¨

WSK 400 for 16 S 151, 16 S 221

WSK 440 for 16 S 251
4130 751 103a
Subject to alterations in design

Copyright by ZF

These repair instructions are 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: 02.00

4130 751 103a

 WSK 400/440 Contents

Page

Preface ....................................................................................................................................................... 4
Important information ................................................................................................................................ 5
Instructions for carrying out repairs ........................................................................................................... 6
Tightening torques ..................................................................................................................................... 8
Consumables .............................................................................................................................................. 10
Adjustment data ......................................................................................................................................... 11
Spring table ................................................................................................................................................ 16
Special tools ............................................................................................................................................... 17

1 Disassembly and assembly of WSK / engine ........................................................................................... 1-1

2 Transmission mounting ........................................................................................................................... 2-1

3 Central wiring harness – WSK 400/440 ................................................................................................. 3-1

4 Oil reservoir – WSK 400/440 ................................................................................................................... 4-1

5 Clutch cylinder WSK 400/440 ................................................................................................................ 5-1

6 WSK / transmission WSK 400/440 ......................................................................................................... 6-1

7 Selector clutch – WSK 400/440 ............................................................................................................... 7-1

8 Converter – WSK 400/440 ....................................................................................................................... 8-1

Converter installation depth “C” ................................................................................................................ 8-2
Axial play of tapered roller bearing “G” .................................................................................................... 8-3
Inductive sensor distance (“n engine”) ....................................................................................................... 8-4
8.1 Dismantling and assembling converter (WSK 440) ................................................................................... 8-5

9 Turbine shaft – WSK 400/440 ................................................................................................................. 9-1

10 Oil filter – WSK 400/440 ......................................................................................................................... 10-1

11 Control unit – WSK 400/440 ................................................................................................................... 11-1

12 Retarder – WSK 400/440 ......................................................................................................................... 12-1

13 Converter housing – WSK 400/440 ......................................................................................................... 13-1

13.1 Oil feed flange ........................................................................................................................................... 13-1
13.2 Gear pump and wiring harness ................................................................................................................... 13-2
13.3 Converter housing ...................................................................................................................................... 13-4
13.4 Screw connection M10 WSK 400 .............................................................................................................. 13-5
13.5 Screw connection M12 WSK 440 .............................................................................................................. 13-6

14 Pressures and measuring points for WSK 400 and WSK 440 ............................................................... 14-1

15 After-Sales Service function test for WSK system ................................................................................. 15-1

 Preface

This repair manual is intended for skilled personnel

trained by ZF Friedrichshafen AG to carry out mainte-
nance 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 updated 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.

Repair work carried out at ZF service points is

subject to the contractual conditions prevailing in
the individual case.

ZF FRIEDRICHSHAFEN AG Damage resulting from work performed by non-ZF

C.V./Special Transmissions personnel in an improper and unprofessional manner
Service Plant 2 and any consequential costs are excluded from the con-
Tel.: (0 75 41) 77-0 tractual liability agreement. Exclusion of liability also
Fax: (0 75 41) 77-5726 applies if genuine ZF spares are not used.

4
 Important information

SAFETY NOTICE GENERAL INFORMATION

Companies repairing 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 products, all

safety regulations and legal requirements which apply to CAUTION
repair and maintenance work must be adhered to. Pictures, drawings and components do not always repre-
Before starting work, mechanics must familiarize them- sent the original object, but are used to illustrate working
selves with these regulations. procedures.
Pictures, drawings and components are not to scale.
Personnel required to carry out repairs on ZF products Conclusions about size and weight should not be drawn
must receive appropriate training in advance. It is the (even within a complete illustration).
responsibility of each company to ensure that their Always follow the working steps as described in the
repair staff is properly trained. text.

After completion of repair work and testing, skilled staff

The following safety instructions appear in this manual: must satisfy themselves that the product is functioning
correctly.

NOTE
Refers to special processes, techniques, data, use ! THREATS TO THE ENVIRONMENT !
of auxiliary equipment, etc. Lubricants and cleaning agents must not be allowed
to enter the soil, ground water or sewage system.
• Ask your local environment agency for
CAUTION safety information on the relevant products
This is used when incorrect, unprofessional and adhere to their requirements.
working practices could damage the product. • Collect used oil in a suitably large container.
• Dispose of used oil, dirty filters, lubricants
and cleaning agents in accordance with
! DANGER environmental protection guidelines.
This is used when lack of care could lead to • When working with lubricants and cleaning
personal injury or death. agents always refer to the manufacturer’s
instructions.

CAUTION
The transmission must NOT be hung by the input
shaft NOR by the output flange.

5
 Instructions for repairs

In case of doubt always turn to the relevant depart- GASKETS, LOCKING PLATES
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed expertly Parts which cannot be removed without being damaged
and under clean conditions. must always be replaced with new parts (e.g. gaskets
Use specified tools to dismantle and assemble trans- and locking plates).
missions.

After removing the transmission from the vehicle,

clean thoroughly with a suitable cleaning agent before SHAFT SEALS
opening.
Pay particular attention to the projections and recesses Always change shaft seals with rough, ripped or
of housings and covers when cleaning. hardened packing washers. Seal contact surfaces must
Parts joined with Loctite are easier to separate if be totally clean and in perfect condition.
warmed with a fan heater.

RE WO RK I NG
CLEANING PARTS
Rework may be carried out on seal contact surfaces
Remove remains of old gaskets on all seal-faces. using plunge-cut grinding only, never use an emery
Carefully remove burrs or similar patches of roughness cloth. Ensure that there are no traces of grinding or
using an oil-stone. riffling.

Lube bores and grooves must be free of anti-corrosion If rework is needed on distance washers, shims etc.
agents and foreign matter; check for perfect passage. because of clearance settings, ensure that the reworked
areas contain no face runout and have the same surface
Carefully cover opened transmissions to prevent foreign quality.
matter from entering.

TRANSMISSION ASSEMBLY
REUSING PARTS
Find a clean site to assemble the transmission. Gaskets
Parts such as ball or roller bearings, multi-discs, thrust are installed without the use of sealing compound or
washers etc., must be inspected by a competent person, grease. When measuring silicon-coated gaskets, take
who should decide whether or not they can be re-used. care not to include the silicon layer in the measure-
Replace parts which are damaged or have suffered from ment.
excessive wear. During assembly, comply with all adjustment data,
checking data and tightening torques in the Repair
Manual.

6
 Instructions for repairs

BEARI N GS d) Dual shaft seals have two sealing

lips. The dust-proof sealing lip (X)
If bearings are mounted in heated condition, they are to must face outwards.
be heated evenly (e.g. heating cabinet). X
Temperature should be at ca. 85 °C and must not exceed e) Fill the gap between the sealing
120 °C. Each mounted bearing must be oiled with lips so it is 60% filled with grease (e.g. produced
operating oil. 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
S E ALI NG mounting or faceplate onto the relevant installation
depth plan.
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 RETAINING AGENTS
sealing agent on the surfaces to be sealed near apertures
to ensure that no sealing agent enters the oil feeds when Retaining agents* may only be used in places as
the surfaces are sealed. 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.
SHAFT SEALS

a) Apply a light coat of sealing agent* on outer edge of

shaft seals with “steel surround”.
TRANSMISSION OIL
b) Never apply sealing agent to shaft seals with
“rubber surround”, but apply a thin coat of Vaseline After completing repairs, fill transmissions with trans-
8420 to the outer edge or wet with a lubricant, e.g. a mission oil. For the procedure and approved oils, refer
water-soluble, concentrated washing-up liquid (e.g. to the transmission operating manual and List of Lubri-
Pril, Coin, Palmolive). cants TE-ML (refer to identification plate) which are
available from any ZF After-Sales Service Point. After
c) Shaft seals with steel and rubber surrounds should be filling the transmission with oil, tighten the screw plugs
treated on the outer edge of the rubber surround as at the oil filling point and the oil overflow to the speci-
described above in section b). fied torques.

* refer to expendable material

7
 Tightening torques

Tightening torques for nuts and bolts, extract from

ZFN 148

This standard applies to bolts acc. to DIN 912, DIN 931, Surface condition of bolts: thermally blackened and
DIN 933, DIN 960, DIN 961 and to nuts acc. to DIN 934. oiled or galvanized and oiled or galvanized, chrome-pla-
This Standard contains data on tightening torques (MA) ted and oiled.
for bolts and nuts in strength categories 8.8, 10.9 and
12.9 and nuts in strength categories 8, 10 and 12. Tighten screws with a calibrated torque spanner.

