Remove/install torque converter clutch

AR25.40-G-0100BB

Remove/install torque converter clutch

10.11.2016

Model

405.100/101/102/103/120/121/122/123/200/201/220/221

with code G31 (Torque converter clutch (TWIN DISC))

1

Compressed-air line

10

Drain screw

20

Hydraulic line

2

Drive shaft

11

Hydraulic line

21

Connector

3

Electrical connectors

12

Timing case

22

Bracket

4

Clip

13

Bolt

23

Left support arm

5

Flexible exhaust pipe

14

Bolt

X66

WSK oil level sensor connector

6

Hydraulic line

15

Engine mount

Y11

WSK decoupler

7

Hydraulic line

16

Eyelet

Y12

Torque converter lockup clutch

8

Hydraulic hose

17

Bolt

9

Oil filter housing

18

Torque converter clutch

19

Torque converter

 Danger !

Risk of death. There is a risk of death to persons located within the tilting range or underneath the raised dump body during operation. Risk of injury There is a risk of body parts being crushed or pinched when the dump body is lowered.

All persons must remain outside the tilting range of the dump body during its operation. Always secure the raised dump body with the dump body support before starting any work underneath it.

AS55.20-Z-0001-01A

 Danger !

Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.

Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

1.1

Raise and secure dump platform

Engine 900, 904

 See operator's manual.

1.2

Remove tipper platform

engine 902, 906

 See operator's manual.

 Bolt, tilt cylinder to platform

*BA60.30-N-1001-01A

2

Detach flatbed auxiliary frame

engine 902, 906

 Installation: Replace nuts.

3

Tilt cab

Model 405

AR60.80-G-0005B

4

Remove compressed-air line (1)

 Installation: Check compressed air line (1) for leaktightness.

5

Remove drive shaft (2) from output flange of torque converter clutch (18), place upwards and strap down

 Screw/bolt, drive shaft to torque converter clutch output flange

*BA25.40-N-1003-01D

6

Detach electrical connections (3)

7

Release clamp (4) and remove flexible exhaust pipe (5) from valve fitting

 Installation: Clean sealing surfaces, check clamp (4) for wear and replace if necessary.

8

Remove both hydraulic lines (6, 7) and collect escaping oil

With work hydraulics

9

Seal open connection fittings using suitable stop plugs

10

Work loose hydraulic hose (8) at oil filter housing (9)

With work hydraulics

 so that air is drawn in.

11

Drain oil of torque converter clutch (18) and collect oil



AP25.40-G-2502B

12

Disconnect WSK oil level sensor connector (X66)

13

Remove hydraulic line (11) and collect escaping oil

14

Seal open connection fittings using suitable stop plugs

15

Remove hydraulic line (20) with connector (21) and collect escaping oil

engine 902, 906

 Installation: Clean sealing surfaces and replace seal of connector (21).

 Screw/bolt, hydraulic line connector to oil pan

*BA25.40-N-1014-01D

16

Seal open connection fittings using suitable stop plugs

17

Detach both brackets (22) from timing case (12)

engine 902, 906

18

Install cranking device (12) at timing case

AR03.30-G-1600-03B

 Inspection hole cap to timing case

*BA01.60-N-1002-01J

 Turning device

*904589046300

19

Remove all 6 bolts (13) from clutch plate

 Crank engine by the crankshaft in the normal direction of rotation until the bolts (13) are visible.
Before each releasing/tightening of the bolt (13),  block cranking device by inserting the pin.

 Screw/bolt, torque converter to drive plate

*BA25.40-N-1002-01D

20

Remove bolts (14) of engine mounts (15) on left and right

 Installation: Insert bushing beforehand.

 Screw/bolt, engine support to engine mount

*BA22.10-N-1005-01M

21

Detach left support arm (23) from torque converter clutch (18)

engine 902, 906

 Screw/bolt, engine support to torque converter clutch housing

*BA22.10-N-1004-01M

22

Lift engine slightly and secure on timing case (12) using jack stand

23

Hook in lifting equipment on the eyelet (16) on the torque converter clutch (18) and on overhead crane or boom crane

24

Remove bolts (17) from timing case (12)

 Screw/bolt, torque converter clutch to timing case

*BA25.40-N-1001-01D

25

Remove torque converter clutch (18)

 Remove some of the cable ties on the cable harnesses above the left and right engine mounts (15).

 Installation: Apply coating of long-life grease to hub (arrow) of torque converter (19).
Replace cable tie.

Long-life grease

*BR00.45-Z-1001-06A

26

Remove drive plates of torque converter clutch (18).

AR25.40-G-1400BB

27

Install in the reverse order



Check

28

Check oil level of torque converter clutch (18)



AP25.40-G-2510B

29

Perform a test drive and check function

30

Check torque converter clutch (18) for leaktightness

 Visual inspection.

 Timing case

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA01.60-N-1002-01J

Inspection hole cap to timing case

Nm

25

 Engine mounts, engine supports

Number

Designation

Engine 900.915/916, 902.923/924/935 with code G31

Engine 904.927/928, 906.935/955 with code G31

BA22.10-N-1004-01M

Screw/bolt, engine support to torque converter clutch housing

Nm

110

110

 Engine mounts, engine supports

Number

Designation

Engine 900.915/916, 902.923/924/935 with code G31

Engine 904.927/928, 906.935/955 with code G31

BA22.10-N-1005-01M

Screw/bolt, engine support to engine mount

Nm

180

180

 Torque converter clutch (WSK)

Number

Designation

ENGINE 900.9, 902.9 with CODE G31

ENGINE 904.9, 906.9 with CODE G31

BA25.40-N-1001-01D

Screw/bolt, torque converter clutch to timing case

Nm

60

60

 Torque converter clutch (WSK)

Number

Designation

ENGINE 900.9, 902.9 with CODE G31

ENGINE 904.9, 906.9 with CODE G31

BA25.40-N-1002-01D

Screw/bolt, torque converter to drive plate

Nm

60

60

 Torque converter clutch (WSK)

Number

Designation

ENGINE 900.9, 902.9 with CODE G31

ENGINE 904.9, 906.9 with CODE G31

BA25.40-N-1003-01D

Screw/bolt, drive shaft to torque converter clutch output flange

Nm

60

60

 Torque converter clutch (WSK)

Number

Designation

ENGINE 900.9, 902.9 with CODE G31

ENGINE 904.9, 906.9 with CODE G31

BA25.40-N-1014-01D

Screw/bolt, hydraulic line connector to oil pan

Nm

36

36

 Platform

Number

Designation

Model 405 with transmission 718.840

BA60.30-N-1001-01A

Bolt, tilt cylinder to platform

Nm

95

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11