RepAnltg ZF Stufe - 3

REPAIR MANUAL
009396
HP 502 / HP 592 / HP 602

Stage 3
4149 751 602
Subject to alterations in design
Copyright by ZF
This repair manual is protected by copyright. Any reproduction and dissemination in whatever
form – also in adapted, paraphrased or extracted form, in particular as a reprint, photomechanical or
electronic reproduction or as a storage in data-processing equipment or data networks – without approval
by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law.
Printed in Germany
Edition:: 2000-05
4149 751 602

HP 502 / HP 592 / HP 602 Table of Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Work Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Expendable Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cross-section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spring Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 Assembly Stand - Insert and Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Assembly Stand - Insert Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Assembly Stand - Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2 Retarder Accumulator - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Retarder Accumulator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Retarder Accumulator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Retarder Accumulator - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Retarder Accumulator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3 Heat Exchanger - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Heat Exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Heat Exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Converter - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Converter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Converter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.1 Converter End Play - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.2 Converter Installation Dimension - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.1 ZFW 380-30 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.2 ZFW 360-10 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.3.3 Stator - Dismantle (ZFW 380-30 and ZFW 360-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.3.4 Stator - Assemble (ZFW 380-30 and ZFW 360-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.3.5 Turbine Wheel and Circuit Cover on ZFW 380-30 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.3.6 Circuit Cover and Turbine Wheel on ZFW 380-30 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.3.7 Turbine Wheel and Circuit Cover on ZFW 360-10 Converter - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.3.8 Circuit Cover and Turbine Wheel on ZFW 360-10 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.4 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.4.1 ZFW 380-30 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.4.2 Axial Bearing End Play on ZFW 380-30 Converter - Measure and Adjust . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.4.3 ZFW 360-10 Converter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4.4.4 Axial Bearing End Play on ZFW 360-10 Converter - Measure and Adjust . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.5 Converter Leak-Tightness - Check (ZFW 380-30 and ZFW 360-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Table of Contents HP 502 / HP 592 / HP 602
Page
5 Cover Plate - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Cover Plate - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Cover Plate - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
6 Oil Pan - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Oil Pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Oil Pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
7 Inductive Pickup - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Inductive Pickup - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Inductive Pickup - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
8 Hydraulic Control Unit - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Control Unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Hydraulic Control Unit - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Oil Level Indicator - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3.1 Oil Level Indicator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3.2 Oil Level Indicator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.4 Hydraulic Control Unit - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.4.1 Throttle Pressure Valve - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.4.2 Throttle Pressure Valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.4.3 Valve Block F2 - Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.4.4 Valve Block for Brake "F" and Clutch "WK", "C" and "A" - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.4.5 Valve Block for Clutch "B", Brake "E" and "D" - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.5 Hydraulic Control Unit - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.5.1 Valve Block for Brake "F" and Clutch "WK", "C" and "A" - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.5.2 Valve Block for Clutch "B", Brake "E" and "D" - Assemble
Hydraulic Control Unit - Assemble (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
9 Retarder Valve - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Retarder Valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Retarder Valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10 Output Cover - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.1 Output Cover/Inductive Pickup - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1.1Inductive Pickup - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Output Cover - Remove (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2 Output Cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.1Sun Gear End Play - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.3 Output Cover - Dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
10.4 Output Cover - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.4.1Tapered Roller Bearing - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.4.2Brake "F" Disc Play - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
HP 502 / HP 592 / HP 602 Table of Contents
Page
11 Mechanical Transmission Section - Remove and Install ................................................................... 11-1

11.1 Mechanical Transmission Section - Remove ......................................................................................... 11-1
11.1.1 Planetary Carrier II - Dismantle; Version HP 502 / 592.......................................................................... 11-5
11.1.2 Planetary Carrier II - Assemble; Version HP 502 / 592 .......................................................................... 11-9
11.1.3 Planetary Carrier I - Dismantle; Version HP 502 / 592 .......................................................................... 11-13
11.1.4 Planetary Carrier I - Assemble; Version HP 502 / 592 ........................................................................... 11-15
11.2 Mechanical Transmission Section - Dismantle; Version HP 592 / 602 .................................................. 11-19
11.2.1 Planetary Carrier II - Dismantle; Version HP 592 / 602.......................................................................... 11-25
11.2.2 Planetary Carrier II - Assemble; Version HP 592 / 602 .......................................................................... 11-26
11.2.3 Planetary Carrier I - Dismantle; Version HP 592 / 602 .......................................................................... 11-29
11.2.4 Planetary Carrier I - Assemble; Version HP 592 / 602 ........................................................................... 11-30
11.2.5 Planetary Carrier II and I - Assemble; Version HP 592 / 602 ................................................................. 11-33
11.2.6 E Piston and Disc Carrier - Remove ....................................................................................................... 11-37
11.2.7 Sun Gear - Remove from Disc Carrier; Version HP 502 / 592 ............................................................... 11-39
11.2.8 Sun Gear - Install in Disc Carrier; Version HP 502 / 592 ....................................................................... 11-39
11.2.9 Sun Gear - Remove from Disc Carrier; Version HP 592 / 602 ............................................................... 11-40
11.2.10Sun Gear - Install in Disc Carrier; Version HP 592 / 602 ....................................................................... 11-40
11.2.11Hollow Shaft/Input Shaft - Remove ....................................................................................................... 11-41
11.3 Mechanical Transmission Section - Install ............................................................................................ 11-43
12 Control Unit - Remove and Install, Dismantle and Assemble ........................................................... 12-1
12.1 Control Unit - Remove ........................................................................................................................... 12-1
12.2 Control Unit - Install .............................................................................................................................. 12-3
12.3 Control Unit - Dismantle ........................................................................................................................ 12-7
12.3.1 Control Insert - Dismantle ...................................................................................................................... 12-9
12.3.2 Control Insert - Assemble ...................................................................................................................... 12-21
12.3.3 Clutch Carrier - Dismantle ..................................................................................................................... 12-35
12.3.4 Clutch Carrier - Assemble ...................................................................................................................... 12-43
12.3.5 Clutch Carrier Leak-tightness and Function - Check ............................................................................. 12-57
12.4 Control Unit - Assemble ......................................................................................................................... 12-59
13 D Brake - Remove and Install ............................................................................................................. 13-1

13.1 D Brake - Remove .................................................................................................................................. 13-1
13.2 D-Brake - Install ..................................................................................................................................... 13-3
Preface HP 502 / HP 592 / HP 602
This manual is intended for skilled personnel who have

been trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.
This manual deals with the standard ZF product in

accordance with the state of development on the date
of issue.
However, due to continuing development of the product,

repair work might require work practices and test or
adjustment data which are not contained in this manual.
We therefore recommend that work done on your ZF
product is carried out only by skilled mechanics who
have had their practical and theoretical knowledge upda-
ted on a regular basis at our After-Sales Service training
courses.
Service points equipped by ZF Friedrichshafen AG all

over the world offer you:
1. Well-trained personnel
2. Specified equipment, e.g. special tools
3. Genuine ZF spares, to our latest specifications
All work performed at these service points is carried out

conscientiously and with care.
Repair work carried out at ZF service points is

guaranteed in accordance with the prevailing
contractual conditions.
Damage resulting from work performed by non-ZF

ZF FRIEDRICHSHAFEN AG personnel in an improper and unprofessional manner,
Division Comm. Vehicle/Special Transmissions together with follow-on costs caused by such work, is
Service Werk 2 excluded from the contractual guarantee agreement.
Tel.: (0 75 41) 77-0 This also applies where genuine ZF spares have not
Fax: (0 75 41) 77-5726 been used.
6
HP 502 / HP 592 / HP 602 Important Information
SAFETY NOTICE GENERAL INFORMATION
Companies who repair ZF units are responsible for their Read this manual carefully before starting any tests or
own work safety. repair work.
To avoid injury to personnel and damage to pro-

ducts, all safety regulations and legal requirements CAUTION
which apply to repair and maintenance work must Pictures, drawings and components do not always
be adhered to. represent the original object, but are used to illustrate
Before starting work, mechanics must familiarize working procedures.
themselves with these regulations. Pictures, drawings and components are not to scale
and no information about size and weight should be
Personnel required to carry out repairs on ZF products inferred (even within a complete illustration).
must receive appropriate training in advance. It is the Always follow the working steps as described in the
responsibility of each company to ensure that their text.
repair staff is properly trained.
After completion of repair work and testing, skilled staff

must satisfy themselves that the product is functioning
The following safety instructions appear in this correctly.
manual:
! THREATS TO THE ENVIRONMENT !

NOTE Lubricants and cleaning agents must not be allowed
Refers to special processes, techniques, data, use to enter the soil, ground water or sewage system.
of auxiliary equipment, etc. • Ask your local environment agency for
safety information on the relevant products
and adhere to their requirements.
CAUTION • Collect used oil in a suitably large container.
This is used when incorrect, unprofessional • Dispose of used oil, dirty filters, lubricants
working practices could damage the product. and cleaning agents in accordance with
environmental protection guidelines.
• When working with lubricants and cleaning
! DANGER agents, always refer to the manufacturer’s
This is used when lack of care could lead to instructions.
personal injury or death.
CAUTION
The transmission must NOT be hung on the
input shaft NOR on the output flange.
7
Repair Instructions HP 502 / HP 592 / HP 602
In any cases of doubt always turn to the the relevant GASKETS, LOCKING PLATES
department within ZF After-Sales Services for
advice. Parts which cannot be removed without being damaged
must always be replaced with new parts (e.g. gaskets
and locking plates).
After removing the transmission from the vehicle, clean
thoroughly before opening.
Pay particular attention to the corners and angles of
housings and covers when cleaning. SHAFT SEALS
Parts held on with Loctite can be slightly loosened if
warmed with a hot air blower. Always renew shaft seals with rough, ripped or
hardened packing washers. Seal contact surfaces must
be totally clean and in perfect condition.
CLEANING PARTS
Remove the old remains of gaskets from mating faces. REWORKING

Carefully remove burrs or other similar patches of
roughness using an oil-stone Rework may only be carried out on the seal contact
surfaces using plunge-cut grinding, never use an emery
Lube bores and grooves must be free of anti-corrosion cloth. Ensure that there are no grinding traces or rifling
agents and foreign matter, check that they can move from grinding.
without encountering any problems.
If rework is needed on spacer washers, shims etc. becau-
Carefully cover opened transmissions to prevent the se of clearance settings, ensure that the reworked areas
entry of foreign matter. contain no face runout and have the same surface quali-
ty.
REUSING PARTS
TRANSMISSION ASSEMBLY
Parts such as ball or roller bearings, multi-discs, thrust
washers etc., must be inspected by a competent person, Find a clean site to assemble the transmission. Gaskets
who should decide whether or not they can be re-used. are installed without the use of sealing compound or
Replace parts which are damaged or have suffered from grease. When measuring silicon-coated gaskets, take
excessive wear. care not to include the silicon layer in the measure-
ment.
During assembly, comply with all adjustment data,
checking data and tightening torques in the Repair
Manual.
8
HP 502 / HP 592 / HP 602 Repair Instructions
BEARINGS d) Duo shaft seals have two packing

washers. The dust-proof packing
If the bearings are fitted while hot, these should be washer (X) must face outwards.
warmed up accordingly (e.g. in a heating cabinet). X
The temperature should be approx. 85 °C and may not e) Fill the gap between the packing
exceed 120 °C. All bearings must be coated with trans- washers so it is 60% filled with grease (use a grease
mission oil after assembly. e.g. produced by Aral such as Aralub HL2 or by
DEA such as Spectron FO 20).
f) If possible, heat shaft seal bores to between 40 and

50°C (this makes fitting easier). Press in the shaft
SEALING seal to the correct depth using a punch or suitable
plate and make sure the seal remains flat.
If a sealing agent* is to be used for carrying out sealing,
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces and
spread evenly. Do not allow sealing agent to enter oil LOCKING AGENTS
ducts and bores. On oil-carrying ducts and bores, wipe
off the sealing agent on the surfaces to be sealed near Locking agents* may only be used in places as
apertures to ensure that no sealing agent penetrates the specified in the parts list.
oil feeds when the surfaces are sealed. Always comply with manufacturer’s directions for use
when using locking agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
SHAFT SEALS
a) Apply a light coat of sealing agent on outer edge of TRANSMISSION OIL

shaft seals with “steel surround”.
After completing repairs, fill the transmission with
b) Never apply sealing agent to shaft seals with transmission oil. For the procedure and approved oils,
“rubber surround” but apply a thin coat of Vaseline refer to the transmission operating manual and List of
8420 to the outer edge or wet with a lubricant, e.g. a Lubricants TE-ML (refer to identification plate) which
water-soluble, concentrated washing-up liquid (e.g. are available from any ZF After-Sales Service center.
Pril, Coin, Palmolive). After filling the transmission with oil, tighten the screw
plugs at the oil filling point and the oil overflow to the
c) Shaft seals with steel and rubber surrounds should be specified torques.
treated on the outer edge of the rubber surround as
described above in section b).
* refer to expendable material
9
Tightening Torques HP 502 / HP 592 / HP 602
Tightening torques for nuts and bolts, extract from

ZFN 148
This Standard applies to bolts to DIN 912, DIN 931, Surface condition of bolts: heat-treated blackened
DIN 933, DIN 960, DIN 961 and nuts to DIN 934. finish and oiled or galvanized and oiled or galvanized,
This Standard contains data on tightening torques (MA) chrome-plated and oiled.
for bolts in strength categories 8.8, 10.9 and 12.9 and
nuts in strength categories 8, 10 and 12. Bolts must be tightened using a calibrated ratchet or tor-
que wrench.
NOTE
Divergent tightening torques are listed separately in the
Repair Manual.
Metric coarse pitch thread Metric coarse pitch thread
Size Tightening torque Size Tightening torque

MA (Nm) for MA (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M 4 2,8 4,1 4,8 M 8x1 24 36 43

M 5 5,5 8,1 9,5 M 9x1 36 53 62
M 6 9,5 14 16,5 M 10 x 1 52 76 89
M 7 15 23 28 M 10 x 1,25 49 72 84
M 8 23 34 40 M 12 x 1,25 87 125 150
M 10 46 68 79 M 12 x 1,5 83 122 145
M 12 79 115 135 M 14 x 1,5 135 200 235

M 14 125 185 215 M 16 x 1,5 205 300 360
M 16 195 280 330 M 18 x 1,5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490

M 20 390 560 650 M 20 x 1,5 430 620 720
M 22 530 750 880 M 22 x 1,5 580 820 960
M 24 670 960 1100 M 24 x 1,5 760 1100 1250

M 27 1000 1400 1650 M 24 x 2 730 1050 1200
M 30 1350 1900 2250 M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800

M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
Edition: August 1991 / checked 1997
10
HP 502 / HP 592 / HP 602 Tightening Torques
Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643
The screw plug tightening torques MA were determined The tightening torques MA were determined for
according to DIN 7604, for screwing into steel, grey screwing into steel, grey cast and aluminium alloys.
cast, and aluminium alloys. The values are based on experience and are inten-
The values are based on experience, and are ded as reference values for the mechanic.
intended as reference values for the mechanic.
The values for the tightening torque MA shall also be General rule: screw/bolt class 5, ZFN 148-1
used for screw plugs according to DIN 908 and Material 9SMnPb28K acc. to DIN 1651
DIN 910, as the thread geometries are almost identical. Surface conditions: as manufactured
General rule: Screw/bolt class 5, ZFN 148-1 (without surface protection) and lightly
Screw/bolt material: steel acc. to oiled or galvanized, chromated and
DIN 7604. Surface condition: as manu- lightly oiled
factured (without surface protection) and
lightly oiled or galvanized, chromated
and lightly oiled
Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)
Dimensions Tightening torque Pipe Thread Tightening-

screwed into outer torque MA
steel/grey cast Al alloy diameter in Nm
M 8x1 20 10 4-5 M8x1 30
M 10 x 1 25 / 30* 15 / 20*
M 12 x 1.5 35 25 6 M 10 x 1 35
M 14 x 1.5 35 25
M 16 x 1.5 40 30 8 M 12 x 1.5 40
M 18 x 1.5 50 35
M 20 x 1.5 55 45 10 M 14 x 1.5 40
M 22 x 1.5 60 / 80* 50 / 65*
M 24 x 1.5 70 60 12 M 16 x 1.5 45
M 26 x 1.5 80 / 105* 70 / 90*
M 27 x 2 80 70 15 M 18 x 1.5 50
M 30 x 1.5 100 / 130* 90 / 130*
M 30 x 2 95 85 18 M 22 x 1.5 60
M 33 x 2 120 110
M 36 x 1.5 130 115 22 M 26 x 1.5 90
M 38 x 1.5 140 120
M 42 x 1.5 150 130 28 M 30 x 1.5 130
M 42 x 2 145 125
M 45 x 1.5 160 140 35 M 38 x 1.5 140
M 45 x 2 150 130
M 48 x 1.5 170 145
M 48 x 2 160 135
M 52 x 1.5 180 150
M 60 x 2 195 165
M 64 x 2 205 175
* DIN 7604 Form C
Status October 1995
11
Expendable Material HP 502 / HP 592 / HP 602
Description Name Approx. Application Remarks

ZF reference no. quantity
Grease For example:

0750 199 001 Spectron FO 20 Gen. assembly aid
Sealing compound WEVO-L100

0666 790 017 Output flange screw connection
Jointing compound Loctite no.: 648 1g Threaded bush on

0666 690 048 transmission housing
Sealing band Elring Pife / 300 mm

0634 307 728 sold by the meter Oil fill pipe Ecomat 2 transm.
Surface sealer Loctite no.: 574 80 mm3 Slotted nut on

0666 790 033 oil fill pipe
Grease Vaseline 8420

0671 190 016 Gen. assembly aid
Operating oil See TE-ML14

List of lubricants Gen. assembly aid
NOTE: Inquire about the size of bundles that can be delivered before placing any orders!
12
HP 502 / HP 592 / HP 602 Cross-section
ZF Ecomat 2 transmission,
4-speed version
1 2 4 5 6 7 9 10 11 12 13
013468
26 25 24 23 22 21 20 19 18 17 16 15 14
013468
Key to drawing
1 Input 15 Inductive pickup “output”

2 Cover plate 16 Brake “F”
4 Control insert 17 Brake “E”
5 Oil feed flange 18 Brake “D”
6 Clutch “A” 19 Shift control
7 Clutch “B” 20 Inductive pickup “turbine”
9 Housing 21 Oil pan
10 Planet gear set I 22 Retarder
11 Planet gear set II 23 Primary pump
12 Planet gear set III 24 Converter
13 Speedo sensor 25 Torque converter and clutch “WK”
14 Output 26 Turbine shaft
13
Cross-section HP 502 / HP 592 / HP 602
ZF Ecomat 2 transmission,
5 & 6-speed version
1 2 4 5 6 7 8 9 10 11 12 13
013467
26 25 24 23 22 21 20 19 18 17 16 15 14
013467
Key to drawing
1 Input
2 Cover plate 15 Inductive pickup “output”
4 Control insert 16 Brake “F”
5 Oil feed flange 17 Brake “E”
6 Clutch “A” 18 Brake “D”
7 Clutch “B” 19 Shift control
8 Clutch “C” 20 Inductive pickup “turbine”
9 Housing 21 Oil pan
10 Planet gear set I 22 Retarder
11 Planet gear set II 23 Primary pump
12 Planet gear set III 24 Converter
13 Speedo sensor 25 Torque converter and clutch “WK”
14 Output 26 Turbine shaft
14
HP 502 / HP 592 / HP 602 Adjustment Data
Designation Dimension Measuring device Comments
Converter
01. Converter installation 2.81 ± 0.02" Depth gauge Installation dimensions

dimension (71.25 ± 0.5 mm) measured between flange
(depending on version) 3.01 ± 0.02" surface on converter and
(77.00 ± 0.5 mm) flange surface on transmis-
3.20 ± 0.02" sion housing. Installation
(81.25 ± 0.5 mm) dimensions can be adjusted
3.40 ± 0.02" using one or more spacer
(86.25 ± 0.5 mm) rings on stator hollow shaft.
02. Converter end play bet- Between Depth gauge End play can be adjusted
ween end face of conver- 0.01 and 0.016" using shim on end face of
ter internal sprag race and (0.3 and 0.4 mm) turbine shaft.
spacer ring on stator hol-
low shaft
03. Disc play of converter Between Feeler gauge Disc play is measured bet-
lock-up clutch 0.02 and 0.043" ween end disc and inner
(0.5 and 1.1 mm) disc.
04. End play on axial bearing Between Measuring bars and Adjusted using shims bet-
in converter 0.004 and 0.01" depth gauge ween housing and turbine
(0.1 and 0.3 mm) wheel flange.
05. Maximum pressure for 36 + 7 psi Forcing device 1X56 Converter test is performed
testing converter for leaks (2.5 + 0.5 bar) 137 129, compressed using air under water.
air unit 1X56 137 130
and water container
06. Tightening torque of Torque wrench

socket head screws on
converter
HP 502 / HP 592 (M8) = 26 ft-lbs (35 Nm)
HP 592 / HP 602 (M10) = 48 ft-lbs (65 Nm)
07. Tightening torque of M16 Between Torque wrench Use counter-support

socket head screw in 133 and 140 ft-lbs and locking device 1X56 137 658 to hold
turbine shaft (180and 190 Nm) 1X56 137 158 converter.
08. Tightening torque of Between Torque wrench Fit copper sealing ring. Use
M33x2 screw plug in 140 and 155 ft-lbs counter-support
converter (190 and 210 Nm) 1X56 137 658 to hold
converter.
09. Tightening torque of 50 ft-lbs (68 Nm) Torque wrench Only ZFW 380-30 converter.
M10x35 hex bolts
15
Adjustment Data HP 502 / HP 592 / HP 602
Output
10. Distance between output Between Depth gauge, measu- Distance can be adjusted
inductive pickup and end 0.02 and 0.027" ring rod 1X56 138 149/ using shims.
face gearing on planetary (0.5 and 0.7 mm) 1X56 138 150
carrier
11. Tightening torque of M6 7 ft-lbs (9.5 Nm) Torque wrench Do not exceed value.
mounting bolt for induc-
tive pickup
12. Distance between speed- Between Depth gauge Clearance is set, do not
ometer pulse generator 0.027 and 0.054" exceed value.
and toothed ring on output (0.7 and 1.4 mm)
13. Tightening torque of 26 ft-lbs (35 Nm) Torque wrench Do not exceed value.
speedo pulse generator
14. Installation dimensions of 0.60 -0.04" Depth gauge Installation dimensions bet-
shaft seal in output cover (15 -1 mm) ween end face of taper roller
bearing inner race and front
face of sealing ring can be
adjusted using special tool
1X56 136 824. Check again
as part of monitoring operat.
15. Preload of taper roller Between Adjuster Set to 1.8 - 6.4 Nm roll tor-
bearing in output cover 0.002 and 0.006" 1P01 136 816, dial que of taper roller bearing.
when cold (approx. 20 ºC) (0.05 and 0.15 mm) gauge and spring Adjusted using spacer was-
preload balance hers. Difference between
speedometer worm and set-
1.3 ft-lbs to 4.7 ft-lbs ting ring = dimension “C”.
(1.8 - 6.4 Nm) Thickness "S" of spacer was-
Roll torque her = C + 0.05 mm.
16. Total end play between Between Measuring bars and Adjusted using shims on
sun gear and output 0.02 and 0.03" depth gauge output.
(0.6 and 0,8 mm)
17. Installation dimensions of 0.10 + 0.04" Depth gauge Measured between thrust
needle bearing in planet (2.5 +1 mm) surface of shim and end face
carrier III of needle bearing. Correct
installation assured if special
tool 1X56 137 101 is used.
16
18. End play on planet Between Feeler gauge Clearance is set, check
gears in planetary carrier 0.02 and 0.05" again as part of monitoring
III (0.5 and 1.2 mm) operation.
19. Tightening torque of M6 Between Torque wrench

studs on output cover 3.7 and 5.6 ft-lbs
(5 and 7.5 Nm)
20. Tightening torque of M6 5 ft-lbs Torque wrench Do not exceed specified

hex bolts on output cover (6 Nm) value.
21. Tightening torque of M12 44 ft-lbs Torque wrench Secure with locking plate.
hex bolts on output flange (60 Nm) Use special tool
1X56 136 471.
Control unit
22. Displacement quantities approx. 18.5 gal/min Graduated vessel and Measured at pump speed n =
of primary pump tested (60 l/min) stopwatch 1500 rpm. Use SAE 10 W
separately (theoretical oil at 80 ºC. The primary
value) pump is a single-piece part.
23. Distance between spring 0.06 + 0.02" Sliding gauge Adjusted by removing or fit-
guide and stator ring guide (1.6 + 0.5 mm) ting disc springs. Measure-
pin ments are taken without pre-
tensioning the disc springs.
Clutch carrier
24. Pressure test (PÜ) for 36 + 7 psi Feed bush Pressure test for leakage:
pistons of clutches “A”, (2.5 + 0.5 bar) 1X56 137 128, Pressure drop of 36 + 7 psi
“B” and “C” compressed air unit to 20 psi (2.5 + 0.5 bar to 1.4
1X56 137 130 bar) after cut-off = 10 sec.
25. Disc play on clutch “A” Between Depth gauge Rectify deviations by fitting
0.13 and 0.15" steel discs of appropriate
(3.2 and 3.7 mm) thickness.
(HP 502 / HP 592 /
HP 602)
17
Adjustment Data HP 502 / HP 592 / HP 602n
26. Disc play on clutch “B” Between Feeler gauge Measured by placing
0.06 and 0.082" feeler gauge between end
(1.6 and 2.1 mm) disc and outer disc. Rectify
(HP 502); deviations by fitting steel
0.08 and 0.10" discs of appropriate thick-
(2.0 and 2.5 mm) ness.
(HP 592 / HP 602)
27. Disc play on clutch “C” Between Feeler gauge Measured by placing
0.05 and 0.06" feeler gauge between R gear
(1.2 and 1.7 mm) pot. and outer disc. Rectify
(HP 502); deviations by fitting steel
0.06 and 0.082" discs of appropriate thickn-
(1.6 and 2.1 mm) ess.
(HP 592 / HP 602)
28. Run-out of inductive + 0.008" Dial gauge Measure from the raised
pickup ring when installed (+ 0.2 mm) point on the inductive pickup
ring. Correct by tapping
with plastic-tip hammer
29. Tightening torque of M8 26 ft-lbs Torque wrench

