Group 4 Disassembly and Assembly

GROUP 4 DISASSEMBLY AND ASSEMBLY
1. ELECTRO-HYDRAULIC SHIFT CONTROL

1) DISASSEMBLY
1 = Duct plate
2 = Shift control component (control circuit "I")
3 = Shift control component (control circuit "II")
4 = Hydraulic pump
H940S4WSTM400
(1) Loosen screw connection of the hydraulic

pump and remove the complete hydraulic
pump.
H940S4WSTM401
(2) Shift control component-control circuit "I"

① Loosen screw connection.
Fit two adjusting screws (see arrows).
(S) Adjusting screws (M6) 5870 204 063
H940S4WSTM402
3-32
② Remove shift control (1).
H940S4WSTM403
③ Remove shift intermediate plate (1).
H940S4WSTM404
④ Replace 2 screws of the cover screw

connection by adjusting screws (M6),
(pos. see arrows), loosen remaining
screws.
※ Now, loosen nuts of the adjusting screws
evenly.
Cover is spring-loaded.
H940S4WSTM405
⑤ Remove cover.
Loosen plug connections of cable
harness/solenoid valves.
Remove flat gasket (arrow).
H940S4WSTM406
3-33
⑥ If necessary, remove cable harness.
Pull off fixing plate (arrow) and remove
subsequently cable harness out of the
cover.
H940S4WSTM407
⑦ Remove compression springs (2 pieces),

shim(s) and spool of the modulation
valve (DMV) as well as compression
spring, shim and spool of the converter
safety valve (WSV).
H940S4WSTM408
⑧ Remove solenoid valves.
※ Solenoid valve (Y3) is spring-loaded.
H940S4WSTM409
⑨ Take compression spring and spool of

the shift valve/neutral (SN) and complete
shift valve - forward/reverse/clutch
K4(S-V/R/K4) out of the valve housing.
H940S4WSTM410
3-34
⑩ Pull fixing plate out (arrow).
Now, remove plug, spacing sleeve,
compression spring and spool of the
reducing valve (RDV) out of the bore.
Plug has only short guide faces and
can therefore (during the pulling out)
easily catch on the control edges.
Do not exert force - danger of damage.
H940S4WSTM411
⑪ Replace 2 screws of the cover screw

connection by adjusting screws (M6),
remove remaining screws.
※ Loosen nuts of adjusting screws evenly
(cover is spring-loaded).
Remove cover and gasket.
(with nuts)
H940S4WSTM412
⑫ Take compression springs, shim and

spool of the control pressure valve (SDV)
as well as spool (with locking disk) of the
modulation valve (DMV) out of the valve
housing.
H940S4WSTM413
⑬ Remove all screw plugs (along with

O-ring).
H940S4WSTM414
3-35
⑭ Orifice C-2 (set screw M5) - check
passage, respective remove if necessary.
The orifice can be also removed,
respective inserted, through the opening
(screw plug M10) in the cover, on the
non-demounted shift control.
ÂTorque limit (M5)
0.25 kgf·m (1.84 lbf·ft)
H940S4WSTM415
(3) Shift control component-control circuit "II"

① Loosen screw connection, remove shift
control (1) and intermediate plate (2).
Fit two adjusting screws (see arrows).
H940S4WSTM416
② Loosen screw connection, remove cover

and flat gasket.
H940S4WSTM417
③ Separate plug connection from solenoid

valve/cable harness.
H940S4WSTM418
3-36
④ If necessary, remove cable harness.
Pull off fixing plate (arrow) and remove
subsequently cable harness out of the
housing.
H940S4WSTM419
⑤ Remove solenoid valves.
※ Solenoid valves are spring-loaded.
H940S4WSTM420
⑥ Remove spools and compression

springs out of the housing.
H940S4WSTM421
⑦ Remove all screw plugs (along with

O-ring).
H940S4WSTM422
3-37
2) ASSEMBLY
※ Check all components for damage, respective wear, and renew if necessary.
※ Prior to the installation, check the free travel of the movable parts in the housing.
※ Oil the components prior to the assembly.
(1) Shift control component - control circuit "I"
H940S4WSTM301
1 = Cable harness
2 = Reducing valve RDV 10 bar
3 = Shift valve S-N/K4 (neutral/K4)
4 = Shift valve S-V/R (forward/reverse)
5 = Control pressure valve SDV 16+3 bar
6 = Modulation valve DMV 3-12 bar
7 = Orifice C2 (for DMV)
8 = Converter safety valve WSV 8+2 bar
9 = Solenoid valves Y1, Y2, Y3
3-38
① Draft + Legend refer figure TM303~307
1 = Compr. spring
2 = Shim
3 = Spool
4 = Spool
5 = Shim
6 = Compression spring
7 = Spool
8 = Shim
9 = Compression spring H940S4WSTM302
10 = Compr. spring
11 = Spool
12 = Locking disk
13 = Orifice C-2 (set screw M5)
② Control pressure valve (SDV)

Insert spool (3), shim (2, S = optional)
and compression spring (1).
Modulation valve (DMV)
Insert spool (11) along with locking disk
(12).
※ Valve position - see figure TM301.
Valve components - see figure TM302.
H940S4WSTM303
③ Screw in 2 adjusting screws (M6), Line

up flat gasket (arrow) - pay attention to
the installation position.
Position cover by means of adjusting
screws and nuts evenly against shoulder.
(with nuts)
H940S4WSTM304
④ Fasten cover with hexagon head screws

(equipped with washer).
On this occasion, replace adjusting
screws.
ÂTorque limit (M6/10.9Ý25)
MA = 0.97 kgf·m (7.0 lbf·ft)
H940S4WSTM305
3-39
⑤ Insert orifice C-2 (13).
Check free passage of orifice.
ÂTorque limit 0.25 kgf·m (1.84 lbf·ft)
H940S4WSTM306
⑥ Converter safety valve (WSV)

Insert spool (4), shim (5, S = optional)
and compression spring (6).
Modulation valve (DMV)
Inser t compression spring (10),
compression spring (9) shim(s) (8, S =
optional) and spool (7).
H940S4WSTM307
⑦ Draft + Legend refer figure TM309~310

1 = Valve (control spool complete)
3 = Spool
4 = Spacing sleeve
5 = Spool
7 = Plug
8 = Fixing plate
H940S4WSTM308
⑧ Shift valve (S-V/R)

Insert valve (1), (control spool complete).
Shift valve (SN/K4)
Inser t compression spring (2) and
spool (3).
Reducing valve (RDV)
Insert spool (5), compression spring
(6), spacing sleeve (4) and plug (7).
※ Valve position - see figure TM301. H940S4WSTM309
3-40
⑨ Reducing valve (RDV)
Press plug (7) in position (spring preload)
until fixing plate (8), (installation position -
see draft No. 8) can be inserted into the
groove of the plug.
Because of short guide faces, the plug
(6) can easily cant during the
H940S4WSTM310
installation - do not exert force.
⑩ Insert solenoid valve (3EA), fasten with

fixing plate, plain washer (installation
position - see figure) and socket head
screw.
※ Pay attention to the installation position
of the solenoid valves (position of the
cable har ness connections - see
figure). Install fixing plate, with the claw
(arrow) facing the valve housing.
H940S4WSTM311
MA = 0.56 kgf·m (4.0 lbf·ft)
⑪ Draft + Legend refer figure TM313:

1 = Cable harness
2 = Fixing plate
3 = Sealing rings
4 = Position/Double locking
5 = Plug (3EA)
6 = Cover
H940S4WSTM312
⑫ Pre-assemble cover:
Insert cable harness (1) and fix it with
fixing plate (2).
of the fixing plate (2) and cable
harness locking (4) - see figure TM312.
H940S4WSTM313
3-41
⑬ Mount flat gasket.
H940S4WSTM314
⑭ Connect cable harness with solenoid

valve (plug connection).
H940S4WSTM315
⑮ Position cover.
Screw in 2 adjusting screws (M6) and
position cover by means of adjusting
screws and nuts evenly against shoulder.
※ Pay attention to the flat gasket.
(with nuts)
H940S4WSTM316
16 Fasten cover with hexagon head screws

On this occasion, remove adjusting
screws.
MA = 0.96 kgf·m (7.0 lbf·ft)
MA = 0.96 kgf·m (7.0 lbf·ft)
H940S4WSTM317
3-42
17 Screw in screw plug (M10Ý1, C-2 Orifice
- assembly opening) along with O-ring.
ÂTorque limit (M10Ý1)
MA = 0.6 kgf·m (4.4 lbf·ft)
H940S4WSTM318
18 Install screw plugs (along with O-ring).

