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TRANSMISSION COUPLING

230 MECHANICAL FLEXIBLE COUPLING 270 TORQUE CONVERTER

Fluid coupling

Description

The fluid coupling receives motion from the engine (1) and transmits it to the gearbox (2) via the shaft (3). The engine (1) transmits motion to the flywheel (4), which carries
the impeller (5). As the impeller rotates, it picks up oil and flings it against the vanes of the turbine (6), causing it to rotate together with the shaft (3) on which it is mounted. A
the speed of the engine (1) increases, the quantity of oil displaced by the impeller (5) also increases, as also does the driving torque transmitted to the turbine (6) by the
impeller (5). 1
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TORQUE
CONVERTER
TYPE OF OIL:
Voith‐Hi‐fluid p/n 04432598 20-litre drum
Fill quantity: 13 litres

Remove grilles from the intermediate housing

(INDICATED IN DRAWING) to
drain and top up
the torque converter

Min 10 litres Max 13 litres 2

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TORQUE CONVERTER

P.T.O. and pump drive shaft

Transmission drive shaft

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RIGHT HAND SIDE VIEW

04431661 n LSA n MOT
Pressure test port 04438438 0.010.2942.0
main clutch 21 bar
04431661

0.010.1214.4

2094 009 015 Mech. Ratio 1.19

2094 009 018 Mech. Ratio 1.29

Components
04431690  red
1. Transmission hydraulic pump Normally closed contact
2. Hydraulic transmission control valve
3. 4WD drive shaft 04438438 04438436 04431661 04416649
4. Transmission oil low pressure sensor
n HK n AB 4WD T°
5. Transmission oil temperature sensor 21 bar
6. 4WD control solenoid valve
7. Transmission oil suction line filter
8. Odometer speed sensor (nAb) Pierce tube for pressure test point
9.
10.
Clutch speed sensor (nHk)
Rear power take-off
four wheel drive 21bar 4WD off 0 bar 4WD on 4
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MECHANICAL RATIOS AND TYRES

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LEFT HAND SIDE VIEW

The transmission can be divided into these sections:

A. Engine-transmission coupling
B. Gearbox
C. Rear axle
D. Rear PTO

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TOP VIEW

10 Nm

Pressure test port

for centre clutch
21 bar Tightening torque for stem
proportional solenoid valv
10 NM

Components
1. Left hand brake cylinder
2. Start enable sensor
3. Speed sensor (Nlsa)
4. Speed sensor (Nlse)
5. Creeper engagement control shaft
6. Gearspeeds control shaft
7. Main clutch control solenoid valve
8. Right hand brake cylinder
9. Rear PTO control solenoid valve
10. Differential lock control solenoid valve
11. 750 PTO selection solenoid valve
12. 100 PTO selection solenoid valve
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REAR END VIEW

DF GEAR EP 90 LS DF GEAR EP 90 LS

DF TOP MULTIFUNCTION Components
1. Lift cross shaft
2. Right axle housing
3. Final drive unit oil filler/level plug
4. Rear PTO speed sensor
5. Left axle housing
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ZF SENSORS
max. 6.9 Volt
40 mm
OUTPUT ~ ∏ ∏ ∏
04438352 Nlse T7200 Shift + Shuttle min. 0.7 Volt
P.T.O. Rear

53 mm
X max.
X max1.5+mm
1.5mm

04438450 Nab T7100 Shift + Shuttle

Nhk T7200

77.75 mm

ZF
0.010.3342.2 Nhk T7100

83.25 mm

04438438 Nlse T7100 Shift + Shuttle

Nlsa T7300 Shift + Shuttle

95 mm

04438449 Nlsa T7100 – T 7200 Shift + Shuttle

100 mm

PIN 3 = POWER
0.010.2942.0 Nlse T7300 Shift + Shuttle
PIN 2 = SIGNAL

125 mm PIN 1 = EARTH

~ 18 KΩ

04438436 Nab T7200 Shift + Shuttle

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TEST INSTRUMENTS

Multitester
P/n 5.9030.490.4/10

KIT
5.9030.743.4 10
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TECHNICAL DIAGRAM