hex bolts on rotor (retar- (35 Nm)
der)
Mechanical transm. section
30. End play of planetary Between 0.02 and 0.05" Feeler gauge End play is fixed, double-
gears in planetary carrier I (0.5 and 1.2 mm) check.
31. Disc play on brake “D” Between Feeler gauge Measure by inserting feeler
0.05 and 0.06" gauge between end disc and
(1.2 and 1.7 mm) outer disc. Correct deviati-
(HP 502); ons by fitting steel discs of
0.06 and 0.082" appropriate thickness.
(1.6 and 2.1 mm)
(HP 592 / HP 602)
32. Installation dimension of 0.16 + 0.04" Depth gauge Measured between thrust
needle bearing in input (4 +1 mm) face of thrust washer and
shaft end face of needle bearing.
If punch 1X56 137 101 is
used, correct installation is
assured
33. End play of planetary Between Feeler gauge End play is fixed, double-
gears in planetary 0.02 and 0.05" check.
carrier III (0.5 and 1.2 mm)
18
34. Disc play on brake “E” Between Feeler gauge Measure by inserting feeler
0.11 and 0.13" gauge betw. sealing ring and
(2.8 and 3.3 mm) outer disc. Correct deviati-
(HP 502 / HP 592 / ons by fitting steel discs of
HP 602) appropriate thickness.
35. Disc play on brake “F” Between Depth gauge Correct deviations by fitting
0.10 and 0.12" steel discs of appropriate
(2.6 and 3.1 mm) thickness.
(HP 502 / HP 592 /
HP 602)
Hydraulic control unit
36. Distance between in- Between Depth gauge, measur- Distance can be adjusted
ductive pickup - turbine 0.02 and 0.03" ing rod 1X56 138 149 using shims.
and pulse generator ring (0.6 and 0.8 mm) und 1X56 138 150
37 Tightening torque of M6 7 ft-lbs (9.5 Nm) Torque wrench

mounting bolt for induc-
tive pickup
Retarder accumulator
38. Tightening torque of M8 Between Torque wrench Only replace stud bolts with
stud bolts on rear cover of 5.6 and 7.4 ft-lbs new ones if damaged.
retarder accumulator (7.5 and 10 Nm)
39. Tightening torque of M8 11 ft-lbs (15 Nm) Torque wrench Fit washers.
lock nuts on retarder accu-
mulator cover
40. Tightening torque of 18 ft-lbs (25 Nm) Torque wrench Fit new copper sealing was-
M12x1.5 screw plug in her.
solenoid valve
19
Adjustment Data HP 502 / HP 592 / HP 602
Other transmission data
41. Installation dimension of 1.57 + 0.04" Depth gauge Measured betw. mating face
oil filler pipe (40 +1.0 mm) of transmission housing (oil
pan flanging face) and end
face of filler pipe.
(Use sealing band on pipe)
42. Tightening torque of approx. 60 ft-lbs Experience Secure slotted nut with Loc-
M30x1.5 slotted nut on oil (80 Nm) tite no. 574.
filler pipe
43. Tightening torque of 37 ft-lbs Torque wrench Fit new copper sealing was-
M22x1.5 oil drain plug in (50 Nm) her
oil pan
44. Tightening torque of 9 ft-lbs Torque wrench Fit new copper sealing was-
M10x1 screw plug on (12 Nm) her
pressure measuring ports
45. Tightening torque of approx. 15 ft-lbs Torque wrench Fit new copper sealing was-
M10x1 union (hollow) (20 Nm) her
screws in cover plate
20
HP 502 / HP 592 / HP 602 Spring Table
Order no. Installation position Number Wire dia- Outer spring Untensioned
of coils meter diameter length
0732 042 113 Control element - 17.50 0.110" 0.61" 2.93"
main pressure valve 2.80 mm 15.66 mm 74.56 mm
0732 042 114 Control element - 11.50 0.118" 0.90" 2.79"

main pressure valve 3.00 mm 22.90 mm 71.14 mm
0732 041 125 Control element - 4.50 0.098" 0.91" 0.89"

lubrication pressure valve 2.50 mm 22.94 mm 22.70 mm
0732 041 102 Control element - 10.50 0.11" 0.736" 2.07"

torque converter press. valve 2.80 mm 18.70 mm 52.60 mm
0732 040 786 Control element - 14.50 0.098" 0.69" 2.65"

cooler changeover valve 2.50 mm 17.54 mm 67.40 mm
0732 041 373 Shift control - 27.50 0.035" 0.21" 1.51"

valve blocks 0.90 mm 5.40 mm 38.40 mm
0732 041 374 Shift control - 13.50 0.051" 0.41" 1.48"

0732 041 148 Shift control - 14.50 0.082" 0.75" 2.49"

0732 041 720 Shift control - 13.75 0.086" 0.76" 2.38"

0732 042 683 Shift control - 12.50 0.062" 0.75" 2.71"

0732 041 095 Shift control - 12.50 0.070" 0.73" 2.63"

0732 041 216 Shift control - 14.00 0.082" 0.75" 2.36"

valve blocks 2.10 mm 19.19 mm 60.10±0,5 mm
0732 041 199 Shift control - 13.50 0.070" 0.74" 2.87"

0732 041 381 Shift control - 6.00 0.088" 0.77" 1.138"

torque converter valve 2.25 mm 19.65 mm 28.90 mm
0732 042 613 Shift control - 25.50 0.049" 0.281" 2.061"

valve block F2 1.25 mm 7.16 mm 52.36 mm
0732 042 274 ZF torque converter 380-30 6.50 0.063" 0.546" 0.939"
1.60 mm 13.87 mm 25.13 mm
21
Spring Table HP 502 / HP 592 / HP 602
Order no. Installation position Number Wire dia- Outer spring Untensioned
of coils meter diameter length
0732 041 934 Retarder - stator ring 13.50 0.055" 0.643" 2.212"
1.40 mm 16.35 mm 56.20 mm
1204 318 011 Retarder - control valve 5.00 0.082" 1.20" 1.496"
2.10 mm 30.50 mm 38.00 mm
0732 042 471 Disc brake “D” 11.50 0.062" 0.417" 1.284"
1.60 mm 10.59 mm 32.62 mm
0732 042 334 Disc brake “E” 22.50 0.062" 0.33" 4.84"
1.50 mm 8.96 mm 62.36 mm
0732 042 259 Disc brake “F” 11.50 0.075" 0.387" 1.421"
1.90 mm 9.8 mm4 36.10 mm
0732 041 421 Clutch carrier, 24.50 0.078" 0.456" 3.114"

Reverse gear pot 2.00 mm 11.60 mm 79.10 mm
22
HP 502 / HP 592 / HP 602 Special Tools
Fig. Diagram Order no. Application Quan- Comments

no. tity
1X56 097 775 2
Assembly hook
1 for lifting planet carrier
out of housing
1X56 122 205 1
Internal extractor / puller

2 for needle bearing (18 x 24 x 16) in
planet carrier II and in input shaft
(in conjunction with 1X56 122 227)
1X56 122 208 1
Internal extractor / puller

conjunction with 1X56 122 227
1X56 122 227 1
Bridge yoke / counter-support

4 in conjunction with internal extractor
1X56 122 205 and 1X56 122 208
1X56 122 306 1
Basic tool
5 in conjunction with gripper
1X56 136 706
23
Special Tools HP 502 / HP 592 / HP 602

no. tity
1X56 122 322 1
Extractor
6 for grooved ball bearing
(0635 331 232) in control element
1X56 124 659 1
Extracting plate
7 for bearing inner race
of stator hollow shaft
1X56 136 260 1
Lifting device
8 for lifting complete output
1X56 136 471 1
Punch
9 for locking plate on output flange
1X56 136 513 1 Available either

Hot air blower 220 Volt as a 220 volt
or version or
10 1X56 137 575 110 volt version
Hot air blower 110 Volt
for heating up various parts
24

no. tity
1X56 136 594 1
Adapter (LH)
11 for securing transmission
(in conjunction with assembly stand
1X56 137 450)
1X56 136 595 1
Adapter (RH)
12 for securing transmission
(in conjunction with assembly stand
1X56 137 450)
1X56 136 605 1 only for

HP 502 / 592
Punch transmission
13 for shaft seal with
(125 x 150 x 10) behind ZFW 360-10
torque converter converter
1X56 136 612 2
M8 hook
14 for lifting control element off the
clutch carrier
1X56 136 706 1
Gripper
15 for taper roller bearing
(0635 370 006) on output
25

no. tity
1X56 136 815 3
Puller
16 for cover plate behind torque
converter
1P01 136 816 1
Adjuster
17 for taper roller bearing on output
1X56 136 818 1
Fixture
18 for oil feed flange to assemble
control element
1X56 136 820 1
Punch
19 for removing bush from stator
hollow shaft
1X56 136 821 2
M8 guide screw
20 for installing control element
and primary pump
26

no. tity
1X56 136 824 1
Punch
21 for radial sealing ring (90 x 125 x 10)
and bearing outer race
on output
1X56 136 862 1
Lifting device
22 for torque converter
1X56 137 101 1
Punch
planet carrier II and in input shaft
1X56 137 103 1
Punch
hub, clutch hub
1X56 137 104 1
Thrust piece / pad

25 for extracting grooved ball bearing
in control element (in conjunction
with 1X56 122 322)
27

no. tity
1X56 137 105 1
Thrust piece / pad

26 for inserting the snap rings
in front of the disc springs of the
A piston
1X56 137 107 1
Device
27 6 13
7 10
7 for inserting spacer ring
1X5
4139 310 018 in control element
1X56 137 108 1
Clamping device
28 for removing and installing the main
and lubrication pressure valve and
converter backpressure valve in con-
trol insert
1X56 137 109 1
Punch
29 for separating clutch carrier
from control insert
1X56 137 126 1
Lifting device
30 for Ecomat transmissions
28

no. tity
1X56 137 127 1
Clamping device
31 for reverse gear pot
1X56 137 128 1
Feed bush
32 for leakage test of clutches in clutch
carrier
1X56 137 129 1
Forcing device
33 for converter leakage test
1X56 137 130 1
Compressed air unit

34 for converter and clutch carrier
leakage test in conjunction with feed
bush 1X56 137 128 and 1X56 137
129
1X56 137 151 1
Caulking tool
35 for punch-marking and caulking the
orifices of the pressure control unit
29

no. tity
1X56 137 152 2
Support
36 for stator bearing
1X56 137 156 1
Caulking tool
37 for knocking out the orifices
1X56 137 158 1
Holding device
38 for loosening and tightening the M16
socket head screw in the converter
1P01 137 173 1
Plug gauge
39 of between 0.7 and 3 mm for
measuring the orifices
1X56 137 213 1
Lifting device
40 for turbine shaft
30

no. tity
1X56 137 273 1
Hexagon socket head insert

41 for socket head screw
on control insert
1X56 137 382 1 only for

HP 592 / 602
Punch transmission
42 for radial sealing ring with
(142 x 162 x 10) behind torque ZFW 380-30
converter converter
1X56 137 388 1 only for HP 602

transmission
Puller
43 for planet carrier II
(in conjunction with 1X56 137 387)
1X56 137 432 1
Puller
44 for forcing the piston ring carrier
off the stator quill shaft
1X56 137 450 1
Assembly stand
45 can be swivelled
31

no. tity
1X56 137 464 1
Support
46 for securing planet gear pins
1X56 137 465 1
Caulking tool
47 for caulking the planet gear pins in
planetary carrier I
1X56 137 466 1
Caulking tool
48 for caulking the planet gear pins in
planetary carrier II and III
1X56 137 658 1
Counter support / bracket brace

49 for loosening and tightening the
screw plug in the converter
1P01 137 906 1
Adjuster
50 for setting NBS (Neutral at bus stop)
32

no. tity
1X56 138 149 1
Measuring rod
51 for measuring distance on inductive
pickup - output. (In conjunction with
test device 1X56 138 150)
1X56 138 150 1
Test device
52 for measuring distance on inductive
pickup - output. (In conjunction with
test device 1X56 138 150)
1X56 150 111 2
M6 threaded pin
53 for control
33
Auxiliary tools for in-house production
Auxiliary drifts for centering the planet gears
ø1
4139 333 041 4139 233 049 / 4139 333 667
ø1 0.9834 - 0.002” 1.1803 - 0.002”

24.98 - 0.05 mm 29.98 - 0.05 mm
ø2 0.5897 - 0.002” 0.7866 - 0.002”
L1
14.98 - 0.05 mm 19.98 - 0.05 mm
L1 3.15” 3.15”
80 mm 80 mm
L2
L2 0.315” 0.315”
ø2 8 mm 8 mm
34
HP 502 / HP 592 / HP 602 Assembly Stand
1 Assembly Stand - Insert and Remove

Transmission
1 2
1.1 Assembly Stand - Insert Transmission
1 Attach adapters 1X56 136 594 and 1X56 136 595

(1/2) to the transmission assembly stand (3).
2 Tighten the M10 hexagon nuts and bolts; 3

4
tightening torque: 46 Nm
3 Undo the hexagon socket head screws (4).

5
4 Adjust the center crossbeam (5) so that the 4
distance “A” is approx. 550 mm.
5 Tighten the hexagon socket head screws (4). 000786
6 Fit lifting device 1X56 137 126 on the output

cover (1).
7 Screw in the four M16x1.5 hexagon bolts;

008385
8 Undo the shackle (1) and insert it into the correct

bore with the ring (2). Fasten the shackle.
2
! DANGER
Insert the shackle carefully. See the instruction plate
on the lifting device.
1
9 Attach the ring (2) to the crane hook. Move the
transmission over the assembly stand, center it bet-
ween the adapters and lower it into the assembly
stand.
008381
1-1
Assembly Stand HP 502 / HP 592 / HP 602
10 Fasten the RH adapter to the transmission.

Screw in the hexagon bolts (1);
1
008382
11 Pivot the LH adapter (1) upwards and fasten

it to the transmission with the M16x1.5
1
hexagon bolts;
12 Remove the crane hook and the lifting device.
13 Unlock the assembly stand and pivot the

transmission into the desired position.
! DANGER
Avoid knocking or hitting the transmission
outside of its axis of rotation.
008383
! DANGER
Stand clear when pivoting the transmission. Always
lock the assembly stand with the pin (1) after pivoting
the transmission. Secure the pin (1) with the tommy 1
nut (2). 2
008384
1-2
HP 502 / HP 592 / HP 602 Assembly Stand
1.2 Assembly Stand - Remove Transmission
1 Fit lifting device 1X56 137 126 on the output

cover. Screw in the four hexagon bolts;
008385
2 Attach the crane hook to the ring (1).
3 Using the lifting device, lift the transmission until

the ring (1) is under slight tension.
!DANGER
Do not lift the assembly stand off the ground.
008386
!DANGER
Secure the LH adapter to stop it swinging down.
4 Unscrew and remove the adapter hexagon bolts.
! DANGER
The transmission may drop slightly. Risk of crushing.
5 Remove the transmission from the assembly

stand.
008387
1-3
1-4
HP 502 / HP 592 / HP 602 Retarder Accumulator
2 Retarder Accumulator - Remove and Install,

Dismantle and Assemble
2.1 Retarder Accumulator - Remove
1 Unscrew and remove both the M8 hexagon bolts

(1).
011583
2 Unscrew and remove the two M8 hexagon bolts

with nuts (2) from the output end of the accumula-
tor.
011584
3 Unscrew and remove the two M8 socket head

screws (1) and remove the accumulator (2).
011587
2-1
Retarder Accumulator HP 502 / HP 592 / HP 602
2-2
2.2 Retarder Accumulator - Install
1 Coat a new O-ring (1) with Vaseline and place it

into the groove on the accumulator.
011588
2 Insert the accumulator. Insert the two M8x25

socket head screws with washers (1) on the input
end.
Tightening torque: 23 Nm.
011587
3 Insert and tighten two M8 hexagon bolts with

washers and M8 nuts (1) on the output end.
011584
2-3
4 Coat a new O-ring (1) with Vaseline and

insert it into the solenoid valve.
008394
5 Insert and tighten the M8x55 hexagon bolts (1).

Tightening torque: 23 Nm
011585
2-4
2.3 Retarder Accumulator - Dismantle
1 Remove the M8 lock nuts (1) and washers.
2 Remove the connection plate (2).
008396
3 Remove the rear cover (1).
4 Slide the complete piston (2) out of the tube

(3).
3
1
008398
5 Slide a suitable tool under the grooved rings (1)

and remove them from the piston. 2
6 Remove the piston guide ring (2) from the

1
piston.
008397
2-5
7 If one of the threaded pins (1) is damaged, use a

bolt drawer or bolt drift to remove it from the rear
cover.
8 Screw in a new threaded pin;

tightening torque: 7.5 to 10 Nm
008399
2-6
2.4 Retarder Accumulator - Assemble

2
NOTE
1
Clean all parts thoroughly before assembly.
Always renew grooved rings, O-rings, piston
guide rings, cap collars etc.
1 Insert the new grooved rings (1) into the piston

groove.
2 Insert the new piston guide ring (2).

1
CAUTION
Insert the grooved rings with the open side facing
outwards.
008400
3 Coat the outside of the piston and the inside

of the tube with grease MIL-G-24 139.
Grease quantity: 2 cc to 4 cc
4 Insert the piston (1) into the tube (2).

2
CAUTION
Take care not to damage the grooved rings when
inserting the piston.
008401
5 Fit a new O-ring (1) onto the rear cover (2)

and coat with Vaseline.
6 Slide the tube (3) and piston onto the rear

cover. 2 3
CAUTION
Slide on the tube with the stamped number on the
piston facing the rear cover.
008402
2-7
7 Coat a new O-ring (1) with Vaseline and fit it on

the connection plate (2).
8 Slide the connection plate (2) onto the

2 1
threaded pins (3).
NOTE
Make sure the shoulder of the connection plate is
facing the bracket on the rear cover.
008403
9 Screw on the M8 lock nuts (1) with washers;

NOTE
Use new lock nuts.
008404
2-8
HP 502 / HP 592 / HP 602 Heat Exchanger
3 Heat Exchanger - Remove and Install
3.1 Heat exchanger - Remove
1 Unscrew and remove the four hexagon bolts (1)

from the heat exchanger bracket.
012364
2 Unscrew and remove the hexagon bolt (1) from

the oil pipe bracket.
NOTE
Hold the M8 lock nut on the rear of the bracket to
stop it from turning. Lay to one side together with
the washers, pipe and bracket.
2
3 Unscrew and remove the seven M8 socket head 1
screws from the fitting (2).
012365
4 Lift the heat exchanger off the transmission com-

plete with the pipes and the fitting.
012366
3-1
Heat Exchanger HP 502 / HP 592 / HP 602
5 Take out the two inserts (1).
012367
6 Take out the two O-rings (1).
012368
7 Remove the gasket from the fitting.
012369
3-2
8 Unscrew and remove the two hexagon bolts (1)

and lay them to one side together with the bracket 2
(2).
012370
9 Use a plastic-tip hammer to knock the fitting (1)

downwards so that it comes off the oil pipes.
2
CAUTION
Do not strike the pipes with the hammer as this could
damage the pipes.
10 Remove the two O-rings (2) from each of the oil

pipes.
1
012371
11 Unscrew and remove the two socket head screws

(1) and lay them to one side together with the
bracket (2).
012372
3-3
12 Lift off the oil pipe (1) and remove the O-rings (2)
from the heat exchanger. 1
13 Unscrew and remove the two hexagon bolts (3)

and lay them to one side together with the bracket.
3
012373
14 Pull out the oil pipe (1) and remove the O-rings
(2).
15 Unscrew and remove the three hexagon bolts (3)

2 3
and lift off the fitting.
012374
16 Unscrew and remove the eight hexagon bolts (1)

and remove the heat exchanger bracket (2).
012375
3-4
3.2 Heat Exchanger - Install
1 Place the heat exchanger bracket (2) on the trans-

mission. Screw in the eight M10x60 hexagon
bolts (1) with washers (Spec List 6030 010 026),
position the bracket horizontally in relation to the
transmission and tighten the bolts.
012375
2 Insert two new O-rings (1) in the groove on the

socket and coat with Vaseline.
3 Fit a new gasket (2) on the heat exchanger

flanging face.
2
012376
4 Attach the fitting (1) as illustrated using three

M8x60 hexagon bolts with washers.
012377
3-5
5 Insert two new O-rings (1) in the grooves on the

pipe and coat with Vaseline.
012374
6 Insert the pipe (1) into the fitting as illustrated. Fit

the bracket (2) using two M8x22 hexagon bolts.
7 Insert the pipe (3) into the fitting.

2
3
012373
8 Fit the bracket (1) using two M8x16 socket head

screws and washers.
01272
3-6
9 Insert two new O-rings (1) in the grooves on each

pipe and coat with Vaseline.
1
012371
10 Align the pipes with the holes in the fitting and

slide the fitting onto the pipes.
CAUTION
Do not strike the pipes with the hammer as this could
damage the pipes.
012378
11 Fit the bracket (1) using two M8x22 hexagon

bolts.
012370
3-7
12 Affix a new gasket to the fitting using Vaseline.
012369
13 Insert two new O-rings (1) in the transmission

holes.
012368
14 Fit the two inserts (1) in the holes as illustrated.
012367
3-8
15 Place the heat exchanger onto the bracket on the

transmission complete with the pipes and the
fitting. Align the fitting with the holes in the
transmission.
NOTE
Make sure the gasket is correctly positioned on the
fitting.
1
16 Insert the seven M8x45 socket head screws into
the fitting (1) and tighten them.
012379
17 Insert the four M10x22 hexagon bolts with

washers (1). Align the heat exchanger with the
holes while doing this.
0121364
18 Mount the bracket (1) as follows:
012365
3-9
19 Insert the M8x55 screw with washer (1) into the

bracket (2). Place the pipe (3) and washer (4) on
the screw (1). Insert the screw into the hole in the
bracket (5) complete with the bracket, pipe and 2
washers. Secure using the M8 lock nut with
washer (6).
Tightening torque: 23 Nm 1
3 4 5 6
012380
3-10
HP 502 / HP 592 / HP 602 Converter
4 Converter - Remove and Install, Dismantle and

Assemble
4.1 Converter - Remove

1
NOTE
Depending on the transmission type, the converter
fitted may be a ZFW 380-30 or a ZFW 360-10 (the
illustration shows a 380-30 converter). The
removal procedure is the same for both converter
types.
1 Rotate the transmission in the assembly stand so

that the converter is facing upwards.
NOTE
Measure and note down the distance "F" (see 012590
4.2.2) before removing the converter.
2 Attach bracket brace 1X56 137 658 (1) to the

converter and the transmission housing.
2
3 Unscrew and remove the screw plug (2).
012381
4 Screw holding device 1X56 137 158 (1) into the

converter circuit cover and tighten it by hand.
NOTE
Make sure the rubber washer is fitted on the
1
holding device thread.
012382
4-1
Converter HP 502 / HP 592 / HP 602
NOTE
It is possible to use ZF mechanical holding device
1X56 136 864 together with hexagon insert 1X56
136 863 instead of the pneumatic holding device.
5 Connect compressed air unit 1X56 137 130 to

holding device 1X56 137 158.
6 Turn the regulator (1) anti-clockwise a few times.

2
7 Open the stopcock (2). The lever must be 1
horizontal.
8 Use the regulator (1) to set a pressure of 1.5 bar.
008427
9 Insert 1/2" socket wrench extension (1) and

undo the socket head screw. 1
NOTE
Use a suitably long grip. The M16 socket head
2
screw is tightened to 190 Nm in the turbine shaft.
10 Close the stopcock.
11 Unscrew and remove holding device 1X56 137

158 (2) from the converter circuit cover.
012592
12 Unscrew the socket head screw (1) and remove it

from the converter.
012383
4-2
13 Screw lifting device 1X56 136 862 into the

converter and tighten it by hand.
14 Remove bracket brace 1X56 137 658.
15 Carefully remove the converter from the

transmission.
NOTE
Before lifting out the converter completely, raise it
to just above the turbine shaft. Then tilt the
converter slightly so that the oil can drain out.
012589
16 Unscrew and remove the lifting device.
17 Turn the converter over and remove the shim(s)

(1) from the converter or from the turbine shaft.
1
! DANGER
The converter weighs approx. 60 kg. Before removing
the lifting device, secure the converter to prevent it
from rolling away.
012384
18 Remove the spacer ring (1) from the stator hollow

shaft.
003 339
003339
4-3
4-4
4.2 Converter - Install
4.2.1 Converter End Play - Measure

converter so that the converter turbine wheel is
clamped tight.
2 Turn the converter over.
!DANGER
The converter weighs approx. 60 kg. Secure the
converter to prevent it from rolling away.
012385
3 Measure the distance "C" between the spur gear

end face and the turbine wheel.
4 Note down distance "C".
012386
5 Measure the distance "B" between the end face of

the spur gear and the end face of the internal sprag
race.
6 Note down distance "B".
012387
4-5
7 Calculate the theoretical distance "D" between the

end face of the internal sprag race and the end
face of the turbine wheel as follows.
C–B=D
Note down distance "D".
D B
C
001580
001580
8 Check the rectangular-section ring (1) for damage.

Renew it if necessary.
9 Align the rectangular-section ring centrally.

