Repair Manual

W 390 MS Torque Converter

4149 751 606b

Subject to technical changes

Copyright by ZF

The present documentation is protected by copy-

right. Any kind of reproduction or dissemination in
whatever form that does not exclusively correspond
to documentation objectives will be prosecuted if
no prior approval by ZF Friedrichshafen AG was
granted.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2002-06

Edition: 2004-01

4149 751 606b

W 390 MS torque converter Table of contents

Page

Preface ........................................................................................................................................................... 5
Safety instructions ......................................................................................................................................... 6
Instructions for repairs .................................................................................................................................. 7
List of changes ............................................................................................................................................... 9
Tightening torques ......................................................................................................................................... 10
Conversion from DIN to ISO standards ........................................................................................................ 12
Consumables .................................................................................................................................................. 14
Adjustment data ............................................................................................................................................. 15
Sectional view ................................................................................................................................................ 16
Special tools ................................................................................................................................................... 17

1 Removing and installing torque converter ........................................................................................ 1-1

1.1 Removing torque converter ................................................................................................................. 1-1

1.2 Installing torque converter .................................................................................................................. 1-4

1.2.1 Measuring torque converter end play ................................................................................................. 1-4

1.2.2 Measuring torque converter installation dimensions ........................................................................ 1-8

2 Dismantling and assembling torque converter ................................................................................. 2-1

2.1 Dismantling torque converter ............................................................................................................. 2-1

2.1.1 Dismantling stator ............................................................................................................................... 2-3

2.1.2 Assembling stator ................................................................................................................................ 2-5

2.1.3 Dismantling circuit cover .................................................................................................................... 2-7

2.1.4 Assembling circuit cover ..................................................................................................................... 2-9

2.1.5 Measuring axial bearing end play / Take measurement as check ..................................................... 2-13

2.2 Assembling torque converter .............................................................................................................. 2-15

4149 751 606 - 2004-01 3

4149 751 606 - 2004-01 4
 Preface

This repair manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out
maintenance and repair work on ZF products.

This manual deals with the standard ZF product

in accordance with the state of development on the
date of issue.

However, due to continuing development of the

product, repair work might require work practices
and test or adjustment data not contained in this
manual.

We recommend that work done on your ZF product

is carried out only by skilled mechanics who have
had their practical and theoretical knowledge up-
dated on a regular basis at our After-Sales Service
training centers.

Service points equipped by ZF Friedrichshafen AG

all over the world offer you:

1. Continually 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 utmost care.

Warranty:
Repair work carried out at ZF service points is
subject to the contractual conditions prevailing in
ZF Friedrichshafen AG the individual case.
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and Damage resulting from work performed by non-ZF
Special Driveline Technology personnel in an improper and unprofessional
Service Werk 2 manner and any consequential costs are excluded
Tel. +49 (0)7541 77-0 from the contractual liability agreement. Exclusion
Fax +49 (0)7541 77-908000 of liability also applies if genuine ZF spares are
Internet: www.zf.com not used.

2003-08 5

Safety instructions
Companies repairing ZF units are responsible for
their own work safety.
To avoid injury to personnel and damage to
products, all safety regulations and legal require-
ments which apply to repair and maintenance
work must be adhered to.
Before starting work, mechanics must familiarize
themselves with these regulations.
Personnel required to carry out repairs on ZF
products must receive appropriate training in
advance. It is the responsibility of each company to
ensure that their repair staff is properly trained.
The following safety instructions appear in this
manual:
NOTE
Refers to special processes, techniques, data, use of
auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional working
practices could damage the product.
! DANGER
This is used when lack of care could lead to personal
injury or death.
2003-08
Safety instructions
General information
Read this manual carefully before starting any tests
or repair work.
CAUTION
Pictures, drawings and components do not always
represent the original object, but are used to illus-
trate working procedures.
Pictures, drawings and components are not to scale.
Conclusions about size and weight should not be
drawn (even within a complete illustration).
Always follow the working steps as described in the
text.
After completion of repair work and testing, skilled
staff must check whether the product is functioning
correctly.
! THREATS TO THE ENVIRONMENT !
Lubricants and cleaning agents must not be allowed
to enter the soil, ground water or sewage system.
• Ask your local environment agency for safety
information on the relevant products and adhere
to their requirements.
• Collect used oil in a suitably large container.
• Dispose of used oil, dirty filters, lubricants and
cleaning agents in accordance with environmental
protection guidelines.
• When working with lubricants and cleaning agents
always refer to the manufacturer’s instructions.
CAUTION
The transmission must NOT be hung by the input
shaft NOR by the output flange.
6

In case of doubt always turn to the relevant depart-
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed
expertly and under clean conditions.
Use specified tools to dismantle and assemble trans-
missions.
After removing the transmission from the vehicle,
clean it thoroughly with a suitable cleaning agent
before opening.
Pay particular attention to the projections and
recesses of housings and covers when cleaning.
Parts joined with Loctite are easier to separate if
warmed with a fan heater.
Cleaning parts
Remove remains of old gaskets on all sealing sur-
faces. Carefully remove burrs or similar patches of
roughness using an oilstone.
Lube bores and grooves must be free of anti-
corrosion agents and foreign matter; check for
perfect passage.
Carefully cover opened transmissions to prevent for-
eign matter from entering.
Reusing parts
Parts such as roller bearings, disks, thrust washers
etc., must be inspected by a competent person, who
should decide whether or not they can be re-used.
Replace parts which are damaged or have suffered
from excessive wear.
2003-08
Instructions for repairs
Gaskets, locking plates
Parts which cannot be removed without being
damaged must always be replaced with new parts
(e.g. gaskets and locking plates).
Shaft seals
Always change shaft seals with rough, ripped or
hardened sealing lips. Seal contact surfaces must be
totally clean and in perfect condition.
Reworking
Rework may be carried out on seal contact surfaces
using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.
If rework is needed on spacer disks, shims etc.
because of clearance adjustment, ensure that the
reworked areas contain no face runout and have
the same surface quality.
Transmission assembly
Find a clean work area to assemble the trans-
mission. Gaskets are installed without sealing
compound or grease. When measuring silicon-
coated gaskets, do not include the silicon layer.
During assembly, comply with all adjustment data
and tightening torques in the Repair Manual.
7

