Remove/install hydrodynamic retarder

AR43.30-G-0064OHA

Remove/install hydrodynamic retarder

22.01.2017

Model

000.001 with transmission 714.140/143

Transmission with hydrodynamic retarder R115 E (integrated), Voith- 153.000188xx, H67.1500xx

1

Coolant connection

9

Sealing surface

3

Bolts

10

Hydrodynamic retarder

4

Bolts

11

Transmission

5

O-rings

12

Angular roller bearing

6

Bearing outer race

13

Gear

7

Shim

14

Speed sensor

8

Sealing surface



Remove

1

Remove transmission (11)

 See information from vehicle manufacturer.

2

Drain oil from hydrodynamic retarder (10)



AP43.30-G-4302OHA

3

Detach clutch housing from transmission (11)

On transmission (11) without integrated clutch housing.

AR26.30-G-0330OHA

4

Attach transmission (11) to assembly device

5

Remove output flange from transmission (11)

AR26.50-G-2000OHA

6

Detach both coolant connections (1) from hydrodynamic retarder (10)

7

Remove speed sensor (14)

8

Cover drive shaft of hydrodynamic retarder (10) using a suitable aid


Protect the drive shaft.
Otherwise the drive shaft could be damaged when removing the hydrodynamic retarder (10).

9

Support hydrodynamic retarder (10) and remove screws (3, 4)

 Pay attention to the different lengths of the screws (3, 4).

10

Detach hydrodynamic retarder (10) from transmission (11)


Do not use any prying tools to remove.
Otherwise the sealing surfaces (8, 9) could be damaged.

11

Detach O-rings (5) from transmission (11)

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

12

Heat bearing outer race (6) using a commercially available heat gun and remove

If the hydrodynamic retarder (10), the transmission (11) or the taper roller bearing (12) is replaced.

 Internal extractor

*000589313300

 Countersupport

*000589353300

13

Remove shim (7)

If the bearing outer race (6) was removed.



Clean

14

Clean sealing surface (8) of housing of hydrodynamic retarder (10) and sealing surface (9) on housing of transmission (11)


The sealing surfaces (8, 9) must be clean, dry and free of grease.
Leaks can occur otherwise.



Install

15

Determine thickness of shim (7)

If the hydrodynamic retarder (10) or the transmission (11) was disassembled or replaced, or if the taper roller bearing (12) was replaced.

AR43.30-G-0002-02OHA

 Installation: Commercially available devices/tools
Measuring device
Order number H67.3224xx
Voith
D-74564 Crailsheim

End play of retarder drive shaft

*BE43.30-N-1001-01B

16

Install determined shim (7)

If the hydrodynamic retarder (10) or the transmission (11) was disassembled or replaced, or if the taper roller bearing (12) was replaced.

17

Install bearing outer race (6) using a suitable drift

If the hydrodynamic retarder (10), the transmission (11) or the taper roller bearing (12) was replaced.

 If the taper roller bearing (12) was replaced, install the bearing outer race (6) of the new taper roller bearing (12).

 Internal extractor

*000589313300

 Countersupport

*000589353300

18

Coat new O-rings (5) with vaseline and install in transmission (11)

VASELINE / DBL 6850.00

*BR00.45-Z-1098-06A

19

Screw two threaded pins into threads (arrows) of transmission (11)



Threaded studs for mounting the retarder housing

WF58.50-N-4330-03B


Use the threaded pins.
Otherwise it might not be possible to fit the sealing surfaces (8, 9) together properly, which can result in leaks.

20

Apply sealant to sealing surface (9) on housing of transmission (11)

Loctite 5203 sealant

*BR00.45-Z-1015-01A

21

Detach cover on drive shaft of hydrodynamic retarder (10)

22

Attach hydrodynamic retarder (10) to transmission (11)

23

Screw in screws (4) up to the stop

 Pay attention to the different lengths of the screws (4).

24

Unscrew threaded pins again and screw in screws (3)

 Pay attention to the different lengths of the screws (3).

25

Tighten bolts (3, 4)

 Screw/bolt, hydrodynamic retarder to transmission

*BA43.30-N-1001-01H

26

Install speed sensor (14)

27

Attach both coolant connections (1) to hydrodynamic retarder (10)

28

Install output flange on transmission (11)

AR26.50-G-2000OHA

29

Detach transmission (11) from assembly device

30

Attach clutch housing to transmission (11)

On transmission (11) without integrated clutch housing.

AR26.30-G-0330OHA

31

Install transmission (11)

 See information from vehicle manufacturer.

32

Pour oil into hydrodynamic retarder (10)



AP43.30-G-4302OHA

Check values for retarder/hydrodynamic retarder, hydraulic

Number

Designation

Model 000.001 with transmission 714.140/143
Transmission with hydrodynamic retarder

BE43.30-N-1001-01B

End play of retarder drive shaft

mm

0,02

 Hydrodynamic retarder

Number

Designation

Model 000.001
with hydrodynamic retarder

BA43.30-N-1001-01H

Screw/bolt, hydrodynamic retarder to transmission

Nm

170

Repair materials

Number

Designation

Order number

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1098-06A

VASELINE / DBL 6850.00

A 000 989 15 51