※ Mount shift control on the transmission -
see page 3-115~116.
H940S4WSTM319
(2) Shift control component - control circuit

"II"
1 = Flat gasket
2 = Valve block
3 = Shift valve
4 = Shift valvel
5 = Shift valve
6 = Solenoid valves (Y4, Y5, Y6)
6 = Cover
H940S4WSTM320
① Insert compression spring and spools of

the shift valves (Item 3, 4 and 5 - see
figure TM320).
H940S4WSTM321
3-43
② Draft + Legend refer figure TM323~326
1 = Cover
2 = Solenoid valves
3 = Cable harness
4 = Cable harness locking
H940S4WSTM322
③ Insert solenoid valve (3EA), fasten with

fixing plate and socket head screw.
※ Pay attention to the installation position of
the solenoid valves (2) (position cable
har ness connections - see figure
TM322).
Install fixing plate with the claw (arrow)
facing the valve housing.
H940S4WSTM323
④ ÂTorque limit (M5/8.8Ý12)

MA = 0.56 kgf·m (4.0 lbf·ft)
H940S4WSTM324
⑤ Insert cable harness (4 along with

sealing rings -arrows).
the cable harness locking (4) - see figure
TM322.
H940S4WSTM325
3-44
⑥ Fix cable harness (1) with fixing plate
(pay attention to the installation position -
tongue in direction of arrow).
Connect cable harness with solenoid
valves (plug connection).
H940S4WSTM326
⑦ Mount gasket.
H940S4WSTM327
⑧ Fasten cover with hexagon head screws

MA = 0.56 kgf·m (4.0 lbf·ft)
H940S4WSTM328
⑨ Install screw plugs (along with O-ring).

H940S4WSTM329
3-45
2. TRANSMISSION
1) DISASSEMBLY
Drain oil (use suitable collector).
Fasten unit on the assembly car.
(S) Assembly car 5870 350 000
(S) Support 5870 350 092
H940S4WSTM201
(1) Hydraulic pump

① Screw off oil filter.
(S) Ribbon spanner 5870 105 000
H940S4WSTM202
② Loosen socket head screws and

remove complete pump.
※ The central shaft can stay in the drive
shaft - see Illustration figure TM204 -
or in the hydraulic pump.
If necessary, the central shaft has to
be pulled out of the pump.
H940S4WSTM203
③ Pull central shaft out of the drive shaft.
H940S4WSTM204
3-46
④ Disassemble components:
Remove spacing sleeve (1), O-ring (2),
angle disk (3), axial needle cage (4),
axial washer (5), O-ring (6) and O-rings
(7).
H940S4WSTM205
⑤ Separate pump halves.

(S) Crow bar 5870 345 071
H940S4WSTM206
⑥ Mark installation position of the pump

gears (assembly aid).
Carry out visual inspection on liners and
pump gears as well as on the pump
housing (traces of wear).
At serious traces of wear, which are
affecting the required pump pressure,
r e s p e c t i ve t h e o i l f l ow ra t e, t h e
complete hydraulic pump has to be
replaced. H940S4WSTM207
Components are not exchangeable.
(2) Remove complete shift control component

※ The complete disassembly of the shift
control is illustrated in the Section 1.
Electro-hydraulic shift control, figure
400~422 - the complete assembly of the
shift control in the Section 2. Electro-
hydraulic shift control, figure TM301~329.
① Loosen screw connection of the shift
control component -control circuit "I".
H940S4WSTM208
3-47
② Remove complete shift control
component - control circuit "I" with
intermediate plate.
H940S4WSTM209
③ Shift control (control circuit "I")
H940S4WSTM210
④ Loosen screw connection of the shift

control components - control circuit "I".
Remove complete shift control
component along with intermediate plate.
H940S4WSTM211
⑤ Shift control (control circuit "I")
H940S4WSTM212
3-48
(3) Duct plate
① Loosen screw cap of the solenoid valves
and pull off coil (along with O-ring, 2
pieces).
※ At the version "without" VA (output to the
front axle), the solenoid valve - see arrow
- has to be replaced by a screw plug
(with O-ring).
H940S4WSTM213
② Remove valve body, equipped with 3

O-rings each.
H940S4WSTM214
③ Loosen screw connection and remove

duct plate along with flat gasket.
H940S4WSTM215
(4) Fork flange/shaft seal (output to the

Rear axle)
① Pull off the flange.
H940S4WSTM216
3-49
② Remove shaft seal.
H940S4WSTM217
(5) Shaft seal (output to the front axle)

※ The illustrated steps of figure TM218 and
219 have to be carried out only if the shaft
seal should not be replaced in the course
of a complete disassembly of the
transmission (see figure TM279~280).
① Equip sealing cover (cover sheet) with an
auxialiary bore (͚about 7 mm) and press
it subsequently from the shaft (cover
H940S4WSTM218
sheet will be destroyed).
Now, remove shaft seal.
(6) Converter
① Pull off converter assembly.
If necessary, loosen screw connection
and remove diaphragm (pay attention to
the released washers).
Remove shaft seal from the converter
bell - see figure TM223 - can be also
replaced without previous separation of
the housing.
H940S4WSTM219
(7) Gearbox housing

① Drive cylindrical pin out (through hole).
H940S4WSTM220
3-50
② Loosen housing screw connection.
※ Mark positions of the retaining clips
(assembly aid).
H940S4WSTM221
③ Screw in 2 eye bolts and separate

gearbox housing / Part I carefully from
Part II.
Aggravated disassembly, cylindrical pin
insertion - see arrow (driving out not
possible, because no through hole).
(S) Set of eye bolts 5870 204 002
H940S4WSTM222
④ Remove shaft seal.
H940S4WSTM223
⑤ L o o s e n s c r ew c o n n e c t i o n o f t h e
converter bell.
H940S4WSTM224
3-51
⑥ Heat stator screw connection (inserted
with locking compound) (disassembly
aid).
(S) Hot-air blower 220 V 5870 221 500
(S) Hot-air blower 110 V 5870 221 501
H940S4WSTM225
⑦ Loosen stator shaft screw connection

and pull stator shaft out.
H940S4WSTM226
⑧ Pull bearing bush out of the stator shaft.

(S) Internal puller 5870 300 007
(S) Counter support 5870 300 003
H940S4WSTM227
⑨ Remove bearing outer races out of the

gearbox housing (part I).
For roller bearings which will not be
replaced, pay attention to the following.
Record (mark) installation position
(shaft) as well as the single bearing
coordination (bearing outer race to
bearing inner race).
H940S4WSTM228
3-52
⑩ Separate gearbox housing (part I) from
the converter bell.
H940S4WSTM229
⑪ Pull bearing bush out of the converter

bell.
(S) Internal puller 5870 300 007
(S) Counter support 5870 300 003
H940S4WSTM230
(8) Clutches, drive shafts and output shafts

Clutch "K1"
① Lift complete clutch pack "K1" out of the
gearbox housing (part II).
H940S4WSTM231
② Unhook and remove both rectangular

rings (arrows).
H940S4WSTM232
3-53
③ Pull off bearing inner race along with
inner plate carrier.
bearing inner race.
(S) Three-leg puller 5870 971 002
H940S4WSTM233
④ Remove roller ring half (with collar

washer) from inner plate carrier and
outer plate carrier.
H940S4WSTM234
⑤ Squeeze circlip out.