Bearings
If bearings are mounted in heated condition, they
are to be heated evenly (e.g. heating cabinet).
Temperature should be at approx. 85 °C and must
not exceed 120 °C. Each mounted bearing must be
oiled with operating oil.
Sealing
If a specific sealing agent* is to be used for sealing,
comply with the manufacturer’s directions for use.
Apply a thin layer of sealing agent to the surfaces
and spread evenly. Do not allow sealing to enter oil
ducts and bores. On oil-carrying ducts and bores,
wipe off the sealing agent on the surfaces to be
sealed near apertures to ensure that no sealing
agent enters the oil feeds when the surfaces are
sealed.
Shaft seals
a) Apply a light coat of sealing agent* on circum-
ference of shaft seals with “steel jacket”.
b) Never apply sealing agent to shaft seals with
“rubber jacket”, but apply a thin coat of
Vaseline 8420 to the circumference or wet with
a lubricant, e.g. a water-soluble, concentrated
washing-up liquid (e.g. Pril, Coin, Palmolive).
c) Shaft seals with steel and rubber jackets should
be treated on the circumference of the rubber
jacket as described above in section b).
2003-08
Instructions for repairs
d) Dual shaft seals have two seal-
ing lips. The dust-proof sealing
lip (X) must face outwards.
X
e) Fill the gap between the sealing
lips so it is 60 % filled with grease (e.g. produced
by Aral, such as Aralub HL2 or by DEA, such as
Spectron FO 20).
f) If possible, heat shaft seal bores to between
40 and 50 °C (makes fitting easier). Press the
seal shaft with mounting or faceplate onto the
relevant installation depth plan.
Retaining agents
Retaining agents* may only be used in places as
specified in the parts list.
Always comply with manufacturer’s directions for
use when using retaining agents (e.g. Loctite).
During assembly, comply with all adjustment data,
checking data and tightening torques.
Transmission oil
After completing repairs, fill transmissions with
transmission oil. For the procedure and approved
oils, refer to the transmission operating manual and
List of Lubricants TE-ML (refer to identification
plate) which are available from any ZF After-Sales
Service Point and on the internet under
www.zf.com.
After filling the transmission with oil, tighten the
screw plugs at the oil filling point and the oil over-
flow using the specified torques.
* refer to expendable material
8
 List of changes: 4149 751 606

Index Issue date Section Originator Comment

4149 751 606 - 2004-01 9

 Tightening torques

Tightening torques for nuts and bolts,

extract from ZFN 148

This standard applies to bolts acc. to DIN 912,
DIN 931, DIN 933, DIN 960, DIN 961 as well as
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676,
and to nuts acc. to DIN 934 as well as ISO 4032,
ISO 8673.
This Standard contains data on tightening torques
(MA) for bolts and nuts in strength categories 8.8,
10.9 and 12.9, and nuts in strength categories 8, 10
and 12.
Surface condition of bolts / nuts: thermally
blackened and oiled or galvanized and oiled or
galvanized, chrome-plated and oiled.
Tighten screws with a calibrated ratchet dialtorque
or wrench.
NOTE
Deviating tightening torques are listed separately in
the Repair Manual.

Regular screw thread Fine screw thread

Size Tightening torque (Nm) for Size Tightening torque (Nm) for
Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12

M4 2,8 4,1 4,8 M8x1 24 36 43

M5 5,5 8,1 9,5 M9x1 36 53 62
M6 9,5 14 16,5 M10x1 52 76 89

M7 15 23 28 M10x1,25 49 72 84
M8 23 34 40 M12x1,25 87 125 150
M10 46 68 79 M12x1,5 83 120 145

M12 79 115 135 M14x1,5 135 200 235

M14 125 185 215 M16x1,5 205 300 360
M16 195 280 330 M18x1,5 310 440 520

M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1,5 430 620 720
M22 530 750 880 M22x1,5 580 820 960

M24 670 960 1100 M24x1,5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1,5 1100 1600 1850

M27x2 1050 1500 1800

M30x1,5 1550 2200 2550
M30x2 1500 2100 2500

Edition: August 1991

2003-08 10
 Tightening torques

Screw plugs DIN 908, 910 and 7604 Union screws DIN 7643

The screw plug tightening torques were determined
according to DIN 7604 for screwing into steel, grey
cast and aluminum alloys.
The values are based on experience and are
intended as reference values for the fitter.
The values for the tightening torque apply
analogously to screw plugs according to DIN 908
and DIN 910, as the thread geometries are almost
identical.
General rule:
Screw/ bolt class 5, ZFN 148-1
Screw/ bolt material: steel acc. to DIN 7604.
Surface condition: as manufactured (without
surface protection) and lightly oiled or galvanized,
chromated and lightly oiled.
The tightening torques were determined for screw-
ing into steel, grey cast and aluminum alloys.
The values are based on experience and are
intended as reference values for the fitter.
General rule:
Screw/ bolt class 5, ZFN 148-1
Material: 9SMnPb28K acc. to DIN 1651
Surface condition: as manufactured (without
surface protection) and lightly oiled or galvanized,
chromated and lightly oiled.