Components 24 - 26
1. Internal combustion engine
2. Coupling joint
3. Hydraulically operated 8-speed gearbox (4 forward, 4 reverse)
4. Creeper unit 24 -49 mech. ratio 1.1997
5. Main clutch
6. Power take-off driving hydraulic pumps
26 -49 mech. ratio 1.2997
7. Mechanically operated 6-speed gearbox
8. Pinion 49
9. 4WD engagement clutch
10. Front axle power take off

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MECHANICAL DIAGRAM
0.900.0057.0

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KEY

1. Hydraulically-operated gearbox
2. "C" clutch
3. "A" clutch
4. Creeper unit
5. Creeper unit synchronizer
6. Main clutch
7. Hydraulic pumps drive gear
8. Mechanical gearbox
9. 3rd/4th gear synchromesh
10. 5th/6th gear synchromesh
11. 1st/2nd speed synchromesh
12. Rear PTO drive shaft
13. 1st/2nd gear drive shaft
14. Pinion
15. 4WD clutch
16. Creeper unit driven shaft
17. "B" clutch
18. "F" clutch
19. "G" clutch
20. "D" clutch 13
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BRAKES

1. Differential lock
2. Axle housing
3. Differential
4. Brake apply mechanism
5. Brake assembly
6. Halfshaft
7. Hub
8. Axle housing
9. Epicyclic first reduction
10. Planet pinion, first reduction
11. Epicyclic second reduction
12. Planet pinion, second reduction
13. Annulus gear, second reduction
14. Annulus gear, first reduction
15. Crown wheel

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P.T.O. REAR

Components
1. P.T.O. drive shaft
2. P.T.O. clutch
3. P.T.O. 1000 drive gear
4. PTO speed selector
5. P.T.O. 750 drive gear
6. P.T.O. output shaft
7. Power take-off
8. P.T.O. 750 driven gear
9. P.T.O. 1000 driven gear

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CLUTCH PEDAL AND ASSOCIATED DEVICES

Remove the instrument panel to access

the clutch pedal compartment Unplug the potentiometer connector Remove the potentiometer

With A.R.T. and SDF Analyser

SDF
ANAL :
YSER

Potentiometer Adjustment Check end float (from 0.1 to 0.6 ) Adjust the position of the sensor relative
Pedal not depressed 0.8 – 0.9 V If necessary, adjust by turning the bolt. to the lever by turning the nuts.
Pedal depressed 4.1 V Distance "D" between lever and sensor 0.5-1 m
Travel A = 155 mm
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POWER SHUTTLE MAIN CLUTCH

The main clutch is an oil-immersed, hydraulically operated multi-disc assembly. Operation of the clutch is entirely
automatic, and piloted by the electronic control unit through the agency of the clutch pedal position sensor. The
system is equipped with a clutch solenoid valve that directs fluid under pressure to the main clutch, according to
the travel of the clutch pedal, thereby providing the necessary force.

Key
1. Clutch pedal
2. Clutch pedal position sensor
3. Transmission ECU:
4. Transmission gear pump
5. Proportional solenoid valve operating the clutch
6. Main clutch
Can be calibrated with SDF Analyser or ART
0,900.0058.2 Hk Shuttle

Caution:
ALWAYS IMMERSE
THE CLUTCH IN
OIL BEFORE
Previous ASSEMBLY

Current

Clutch discs adopted in production as of 25/05/2008, cutting in

from transmission serial n° 1667276 Stuck Liste 2094 009 015 17
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L – M – H - S TRANSMISSION HYDRAULIC UNIT