NOTE
Irregular tightening torques are listed separately in the
Repair Manual.

Regular screw thread Fine screw 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

8
 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 aluminum alloys.
cast and aluminum alloys. The values are based on experience and are inten-
The values are based on experience and are ded as reference values for the fitter.
intended as reference values for the fitter. General rule: screw/bolt class 5, ZFN 148-1
The values for the tightening torque MA apply analo- Material: 9SMnPb28K acc. to DIN 1651
gously for screw plugs according to DIN 908 and Surface condition: as manufactured
DIN 910, as the thread geometries are almost identical. (without surface protection) and lightly
General rule: Screw/bolt class 5, ZFN 148-1 oiled or galvanized, chromated and
Screw/bolt material: steel acc. to lightly oiled.
DIN 7604. Surface condition: as manu-
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/gray cast Al alloy diameter in Nm
M 8x1 20 10 4-5 M8x1 20 - 25
M 10 x 1 25 / 30* 15 / 20*
M 12 x 1.5 35 25 6 M 10 x 1 25 - 35
M 14 x 1.5 35 25
M 16 x 1.5 40 30 8 M 12 x 1.5 30 - 40
M 18 x 1.5 50 35
M 20 x 1.5 55 45 10 M 14 x 1.5 35 - 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

9
 Consumables WSK 400/440

Description Name Approx. Application Remarks

ZF ref. no quantity

Jointing compound
0666 690 017 Loctite no. 241 30 mm3 M3x22 cyl. screw / wiring harness Chapter 13

Sealing compound
0666 790 017 WEVO L 100 20 g Oil feed flange Chapter 13
Gear pump Chapter 13

Grease
0671 190 050 Olista Longtime 3EB 7g Separating clutch Chapter 7

Grease
0671 195 016 Molycote BR2 plus 4g Release device Chapter 7

Grease For example:

0750 199 001 Aralub HL2 50 g - Split ring / converter Chapter 8
5g - Needle sleeve / turbine shaft Chapter 9
2g - Shaft seal / retarder housing Chapter 12
2g - Shaft seal / converter housing Chapter 13

Graphite grease Converter centring journal Chapter 1

NOTE: Inquire about the size of bundles that can be delivered before placing any orders !

10
WSK 400/440 Adjustment data

Description Dimension Measurement device Remarks

01. Setting converter WSK 400 Depth gauge Adjust using appropriate
installation dimension 80.7 mm ± 0.20 mm adjusting disc and/or
WSK 440 shim (7) at the oil feed
81.6 mm ± 0.20 mm flange

02. Distance of “n engine” 0.80 mm ± 0.20 mm Depth gauge and Adjust using appropriate
inductive sensor 1P01 137 833 washer

03. Axial play of tapered 0.05 - 0.15 mm Depth gauge Adjust using appropriate
roller bearing washer (6) on turbine shaft

04. Tightening torque 83 Nm Torque wrench

M12x1.5 at adapter
ring / converter

05. Tightening torque of 190 Nm Torque wrench

anti-fatigue bolt on
converter

06. Tightening torque 1.3 Nm Torque wrench

M3x22 on wiring
harness

07. Tightening torque 46 Nm Torque wrench

M10x16 on wiring
harness

08. Tightening torque at 40 Nm Torque wrench Use correct size of washer

inductive sensor /
“n engine” converter

09. Tightening torque of 35 Nm Torque wrench Use new sealing ring

M12x1.5 screw plug at
control unit

11
 Adjustment data WSK 400/440

Description Dimension Measurement device Remarks

10. Tightening torque 9.5 Nm Torque wrench

M6x40 at valve
housing

11. Tightening torque 5.5 Nm Torque wrench

M5x12 at solenoid
valve

12. Tightening torque Torque wrench

M6x18 14 Nm
M6x12 10 Nm
at cover / control unit

13. Tightening torque 23 Nm Torque wrench

M8x25, M8x35
M8x40, M8x60
at control unit housing

14. Tightening torque 46 Nm Torque wrench

M10x55 at pressure
plate

15. Tightening torque 46 Nm Torque wrench

M10x16 at spacer
plate

16. Tightening torque of 60 Nm Torque wrench Use new sealing ring

M24x1.5 screw plug
on oil reservoir

17. Tightening torque 46 Nm Torque wrench

M10x60 at oil reservoir

18. Tightening torque 23 Nm Torque wrench

M8x28 at piping

12
WSK 400/440 Adjustment data

Description Dimension Measurement device Remarks

19. Tightening torque of 45 Nm Torque wrench Use new sealing rings

hollow screw on retarder
housing

20. Tightening torque Torque wrench As of 1999, M10 cylindrical

WSK 440 WSK 400 WSK 440 WSK 400 screws and M10 dowel pins
Cylindrical screws and M10 nuts are replaced
M12x115 M10x115 100 Nm 48 Nm by M12 versions in the
M12x110 M10x110 43 Nm 46 Nm WSK 400 + Ecosplite III
Dowel pins transmissions (refer to
M12x175 M10x175 18 Nm 14,5 Nm WSK 440)
Nuts
M12 M10 90 Nm 48 Nm
M12 (2x) ------- 43 Nm -------
Hex bolts
M8x80, M8x50 23 Nm 23 Nm
on retarder housing

21. Tightening torque 23 Nm Torque wrench

M8x35 on plug

22. Tightening torque 23 Nm Torque wrench

M8x22 on connecting
piece

23. Tightening torque of 30 Nm Torque wrench Use new sealing ring

temperature sensor

24. Tightening torque Torque wrench

Hex bolts
M8x25, M8x28 23 Nm
M8x35, M8x45
cylindrical screw
M8x22 23 Nm
dowel pin M8x25 10 Nm
nut M8 23 Nm
on retarder housing

13
 Adjustment data WSK 400/440

Description Dimension Measurement device Remarks

25. Tightening torque 46 Nm Torque wrench

M10x55 on gear pump

26. Tightening torque of 10 Nm Torque wrench

vent / converter housing

27. Tightening torque Torque wrench Use new sealing rings

of screw plugs
M24x1.5 50 Nm
M26x1.5 65 Nm
on converter housing

28. Tightening torque 46 Nm Torque wrench

M10x40 on oil feed
flange

29. Tightening torque Torque wrench

of dowel pins
M8SK6, M8x16 10 Nm
nuts M8 23 Nm
at strainer insert / filter

30. Tightening torque 120 Nm Torque wrench Use new locking plate
of slotted nut in clutch
housing

31. Tightening torque 30 Nm Torque wrench Use new o-ring/round.

of inductive sensor / Distance is specified.
“n turbine” connection
plate

32. Temperature of outer Approx. 100 °C Temperature probe

bearing race / oil feed
flange

14
WSK 400/440 Adjustment data

Description Dimension Measurement device Remarks

33. Tightening torque 140 Nm Torque wrench Only for WSK 400,
of screw plug M39x2 depending on version.
on converter Use new sealing ring.

34. Installation depth of 83.25 ± 0.8 mm Depth gauge Shim

WSK /engine

35. Thickness of dia- WSK 400 (2 diaphragms)

phragms (engine / WSK) 2.4 ± 0.14 mm
WSK 440 (1 diaphragm)
1.5 ± 0.14 mm

36. Tightening torque M10 = 49 Nm or Torque wrench

of hex bolt on M12 = 79 Nm
converter housing /
flywheel housing

37. Tightening torque 90 Nm Torque wrench

of M12x1.5 hex bolt
on flywheel /
converter

38. Tightening torque 48 Nm Torque wrench WSK converter 440

of M10x45 cylindrical
screw on converter
cover

39. Tightening torque 35 Nm Torque wrench WSK converter 440

of M8x35 cylindrical
screw on piston

40. Tightening torque 25 Nm Torque wrench WSK converter 440

of M8x18 cylindrical
screw on pump

41. Disc clearance or piston 0.70 - 1.70 mm Feeler gauge WSK converter 440
clearance in converter
cover

15
 Adjustment data WSK 400/440

Description Dimension Measurement device Remarks

42. Converter monitoring 149.8 -0.2 mm Depth gauge WSK converter 400
depth Adjust using appropriate
adjusting disc.

16
WSK 400/440 Spring table

Installation point Trans- Order no. No. of Wire diam. Spring diam. Untensioned
mission windings in mm in mm length in mm
Safety valve WSK 400 0732 042 511 17.5 2.50 20.1 96.3

WSK 440 0732 042 692 17.0 2.80 20.1 85.0

Lock-up clutch shift WSK 400

valve 0732 040 769 12.5 1.25 11.45 42.3
WSK 440

Lock-up clutch WSK 400

pressure valve 0732 042 444 16.5 2.50 19.5 89.9
WSK 440

Converter back WSK 400 0732 040 972 14.5 2.50 24.6 126.0
pressure valve
WSK 440 0742 042 691 17.0 3.00 24.5 113.4

Housing WSK 400

0732 041 246 48.5 2.80 18.45 250
WSK 440

NMV shift valve / WSK 400 0732 041 217 17.5 1.60 15.4 87.4
safety valve with NMV

17
 Special tools WSK 400/440

Fig. Special tools Order no. Application Qty. Remarks

no.