NOTE
The rectangular-section ring has hooked ends.
10 Slide the spacer ring (2) onto the stator hollow

shaft so that there is no end play.
2

turbine shaft. 008436
12 Tighten the lifting device by hand until there is no

end play on the turbine shaft.
13 Place a depth gauge in the recess of the lifting

device on the end face of the turbine shaft.
14 Measure the distance "A" between the end face of

the turbine shaft and the spacer ring (1) on the
stator hollow shaft.
1
15 Note down distance "A".
16 Unscrew the lifting device from the turbine shaft.

003 348
003348
4-6
17 Calculate the shim thickness "S" (1).

D –A = E
Distance "E" plus the specified converter end play
(distance "G" = 0.3 to 0.4 mm) gives the required
shim thickness "S" (1). E + 0.3 to 0.4 mm = S
Calculation example:
C = 174.7 mm D = 119.50 mm
– B= 55.2 mm – A = 118.30 mm
D = 119.5 mm E = 1.20 mm
* + G = 0.35 mm
S = 1.55 mm
CAUTION
Distance "G" must be added and not subtracted.
Otherwise the bearings will be damaged!
Shims WTB 0730 005 591 are available in

thicknesses ranging from 2.6 mm to 1.0 mm, in 0.1
to 0.3 mm steps.
NOTE
Thicker shims mean greater play.
18 Thinly coat the shim (1) with grease and affix it.
1
19 Center the shim.
20 Center the rectangular-section ring (2).
21 Thinly coat the contact surface of the sealing ring

(see arrow) with oil.
003 349
003349
4-7

converter.
23 Carefully lower the converter so that it is centered

on the turbine shaft. Fit the converter so that there
is no end play.
012588
24 Loosen lifting device 1X56 136 862 by

unscrewing it a few turns.
CAUTION
Take care not to damage the sealing ring. Ensure the
shim is correctly positioned on the turbine shaft.
NOTE
The turbine shaft and stator hollow shaft splines
must mesh inside the converter. Rotate the
converter slightly if necessary. The gear on the
converter must also mesh with the input gear of
the primary pump.
012589
NOTE
The example illustrated shows the ZFW 360-10
converter.
008440
4-8
4.2.2 Converter Installation Dimension - Measure
1 Make sure the converter is fitted correctly and

without any end play.
2 Measure the distance "F" between the converter

flanging face and the transmission flanging face.
3 Measure the distance at several points around the

edge and calculate the average value.
NOTE
Distance "F" must be X ± 0.5 mm. Ecomat
transmissions can be equipped with different types
of converter. The table below gives the
distance "F" (converter installation dimension) for
each converter type.
012581
ZFW 360-10 ZFW 380-30

X = 71.25 mm Außen Ø
X = 77.00 mm X = 77.00 mm
X = 81.25 mm X = 81.25 mm
X = 86.25 mm
F
F
If the distance "F" is between X + 0.5 mm and

X – 0.5 mm, then the setting is correct.
4 If the distance is less than X – 0.5 mm, fit a

second spacer ring on the stator hollow shaft.
5 If the distance is more than X + 0.5 mm, remove

the spacer ring.
NOTE
The spacer ring is 1 mm thick.
001581
CAUTION
If the distance “F” is changed by adding/removing a
spacer ring on the stator hollow shaft, the shim on the
turbine shaft must also be changed accordingly.
Otherwise the bearings will be damaged!
6 Unscrew and remove lifting device 1X56 136 862

from the converter.
1
7 Screw the M16 socket head screw (1) into the con-
verter
8 Re-check the installation dimension.
012383
4-9
9 Attach brace bracket 1X56 137 658 in the

transmission housing and bolt it to the converter.
10 Screw holding device 1X56 137 158 into the

converter circuit cover and tighten it by hand.
NOTE
Ensure rubber washer is fitted on the holding
device thread.
11 Connect compressed air unit 1X56 137 130 to hol- 2

ding device 1X56 137 158. 1
12 Turn the regulator (1) anti-clockwise a few times.
13 Open the stopcock. Move the lever (2) to the

horizontal position.
008443
15 Insert 1/2" socket wrench extension and tighten

the hexagon socket head screw;
tightening torque: 180 - 190 Nm 4
16 Close the stopcock.
17 Remove holding device 1X56 137 158 (4) from

the converter circuit cover.
012592
18 Fit a new copper sealing washer on the screw plug

(1).
19 Tighten the M33x2 screw plug;

tightening torque: 190 - 210 Nm
1
012381
4-10
4.3 Converter - Dismantle

4.3.1 ZFW 380-30 Converter - Dismantle
1 Place the converter on planks or wooden blocks.
2 Unscrew and remove all the M10 socket head 2

screws (1).
3 Attach the hoisting rope to lifting device 1X56

136 862 and lift the circuit cover (2) off the
impeller using the hoist.
! DANGER 1
The turbine wheel is only held by the bearing seat in
the circuit cover. Only lift the circuit cover as high as
necessary and immediately lay it to one side next to
the impeller. 012385
4 Remove the shim (1), housing disc (2), axial

needle cage (3) and shaft disc (4) from the stator.
CAUTION 1 2 3 4
Do not mix up the bearing assemblies when
installing. The shaft and housing discs must not be
mixed up with any other bearing assemblies. Clearly
mark all the parts.
012390
5 Remove the complete stator from the impeller,

rotate it through 180° and lay it to one side.
6 Remove the shaft disc (1) from the stator.
012391
4-11
7 Remove the roller bearing (1) and the housing disc

(2).
CAUTION
The shaft and housing discs must not be mixed up
1 2
with any other bearing assemblies. Clearly mark all
the parts.
012392
8 Unscrew and remove the twelve M8 Torx-

Powerlok screws.
9 Slightly raise the impeller and knock out the spur

gear using a plastic-tip hammer.
012393
10 Remove the O-ring (1) and the gasket (2) from the
spur gear.
3
11 Knock out the roll pins (3) if necessary.
2
1
012394
4-12
4.3.2 ZFW 360-10 Converter - Dismantle
1 Turn the converter over and place it on planks.
2 Unscrew and remove all the M8 and M10 socket

head screws (1).
3 Force the circuit cover off the impeller by

screwing in lifting device 1X56 136 862.
CAUTION 1
Do not strike the circuit cover or the impeller.
008446
4 Remove the roller bearing and the shaft disc from

the stator.
008448
5 Unscrew and remove the twelve M8 socket head

screws (1).
6 Slightly raise the impeller (2) and knock out the

spur gear (3) using a plastic-tip hammer
NOTE 1
Knock out the roll pins if necessary.
2 3
008447
4-13
7 Remove the housing disc (1) from the spur gear 2

(2).
8 Remove the O-ring (3) and the gasket (4) from the
spur gear.
CAUTION
The shaft and housing discs must not be mixed up
with any other bearing assemblies. Clearly mark all 3 1
the parts.
008449
9 Remove the complete stator from the turbine

wheel.
10 Remove the shaft disc (1) from the stator.
11 Remove the needle bearing (2) from the turbine

wheel.
008450
12 Remove the housing disc (1) and the shim (2)

from the turbine shaft.
CAUTION
Do not mix up the bearing assemblies when
installing.
008451
4-14
4.3.3 Stator - Dismantle

(ZFW 380-30 and 360-10)
1 Place the stator (1) on a support. 3 2
2 Place a suitable pad (2) on the internal sprag race

(3). 1
3 Press the internal sprag race out of the stator.
008452
4 Remove the rollers (1) from the internal sprag

race.
5 Remove the ring (2) from the internal sprag race.
2
008453
6 Press the internal sprag race (1) out of the ball

bearing (2).
2
! DANGER
Do not clean bearings using compressed air. The
bearing races could come loose and damage the
bearing due to lack of lubrication.
1
008454
4-15
7 Place the stator (1) on the press using a suitable

support (2).
8 Use a suitable pad (3) to press the ball bearing out

of the stator.
3
CAUTION
The diameter of the pad must match the outside
diameter of the bearing.
008455
9 Remove the ball bearing (1) and the ring (2) from
the stator. 1
008457
4-16
4.3.4 Stator - Assemble

(ZFW 380-30 and 360-10)
1 Insert the ring in the stator.
2 Place the stator and ball bearing in the press using

a suitable support.
3 Use special tool 1X56 137 152 to press the

bearing in as far as it will go.
008456
4 Insert support 1X56 137 152 into the press with

the hollow facing upwards.
5 Turn the stator over and place it on support 1X56 1

137 152.
6 Insert the internal sprag race (1) into the stator

with the longer collar facing downwards and press
it in.
NOTE
Using support 1X56 137 152 ensures that the
internal sprag race is fitted in the correct position.
008459
7 Insert the rollers in the stator.

NOTE
After insertion, moderately oil the rollers and
rotate the stator several times.
8 Insert the ring (1) in the stator.
008460
4-17
9 Insert support 1X56 137 152 in the press and

place the stator on the support complete with the
ball bearing.
10 Place second support 1X56 137 152 onto the ball

bearing.
11 Press the ball bearing into the stator.

NOTE
Ensure that the hollows on both supports 1X56
137 152 are facing the stator. Using the supports
ensures that the bearing is fitted in the correct
position.
008458
4-18
4.3.5 Turbine Wheel and Circuit Cover on

ZFW 380-30 Converter - Dismantle
1
1 Remove the gasket (1).
012395
2 Lever the turbine wheel (1) off the circuit cover

using suitable pry-bars.
012396
3 Remove the rectangular-section ring (1) from the

groove.
NOTE
The rectangular-section ring has sharp edges.
Press one end of the rectangular-section ring into
the groove using your thumb.
Slide your index finger along to the other end of
the ring until the ring comes out.
1
012397
4-19
4 Force the ball bearing (1) off the turbine wheel

using two assembly levers.
NOTE 2
Do not remove the disc (2) unless it is damaged.
012398
5 If necessary, knock the disc (2) out of the turbine

wheel from the rear using a suitable punch (see
step 4).
012399
6 Unscrew and remove the twelve M10 hexagon

bolts (1) from the circuit cover and remove the end 1 2
disc (2).
012400
4-20
7 Remove the inner and outer discs (1) from the

circuit cover.
1
NOTE
The compression springs (2) are located on the
last outer disc.
8 Remove the compression springs (2) with the last

outer disc.
9 Remove the twelve rollers (3).
3
2
012401
10 Remove the disc spring (1).
11 Grip the plate piston (2) with pliers. Tap the 1

circuit cover with a plastic-tip hammer to loosen
and remove the plate piston.
012402
12 Hook a suitable tool (0.5 - 0.75 mm thick) under

the rectangular-section ring (2) and carefully 11
remove it from the plate piston.
!DANGER
The grooved edge of the plate piston may be sharp.
Wear protective gloves.
2
13 Apply pressure on both sides of the rectangular-
section ring (1) (see arrows). Then grasp the
bulging section of the ring and remove it from the
groove.
The removal procedure is the same for all outer

rectangular-section rings.
001569
001569
4-21
4-22
4.3.6 Circuit Cover and Turbine Wheel on

ZFW 380-30 Converter - Assemble
1
NOTE
Thoroughly clean all the components and dry
them using compressed air. Use lint-free cloths
only when wiping off the rectangular-section
2
rings.
1 Check the rectangular-section rings for damage

and renew them if necessary.
2 Coat the inner rectangular-section ring (2) and the

outer rectangular-section ring (1) with Vaseline
and insert them into the plate piston.
NOTE 008468
Stretch the inner rectangular-section ring a little

before installing it so that it sits firmly in the base 2
of the groove.
CAUTION
Insert the plate piston (1) into the circuit cover
without tilting it. Ensure that the rectangular-section
rings are firmly seated in the base of the groove all
the way around.
3 Tap around the edge of the plate piston with a 1

plastic-tip hammer. Make sure that the plate piston
is correctly positioned.
4 Place the disc spring (2) onto the plate piston with
the camber facing downwards.
012403
1
5 Insert the twelve rollers (1) into the holes around
the edge.
012404
4-23
6 Use a straight edge to check that the outer and inner

discs are flat and not distorted. Perform a visual
check. Check the discs against the end disc or a flat
surface.
CAUTION
Replace any discs that are dished or corrugated.
Maximum permitted wear is 0.3 mm. Replace lined
discs that have damaged or blackened linings.
Replace inner discs that have damaged tooth flanks.
Maximum permitted wear per tooth flank is 0.2 mm.
008469
7 Insert the first outer disc (1) so that the holes slide
over the rollers. 5 4 3 1
8 Place the four springs (2) over the rollers and onto
the outer disc at 90° intervals. Check the position
of the springs in relation to the countersink on the
circuit cover.
9 Insert the inner disc (3).
10 Insert the two outer discs (4).
11 Insert the inner disc (5) in the circuit cover.
2
012405
NOTE
Insert the two outer discs (4) so that the tooth
spaces for the springs (see arrow) and bores are
lying above the remaining rollers.
012406
4-24
12 Insert the two M10 threaded pins at an angle.
13 Line up the holes on the end disc with the holes in

the circuit cover. Fit the end disc over the threaded
pins and onto the springs in the circuit cover.
012407
14 Screw in the twelve M10x35 hexagon bolts;

2
NOTE
Before tightening the hexagon bolts, tap the plate
piston fully home with a plastic-tip hammer.
15 Use a feeler gauge (1) to measure the play

between the last inner disc and the end disc (2).
1
Note down as distance “A".
16 The disc play (distance "A") may be between 0.5

mm and 1.1 mm.
012408
NOTE
If the disc play is less than 0.5 mm or more than
1.1 mm, fit new outer discs as necessary. Then
re-measure distance "A".
A
Outer discs can be supplied in the following

thicknesses:
A
4139 334 202 = 3.0 mm
004 234
4139 334 206 = 3.5 mm
004234
4-25
17 Turn over the turbine wheel. Knock the spacer

disc (1) into the turbine wheel as far as it will go
(if it was previously removed). 1
2
18 Strike the spacer disc at four points around the
edge to secure it.
NOTE
Install the spacer disc with the holes facing
upwards.
19 Knock the ball bearing (2) onto the turbine wheel

using a suitable piece of pipe. 3
20 Insert the rectangular-section ring (3) in the

groove and hook in the open ends of the ring.
012409
! DANGER
The rectangular-section ring has sharp edges. Wear
protective gloves.
1
21 Align the inner discs. The discs have to cover each
other.
22 Insert the turbine wheel (1) in the circuit cover.
CAUTION
Ensure that the teeth on the turbine wheel mesh in
the gaps on the inner discs. Rotate the turbine wheel
back and forth until it engages. Ensure that the
turbine wheel is fully engaged and inserted as far as it
will go. If necessary, tap the edge of the inner teeth 012410
with a plastic-tip hammer. Take care not to damage

the inner discs.
4-26
4.3.7 Turbine Wheel and Circuit Cover on

ZFW 360-10 Converter - Dismantle
1 Lever the turbine wheel (1) out of the circuit cover

(2) using suitable pry-bars.
008462

groove.
NOTE
The rectangular-section ring has sharp edges.
Press the end of the rectangular-section ring into
the base of the groove using your thumb. Slide
your index finger to the other end of the ring until 1
the ring comes out.
008463
3 Force the ball bearing (1) off the turbine wheel (2)
using two assembly levers.
NOTE 3
Do not remove the disc (3) unless it is damaged. 1 2
008461
4-27
4 Knock the disc (3) out of the turbine wheel from

the rear using a suitable punch (see step 3).
008464
5 Unscrew and remove the twelve hexagon bolts (1)

from the end disc (2) and remove the end disc.
008466
6 Remove the inner and outer disc from the circuit

cover.
7 Remove the disc spring (1).

1
8 Remove the rollers.
008465
4-28
9 Grip the plate piston (1) with a pair of pliers.
10 Tap the mating face (2) of the circuit cover with a

plastic-tip hammer to loosen and remove the plate
1
piston.
008467
11 Hook a suitable tool (0.5 - 0.75 mm thick) under

the inner rectangular-section ring (2) and carefully
remove it from the plate piston. 11
!DANGER
The grooved edge of the plate piston may be sharp.
Wear protective gloves.
2
12 Apply pressure on both sides of the outer

rectangular-section ring (1) (see arrows). Grasp
the bulging part of the ring and remove it from the
groove.
001569
The removal procedure is the same for all

rectangular-section rings. 001569
4-29
4-30
4.3.8 Circuit Cover and Turbine Wheel on

ZFW 360-10 Converter - Assemble
1
NOTE
Thoroughly clean all the parts and blast them with
compressed air. Only use lint-free cloths when
wiping the rectangular-section rings.
2
1 Check the rectangular-section rings for damage
and renew them if necessary.
2 Coat the inner rectangular-section ring (2) and the

outer rectangular-section ring (1) with Vaseline
and insert them into the plate piston.
NOTE
Slightly stretch the inner rectangular-section ring 008468
before installing it so that it locates firmly against

the groove base.
CAUTION
Insert the plate piston (1) in the circuit cover without
tilting it. Ensure the rectangular-section rings are
firmly located against the groove base all the way aro-
und.
3 Tap the edge of the plate piston with a plastic-tip

hammer. Ensure that the plate piston is inserted as
far as it will go.
4 Insert the twelve rollers (2) into the holes around 2

1
the edge.
008470
5 Place the disc spring on the plate piston with the
camber facing downwards.
6 Use a straight edge to check that the outer and

inner discs are flat and not distorted. Perform a
visual check. Check the discs against the end disc
or a flat surface.
CAUTION
Replace dished or corrugated discs. Maximum
permitted wear is 0.3 mm. Replace lined discs that
have damaged or blackened linings. Replace inner
discs that have damaged tooth flanks. Maximum
permitted wear per tooth flank is 0.2 mm.
008469
4-31
7 Insert the outer disc (1).
8 Insert the inner disc (2).
9 Depending on the version, insert one or two outer

discs (3).
10 Insert the inner disc (4) into the circuit cover.

4
NOTE
Insert the outer discs (3) so that the holes slide
3
over the rollers.
2
1
008471
11 Insert the end disc (1) into the circuit cover.

1
12 Align the holes in the end disc with the holes in
the circuit cover.
13 Tighten the M8 hexagon bolts;

NOTE
Before tightening the hexagon bolts, tap the plate
piston once again with the plastic-tip hammer to
ensure it is inserted as far as it will go.
008472
14 Use a feeler gauge (1) to measure the play

between the last inner disc and the end disc (2)
and note it down as distance “A".
15 The disc play may be between 0.5 and 1.1 mm.
008473
4-32
NOTE
If the disc play is less than 0.5 mm or more than
1.1 mm, install new outer discs as necessary.
Then re-measure distance "A".
A
Outer discs can be supplied in the following thicknesses:
A
4139 334 005 = 3.5 mm
4139 334 006 = 4.0 mm
001 570
001570
16 Turn over the turbine wheel and drive the spacer

disc (1) into the turbine wheel as far as it will go
(if it was removed beforehand). 1
17 Use a caulking tool to secure the spacer disc at

four points around the edge.
NOTE
Install the spacer disc with the holes (2) facing
upwards.
008474
18 Knock the ball bearing onto the turbine wheel

using a suitable piece of pipe.
1
19 Inset the rectangular-section ring (1) in the groove
and hook in the open ends of the ring.
! DANGER
The rectangular-section ring has sharp edges. Wear
protective gloves.
008475
4-33
20 Align the inner discs. The discs must cover each

other. 1
21 Insert the turbine wheel (1) into the circuit cover.
CAUTION
The teeth on the turbine wheel must engage in the
gaps on the inner discs. Rotate the turbine wheel
back and forth until it engages. Ensure that the
turbine wheel is fully engaged and inserted as far as it
will go. If necessary, tap the edge of the inner teeth
with a plastic-tip hammer. Take care not to damage
the inner discs.
008476
4-34
4.4 Converter - Assemble

4.4.1 ZFW 380-30 Converter - Assemble
1 2
1 Clean the spur gear. Use an oil stone to rub the
mating surface.
2 Insert a new O-ring (1) in the spur gear.
3 Place a new gasket (2) on the mating face of the

spur gear and align it with the holes.
012394
4 Align the spur gear with the holes in the impeller.
5 Insert the spur gear in the impeller.
012411
6 Turn over the impeller complete with the spur

gear.
7 Knock in the two roll pins (10x20 and 6x20) if

they were removed previously.
8 Insert twelve new M8x28 Torx-Powerlok screws

and tighten them;
CAUTION
Always use new Powerlok screws. The countersunk
screwhead bores in the impeller must be flat. If
required, sink once by max. 0.5 mm.
012393
4-35
9 Prepare the bearing pack for the spur gear. Check

the markings!
NOTE
The shaft disc (1) is recognizable by the "WS"
marking, the housing disc (2) by the "GS" mar-
king. 1
008478
10 Insert the housing disc ("GS") into the spur

gear.
CAUTION
The chamfered side must be facing the spur gear.
012412
11 Place the roller bearing onto the housing disc in

the spur gear.
012413
4-36
12 Place 0.5 mm-thick shim (1) onto the ball bearing

on the stator (3). 3
13 Place the shaft disc ("WS") (2) onto the shim on

the stator with the chamfer facing downwards. 2 1
012414
14 Insert the complete stator (1) into the impeller.

1
CAUTION
The longer collar (2) of the internal sprag race must
face the impeller. When inserting the stator,
ensure that the internal sprag race, bearings and
discs do not fall out of the stator.
NOTE
Place support 1X56 137 152 onto the stator 2
bearing. Use a plastic hammer to tap in the stator
and complete bearing pack as far as they will go.
012415
15 Prepare the marked bearing pack.

1 2 3
16 Place the shaft disc (1) onto the stator.
17 Place the needle cage (2) onto the shaft disc.
18 Place the housing disc (3) onto the needle

cage.
012416
4-37
4-38
4.4.2 Axial Bearing End Play on ZFW 380-30

Converter - Measure and Adjust
1 Place the measuring blocks on the mating face of

the impeller.
2 Place the measuring bar on the measuring

blocks.
3 Place a depth gauge on the measuring bar and

measure distance "A" between the measuring bar
and the impeller mating face (without gasket).
Note down dimension "A".
NOTE
The measuring bar must not lie on the stator.
012417
4 Move the depth gauge to the center.
5 Measure the distance "B" between the measuring

bar and the face of the housing disc (1).
6 Note down distance "B" and subtract it from

distance “A".
1
Distance "A" – Distance "B" = Distance "C"
012418
7 Place a new gasket (1) on the circuit cover mating

face.
8 Place the measuring apparatus on the circuit cover

gasket.
9 Use a depth gauge to measure the distance "D"

between the measuring bar and the circuit cover
mating face (with gasket).
10 Note down distance "D".

1
012419
4-39
11 Measure the distance "E" between the measuring

bar and the shim (1) on the turbine wheel.
12 Note down distance "E" and subtract it from

distance "D".
Distance "D" – Distance "E" = Distance "F" 1

Subtract distance "F" from distance “C"
Distance "C" – Distance "F" = Distance "G"
13 Calculate the required shim thickness "S" as

follows:
G – (0.10 to 0.30 mm) = S

0.10 to 0.30 mm = End play of axial bearing
Calculation example: 012420
G = 1.40 mm
–*H = 0.20 mm
S = 1.20 mm
*H = average of 0.10 mm and 0.30 mm end play
Shim thickness "S" = 1.20 mm
CAUTION
The figures used in this calculation are purely
theoretical.

thicknesses ranging from 2.0 mm to 1.0 mm, in
0.10 mm steps.
012421
14 Insert the shim (1) into the turbine wheel.
15 Remove the upper housing disc from the stator. 1 2 3
16 Insert the housing disc (2) into the turbine wheel

with the chamfered side facing the shim.
17 Remove the needle cage (3) from the stator and

place it on the housing disc in the turbine wheel.
012422
4-40
18 Remove the complete stator (1) from the impeller

and insert it into the turbine wheel with the short
collar of the internal sprag race facing the turbine 1
wheel.
NOTE
Coat all the bearings with oil before installation.
012423
19 Remove 0.5 mm shim (1), shaft disc (2) and roller

bearing (3) from the impeller.
1 2 3
012424
20 Place 0.5 mm shim, shaft disc onto the stator with

the chamfered side facing the stator. 1
21 Place the roller bearing (1) onto the shaft disc on

the stator.
22 Place the gasket (2) on the circuit cover and align

it with the holes.
012425
4-41
23 Fit the impeller (1) and align it with the holes in

the circuit cover.
24 Screw the four M10x55 socket head screws (2)

(90° apart) into the impeller via the holes in the
circuit cover and tighten them.
2
1654
NOTE
Ensure that there is no play between the impeller
and the circuit cover once they have been screwed 1
together.
25 Check the end play on the internal sprag race (1).

To do this, grasp the internal sprag race with both
hands and move it back and forth. You must be
able to feel the end play.
012427
26 Turn over the converter.
1
! DANGER
The converter weighs approx. 60 kg. Screw the M10
hook into the tapped hole on the impeller and slightly
raise the converter using a rope and hoist in order to
turn it over. Then secure the converter to prevent it
from rolling away.
27 Insert and tighten all 48 M10x55 socket head

screws (1). Tightening torque: 65 Nm
012428
4-42
4.4.3 ZFW 360-10 Converter -Assemble

2
1 Clean the spur gear. Rub the mating face (1) with
an oil stone.
2 Prepare the bearing pack for the spur gear. Check 1

the markings!
3 Insert the housing disc "GS" (2) into the spur

gear.
CAUTION
The chamfered side must face the spur gear. 3
NOTE
2
The housing disc (2) is recognizable by the "GS"
marking, the shaft disc (3) by the "WS" marking. 008477/008478
4 Insert a new O-ring (1) into the spur gear (2). 1
5 Place a new gasket (3) on the mating face of the

spur gear (2) and align it with the holes
3
6 Align the spur gear with the holes in the impeller.
008479
7 Insert the spur gear into the impeller.
NOTE
Drive in the roll pins if necessary.
8 Turn over the impeller complete with the spur

gear.
9 Insert and tighten twelve new Torx-Powerlok scr- 1

ews;
CAUTION
Always use new Powerlok screws. The countersinks in
the screwhead bores in the impeller must be flat. Sink
once (max. 0.5 mm) if necessary.
008480
4-43
10 Place the roller bearing (1) onto the housing disc

in the impeller.
11 Place the shaft disc (2) onto the roller bearing with
the chamfer facing upwards.
12 Place a 0.5 mm-thick shim (3) onto the shaft disc.
2 3
1
008481
13 Insert the complete stator (1) into the impeller.

