Figure 332
18. Heat housing bore (about 120°C (248°F)).

Figure 333
19. Install two adjusting screws and mount
gasket (1, Figure 334) Install converter bell
by means of lifting device until contact is
obtained and fasten it by means of hex.
head screws.
NOTE: Pay attention to radial
installation position. Slight
rotary motions of drive shaft will
facilitate insertion.
NOTE: Torque limit (M8/10.9) 3.47
kg•m (25.08 ft lbs).
NOTE: Torque limit (M12/10.9) 11.73 Figure 334
kg•m (84.82 ft lbs).

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CONVERTER
1. Fasten diaphragms (3x) on converter,
using hex. head screws (mount plain
washer).
NOTE: Insert hex. head screws with
Loctite #243.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (33.93 ft lbs).

Figure 335
2. Install and engage rectangular ring (Figure
336). Now, grease rectangular and align it
centrically.

Figure 336
3. Install converter by means of lifting drive
until contact is obtained.

Figure 337
4. Tilt transmission 90°. Install breather
(Figure 338) Insert pot flush mounted to
housing surface.
NOTE: Wet sealing surface with Loctite
#262.

Figure 338

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5. Equip screw plug (1 and 2, Figure 339)

with new O-rings and install them. Install
both fixing plates (3).
NOTE: Torque limit (screw plug M42x2)
14.79 kg•m (106.95 ft lbs).
NOTE: Torque limit (M16/8.8) 19.88
kg•m (143.82 ft lbs).

Figure 339
MOUNT HYDRAULIC CONTROL UNIT
(HSG-94)
1. Pre-assemble and mount plate (Figure 340
thru Figure 344).
2. Equip fittings (1 thru 6, Figure 340) with
new O-rings and install them. Install screw
plug (7 and 8).
NOTE: Install new O-rings each time.

Figure 340
3. Install two adjusting screws (M6) and
mount housing gasket.
NOTE: At the following steps (Figure
341 thru Figure 345) pay
attention to installation position
of different gaskets.

Figure 341
4. Mount intermediate plate.

Figure 342

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5. Mount 2nd gasket.

Figure 343
6. Mount plate and fasten it uniformly by
means of socket head screws.
NOTE: Torque limit 2.35 kg•m (16.96 ft
lbs).

Figure 344
7. Mount gasket.

Figure 345
8. Assemble complete control unit and fasten
it uniformly by means of socket head
screws (2x M6 x 105 and 21 x M6 x 80
mm)
NOTE: Pay attention to position of two
socket head screws M6 x 105,
see Figure 346.
NOTE: Torque limit 9.50 kg•m (68.71 ft
lbs).

Figure 346

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9. Install pressure lines according to following

draft.

IMPORTANT
The arrangement of lines is different
according to the Version. In this
connection, pay attention to the
Perspective Illustration in the
corresponding Spare-Parts List.

Reference
Description
Number
KV Hydraulic Line Clutch
KV
KR Hydraulic Line Clutch
KR
K1 Hydraulic Line Clutch
K1
K2 Hydraulic Line Clutch
K2
K3 Hydraulic Line Clutch
K3
K4 Hydraulic Line Clutch Figure 347
K4
S1 Lubricating Oil Line
Clutch KR/K2
S2 Lubricating Oil Line
Clutch K4/K3

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INDUCTIVE TRANSMITTER AND SPEED

SENSOR
1. The following illustrations show installation
position of single inductive transmitters
and speed sensor.

Reference
Description
Number
5 Inductive
Transmission N-
central Gear Train
9 Inductive
Transmission N-
engine
14 Inductive
Transmission N-
turbine
13 Speed Sensor N-
output and
Speedometer
Figure 348

Figure 349

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SETTING INDUCTIVE TRANSMITTER

1. The following illustrations describe the reassembly, resp. the setting of the Inductive transmitter N
engine (9, Figure 348). The reassembly of the Inductive transmitter N turbine (14) and N central gear
train (5) has to be carried out accordingly.

IMPORTANT
Pay attention to different setting dimensions. Setting dimension corresponds to distance
between contact face-Inductive transmitter and tooth tip, see Figure 350.

2. Setting dimensions - Inductive transmitter

N engine (9, Figure 348) and n turbine (14,
Figure 348) = 0.03 - 0.08 mm (0.0012 -
0.0031 in.).
3. Setting dimension - Inductive transmitter N
central gear train (5, Figure 348) = 0.03 -
0.04 mm (0.0012 - 0.0016 in.).

Figure 350
4. Turn counting disk radially until one tooth
tip is situated centrally to inductive
transmitter hole.
5. Insert measuring pin (S) until end face has
got contact on tooth tip, resp. the snap ring
on screw - in face of housing.

Figure 351
6. Remove measuring pin and measure
Dimension I from end face/measuring pin
to snap ring.
NOTE: Dimension I e.g. 30.10 mm
(1.1850 in.).
7. Measure Dimension II from contact face-
inductive transmitter to contact face.
NOTE: Dimension II e.g. 30.00 mm
(1.1811 in.).

Figure 352

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EXAMPLE L:

Dimension I 30.10 mm (1.1850 in.)

Required Gap (0.03 - 0.08 - 0.60 mm (0.0236 in.)
mm (0.0012 - 0.0031 in.)) e.g
Gives Installation Dimension = 29.50 mm (1.1614 in.)

EXAMPLE L:

Dimension II 30.00 mm (1.1811 in.)

Installation Dimension - 29.50 mm (1.1614 in.)
Difference = Shim = 0.50 mm (0.0197 in.)

8. Assemble corresponding shim and wet

thread (Figure 353) with Loctite #574.

Figure 353
9. Install inductive transmitter N engine
(9Figure 354), N turbine (14) and N central
gear train (5).
NOTE: Torque limit 3.06 kg•m (22.13 ft
lbs).
10. Now, install screw plugs (Figure 354).
NOTE: Equip screw plugs with new O-
ring.
NOTE: Torque limit (M26x1.5) 8.16
kg•m (59.0 ft lbs).
NOTE: Torque limit (M18 x 1.5) 5.10 Figure 354
kg•m (36.88 ft lbs).

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SPEED SENSOR (HALL SENSOR) N

OUTPUT AND SPEEDOMETER
1. Illustration on right shows speed sensor
13.

Reference
Description
Number
1 Speed Sensor
2 Plate
3 O-ring

Figure 355
2. Grease O-ring and fasten speed sensor
(Figure 356) by means of socket head
screw.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(16.96 ft lbs).

IMPORTANT
Prior to putting transmission into
service, carry out oil filling according
to Operation and Maintenance
Manual. Figure 356

3. Setting dimension - speed sensor = 1.0 -

1.5 mm (0.0394 - 0.0591 in.).

Figure 357

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