(S) Set of external pliers 5870 900 015
H940S4WSTM235
⑥ Squeeze snap ring out.
H940S4WSTM236
3-54
⑦ Take end shim and plate pack out of the
plate carrier.
H940S4WSTM237
⑧ Neutralize preload of the cup spring pack

by means of press and pressing sleeve.
Now, squeeze circlip out.
(S) Pressing sleeve 5870 506 128
H940S4WSTM238
⑨ Remove shim and cup spring pack.
H940S4WSTM239
⑩ Press spool by means of compressed

air from the shaft, respective out of the
plate carrier.
H940S4WSTM240
3-55
⑪ Take both O-rings out of the spool.
Check function of bleeder valve (ball)
(staked in the spool - however free
movable in the hole) (arrow).
H940S4WSTM241
⑫ Pull off bearing inner race.

Do not carry out any further disassembly
- shaft (with helical gear and plate carrier)
H940S4WSTM242
can be replaced only as subassembly.
(S) Grab sleeve "Super"
Clutch(K1/K2) 5873 001 036
Clutch (K4) 5873 011 011
(S) Basic tool 5873 001 000
Clutch "KR"
⑬ Lift complete clutch pack "KR" out of the
H940S4WSTM243
3-56
⑭ Squeeze out and remove both
rectangular rings (arrows).
H940S4WSTM244
⑮ Pull off bearing inner race.

(S) Grab sleeve "Super" 5873 000 029
(S) Basic tool 5873 000 000
H940S4WSTM245
16 Squeeze circlip out.

H940S4WSTM246
17 Pull off plate carrier (inner plates) along

with roller bearing.
If necessary, remove both bearing outer
races out of the plate carrier.
H940S4WSTM247
3-57
18 Squeeze snap ring out.
H940S4WSTM248
19 Take end shim and plate pack out of the

plate carrier.
H940S4WSTM249
20 Pull off bearing inner race.

(S) Basic tool 5873 001 000
H940S4WSTM250
21 Remove shim and cup spring pack.
H940S4WSTM251
3-58
22 Press spool by means of compressed air
from the shaft, respective out of the plate
carrier.
H940S4WSTM252
23 Take both O-rings out of the spool.

Check function of the bleeder valve (ball)
H940S4WSTM253

Do not carry out any further disassembly
- shaft (with helical gear and plate carrier)
H940S4WSTM254
can be replaced only as subassembly.
(S) Grab sleeve "Super"
Clutch(KR) 5873 001 036
Clutch (KV) 5873 011 011
(S) Basic tool 5873 001 000
3-59
Clutch "KV"
25 Lift complete clutch pack "KV" out of the
※ Carry out further diassembly of clutch
"KV" - in the same way as shown in
Illustration clutch "KR" - see figure TM
244~254.
H940S4WSTM255
Clutch "K4"
26 Lift complete clutch pack "K4" out of the
"K4" - in the same way as shown in
Illustration clutch "K1" - see figure TM
232~242.
H940S4WSTM256
Drive shaft
27 Squeeze circlip (duct plate-side) out of
the ball bearing groove.
H940S4WSTM257
28 Remove complete drive shaft out of the

H940S4WSTM258
3-60
29 Unhook and remove both rectangular
rings (position of the second rectangular
ring - see arrow).
H940S4WSTM259

H940S4WSTM260
31 Pull off the ball bearing.

H940S4WSTM261
32 Loosen screw connection and remove oil

pipe along with O-ring.
H940S4WSTM262
3-61
Clutch "K2"
"K2" - in the same way as shown in
Illustration clutch "K1" - see figure TM
332~342.
H940S4WSTM263
Clutch "K3" (Output to the Rear axle)

H940S4WSTM264
35 Unhook and remove rectangular rings

(3EA) (position see arrows).
H940S4WSTM265

(S) Basic tool 5873 000 000
H940S4WSTM266
3-62
H940S4WSTM267
38 Pull off plate carrier (inner plates) along

with roller bearing.
H940S4WSTM268
39 Squeeze snap ring out.
H940S4WSTM269
40 Take end shim and plate pack out of the

plate carrier.
H940S4WSTM270
3-63
(S) Basic tool 5873 001 000
H940S4WSTM271
42 Remove thrust washer and cup spring

pack.
H940S4WSTM272
43 Press spool by means of compressed air

from the shaft, respective out of the plate
carrier.
H940S4WSTM273
44 Take both O-rings out of the spool.

Check function of bleeder valve (ball)
H940S4WSTM274
3-64
(S) Basic tool 5873 002 001
H940S4WSTM275
Do not carry out any fur ther

disassembly - shaft and plate carrier
can be only replaced as sub-assembly.
H940S4WSTM276
Output (clutch VA) to the front axle

1 = Gearbox housing
2 = Clutch "VA"
3 = Clutch "K1"
H940S4WSTM278
46 Pull off screening plate.

Disassembly of the shaft seal (and
screening plate) without complete
disassembly of the transmission - see
figure TM218.
(S) Two-leg puller 5870 970 004
H940S4WSTM279
3-65
47 Pull off shaft seal and remove bearing
outer race.
H940S4WSTM280

(S) Basic tool 5873 001 000
H940S4WSTM281
49 Loosen socket head screws and remove

screening plate/part I.
H940S4WSTM282
50 Lift complete output shaft (clutch - VA)

out of the gearbox housing (part II).
H940S4WSTM283
3-66
51 Separet complete plate carrier from the
output shaft.
H940S4WSTM284
52 Load cup spring pack through the plate

pack - position suitable pressure piece
upon the end shim - with 22 KN
(necessary to neutralize the cup spring
preload), and squeeze snap ring out.
For this pupose, the plate carrier must
no be supported on the cup spring
pack.
H940S4WSTM285
53 Remove complete plate pack (along with

end shim) out of the plate carrier.
H940S4WSTM286
54 Preload cup spring pack only until the

circlip will be releasd. and can be
squeezeed out.
Danger of damage of the sealing scat
on the plate carrier.
(S) Pressure piece 5870 506 128
H940S4WSTM287
3-67
55 Remove spacer ring and cup spring
pack.
H940S4WSTM288
※ Pry piston out of the plate carrier - use

suitable support - and pay atention to the
released rollers (3EA).
H940S4WSTM289
56 Remove both O-Rings (arrows)
H940S4WSTM290

H940S4WSTM291
3-68
58 Remove shim, cup spring and fixing
plate.
H940S4WSTM292
59 Unhook and remove rectangular ring.
H940S4WSTM293

(S) Basic tool 5873 001 000
H940S4WSTM294

H940S4WSTM295
3-69
62 Pull off thrust washer, helical gear and
remove O-ring (arrows) from the output
shaft.
H940S4WSTM296
63 Loosen screw connection and remove

screening plate/part II.
H940S4WSTM297
64 Pull bearing outer races out of the

H940S4WSTM298
65 Loosen screw connections and remove

oil pipes.
H940S4WSTM299
3-70
2) ASSEMBLY
(1) Oil pipes
① Grease O-ring (2) and insert it into the
annular groove of the oil pipe (1).
1 = Oil pipe
2 = O-ring 14Ý2
3 = Fixing plate
4 = Socket head screw M18Ý16
H940S4WSTM001
② Insert all oil pipes (pre-assembled) and

fasten by means of fixing plate (3) and
socket head screws (4).
MA = 2.35 kgf·m (17.0 lbf·ft)
H940S4WSTM002
③ Installation position of the different oil

pipes in the gearbox housing/part II - see
Illustration.
Duct plate-side connection of the oil pipe
(arrow) for the front axle output clutch
(VA) is realized with one hollow screw -
along with two sealing rings 16×20 -.
ÂTorque limit (M16Ý1.5)
MA = 4.6 kgf·m (33.2 lbf·ft)
H940S4WSTM003
Version "with" output

1 = Gearbox housing
2 = Clutch "VA"
3 = Clutch "K1"
H940S4WSTM005
3-71
H940S4WSTM006
Legend refer figure TM006~035.