2
CAUTION
The longer collar (2) of the internal sprag race must
face the impeller. When inserting the impeller, ensure 1
that the internal sprag race bearings do not fall out of
the stator.
NOTE
Place support 1X56 137 152 onto the stator
bearing. Knock in the stator and complete bearing
pack as far as they will go by tapping with a
plastic-tip hammer.
008482
14 Prepare the marked bearing pack.
15 Place the shaft disc (1) onto the stator.
16 Place the needle cage (2) onto the shaft disc.
17 Place the housing disc (3) onto the needle cage.
008483
4-44
4.4.4 Axial Bearing End Play on ZFW 360-10

Converter - Measure and Adjust
1 Place a new gasket (3) on the mating face.

2
2 Place the measuring blocks (1) onto the impeller
mating face.
3 Place the measuring bar (2) on the measuring
blocks.
4 Place a depth gauge on the measuring bar and 1
measure distance “A” between the measuring bar
and the impeller mating face with fitted gasket.
NOTE 3
The measuring bar must not lie on the stator.
008485
5 Move the depth gauge to the center.
6 Measure distance "B" between the measuring bar

and the face of the housing disc (1).
7 Note down distance "B" and subtract it from

distance "A".
Distance "A" - Distance "B" = Distance “C"
1
008484
8 Place the measuring apparatus on the circuit cover

mating face.
NOTE
Do not fit a gasket on the circuit cover when
taking measurements.
9 Determine distance "D" between the measuring

bar and the circuit cover mating face using a depth
gauge.
10 Note down distance "D".
008486
4-45
11 Determine distance "E" between the measuring

bar and the shim (1).
12 Note down distance "E" and subtract it from

distance "D".
Distance "D" - Distance "E" = Distance "F"

Subtract distance "F" from distance "C"
Distance "C" - Distance "F" = Distance "G"
13 The required shim thickness "S" is calculated as

follows: 1
G - (0.1 to 0.3 mm) = S
0.1 to 0.3 mm = End play on the axial bearing
Calculation example G = 1.4 mm

– H = 0.2 mm 008487
S = 1.2 mm
*H = Average of 0.1 mm and 0.3 mm end play
CAUTION
The figures used in the calculation example are
purely theoretical.
Shims are available in the following thicknesses in 0.2

mm steps: 1
0630 000 219 = 1.0 mm
0630 004 152 = 1.2 mm
0630 004 154 = 1.4 mm
0630 004 156 = 1.6 mm
0630 004 158 = 1.8 mm
0630 004 127 = 2.0 mm
0730 000 982 = 2.2 mm
008488
14 Insert the shim (1) in the turbine wheel.
15 Remove the upper housing disc from the stator.
16 Insert the housing disc (2) into the turbine wheel

with the chamfered side facing the shim (1).
17 Remove the needle cage from the stator and insert 2

it into the turbine wheel. 1
008489
4-46
18 Remove the complete stator (1) from the impeller

and insert it into the turbine wheel with the short
collar of the internal sprag race facing the turbine
wheel.
NOTE
Coat all the bearings with oil before installation. 1
19 Remove the shaft disc (2) from the impeller and 2

place it on the stator with the chamfered side
facing the stator.
008490
20 Remove the roller bearing (1) from the impeller

and place it on the stator.
008491
21 Place the gasket (1) on the circuit cover.
22 Screw two M8 threaded pins (2) 1X56 136 821

into the circuit cover flange at two-opposite-facing
points. 2
2
008492
4-47
23 Place the impeller (1) onto the circuit cover.
24 Unscrew and remove the M8 threaded pins (2)

1X56 136 821.
2
008493
25 Fit washers on each of the 36 M8 socket head

screws (1).
26 Tighten the socket head screws;

1
008494
27 Check the end play on the internal sprag race (1).
28 Grasp the inside of the internal sprag race with

both hands and move it back and forth. You must
be able to feel the end play.
008495
4-48
4.5 Converter Leak-tightness - Check

(ZFW 380-30 and 360-10)
1 Insert forcing device 1X56 137 129 into the

converter on the spur gear end.
012429
2 Screw the lock nut onto the forcing device.
!DANGER
The converter weighs approx. 60 kg.
012430
3 Lower the converter into a basin using lifting gear

so that the mating face (1) between the impeller
and the spur gear is just about in the water.
1
4 Connect compressed air unit 1X56 137 130 to the
forcing device.
CAUTION
The water in the basin must contain 1 part antifreeze
to 120 parts water. Water temperature = 20°C.
003 127
003127
4-49
5 Turn the regulator (1) anti-clockwise.
6 Open the stopcock (2).

11 22
CAUTION
The converter must be absolutely leak-tight.
003126
8 Close compressed air device 1X56 137 130 and

remove it from forcing device 1X56 137 129.
9 Lift the converter out of the basin using lifting

gear and lay it to one side on the work surface.
10 Detach the converter from the lifting gear and turn

it over.
1
11 Screw off the lock nut (1).
012430
12 Place the converter on the circuit cover and

remove forcing device 1X56 137 129 from the
converter.
NOTE
Dry the converter using compressed air. Lightly
coat the spur gear with oil.
012429
4-50
HP 502 / HP 592 / HP 602 Cover Plate
5 Cover Plate - Remove and Install
5.1 Cover Plate - Remove
-Remove the converter, see section 4.1

1
NOTE
Tilt the transmission to drain the oil before
removing the cover plate. 2
1 Unscrew the hollow screws (1).
2 Remove the hollow screws, sealing rings and oil 1

pipe (2) from the cover plate.
013106
NOTE
The type of cover plate varies depending on the
transmission type and the converter version.
The transmission version with ZFW 360-10

converter has a 125x150x10 shaft seal (1) on the 1 2
cover plate and hexagon bolts at position (2) (see
figure 008501)
008501
The version with ZFW 380-30 converter has a

142x162x10 shaft seal (1) and socket head screws
at position (2) (see figure 013107)
013107
5-1
Cover Plate HP 502 / HP 592 / HP 602
3 Unscrew and remove from the cover plate the

eight M8 socket head screws (1) (ZFW 380-30) or
M8 hexagon bolts and sealing rings (ZFW 360-
10).
4 Unscrew and remove the eleven M8 hexagon bolts

(2).
5 Unscrew and remove the fifteen M8 socket head 3

screws (3) and sealing rings from around the edge
of the cover plate.
1 2
013107
6 Screw the three threaded spindles (1) from

extractor 1X56 136 815 into the tapped holes
provided.
1 2
7 Place the bars (2) from extractor 1X56 136 815
onto the threaded spindles and screw on the
tommy nuts (3). 3
8 Tighten the tommy nuts evenly, alterating between

the bars, and pull out the cover plate.
9 Undo extractor 1X56 136 815 and remove it from

the cover plate.
013108
5-2
HP 502 / HP 592 / HP 602 Cover Plate
5.2 Cover Plate - Install
1 Check the shaft seal (1) for damage.
2 If necessary, press the shaft seal out of the cover

plate from the rear.
1
3 Insert a new O-ring (2) in the cover plate.
4 Thinly coat the O-ring and the mating face of the

cover plate with Vaseline.
2
013109
5 Screw a stay-bolt into the control insert (for fixing

purposes) and insert the cover plate in the correct
position.
6 Knock in the cover plate by evenly tapping around

the edge with a plastic-tip hammer. Ensure the
cover plate is inserted as far as it will go.
CAUTION
Place a new copper seal, washer and new copper seal
(in this order) under the socket head bolts at each of
the three tapped bolt holes (see arrows).
This is a special seal combination.
7 Tighten the fourteen M8x130 socket head screws

(1) around the edge of the cover plate. Make sure
that new copper seals are fitted. 013110
8 Tighten one M8x35 socket head screw (2) with

new copper seal.
2
9 Tighten the eight M8x85 socket head screws (380-
30) or hexagon bolts (360-10) (3) with new
copper seals.
10 Tighten the eleven M8x20 hexagon bolts (4) with 4

new copper seals.
1
Tightening torque for all hexagon bolts and socket 3
head bolts on the cover plate: 23 Nm
013107
5-3
Cover Plate HP 502 / HP 592 / HP 602
11 Insert the oil pipe (1).
12 Tighten the hollow screws (2).

CAUTION 2
Fit a new copper seal under the bolt head and the
pipe connection at each hollow screw connection.
1
013106
13 Fit the shaft seal as follows:
14 Lightly lubricate the outside edge of the shaft seal.
NOTE
Use water-soluble concentrated washing-up liquid
as a lubricant.
15 Grease the sealing lip(s) with Vaseline. 1
16 Position the shaft seal against the hole with the

sealing lip(s) facing the cover plate.
17 Knock in the 142x162x10 shaft seal (ZFW 380-

30) as far as it will go using punch 1X56 137 382
(1).
013111
Knock in the 125x150x10 shaft seal (ZFW 360-

10) as far as it will go using punch 1X56 136 605
(1).
008507
5-4
HP 502 / HP 592 / HP 602 Oil Pan
6 Oil Pan - Remove and Install
6.1 Oil Pan - Remove 2
1 Unscrew the four M8 hexagon bolts (1) and

remove them together with the washers.
1
2 Remove the cover (2) from the filter housing.
011578
3 Pull the screen filter (1) off the intake pipe.
4 Unscrew the thirty three M8 hexagon bolts (2) 1

from around the edge of the oil pan and remove
them together with the washers. 2
5 Remove the oil pan (3) and gasket from the trans-
mission. 3
011579
CAUTION
If the transmission is fitted with a converter drain
valve, take care not to damage the actuation pin (1)
for the converter drain valve when removing the oil
pan. 1
016072
6-1
Oil Pan HP 502 / HP 592 / HP 602
6-2
HP 502 / HP 592 / HP 602 Oil Pan
6.2 Oil Pan - Install
1 Place a new gasket (1) on the mating face.
011602
2 Before fitting the oil pan, check that serrated ring

ZA 5 (1) is securely engaged in the groove of the
actuation pin for the converter drain valve.
1
016073
3 Check that the actuation pin (1) for the converter

drain valve can move freely.
016072
6-3
Oil Pan HP 502 / HP 592 / HP 602
4 Place the oil pan on the transmission.
NOTE
Make sure that the gasket is not displaced when
fitting the oil pan.
5 Insert the M8x60 hexagon bolts (1) with washers 2

into the oil pan and tighten them; 1
CAUTION
Fit new copper seals on the two central hexagon bolts
(2) at the front of the oil pan. Use steel washers for the
rest of the oil pan hexagon bolts.
011601
6 Lightly coat the O-ring (1) in the screen filter with

Vaseline. 1
008513
7 Push the screen filter (1) onto the intake pipe as

far as it will go.
1
011579
6-4
HP 502 / HP 592 / HP 602 Oil Pan
8 Insert a new O-ring (1) into the cover (2).
9 Lightly coat the O-ring with Vaseline.

1
010483
10 Place the cover (1) onto the oil pan.
11 Tighten the M8x80 hexagon bolts (2) with was-

hers;
011605
12 Insert and tighten the oil drain plug (1).

CAUTION
Always use the original oil drain plug in
transmissions with converter drain valve. The drain
plug controls and closes the converter drain valve.
011578
6-5
Oil Pan HP 502 / HP 592 / HP 602
6-6
HP 502 / HP 592 / HP 602 Inductive Pickup
7 Inductive Pickup - Remove and Install
7.1 Inductive Pickup - Remove

1
1 Unscrew and remove the screw plug (1).
011607
2 Remove the cable plug (1) from the inductive

pickup.
These are flat-pin plugs that are pulled out
straight.
1
3 Unscrew and remove the Torx screw (2) and take
out the inductive pickup.
2
011608
4 Remove the O-ring (1), shims (2) and Torx screw

(3) from the inductive pickup (4).
4
1 2 3
011776
7-1
Inductive Pickup HP 502 / HP 592 / HP 602
7-2
7.2 Inductive Pickup - Install
1 Turn the output flange using an assembly lever. At

the same time, use a small screwdriver to establish 1
the position of the projections on the pulse
generator ring (1).
011783
2 When one of these projections is located under the

inductive pickup insert bore, measure the distance
“a” between the inductive pickup (3) and one of 1 2 4
the projections on the pulse generator ring (1).
CAUTION
It is important to measure one of the projections on 5
the pulse generator ring. Otherwise, the projection
will damage the inductive pickup when the engine is
started.
3
011622
3 Insert measuring rod 1X56 138 149 into the

inductive pickup bore and attach it (1).
Tightening torque: 9.5 Nm
011784
7-3
4 Move the sensor (1) until it stops against the

projection on the pulse generator ring and secure 1
by tightening the screw (2).
5 Unscrew and remove the measuring rod mounting 2

bolt (3) and carefully pull out the measuring rod.
011785
6 Measure the distance between the face of the

sensor and the contact face on the measuring rod
bracket and note it down as dimension "b"
b
011778
7 Screw the inductive pickup into the test device

1X56 138 150.
011779
7-4
8 Measure the distance between the contact face of

the inductive pickup and the contact face of the
inductive pickup bracket and note it down as
dimension “c”.
The inductive pickup dimension "a" must be 0.6 - 0.8

mm. c
Set using shims
Equation:
c-b=d
d + a = shim thickness "S"
Measuring example:
Distance "c" = 52.6 mm
Distance "b" = 50.9 mm 011780
Distance "a" = 0.7 mm (0.6 - 0.8 mm)
1 2 4
52.6 mm - 50.9 mm = 1.7 mm
1.7 mm + 0.7 mm = 2.4 mm
5
Calculated shim thickness "S" = 2.4 mm

thicnkesses ranging from 0.80 to 6.00 mm in 3
0.1mm steps.
1 Pulse generator ring

2 Holding plate a
3 Inductive pickup
4 Shims 011622
5 Torx screw with washer

2
9 Insert the Torx screw (1) with washer into the bore
on the inductive pickup (2). Slide the selected
shims (3) onto the Torx screw and secure using the
O-ring (4).
4 3 1
011776
7-5
10 Insert the inductive pickup and secure using the

M6x45 Torx screw (1).
2
11 Fit the cable plug (2) on the inductive pickup.
011610
12 Insert the M42x2 screw plug into the duct plate

and tighten it.
Tightening torque: 90 - 100 Nm
011607
Install the oil pan, see section 6.2.
011578
7-6
HP 502 / HP 592 / HP 602 Hydraulic Control Unit
8 Hydraulic Control Unit - Remove and Install,

Dismantle and Assemble
8.1 Hydraulic Control Unit - Remove

(1) and washers from the Kostal socket.
011624
2 Disconnect the flat-pin plug for the inductive

pickup (1) and the flat-pin plug for the retarder
resistor (2) from the valve body using a
screwdriver and separate from the sockets.
5
NOTE
The sump temperature sensor is integrated in the
plug (3). Only remove if necessary.
3 Remove the cables (4) from the protective 4 3

sleeve (5). 1 2
015825
4 If the transmission is fitted with an oil level

indicator, pull the protective cap (1) off the plug
and disconnect the plug (2) from the oil level
ECU.
2
1
015826
8-1
Hydraulic Control Unit HP 502 / HP 592 / HP 602
5 Unscrew and remove the 39 M8 Torx screws from

the shift control (1).
015827
!DANGER
Watch out for sharp edges.
The hydraulic control unit weighs approx. 18 kg.
6 Remove the complete hydraulic control unit.
CAUTION
Make sure that the shift control cable terminals do
not get caught and torn off in the transmission.
NOTE
The figures, drawings and parts illustrated do not
always depict the original, they are merely
intended to show the work involved. For
example, the hexagon bolts illustrated (on the shift
control) have been replaced by Torx screws. 011630
8-2
8.2 Hydraulic Control Unit - Install
1 Insert the hydraulic control unit into the

transmission.
NOTE
The Kostal socket (see arrow) must be inserted in
the seat of the transmission housing.
!DANGER
Watch out for sharp edges.
The hydraulic control unit weighs approx. 18 kg.
CAUTION
Do not trap the cables.
015827
2 Insert the new M8x35 Torx screws (1); however,

do not tighten them as yet.
1
NOTE
The 9 shorter Torx screws (1) are inserted in the
indented areas.
3 Insert the thirty M8x43 Torx screws (2). 2

Tighten all the Torx screws, including those
inserted in step 2 (see above); tightening torque:
23 Nm
NOTE
Work from the center of the control unit outwards
when tightening these screws.
015827
4 Install the inductive pickup (1) if it was removed

previously, see section 7.2.
1
NOTE
The gap to the inductive pickup only needs to be
re-adjusted if the shift control is renewed.
5 Screw the M42x2 screw plug (2) into the duct 2

plate if it was removed previously, see section 7.2.
011611/011607
8-3
6 If the transmission is fitted with an oil level

indicator, insert the plug (1) into the oil level ECU
socket.
1
CAUTION 3
The oil level ECU (2) is very sensitive and must not be
bent when inserting the plug. Hold the rear of the 2
ECU firm when inserting the plug.
7 Place the protective cap (3) over the plug on the

oil level ECU.
NOTE
The protective cap must engage.
015828
8 Connect the flat-pin plug on the side of the shift

control as illustrated.
1 Inductive pickup output plug

2 Retarder resistor plug 5
3 Sump temperature sensor
4
NOTE
plug (3).
1 2
9 Insert the temperature sensor cable (4) into the
protective sleeve (5). 3
015825
10 Attach the Kostal socket using two M8x20

hexagon bolts and washers.
011624
8-4
8.3 Oil Level Indicator - Remove and Install

8.3.1 Oil Level Indicator - Remove
Installation position of the complete oil level

indicator (1).
015829
1 Unscrew and remove the two M6 Torx screws (1)

from the oil level ECU.
CAUTION
Handle the oil level ECU carefully since it is very
sensitive to shocks and impact.
1
015830
2 Unscrew and remove the two M6 Torx screws (1)

and take out the oil level indicator complete with 1
the holding plate, sensor and oil level ECU.
NOTE
Do not undo the M6 Torx screw (2).
015831
8-5
8.3.2 Oil Level Indicator - Install
1 In the case of new oil level sensors that have not

yet been set, straighten the lock (1) and remove it
from the holding plate (2) and the sensor (3).
1
2
3
015832
2 Insert new oil level sensors that have not yet been
set or locked complete with the holding plate and 1
attach using two M6x30 Torx screws (1).
015833
CAUTION
The holding plate Torx screws each have two O-rings 1
fitted for damping purposes.
Check to ensure that the O-rings are correctly seated. 3 2
4
1 Torx screw
2 Washer
3 O-ring 9 x 2.5 5
4 Holding plate 6
5 O-ring 14 x 2.5
6 Bushing
7 O-ring for locking
7 Dim. X =
5.0 +3 mm
015834
8-6
3 Undo the M6x16 Torx screw (1).
015833
4 Correctly set the oil level sensor by ensuring the

correct distance between the end face of the
sensor and the housing mating face.
CAUTION
The setting dimension varies depending on the spec
list! Refer to the relevant spec list for the setting
dimension.
Example: Maß X
Oil level indicator spec list 4149 043 005

Setting dimension X = 15.7 ± 0.5 mm
5 After setting the sensor, tighten the M6x16 Torx

screw (1) on the holder and ensure it is fixed in the
correct position. 015835
6 Remove the complete oil level indicator again.

Insert the lock (1) in the relevant hole on the
holder and secure the oil level sensor by bending
the lock 90° (2).
2
015832
8-7
7 Re-insert the locked oil level sensor and attach it

using two M6x30 Torx screws (1). ßX
1 Ma
8 Re-check the sensor installation dimension "X".
015831
9 Attach the oil level ECU using two M6x30 Torx

screws (1) as illustrated.
CAUTION
Handle the oil level ECU with care since it is very sen-
sitive to shocks and impact. 1
015830
8-8
8.4 Hydraulic Control Unit - Dismantle
NOTE 8 9 11 4
The figures, drawings and parts illustrated do not 7 3
always depict the original. They are merely 6 2
intended to show the work involved. For example, 5 1
the hexagon bolts illustrated (on the shift control)
have been replaced by Torx screws.
10
Valve block A:
1 = Solenoid valve, clutch "A"
2 = Solenoid valve, clutch "C"
3 = Solenoid valve, clutch "WK"
4 = Solenoid valve, brake "F"
Valve block B:
5 = Solenoid valve, clutch "B" 015652
6 = Solenoid valve. brake "E"

7 = Solenoid valve, brake "D"
8 = Solenoid valve "F2"
9 = Valve block "F2"

10 = Throttle pressure valve
11 = Solenoid valve, retarder
1
1 Pull the flat-pin plugs (1) off the solenoid valves
on valve block "A" and the throttle pressure valve.
015653
2 Pull the flat-pin plugs (1) off the solenoid valves

on valve block "B".
3 Undo the Torx screws (2) on the holding plates 2

and remove the three sockets (3) with holding pla-
tes. The plug for the sump temperature sensor (4)
can remain connected to the wiring harness. 1
4
3
015836
8-9
4 Screw off the wiring harness; to do this, unscrew

and remove the M6 Torx screws (1) from the
holding plate.
015655
5 Lay the complete wiring harness to one side.
015656
6 Unscrew and remove the M5 socket head screws

from the solenoid valves (1).
1
7 Pull the solenoid valves out of the valve blocks.
015657
8-10
8 Remove the four dirt-collecting magnets (1).
015658
9 Unscrew and remove the M6 Torx screws (1) and

lay the throttle pressure valve to one side.
015659
10 Unscrew and remove the M6 Torx screws (1) and

lay valve block F2 to one side. 1
015660
8-11
11 Unscrew and remove the M6 Torx screws and take

off valve block "A" (1).
015661
12 Unscrew and remove the M6 Torx screws and take

off valve block "B" (1).
015662
13 Take off the intermediate plate (1)
015663
8-12
14 Use a plastic-tip hammer to drive the converter

safety valve (1) into the duct plate until the snap
ring is accessible.
15 Detach the snap ring (2).

1
2
015664
16 Press out the converter safety valve (1) in

downwards direction. 2
1
17 If the transmission is fitted with a converter drain
valve (2), rotate the duct plate through 180°.
015837
18 Unscrew and remove the Torx screw (1) and remo-

ve the plate (2) from the converter drain valve.
015838
8-13
19 Use a suitable tool to carefully press out the

converter drain valve (1) in downwards direction. 1
NOTE
The converter drain valve (1) is a complete part
and is not dismantled any further.
015839
8-14
8.4.1 Throttle Pressure Valve - Dismantle
1 Unscrew and remove the M5 Torx screws (1).
2 Remove the magnet (2) from the throttle pressure

valve. 1
015666
3 Remove the plunger (1).
015667
4 Remove the holding plate (1) and compression

spring (2) and take out the plunger (3). 1 2 3
! DANGER
The holding plate is held under spring load. When
taking out the holding plate, hold the springs using a
suitable tool and then release them carefully.
015840
8-15
8.4.2 Throttle Pressure Valve - Assemble
1 Insert the plunger (1) and the compression spring

3 2 1
(2) as illustrated.
2 Press the compression spring into the hole on the

end (see arrow) using a suitable tool and insert
the holding plate (3).
! 3
DANGER
The compression springs are held under spring load.
When inserting the holding plate, hold the
compression springs and then release them carefully.
015841
3 Insert the plunger (1) as illustrated.
015667
4 Insert the magnet (1) and tighten it using two

M5x12 Torx screws.
015666
8-16
8.4.3 Valve Block F2 - Dismantle and Assemble
1 Unscrew and remove the screw plug (1) with sea-

ling ring. Take out the compression spring (2) and
the plunger (3).
Assembly:
3 2 1
(2) as illustrated.
015669
2 Insert the M16x1.5 screw plug (1) with a new

sealing ring.
015670
8-17
8-18
8.4.4 Valve Block for Brake "F" and Clutch "WK",

"C" and "A" - Dismantle
1 Loosen the cover plate (1) using a plastic-tip

hammer and remove it from the valve block.
2 Remove the gasket.

1
CAUTION
Do not lever off the cover plate using a pry bar since
this could damage the mating face.
012453
3 Remove the valve ball (1) from the "WK" duct.
012454
4 Unscrew and remove the eight M6 Torx screws

(1). 3
5 Press the cover plate (2) against the valve block

2
and unscrew and remove the Torx screw (3).
6 Take off the cover plate and remove the

gasket.
! DANGER 1
The cover plate is held under spring load. Release
carefully when taking off the cover plate.
008560
8-19
7 Mark the installation position of the

compression springs (1).
8 Remove the plunger (2) and compression springs

from the valve block.
CAUTION
Do not mix up the compression springs. There may
also be a stop in the different plungers. Mark the stop
for each plunger. Do not mix up plungers that have a
stop.
1
2
008561
9 Unscrew and remove the M6 Torx screws from the

tapped holes (1). 1 2
CAUTION
Leave the Torx screw (2) inserted in the valve strip.
10 Insert the two M6 guide screws. 3
11 Press the cover plate (3) against the valve strip (4).
12 Unscrew and remove the Torx screw (2) and remo-

ve the cover plate.
4
! DANGER
carefully when taking off the cover plate.
015671
13 Remove the gasket from the valve strip.
14 Remove the valve strip from the valve block.
15 Unscrew and remove the guide screws from

the valve block.
015672
8-20
16 Remove the compression springs (1/2) from the

control plungers and ventilation plunger.
17 Pull the ventilation plungers (3) out of the valve

strip.
1
3
015673
18 Remove the bushes (1) from the valve strip

complete with O-rings (2).
19 Remove the control plunger (3) from the valve

strip.
20 Remove the O-ring (4) from the valve strip.
3
4
1
015674
21 Remove the plungers (1) from the valve block

(2).
22 Remove the stop washers (3) from the valve

block.
2
008566
8-21
8-22
8.4.5 Valve Block for Clutch "B", Brake "E" and

"D" - Dismantle
1 Loosen the cover plate (1) using a plastic-tip

hammer.
2 Take the cover plate off the valve block and

remove the gasket.
1
CAUTION
Do not lever off the cover plate using a pry bar since
this could damage the mating face.
015675
3 Unscrew and remove the M6 Torx screws from the

tapped holes (1). 1 3
4 Press the cover plate (2) against the valve block

and unscrew and remove the Torx screw (3). 2
5 Remove the cover plate.
! DANGER
carefully when removing.
015676
6 Remove the gasket.