Screw plugs (DIN 908, 910, 7604) Union screws (DIN 7643)

Dimensions Tightening torque Pipe Thread Tightening

in Nm screwed into outer torque
steel / gray cast Al alloy diameter in Nm
M8x1 20* 10*
M10x 1 25 / 30* 15 / 20* 4-5 M8x1 20 - 25
M12x1,5 35 25
M14x1,5 35 25 6 M10x1 25 - 35
M16x1,5 40 30
M18x1,5 50 35 8 M12x1,5 30 - 40
M20x1,5 55 45
M22x1,5 60 / 80* 50 / 65* 10 M14x1,5 35 - 40
M24x1,5 70 60
M26x1,5 80 / 105* 70 / 90* 12 M16x1,5 45
M27x2 80 70
M30x1,5 100 / 130* 90 / 130* 15 M18x1,5 50
M30x2 95 85
M33x2 120 110 18 M22x1,5 60
M36x1,5 130 115
M38x1,5 140 120 22 M26x1,5 90
M42x1,5 150 130
M42x2 145 125 28 M30x1,5 130
M45x1,5 160 140
M45x2 150 130 35 M38x1,5 140
M48x1,5 170 145
M48x2 160 135
M52x1,5 180 150
M60x2 195 165
M64x2 205 175
* DIN 7604 Form C Edition: October 1995
11
2003-08
 Conversion from DIN to ISO standards

Withdrawn Title Substitute Result of check / measures 1)

DIN ISO standard

DIN 1 Tapered pins ISO 2339 - some can be replaced → changed to ISO 2339
- parts which cannot be replaced (e.g. where 1 = 36 mm)
documented as DIN 1 OLD

DIN 7 Cylindrical ISO 2338 - some can be replaced → changed to ISO 2338
pins - parts which cannot be replaced (e.g. diameter 13 and 14 and/or
where 1 = 36 mm) documented as DIN 7 OLD

DIN 84 Cylindrical ISO 1207 - some can be replaced → changed to ISO 1207
screws - parts which cannot be replaced (e.g. M2.6) documented as DIN 84 OLD

DIN 85 Flat head bolts ISO 1580 - can be replaced → changed to ISO 1580

DIN 94 Split pins ISO 1234 - can be replaced → changed to ISO 1234

DIN 417 Threaded pins ISO 7435 - can be replaced → changed to ISO 7435

DIN 439-1 Hex nuts ISO 4036 - cannot be replaced → documented as DIN 439 OLD
DIN 439-2 Hex nuts ISO 4035
ISO 8675

DIN 551 Threaded pins ISO 4766 - can be replaced → changed to ISO 4766

DIN 553 Threaded pins ISO 7434 - can be replaced → changed to ISO 7434

DIN 555 Hex nuts ISO 4034 - cannot be replaced → documented as DIN 555 OLD

DIN 558 Hex bolts ISO 4018 - some can be replaced → changed to ISO 4018
- parts which cannot be replaced (e.g. M12, with new SW) documented as
DIN 558 OLD

DIN 601 Hex bolts ISO 4016 - some can be replaced → changed to ISO 4016
- parts which cannot be replaced (e.g. M10 and M12, with new SW)
documented as DIN 601 OLD

DIN 912 Cylindrical ISO 4762 - some can be replaced → changed to ISO 4762
screws - parts which cannot be replaced (e.g. M18, M22, M27 and M33)
documented as DIN 912 OLD

DIN 931-1 Hex bolts ISO 4014 - some can be replaced → changed to ISO 4014
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with
new SW) documented as DIN 931 OLD

DIN 933 Hex bolts ISO 4017 - some can be replaced → changed to ISO 4017
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with
new SW) documented as DIN 933 OLD

DIN 934 Hex nuts ISO 4032 - cannot be replaced replaced as a result of uneven nut height and for
ISO 8673 M10, M12, M14 and M22 with new SW.

DIN 960 Hex bolts ISO 8765 - some can be replaced → changed to ISO8765
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with
new SW) documented as DIN 960 OLD

DIN 961 Hex bolts ISO 8676 - some can be replaced → changed to ISO 8676
- parts which cannot be replaced (e.g. M10, M12, M14 and M22 with
new SW) documented as DIN 961 OLD

DIN 963 Countersunk ISO 2009 - cannot be replaced as a result of modified head dimensions → documented
bolts as DIN 963 OLD

DIN 964 Countersunk ISO 2010 - cannot be replaced as a result of modified head dimensions → documented
bolts as DIN 964 OLD

1) refers to the productive components numbered at ZF

2003-08 12
 Conversion from DIN to ISO standards

Withdrawn Title Substitute Result of check / measures 1)

DIN ISO standard

DIN 965 Countersunk ISO7046 - cannot be replaced as a result of modified head dimensions → documented
bolts as DIN 965 OLD

DIN 980 Locking nuts ISO 7042 - cannot be replaced → documented as DIN 980 OLD
ISO 10513

DIN 985 Locking nuts ISO 10511 - cannot be replaced → documented as DIN 985 OLD

DIN 1440 Washers ISO 8738 - some can be replaced → changed to ISO 8738
- parts which cannot be replaced documented as DIN 1440 OLD