1 = Gearbox housing 16 = O-ring 55Ý3
2 = Output shaft 17 = O-ring 135Ý3
3 = Roller bearing 18 = Cup spring pack
4 = Sceeing plate/part II 19 = Spacer ring
5 = Inner plate carrier (helical gear) 20 = Circlip
6 = Thrust washer 21 = End shim
7 = Circlip 55Ý3 22 = Plate pack
8 = O-ring 42Ý4 23 = End shim
9 = Outer plate carrier 24 = Snap ring 54Ý2
10 = Fixing plate 25 = Recrangular ring 30Ý2
11 = Cup spring 26 = Screening plate/part I
12 = Shim 27 = Roller bearing
13 = V-ring (circlip) 28 = Shaft seal 40Ý62Ý7
14 = Roller (3EA) 6Ý18 29 = Sealing cap (cover plate)
15 = Piston 30 = Clutch "K1"
3-72
④ Mount bearing outer races (output shaft
VA) into the bore until contact os
obtained.
Bohrung setzen.
and bearing coordination.
See also disassembly note - figure TM
028.
H940S4WSTM007
⑤ Install screening plate/part II.

※ Insert socket head screws with locking
compound loctite (Type-No. 262).
MA = 2.35 kgf·m (17.0 lbf·ft)
H940S4WSTM008
⑥ Pre-assemble Output shaft VA (2)

Line up inner plate carrier (5) and thrust
washer (6).
Line up and oil O-Ring 42Ý4 (8/arrow).
H940S4WSTM009
⑦ Squeeze circlip 55Ý3 (7) in.
H940S4WSTM010
3-73
⑧ Insert fixing plate (10).
※ Pay attention to the installation position -
see detail /figure TM006.
H940S4WSTM011
⑨ Aign cup spring (11) in the fixing plate

and mount shim (12).
see detail /figure TM006.
H940S4WSTM012
⑩ Squeeze V-ring (13) in.
H940S4WSTM013
⑪ Insert rollers 6Ý18 (14) (3 pieces).
H940S4WSTM014
3-74
⑫ Insert both O-rings 55Ý3 und 135Ý3
(16 and 17/arrows) into the piston (15)
and oil it.
H940S4WSTM015
⑬ Oil sealing surfaces of the outer plate

carrier (9).
Press pre-assembled piston (15) into the
outer plate carrier until contact is
obtained.
of the piston - see figure TM006.
H940S4WSTM016
⑭ Line up cup spring pack (18).

※ Pay attentionto the installation position
and stacking of the cup spring pack - see
figure TM006.
H940S4WSTM017
⑮ Line up spacer ring (19).

Pay attention to the installation position
- the chamfered end face of the spacer
ring must be facing the cup springs
(figure/-downward).
H940S4WSTM018
3-75
16 Lay on circlip 55×2 (20) not attached.
Preload cup spring pakc (18) by means
of press and pressure piece only until the
circlip (20) can be squeezed in.
Danger of damage - if the cup spring
pack will be loaded until contact is
obtained, this will cause a damage of the
sealing seat on the outer plate carrier.
H940S4WSTM019
17 Insert end shim (21).

see figure TM006.
H940S4WSTM020
Immerge lined plates (inner plates) 30

minutes in oil - oil according to ZF-List
of lubricants TEML 03.
※ Insert plate pakc (22) alternately, starting
with one outer plate, and mount end
shim (23).
H940S4WSTM021
Adjust/check Plate clearance

X = Plate clearance (total 1.4~1.9 mm)
F = 1.84~2.04 kg·f (13.3~14.8 lb·f)
9 = Outer plate carrier
15 = Piston
18 = Cup spring pack
21 = End shim
22 = Plate pack
Âouter plate 14EA
Âinner plate 14EA H940S4WSTM022
23 = End shim
24 = Snap ring (S = optional)
D = Pressure piece
3-76
18 Mount the snap ring (S = e.g. 3.5 mm,
empirical value) not attached.
Place the plate pack (along with end
shims) - position suitable pressure piece
upon the end shim (23) - by means of
press against shoulder (F = 1.84~2.04
kg·f (13.3~14.8 lb·f)) - necessary to
neutralize the cup spring preload).
For this purpose, the plate carrier must
no be supported on the cup spring H940S4WSTM023
pack - see figure TM022.
19 Hold plate pack on contact - see figure

TM023 - and determine dimension "I".
Dimension "I" e.g. ....................... 7.60 mm
H940S4WSTM024
20 Unload the plate pack and determine

Dimension "II".
Dimension "II" ............................. 5.90 mm
※ Plate clearance : 1.4~1.9 mm
Example
Dimension "I" e.g. ....................... 7.60 mm
Dimension "II" e.g. .................... - 5.90 mm
gives Dimension "X" = 1.70 mm
(Plate clearance) H940S4WSTM025
If the required plate clearance e.g.

1.4~1.9 mm should not be obtained,
correct with a corresponding snap ring
(24) (S = optional).
3-77
21 Demount cup spring pack (18) again.
Preload cup spring pack only until the
circlip (20) will be released and can be
squeezed out.
obtained, this will cause a damage of
the sealing seat on the outer plate
H940S4WSTM026
carrier.
22 Remove cup spring pack (18) and spacer

ring (19).
Hold piston (15) in position.
H940S4WSTM027
23 Place outer plate carrier upon suitable

support (pipe).
Align plates radially and centrically
(assembly aid).
Introduce pre-assembled inner plate
carrier (5, with output shaft) until al inner
plates are lined up.
H940S4WSTM028
24 Hold outer plate carrier in lined-up

position.
Line up cup spring pack (18) and mount
spacer ring (19).
and stacking of the cup spring pack -
see figure TM006.
Pay attention to the installation position of
the spacer ring - the chamfered end face
H940S4WSTM029
of the spacer ring must be facing the cup
springs (figure/downward).
3-78
25 Mount circlip (20) not attached.
Preload cup spring pack (18) by means
of press and pressure piece only until the
circlip (20) can be squeezed in.
obtained, this will cause a damage of
the sealing seat on the outer plate
carrier.
H940S4WSTM030
26 Press bearing inner race (3) against

shoulder.
and bearing coordination - see also
disassembly note figure TM294.
H940S4WSTM031
27 Squeeze in and engage rectangular ring

30Ý2 (25).
※ Grease rectangular ring and position it
centrically (assembly aid).
H940S4WSTM032
28 Insert pre-assembled output shaft (clutch

VA).
H940S4WSTM033
3-79
29 Mount screening plate/part II (26) and
fasten by means of socket head screw.
Insert socket head screws with locking
MA = 0.97 kgf·m (7.0 lbf·ft)
H940S4WSTM034
30 Line up heated bearing inner race (27)

and reset it after the cooling down.
and bearing coordination - see
H940S4WSTM035
3-80
(3) Clutch "K3" (input to the rear axle)
H940S4WSTM036
Legend refer draft figure TM036~058