2
7 Pull the three plungers (1) out of the valve block.
NOTE 1
There is no plunger fitted in hole (2).
012456
8-23
8 Mark the installation position of the compression

springs (1).
1 2
9 Remove the compression springs and, if
necessary, the stops (2) from the valve block.
CAUTION
Do not mix up the compression springs. There may be
a stop in the different plungers. Mark the stop (2) for
each compression spring and plunger.
015677
10 Unscrew and remove the M6 Torx screws (1).

1
CAUTION
Leave the torx screw (2) inserted in the valve strip. 2
015706
11 Insert the two M6 guide screws and press the

cover plate (1) against the valve strip.
12 Unscrew the Torx screw (2) and remove it with the 2

lug.
1
! DANGER
carefully when removing.
015671
8-24
13 Remove the cover plate (1) with gasket (2).
14 Remove the valve strip (3) from the valve block. 3
15 Unscrew and remove the guide screws from

the valve block.
015672
16 Remove the compression springs (1) from the

control plungers.
17 Pull the compression springs (2) out of the valve

strip with the ventilation plungers.
015673
18 Remove the bushes (1) from the valve strip

complete with control plungers (2) and
O-rings (3).
19 Remove the O-ring (4) from the valve strip.
2
4
1
015674
8-25
20 Remove the plungers (1) and stop rings (2) from

the valve block (3).
008566
8-26
8.5 Hydraulic Control Unit - Assemble
NOTE
Check the duct plate for damage and renew it if
necessary. 1
1 If the transmission is fitted with a converter drain

valve (1), check the valve O-ring and ball and
insert the complete converter drain valve into the
duct plate.
015842
2 Insert the converter safety valve (1) into the duct

1
plate from the rear.
3 Insert the snap ring (2) in the converter safety

valve.
015843
4 Push back the converter safety valve (1) until the

snap ring is lying flat in the duct plate. 1
5 Place the cover plate (2) onto the duct plate.
015844
8-27
6 Turn over the duct plate and place the plate (1)
over the converter drain valve (see arrow) on the
duct plate.
015845
7 Tighten the plate using the M6x16 Torx screw.

NOTE
Do not move the plate. Align the plate and hold it
in place using a suitable tool.
015846
CAUTION
Check the position of the plate. The lug on the plate
(see arrow) must be central when it is over the ball on
the converter drain valve.
015847
8-28
8.5.1 Valve Block for Brake "F" and Clutch "WK",

"C" and "A" - Assemble
NOTE
Check the valve block for damage. 1 2 3 4
1 Check that the orifices (1, 2, 3, 4) are perfectly

seated.
2 Check the diameter of the orifice holes using

gauge 1P01 137 173 and renew the orifices if
necessary.
008580
3 If necessary, knock out the orifices using punch

1X56 137 156.
CAUTION
Loosen the orifices before knocking them out.
008581
4 Insert the new orifices and secure them using

punch 1X56 137 151.
NOTE
Always secure new orifices at two points 90° apart
using the punch.
008582
8-29
5 Insert the four stop washers (1) into the valve

2
block with the collar facing downwards.
6 Slide the four plungers (2) into the valve block as

illustrated.
008583
NOTE
1
The plungers may fall out when the valve block is
turned over.
7 Insert all the compression springs (1) for the

plungers for the "A", "C" and "WK" clutch and
the "F" brake.
8 Slide in the plungers (2) with or without stop. 2
CAUTION
Do not mix up plungers with stop and springs.
Replace damaged springs, see spare parts catalog.
008584
A clutch
C clutch
WK clutch
F brake
9 When using a new spring, measure the wire

diameter and spring length (untensioned) as a
check.
10 Compare these measured values with the values

indicated in the spring table.
008585
8-30
11 Fit a new gasket (3).

2 1 3
12 Fit the cover plate (2), press it onto the valve block
and tighten the M6x16 Torx screw (1) by hand.
! DANGER
Make sure the cover plate is held secure until the Torx
screw (1) has been screwed in.
008586
13 Tighten the eight M6x16 Torx screws (1);

tightening torque: 9.5 Nm
008587
14 Screw M6 guide screws 1X56 150 111 into the

duct plate as illustrated.
008588
8-31
15 Place the valve block (1) over the M6 guide

screws and onto the intermediate plate.
16 Insert the valve ball (2) for the ventilation valve in 2

the "WK"duct. 1
CAUTION
Valve diameter must be ø = 5 mm. Renew if
necessary.
015678
CAUTION
The ventilation hole (2) must be positioned above the 2
ventilation valve "WK" duct.
1
015679
18 Place the cover plate (1) onto the valve block.
19 Secure the valve block using two M6x65 Torx

screws.
20 Unscrew and remove the guide screws.

1
21 Insert and tighten the remaining Torx screws as
illustrated;
22 Screw the two guide screws 1X56 150 111 into the
side of the valve block.
015680
8-32
23 Insert the pressure control plunger (2) into the

valve strip.
24 Coat a new O-ring (1) with Vaseline and insert it

in the valve strip.
2
1
008592
25 Insert the bushings (1) with the collar facing the

valve strip.
26 Coat the new O-rings (2) with Vaseline and insert

them into the bushings (1).
1 2
015681
27 Place the valve strip (1) onto the valve block using
the guide screws (2).
28 Insert each of the four ventilation plungers (3)

with a compression spring (4).
29 Insert the four compression springs (5) for the

control plungers.
3
5 1 2
4
015682
8-33
30 Fit a new gasket (1) on the valve strip.

1
31 Push the cover plate (2) onto the guide screws and
against the valve strip.
015683
32 Screw in the three M6x65 Torx screws (1) and pull

on the cover plate.
015684
34 Screw in the eleven M6x16 Torx screws (1) and

the remaining M6x65 Torx screws (2).
Tightening torque for all Torx screws on the cover 2
plate: 9.5 Nm
015707
8-34
8.5.2 Valve Block for Clutch "B", Brake "E" and

"D" - Assemble
NOTE
Valve block "B" is assembled in practically the
same way as valve block "A", see section 8.5.1.
The differences are described below.
015685
1 Insert the four stop washers (1) into the valve

block with the collar facing downwards.
015686
2 Slide the four plungers (1) into the valve block as

illustrated. 1
015687
8-35
NOTE
The plungers may fall out when the valve block is
turned over. 4 3 2 1
3 Insert all the compression springs for the "B”

clutch (1) , "E" brake (2) and "D" brake (3) and
"F2" valve (4).
CAUTION
Do not mix up the springs.
Replace any damaged springs, see spare parts
catalog.
015688
4 Fit the stop washers (1) on the springs if neces-

sary. 1
015689
5 Slide in the plungers (1).

2 1
NOTE
The hole for the F2 valve (2) does not have a
plunger inserted.
6 Screw in the M6 guide screws and fit a new gasket

(3).
015690
8-36
7 Fit the cover plate (1), press it against the valve

block and tighten the one M6x16 Torx screw (2) 2
by hand.
! DANGER 1
The cover plate is held under spring load. Secure it
until the Torx screws (2) have been screwed in.
8 Unscrew and remove the M6 guide screws from

the valve block and screw them into the duct plate.
9 Screw in and tighten the remaining M6x16 Torx

screws;
015691
10 Place the valve block (1) over the guide screws

and onto the intermediate plate. 1
015692

1
015693
8-37
12 Place the cover plate (1) on the valve block.
13 Insert and tighten the M6x65 Torx screws as illu-

strated;
tightening torque: 9.5 Nm.

1
015694
15 Fit the F2 valve block (1) and attach it using seven

M6x80 Torx screws.
1
16 Screw two guide screws 1X56 150 111 into the
side of the valve block.
015695
17 Insert the pressure control plunger (1) into the

valve strip.
18 Coat a new O-ring (2) with Vaseline and insert it

into the valve strip.
19 Insert the bushings (3) with the collar facing the

1
valve strip.
20 Coat the new O-rings (4) with Vaseline and insert

them into the bushings (3).
4
3 2
015681
8-38
21 Insert the compression springs (1) for the control

plungers as illustrated.
22 Insert each ventilation plunger (2) with one

compression spring (3) as illustrated.
3
015673
23 Place the valve strip (1) over the guide screws and
onto the valve block.
015682
24 Fit a new gasket on the cover plate.
25 Slide the cover plate (1) onto the guide screws.

Press the valve strip and the cover plate against the
valve block, screw in the three M6x65 Torx screws
and pull on the cover plate.
CAUTION
The control plungers, springs and O-rings must not
jam.
015696
8-39
26 Screw in the M6x65 (1) and M6x16 (2) Torx

screws.
015697
27 Fit the throttle pressure valve (1) and attach it

using five M6x65 Torx screws.
NOTE
Do not insert a screw in the hole (2) as yet.
015698
28 Check the O-rings on the solenoid valves.
29 Insert the solenoid valves (1) in the valve strip

"A", the solenoid valve (2) and retarder solenoid
valve (3) in the throttle pressure valve and attach
each one using two M5x12 socket head screws. 1
NOTE
Check the installation position of the solenoid
valves.
3
2
015699
8-40
30 Insert the solenoid valves (1) in valve strip "B"

and attach each one using two M5x12 socket head
screws.
015700
31 Fit the complete wiring harness (1) and attach it

using two M6x80 Torx screws (2).
015701
32 Connect the flat-pin plugs on the solenoid valves.
CAUTION
The cables are marked (B,E,D,F2); assign each one to
the respective solenoid valve and ensure that the 4 3 2 1
plugs are fully pushed on and properly engaged.
1 Solenoid valve, clutch “B“

2 Solenoid valve, brake “E“
3 Solenoid valve, brake “D“
4 Solenoid valve "F2"
015702
8-41
33 Attach each of the sockets with bracket to the side

of the shift control using two M6x65 Torx screws
as illustrated.
1 Socket, inductive pickup - output

2 Socket, retarder resistor 3 2
3 Socket, sump temperature sensor
1
NOTE
plug (3).
2242
34 Connect the flat-pin plugs on the solenoid valves.

4
CAUTION
The cables are marked (A,C,WK,F); assign each one 3
to the respective solenoid valve and ensure that the
2
plugs are fully pushed on and properly engaged.
1
1 = Solenoid valve, clutch "A"
2 = Solenoid valve, clutch "C"
3 = Solenoid valve, clutch "WK"
4 = Solenoid valve, brake "F"
015703
35 Connect the flat-pin plugs on the retarder solenoid

valve (1) and throttle pressure valve (2).
1
015921
8-42
36 Fit the cable plug (1) on the turbine inductive

pickup if necessary.
015922
37 Fit the two dirt-collecting magnets (1) on valve

block "A" as illustrated.
015704
38 Fit the two dirt-collecting magnets (1) on valve

block "B" as illustrated.
015705
8-43
8-44
HP 502 / HP 592 / HP 602 Retarder Valve
9 Retarder Valve - Remove and Install
9.1 Retarder Valve - Remove

(1) and take off the retarder solenoid valve (2).
2
016099
2 Pull the plunger (1) out of the valve housing.

1
016100
3 Pull the plunger (1) out of the plunger (2).
1 2
016101
9-1
Retarder Valve HP 502 / HP 592 / HP 602
4 Remove the compression springs (1) and the

plungers (2).
1 2
016102
5 Detach the snap ring (1) and remove the plunger

(2) from the plunger (3).
3 2 1
016103
9-2
HP 502 / HP 592 / HP 602 Retarder Valve
9.2 Retarder Valve - Install
1 Insert the plunger (1) in the plunger (2).
2 1
016103
2 Clip the snap ring (1) into the groove on the

plunger (2).
1
016104
3 Insert the plunger parts into the housing bore in

the following order: Plunger (1), spring (2),
plunger (3) and plunger (4) - see illustration. 4
016105
9-3
Retarder Valve HP 502 / HP 592 / HP 602
Plunger (1)
Spring (2)
Plunger (3/4)
1
016100
4 Insert a new O-ring (1) in the groove on the

solenoid valve.
NOTE
Coat the O-ring with Vaseline.
016106
5 Insert the retarder solenoid valve (1) and attach

using two M8 hexagon bolts (2).
016099
9-4
HP 502 / HP 592 / HP 602 Output Cover
10 Output Cover - Remove and Install, Dismantle

and Assemble
10.1 Output Cover/Inductive Pickup - Remove
CAUTION 1
With the converter removed, screw lifting
device (1) 1X56 137 213 into the turbine shaft.
008631
1 Remove the cover (1) for the inductive

pickup.
012486
2 Disconnect the cable terminals (1) at the inductive

pickup.
These are flat-pin plugs that are pulled off 1
straight.
3 Unscrew and remove the Torx screw (2) and take

2
out the inductive pickup.
011775
10-1
Output Cover HP 502 / HP 592 / HP 602
4 Remove the O-ring (1), shims (2) and Torx screw

(3) from the inductive pickup (4). 4
1 2 3
011776
10-2
10.1.1 Inductive Pickup - Install
1 Turn the output flange until the tooth (1) on the

planetary carrier becomes visible in the middle of
the bore for the inductive pickup.
011598
2 Insert measuring rod 1X56 138 149 (1) into the

inductive pickup bore and attach it (2). 1
3 Push the sensor (3) forwards until it reaches the

stop on the face of the tooth and secure by 2
tightening the screw (4).
4
4 Unscrew and remove the measuring rod mounting
bolt (2) and carefully pull out the measuring rod.
011777
5 Measure the distance between the end face of the

sensor and the contact face of the measuring rod
bracket and note it down as dimension "b".
b
011778
10-3
6 Insert a new inductive pickup in testing device

1X56 138 150 and attach it.
7 Measure the distance between the inductive 011779
pickup contact face and the contact face of the

inductive pickup bracket and note it down as
dimension "c".
The inductive pickup distance (dimension “a”) must be

0.6 to 0.8 mm.
c
Set the distance using shims
Measuring equation:
c-b=d
d + a = shim thickness "S"
Measuring example:
Distance "c" = 52.6 mm
Distance "b" = 51.3 mm
Distance "a" = 0.7 mm (0.6 to 0.8 mm) 011780
52.6 mm - 51.3 mm = 1.3 mm 2 3
1.3 mm + 0.7 mm = 2.0 mm
Determined shim thickness "S" = 2.0 mm

thicknesses ranging from 0.80 to 6.00 mm in 0.2
mm steps.
1 Planetary carrier tooth

2 Output cover, housing
3 Inductive pickup 1
4 Shims a 4 5
5 Inductive pickup mounting bolt
011620
10-4
8 Insert the Torx screw (1) into the bore on the

inductive pickup (2). Slide the selected shims (3) 2
onto the Torx screw and secure using O-ring (4).
4 3 1
011776
9 Connect the cable plug (1) to the inductive pickup.
10 Insert the inductive pickup and tighten the M6x45 1

Torx screw (2).
011775
11 Fit a new O-ring on the cover (1) and secure the

cover using two M6 hexagon nuts with washers.
012486
10-5
10-6
Output Cover - Remove (continued):
5 Unscrew and remove the pulse generator for the

speedometer (1).
1
011636
6 Remove the locking plate (1) from the output

flange.
! DANGER
Wear protective goggles since metal splinters may fly
off.
011638
7 Screw off both the M12 hexagon bolts.
NOTE
When doing this, use a suitable lever to hold the
output flange to stop it from turning.
1
8 Remove the thrust washer (1), using a plastic-tip
hammer to loosen it if necessary.
011639
10-7
9 Pull off the output flange using a standard two or

three-arm puller.
CAUTION
Never use the two or three-arm puller without the
thrust piece since the thread on the output shaft may
become damaged.
NOTE
Use a flange holder as a brace when pulling off the
output flange.
012487
10 Pivot the transmission so that the output end is

facing upwards.
11 Bolt lifting device 1X56 136 260 to the output

shaft. Unscrew and remove all the M10 hexagon
bolts from around the edge of the output cover.
NOTE
The cable plug for the inductive pickup must be
pulled off the control unit.
016121
12 Grasp the output cover using the lifting gear and

carefully lift it off the transmission.
CAUTION
Carefully guide the cable (1) for the inductive pickup
through the housing bore.
13 Remove the gasket (2). 2

1
14 Remove the lifting device 1X56 136 260.
016122
10-8
10.2 Output Cover - Install
10.2.1 Sun Gear End Play - Measure
1 Remove the shim (1) from the sun gear (2).
NOTE
1
The shim (1) may also be in the planetary carrier.
016123
3 Place the measuring apparatus on the housing

mating face. 1
016124
4 Measure distance "A" between the measuring bar

and the contact surface for the shim on the sun
gear and note it down.
016125
10-9
5 Measure distance "M" between the measuring bar

and the gasket and note it down.
6 Distance "A" minus distance "M" gives the theo-

retical distance "C" between the gasket and the
contact surface for the shim.
A-M=C
016126
7a NOTE
The HP 502 / 592 version has a planetary carrier
without locked thrust washer.
016127
7b In the case of version HP 592 / 602, ensure that

the thrust washer (1) is lying on the contact face of 2
the planetary carrier and that the locking element 1
(2) is engaged in the bores.
NOTE
After measuring, affix the thrust washer using
Vaseline.
013018
10-10
8a In the case of version HP 502 / 592, use a depth

gauge to measure the distance "B" between the
measuring bar and the shim contact face on the
output cover and note it down.
(Fig no..: 016128)
8b In the case of version HP 592 / 602, use a depth

gauge to measure the distance “B” between the
measuring bar and the thrust washer on the output
cover and note it down.
(Fig. no.: 016147)
9 Calculate the required shim thickness "X" as

follows:
CAUTION
The measuring apparatus for measuring the distance
016128
"B" must be at the same height as for measuring the
distances "A" and "M".
M-B=D
C-D=E
X = E - (0.6 to 0.8 mm)
0.6 to 0.8 mm = Shim end play.
CAUTION
The distances used in the calculation example are
purely theoretical.
A = 46 mm
B = 40 mm
M = 41.5 mm
It follows that: 016147

A-M=C 46 - 41.5 = 4.5 mm
M-B=D 41.5 - 40 = 1.5 mm
C-D=E 4.5 - 1.5 = 3.0 mm
X = E - (0.6 to 0.8 mm)

X = 3.0 mm - (0.6 to 0.8 mm)
X = 2.2 to 2.4 mm
The shim can be between 2.2 and 2.4 mm thick.
Shims WTB 0730 104 779 are available in thicknesses

ranging from 1.8 to 7.00 mm in 0.2 mm steps
CAUTION
Do not grind down the shims. Shim centering must be
guaranteed.
10-11
10a In the case of version HP 502 / 592, affix the

selected shim (1) in the planetary carrier using
Vaseline.
1
016129
10b In the case of version HP 592 / 602, insert the

selected shim (1) in the sun gear.
11 Bolt the lifting device 1X56 136 260 to the output

shaft.
12 Grip the output cover with the lifting gear and

align it with the bolt holes above the transmission. 016123
13 Slowly lower the output cover.
14 While lowering the cover, guide the cable (1) for

the inductive pickup into the output cover bore
(see arrow).
15 Completely lower the output cover and remove the

lifting gear.
1
CAUTION
When the output cover is lowered, the planet gears
must engage in the disc carrier and ring and sun gear
teeth. Turn the output shaft slightly if necessary. Take
care not to damage the cable to the inductive pickup.
016122
10-12
16 Screw in the ten M10x55 hexagon bolts (1) with

washers as illustrated.
17 Screw in the two M10x75 hexagon bolts (2) with

washers.
NOTE
Leave free the holes for the retarder accumulator 1
and heat exchanger bracket.
18 Alternately tighten the hexagon bolts working dia-

gonally across and pull the output cover onto the 2
2
transmission.
013003
19 Screw off lifting device 1X56 136 260.

1
NOTE
Clean the mating face on the output flange (1) and
on the thrust washer.
012492
20 Coat the thrust washer mating face (1) with

sealant (WEVO-L100, WEVOCHEMIE) and
place it on the output flange.
011646
10-13
21 Take two new M12 x 30 hexagon bolts (1) and

coat the underside of the bolt heads with sealant 1
(WEVO-L100, WEVOCHEMIE). Then screw in
and tighten the bolts. While doing this, hold the
output flange steady using a flange holder.
NOTE
The chamfered side of the thrust washer must face
outwards.
012493
22 Knock the locking plate onto the M12 hexagon

bolts using punch 1X56 136 471 until the locking
plate is firmly seated on the thrust washer.
012494
! DANGER 1
A sharp-edged groove may be formed when the
locking plate (1) is fitted. Carefully smooth the
groove using a file or other suitable tool.
CAUTION
Maintain cleanliness at all times! Cover the
transmission openings. Carefully remove any
shavings or other debris.
012495
10-14
23 Install the inductive pickup, see section 10.1.1
011775
24 Coat the thread of the pulse generator for the

speedometer (1) with oil and screw it in. 1
011636
25 Fit the bracket for the heat exchanger (1) onto the
transmission. Screw in the eight M10x60 hexagon
bolts (2) with wide washers (spec list 6030 010
026), position the bracket horizontally in relation
to the transmission and tighten the bolts.
Tightening torque: 46 Nm 2
012375
10-15
26 Bolt on the brackets for the oil pipes (1) and retar-
der accumulator (2) as illustrated using two 2
M10x60 hexagon bolts with washers in each case.
1
013002
10-16
10.3 Output Cover - Dismantle
1 Loosen the valve (1) by tapping the output cover

with a plastic-tip hammer and remove the valve
from the valve bore.
1
012496
2 Place the output cover on the output shaft.
3 Grasp the F piston (1) with pliers and knock it out

of the output cover using a plastic-tip hammer.
NOTE
Knock out the F piston by striking it evenly
around the edge. 1
012497
4 Place the output cover in a press and support it so

that the planetary carrier can be pressed out.
CAUTION
Use soft material to support the planetary carrier.
! DANGER
Do not put your hands underneath the planetary
carrier.
5 Press the planetary carrier out of the output cover.
008662
10-17
6 Press the shaft seal out of the output cover.

1
NOTE
To make removal of the shaft seal easier, drive it in
deeper on one side and lever it out using a pry bar.
7 Remove the tapered roller bearing (1) from the

output cover.
8 Heat the output cover to approx. 85°C using hot

air blower 1X56 136 513.
008663
!DANGER
Always wear protective gloves when handling the hot
output cover.
9 Drive out the two bearing outer races (1) using a

plastic drift.
NOTE
Always insert the plastic drift in the grooves (2).
2
Drive out the input end bearing outer race from
the output end and the output end bearing outer 1
race from the input end.
008665
10 Remove the shim(s) (1) from the toothed ring (2).
012498
10-18
11 Fit a three-arm puller onto the toothed ring.
CAUTION
Fit a thrust piece (1) on the end of the output shaft.
12 Pull the toothed ring off the output shaft.