1X56 091 173 Chapter 13

Adapter
1 for shaft seal in converter housing 1

1X56 104 910 Chapter 7

Clamping bar
2 for pressure plate / clutch 2

1X56 112 761 Chapter 12

Chapter 13
Adapter
3 for outer bearing race /oil feed flange 1
and shaft seal / retarder housing on
output side

1X56 119 917 Chapter 9

Adapter
4 for needle sleeves and shaft seal 1
in turbine shaft

1X56 136 242 Chapter 6

Chapter 7
Lifting tool Chapter 9
5 for WSK housing parts 1

18
WSK 400/440 Special tools

Fig. Special tools Order no. Application Qty. Remarks

no.

1X56 136 914 Chapter 7

Centring punch
6 for clutch disc 1

1X56 137 539 Chapter 8

Lifting device
7 for converter 1 WSK 440
WSK 400

1X56 136 577 Chapter 8

Lifting device
8 for converter in conjunction 1 WSK 400
with M39x2screw plug

1P01 137 833 Chapter 8

Measuring device
9 for adjusting “n engine” 1
inductive sensor

1X56 138 107 Chapter 8

Gripper
10 for adapter 1X56 138 224 1 WSK 440

19
 Special tools WSK 400/440

Fig. Special tools Order no. Application Qty. Remarks

no.

1X56 138 151 Chapter 8

Clutch fixation
11 for release fork 1
(exchange of converter with
attached torque converter clutch)

1X56 138 159 Chapter 7

Downhold device
12 for installation and removal of 1
release device on pressure plate

1X56 138 116 Chapter 5

Chapter 6
Fixing plate
13 for changing the clutch release 1
cylinder or for supplies
without the release cylinder

1X56 138 217 Chapter 8

Ring
14 used for several purposes 1 WSK 440
on the converter

1X56 138 218 Chapter 8

Adapter
15 used for several purposes 1 WSK 440
on the converter

20
WSK 400/440 Special tools

Fig. Special tools Order no. Application Qty. Remarks

no.

1X56 138 224 Chapter 8

Adapter
16 for angular ball bearing with 1 WSK 440
gripper 1X56 138 107

1X56 139 137 Chapter 2

Chapter 6
Assembly fixture
17 for complete Transmatic 1

21
22
Special tools

1X56 136 242 1X56 091 173 1X56 119 917 1X56 138 159

1X56 137 539 1X56 136 914

1X56 136 577 1X56 138 116

WSK 400

1P01 137 833 1X56 112 761 1X56 104 910 1X56 138 151 1X56 139 137
 WSK 440

1X56 138 107 1X56 136 242 1X56 091 173 1X56 119 917 1X56 138 159

5
19

1X56 138 224 20x

1X56 138 218 1X56 136 914

1X56 137 539 1X56 138 116

Special tools

1X56 138 217 1P01 137 833 1X56 112 761 1X56 104 910 1X56 138 151 1X56 139 137

23
 WSK 400/440 WSK /engine

1 WSK /engine

Disassembly

NOTE
3
The diagram shows the diaphragm connection
between the WSK and engine. The converter of
the WSK is connected to the flywheel using
10 hex bolts located on the circumference via
2 diaphragms in the WSK 400 and 1 diaphragm 2
in the WSK 440.

1 Use a mounting lever to rotate the starter crown 1

wheel (1) until one of the retaining bolts (2) on
the converter is accessible through the assembly
aperture of the flywheel housing (3). Use a socket
015063
wrench to unscrew the M12x1.5 hex bolts (2) and
spring washer.
Continue rotating the starter crown wheel (1)
until it reaches the next hex bolt and remove all
hex bolts from the converter in this manner. 6

2 Fit lifting device under WSK ensuring that the

transmission is horizontal. Unfasten and remove
8
retaining bolts (5) holding circumference of
converter housing (4) with flywheel housing. 7

3 Move WSK out approx. 100 mm in the direction

of the axle. The engine and WSK are only
separated once the converter centring journal (6)
4
has slipped out of the flywheel (7).

NOTE 5
Once the transmission has been removed, take 015064

off the diaphragms (8) located on the flywheel

and check that they are in perfect condition.

1-1
 WSK /engine WSK 400/440

Monitoring measurement for engine

connection

NOTE
Take the following measurement to determine 3
whether the diaphragms (8) have possibly been 8
bent. A 9
7
1 Use the converter installation depth on the trans-
mission side to calculate “C”
WSK 400 = 80.7 ± 0.2 mm B
WSK 440 = 81.6 ± 0.2 mm.

2 On the engine side, measure length “A” between C

the connecting and sealing surface of the flywheel TS
housing (3) and the contact surface for the dia-
phragms on the flywheel (7). Take this measure- 015065

ment at two opposite points. The installation

depth “A” must be 83.25 ± 0.8 mm. Deviations
should be corrected by placing shims between the
flywheel and diaphragms.

3 Measure the thickness of the diaphragms (8),

dimension “B”.
The dimension of the diaphragms is specified:
WSK 400 = 2.4 ± 0.14 mm (2 diaphragms)
WSK 440 = 1.5 ± 0.14 mm (1 diaphragm)

4 Dimension “A” – dimension “C” produces the

axial distance between converter (9) and flywheel
(7) when installed. This dimension must not
deviate from the measured dimension “B”
(thickness of diaphragms) by any more than
± 1 mm (otherwise the diaphragms are bending).

5 The face runout “TS” on the flywheel housing

must not exceed 0.2 mm.

1-2
 WSK 400/440 WSK /engine

Assembly

1 Before the WSK is assembled on the engine,

the diaphragms (8) should be fastened onto the 6
flywheel (7) using the clamping washer (10). The
tightening torques of the hex bolts (11) required
should be obtained from the vehicle manufacturer 8
in question.
7
2 Rub grease into the centring journals (6) before 9
installing them on the converter (9).

3 Run-in WSK in direction of axle and fit lifting

device under WSK ensuring that the transmission
is horizontal. 4

4 Insert retaining bolts (5) between circumference 015066

of converter housing and flywheel housing (3) and

tighten ;
M10 tightening torque = 49 Nm or
11
M12 tightening torque = 79 Nm.
10
5 Use a mounting lever to rotate the starter crown 3
wheel (1) until one of the threaded bores on the
converter (9) is accessible through the assembly
aperture of the flywheel housing (3). Use a socket 2
wrench to insert the M12x1.5 hex bolts (2) and
spring washer and tighten;
Tightening torque = 90 Nm
Continue rotating the starter crown wheel (1) until 1
it reaches the next threaded bore and screw in all
5
hex bolts on the converter in this manner.

015067

1-3
 WSK 400/440 WSK /transmission

2 Transmission mounting

2.1 Draining oil from transmission

CAUTION
Do not let any oil enter the soil, ground water
or sewage system. Catch any overflowing oil in a
suitable container and dispose of in accordance
with environmental regulations.

1 Unscrew oil drain screw on transmission and

catch used oil in suitable vessel.
1
NOTE
• Not all the oil in the converter can be drained.
An additional approx. 7 dm3 can however be
009517
drained by unscrewing the pressure measuring
stop (1) on the WSK control unit and the amount
of oil left in the converter is therefore reduced to
approx. 6 dm3.
• Depending on version and arrangement, a
certain amount of oil also remains in the heat
exchange and connection lines. This can also not
be drained.

2.2 Assembly device 1X56 139 137

1 Screw assembly device (2) onto output flange (3)

of transmission.

CAUTION
Do not attach lifting tackle directly onto converter
(see arrow). Attach rope and chain (4) as shown in
diagram.