1 = Shaft complete (with plate carrier and circlip) 10 = Roller bearing
2 = Spool complete (with ball) 11 = Plate carrier (inner)
3 = O-ring 55Ý3 12 = Roller bearing
4 = O-ring 135Ý3 13 = Circlip (S = optional)
5 = Cup spring pack 14 = Roller bearing
6 = Support plate 15 = ----------------
7 = Plate pack 16 = Roller bearing
8 = End shim 17 = Rectangular rings 50Ý2.4
9 = Snap ring (S = optional) 18 = Rectangular ring 30Ý2
① Check passage of pressure oil supply

bores and lube oil supply bores (by means
of compressed air).
H940S4WSTM037
3-81
② Insert both O-rings 52Ý3 and 115Ý3 (3
and 4) into the spool (2) and oil them.
Check function of the bleeder valve
(arrow) (mounting bore staked -
however, ball free movable in the
spool).
H940S4WSTM038
③ Oil sealing surface of shaft and plate

carrier.
Insert pre-assembled spool (2) until
contact is obtained (pay attention to the
installation position - see Illustration).
H940S4WSTM039
④ Line up cup spring pack (5) - stacking

and installation position of the single cup
springs - see figure TM036.
※ Position cup spring and top - with grease
- centrally (assembly aid).
H940S4WSTM040
⑤ Line up support plate (6).
H940S4WSTM041
3-82
Press bearing inner race (10) against
shoulder.
Check position (centric) of the cup
spr ing on top, see note of figure
TM023.
H940S4WSTM042
Immerse lined plates (inner plates)

prior to the assembly 30 minutes in oil
- oil according to ZF-List of lubricants
TE-ML 03.
※ Insert plate pack (7) alternately, starting
with one outer plate.
H940S4WSTM043
⑥ Mount end shim (8) and squeeze in snap

ring (9) (S = optional).
H940S4WSTM044
Adjust/check plate clearance

X = Plate clearance
F = 1.84~2.04 kg·f (13.3~14.8 lb·f)
1 = Shaft with plate carrier - see draft 236
7 = Plate pack
ÂOuter plate 8Ý
ÂInner plate 8Ý
8 = End shim
9 = Circlip (S = optional)
H940S4WSTM045
※ Plate clearance : 1.6~ 2.4 mm
3-83
⑦ Press plate pack against shoulder (F =
about 1.84~2.04 kg·f (13.3~14.8 lb·f)).
Determine dimension I from the end face
of the plate carrier to the end shim.
Dimension I e.g. .......................... 9.30 mm
(S) Digital-Depth gauge 5870 200 072
H940S4WSTM046
⑧ Position end shim (8) and snap ring (9)

on the outer face of the recess/plate
carrier against shoulder - see figure.
Determine dimension II from the end
face of the plate carrier to the end shim.
Dimension II e.g. ......................... 7.40 mm
Example
Dimension "I" e.g. ....................... 9.30 mm
H940S4WSTM047
(plate clearance)
If the required total plate clearance
e. g . ( 1 . 6 ~ 2 . 4 mm
mm)) s h o u l d n o t b e
obtained, correct it with a
corresponding snap ring (9) (S =
optional).
⑨ If disassembled - insert both bearing

outer races of the roller bearings (10 and
12) into the plate carrier until contact is
obtained.
H940S4WSTM048
3-84
※ Align plates radially and centrally
(assembly aid).
⑩ Introduce plate carrier (11) until all inner
H940S4WSTM049
Press on bearing inner race (12) until

rollers of the roller bearings (10 and
12) have a playfree contact, however
no preload will be achieved.
At the same time, rotate the plate
carrier several times to and fro, to
ensure the accommodation of he
single rollers.
H940S4WSTM050
⑪ Determine thickness of the Circlip for the

Plate carrier fixing:
Determine thickness of the required
circlip (13 by means of feeler gauge
(from end face/bearing inner race to
outer locating face/groove).
Basis for an exact determination of the
r e q u i r e d c i r c l i p, i s t h e c o r r e c t
positioning of the roller bearing.
H940S4WSTM051
S e l e c t t h i ck n e s s o f c i r c l i p ( S =
optional) in such a way that a playfree
fixing of the plate carrier bearing will
be obtained.
⑫ Squeeze in the determined circlip (13).
Reset circlip until contact on the
groove base is obtained.
H940S4WSTM052
3-85
⑬ Press bearing inner race (14) against
shoulder.
and the bearing coordi-nation - see also
disassembly note - figure TM266.
H940S4WSTM053
⑭ Press bearing inner race (16) against

shoulder.
H940S4WSTM054
H940S4WSTM055
⑮ Squeeze in and engage rectangular

rings 30Ý2 and 55Ý2.5 (17 and 18).
H940S4WSTM056
3-86
16 Inser t bearing outer race into the
gearbox housing/part II.
※ Pay atention to the installation position
H940S4WSTM057
17 Insert complete clutch "K3".
H940S4WSTM058
3-87
(4) Clutch "K1"
H940S4WSTM059
Legend refer draft figure TM059~078

1 = Shaft complete (with spur gear, plate carrier and circlip) 10 = Snap ring (S = optional)
2 = Spool 11 = Circlip 40Ý175
3 = O-ring 40Ý3 12 = Collar washer
4 = O-ring 115Ý3 13 = Roller ring
5 = Cup spring pack 14 = Plate carrier (inner)
6 = Support plate 15 = Roller bearing
7 = Circlip 40Ý1.75 16 = Roller bearing
8 = Plate pack 17 = Rectangular ring 30Ý2
9 = End shim 18 = Rectangular ring 30Ý2

bores and lube oil supply bores (by means
of compressed air).
H940S4WSTM060
3-88
and 4) into the spool and oil them.
(arrow) (assembly bore staked -
however, ball free movable in the
spool).
H940S4WSTM061

carrier.
Insert pre-assembled spool (2) until
H940S4WSTM062
④ Line up cup spring pack (5) - stacking

and installation position of the single cup
springs - see figure TM059.
※ Position cup spring and top - with grease
- centrally (assembly aid).
H940S4WSTM063
⑤ Line up support plate (6).
H940S4WSTM064
3-89
⑥ Preload cup spring pack (5) - by means
of sleeve - until the circlip 40Ý1.75 (7)
can be squeezed in.
(S) Sleeve 5870 506 128
H940S4WSTM065
※ Immerse lined plates (inner plates) prior

to the assembly 30 minutes in oil.
H940S4WSTM066
⑦ Mount end shim (9) and squeeze in snap

H940S4WSTM067
Adjust/check plate clearance

X = Plate clearance
F = 1.84~2.04 kgf·m (13.3~14.8 lbf·ft)
1 = Shaft with plate carrier - see draft 259
8 = Plate pack
ÂOuter plate 12EA
ÂInner plate 12EA
9 = End shim
10 = Snap ring (S = optional)
H940S4WSTM068
※ Plate clearance K1 : 2.4~3.6 mm
3-90
Plate clearance K2 : 1.6~2.4 mm
• Plate pack
ÂOuter plate 8EA
ÂInner plate 8EA
Plate clearance K4 : 1.6~2.4 mm
• Plate pack
ÂOuter plate 8EA
ÂInner plate 8EA
⑧ Press plate pack against shoulder

(1.84~2.04 kg·f (13.3~14.8 lb·f)).
Dimension I e.g. .......................... 7.30 mm
H940S4WSTM069
⑨ Position end shim (9) and snap ring (10)

carrier until contact is obtained - see
figure.
face of the plate carrier to the end shim.
Dimension II e.g. ......................... 4.30 mm
H940S4WSTM070
Example
Dimension "I" e.g. ....................... 7.30 mm
(Plate clearance)
If the required plate clearance
K1 : 2.4~3.6 mm
K2 : 1,6~2.4 mm
K4 : 1,6~2.4 mm
Should not be obtained, correct it with a
corresponding snap ring (10) (S =
optional).
3-91
⑩ Squeeze in circlip 40Ý1.75 (11).
H940S4WSTM071
⑪ Line up one collar washer (12).
H940S4WSTM072
⑫ Make one roller ring (13) adhere with

grease into the inner plate carrier
(assembly aid).
of the roller ring - large /small roller
cage diameter - see in this connection
figure TM059.
H940S4WSTM073