DIN 1443 Bolts ISO 2340 - can be replaced → changed to ISO 2340

DIN 1444 Bolts ISO 2341 - can be replaced → changed to ISO 2340

DIN 1471 Grooved pins ISO 8744 - some can be replaced → changed to ISO 8744
- parts which cannot be replaced (e.g. 1 = 6 mm) documented as
DIN 1471 OLD

DIN 1472 Grooved pins ISO 8745 - some can be replaced → changed to ISO 8745
- parts which cannot be replaced (e.g. 1 = 6 and 25 mm) documented as
DIN 1472 OLD

DIN 1473 Grooved pins ISO 8740 - some can be replaced → changed to ISO 8740
- parts which cannot be replaced (e.g. 1 = 4, 5, 6, 25 and 50 mm)
documented as DIN 1473 OLD

DIN 1474 Grooved pins ISO 8741 - can be replaced → changed to ISO 8741

DIN 1475 Grooved pins ISO 8742 - can be replaced → changed to ISO 8742

DIN 1476 Grooved stud ISO 8746 - can be replaced → changed to ISO 8746

DIN 1477 Grooved stud ISO 8747 - can be replaced → changed to ISO 8747

DIN 1481 Clamping pins ISO 8752 - some can be replaced → changed to ISO 8752
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 1481 OLD

DIN 6325 Cylindrical pins ISO 8734 - some can be replaced → changed to ISO 8734
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 6325 OLD

DIN 7346 Clamping pins ISO 13337 - some can be replaced → changed to ISO 13337
Flange - parts which cannot be replaced (∅ 7, 11 and 23 mm) documented as
DIN 6325 OLD

DIN 7976 Self-tapping ISO 1479 - can be replaced → changed to ISO 1479
screws

DIN 7978 Tapered pins ISO 8736 - some can be replaced → changed to ISO 8736
- parts which cannot be replaced (e.g. 1 = 36) documented as DIN 7978 OLD

DIN 7979 Cylindrical pins ISO 8733 - some can be replaced → changed to ISO 8733/8735
ISO 8735 - parts which cannot be replaced documented as DIN 7979 OLD

DIN 7981 Self-tapping ISO 7049 - can be replaced → changed to ISO 1479
screws

DIN 7982 Self-tapping ISO 7050 - cannot be replaced → documented as DIN 7982 OLD
screws

DIN 7985 Cheese-head ISO 7045 - can be replaced → changed to ISO 7045
Screws

1) refers to the productive components numbered at ZF

2003-08 13
W 390 MS torque converter Consumables

Description Name Approx. Application Comments

ZF item number Quantity

Grease For example General assembly aid

0750 199 001 Spectron FO 20

Grease Techn. Vaseline 8420 General assembly aid

0671 190 016

NOTE: Inquire as to size of containers before placing any orders.

4149 751 606 - 2004-01 14

W 390 MS torque converter Adjustment data

Description Dimension Measurement device Comments

01. Torque converter 81.25 ± 0.5 mm Depth gauge Installation dimension

installation dimension measured from mounting
(depending on version) face on torque converter to
mounting face on transmission
housing.
Installation dimension can be
adjusted using one or more
spacer rings on the stator
hollow shaft.

02. Torque converter end play 0.3 to 0.4 mm Depth gauge End play can be adjusted
between face end of con- using shim on face end of
verter internal sprag race turbine shaft.
and spacer ring on stator
hollow shaft OTK 0730 005 591

03. Clutch disk clearance of 0.6 to 1.2 mm Feeler gauge Clutch disk clearance is
torque converter lock-up measured between end disk
clutch and inner clutch disk

04. End play of axial bearing in 0 to 1.1 mm GO gauge and depth Only take check measurement
torque converter gauge

05. Tightening torque of 65 Nm Torque wrench Use counter holder

36 hex bolts (M10x22) 1X56 137 658 to lock torque
on torque converter converter

06. Tightening torque of M16 180 to 190 Nm Torque wrench and Fit new Cu seal. Use counter
cylindrical screw in turbine retaining fixture holder 1X56 137 658 to lock
shaft 1X56 137 158 torque converter in place

07. Tightening torque of 190 to 210 Nm Torque wrench

M33x2 screw plug in
torque converter

08. Tightening torque of 69 Nm Torque wrench

24 cylindrical screws
(M10x30) on circuit cover

4149 751 606 - 2004-01 15

W 390 MS torque converter Sectional view

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

31 30 29 28 27 26 25 24 23 22 21 20 19 18
018009

1 M10x20 (SW 16) hex bolt with shim 17 O-ring

2 Compression spring with shim 18 Inner clutch disk
3 Roller 19 Outer clutch disk
4 Impeller 20 Inner clutch disk
5 Stator 21 Outer clutch disk
6 Thrust disk 22 Plate piston
7 Axial roller bearing 23 Inner piston ring, plate piston
8 Thrust disk 24 Ball bearing
9 Freewheel inner ring 25 Thrust disk
10 Ball bearing 26 Axial needle cage
11 Thrust disk 27 Housing disk
12 Rollers 28 Turbine wheel
13 Thrust disk 29 Outer piston ring, plate piston
14 Ball bearing 30 Cup spring
15 End shim 31 Circuit cover
16 M10x30 cylindrical screws

4149 751 606 - 2004-01 16

W 390 MS torque converter Special tools

Fig. Special tools Order no. Application Qty. Comments

no.