1
012499
13 Push gripper 1X56 136 706 onto the tapered roller

bearing inner race (1).
012500
14 Tighten the pulling edge using the threaded ring

on the gripper until the pulling mechanism firmly
grabs behind the tapered roller bearing.
15 Screw the basic tool 1X56 122 306 onto gripper

1X56 136 706.
16 Pull off the tapered roller bearing inner race.
012501
10-19
17 Insert internal puller 1X56 122 205 into the bea-

ring bore and place the pulling edge behind the
needle bearing.
18 Screw counter support 1X56 122 227 onto the

internal puller.
19 Pull the needle bearing (1) out of planetary carrier 1

III.
012502
20 Release the planet gear pins (1). To do this,

carefully knock the roll pins (2) into the center of
1
the planet gear pins.
CAUTION
Never knock the roll pins in as far as the stop.
012503
21 Remove the planet gear pins from the planetary

carrier.
22 Knock the roll pins (1) out of the bore in the pla-
net gear pins.
012504
10-20
a Version HP 502/ 592 : 4
23a In the case of version HP 502 / 592, remove each

planet gear (1) with the two roller bearings (2) and
thrust plates (3) from planet carrier III.
NOTE
In the case of version HP 502 / 592, 1
Each planet gear (1) has two roller bearings (2) 2
and each planetary carrier has two upper and
lower thrust plates (3/4).
3
016130
b Version HP 592 / 602:
23b In the case of version HP 592 / 602, remove planet

gears (1), roller bearings (2) and thrust washers
(3) from planetary carrier III.
012505
NOTE
In the case of version HP 592 / 602, each planet
gear (1) has two upper thrust washers (2), one
roller bearing (3) and two lower thrust washers
(4).
4 3 1 2
012506
10-21
10-22
10.4 Output Cover - Assemble 2
NOTE 1
When assembling, it is best to rotate the planetary
carrier through 180° from the position illustrated
so that it is standing on its end face.
a Version HP 502 / 592 : 3

6
1a Before installation, grease the bearing bores, 4
planet gear pins and thrust plates using Vaseline.
Also oil the roller bearings.
5
2a Insert the two lower thrust plates (1/2) into the pla-
netary carrier.
2008
CAUTION
The plates used in the double and triple thrust plates
are made from two different materials. One surface is
steel, the other aluminum. The steel surface is mar-
ked (see arrow) and must lie on the planetary carrier.
005779
3a Insert each planet gear (3) into the planetary

carrier complete with two roller bearings (4). 6 5
CAUTION
Always renew the planet gears as a complete set.
4a Place the two upper thrust plates (5/6) on the

planet gears in the planetary carrier.
CAUTION
The steel surface of the thrust plates must be facing
the planetary carrier.
016146
10-23
1b Before installation, grease the bearing bores, pla-

net gear pins and thrust washers with Vaseline.
Also oil the roller bearings.
2b Insert the two lower thrust washers (1/2) for each

planet gear.
1 2 3 4 5 6
012506
3b Insert the planet gears (4) into the planetary

carrier complete with roller bearing (3).
CAUTION
4b Insert the two upper thrust washers (5/6) for each

planet gear.
5 3
012505
5 Align the planet gears, roller bearings and thrust

washers or plates centrally in relation to the pin
bores in the planetary carrier.
Install the planet gear pins as follows:
NOTE
Use new planet gear pins.
6 Slide the planet gear pins into the planetary carrier

until they are flush; align the bore for the roll pin
with the bore in the planetary carrier (1) while
doing this. 1
012504
10-24
7 Knock the new roll pin (1) into the planetary carri-
er and planet gear pin until it reaches the surface
of the planetary carrier casing surface.
NOTE
The installation procedure is the same for all
planet gear pins.
012507
8 Secure the roll pins by striking them at two points

that are 180° apart.
012508
9 Measure the planet gear end play between the

thrust washer and the planetary carrier.
NOTE
The end play must be between 0.5 and 1.2 mm.
Measure it on all the planet gears.
012509
10-25
10 When the needle bearings are inserted, the needle

bearing with the thicker surround and imprint (see
arrow) must be facing the punch Oil the needle
bearings.
012510
a Version HP 502 / 592:
11a Drive the new needle bearing into planetary

carrier III using punch 1X56 137 101.
NOTE
The installation position of the needle bearing will
be correct if punch 1X56 137 101 is used.
012511
11b Affix the thrust washer (1) in the planetary carrier

using Vaseline.
12b Drive the new needle bearing into planetary

carrier III using punch 1X56 137 101.
NOTE
The installation position of the needle bearing will
be correct if punch 1X56 137 101 is used.
012490
10-26
10.4.1Tapered Roller Bearing - Adjust
1 Clamp adjuster 1P01 136 816 in a vice.
NOTE
Both tapered roller bearings must be washed clean
and lightly oiled.
008684
2 Slide the input end tapered roller bearing inner

race (1) onto the adjuster.
3 Drive the clamping sleeves (2) at least 5mm out of

the setting ring beforehand.
2
4 Slide the spacer bush and setting ring (3) onto
adjuster 1P01 136 816.
3
CAUTION
The clamping sleeves (2) must be facing upwards.
1
008683
5 Heat the output cover to approx. 85°C using hot

1
6 Insert the input end bearing outer race (1) into the
output cover with the wider collar facing upwards
and knock it in as far as it will go using punch
1X56 136 824.
!DANGER
output cover.
008685
10-27
7 Turn over the output cover.
8 Install the output end bearing outer race (1) as

described in step 6.
1
CAUTION
Do not allow the output cover to cool down to below
85°C before fitting the bearing outer races.
008687
9 Place the output cover on adjuster 1P01 136 816

so that it is lying flat.
10 Insert the output end tapered bearing inner race

(1) so that it is lying flat. 1
008686
11 Position the adjuster disc (1) so that the projection

is facing the adjuster.
1
12 Screw in the M12 hexagon bolt (2) until it grabs.
2
NOTE: The parts on the adjuster must be at
approx. 20°C for subsequent adjustment.
Specified bearing setting

= 0.05 to 0.15 mm preload
This is equivalent to a bearing roll torque of

1.8 to 6.4 Nm at ambient temperature.
008688
10-28
13 Wind the neck of the output cover several times

using a T-handle and attach a spring balance.
14 Pull evenly to start the output cover turning. The

force required must be between 15 and 20 N.
15 Tighten the hexagon bolt if the force is less than

15 N.
CAUTION
If the hexagon bolt has been tightened too much, i.e.
the tensile force is greater than 20 N, the adjuster has
to be fully prepared for measuring again, starting
right at the beginning.
008689
16 Undo the hexagon bolt (1) and remove the washer.
17 Take the output cover off the adjuster. 1
CAUTION
Do not adjust the clamping sleeves when undoing the
hexagon bolt.
18 Take off the setting ring. 008690
19 Place the setting ring on a flat surface with the

clamping sleeves facing downwards.
20 Use a depth micrometer to measure the distance

"A" between the end face of the setting ring and
the end face of the clamping sleeve.
008691
10-29
21 Use a micrometer to measure distance "B" on the

toothed ring (1) and note it down.
22 Distance "A" minus distance "B" gives distance

"C" .
The required spacer disc thickness "S" is

calculated as follows:
S = C + 0.05 mm
0.05 mm = constant allowance factor
012512
23 Check the calculated spacer ring thickness using a

micrometer.
Spacer discs are available in the following

thicknesses:
0730 103 586 = 1.20 mm

0730 103 587 = 1.10 mm
0730 106 668 = 1.05 mm
0730 103 588 = 1.00 mm
0730 106 667 = 0.95 mm
0730 106 666 = 0.90 mm
0730 103 589 = 0.80 mm
0730 103 590 = 0.60 mm
0730 103 591 = 0.40 mm
008692
24 Heat the input end taper roller bearing inner race

(1) to approx. 85°C using hot air blower 1X56 136
513 and slide it fully home onto the output shaft.
1
CAUTION
Do not strike the rollers. The tapered peak of the
bearing must face the output end.
12500
10-30
25 Heat the toothed ring (1) to approx. 85°C using

hot air blower 1X56 136 513 and slide it onto the
output shaft.
1
012513
26 Once they have cooled down, press the toothed

ring and bearing inner race fully home using
punch 1X56 136 824.
012514
27 Place the selected spacer disc(s) (1) onto the

toothed ring.
012498
10-31
28 Place the output cover onto the planetary

carrier.
29 Heat the output end bearing inner race (1) to

approx. 85°C using hot air blower 1X56 136 513.
30 Insert the bearing inner race fully home into the

output cover.
012515
31 Smear washing-up liquid around the outside edge

of the shaft seal (1).
32 Slide the shaft seal onto punch 1X56 136 824 with
the sealing lip facing the output cover.
008699
33 Press the shaft seal into the output cover as far as

it will go using punch 1X56 136 824.
34 Sealing ring installation dimension = 15 -1 mm

between end face of bearing inner race and end
face of sealing ring is assured if punch 1X56 136
824 is used.
CAUTION
Pack the sealing and dust lip of the shaft seal with
acid-free grease.
008701
10-32
NOTE
Insert the hexagon bolts before mounting the
output flange, if ncessary.
35 Heat the output flange (1) to approx. 110°C using

hot air blower 1X56 136 513.
36 Press the output flange fully home onto the output 1

shaft.
008700
37 Fit the thrust washer (1) and attach the output

flange using the two M 12 x 30 hexagon bolts (2).
Use a flange holder to hold the output flange still
while doing this;
1
CAUTION
The flange is only bolted on to check the bearing roll
torque. Once the roll torque has been checked,
remove the bolts and thrust washer again and bolt 2
lifting device 1X56 136 260 to the output shaft.
See section 10.2 for output flange fitting procedure
12493
NOTE:
Let the output end cool down to ambient
temperature.
38 Check the bearing roll torque again. To do this,

wind the neck of the output cover several times
using a T-handle and attach a spring balance.
39 Start the output cover turning by pulling evenly.

The force required must be between 13 and 45 N.
This is equivalent to a bearing roll torque of bet-
ween 1.8 and 6.4 Nm.
CAUTION
If the bearing roll torque is out of tolerance, correct
the setting.
015824
10-33
40 Check the O-ring on the ventilation valve (1),

thinly coat it with Vaseline and insert the valve as
illustrated.
012496
NOTE
Installation position of the ventilation valve (see
arrow).
012497
10-34
10.4.2 F Brake Disc Play - Adjust

1
1 Fit a gasket (1) on the housing mating face and
attach the measuring apparatus.
2 Use a depth gauge to measure between the

measuring bar and the disc spring (2) on the
outside edge / at the highest point. Note down as
distance "A".
2
008702
3 Use a depth gauge to measure between the

measuring bar and the gasket and note down as
distance "B".
4 Subract distance "A" from distance "B" and note

down as distance "C"
B -A = C
008703
5 Insert the F piston into the output cover as far as it

will go.
6 Use a depth gauge to measure between the output

cover mating face (without gasket) and the "F
piston" thrust face. Note down as distance "D".
7 Disc play = D - C
The disc play must be between 2.6and 3.1 mm.
Adjust by using different outer discs. The discs are
available in the following sizes:
2.0 mm 2.5 mm 3.0 mm
CAUTION
Do not use the F piston outer disc to balance the play.
008704
10-35
8 To adjust NBS, grip F piston (1) with pliers and

tap around the edge of the output cover with a
plastic-tip hammer.
9 Remove the F piston.
012497
10 Insert the outer lipped sealing ring (1) into the F

piston with the sealing lip facing the pressure side.
1
11 Insert the rectangular-section ring (2).
2
12 Insert the inner rectangular-section ring.
008707
13 Measuring device 1P01 137 906 for NBS
008706
10-36
14 Position adjuster 1P01 137 906 with “Piston-

Side” (see engraving) on the F piston. The device
fixing bolts (1) must be loosened.
15 Press the device rings (2) against the piston and

carefully tighten the fixing bolts.
008709
16 Insert the spring elements into the transmission

housing without the springs.
008708
17 Position the adjuster with “Disc-Side” on the disc

spring of the disc pack. Centrally and radially
align the device with the spring elements.
008710
10-37
18 Insert the measuring tubes into the device and use

a Torx screwdriver to set each spring element so
that the face end of the measuring tube is flush
with the outer ring of the device.
008711
19 Check step 18 using a straight edge.
008712
20 Lift off the device. Position the F-piston and place

the device on the F-piston to ensure more precise
measurement.
008713
10-38
21 Check the NBS play by measuring between the F

piston and the disc spring using a feeler gauge.
Permitted play: 0.05 to 0.25 mm.
008714
10-39
10-40
HP 502 / HP 592 / HP 602 Mechanical Transmission Section
11 Mechanical Transmission Section - Remove

and Install
11.1 Mechanical Transmission Section - Remove

Version HP 502 / 592: 1
1 Remove the shim (1) from the sun gear.
016123
2 Take out the NBS spring elements and springs.
008718
3 Take the sun gear (1) off the input shaft.
16396
11-1
Mechanical Transmission Section HP 502 / HP 592 / HP 602
4 Take the thrust washer (1) off the input shaft.

1
NOTE
The thrust washer may stick on the rear of the sun
gear.
016397
5 Grip planetary carrier II (1) with assembly hooks

1X56 097 775 and remove it from the
transmission.
! DANGER
The planetary carrier is not held stable by the
assembly hooks.
1
008720
6 Take the thrust washer (1) out of the transmission.
NOTE
The thrust washer may be located on the rear of 1
planetary carrier II.
016398
11-2
7 Remove the disc spring (1) and the spring holder

(2) from the transmission.
016399
8 Remove the F brake disc pack (1) from the

transmission.
CAUTION
Clearly mark the disc pack. Do not mix up discs from
different packs. 1
016400
9 Remove the compression springs, pins and guide

tubes (1) from the transmission.
016401
11-3
10 Grip planetary carrier I with assembly hooks

1X56 097 775 and lift it out of the transmission.
! DANGER
The planetary carrier is not held stable by the
assembly hooks.
008743
11 Remove the thrust washer (1) from the

3
transmission.
NOTE
The thrust washer may stick on the rear of 2
planetary carrier I.
1
12 Rotate the thrust ring (2) until the thrust ring teeth
are located between the teeth (3) on the
transmission housing.
008756
13 Remove the thrust ring (1) from the transmission.
14 Remove the disc pack (2) from the transmission.

3
CAUTION
Clearly mark the disc pack. Do not mix up discs from
different packs.
15 The centering pins (3) can be left on the last disc.

Remove centering pins carefully.
! 2
DANGER
Never let the centering pins fall into the transmission.
1
008758
11-4
11.1.1Planetary Carrier II - Dismantle

Version HP 502 / 592:
1 Detach the snap ring (1) at all four recesses (2)

using a screwdriver.
CAUTION
Make sure that the snap ring does not spring back
into the groove. 2
1
008723
2 Pull the output end ring gear (1) off planetary

carrier II (2) and remove the snap ring.
NOTE
Use a plastic-tip hammer to separate the ring gear
and planetary carrier II if necessary.
1
008724
3 Release the planet gear pins (1) using a suitable

caulking tool.
! DANGER 1
Wear safety goggles when releasing the planet gear
pins.
008725
11-5
4 Knock out the planet gear pins (1) in downwards

direction using a drift.
5 Remove the planet gears (2) from planetary

carrier II.
008726
6 Remove the roller bearings (1) from each planet

gear.
1 1
008727
7 Remove the thrust plates (1) from planetary

carrier II.
NOTE
Remove the three-ring plates first of all.
008728
11-6
8 Insert a suitable drift in the hole (2) to press out

the snap ring (1).
9 Release the snap using a screwdriver.
10 Place a plastic drift against the shoulder (see

arrow) of the ring gear (3).
11 Knock the ring gear off planetary carrier II.

See section 11.1.3, step 3
1 2
008729
11-7
11-8
11.1.2 Planetary Carrier II - Assemble

1 Insert the lower thrust plates (1).
008730
CAUTION
The thrust plates are made from two different
materials. One surface is steel, the other is aluminum.
The steel surface is marked (1) and must always lie on
1
008731
2 Insert the two roller bearings (2) for each planet

gear (1).
NOTE
Grease the planet gear bearing bore and the roller
bearings with Vaseline before installation. 2
008732
11-9
3 Fit all the planet gears (1) into the planetary

carrier.
4 Insert the upper thrust plates (2) with the steel side 1
facing the planetary carrier.
008733
5 Align the bearings, thrust plates and planet gear

with the holes in the planetary carrier.
6 Drive in the planet gear pin as far as it will go.
CAUTION
NOTE
The installation procedure is the same for all the
planet gears. Always renew planet gears as a
complete set.
008734
7 Place support 1X56 137 464 in the press.
8 Place the planet gear carrier (1) on the support.
9 Secure all the planet gear pins by caulking the

collars with special tool 1X56 137 466 under the
press.
008735
11-10
CAUTION
The pin (1) must engage in the planet gear pin hole.
Always place the planet gear pin that needs to be
secured on the pin.
008736
10 Use a feeler gauge to measure the planet gear end

play between the thrust washer and the planetary
carrier.
NOTE
End play 0.5 to 1.2 mm. Measure on all the planet
gears.
008738
11 Insert the output end ring gear (1) in the press with
the groove facing upwards.
12 Place planetary carrier II (2) onto the ring gear.
13 Align the teeth.

2
14 Place a pressing device of suitable diameter onto
15 Press the ring gear onto the planetary carrier.
008737
11-11
16 Insert the snap ring (1).
CAUTION
Insert the snap ring so that the ring ends are at the
hole (2). The snap ring must fully engage in the
groove.
1 2
008739
17 Place planetary carrier II in the press.
18 Fit the snap ring.
19 Fit the input end ring gear (1) with the groove
1
facing the planetary carrier.

21 Press the ring gear onto the planetary carrier so

that there is still play on the snap ring.
008741
22 Insert the snap ring in the ring gear groove using a

screwdriver. 2
1
23 Fully press on the ring gear and press the snap
ring (1) into the groove by inserting a screwdriver
through all the recesses (2).
CAUTION
Insert the snap ring so that the ring ends are at recess
(2). The snap ring must fully engage in the groove.
008740
11-12
11.1.3Planetary Carrier I - Dismantle

1
1 Insert a drift in the hole (2) to press out the snap

ring (1).
2 Release the snap using a screwdriver.
008744
3 Place a plastic drift against the shoulder of the

ring gear and knock the ring gear off the planetary
carrier.
008745
4 Release the planet gear pins (1) using a caulking

tool.
! DANGER
Wear protective goggles when releasing the planet
gear pins (1).
5 Knock out the planet gear pins (1) in downwards

direction using a drift.
1
008746
11-13
6 Remove the planet gears (1) with thrust washers

1
(2) from planetary carrier I, working inwards.
7 Remove the needle bearings from the planet gears.
008747
11-14
11.1.4Planetary Carrier I - Assemble

1
1 Insert the lower thrust washer (1) into planetary
carrier I with the radius facing outwards.
CAUTION
The thrust washers are made from two different
materials. One of the surfaces is steel, the other is
aluminum. The steel surface is marked (1) and must
always face the planetary carrier.
008748
2 Insert the needle bearings (2) in each planet gear

(2).
NOTE 2
Grease the planet gear bearing bore and needle
bearings with Vaseline before installation.
008750
3 Insert the planet gear into planetary carrier I

complete with the bearing.
4 Insert the upper thrust washer (1) with the steel

side facing the planetary carrier.
008749
11-15
5 Align the bearings, thrust washer and planet gear

with the holes in the planetary carrier.
6 Drive in the planet gear pin (1) as far as it will go.

1
CAUTION
Always use new planet gear pins. Always renew
planet gears as a complete set.
NOTE
planet gears.
008751
7 Place support 1X56 137 464 in the press and lay

the planetary carrier (1) on the support.
8 Insert caulking tool 1X56 137 465 in the press and

secure all the planet gear pins by caulking the 1
collars.
CAUTION
The lug (2) must engage in the hole in the planet gear
pin. Always place the planet gear pin that needs to be
secured on the lug.
008752
9 Use a feeler gauge to measure the planet gear end

1
play between the thrust washer and the planetary
carrier.
CAUTION
Do not measure on the recess (1).
NOTE
The specified end play is 0.5 to 1.2 mm.
Measure on all the planet gears.
008753
11-16
10 Place the ring gear (1) in the press with the groove
facing upwards.
11 Place planetary carrier I (2) onto the ring gear.
12 Align the teeth.
13 Place the pressing device on the planetary carrier

and press on the ring gear. 2
008755
14 Insert the snap ring (1).
CAUTION
Insert the snap ring so that the ring ends are at the
hole (2). The snap ring must fully engage in the
groove.
1 2
008754
11-17
11-18
11.2 Mechanical Transmission Section - Remove

NOTE
Illustrations do not show NBS!
Remove the spring elements and springs for NBS 3
as well as the disc spring and spring holder from
the transmission, see section 11.1. 2
1 If necessary, remove the cable (1) for the inductive

pickup from the transmission (shift control must 4
be removed).
1
2 Remove the compression springs (2) with pins (3)
and guide tubes (4) from the transmisssion.
013062
NOTE
The lower pins (3) are located on the last E disc.
Take them out using a bar magnet.
3 Pull the sun gear (1) off the input shaft together
with the thrust washer (2). 2
1
3
013063
4 Remove the thrust washer from the input shaft.
NOTE
The thrust washer may also stick on the rear of the
sun gear.
013064
11-19
5 Lift the F brake disc pack out of the transmission

housing using assembly hooks 1X56 097 775.
6 Remove the last outer disc from the transmission

housing.
NOTE
Tie the disc pack together using wire and mark it
clearly. Do not mix up the discs from different
packs.
013065

thrust ring (1).
8 Rotate the thrust ring until its teeth are located in

the gaps between the transmission housing teeth.
1
9 Lift the thrust ring out of the transmission hou-
sing.
013066
10 Screw hooks 1X56 136 612 into planetary carrier

II and lift planetary carriers II und I out of the
transmission together with the E brake discs.
013067
11-20
11 Lift the discs off the planetary carrier.
NOTE
Tie the disc pack together with wire and mark it
clearly. Do not mix up the discs from different
packs.
013068
12 Turn the planetary carrier over and remove the

thrust washer (1) from planetary carrier I.
1
NOTE
The thrust washer may also be located on the disc
carrier in the transmission.
013069
13 Insert a suitable drift in the hole (2) and press the

snap ring (1). Remove it from the groove using a 1
screwdriver.
013070
11-21
14 Take planetary carrier I (1) off the ring gear.
NOTE 1
Use a plastic-tip hammer to separate planetary
carrier I and the ring gear if necessary.
013071
15 Remove the snap ring (1) from the groove using a

suitable screwdriver.
NOTE
Make sure that the snap ring does not spring back
into the groove. 1
16 Remove the thrust washer (2) from planetary 2

carrier II.
NOTE
The thrust washer may also stick on planetary
carrier I.
013072
17 Remove the ring gear (1).
NOTE
Use a plastic-tip hammer to separate the ring gear
and planetary carrier II if necessary. 1
013073
11-22
18 Remove the ring gear (1) from planetary carrier II.
013074
19 Insert a suitable drift through the hole (2) and

press the snap ring (1). Use a screwdriver to
remove the ring from the groove.
1
2
013075
20 Remove planetary carrier II (1) from the ring gear.
NOTE
Use a plastic-tip hammer to separate planetary
carrier II and the ring gear if necessary.
013076
11-23
11-24
11.2.1Planetary Carrier II - Dismantle

Version HP 592 / 602: 1
NOTE
The removal procedure is the same for all planet
gears.
1 Release the planet gear pins (1) using a suitable

caulking tool.
! DANGER
gear pins since metal splinters may fly off.
013077
2 Use a drift to knock out the planet gear pins in

downwards direction.
013078

carrier II together with the roller bearings (2) and
the lower and upper thrust washers (3/4).
4 3 3 4
2 1
013079
11-25
11.2.2 Planetary Carrier II - Assemble

NOTE
planet gears.
CAUTION
1 Insert the two lower thrust washers (1/2).

1 2
013080
2 Insert the roller bearing (1) in the planet gear (2)

and place the gear and bearing onto the lower
thrust washers in the planetary carrier.
2
NOTE
Grease the planet gear bearing bore and the roller
bearing with Vaseline before installation.
013081
3 Insert the two upper thrust washers (1/2).
1 2
013082
11-26
4 Align the bearing, thrust washers and planet gear

with the bore in the planetary carrier.
5 Insert the planet gear pin (1) as far as it will go.
CAUTION
013085
CAUTION
The pin (1) must engage in the planet gear pin bore.
Always place the planet gear pin to be secured on the
pin.
008736
7 Place the planetary carrier (1) on the support.
8 Use caulking tool 1X56 137 466 (2) in the press to 2 1

secure the planet gear pin by caulking the collar.
NOTE
planet gears.
CAUTION
013086
11-27
9 Measure the planet gear end play by placing a

feeler gauge (1) between the thrust washer and the
planetary carrier.
NOTE
Specified end play: 0.5 to 1.2 mm. Measure on all
the planet gears.
013087
11-28
11.2.3 Planetary Carrier I - Dismantle

Version HP 592 / 602: 2
1
1 Release the planet gear pins (1) using a caulking
tool (2).
! DANGER
gear pins (1) since metal splinters may fly off.
2 Use a drift to knock out the planet gear pins (1) in

downwards direction.
013083

carrier I together with the needle cages (2) and the
lower and upper thrust washers (3/4).
3 3 2 1 4 4
013084
11-29
11.2.4 Planetary Carrier I - Assemble

NOTE
The installation procedure is the same for all the 2
planet gears.
CAUTION
1 Insert the first 2.00 mm thrust washer (1) in the 1

planetary carrier.
2 Place the second 1.00 mm thrust washer (2) on the

first thrust washer.
013088
3 Insert the needle cage (1) in the planet gear (2)

and place the gear and needle cage on the lower
thrust washer in the planetary carrier.
NOTE
Grease the planet gear bearing bore and needle
cage with Vaseline before installation. 2
013089
4 Place the first 1.00 mm thrust washer (1) on the

planet gear.
5 Place the second 2.00 mm thrust washer (2) on the

first thrust washer.
2
CAUTION
The 2.00 mm thrust washer must be facing the
planetary carrier.
013090
11-30
6 Align the needle cage, thrust washers and planet

gear with the bore in the planetary carrier.
7 Insert the planet gear pin (1) as far as it will go.
CAUTION
1
013091
CAUTION
The pin (1) must engage in the planet gear pin bore.
Always place the planet gear pin that needs to be
secured on the pin.
9 Place the planetary carrier (1) on the support.

1
2
10 Place caulking tool 1X56 137 465 (2) in the press
and caulk the collar to secure the planet gear pins.
NOTE
planet gears.
CAUTION
013092
11-31
11 Measure the planet gear end play by placing a

feeler gauge (1) between the thrust washer and the
planetary carrier.
NOTE
Specified end play: 0.5 to 1.2 mm. Measure on all
the planet gears.
1
013093
11-32
11.2.5 Planetary Carrier II and I - Assemble

1 Heat the ring gear (1) to approx. 85°C using hot

air blower 1X56 136 513 or a heating furnace.
! DANGER
3
Always wear protective gloves when handling hot
parts. 2
2 Place the ring gear (1) in the press with the groove
facing upwards. 1
3 Place planetary carrier II (2) on the ring gear and

align the teeth.
4 Place a pressing device (3) of suitable diameter 013094
onto the planetary carrier and press the ring gear

onto the planetary carrier.
5 Insert the snap ring (1) into the planetary carrier

groove.
CAUTION
Insert the snap ring so that one of its ends is above
the hole (2). The snap ring must fully engage in the
groove.
1 2
013095
6 Place a spacer plate (1) that is approx. 7.0 mm

thick onto the ring gear.
013096
11-33
7 Slide the ring gear (1) over the planetary carrier

teeth and place it on the spacer plate.
8 Insert planetary carrier II into the press complete

with the ring gears.
013097
9 Heat the input end ring gear (1) to approx. 85°C

using hot air blower 1X56 136 513 or a heating 1
furnace.
! DANGER
Always wear protective gloves when handling hot
parts.
10 Position the ring gear (1) with the groove facing

the planetary carrier and align the teeth.

the ring gear.
12 Press the ring gear (1) onto the planetary carrier

until the groove for the snap ring on the ring gear
overlaps with the groove on the planetary carrier. 013098
13 Insert the snap ring (1) in the groove on the

planetary carrier.
14 Insert the snap ring in the ring gear groove using a 1

screwdriver.
2
CAUTION
The snap ring must fully engage in the groove. Use a
screwdriver if necessary.
15 Affix the thrust washer (2) to planetary carrier II

using Vaseline.
013099
11-34
16 Place planetary carrier II in the press complete

with the ring gears.
1
17 Place planetary carrier I (1) on the ring gear and
align the teeth.