! DANGER
The weight of the complete transmission is approx.
600 kg. It is essential that appropriate lifting tackle is
used. Do not stand in the hazardous area.

2 Place complete transmission in vertical position.

3 2
3 The WSK can only be removed from above when
in this position (refer to chapter 6).

014920

2-1
 WSK 400/440 Central wiring

3 Central wiring
d
Disassembly

NOTE
1
Label central wiring (1) according to its
connectors before dismantling.

1 Disconnect all connectors and remove central e

wiring.

Assembly

1 Assemble central wiring (1) according to its

connectors.
015212

2 Tightening torque (2) = 2 Nm.

2
a c

015213

f
015214

3-1
 Central wiring WSK 400/440

3 1 b

d
2
a
c

011901

1 Central wiring
2 M4x10 hex bolts
3 Cable clamp

a) ZVK connection to chassis 19-pin

b) “n turbine” inductive sensor 3-pin
c) ZVK connection to internal WSK 10-pin
(nEng/WK)
d) T sensor to electronics unit 2-pin
(oil temp. of ret. feedback)
e) N switch for transmission 2-pin
f) Clutch switch on servo cylinder 2-pin

3-2
 WSK 400/440 Oil reservoir

4
8
1 2

7
4
8
5
8
1
8

1
011902

4 Oil reservoir for WSK oil supply

Disassembly Assembly

CAUTION – RESIDUAL OIL 1 Insert greased new O-rings (8) in pipes.

Do not let any oil enter the soil, ground water or
sewage system. Catch any overflowing oil in a 2 Insert return pipe (5) and intake pipe (4) in oil
suitable container and dispose of in accordance reservoir (3).
with environmental regulations.
3 Attach oil reservoir with new gasket (6) on trans-
1 Loosen hex bolts (1 and 2). mission.

2 Remove oil reservoir (3) with intake pipes (4) and 4 Insert hex bolts (2) and tighten ;
return pipe (5). Tightening torque = 46 Nm

3 Remove gasket (6). 5 Screw pipes onto WSK with hex bolts (1);
Tightening torque = 23 Nm
4 Remove pipes from oil reservoir and take off
O-rings (8). 6 Screw in oil drain plug (7) with new sealing ring
and tighten ;
5 Loosen and remove oil drain plug (7). Tightening torque = 60 Nm

4-1
 WSK 400/440 Clutch cylinder

1 2 5

4
5
3

013464

5 Clutch cylinder

Disassembly Assembly

1 Loosen screws (1) and remove clutch cylinder (2) 1 Insert clutch cylinder (2) with new gasket (4 in
with gasket (4). fordable version) in transmission.

NOTE NOTE
No gasket with first version. Remove sealing Apply some sealing compound (Silastic 732 RTV)
compound. to the groove on the clutch housing (optional)
(before 03.99).
2 Remove sealing cap (3). Use a suitable sealing material to seal the clutch
housing at the opening and closing points.
CAUTION
When changing the clutch cylinder or transporting 2 Insert hex bolts (1) and tighten crosswise:
the transmission without the clutch cylinder, fixing Tightening torque = 23 Nm
plate 1X56 138 116 must be used. The release device
must not be incorrectly rotated. 3 When working with the fordable version,
insert Vaseline with sealing cap (3) and check
NOTE that connection of hose ventilation (5) can be
Sealing cap (3), gasket (4) and hose ventilation (5) accessed.
are only fitted in the fordable version.

5-1
 WSK 400/440 WSK /transmission

6 WSK /transmission

Disassembly
2
NOTE
Place complete Transmatic in vertical position
(refer to Chapter 2).

1 Loosen and remove hex bolts (1) between WSK

and transmission.
1
2 Attach lifting equipment 1X56 136 242 to WSK
and lift it slowly.

! DANGER
Do not lift WSK when aligning release device – 011904

danger of crushing !

CAUTION
The release fork (a) is still engaged. Rotate release b
device (b) in transmission by 90° and lift WSK
a
carefully (see arrows).

3 Remove metal gasket (2) from transmission.

NOTE
When depositing WSK, ensure it is adequately
supported to prevent screws from being damaged.

011905

011906

6-1
 WSK /transmission WSK 400/440

Assembly

1 Place metal gasket (2) on transmission.

2 Use lifting equipment 1X56 136 242 to lift WSK b

over transmission and then lower slowly.
a

! DANGER
Do not lower WSK when aligning release device –
danger of crushing.

CAUTION
Ensure that the driver of the release device (b) is at
90° to the release fork (a) (see arrows).
011905

3 Lower WSK slowly to the unit and bring release

device into position. The spot-faced surface (C) b
must face the release cylinder.

4 Attach fixing plate 1X56 138 116 or fix clutch

release cylinder (refer to Chapter 5.1 and 5.2). C

5 Insert and tighten hex nuts (1);

WSK 400 - M10 tightening torque = 48 Nm
WSK 440 - M12 tightening torque = 90 Nm
M12 tightening torque = 43 Nm (2x)

NOTE
Tighten 2 hex nuts with a torque of 43 Nm.
(For position, refer to screw connection WSK 440
in Chapter 13.5)
015071

011904

6-2
 WSK 400/440 WSK /transmission

2
013411

“n turbine” inductive sensor

Disassembly Assembly

1 Pull and remove cable connection (1) from 1 Screw in and tighten inductive sensor (2) together
inductive sensor (2). with new O-ring ;
Tightening torque = 30 Nm
2 Loosen slotted nut (3) and remove together with
locking plate. Remove cable connection (1) from 2 Insert and tighten cable connection (1) and slotted
clutch housing. nut (3) with new locking plate in clutch housing ;
Tightening torque = 120 Nm.
3 Loosen inductive sensor (2) and remove from
connection plate. 3 Connect cable connection and inductive sensor.

* depending on parts list

6-3
 WSK 400/440 Selector clutch

7 Selector clutch

Disassembly

NOTE
Ensure that selector clutch cannot be misaligned.

1 Since the plate springs have been pretensioned,

insert 4 spacers (see arrow) in pressure plate (1)
before disassembling the clutch to ensure that the 1
pressure plate can be refitted at a later date.
Loosen and remove screws (2). 011908

NOTE
Make your own spacers. 3
We recommend the following dimensions:
4x8x55 mm

2 Lift up pressure plate and place to one side.

3 To remove release device, use brace 1X56 138 159

and compress spring elements (3). 4

4 Remove tension ring (4). Release and remove 011933

brace.

5 Remove tension ring (4) and ring (5) from the WSK 400
pressure plate.
9 1 6 7
6 Remove plate spring (6), disc (7) and release
device (8) from pressure plate.
8
7 WSK 400 2
11 10
Remove clutch disc (9) and torsion damper.
WSK 440 4 5 9a
Remove clutch disc (9a) without torsion damper.

NOTE
Ensure spacer plate (11) cannot rotate.

8 Loosen and remove screws (10). WSK 440

013412
9 Remove spacer plate (11).

7-1
 Selector clutch WSK 400/440

Assembly
WSK 400
1 Insert spacer plate (11).
9 1 6 7
2 Insert and tighten hex bolts (10);
tightening torque = 46 Nm.
8
3 Use centring punch 1X56 136 914 to place clutch
11 10 2
disk (9 or 9a) on spacer plate.
NOTE 4 5 9a
Evenly pack O-ring (12) of thrust bush of release
device with grease (Molykote BR2 plus).
4 Place release device (8) on brace 1X56 138 159.
Place disc (7) and plate spring (6) on top.
5 Place pressure plate (1) on brace. Place ring (5) WSK 440
on tension ring (4) on top. 013412

6 Mount brace and compress spring elements (3).

7 Engage tension ring (4), release and remove brace.
NOTE
Rub grease (Olista Longtime 3EB : 7g) into key-
groove of clutch disc (9 or 9a). 12
8 Place completed pressure plate (1) on spacer plate
(11).
NOTE
Ensure pressure plate cannot rotate.
015072
9 Insert hex bolts (2) and tighten down crosswise;
Tightening torque = 46 Nm
3
10 Remove 4 spacers.