1X56 137 213 1

Lifting device
1 for turbine shaft

1X56 136 862 1

Lifting device
2 for torque converter

1X56 136 864 1

Holding fixture
3 for unfastening and tightening M16
cylindrical screw in torque converter

1X56 137 152 1

Support
4 for stator bearing

1X56 137 658 1

Counter holder
5 for unfastening and tightening screw
plug in torque converter

4149 751 606 - 2004-01 17

W 390 MS torque converter Special tools

Fig. Special tools Order no. Application Qty. Comments

no.

1X56 137 158 1

Holding fixture
6 for unfastening and tightening M16
cylindrical screw in torque converter

1X56 137 130 1

Pneumatic unit
7 for seal integrity test of torque
converter and clutch carrier,
used in conjunction with feed bush
1X56 137 128 and forcing device
1X56 137 129

1P46 173 831 1

Feeler gage
8 for measuring clutch disk clearance

4149 751 606 - 2004-01 18

W 390 MS torque converter Removing and installing torque converter

1. Removing and installing torque converter

1
1.1 Removing torque converter

1 Turn the transmission in the swivel stand so

that the torque converter is facing upwards.
2

2 Attach counter holder 1X56 137 658 (1) to

torque converter and transmission housing
and screw in.

3 Unscrew screw plug (2).

017950

4 Screw retaining fixture 1X56 137 158 (3) into

torque converter circuit cover and tighten by
3
hand.

NOTE
Make sure rubber washer is fitted onto
retaining device thread.

017951

5 Connect pneumatic unit 1X56 137 130 onto

retaining fixture 1X56 137 158.

6 Turn the regulator (1) counterclockwise a few

times.

7 Open stopcock (2). The lever must be 2

horizontal.

8 Use the regulator (1) to set a pressure level

of 1.5 bar. 1

017952

4149 751 606 - 2004-01 1-1

W 390 MS torque converter Removing and installing torque converter

9 Insert 1/2” socket wrench extension (1) and

unfasten cylindrical screw.
1

NOTE
Use a suitably long grip.
The M16 cylindrical screw is tightened to
190 Nm in the turbine shaft. 2

10 Close stopcock.

11 Unscrew retaining fixture 1X56 137 158 (2)

from torque converter circuit cover.

017953

NOTE
In addition to the pneumatic retaining device,
ZF can also use a mechanical retaining device
1X56 136 864 in conjunction with the hex
insert 1X56 136 863.

021372

12 Unscrew cylindrical screw (1) and take out

torque converter.

017954

4149 751 606 - 2004-01 1-2

W 390 MS torque converter Removing and installing torque converter

13 Screw lifting device 1X56 136 862 (1) into

torque converter and tighten by hand. 1

14 Remove counter holder 1X56 137 658.

! DANGER
Torque converter weighs approx. 50 kg.
Risk of injury.
Before removing the lifting device, secure the
torque converter to prevent it from rolling away.

15 Carefully take torque converter out of trans-

mission.

NOTE
Before lifting out the torque converter, raise it 017955
to just above the turbine shaft.
Then tilt the torque converter slightly so that
the oil can drain out.

16 Unscrew lifting device. 1

17 Turn the torque converter over and remove

the shim(s) (1) from the torque converter or
turbine shaft.

017956

18 Remove spacer ring (2) from stator hollow

shaft.

021373

4149 751 606 - 2004-01 1-3

W 390 MS torque converter Removing and installing torque converter

1.2 Installing torque converter

1
1.2.1 Measuring torque converter end play

1 Screw lifting device 1X56 136 862 (1) into

torque converter so that the torque converter
turbine wheel is clamped tight.

! DANGER
Torque converter weighs approx. 50 kg.
Risk of injury.
Secure torque converter to prevent it from
rolling away.

017958

2 Turn torque converter over.

3 Measure the distance “C” between the face

end of the spur gear and the turbine wheel.

4 Note down distance “C”.

021374

5 Measure the distance “B” between the face

end of the spur gear and the face end of the
freewheel inner ring.

6 Note down distance “B”.

021375

4149 751 606 - 2004-01 1-4

W 390 MS torque converter Removing and installing torque converter

7 Calculate the theoretical distance “D” between

the face end of the freewheel inner ring and
the plane face of the shim as follows.

C–B=D
Note down distance “D”.

D B
C
017961

8 Check rectangular ring (1) for damage.

Replace if necessary.

9 Align rectangular ring centrally.

NOTE
Rectangular ring has hooked ends.

10 Slide spacer ring (2) onto stator hollow shaft

so that there is no end play. 2

021373
11 Screw lifting device 1X56 137 213 into turbine
shaft.

12 Tighten lifting device by hand until there is

no end play on the turbine shaft.

13 Place depth gage in recess of lifting device on 1

end face of turbine shaft.

14 Measure distance “A” between face end of A

turbine shaft and spacer ring (1) on stator
hollow shaft.

15 Note down distance “A”.

16 Unscrew lifting device from turbine shaft.

021376

4149 751 606 - 2004-01 1-5

W 390 MS torque converter Removing and installing torque converter

17 Calculate thickness “S” of shim (1).

D–A=E
Distance “E” plus the specified torque
converter end play (distance “G”)
(* 0.3 to 0.4 mm) gives the required thickness
“S” of the shim (1) to be fitted.
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 (OTK) 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 end play.

18 Thinly coat shim (1) with grease and affix.

19 Center the shim.

20 Center rectangular ring (2). 1

21 Thinly coat race of seal (arrow) with oil.

021377

4149 751 606 - 2004-01 1-6

W 390 MS torque converter Removing and installing torque converter

22 Screw lifting fixture 1X56 136 862 into torque

converter.