19 Press the planetary carrier onto the ring gear.
20 Remove the spacer plate (2) from between the ring

gears.
2
013100
21 Insert the snap ring (1) in the ring gear groove.
CAUTION
Insert the snap ring (1) so that one of its ends is above
the hole (2). The snap ring must fully engage in the
groove.
013070
11-35
11-36
11.2.6 E Piston and Disc Carrier - Remove

(2) from the transmission housing.
016410
2 Remove the E piston (1) from the transmission

housing.
016411
NOTE
If the E piston is firmly seated, blow compressed
2
air into one of the oil ducts (1) to loosen the E
piston.
3
! DANGER
Cover the transmission housing with a cloth before
attempting to loosen the E piston using compressed
air. Protect your eyes from oil spray.
3 Remove the lipped sealing rings (2/3) from the E

piston. 1
016412
11-37
4 Lift the disc carrier (1) out of the transmission.
016413
6 Remove the upper needle bearing (1) from the

disc carrier.
1
008763
5 Take the needle bearing (1) and the thrust washer

(2) off the hollow shaft.
NOTE
The needle bearing (1) and the thrust washer may
also be located on the rear of the disc carrier.
016414
11-38
11.2.7 Sun Gear - Remove from Disc Carrier

1 Detach the outer and inner snap rings.
2 To do this, rotate each snap ring until the end

1
appears in the groove (1).
2
3 Knock the sun gear (2) out of the disc carrier
using a suitable drift.
008764
11.2.8 Sun Gear - Install in Disc Carrier

1
1 Insert the sun gear (1) in the disc carrier with the
long collar facing upwards.
2 Knock in the sun gear as far as it will go.
008765
3 Insert the inner and outer snap rings and engage

them in the groove.
NOTE
To do this, rotate each snap ring so that the ends of
the rings are facing the recess (1).
008766
11-39
11.2.9 Sun Gear - Remove from Disc Carrier

21
1 Detach the snap ring (1).
005400
2 Knock the sun gear (1) out of the disc carrier

using a suitable drift.
1
003751
11.2.10 Sun Gear - Install in Disc Carrier

1 Insert the snap ring (1) in the groove on the sun 21

gear.
2 Insert the sun gear (2) in the disc carrier and let
the snap ring (1) engage in the disc carrier.
008779
11-40
11.2.11 Hollow Shaft / Input Shaft - Remove
NOTE
The hollow shaft is only fitted in the 5 and 6-
speed versions!
1 Lift the hollow shaft out of the transmission

housing.
NOTE
While doing this, turn the hollow shaft so that it is
aligned with the teeth on the inner discs for the B
and C clutches.
008768
2 Remove both the needle cages from the hollow

shaft.
3 Remove the thrust washer from the input shaft /

hollow shaft.
008769
4 Remove the input shaft (1) from the transmission.
008770
11-41
5 Take the thrust washer (1) off the turbine shaft.

NOTE
The thrust washer may stick to the input shaft.
008772
6 Insert internal puller 1X56 122 205 into the

bearing bore and place the pulling edge behind the
needle bearing.
008771
7 Screw counter-support 1X56 122 227 onto the

internal puller.
8 Tighten the lock nut (1) by hand and pull the 1

needle bearing out of the input shaft.
008773
11-42
11.3 Mechanical Transmission Section - Install
1 Knock a new needle bearing into the input shaft as

far as it will go using punch 1X56 137 101.
NOTE
The needle bearing will be installed in the correct
position if punch 1X56 137 101 is used. Place the
punch against the side of the bearing with
reinforced surround.
008774
2 Affix the thrust washer (1) in the input shaft using

Vaseline.
008775
3 Align the outer discs (1) of the A clutch using a

screwdriver and center them.
016415
11-43
4 Insert the input shaft (1).
CAUTION
The input shaft must be inserted as far as it will go.
5 Place the thrust washer (2) on the input shaft.

NOTE
Coat the thrust washer with Vaseline.
1
008777
6 Insert both the needle cages (2) into the hollow

shaft.
NOTE
The hollow shaft is only fitted in the 5 and 6-
speed versions!
008769
7 Align the inner discs for the B and C clutches

using a screwdriver.
8 Insert the hollow shaft (1) into the transmission

housing.
1
9 Place the thrust washer (2) on the hollow shaft.
NOTE
Coat the thrust washer with Vaseline.
008767
11-44
10 Coat the output end needle bearing (1) with

Vaseline and insert it into the sun gear (2). 2 1
008779
11 Coat the lower needle bearing (1) with Vaseline
and insert it into the sun gear (2). 1 2
008778
12 Place the complete disc carrier (1) onto the hollow

shaft (or the input shaft in the 4-speed version).
CAUTION
Pay attention to the lower needle bearing. The disc
carrier must be fitted as far as it will go. Carefully
move the disc carrier back and forth if necessary.
008783
11-45
13 Insert the inner (1) and outer lipped sealing ring

(2) in the E piston.
1
CAUTION
Check the lipped sealing rings and renew if
necessary. The groove in both the lipped sealing rings
must be facing the pressure side. Stretch the inner 2
lipped sealing ring before installing it to ensure that it
is firmly seated in the base of the groove.
14 Lightly coat the mating faces of the E piston and

the lipped sealing ring with Vaseline.
01612
15 Insert the E piston (1) into the transmission.

Carefully knock it in as far as it will go using a
plastic-tip hammer.
CAUTION
Take care not to damage the lipped sealing rings
when installing them. 1 3
It must be possible to smoothly insert the E piston.
16 Place the spring holder (2) and the disc spring

(3) onto the E piston as illustrated. The inner 2
diameter of the disc spring lies on the spring
holder.
016410
17 Measure the first outer disc for the E brake.
CAUTION
The first outer disc for the E brake is 3 mm thick.
18 Check the outer and inner discs for wear.
19 Check that all the discs are flat using a straight

edge.
20 Renew any discs that are uneven, dished or

damaged.
008784/008785
11-46
a Version with "NBS"

Insert the discs for the E brake as follows.
21a Insert the first outer disc so that the center tooth
(1) of each disc segment comes to lie under the 2
recesses for the spring elements (2).
1
016416
22a Insert one inner disc.
23a Insert the second outer disc so that the recesses (1)
come to rest above the center tooth of each disc
segment on the first outer disc.
1
24a Fit the remaining discs in the same order.
NOTE
See spare parts list for outer and inner discs.
25a Mark the two holes (see arrows) for the long
spring elements.
016417
26a Mark the two recesses on the thrust ring (2) and
insert the thrust ring. At the same time, make sure
that the recesses in the thrust ring are next to the
holes for the long spring elements.
27a Slightly lift the thrust ring and turn it so that the 2
teeth on the thrust ring slide under the housing
teeth. The two recesses on the thrust ring (2) and
the two holes (see arrow) for the long spring ele-
ments must be aligned.
016418
11-47
b Version without "NBS"

Insert the discs for the E brake as follows.
28b Mark the lower cast housing bores (see arrow).
29b Insert the first outer disc so that the center tooth (1) in
each disc segment comes to lie above the marked
housing bores (see arrow).
30b Insert one inner disc.

1
31b Insert the second outer disc so that the recesses
come to lie above the center tooth (1) in each disc
segment on the first outer disc.
013105
32b Insert the remaining discs in the same order..
NOTE
See spare parts list for outer and inner discs.
016417
33b Insert the thrust ring in the housing groove.

Slightly lift the thrust ring and turn it so that the
thrust ring teeth slide under the housing teeth.
34 Use a feeler gauge to measure the E brake disc

play.
Permitted disc play = 2.8 to 3.3 mm.

Balance out any deviations by using a last outer
disc of appropriate size.
NOTE
Remove the thrust ring and the complete disc pack
from the transmission again.
008788
11-48
35 Affix the thrust washer (1) to the disc carrier

using Vaseline.
016419
a Version HP 502 / 592:

Install planetary carrier I and II
36a Grasp the planetary carrier (1) with assembly

hooks 1X56 097 775 and insert it into the trans-
mission.
016420
37a Install the E brake disc pack as described pre-

viously.
CAUTION
The first outer disc must be the 3 mm-disc.
016421
11-49
38a Install the thrust ring as described previously.
39a Insert the two longer spring elements (1) for

fixing the thrust ring.
1
016422
40a Affix the thrust washer (1) to the input end of

planetary carrier II using Vaseline.
Turn over planetary carrier II.
008793
41a Grip planetary carrier II (1) with assembly hooks

1X56 097 775 and insert it into the transmission.
CAUTION
Make sure that the input end thrust washer does not
fall off the planetary carrier.
016423
11-50

Install planetary carrier I and II
42b Screw two hooks 1X56 136 612 into planetary

carrier II and place complete planet carrier I and.
II onto the disc carrier. Remove the hooks.
013101
43b Re-install the E brake disc pack and the thrust ring
as described in section 11.3.
NOTE 1
To install the thrust ring, screw M6 guide screws
1X56 136 821 into the thrust ring (1) and insert
the thrust ring into the housing groove. When
doing this, slightly raise the thrust ring and turn it
so that the teeth slide under the housing teeth.
013066
NOTE
If NBS is fitted, the recesses on the thrust ring
must be aligned with the holes for the long spring
elements (1).
44b If NBS is fitted, insert the two longer spring ele- 1

ments (1) for fixing the thrust ring.
1
016423
11-51
45 Check the outer and inner discs for wear. Use a

straight edge to check that all the discs are flat.
Renew any discs that are uneven, dished or dama-
ged.
CAUTION
Renew dished, deformed or corrugated discs.
Maximum permitted wear is 0.3 mm. Renew lined
discs that have damaged or blackened linings. Renew
inner discs that have damaged tooth flanks.
Permitted wear per tooth flank is 0.2 mm.
008796
46 Install the F brake disc pack, first fitting an inner

disc and then an outer disc and so on. Measure the
F brake disc pack (see section 10.4.2).
NOTE
Refer to the spare parts lists for the number of
outer and inner discs.
013102
NOTE
Insert the outer discs so that the disc recesses are
lined up with the recesses for the compression
springs and spring elements (see arrow).
CAUTION
The last outer disc for the F piston must be 3 mm-
thick.
013064
11-52
47 Affix the thrust washer (see arrow) to the input

end (lower) contact face of the sun gear using
Vaseline.
48 Slide the sun gear (1) onto the input shaft as far as
it will go.
016424
Measure the end play on the sun gear, see

section 10.2.1
49 In the case of version HP 592/602, affix the

selected shim (1) to the sun gear using Vaseline. 1
In the case of version HP 502/592, affix the
selected shim in planetary carrier I using Vaseline.
013103
50 Place the spring holder (1) and the disc spring (2)
onto the last outer disc as illustrated. The inner
diameter of the disc spring must be lying on the
spring holder.
016425
11-53
a Version with NBS

4
51a Insert the pins, guide tubes and springs into the
recesses as illustrated.
Insert in the following order:

Guide tubes (1)
Pins (2)
Springs (3) 1
Pins (4)
008722
NOTE
The pins (4) have a hole on their end faces. 4
016426
52a Place the spring elements (1) onto the pins (4) in
the holes.
016427
11-54
b Version without NBS

4
53b Insert the pins, guide tubes and springs into the 3
recesses as illustrated.
Insert in the following order: 1

Guide tubes (1)
Pins (2)
Springs (3) 2
Pins (4)
NOTE
The guide tubes are conical. Insert the guide tubes
with the longer chamfer (see arrow) facing
upwards.
013104
54b Place the gasket (1) for the output cover onto the
55 Insert the cable (2) for the inductive pickup into 1

the transmission housing if necessary.
CAUTION
Insert the cable for the inductive pickup in the
correct housing duct.
Install the output cover, see section 10.2

2
013014
11-55
11-56
HP 502 / HP 592 / HP 602 Control Unit
12 Control Unit - Remove and Install, Dismantle

and Assemble
2
12.1 Control Unit - Remove 1
1 Unscrew and remove the M8 hexagon bolts (1),

and remove the locking plate (2) for the intake 3
pipe (3).
005548
2 Pull the intake pipe (1) out of the transmission

housing using internal extractor 1X56 122 208
and counter-support 1X56 122 227.
008802
3 Remove the O-ring (1) from the intake pipe (2).
008803
12-1
Control Unit HP 502 / HP 592 / HP 602
4 Pivot the transmission so that the input end faces

upwards.
5 Unscrew the M8 socket head screws (1) around

the edge and remove them together with washers.
1
CAUTION
Unscrew and remove the socket head screws from
around the edge using hexagon socket head insert
1X56 137 273. Take care not to damage the mating
plate for the cover plate when doing this.
008804
6 Connect lifting gear to lifting device

1X56 137 213.
7 Heat the transmission housing at the height of the

control unit to approx. 85 ºC using hot air blower
1X56 136 513.
!DANGER
008806
8 Lift the control unit out of the transmission

housing and place it onto planks or wooden
blocks.
! DANGER
Do not remove lifting device 1X56 137 213, otherwise
the turbine shaft will fall out through the control
unit.
008805
12-2
12.2 Control Unit - Install
1 Align the holes on the intermediate plate (1) with

the holes on the control unit.
NOTE
The lug of the intermediate plate must engage in
the recess on the sealing ring.
(See section 12.4)
2 Insert two socket head screws to assist centering.
008808

transmission housing to assist centering.
4 Screw lifting device 1X56 137 213 onto the

turbine shaft.
008807
5 Heat the machined seat for the control unit in the

transmission housing to approx. 85 ºC using hot
6 Use lifting gear to move the control unit above the

transmission. Align the control unit with the guide
screws and lower it into the transmission.
NOTE
The control unit must be fitted immediately.
! DANGER
housing.
008809
12-3
8 Screw the five M8x65 socket head screws (1) into

the control unit. Do not tighten them as yet!
1
008811
9 Screw in M8x55 socket head screw (see arrow).

Do not tighten it as yet!
10 Screw in M8x70 socket head screw (see arrow).

Do not tighten it as yet!
008810
11 Attach control unit at the housing bore using two

M8 bolts and wide intermediate plate or wide
washers (see arrow). Make sure there is zero play.
CAUTION
Failure to follow these instructions could result in
transmission leaks.
NOTE
- These measures help prevent a drop in
lubrication pressure.
- Use wide intermediate plate.
- Do care not to damage the mating face.
003140
12-4
12 Tighten all the socket head screws (1/2/3) using

insert 1X56 137 273.
CAUTION
Take care not to damage the mating faces when scr-
ewing in and tightening the hexagon socket head scr-
13
2
11
3
ews.
13 Unscrew the M8 screws inserted in step 11 and 003 598
remove them together with the intermediate plate

or washers.
1
003598/003597
14 Coat the O-ring (1) with Vaseline and insert it in

the transmission housing.
1
003599
15 Coat the intake pipe (1) with Vaseline and insert it

in the transmission housing. 4
3
NOTE 2
If the intake pipe is difficult to insert, carefully
knock it in using a plastic-tip hammer.
1
16 Fit the locking plate (2) for securing the intake
pipe using two M8x18 hexagon bolts.
17 Secure each hexagon bolt (3) once using the

locking plate tabs (4).
005548
12-5
12-6
12.3 Control Unit - Dismantle
1 Unscrew lifting device 1X56 137 213 from the

turbine shaft.
1
CAUTION
Hold the turbine shaft by hand to prevent it from fal-
ling out when the lifting device is unscrewed.
2 Lower the turbine shaft out of the control unit

until the snap ring (1) is accessible.
3 Remove the snap ring using circlip pliers.
008812
4 Lift the turbine shaft (1) out of the stator hollow

shaft (2). 1
008813
5 Screw hooks 1X56 136 612 into the control unit.
6 Attach lifting gear.
7 Lift the control unit slightly off its base.
8 Use drift 1X56 137 109 to knock the clutch carrier

off the control insert.
9 Remove the clutch carrier and lay the control

insert to one side.
! DANGER
Do not put your hand s under the clutch carrier while
it is being separated.
008814
12-7
12.3.1 Control Insert - Dismantle
1 Hold the spacer ring (1) and pull out the

cylindrical pin (2).
2
2 Remove the spacer ring.
! DANGER
1
The spacer ring is held under spring load.
008815
3 Remove the compression spring.
4 Remove the plunger (1) for the cooler change-over

valve from the valve housing.
008816
5 Slide clamping device 1X56 137 108 onto the

control insert.
6 Screw the spindle onto the converter backpressure

valve.
008817
12-8
7 Release the snap rings using the spindle.
8 Remove the snap ring (1) using circlip pliers.
9 Unscrew the spindle and remove the sealing

washer (2) and the snap ring (1).
! DANGER
The sealing washer is held under spring load. Make
sure that the sealing washer does not fly out when
unscrewing the spindle.
1
2
NOTE 3
The removal procedure is the same for the main
pressure valve (3).
008818
10 Remove the compression spring (1) and the plun-

ger (2) for the converter backpressure valve from
the housing bore.
1
2
008819
11 Screw device 1X56 137 107 into the spacer ring.
12 Hold the spacer ring with the device and remove

the cylindrical pin (1).
13 Pull out the spacer ring using device 1X56 137

107. 1
! DANGER
The spacer ring is held under spring load.
008820
12-9
14 Push the lubrication pressure valve plunger (1)

forwards using a screwdriver and pull out the
plunger with the compression spring.
! DANGER
The housing has sharp edges. Never reach inside with
your bare hands.
008822
15 Exploded view of valves and compression.
CAUTION
There are different types of main pressure valve
available. See spare parts catalog and spec list.
008821
16 Press out the plug (1) for the pressure line using
two screwdrivers.
CAUTION
Take care not to damage the control insert mating
face.
17 Remove the O-ring (2) for the intake pipe.

1
2
008823
12-10
18 Turn the control unit over.
19 Place pad 1X56 137 104 on the oil feed flange.
008824
20 Insert puller 1X56 122 322 into the grooved ball

bearing (1) and clamp on the ring. 2
21 Pull the grooved ball bearing off the oil feed

flange.
1
NOTE
Use a size 46 (WAF) open-jaw wrench to brace
the puller lock nut (2).
008825
22 Remove the four rectangular-section rings (1).
008826
12-11
NOTE
Remove the rectangular-section rings with
intersecting ends as follows:
Press one end of the rectangular-section ring into

the base of the groove using your thumb.
Slide your index finger around the ring until the

ring releases.
001582
001582
! DANGER
The rectangular-section ring has sharp edges. Risk of
injury. Always wrap a cloth around the ring or wear
protective gloves when pressing it out.
008827
23 Unscrew and remove all the M8 hexagon bolts (1)

from the oil feed flange.
008828
12-12
24 Remove the spring guide (1) together with the

compression springs (2), the disc spring (3) and
the guide pins (4) from the stator ring.
! DANGER
Do not allow the springs to fly out.
2 1 3 4
CAUTION
The spring guide pins each have 48 disc springs. Do
not allow the spring guide pins to fly out.
008829
25 Remove the compression spring (1), the spring

guide (2) and the disc springs (3) from the guide
pin (4). The spring seat (5) may stick to the
compression spring.
5 1 2 4
008831
26 If necessary, remove the spring seat (1) from the

stator ring.
008830
12-13
27 Turn over the control insert.
28 Unscrew and remove the M8 socket head screws

(1).
008832
29 Unscrew and remove the socket head screw (1)

from the primary pump (2) using hexagon socket
head insert 1X56 137 273.
008833
30 Lift the control insert off the oil feed flange.
008834
12-14
31 Screw two M8 hexagon bolts (1) into the stator

hollow shaft 180º apart.
32 Loosen the stator hollow shaft by tapping the

hexagon bolts (1) with a plastic-tip hammer.
008835
33 Unscrew and remove the hexagon bolts from the

34 Remove the stator hollow shaft (1) from the

control insert.
NOTE
Both roll pins can remain installed.
008837
35 Remove the rectangular-section ring (1).
008836
12-15
NOTE
Remove rectangular-section ring with intersecting
ends as follows.
Press the end of the rectangular-section ring into

the base of the groove using your thumb.
Slide your index finger around the ring until the

ring releases.
001582
001582
! DANGER
The rectangular-section ring has sharp edges. Risk of
injury! Always wrap a cloth around the ring or wear
protective gloves when pressing it out.
11
36 Detach the snap ring (1) using a screwdriver.
003161
003161
37 Insert puller 1X56 137 432 into the groove on the

piston ring carrier.
38 Place the pad (1) on the stator hollow shaft.
39 Attach two-arm puller 1X56 137 432 as

illustrated. 1
40 Pull the piston ring carrier off the stator hollow

shaft.
41 Remove the puller and the pad.
42 Remove the needle cage (2). 2
008838
12-16
43 Check the bearing inner race (1) for damage.

Renew it together with the needle cage if
necessary.
44 Attach extractor plate 1X56 124 659 to the

bearing inner race with the stamped number
facing upwards.
45 Evenly screw in both the M8 hexagon bolts. 1
CAUTION
Ensure that the stamped number on each section of
the extractor plate are lined up.
008839
46 Place the pad (1) on the stator hollow shaft.
47 Place the stator hollow shaft and the extractor

plate into the press and press the bearing inner
1
race off the stator hollow shaft.
008841
48 Check the bush and the rectangular-section rings

in the stator hollow shaft for damage.
49 If necessary, knock out the bush using punch

1X56 136 820.
CAUTION
Only remove the bush if it is damaged.
008840
12-17
NOTE
The bush and the rectangular-section rings (1)
constitute a single component.
11
001583
001583
CAUTION
Do not knock or strike the primary pump.
50 Place the complete control insert in a heating

furnace (approx. 100 mm high) and heat it to
approx. 150 ºC.
51 Leave the control unit in the heating furnace until

the primary pump falls out under its own weight.
NOTE
Place the control insert in the furnace with the
primary pump input gear facing upwards.
008842
52 Unscrew the three M8 socket head screws (1)

from the rear of the oil feed flange (2).
53 Remove the socket head screws together with the

washers. 1
008843
12-18
54 Turn over the oil feed flange.
55 Remove the thrust ring (1). 1
56 Lift the stator ring (2) out of the oil feed flange.
2
008844
12-19
12-20
12.3.2 Control Insert - Assemble
1 Insert the stator ring (1) in the oil feed flange so

that the vanes overlap. 1
2 Place the thrust ring (2) in the stator ring and align
with the tapped holes.
NOTE
Make sure that the recess in the thrust ring faces
the stator ring. It must be possible to easily turn
the stator ring.
008845
3 Turn over the oil feed flange.
4 Screw in the M8 socket head screws with washers

and tighten them to 16 Nm.
008846
5 Place the oil feed flange onto device 1X56 136

818.
6 Place the control insert (1) onto the oil feed flange
(2) and align with the holes.
2
008847
12-21
7 Screw in the three M8x70 socket head screws (1)

with washers and tighten them by hand.
008848
8 Screw in the four M8x55 socket head screws (1)

with washers and tighten them by hand.
1
008849
9 Screw in the M8x40 (1) and M8x45 (2) socket

head screws with washers and tighten them by
hand.
10 Tighten all the socket head screws to 23 Nm.
1
2
008850
12-22
11 Screw guide screw 1X56 136 821 into the bore for
the primary pump bolt.
003638
12 Heat the control insert to approx. 150 ºC in a

heating furnace.
13 Slide the primary pump (1) over the guide screws

and into the pump seat. 1
! DANGER
Always wearing protective gloves when handling the
hot control insert.
008851
CAUTION
If the control unit is heated correctly, the primary 1
pump will drop into the pump seat of its own accord.
Never knock or strike the primary pump. The pri-
mary pump must be inserted as far as it will go.
14 Remove the guide screw (1).
15 Screw the M8x40 socket head screw with washer

into the guide screw bore and tighten it by hand.
NOTE
Once the control insert has cooled down to
ambient temperature, fully tighten the socket head
screw. Tightening torque: 23 Nm
12-23
NOTE
The bush and the rectangular-section rings (1)
constitute a complete component.
001583
001583
16 Heat the stator hollow shaft to approx. 150 ºC

using hot air blower 1X56 136 513.
NOTE
Line up the bore in the bush with the bore in the
17 Insert the bush into the stator hollow shaft as far

as it will go.
008853
18 Heat the bearing inner race to approx. 85 ºC using

hot air blower 1X56 136 513.
19 Slide the bearing inner race onto the stator hollow

shaft as far as it will go.
! DANGER
bearing inner race.
008854
12-24
20 Oil the needle cage (1) and slide it onto the stator
hollow shaft.
21 Heat the piston ring carrier (2) to 85 ºC using hot

air blower 1X56 136 513 and slide it on as far as it
will go.
! DANGER
2
piston ring carrier. 1
CAUTION
Do not knock or strike the piston ring carrier.
008855
22 Fit the snap ring in the groove on the stator hollow

shaft.
23 Insert the rectangular-section ring (1) in the piston

ring carrier and hook in the ends.
CAUTION
Ensure that the ring is inserted correctly and that its
ends are hooked together.
008857
24 Center the stator hollow shaft on the roll pins (1).
25 Knock the stator hollow shaft fully home by

tapping it with a plastic-tip hammer.
! DANGER
Before installing the stator hollow shaft, ensure that
the control insert has already cooled down.
1
008856
12-25
26 Turn over the control insert.
27 Screw the M8x45 hexagon bolts (1) with washers

into the stator hollow shaft.
008858
28 Insert the four rectangular-section rings (1) in

sequence.
1
NOTE
Always insert the lowest rectangular-section ring
first. Ensure that the ring ends are correctly
engaged and hooked together.
008859
29 Heat the oil feed flange bearing bore to approx.