! DANGER
The WSK must be rotated before the converter
can be installed.You MUST attach clamping bar
1X56 104 910 to selector clutch because it is not
attached to anything in the WSK (see Chapter 8). 4
011933

011908

7-2
 WSK 400/440 Converter

8 Converter

Disassembly

NOTE (WSK removed from transmission)

If only the converter needs to be changed, then
you must ensure that the selector clutch is secured
by means of the clamping bar 1X56 104 910.
This is the only means by which oil can be
stopped from running over the clutch disc.
Use a depth gauge to measure the distance bet-
ween the faces of several threaded journals at con-
verter and the connecting face of the converter
housing.
Note down dimensions “C”.
WSK 400 = 80.7 mm
WSK 440 = 81.6 mm 011910

NOTE (WSK attached to transmission)

When changing converter, use clutch fixation
1X56 138 151 to stop release fork. Use this to
press and hold release device to input.
C
1 Release and remove retaining ring (1).
2 Remove washer (2) with O-ring (3).
NOTE
As an aid, insert hex bolt and pull off using
mounting lever.
3 Remove O-ring (3) from washer.
NOTE
WSK 400 may have a M39x2 screw plug and
seal ring rather than a washer (2).
011911
4 Loosen and remove tension bolt (4).
NOTE
Use mounting lever to ensure converter cannot
rotate.
5 Use lifting device 1X56 137 539 or 1X56 136 577 5 7
to engage retaining ring and remove converter (5)
from converter housing.
6 Remove shims (6 and 7) from turbine shaft and
oil feed flange. 6

3
2
1
4

011912

8-1
 Converter WSK 400/440

Installation WSK 400 WSK 440

NOTE a
Only use converter after turbine shaft is inserted
and the selector clutch has been mounted. 5

Adjust converter installation depth “C” 10

10
(by placing shims on oil feed flange)

1 Screw in lifting device 1X56 136 539 (8) until b

there is no axial play on sealing washer (10) in
converter; 9 8
Tightening torque = 25 Nm.

NOTE
When working with the WSK 400 (version
013417 011913
with M39x2 screw plug), use lifting device
1X56 136 577 (9).

2 Use depth gauge to measure the distance between

the face of the threaded journal and the face of the
converter gear and note down as dimension “a”.

3 Use depth gauge to measure the distance between

face of converter gear and inner bearing race
of converter ball bearing and note down as
dimension “b”.

4 a–b=D
Note down dimension “D” for additional
measuring procedure. d
c
5 Using strip, measure distance between converter
housing and converter bearing when firmly in 011914

contact with the oil feed flange and note down as

dimension “c”.

6 Measure distance between strip and contact face

of converter housing and note down as dimension
“d”.

7 c–d=F
Note down dimension “F”. 77

8 D–F=C
Dimension “C” (converter installation depth) must
be: WSK 400 = 80.7 mm ± 0.2 mm
WSK 440 = 81.6 mm ± 0.2 mm.
Divergences must be rectified using the appro-
priate shim (7).
011915

8-2
 WSK 400/440 Converter

Adjustment of axial play of the tapered roller WSK 400 WSK 440
bearing “G” (shim on turbine shaft)

9 Use depth gauge to measure distance between the 5

face of the converter gear and the sealing washer

in the converter. Note down as dimension “e”.

10 e–b=G
e
Note down dimension “G”. G b
11 Use a crane to life turbine shaft (11) or fit appro-
priate device under shaft for measurement. Rotate
the converter housing to ensure that the tapered
roller bearing is free of clearance. Use depth
gauge to measure distance between face of turbine
shaft and point of contact between converter
bearing and oil feed flange with shim (7) on top. 013416 011916

Note down as dimension “H”.

12 G – H + (axial play of 0.05 to 0.15 mm) = S

Correct variances with appropriate grade of shim
(6).

13 Grease correct shim and place on centre of turbine

shaft. 11

14 Carefully push converter onto spline of turbine H 7

shaft and lower until firmly home.

15 If converter cannot be inserted completely, then

it is located on spline of oil feed flange. If this
occurs, raise crane hook until there is slight slack
in wires. Pull central wire with both hands to raise
the converter slightly, rotate and then release. 011917

Repeat until converter slides onto spline of oil

feed flange.

16 Carefully lower converter to next point of contact.

Here, the converter can be located on the gear
pump impeller. Rotate converter slightly again
until teeth mesh.

CAUTION
Never use a hammer to insert converter.
6

011918

8-3
 Converter WSK 400/440

17 Remove lifting device 1X56 136 539 or

1X56 136 577 from converter.
NOTE
The converter is only firmly in place once the
anti-fatigue bolt is tightened.
18 Ensure converter cannot rotate. Screw in and
tighten anti-fatigue bolt (4);
Tightening torque = 190 Nm
19 Use some grease to insert new O-ring (3) into 3 4
disc (2) and insert into converter. 2
1
20 Insert retaining ring (1) in converter.
NOTE
WSK 400 may have a M39x2 screw plug rather
than a washer (2) (use new seal ring). 011919
Tightening torque = 140 Nm

a
Adjusting “n engine” inductive sensor
21 Push retaining ring forwards into measuring
device 1P01 137 833 and insert in bore until it
reaches the tooth tip of the converter gear.
Measure and note down dimension “a” on
measuring device.
22 Measure distance between contact face and point
of contact with inductive sensor. Note down as
dimension “b”.
23 Example:
a–b=T
35.5 mm – 35.1 mm = 0.4 mm
If there is a permissible distance of 0.8 ± 0.2 mm, 1P01 137 833

a washer with a thickness of 0.4 mm can be

inserted.
24 Screw in and tighten “n engine” inductive sensor
with selected washer;
Tightening torque = 40 Nm T
b
NOTE
Use remachined socket (SW = 24) to screw in
inductive sensor (see Chapter 13.2).
25 Connect plug from cable harness with inductive
sensor.

011920

8-4
 WSK 440 Converter

4
5
11
6
7
6
7
8
R
9
10
1 R
2

015075

8.1 Dismantling and assembling converter

(WSK 440)

8.1.1 Converter cover 2 Carefully lift off and put down converter cover.
Disassembly and dismantling Remove lifting device and rotate converter cover.

NOTE 3 Take off O-ring (3), unfasten and remove

The circumference of the converter cover and cylindrical screws (4).
pump are marked with an “R” (= residual
imbalance). These marks must be set at opposing 4 Take off pressure ring (5), remove inner discs (6)
180° positions. and outer discs (7).

1 Insert lifting device 1X56 137 539 in converter 5 Use compressed air to press off and remove piston
cover (1) and unfasten cylindrical screws (2). (8) through oil bore.
If necessary, mark converter cover and pump.
6 Take O-rings (9 and 10) off piston.
CAUTION
Keep converter cover horizontal so that the turbine 7 Remove grooved ball bearing (11) from converter
gear does not misalign with the inner discs in the cover.
converter cover.
NOTE
The grooved ball bearing (11) may also sit on the
turbine gear.

Index: a 8-5
 Converter WSK 440

4
5
11
6
7
6
7
8
9
10
1

015159

Assembling converter cover

1 Insert grooved ball bearing (11) into contact point 6 Use grease to fit new O-ring (3) on converter
in converter cover (1). cover.

2 Use grease to insert new O-rings (9 and 10) in NOTE

piston (8) and insert pistons into contact point in Instructions for installation of the converter cover
converter cover. can be found in Chapter 8.1.5

3 Insert outer (7) and inner discs (6). Insert in turn,

starting with an outer disc, then an inner disc.

4 Attach pressure ring (5) and screw in and tighten

cylindrical screws (4);
Tightening torque = 35 Nm.

5 Use feeler gauge to check disc clearance or piston

clearance.
Clearance = 0.7 – 1.7 mm

8-6 Index: a
 WSK 440 Converter

3
5

4
2

015076

8.1.2 Dismantling turbine gear Assembling turbine gear

1 Remove sealing washer (1) and O-ring (2) from 1 Snap piston ring (4) into turbine gear (3).
turbine gear (3).
2 Use grease to insert new O-ring (2) in sealing
2 Take O-ring off washer. washer (1) and press the complete sealing washer
into contact point into the turbine gear.
3 Snap piston ring (4) off turbine gear and take off.
3 Insert axial bearing (5) in turbine gear.
4 Take axial bearing (5) off stator and check for
wear. NOTE
The instructions for turbine gear installation can
be found in Chapter 8.1.5.

Index: a 8-7
 Converter WSK 440

1
8

4
3

015077

8.1.3 Dismantling stator

CAUTION
When removing the free-wheel inner race, ensure
that parts cannot spring out.