23 Carefully lower torque converter so that it is

centered on the turbine shaft. Fit the torque
converter so that there is no end play.

017955

24 Loosen lifting device 1X56 136 862 by

unscrewing a few turns.

CAUTION
Take care not to damage the seal. Ensure the shim
is correctly positioned on the turbine shaft.

NOTE
The turbine shaft and stator hollow shaft
splines must mesh inside the torque converter.
Rotate the torque converter slightly if
necessary. The gear on the torque converter
must also mesh with the input gear of the
primary shaft.

017965

4149 751 606 - 2004-01 1-7

W 390 MS torque converter Removing and installing torque converter

1.2.2 Measuring torque converter installation

dimensions

1 Make sure the torque converter is fitted

correctly and without any end play.

2 Measure installation distance “F” between

torque converter mounting face and trans-
mission mounting face.

3 Measure the distance at several points around

the circumference and calculate the average
value.

NOTE
Installation dimension “F” has a tolerance
of ± 0.5 mm. Ecomat transmissions can be
017966
equipped with different types of torque con-
verter.

Distance “F” (torque converter installation

dimension) may vary depending on version:
Pay close attention to parts lists. F

Distance “F” = 81.25 mm ± 0.5 mm

If installation dimension “F” is between

81.25 mm + 0.5 mm and 81.25 mm – 0.5 mm,
then the setting is correct.

4 If the installation dimension is less than

81.25 mm – 0.5 mm, fit a second spacer ring
on the stator hollow shaft.

5 If the distance is more than 81.25 mm

+ 0.5 mm, remove the spacer ring.
017967

NOTE
The spacer ring is 1 mm thick.

CAUTION
If the distance “F” is changed by adding / removing
a spacer ring on the stator hollow shaft, the shim 1
on the turbine shaft must also be changed accord-
ingly. Otherwise the bearings will be damaged.

6 Unscrew lifting device 1X56 136 862 from

torque converter.

7 Screw M16 cylindrical screw (1) into turbine

shaft.

8 Re-check the installation dimension.

017954

4149 751 606 - 2004-01 1-8

W 390 MS torque converter Removing and installing torque converter

9 Attach counter holder 1X56 137 658 to

transmission housing and bolt it to torque
converter.

10 Screw retaining fixture 1X56 137 158 into

torque converter circuit cover and tighten by
hand. 2
NOTE
Make sure rubber washer is fitted onto retain-
ing device thread.
1
11 Connect pneumatic unit 1X56 137 130 onto
retaining fixture 1X56 137 158.

12 Turn the regulator (1) anti-clockwise a few

017952
times.

13 Open stopcock. Move the lever (2) into

horizontal position.

14 Use regulator (1) to set a pressure level of

1.5 bar.
3
15 Insert 1/2” socket wrench extension and
tighten hexagon socket head screw;
tightening torque: 180 – 190 Nm

16 Close stopcock.

17 Remove retaining fixture 1X56 137 158 (3)

from torque converter circuit cover.
017953

18 Fit new copper seal on screw plug (1).

1
19 Tighten M33x2 screw plug; tightening torque:
190 – 210 Nm

017968

4149 751 606 - 2004-01 1-9

4149 751 606 - 2004-01 1-10
W 390 MS torque converter Dismantling and assembling torque converter

2 Dismantling and assembling torque

converter

2.1 Dismantling torque converter

1 Place torque converter on squared lumber so

that impeller faces upwards. 1

2 Unscrew all M10x22 (SW 16) hex bolts and

washers (1) leaving only one hex bolt on each
opposite side.

3 Turn torque converter over so that impeller

faces downwards or circuit cover faces
upwards.
017969
4 Remove two remaining hex bolts on opposite
sides.

! DANGER 2
Turbine wheel may remain in circuit cover and
still fall off.
Risk of injury. 3
Place circuit cover close by.

5 Attach hoisting rope to lifting device

1X56 136 862 (2) and lift circuit cover (3)
off impeller using hoist.

017970

6 Take off turbine wheel (1).

017971

4149 751 606 - 2004-01 2-1

W 390 MS torque converter Dismantling and assembling torque converter

7 Take housing disk (1), axial needle cage (2)

and thrust disk (3) off stator (4). 3
1
CAUTION
Do not mix the bearing assemblies when installing.
2
The thrust and housing disks must not be mixed up
with any other bearing modules. Clearly mark all
parts.

8 Take stator (4) out of impeller (5). 4

021378

9 Take out thrust disk (6), roller bearing (7), and

thrust disk (8). 5

6
CAUTION
The thrust and housing disks must not be mixed up
with any other bearing modules.
Clearly mark all parts.

017973

4149 751 606 - 2004-01 2-2

W 390 MS torque converter Dismantling and assembling torque converter

2.1.1 Dismantling stator

1 Place stator (1) on support with collar (2)

facing downwards.

021379

2 Place suitable pressure piece (1) on freewheel

inner ring.
1
3 Press freewheel inner ring out of stator.

021380

4 Remove roller (1) from freewheel inner ring (2).

2
5 Take off thrust disk (3) from freewheel inner
ring.
1

017976

4149 751 606 - 2004-01 2-3

W 390 MS torque converter Dismantling and assembling torque converter

6 Press freewheel inner ring (1) out of ball

bearing (2). Use suitable pressure pieces for
this, for example: 4
Lower pressure piece (3): 1X56 136 818
(remove metal ring) 1
Upper pressure piece (4): outside diameter
approx. 63.0 mm to 69.0 mm
2

CAUTION
3
Do not clean bearings using compressed air.
Bearing races could come loose and damage the
bearing due to lack of lubrication.