(assembly aid).
⑬ Introduce plate carrier (14) until all inner
H940S4WSTM074
3-92
⑭ Insert outer roller ring (13) and line up
second collar washer (12).
※ At a correct assembly (all plates lined up,
correct installation position of both roller
rings), the collar washer must not
protrude beyond the locating face of the
bearing inner race (15) - check.
H940S4WSTM075
⑮ Press bearing inner race (15) against

shoulder.
H940S4WSTM076
16 Press bearing inner race (16) against

shoulder.
H940S4WSTM077
17 Squeeze in and engage rectangular

rings 30Ý2 (17 and 18).
H940S4WSTM078
3-93
(5) Clutch "K2" and "K4"
H940S4WSTM079
1 = Shaft complete (with spur gear, plate carrier and circlip) 10 = Snap ring (S = optional)
2 = Spool 11 = Circlip 40Ý175
3 = O-ring 40Ý3 12 = Collar washer
4 = O-ring 115Ý3 13 = Roller ring
5 = Cup spring pack 14 = Plate carrier (inner)
7 = Circlip 40Ý1.75 16 = Roller bearing
The assembly of the clutches "K2" and "K4" has to be carried out in the same way as at clutch "K1"
Âsee section clutch "K1", figure TM060~078.
ÂIn this connection however, the differing number of plates and with it the changed plate clearance
has to be considered - see specification page 3-91.
① Pre-assembled clutches "K1" - "K2" - "K4"
H940S4WSTM080
3-94
② Insert bearing outer race ("K2") into the
and the bearing coordi-nation - see
also disassembly note - figure TM298.
H940S4WSTM081
③ Insert complete clutch "K2".
H940S4WSTM082
(6) Oil suction pipe

① Insert O-ring 30Ý3 (arrow) into the
groove of the oil suction pipe and oil it.
H940S4WSTM083
② Insert pre-assembled oil suction pipe.

MA = 2.35 kgf·m (17.0 lbf·ft)
H940S4WSTM084
3-95
(7) Drive shaft
Legend refer figure TM085~090.
Insert pre-assembled drive shaft into the
1 = Drive shaft
2 = Turbine shaft
3 = Snap ring
4 = Ball bearing
5 = Circlip 55Ý2
H940S4WSTM085
6 = Snap ring 55Ý3
7 = Rectangular ring
※ Install turbine shaft (2) (figure TM086) -

only necessary at a new-part installation!
① Insert snap ring SW30 (3) into the groove
of the turbine shaft (2), now introduce
turbine shaft (2) into the profile of the
drive shaft (1) until the snap ring (3)
snaps into the groove of the drive shaft
(1). (See in this connection also figure
TM085).
H940S4WSTM086
② Press ball bearing (4) upon the drive

shaft (1) until contact is obtained.
the ball bearing - see figure - groove for
snap ring SP100 (6) on top.
H940S4WSTM087
③ Squeeze in circlip 55Ý2 (5).

H940S4WSTM088
3-96
④ Insert pre-assembled drive shaft into the
H940S4WSTM089
⑤ Squeeze snap ring (6) into the groove of

the ball bearing (4).
H940S4WSTM090
⑥ Insert bearing outer race ("K4") into the

H940S4WSTM091
⑦ Insert complete clutch "K4".
H940S4WSTM092
3-97
(8) Clutch "KR"
H940S4WSTM093
1 = Shaft complete (with plate carrier, 9 = Snap ring (S = optional)

helical gear and circlip) 10 = Roller bearing
3-98
bores and lube oil supply bores (by
means of compressed air).
H940S4WSTM094

and 4) into the spool (2) and oil them.
(arrow) (assembly bore staked - however
ball free movable in the spool)!
H940S4WSTM095

carrier.
※ Insert pre-assembled spool (2) until
H940S4WSTM096
※ Line up cup spring pack (5) - stacking

and installation position - of the single
cup springs - see figure TM093.
※ Position cup spring on top - with grease -
centrally (assembly aid).
H940S4WSTM097
3-99
④ Line up support plate (6).
H940S4WSTM098
Immerse lined plates (inner plates)

prior to the assembly 30 minutes in oil
- oil according to ZF-List of lubricants
TE-ML 03.
H940S4WSTM099
⑤ Mount end shim (8) and squeeze in snap

H940S4WSTM100
Adjust/check Plate clearance

X = Plate clearance
F = 1.84~2.04 kgf·m (13.3~14.8 lbf·ft)
1 = Shaft
(with plate carrier - see figure TM093)
7 = Plate pack
ÂOuter plate 11EA
ÂInner plate 11EA
8 = End shim
9 = Snap ring (S = optional) H940S4WSTM101
※ Plate clearance KR : 2.2~3.3 mm
3-100
⑥ Press plate pack against shoulder (F =
about 1.84~2.04 kg·f (13.3~14.8 lb·f)).
Dimension I e.g.. ......................... 9.90 mm
H940S4WSTM102
⑦ Position end shim (8) and snap ring (9)

carrier against shoulder - see figure.
face of the plate carrier to the shim.
Dimension I e.g.. ......................... 7.10 mm
H940S4WSTM103
Example:
Dimension I e.g. .......................... 9.90 mm
Dimension II e.g. ...................... - 7.10 mm
gives Dimension X = 2,80 mm
(Plate clearance)
If the required total plate clearance e.g.
(2.2 till 3.3) should not be obtained,
correct it with a corresponding snap
⑧ Press bearing inner race (10) against

shoulder.
Check position (centric) of the cup spring
on top, see note of figure TM080.
Disassembly Note - figure TM250.
H940S4WSTM104
3-101
⑨ If disassembled - insert both bearing
outer races of the roller bearings (10 and
12) until contact in the plate carrier is
obtained.
H940S4WSTM105

(assembly aid).
⑩ Introduce plate carrier (11) until all inner
H940S4WSTM106
⑪ Press on bearing inner race (12) until the

rollers of the roller bearings (10 and 12)
have a playfree contact, however no pre-
load will be achieved.
At the same time, the plate carrier has to
be rotated several times to and fro, to
ensure the accommodation of the single
rollers.
and the bearing coordi-nation - see H940S4WSTM107
also disassembly note - figure TM247.
⑫ Determine thickness of the Circlip for the

Plate carrier fixing:
Determine thickness of the required
circlip (13) by means of feeler gauge
(from end face/bearing inner race to
outer locating face/groove).
Basis for an exact determination of the
r e q u i r e d c i r c l i p, i s t h e c o r r e c t
positioning of the roller bearing.
H940S4WSTM108
3-102
S e l e c t t h i ck n e s s o f c i r c l i p ( S =
optional) in such a way that a playfree
fixing of the plate carrier bearing will
be obtained.
⑬ Squeeze in the determined circlip (13).
Reset circlip until contact on the
groove base is obtained.
H940S4WSTM109
⑭ Press bearing inner race (14) against

shoulder.
H940S4WSTM110
⑮ Press bearing inner race (15) against

shoulder.
and the bearing coordination - see also
disassembly Note - figure TM254.
H940S4WSTM111
16 Squeeze in and engage rectangular

rings 30Ý2 (16 and 17).
H940S4WSTM112
3-103
(9) Clutch "KV"
H940S4WSTM113
1 = Shaft complete (with plate carrier, 9 = Snap ring (S = optional)

helical gear and circlip) 10 = Roller bearing
※ Pre-assemble clutch "KV" as clutch "KR" - see figure TM094~112.
3-104
① Pre-assembled clutches "KR" - "KV" and
"K1".
H940S4WSTM114
② Insert bearing outer race ("KV") into the