1 Place stator (1) on ring 1X56 138 217 (diameter

131 mm) and use adapter 1X56 138 218 (diameter
84 mm) to drive out free-wheel inner race (2) with
grooved ball bearing (3) and thrust washer (4).

NOTE
When driving out the free-wheel inner race, the
cylindrical rollers (5) are also removed. The spring
caps (6) and the cylindrical springs (7) may also
be loosened during this process.

2 Take thrust washer (8) off stator.

3 Use a suitable plastic mandrel to drive off grooved

ball bearing (9).

8-8 Index: a
 WSK 440 Converter

5
3

4 6
8

7
2

Input Output
015073

Assembling stator

1 Use ring 1X56 138 217 (diameter 130 mm) and 6 Fit thrust washer (8) and use adapter
adapter 1X56 138 218 to press grooved ball 1X56 138 218 (diameter 84 mm) to drive free-
bearing (3) into contact point into stator. wheel inner race firmly home.

2 Insert thrust washer (4) in stator (1). 7 Place stator (1) and grooved ball bearing (3) on
ring 1X56 138 217 (diameter 130 mm).
3 Use grease to insert all cylindrical springs (7) and
spring caps (6) in free-wheel inner race (2). 8 Use adapter 1X56 138 218 to press grooved ball
bearing (9) firmly home in stator.
4 Place free-wheel inner race in correct position
on stator and use adapter 1X56 138 218 (diameter 9 Check free-wheel:
84 mm) to drive in approx. 1/2 of the width of the Free-wheel must lock in the direction shown
bearing. above when the inner race is retained (see arrow).

5 Insert cylindrical rollers (5) by sliding back the NOTE

spring caps. The instructions for stator attachment can be
found in Chapter 8.1.5.
NOTE
To simplify the assembly of the cylindrical rollers,
firstly insert 4 cylindrical rollers at angles of 90°.

Index: a 8-9
 Converter WSK 440

67

015078

8.1.4 Dismantling pump Assembling pump

1 Take spacer (1) off pump (2) and rotate pump. 1 Use grease to insert new O-ring (5) in pump hub
(4).
2 Unfasten cylindrical screws (3) and take off with
washers. 2 Insert pump hub in accordance with the mark
made on the pump (2).
NOTE
Mark position of pump hub (4) in relation to NOTE
pump (2). To simplify the installation, use suitable
cylindrical pins.
3 Remove pump hub (4) from pump (2).
3 Insert cylindrical screws (3) with washers and
4 Take off O-ring (5) and use mounting lever to tighten;
remove angular ball bearing (6). Tightening torque = 25 Nm.

NOTE
For installation of the angular ball bearing (6),
the spacer (1) and attachment of pump, refer to
Chapter 8.1.5.

8-10 Index: a
 WSK 440 Converter

8.1.5 Measuring and completing converter

1 Place turbine gear (1) and axial bearing (2) on

thrust piece (diameter 40 mm). 4
5

2 Place stator (3) in correct position on axial

bearing.
3
9
3 Place spacer (4) and angular ball bearing (5) on 2
stator.
1
4 Use depth gauge to measure from angular ball
bearing inner race to sealing washer (8).
Monitoring length (9) = 149.8 – 0.2 mm 8

5 Take all parts off again.

015081

6 Place turbine gear (1) on converter cover above 7

the inner disc spline of the converter cover (6).

7 Place axial bearing (2) on turbine gear and attach 5

4
stator (3) in correct position. Blade outlet side 3
faces the turbine gear. R 1
2
8 Place spacer (4) on stator. 6

9 Use adapter 1X56 138 224 to press angular ball

bearing (5) firmly into pump hub. The wide side R
of the inner bearing race faces the input.

10 Attach pump (7) in accordance with marking

(“R” at 180° to the converter cover).

11 Screw in 4 cylindrical screws at an angle of 90°, 015079

tighten by hand and invert the complete converter.

12 Insert the remaining cylindrical screws and

tighten ;
Tightening torque = 48 Nm.

13 Insert lifting device 1X56 136 539 and again

check monitoring length of 149.8 – 0.2 mm
(as described under point 4).

015080

Index: a 8-11
 WSK 400/440 Turbine shaft

9 Turbine shaft

Disassembly 1
4
3
NOTE
Turbine shaft can be taken off after disassembling
the selector clutch and removing the converter.

1 Use lifting device 1X56 136 242 to lift converter

housing with retarder over turbine shaft (1).
2
2 Remove piston rings (2) from turbine shaft.

3 Use conventional two-armed extractor to grip

needle sleeve (3) from below and remove from
turbine shaft with shaft seal (4).
011921

Assembly

1 Use adapter 1X56 119 917 to press greased needle

sleeve (3) into contact point of turbine shaft (1).

2 Use adapter 1X56 119 917 to insert shaft ring (4)

into contact point.

3 Insert piston rings (2) in turbine shaft.

4 Insert turbine shaft in housing.

9-1
 WSK 400/440 Oil filter

10 Oil filter

Disassembly

1 Loosen hex bolts (1). Remove with washers and

pan (2).

2 Loosen hex bolts (3). Remove with leaf spring (4)

and washer (5).

3 Remove filter (6) with bush (7) and gasket (8).

4 If necessary, remove dowel pin (9).

6
7 9
Assembly 2
4
1 Screw in and tighten dowel pin (9); 3
Tightening torque = 10 Nm. 8
5
2 Insert bush (7). Put on gasket (8) and insert filter
1
(6).

NOTE
011922
Replace filter. The plate cover (a) of filter must
face outwards.

3 Insert washer (5), leaf spring (4). Tighten with

hex bolt (3);
Tightening torque = 23 Nm.
c
4 Put on pan (2).
a
005599
NOTE
Attach pan in such a way that its deeper side (b) is b
over the intake aperture (c).

5 Put on hex bolts (1) with washers and tighten ; 009516

Tightening torque = 23 Nm.

10-1
 WSK 400/440 without NMV Control unit

25 26
63 5

24 6 27

7
23
2
21
1
25
3 8
24
4

14 7
13

90 16
15
12 19
64 18
10 17 23
22

37

9 40
11 21
20

011923

11 Control unit

11.1 WSK without NMV NOTE

Removal and disassembly Cover is spring loaded. Carefully loosen screws
and press cover against control housing until all
1 Loosen hex bolts (1, 2, 3 and 4) and remove with screws have been removed.
control unit.
6 Pressure spring (13) with ball (14);
NOTE Pressure spring (15) with piston (16);
When removing control unit, loosen solenoid Remove pressure spring (17), bush (18) with
valve cable. piston (19) and bush (20) with pressure spring
(21) and piston (22) from control unit housing.
2 Loosen hex bolts (5) and remove “WK” solenoid
valve (6) with valve housing (27). 7 If necessary, loosen 2 screw plugs (23) and
remove with sealing rings.
3 Loosen cylindrical screws (24), remove with
spring clips and flat plug (25). Pull solenoid valve Item no. Designation
out of housing (27) and remove O-rings (26). 90 Safety valve
64 Lock-up clutch shift valve
4 Remove gasket (7) and cover sheet (8) from 37 Lock-up clutch pressure valve
control unit housing. 40 Converter back pressure valve
63 Preselector valve
5 Loosen hex bolts (9 and 10), remove cover (11)
with gasket (12).

11-1
 Control unit WSK 400/440 without NMV

25 26
5

24 6 27

7
23
2
21
1
25
3 8
24
4

14 7
13

16
011924 15
12 19
18
10 17 23
22

9 21
11
20
011923

Assembly and installation

7 Fix solenoid valve and flat plug (25) to valve
1 Screw in and tighten 2 screw plugs (23) together housing (27) with cylindrical screws (24);
with new gaskets ; Tightening torque = 5.5 Nm.
Tightening torque = 35 Nm.
8 Screw complete “WK” solenoid valve (6) with
2 Insert pressure spring (13) with ball (14); pressure hex bolts (5) to control housing ;
spring (15) with piston (16); pressure spring (17), Tightening torque = 9.5 Nm.
bush (18) with piston (19) and bush (20) with
pressure spring (21) and piston (22) in correct NOTE
positions in control unit housing. Before installing control unit, measure and install
inductive sensor (refer to Chapter 8).
3 Put on new gasket (12) with cover (11).
9 Insert solenoid valve cable and attach control unit
4 Insert and tighten hex bolts (9 and 10) ; to WSK by means of 2 cylindrical pins.
M6x12 tightening torque (9) = 10 Nm;
M6x18 tightening torque (10) = 14 Nm. 10 Screw in and tighten hex bolts (1, 2, 3 and 4);
Tightening torque = 23 Nm.
5 Put on new gaskets (7) with cover plate (8).