021381

7 Place stator (1) on press using suitable

support (2).
3
8 Use suitable pressure piece (3) to press ball
bearing out of stator.
The maximum outside diameter for the upper
pressure piece (3) is 82 mm. The inner
diameter of the lower pressure piece (2) must
be a minimum of 115 mm.

021382

9 Remove ball bearing (1) and thrust disk (2)

from stator. 1

021383

4149 751 606 - 2004-01 2-4

W 390 MS torque converter Dismantling and assembling torque converter

2.1.2 Assembling stator

1
1 Insert thrust disk (2) and ball bearing (1) in
stator. 2

021383

2 Insert stator on suitable support in press with

collar (2) facing upwards.

3 Use special tool 1X56 137 152 (1) to press ball

bearing (3) in as far as it will go. 1

021384

4 Insert support 1X56 137 152 into press with

hollow facing upwards.

5 Turn stator over (collar (2) facing upwards)

and place on support 1X56 137 152.

6 Insert freewheel inner ring (1) into stator with

the longer collar facing downwards and press 1
in.

NOTE
Using support 1X56 137 152 ensures that the 2
freewheel inner ring is fitted in the correct
position.

021386

4149 751 606 - 2004-01 2-5

W 390 MS torque converter Dismantling and assembling torque converter

7 Insert rollers (1) in stator.

NOTE
After insertion, moderately oil the rollers and
rotate the stator several times.
2
8 Insert thrust disk (2) in stator.

021387

9 Insert support 1X56 137 152 in press and

place stator on support complete with ball 3
bearing (3).

10 Place second support 1X56 137 152 (4) on ball

bearing (5).

11 Press ball bearing into stator until firmly

home.

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.
021385

021388

4149 751 606 - 2004-01 2-6

W 390 MS torque converter Dismantling and assembling torque converter

2.1.3 Dismantling circuit cover

1 Unscrew 24 M10 cylindrical screws (1) from 1

circuit cover.

2 Remove O-ring (2).

017984

3 Remove end disk (3).

4 Remove inner and outer clutch disks (4) from 3

circuit cover.

NOTE 4
Compression springs with disks (5) can be
found on the last outer clutch disk.
5

5 Remove compression springs, disks (5) and

last outer clutch disk.
6

6 Take out 12 rollers (6).

017985

7 Take out cup spring (1).

017986

4149 751 606 - 2004-01 2-7

W 390 MS torque converter Dismantling and assembling torque converter

8 Use a drift against the back of the circuit cover

to push the ball bearing out (1).
1

021390

9 Gently strike circuit cover (3) with plastic

hammer to remove plate piston (2). 2

3
021434

! DANGER
Grooved edge of plate piston may have sharp
edges. 5
Risk of injury.
Wear protective gloves.
4
10 Use appropriate tool (0.5 – 0.75 mm thickness)
to grasp inner seal (5) and carefully remove
from plate piston.

11 At the same time slide both sides of outer

seal (4) in direction indicated by arrows.
Grasp protruding part of seal and take out of
annular groove.

021391

4149 751 606 - 2004-01 2-8

W 390 MS torque converter Dismantling and assembling torque converter

2.1.4 Assembling circuit cover

NOTE
Thoroughly clean all components and dry 2
using compressed air. Only use lint-free cloth
to wipe off seals.
1

1 Check seals for damage. Replace if necessary.

2 Coat inner seal (2) and outer seal (1) with

Vaseline and insert them into the plate piston.

NOTE
Stretch the inner seal a little before installing
so that it sits firmly in the base of groove.
021391
CAUTION
Insert plate piston (3) in circuit cover without 3
4
tilting it. Ensure that the seals are firmly seated in
the base of the groove all the way around.
5
3 Tap around the edge of the plate piston with
a plastic hammer. Make sure that the plate
piston is correctly positioned.

4 Place cup spring (4) onto plate piston with

camber facing downwards.

5 Insert 12 rollers (5) into holes around the edge.

6 Use a straight edge to check that the outer and

inner clutch disks are flat and not distorted
021392
or perform a visual check. Check the disks
against the end disck or a flat surface.

CAUTION
Replace any disks that are dished or corrugated.
Replace lined disks that have damaged or
blackened linings.
Replace steel disks that have been discolored or
stained by heat. Replace clutch disks that have
damaged or dented tooth flanks.

021393

4149 751 606 - 2004-01 2-9

W 390 MS torque converter Dismantling and assembling torque converter

7 Insert first outer clutch disk (1) so that the

5
holes slide over the rollers. 4

8 Place four disks and four springs (2) over

the rollers and onto the outer clutch disk at 1
90° intervals (see detail below).
3
9 Insert first inner clutch disk (3).

10 Insert second outer clutch disk (4) offset at an

angle to the first outer clutch disk (see note
below).

2
11 Insert second inner clutch disk (5) in circuit
cover.
021394
Details of step 8:
– Roller (6) must be inserted in hole (arrow)
– Slide disk (8) onto roller
– Place spring (7) on top of disk

021395

NOTE
Insert outer clutch disk (4) so that the tooth
spaces for the springs (arrow) and bores
are above the remaining rollers. Outer clutch
disk (4) must not rest on the springs.

021396

4149 751 606 - 2004-01 2-10

W 390 MS torque converter Dismantling and assembling torque converter

12 Insert two M10 threaded pins (1) opposite one 1

another.