※ Pay attention of the installation position
H940S4WSTM115
③ Insert complete clutch "KV".
H940S4WSTM116
④ Insert bearing outer race ("KR") into the

H940S4WSTM117
3-105
⑤ Insert complete clutch "KR".
H940S4WSTM118
⑥ Insert bearing outer race ("K1") into the

※ Pay attention of the installation position
H940S4WSTM119
⑦ Insert complete clutch "K1".
H940S4WSTM120
⑧ Total view of the clutches in the gearbox

housing /part II.
Clutch arrangement:
1 = VA
2 = K1
3 = KV
4 = KR
5 = K4
6 = K2
7 = K3 H940S4WSTM121
3-106
(10) Gearbox housing/Converter bell
① Legend refer figure TM122~124
1 = Converter bell
2 = Shaft seal 55Ý75Ý8
3 = Bearing bush
H940S4WSTM122
② Install shaft seal (2) into the converter

bell (1).
※ Shaft seal installation position - sealing
lip facing the oil chamber - (see draft).
Cover outer shell of the shaft seal with
sealing compound loctite (Type-No. 574)
(S) Driver 5870 048 219
H940S4WSTM123
③ Insert bearing bush (3) with sealing

compound loctite (Type-No. 574) until
contact is obtained.
Now, oil bearing bush.
(S) Driver 5870 048 219
H940S4WSTM124
④ Screw in 2 adjusting screws (M10) into

the gearbox housing/ Part I (outer hole
circle/converter bell screw connection).
Cover mounting face (contact face) of
converter bell/gearbox housing (part I)
with sealing compound loctite (Type-No.
574).
Unite gearbox housing/par t I with
converter bell.
(S) Adjusting screws (M10) 5870 204 007 H940S4WSTM125
3-107
⑤ Mount bearing bush - with sealing
compound loctite (Type-No. 574) - into
the stator shaft.
Now, oil bearing bush.
H940S4WSTM126
⑥ Screw in 2 adjusting screws (M10).

Insert pre-assembled stator shaft.
H940S4WSTM127
⑦ Fasten stator shaft by means of socket

head screws.
MA = 4.7 kgf·m (33.9 lbf·ft)
H940S4WSTM128
⑧ Insert all bearing outer races into the

gearbox housing/part I (make adhere
with grease - assembly aid).
Clutch arrangement:
1 = VA 2 = K1
3 = KV 4 = KR
5 = K4 6 = K2
7 = K3
H940S4WSTM129
and the bearing coordi-nation - see
3-108
⑨ Remove adjusting screws and screw in
hexagon head screws of the converter
bell screw connection.
MA = 4.7 kgf·m (33.9 lbf·ft)
H940S4WSTM130
⑩ Cover mounting face (contact face) of the

two gearbox housing halves with sealing
Check centric position of the
rectangular rings on the different
shafts (assembly aid).
Unite gearbox housing halves carefully!
H940S4WSTM131
⑪ Screw in hexagon head screws - do not

tighten.
Locate bracket (3EA), position - see
Insert both cylindrical pins 12Ý24
(gearbox housing halves fixing).
※ Pay attention to the different screw
lengths.
H940S4WSTM132
⑫ Tighten hexagon head screws finally.

MA = 4.7 kgf·m (33.9 lbf·ft)
MA = 4.7 kgf·m (33.9 lbf·ft)
H940S4WSTM133
3-109
(11) Shaft seal - output to front axle
(only at version "with" output to front
axle - see also figure TM005~006)
Legend refer figure TM134~136
1 = Drive shaft
3 = Sealing cover (cover sheet)
4 = Gearbox housing
H940S4WSTM134
① Wet shaft seal (2) if

ÂOuter shell/rubber-coated : with spirit
ÂOuter shell/metal : cover with sealing
compound loctite (Type No. 574) and
install, with the sealing lip facing the oil
chamber.
Grease area of sealing lip/dust lip.
※ At application of the prescribed driver,
the exact installation position is obtained
- see also figure TM134. H940S4WSTM135
(S) Driver 5870 048 199
② Insert sealing cover (3) until contact is

obtained.
(S) Driver 5870 048 199
H940S4WSTM136
(12) Shaft seal/Output flange

(Output to the Rear axle)
2 = Output flange
3 = Gearbox housing
4 = Output shaft
H940S4WSTM137
3-110
① Install shaft seal (1) - with sealing lip
facing the oil chamber.
Wet rubber-coated outer shell of shaft
seal with spirit (assembly aid).
Grease sealing lip area.
(S) Driver 5870 048 200
※ At application of the prescribed driver,
the exact installation position is obtained.
H940S4WSTM138
② Line up pre-assembled output flange (2).
H940S4WSTM139
(13) Duct plate

① Position drive shaft against shoulder.
H940S4WSTM140
② Line up and engage rectangular ring

55Ý3.
※ Position rectangular ring - with grease -
centrally (assembly aid).
H940S4WSTM141
3-111
③ Screw in 2 adjusting screws (M8)
(arrows).
Line up flat gasket and make it adhere
with grease (assembly aid).
(S) Adjusting screws 5870 204 011
H940S4WSTM142
④ Insert orifice.
ÂTorque limit (M5)
MA = 0.25 kgf·m (1.84 lbf·ft)
H940S4WSTM143
⑤ Insert ball and compression spring

(check valve).
H940S4WSTM144
⑥ Line up duct plate until contact is

obtained and fasten by means of socket
head screws (torxform).
Tightening sequence of screws - inner
screws first - and continuing toward
outward.
MA = 2.35 kgf·m (16.7 lbf·ft)
(S) Insert TX 40 5873 042 004
H940S4WSTM145
3-112
1 = Solenoid valve/Differential lock
2 = Solenoid valve/Parking brake
3 = Solenoid valve/
Front axle disconnection
4 = Duct plate
5 = Shift control (Control circuit II)
6 = Shift control (Control circuit I)
H940S4WSTM146
⑦ Solenoid valve - components:

1 = Screw cap
2 = Coil
3 = O-ring 21.95Ý1.78
4 = Valve body
5 = O-ring 16.36Ý2.2
6 = O-ring 12.42Ý1.78
7 = O-ring 10.82Ý1.78
H940S4WSTM147
⑧ Screw in valve body (4) with O-rings (5,

6, 7).
See also note, figure TM146.
ÂTorque limit (3/4-16 UNF-2B)
MA = 2.75 kgf·m (19.9 lbf·ft)
H940S4WSTM148
⑨ Line up coil (2) with O-r ings (3)

(installation position - see figure TM146)
and fix with screw cap (1).
ÂTorque limit
MA = 0.61 kgf·m (4.43 lbf·ft)
H940S4WSTM149
3-113
(14) Install Shift control complete
Complete assembly of the shift control -
see Section 2) ASSEMBLY - ELECTRO-
HYDRAULIC SHIFT CONTROL - figure
TM301~329.
Control circuit II
See figure TM150.
H940S4WSTM150
① Insert 2 adjusting screws (M6) - see

arrows.
H940S4WSTM151
② Line up intermediate plate (1).