85 ºC using hot air blower 1X56 136 513.
30 Insert the grooved ball bearing (1) into the bearing

bore and knock it fully home by tapping around
the edge with a plastic-tip hammer. 1
! DANGER
Do not touch the hot surfaces.
CAUTION
Ensure that the grooved ball bearing remains level
and does not get tilted during fitting.
008860
12-26
31 Push the stator ring open and insert the spring seat
(1).
008861
32 Fit the spring guide pin (1) with the 48 disc

springs (2).
CAUTION
Always fit the disc springs in groups of six with each
group facing the opposite direction to the previous
one.
33 Slide the spring guide (3) and the compression

spring (4) over the assembled guide pin (1).
34 Measure the clearance between the spring guide

and the guide pin.
35 The clearance must be 1.6 + 0.5 mm. If necessary

correct by adding or removing disc springs.
4 3 2 1
NOTE
Repeat this procedure for all three spring guides.
1,6 ± 0,5
003831
12-27
36 Insert the three complete spring assemblies (1) in

stator ring.
CAUTION
The spring guide pins must be precisely located on
the oil feed flange.
008862
CAUTION
Handle the plungers for the control insert compo-
nents with extreme care and maintain cleanliness at
all times.
NOTE
There are several types of main pressure valve
available - see spare parts catalog or spec list.
37 Assemble the plungers and springs for the main

pressure valve as illustrated.
008874
38 Insert the complete plunger (1) for the main

pressure valve into the control insert.
008863
12-28
39 Fit clamping device 1X56 137 108 to the control

insert.
40 Push the ring (1) onto the spindle.
41 Insert a new O-ring (2) in the spacer.
42 Thinly coat the O-ring with Vaseline.
43 Place the spacer against the main pressure valve

plunger and carefully press it into the housing
bore using the spindle. 1
2
008865
44 Using the spindle to press the main pressure valve

plunger approx. 4 mm behind the groove for the
snap ring.
45 Insert the ring (1) in the valve bore.
46 Insert the snap ring (2) and clip it into the groove.
! DANGER
Before unscrewing the spindle, make sure that the
snap ring is correctly engaged in the groove.
47 Remove clamping device 1X56 137 108. 1
008867
48 Insert the plunger (1) for the lubrication pressure

valve.
008866
12-29
49 Insert the compression spring (1) into the

lubrication pressure valve plunger.
008868
50 Screw the spacer ring onto device 1X56 137 107.
51 Use device 1X56 137 107 to push the spacer ring

into the lubrication pressure valve bore until it
reaches bore (1).
008869
52 Line up the spacer ring bore with the housing bore

(1). 1
008870
12-30
53 Insert the cylindrical pin into the bores.
54 Unscrew and remove device 1X56 137 107.
008871
55 Insert the converter backpressure plunger (1) and

compression spring (2) into the valve bore.
2 1
008872
56 Fix clamping device 1X56 137 108 to the control

insert.
57 Fit the thrust washer (2) with the convex side

facing the valve and clamp it slightly using the
spindle.
58 Attach the snap ring (1) to the spindle.
2
1
008873
12-31
59 Use the spindle to press the thrust washer into the

valve bore without tilting it.
60 Clip the snap ring (1) into the groove.
61 Unscrew and remove the spindle and remove the

clamping device.
! DANGER
Before unscrewing the spindle, make sure that the
snap ring is fully engaged in the groove.
008874

into the bore for the cooler changeover valve.
008876
63 Insert the spacer ring (2) in the valve bore.
NOTE
Line up the spacer ring bore with the housing
bore.
64 Insert the roll pin (1).
008875
12-32
65 Thinly coat the O-ring with Vaseline.
66 Insert a new O-ring (2) into the plug (1) for the
pressure line.
67 Insert the plug in the pressure line.
008877
12-33
12-34
HP 502 / HP 592 / HP 602 Control unit
12.3.3 Clutch Carrier - Dismantle
1 Remove the intermediate plate (1) from the clutch

carrier. 1
! DANGER
The clutch carrier weighs approx. 25 kg. Always make
sure there are at least two people when moving it.
008878
2 Unscrew and remove the M8 hexagon bolts (1)

and remove the rotor (2) from the clutch carrier.
008879
3 Remove the sealing washer (1) from the clutch

2
carrier.

sealing washer.
1
008880
12-35
Clutch carrier, 4-speed version:
5 Screw on clamping device 1X56 137 127 and

press the inductive pickup ring (1) against the
clutch carrier.
6 Unscrew and remove the three hexagon bolts (see

arrows).
7 Screw off clamping device 1X56 137 127 and take

the inductive pickup ring (1) off the clutch carrier.
NOTE
Remove inner components as described below.
1
008828
Clutch carrier, 5 and 6-speed version:
8 Turn over the clutch carrier.
9 Place the insert for clamping device 1X56 137

127 into the clutch carrier. Lay the pressure plate
on top and screw on the hand wheel.
10 Clamp the clutch carrier together by tightening the

hand wheel.
008881
11 Release and unclip the snap ring (1).

1
NOTE
Tap the C piston to assist with unclipping the snap
ring.
12 Remove the snap ring and the C piston from the

clutch carrier.
008882
12-36
14 Remove clamping device 1X56 137 127.
15 Remove the reverse gear pot.
16 Pull the O-ring out of the reverse gear pot.
008883
17 Remove the last outer disc from the clutch carrier.
008884
18 Remove the pins (1) and the springs (2) from the 1
holes.
2
19 Remove the complete disc pack from the clutch
carrier.
008885
12-37
20 Use a bar magnet to draw out the two anti-rotation

pins (1) from the clutch carrier.
008886
21 Turn the end disc (1) so that its teeth line up with
the recesses in the clutch carrier.
1
22 Remove the end disc from the clutch carrier.
008887
23 Remove the complete B clutch disc pack (1) and

pins (2) from the clutch carrier. 1
24 Remove the pins from the disc.
008888
12-38
25 Use a pair of pliers to remove the roll pins (2)

toward the inside.
1 2
26 Remove the split rings (1).
27 Remove the end disc (3).
008889
28 Remove complete A clutch disc pack (1) from the

clutch carrier.
29 Remove the holding plate and disc spring.
008890
30 Turn over the clutch carrier and remove the C

piston (1).
31 Remove the inner lipped sealing ring for the C

piston.
32 Remove the lipped sealing ring (2) from the

clutch carrier.
008892
12-39
33 Place the clutch carrier on the bottom part of

clamping device 1X56 137 127.
34 Place pad 1X56 137 105 on the remaining disc

spring (1). 1
35 Screw on the hand wheel and use this to push the

disc spring downwards until the snap ring can be
unclipped.
36 Unclip the snap ring and slide it over the groove

with the holding plate.
NOTE
Fit pad 1X56 137 105 with the opening facing the
ends of the ring.
008893
37 Remove the pad.
38 Remove the snap ring (1) and the holding plate

(2).
39 Remove the disc spring (3) from the clutch carrier.
2
3
008894
40 Grip the A piston (1) with a pair of pliers and

loosen it by tapping the hub with a plastic-tip 1
hammer.
008895
12-40
41 Remove the A piston (1) from the clutch carrier.
42 Remove the outer lipped sealing ring (2) from the

A piston.
43 Remove the inner lipped sealing ring (3) from the

A piston.
2
1
008896
44 Loosen and remove the B piston (1) by striking

the end face of the clutch carrier with a plastic-tip
hammer.
008897
45 Remove the outer rectangular-section ring (2)

from the B piston.
46 Remove the inner rectangular-section ring (3)

3
from the B piston.
008898
12-41
47 Grip the needle bearing with internal extractor

1X56 122 208.
1
48 Screw counter-support 1X56 122 227 onto
internal extractor 1X56 122 208.
49 Tighten the lock nut (1) by hand.
50 Remove the needle bearing from the bearing bore.
008899
51 Heat the clutch carrier to approx. 150 ºC in a

heating furnace.
2
51 Knock the hub (1) out of the clutch carrier using a
plastic-tip hammer.
! DANGER
clutch carrier.
008900
12-42
12.3.4 Clutch Carrier - Assemble
1 Screw two guide screws 1X56 136 821 into

opposite sides of the clutch carrier. 1
2 Heat the clutch carrier to approx. 150 ºC in a

heating furnace.
Slide the hub (1) over the guide screws so that the
hub is evenly seated and in the correct radial
position.
3 Unscrew the guide screws.
! DANGER
Always wear protective gloves when handling the hot 008901
clutch carrier.
4 Insert the needle bearing into the hub and knock in

the needle bearing as far as it will go using punch
1X56 137 103.
NOTE
Coat the needle bearing with Vaseline before
installation. Place the punch on the side of the
bearing with reinforced surround. The side of the
needle bearing with writing on is the impact side.
008902
12-43
5 Insert the A piston (1) into the clutch carrier

without lipped sealing rings.
1
6 Place the disc spring without slots onto the A
piston so that the edge of the bore is on the piston.
7 Slide the holding plate over the disc spring with

the closed side facing upwards.
008903
8 Check the inner (1) and outer (2) discs for wear.
9 Using a straight-edge to check that all the discs

1
are flat. Use a flat surface.
2
10 Renew any uneven, bowed or damaged discs.
008905
11 Insert the complete A clutch disc pack (1) into the

clutch carrier, starting with an inner disc.
NOTE 1
The last disc must be an outer disc. Refer to the
appropriate spec list for the number and type of
discs.
008904
12-44
12 Fit the end disc (1).
13 Insert the split ring (2).
008906
14 Measure the distance “A”’ between the end face of

the hub and the front of the end disc.
15 Note down distance “A”.
008907
16 Press the end disc upwards until it stops against

the split ring.
17 Measure the distance “B” between the end face of

the hub and the front of the raised end disc.
18 Note down distance “B”.
19 Distance “A” – Distance “B” gives the disc play.
008908
12-45
NOTE
The A clutch disc play may be 3.2 to 3.7 mm.
20 The disc play can be adjusted by using steel discs

of different thicknesses (2.0 and 2.5 mm).
21 Remove the complete disc pack from the clutch

carrier together with the holding plate and the disc
spring.
22 Remove the A piston from the clutch carrier.
23 Check the B piston rectangular-section rings for

damage and renew them if necessary.
24 Insert the rectangular-section rings in the B-piston

grooves.
NOTE
Both sealing rings must be firmly seated in the
base of the groove with no play.
008909
25 Coat the sealing rings and contact surface of the B

piston with Vaseline.
1
26 Insert the B piston (1) into the clutch carrier
centrally and without tilting it.
27 Tap the B piston fully home with a plastic-tip

hammer.
CAUTION
Take care not to damage the sealing rings. It must be
possible to smoothly fit the piston.
008910
12-46
28 Insert the inner and outer lipped sealing ring into

the A piston groove with the groove facing the
pressure side.
NOTE
Stretch the inner lipped sealing ring before instal-
ling. Make sure that both lipped sealing rings are
fitted firmly in the base of the groove with no
clearance.
008911
29 Insert the A piston (1) in the clutch carrier and tap

the A piston fully home using a plastic-tip ham- 1
mer.
CAUTION
Coat the lipped sealing rings and the contact surface
of the A piston with Vaseline before installing. Take
care not to damage the lipped sealing rings when
installing.
30 Place the disc spring (2) on the A piston so that the

recesses in the spring mesh with the projections 2
on the piston.
008912
31 Slide the holding plate (1) over the hub with the
recess facing upwards.
32 Slide the snap ring (2) over the hub.
1
2
008913
12-47
33 Place pad 1X56 137 105 on the disc spring.
NOTE
Turn the pad so that the ends of the snap ring are
visible in the opening.
34 Press the disc spring downwards using clamping

device 1X56 137 127.
35 First slide the holding plate (1) over the groove

and then clip in the snap ring (2).
CAUTION
The snap ring must be clipped in all the way around. 1
2
008914
36 Check the inner and outer discs of the B and C

clutch for wear.
37 Check that all the discs are even using a straight-

edge.
38 Renew uneven, bowed or damaged discs.
Also see the test details in section 4.3.8
008916
39 Lay the first B clutch disc (1) in the clutch carrier.
CAUTION
The first disc is a 3mm-thick outer disc. The first disc
does not have any slots.
008915
12-48
40 Place an inner disc (1) and then an outer disc (2)

in the clutch carrier.
1
CAUTION
Insert the second and all subsequent B clutch outer
discs so that the recesses (3) are positioned over the 2
bores (4). Check whether teh discs have groups of
three or four teeth.
41 Insert complete disc pack into the clutch carrier,

alternately fitting one outer and one inner disc.
3
NOTE
Refernto the spec list and spare parts catalog for
4
the number and type of discs.
008917
42 Insert the end disc and rotate it into position.
CAUTION
Insert the end disc, so that the hardened bores (1) are
lined up precisely with the bores (2) that have rectan-
gular milled recesses in the clutch carrier. Hardened 1
bores are recognizable by their sheen.
2
008919
43 Insert the two retaining pins (1) in the bores with

rectangular groove (2).
008918
12-49
44 Measure the B clutch disc play by placing a feeler

gauge between the end disc and the last outer disc.
45 Take measurements at several points around the

edge.
NOTE
Permitted B clutch disc play:
HP 502 = 1.6 to 2.1 mm
HP 592 / 602 = 2.0 to 2.5 mm.
The disc play can be adjusted using steel discs of

various thicknesses (2.0 and 2.5 mm).
008920
46 Place the disc springs without slots onto the

A piston so that the edge of the bore is in contact
with the piston.
47 Slide the holding plate over the disc spring with

the closed side facing upwards.
008921
48 Insert the complete A clutch disc pack into the

clutch carrier.
CAUTION
The first disc is an inner disc and the last must be an
outer disc.
008922
12-50
49 Insert the end disc (1) in the clutch carrier.
50 Insert the split rings (2).
1
2
008923
51 Lift up the end disc and insert the three pins (1).
008925
12-51
Clutch carrier, 4-speed version:
52 Insert the pins in the compression springs.
53 Insert the pins and compression springs into the

clutch carrier.
008924
54 Insert the insert for clamping device 1X56 137

127 in the clutch carrier.
55 Place the inductive pickup ring on the clutch

carrier.
56 Align the inductive pickup ring bores with the

clutch carrier bores and insert two threaded pins
into the bores.
008927
57 Fit the plate for clamping device 1X56 137 127.

Screw on the hand wheel of the clamping device
and press teh inductive pickup ring against the
clutch carrier.
58 Unscrew and remove the threaded pins and insert

and tighten the hexagon bolts with washers.
008828
12-52
Clutch carrier, 5 and 6-speed version:
59 Check the C clutch discs as described in section

4.3.8.
60 Insert the complete disc pack in the clutch carrier.
008926
61 Insert the pins in the compression springs.
62 Insert the pins and compression springs in the

clutch carrier.
008929
63 Insert the lipped sealing ring (1) around the edge

of the clutch carrier. The groove must face the
pressure side.
008930
12-53
64 The last disc to be fitted is an outer disc with a full

set of broad outer teeth. Place this last disc on the
compression spring pins.
008931
65 Place clutch carrier onto clamping device

1X56 137 127.
008932
66 Oil a new O-ring and insert it in the reverse

gear pot.
67 Position the reverse gear pot on the clutch carrier

so that the guide grooves engage wíth the guide
ridges.
008934
12-54
68 Press together the reverse gear pot and the clutch

carrier using the clamping device.
008933
70 Insert the inner lipped sealing ring into the C

piston groove with the groove facing the pressure
side.
NOTE
Stretch the inner lipped sealing ring before instal-
ling. The lipped sealing ring must be firmly seated
at the base of the groove with no clearance.
71 Insert the C piston in the reverse gear pot.
NOTE
Take care not to damage the lipped sealing ring.
Insert the piston with a sliding fit.
008935
72 Clip the snap ring (1) into the groove.
NOTE
The snap ring must be seated at the base of the
ring groove all the way around. 1
008936
12-55
73 Measure the C clutch disc play between the outer

disc and the reverse gear pot using a feeler gauge.
Take measurements at several points around the
circumference and note down average.
NOTE
Permitted C clutch disc play:
HP 502 = 1.2 to 1.7 mm
HP 592 / 602 = 1.6 to 2.1 mm.
The disc play can be adjusted using steel discs of

various thicknesses (2.0 and 2.5 mm).
008937
74 Turn over clutch carrier. 2
75 Place the sealing washer (1) on the clutch carrier.
76 Clip in the rectangular-section ring (2) with the

inscription ‘TOP’ or ‘R’ facing upwards.
008938
77 Screw two guide screws 1X56 136 821 into the

clutch carrier.
78 Align the rotor (1) with the bores and fit it.
NOTE
The irregular hole pattern means that the rotor can
only be installed in one position.
008939
12-56
72 Unscrew the threaded pins.
73 Screw in the eighteen M8x40 hexagon bolts (1) 1

and tighten them to 32 Nm.
008940
12-57
12.3.5 Clutch Carrier Leak-tightness and Function -

Check
1 Push feed bush 1X56 137 128 into the clutch

carrier.
NOTE
Lightly oil the sealing rings (1) before pushing in
the feed bush.
008941
2 Screw the knurled nut (1) onto the feed bush until
the feed bush is evenly seated.
3 Connect compressed air unit 1X56 137 130 at the

port for the A, B or C piston.
1
4 Turn the regulator (1) anti-clockwise several
times.
008942
5 Open the stopcock by moving the lever (2) to the

horizontal position. Use the regulator (1) to set a
maximum pressure of 3 bar.
6 Close the stopcock by moving the lever (2) to the

vertical position. The pressure must not fall by
more than 2.5 + 0.5 bar down to 1.4 bar within ten
seconds.
7 Remove the compressed air unit. 1
CAUTION
If the pressure loss on a given piston is too great, the
piston in question must be removed in order to cor-
rect the leak.
2
008943
12-58
12.4 Control Unit - Assemble
1 Fit the intermediate plate (1).
CAUTION
Make sure that the lug (2) on the intermediate plate
meshes with the recess (3) in the sealing washer.
3
2
008944
2 Screw hooks 1X56 136 612 into the control insert

at opposite points.
008945
3 Attach lifting gear to the hooks and move the

control insert over the clutch carrier.
4 Heat the grooved ball bearing (1) to approx. 85 ºC

using hot air blower 1X56 136 513.
! DANGER
Do not touch the hot grooved ball bearing.
1
008946
12-59
5 Slide the control insert (1) into the clutch carrier

(2).
6 Knock the control insert into position by tapping it

with a plastic-tip hammer.
7 Insert the O-ring (3) for the intake pipe in the con-
trol unit. Check the O-ring.
008947
8 Remove the lifting gear and insert the turbine

shaft (1) into the control unit.
008948
CAUTION
Before inserting the turbine shaft, make sure that
the three pins (1) do not protrude into the hub (2).
008949
12-60
9 Push in the turbine shaft so that the groove is

accessible.
10 Clip the snap ring (1) into the turbine shaft groo-
ve.
11 Screw lifting device 1X56 137 213 into the turbi-

ne shaft.
1
CAUTION
Take care not to damage the oil pipe when lifting the
control unit.
008950
12 Support the control unit so that the turbine shaft

does not stand up.
- Install the control unit: see section 12.2.
008951
12-61
12-62
HP 502 / HP 592 / HP 602 D Brake
13 D Brake - Remove and Install

13.1 D brake - Remove
1 Use two screw clamps to press the end disc (1)

against the stop. Make sure the disc remains
parallel.
2
2 Detach the snap ring (2) using a screwdriver.
016429
3 Evenly unscrew the screw clamps and remove

them.
! DANGER
Evenly loosen the screw clamps since the end disc is
held under spring load.
4 Remove the end disc (1) from the transmission.
016430
5 Remove the compression springs and pins (1).
6 Remove the complete disc pack (2) from the

016431
13-1
D Brake HP 502 / HP 592 / HP 602

(2) from the D piston.
016432
8 Cover the transmission housing with a cloth.
9 Loosen the D piston (1) by blowing compressed

air into the oil duct (2). 1
! DANGER
Cover the transmission housing with a cloth before
attempting to loosen the D piston using compressed
air. Protect your eyes from oil spray.
016433
10 Lift the D brake piston out of the transmission

housing.
5
11 Take the outer and inner lipped sealing ring out of
the D piston.
Outer lipped sealing ring (1)

Inner lipped sealing ring (2) 4
2
Piston (3)
Spring holder (4)
Disc spring (5)
1 3
016434
13-2
HP 502 / HP 592 / HP 602 D Brake
13.2 D Brake - Install

2
1 Insert the inner lipped sealing ring (1) into the D
piston with the groove facing the pressure side.
CAUTION
Check the lipped sealing rings for damage before
installing them and renew them if necessary.
1
2 Insert the outer lipped sealing ring into the D
piston with the groove facing the pressure side.
NOTE
Lightly coat the outer and inner lipped sealing
rings with Vaseline.
008958
NOTE
Installation position of the D piston (1), spring
holder (2) and disc spring (3)
016435
3 Insert the D piston (1) into the transmission.

Carefully knock it in as far as it will go using a
plastic-tip hammer.
CAUTION
Take care not to damage the lipped sealing rings
during installation.
It must be possible to smoothly insert the D piston.
1
2
4 Place the spring holder (2) and the disc spring
(3) onto the D piston as illustrated. The inner 3
diameter of the disc spring must lie on the spring
holder.
016432
13-3
D Brake HP 502 / HP 592 / HP 602
5 Check the outer and inner discs for wear.
6 Check that all the discs are flat using a straight

edge.
7 Renew discs that are uneven, dished or damaged.
008959
8 Mark the housing teeth (see arrow) between the

two holes (1) in the housing.
016436
9 Insert the first outer disc (1). Insert this first outer
disc so that the hole (2) for the center tooth on a
disc segment comes to lie at the marked housing
tooth (see arrow).
CAUTION
None of the holes on the disc segments must come to
lie over any of the holes in the housing.
2
016437
13-4
HP 502 / HP 592 / HP 602 D Brake
10 Insert one inner disc.
016438
11 Insert the next outer disc so that the tooth recess

(see arrow) comes to lie above the center tooth on
each disc segment on the first outer disc.
12 Insert the complete disc pack, fitting an inner disc

and then an outer disc and so on.
NOTE
The last disc must be an outer disc. Refer to the
spare parts catalogs for the number of discs.
016439
13 Insert the pressure pins (1) in the bores on the first

outer disc.
14 Insert the compression springs (2) on the pressure

pins.
016431/016440
13-5
D Brake HP 502 / HP 592 / HP 602
15 Fit the end disc (1).
CAUTION
The ridged surface of the end disc must be facing
upwards.
016430
16 Insert two screw clamps and press the end disc

against the stop, making sure that it remains
parallel.
17 Insert the snap ring (1) in the groove.
18 Remove the screw clamps.

1
! DANGER
Make sure that the snap ring is fully engaged in the
groove all the way around before removing the screw
clamps.
016429
19 Measure the disc play on the D brake by placing a

feeler gauge between the end disc and the last
outer disc. Measure at several points around the
edge and calculate the average play.
NOTE
Permitted disc play on D brake:
HP 502 = 1.2 to 1.7 mm
HP 592 / 602 = 1.6 to 2.1 mm.
The outer discs can be supplied in the following

thicknesses: 2.00 mm; 2.50 mm; 3.00 mm; 3.50
mm
008966
13-6

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REPAIR MANUAL

HP 502 / HP 592 / HP 602

4149 751 602

1 Assembly Stand - Insert and Remove Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 Retarder Accumulator - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 Heat Exchanger - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 Converter - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 Cover Plate - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 Oil Pan - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7 Inductive Pickup - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

9 Retarder Valve - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10 Output Cover - Remove and Install, Dismantle and Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11 Mechanical Transmission Section - Remove and Install ................................................................... 11-1

13 D Brake - Remove and Install ............................................................................................................. 13-1

This manual is intended for skilled personnel who have

This manual deals with the standard ZF product in

However, due to continuing development of the product,

Service points equipped by ZF Friedrichshafen AG all

2. Specified equipment, e.g. special tools

3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out

Repair work carried out at ZF service points is

Damage resulting from work performed by non-ZF

SAFETY NOTICE GENERAL INFORMATION

To avoid injury to personnel and damage to pro-

After completion of repair work and testing, skilled staff

! THREATS TO THE ENVIRONMENT !

Remove the old remains of gaskets from mating faces. REWORKING

BEARINGS d) Duo shaft seals have two packing

f) If possible, heat shaft seal bores to between 40 and

a) Apply a light coat of sealing agent on outer edge of TRANSMISSION OIL

* refer to expendable material

Tightening torques for nuts and bolts, extract from

Metric coarse pitch thread Metric coarse pitch thread

Size Tightening torque Size Tightening torque

M 4 2,8 4,1 4,8 M 8x1 24 36 43

M 12 79 115 135 M 14 x 1,5 135 200 235

M 18 280 390 460 M 18 x 2 290 420 490

M 24 670 960 1100 M 24 x 1,5 760 1100 1250

M 27 x 2 1050 1500 1800

Edition: August 1991 / checked 1997

Screw plugs (DIN 908, 910, 7604) Union screws (DIN7643)

Dimensions Tightening torque Pipe Thread Tightening-

Status October 1995

Description Name Approx. Application Remarks

Grease For example:

Sealing compound WEVO-L100

Jointing compound Loctite no.: 648 1g Threaded bush on

Sealing band Elring Pife / 300 mm

Surface sealer Loctite no.: 574 80 mm3 Slotted nut on

Grease Vaseline 8420

Operating oil See TE-ML14

1 Input 15 Inductive pickup “output”

Designation Dimension Measuring device Comments

01. Converter installation 2.81 ± 0.02" Depth gauge Installation dimensions

06. Tightening torque of Torque wrench

07. Tightening torque of M16 Between Torque wrench Use counter-support

Designation Dimension Measuring device Comments

Designation Dimension Measuring device Comments

19. Tightening torque of M6 Between Torque wrench

20. Tightening torque of M6 5 ft-lbs Torque wrench Do not exceed specified

Designation Dimension Measuring device Comments

29. Tightening torque of M8 26 ft-lbs Torque wrench