13 Line up the holes on the end disk (2) with the

holes in the circuit cover.
The depressions (3, blind hole) in the end disk
must be lined up over the springs. Insert end
disk over guide pins (1) and onto springs in
circuit cover.

021398

021397

14 Screw in 24 M10x30 cylindrical screws (4).

Tightening torque: 69 Nm
4

NOTE
Before tightening the hex bolts, tap the plate
piston fully home with a plastic hammer.

5
15 Use a feeler gage (5) to measure the play
between the last inner clutch and the end
disk (6) and note down as distance “A”.

021399

4149 751 606 - 2004-01 2-11

W 390 MS torque converter Dismantling and assembling torque converter

16 Disk play (distance “A”) must be between

0.6 mm and 1.2 mm.

NOTE
If the disk play is less than 0.6 mm or more
than 1.2 mm, fit new outer clutch disks as
necessary. Then re-measure distance “A”.
A

017995

17 Turn over turbine wheel and drive spacer disk

(1) (if previously removed) with hole facing
upwards into turbine wheel as far as it will go.
1
18 Crimp metal of spacer disk at four points to
secure it (1).

19 Place bearing (3) onto turbine wheel.

! DANGER
2

Rectangular ring has sharp edges.

Risk of injury.
Wear protective gloves. 3

20 Insert rectangular ring (2) in annular groove

and hook in the open ends of the ring. 021400

21 Align inner clutch disks. The discs must cover

each other.

22 Insert turbine wheel (1) in circuit cover.

1
CAUTION
Ensure that the teeth on the turbine wheel mesh
in the gaps on the inner clutch disks. Rotate the
turbine wheel back and forth until it engages.
Ensure that the turbine wheel is fully engaged and
inserted as far as it will go. If necessary, tap edges
of inner teeth with plastic hammer. Take care not
to damage inner clutch disks.

017997

4149 751 606 - 2004-01 2-12

W 390 MS torque converter Dismantling and assembling torque converter

2.1.5 Measuring axial bearing end play /

Take measurement as check
1

NOTE
Production tolerances give the specified axial
play. There are no provisions for adjusting the
axial play using shims. 2
Measuring is for checking purposes only.

1 Insert the axial disk (3) in the impeller (4).

3
2 Insert the axial roller bearing (2).

4
3 Insert the axial disk (1).

017973

4 Insert the stator (5) in the impeller with the

longer collar of the freewheel inner ring facing
downwards. 1

5 Fit the axial disk (3) on the shorter collar of 2

the freewheel inner ring (4) on the stator.

6 Fit the axial needle cage (2). 3

7 Fit the housing disk (1).

4

017972

8 Place the measuring plates (3) on the mating

3
face of the impeller.
2
9 Fit the measuring strip (2).

10 Place the depth gage on the measuring strip

and measure the distance “A” between the
measuring strip and the impeller mating
face (1). Note down distance “A”.

1
NOTE
The measuring strip must not lie on the stator.

017998

4149 751 606 - 2004-01 2-13

W 390 MS torque converter Dismantling and assembling torque converter

11 Move the depth gage to the middle.

12 Measure the distance “B” between the

measuring strip and the front face of the
housing disk (1).

13 Note down distance “B” and subtract distance

“A” from it.

B – A = Distance “C”

017999

14 Mount the measuring setup on the circuit

cover mating face.

NOTE
Do not insert an O-ring in the circuit cover for
the purpose of measuring.

15 Use the depth gage to determine the distance

1
“D” between the measuring strip and the mat-
ing face of the circuit cover (1).

16 Note down distance “D”.

17 Determine the distance “E” between the

measuring strip and the point of contact with
the shim (2). 018000

18 Note down distance “E” and subtract it from

distance “D”.

D – E = Distance “F”
2
Subtract distance “F” from distance “C”.

C – F = Distance “G”

Distance “G” = axial play of the axial bearing

Specified axial play of the axial bearing

= 0.0 to 1.1 mm

NOTE
Distance “G” must be within the specified
axial play of 0.0 to 1.1 mm.
018001

4149 751 606 - 2004-01 2-14

W 390 MS torque converter Dismantling and assembling torque converter

2.2 Assembling torque converter

1 Insert housing disk (1) in the turbine wheel.

1
2 Insert axial needle cage (2) and thrust disk (3)
in turbine wheel.

018002

3 Insert stator (1) in turbine wheel with short

collar of freewheel inner ring facing the 5
1
turbine wheel.

NOTE 2
Coat all bearings with oil before installation.

4 Place thrust disk (2) on long collar of free-

wheel inner ring. 3

5 Fit roller bearing (3).

6 Fit thrust disk (4).

5

7 If not already present, fasten 2 cylindrical 4

pins (5) opposite one another. 018003

8 Insert O-ring (2). 1

9 Screw two M10 threaded pins (1) opposite one

another in circuit cover flange.

018004

4149 751 606 - 2004-01 2-15

W 390 MS torque converter Dismantling and assembling torque converter

10 Line up impeller (1) over cylindrical pins and

2
place it on circuit cover.

CAUTION
To prevent damage, make sure that the holes are
correctly lined up with the cylindrical pins.

11 Screw in two of the M10x22 (SW 16) hex bolts

with washers.
1

12 Unscrew M10 threaded pins (2).

13 Screw in remaining M10x22 hex bolts.

018005

14 Tighten M10x22 hex bolts (SW16),

Tightening torque: 65 Nm

018006

15 Check end play of freewheel inner ring (1).

16 Use both hands to grasp inside of freewheel

inner ring and move in axial direction. End
play must be palpable.
1

017956

4149 751 606 - 2004-01 2-16