※ It is not permitted to re-assemble the
intermediate plate after opening the
threaded joint shift unit/gearbox housing.
In case of repair it is always necessary to
mount a new intermediate plate.
H940S4WSTM152
③ Line up complete shift control/control

circuit II (1).
H940S4WSTM153
3-114
④ Fasten complete shift control/control
circuit II by means of hexagon head
screws and washers (1).
H940S4WSTM154
⑤ ÂTorque limit (M6/10.9Ý55)

0.97 kgf·m (7.0 lbf·ft)
H940S4WSTM155
Component - control circuit I

⑥ See figure TM116.
H940S4WSTM156
⑦ Insert 2 adjusting screws (M6) - see

arrows.
H940S4WSTM157
3-115
⑧ Line up intermediate plate (1).
※ It is not permitted to re-assemble the
intermediate plate after opening the
threaded joint shift unit/gearbox housing.
In case of repair it is always necessary to
mount a new intermediate plate.
H940S4WSTM158
⑨ Line up complete shift control/control

circuit I (1).
H940S4WSTM159
⑩ Fasten complete shift control/control

circuit I by means of hexagon head
screws and washers (1 and 2).
1 = M6Ý60
2 = M6Ý75
H940S4WSTM160

0.97 kgf·m (7.0 lbf·ft)
0.97 kgf·m (7.0 lbf·ft)
H940S4WSTM161
3-116
(15) Hydraulic pump
① Oil components of the pump and insert
them into the pump housing (1).
Legend refer figure TM162~164:
1 = Pump housing 4 = Pump wheel II
2 = O-ring 5 = Cylindrical pins
3 = Pump wheel I
of the pump wheels - inser t pump H940S4WSTM162
wheels with the chamfered tooth side

showing down-ward - see also
② Mount pump cover.
H940S4WSTM163
③ Insert O-rings (see arrows).

1 = 40.95Ý2.62
2 = 94Ý3
Locate O-rings with grease (assembly
aid).
H940S4WSTM164
④ Legend refer figure TM165~170:

1 = Pump
2 = O-ring 36Ý2.5
3 = Axial washer
4 = Axial needle cage
5 = Angle disk
6 = Stop sleeve
7 = Central shaft
H940S4WSTM165
3-117
⑤ Line up axial washer (3) and axial needle
cage (4).
H940S4WSTM166
⑥ Mount angle disk (6)

see figure TM165.
H940S4WSTM167
⑦ Insert O-ring 36Ý2.5(2).

Grease O-ring (assembly aid).
H940S4WSTM168
⑧ Line up stop sleeve (6).

The spacing sleeve has to be mounted
on the pump (as illustrated) and not
asasembled on the central shaft –
ensures the operational funktion.
H940S4WSTM169
3-118
⑨ Insert central shaft (7) until contact is
obtained.
※ Installation position - see figure TM165.
H940S4WSTM170
⑩ Mount pre-assembled pump.
H940S4WSTM171
Position pump evenly against shoulder,

using socket head screws and fasten it.
MA = 11.7 kgf·m (84.8 lbf·ft)
H940S4WSTM172
⑪ Install filter.
Carry out filter assembly - according to
specification/see filter shell (ZF -
original filter).
H940S4WSTM173
3-119
(16) Converter
① Position 1 shim each (s = 1.00 mm) upon
the diaphragm mounting webs (4Ý).
H940S4WSTM174
② Mount diaphragm (2 pieces).

Pay a t t e n t i o n t o t h e i n s t a l l a t i o n
position.
Spot-welded reinforcement disks of the
diaphragm always exter nal - see
arrows.
arrows
H940S4WSTM175
③ Fasten diaphragm by means of hexagon

head screws (equippedwith washer).
Pay attention to the washers installed
under the diaphragm - see figure TM174.
Insert hexagon head screws with loctite
(Type-No. 262).
MA = 4.7 kgf·m (33.9 lbf·ft)
H940S4WSTM176
④ Introduce complete converter until profile

splines of central shaft, turbine shaft and
stator shaft are accommodated.
H940S4WSTM177
3-120
⑤ Control dimension for lined up converter -
from diaphragm on top to mounting face/
converter bell (see figure) L = about 59
mm.
※ The indicated control dimension serves
only for the converter assembly, however
not for engine/transmission mounting.
(S) Straightedge 5870 200 022
H940S4WSTM178
⑥ Secure converter by means of quick

hardener (transport protection).
H940S4WSTM179
⑦ Install bleeder (arrow).

H940S4WSTM180
⑧ Mount temperature sensor (1) with

O-ring 11Ý2.
ÂTorque torque
MA = 2.5 kgf·m (18.4 lbf·ft)
Mount inductive sensors (1) with O-ring
15Ý2.
ÂTorque torque
MA = 3.1 kgf·m (22.1 lbf·ft)
H940S4WSTM181
3-121
(17) Oil drain plug
① Screw in oil drain plug and remaining
screw plugs (along with O-ring).
Position - see also various illustrated
tables page 3-35~36.
ÂTorque limit
1/2-20 UNF 1.1 kgf·m (8.1 lbf·ft)
9/16-18 UNF 3.6 kgf·m (25.8 lbf·ft)
3/4-16 UNF 2.9 kgf·m (20.7 lbf·ft) H940S4WSTM182
7/8-14 UNF 3.6 kgf·m (25.8 lbf·ft)

15/8-12 UNF 12.2 kgf·m (88.5 lbf·ft)
Prior to the commissioning of the unit,
pay attention to the indications,
respective specifications and
Instr uctions of the ZF-operating
Instructions as well as to the
specifications and instructions of the
vehicle manufacturer.
3-122

Group 4 Disassembly and Assembly

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Group 4 Disassembly and Assembly

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GROUP 4 DISASSEMBLY AND ASSEMBLY

1. ELECTRO-HYDRAULIC SHIFT CONTROL

(1) Loosen screw connection of the hydraulic

(2) Shift control component-control circuit "I"

③ Remove shift intermediate plate (1).

④ Replace 2 screws of the cover screw

⑦ Remove compression springs (2 pieces),

⑧ Remove solenoid valves.

※ Solenoid valve (Y3) is spring-loaded.

⑨ Take compression spring and spool of

⑪ Replace 2 screws of the cover screw

⑫ Take compression springs, shim and

⑬ Remove all screw plugs (along with

(3) Shift control component-control circuit "II"

② Loosen screw connection, remove cover

③ Separate plug connection from solenoid

⑤ Remove solenoid valves.

※ Solenoid valves are spring-loaded.

⑥ Remove spools and compression

⑦ Remove all screw plugs (along with

(1) Shift control component - control circuit "I"

② Control pressure valve (SDV)

③ Screw in 2 adjusting screws (M6), Line

④ Fasten cover with hexagon head screws

⑥ Converter safety valve (WSV)

⑦ Draft + Legend refer figure TM309~310

⑧ Shift valve (S-V/R)

Valve components - see figure TM308.

⑩ Insert solenoid valve (3EA), fasten with

⑪ Draft + Legend refer figure TM313:

⑭ Connect cable harness with solenoid

16 Fasten cover with hexagon head screws

18 Install screw plugs (along with O-ring).

(2) Shift control component - control circuit

① Insert compression spring and spools of

③ Insert solenoid valve (3EA), fasten with

④ ÂTorque limit (M5/8.8Ý12)

⑤ Insert cable harness (4 along with

⑧ Fasten cover with hexagon head screws

⑨ Install screw plugs (along with O-ring).

(1) Hydraulic pump

② Loosen socket head screws and

③ Pull central shaft out of the drive shaft.

⑤ Separate pump halves.

⑥ Mark installation position of the pump

Components are not exchangeable.

(2) Remove complete shift control component

③ Shift control (control circuit "I")

④ Loosen screw connection of the shift

⑤ Shift control (control circuit "I")

② Remove valve body, equipped with 3

③ Loosen screw connection and remove

(4) Fork flange/shaft seal (output to the

(5) Shaft seal (output to the front axle)

(7) Gearbox housing

③ Screw in 2 eye bolts and separate

④ Remove shaft seal.

⑦ Loosen stator shaft screw connection

⑧ Pull bearing bush out of the stator shaft.

⑨ Remove bearing outer races out of the

⑪ Pull bearing bush out of the converter

(8) Clutches, drive shafts and output shafts

② Unhook and remove both rectangular