6 Insert greased O-rings (26) in solenoid valve.

Place solenoid valve in correct position on axial
support in housing (27).

11-2
 WSK 400 with NMV Control unit

63
25 26
5
3 24
6 27

1
8
2

7
30 29
31
90 33 32
12 16
11 15
28 19
9 18
64 17 23
37
37 36 38
10 22
21
20
40 35
34
39

015074

11.2 WSK with NMV

Removal and disassembly NOTE

Cover is spring loaded. Carefully loosen screws
1 Loosen hex bolts (1 and 2) and remove with and press cover against control housing until all
control unit. screws have been removed.

NOTE 6 Gear shift piston (33), pistons (32, 31 and 30)

When removing control unit, loosen solenoid with pressure spring (29);
valve cable. Bush (28), pressure spring (15) with piston (16);
Remove pressure spring (17), bush (18) with
2 Loosen hex bolts (5) and remove “WK” solenoid piston (19) and bush (20) with pressure spring
valve (6) with valve housing (27). (21) and piston (22) from control unit housing.

3 Loosen cylindrical screws (24), remove with 7 If necessary, loosen 2 screw plugs (23) and take
spring clips and flat plug (25). Pull solenoid valve off with sealing ring.
out of housing (27) and remove O-rings (26).
Item no. Designation
4 Loosen retaining screw (3), remove gaskets (7) 90 NMV gear shift valve + safety valve
and cover sheet (8) from control unit housing. 64 Lock-up clutch selector valve
37 Lock-up clutch pressure valve
5 Loosen hex bolts (9, 10 and 37), remove cover 40 Converter back pressure valve
(11) with gasket (12). Loosen hex bolts (38 and 63 Preselector valve
39), remove cover (34) and gasket (35).

11-3
 Control unit WSK 400 with NMV

25 26
5
3 24
6 27

1
8
2
011924
7
30 29
31
32
12 33 16
11 15
28 19
9 18
17 23

37 36 38
10 22
21
20
35
34
39

015074

Assembly and installation

1 Screw in and tighten 2 screw plugs (23) together 6 Install greased O-rings (26) in solenoid valve.
with new gaskets ; Place solenoid valve in correct position on axial
Tightening torque = 35 Nm. support in housing (27).

2 Insert gear shift piston (33), pistons (32, 31 and 7 Fix solenoid valve and flat plug (25) to valve
30) with pressure spring (29); bush (28), pressure housing (27) with cylindrical screws (24);
spring (15) with piston (16); pressure spring (17), Tightening torque = 5.5 Nm.
bush (18) with piston (19) and bush (20) with
pressure spring (21) and piston (22) in correct 8 Screw complete “WK” solenoid valve (6) with
position in control unit housing. hex bolts (5) to control unit housing ;
Tightening torque = 9.5 Nm.
3 Put on new gasket (12 and 35) with cover (11 and
34). NOTE
Before installing control unit, measure and install
4 Insert and tighten hex bolts (9, 10, 37, 38 and 39) ; inductive sensor (refer to Chapter 8).
M6x12 tightening torque (9, 38) = 10 Nm ;
M6x18 tightening torque (10, 39) = 14 Nm ; 9 Insert solenoid valve cable and attach control unit
M6x35 tightening torque (37) = 9.5 Nm. by means of 2 cylindrical pins.

5 Put on new gaskets (7) and cover plate (8). 10 Screw in and tighten hex bolts (1, 2, 3 and 4);
Insert and tighten retaining screw (3); Tightening torque = 23 Nm.
M8x16 tightening torque = 45 Nm.

11-4
 WSK 400/440 Retarder

18 13 11
14
4
10
19 20
14
21 5
15 11
16 7
2
12
17
5
6 9
5
1
6 22
5
5

5 23
5
5 22
8
5a
5 3
5
5a
35
5

011925

12 Retarder

Removal and disassembly 3 Loosen temperature sensors (9 and 10) and

remove with sealing ring.
1 Loosen screws and hex bolts and remove with
4 Loosen hex bolts (11), take off connecting pieces
washers and/or spring washers;
(12 and 13) and remove O-rings (14).
Hex bolts M8x 25 (1)
M8x 35 (2) CAUTION
M8x 50 (3) Connecting piece (16) is spring-loaded.
M8x 80 (4) Loosen screws carefully.
Cylindrical screws
5 Loosen hex bolts (15) with spring washers,
WSK 440: M12x115 (5)
carefully take off connecting piece (16) and
M12x110 (5a)
gasket (17).
WSK 400: M10x115 (5)
M10x110 (5a) 6 Remove piston (18) with grooved rings (19) and
Hex nuts M8 (6) slide valve (20) with pressure spring (21) from
bore.
NOTE
Hex bolts (1 and 2) and hex nuts (6) are located 7 Remove grooved rings (19) from piston.
on input end of retarder housing.
8 Loosen union screws (22). Remove pressure line
2 Remove retarder housing (7) on output side and (23) with sealing rings.
remove shaft seal (8).
9 If necessary, remove cylindrical pins (35).

12-1
 Retarder WSK 400/440

25
26

31 27
24 29

26
30 28

32

34 33
011926

10 Remove gasket (24).

11 Remove rotor (25). Remove piston rings (26) and

washer (27) with pins (28).

12 Remove inner bearing race (29) from oil feed

flange.

13 Loosen cylindrical screws (30) and take off with

stator (31).

14 Loosen and remove hex bolts (32 and 33).

15 Remove retarder housing (34) at input side from

converter housing.

12-2
 WSK 400/440 Retarder

25
26

31 27
24 29

26
30 28

32

34 33
011927

Assembly and installation

1 Slightly grease input side of retarder housing (34) 6 Insert piston rings (26) in rotor and place rotor
at oil feed flange and put on converter housing. in housing.

NOTE 7 Fit new gasket (24).

For ease of installation, screw in 2 guide pins
(see arrows).

2 Insert and tighten hex bolts (32 and 33) with

spring washers ;
Tightening torque = 23 Nm.

3 Place stator (31) in correct position in output side

of retarder housing. Insert and tighten cylindrical
screws (30) with washers ;
Tightening torque = 23 Nm.

4 Put inner bearing race (29) on oil feed flange.

5 Fit washer (27) with clamping pins (28) on rotor

(25).

12-3
 Retarder WSK 400/440

18 13 11
14
4
10
19 20
14
21 5
15 11
16 7
2
12
17
5
6 9
5
1
6 22
5
5

5 23
5
5 22
8
5
5a 3
5
5a
35
5
011925

8 Fit pressure line (23) with hollow screws (22) Temperature sensor (10 – indicating device) is
and new sealing rings to retarder housing at output marked in black.
side ; Never confuse them.
Tightening torque = 45 Nm.
14 Drive shaft seal (8) into housing with adapter
9 Place grooved rings (19) on piston (18). 1X56 112 761 until flush.
10 Insert spring (21), slide valve (20) and piston (18) 15 Align retarder housing (7) at output side with
in housing. input side of retarder housing and place on top.
Drive cylinder pins (35) home.
11 Secure new gasket (17) with connecting piece
(16) at housing with hex bolts (15) and spring 16 Insert and tighten:
washers ; Hex bolts : M8x 25 (1) = 23 Nm
Tightening torque = 23 Nm. M8x 35 (2) = 23 Nm
M8x 50 (3) = 23 Nm
12 Insert new greased O-rings (14) in connecting
M8x 80 (4) = 23 Nm
pieces (12 and 13) and secure to housing with
Cylindrical screws
hex bolts (11);
WSK 440: M12x115 (5) = 100 Nm
Tightening torque = 23 Nm.
WSK 400: M10x115 (5) = 49 Nm
13 Screw in and tighten temperature sensors (9 and M10x110 (5a)= 46 Nm
10) with new sealing rings ; Hex nuts : M8 (6) = 23 Nm
Tightening torque = 30 Nm.
NOTE
CAUTION In WSK 440, M12x110 2 cylindrical screws (5a)
Temperature sensor (9 – electronic unit) is marked are tightened at tightening torque = 43Nm.
in white;

12-4
 WSK 400/440 Converter housing

13 Converter housing
1
13.1 Oil feed flange
Disassembly

1 Remove gasket (1).

2 Loosen cylindrical screws (2) and remove with

spring washers. 6 5

3 Remove oil feed flange (3) from converter

housing.
4
4 Remove piston ring (4) from oil feed flange.
3
2
5 Remove outer bearing race (5) from oil feed
flange. 011928

6 Remove O-ring (6).

Assembly

1 Place greased O-ring (6) and piston ring (4) in oil

feed flange (3).

! DANGER
Wear gloves when handling hot components.

2 Heat oil feed flange to approx. 100 °C using hot

air blower. Use adapter 1X56 112 761 to firmly
press on outer bearing race (5).

3 Coat contact surface face of oil feed flange (3)

with sealing compound WEVO L100 and insert,
in correct position, in converter housing by means
of 2 guide pins.

4 Insert and tighten cylindrical screws (2);

Tightening torque = 46 Nm.

5 Fit new gasket (1) on converter housing.

13-1
 Converter housing WSK 400/440

13.2 Gear pump and wiring harness

Disassembly 7
9
1 Loosen hex bolts (1 and 2) and remove with 8
spring washers. 5
1
2 Lift gear pump (3) out of converter housing.

NOTE 2
Open pump and check parts for wear:
If necessary, replace pump.
Tightening torque : 6
Hex bolts M8 = 21 Nm, 4 3
Cylindrical screw M6 = 9 Nm,
Hex bolts M8 = 7 Nm.
011929

3 Remove O-ring (4) from pump.

4 Mark fixation point and then remove cable SW 24 ¯ 18

harness (5).

5 Loosen “n engine” inductive sensor (6) with

remachined socket (SW 24, refer to sketch) and
remove together with washer.
0.5r
26

28.8 +0.1

011930

13-2
 WSK 400/440 Converter housing

Assembly

1 Insert greased O-ring (4) in gear pump (3). 7

9
2 Insert gear pump into converter housing. 8
10 5
Insert hex bolts (1 and 2) with spring washers
and tighten. 1

NOTE
Coat sealing face suction channel (10) of gear 2
pump with sealing compound WEVO L100 A.
Always ensure that suction channel is left free.
Pull pump in direction of converter housing wall 6
to attain sufficient tooth flank clearance. Tighten 4 3
hex bolts;
Tightening torque = 46 Nm.
011929

3 Install wiring harness (5) with new gaskets (7)

and fix with pipe clamps;
Tightening torque (8) = 46 Nm;
Tightening torque (9) = 1.3 Nm.

NOTE
Insert cylindrical screws (9) with Loctite no. 241.

NOTE
The measurement and installation of the “n engine”
inductive sensor (6) are contained in Chapter 8.

13-3
 Converter housing WSK 400/440

13.3 Converter housing

4
Disassembly
8
1 If necessary, remove dowel pins (1) from
converter housing. 6

2 Remove shaft seal (2) and washer (3) from 1

converter housing. 3
2
3 Loosen ventilator (4), screw plugs (5, 6 and 7)
and remove with sealing rings.

4 Remove O-ring (8) from converter housing.

5
7
Assembly 011931

1 Insert greased O-ring (8).

2 Check ventilator (4) for through-flow, screw in

and tighten;
Tightening torque = 10 Nm.

NOTE
There is an optional connection for hose
ventilation (4) in fordable versions.

3 Insert and tighten screw plugs (5, 6 and 7)

with new sealing rings ;
Tightening torque (5 und 6) = 50 Nm,
Tightening torque (7) = 65 Nm.

4 Insert washer (3) in converter housing.

5 Use adapter 1X56 091 173 to press shaft seal (2)

into converter housing until flush.

NOTE
Sealing lip of shaft seal points towards output.

6 Screw in and tighten dowel pins (1) into converter

housing ;
WSK 440 M12x175
Tightening torque = 18 Nm,
WSK 400 M10x175
Tightening torque = 14.5 Nm.

13-4
 WSK 400 Converter housing

1 2
1
2
1
1
2
2
1
1

2
2
1 1

2 2
1
1

3 1 3 1 2

013415

13.4 Screw connection M10

(WSK 400)

Position Designation Tightening

torque

1 Dowel pin 14.5 Nm

M10x175

Hex nut 48 Nm
M10

2 Cylindrical screw 48 Nm
M10x115

3 Cylindrical screw 46 Nm
M10x110

13-5
 Converter housing WSK 440

1 3

3
1
1
3

1
1

1 1

3 3

4 2 4 2 3

011932

13.5 Screw connection M12

(WSK 440 and WSK 400* as of 1999)

Position Designation Tightening

torque

1 Dowel pin 18 Nm
M12x175

Hex nut 90 Nm
M12

2 Dowel pin 18 Nm
M12x175

Hex nut 43 Nm
M12

3 Cylindrical screw 100 Nm

M12x115

4 Cylindrical screw 43 Nm * exception: “WSK NMV” version

M12x110

13-6
 WSK 400/440 Pressures and measuring points

14 Pressures and measuring points

WSK 400 and WSK 440

14.1 Retarder PVR

PRA
Retarder pretension pressure PVR
Measuring point: temperature sensor at retarder
output
WSK 400 2.0 bar ± 0.5 / 600 rpm
WSK 440 2.0 bar ± 0.5 / 600 rpm

Retarder outlet pressure PRA

Measuring point: PRA - pipe connection
WSK 400 max. 4.5 bar ± 0.5
WSK 440 max. 4.5 bar ± 0.5

013479

14.2 Lock-up clutch

Lock-up clutch closing pressure PWK

Measuring point: PWK
WSK 400 8.5 bar ± 0.5
WSK 440 10.5 bar ± 0.5

Converter back pressure PWA

Measuring point: PWA
WSK 400 3.7 to 4.3 bar
WSK 440 5.5 to 6.0 bar
PWA
PWK

009517

14.3 NMV (only in WSK 400)

Lubricating pressure (1)

Measuring point: Plubr.
WSK 400 0.05 to 0.25 bar / 1500 rpm (1) Plubr.

Shift pressure (2)

Measuring point: Pshift
WSK 400 10 to 11 bar / 1500 rpm

(2) Pshift

009514

14-1
 After-Sales Service function test Tester:
WSK system
Protocol for test procedure Date:

Main parts list: 4130 . . . . . . . . . . . . . . . . Product no.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Converter no.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converter designation F + S: . . . . . . . . . . . . . . . . . . . . . .

1. Oil filling: nin nout PWA (bar)

Test oil: Renolin MR 10 Z / 800 0 Fill until overflow Nominal 3.9 - 4.3
Shell S 7294 monitoring screw Actual: . . . . . .
2. Transmission function: t = approx. 40 °C
Shifting and synchronizing in accordance with test instructions 1Q49 150 050, 053, 063 and 547

3. Sensor signals: nin: 1500 rpm, t = approx. 40 °C

Number of teeth
Engine: . . . . . . . VSS Turbine: . . . . . . . VSS (min. 2 VSS) of toothed washer: . . . . . . . . teeth

4. Pressure and oil through-flow measurement: t = 80 °C

NMV
Unit nin PWA PWK Plubr. Pshift Plubr. QK
rpm (bar) (bar) (bar) (bar) (bar) 1/min
– – – – – 10±0.5 0.15±0.1 nominal actual
WSK 600 – min. 10
WSK 1 500 min. 45

5. Converter test: t = 80 °C
nin: . . . . . . . rpm nout: 0 rpm Tin: . . . . . . . . . . . . Nm

6. WK test (filling time measurement): t = 80 °C

Nominal: 1.0 – 3.5 sec. Actual: . . . . . . . Sek.

7. Coasting free-wheel test:

Findings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Retarder test: t = 80 °C
nin: 600 rpm PRet.: actual: . . . . . . . . . . . . bar
PVR: nominal = 2.0±0.2 bar nout : nominal: 1 500 rpm
PVR: actual = . . . . . . . . . . . . bar Tout : actual: . . . . . . . . . . . . Nm

9. Leak test: test instructions as for item 2 t = 80 – 100 °C

Findings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean oil sieve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Miscellaneous: System pressures nominal: WSK 400 WSK 440

PWA = 3.7 – 4.3 bar 5.5 – 6.0 bar
PWK = 8.0 – 9.0 bar 10.0 – 11.0 bar

MKS-IQ Test rig no.:

MKS-IQ, 03/91 / Wesener (letzte Änderung: 98-07-27) 4130 754 104a