Key

B1 Breather valve
G1 Selection valve for A/B or F/G clutches
S1 Relief valve
H2 Engagement valve for C/D clutches
H1 Engagement valve for A/B or F/G clutches
Y3 Pilot solenoid valve for engagement valve H2
Y4 Pilot solenoid valve for engagement valve H1
Y1 Pilot solenoid valve for clutch selection valve G1
Y5 Pilot solenoid valve for road/field selection valve
Y2 Pilot solenoid valve for C or D clutch selection valve G2
P3 Pilot pressure regulating valve
G2 Clutch selection valve for C or D clutches
P4 General pressure regulating valve
U Selection valve for road/field operating mode
P1 Pressure modulating valve
P2 Two stage valve
R1 Reset valve Y2 - Y5 – Y1 0441 6685
Y4 – Y3 0443 6315
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L – M – H - S TRANSMISSION HYDRAULIC UNIT

Caution be certain Caution if valve Caution if valve P3 is locked up, in certain

to install the spool the right B1 is locked up, this can instances this can result in breakage of the
way round prolong engagement retaining forks for solenoid valves Y3 and Y4
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SHUTTLE VALVE ASSEMBLY

0441 6685 8 – 9 BAR

Key

Y6 Pilot solenoid valve for FORWARD drive

Y7 Pilot solenoid valve for REVERSE drive
VR FORWARD/REVERSE selection spool valve
S2 Relief valve
1 Neutral recentring device
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CLUTCH OIL DUCTS

Having removed the solenoid valve assembly with the
relative seals, the internal fluid-tightness of the powershift
clutches can be tested with compressed air.

Use a minimum pressure of 8-10 bar.

Blow air into the holes communicating with the clutches,

and listen for the sound of the discs compacting.

Remove the air gun quickly several times (4-5)

after directing air repeatedly into the holes, so as to detect
the return of air that will confirm a fluid-tight seal.

This test is conducted principally to establish whether or not

the transmission requires attention.

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HYDRAULIC CLUTCH TEST POINTS

COORDINATION OF SOLENOID VALVES

SOLENOID
VALVES REVERSE FORWARD

CLUTCHES

POINTS
PRESSURE

S‐V ACTIVATED
S‐V BRIEFLY
ACTIVATED

*
PROPORTIONAL S‐V
04431690 21 bar pressure
general
0.900.0069.0

0.010.2802.3 Complete assembly
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SUNDRY ADJUSTMENTS

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MAIN CLUTCH, T7336 PS TRANSMISSION

Shim for adjustment of disc pack end float 
End float from 6.3 to 6.7 

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Measurement “ I “
Fit the piston on the shaft without seals

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Fit the pressure plate on the piston Position the 3 springs 120° apart
on the pressure plate.

Fit the end plate on the clutch hub Position the plate with the clutch hub as shown
in the picture.
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Load the springs with the aid of a press Distance "X"

Fit the circlip Measurement “ X “ e.g. 55.75 mm

Measurement “A” (thickness of pack of plates)

Thickness of single steel plate e.g. s = 2.85
Overall thickness of pack of plates
Measurement “ A “ s = 22.80 mm

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Measurement "B" (thickness of pack of discs)

Thickness of single friction disc e.g. s = 2.55
Overall thickness of pack of discs Measurement “ B “ s = 22.95 mm
Calculation example "A"
Measurement “ A “ e.g. 22.80 mm
Measurement “ B “ e.g. +22.95 mm
Measurement “ Y “ e.g. 45.75 mm

Calculation example

Measurement “ X “ e.g. …………. 55.75 mm

Measurement “ YI “ e.g. ……… .- 45, 75 mm
10.00 mm
Clearance 6.7 – 0.4 …… .- 6.50 mm
Thickness s = 3.50 mm

Assembly of the main clutch

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Fit the shim of calculated thickness = 3.50 mm Fit the plate 7

Fit the single discs and plates of the pack 2) Position the friction disc.
in alternation on the hub WARNING:
as illustrated Before assembly, immerse the discs
Fit the circlip. in oil!
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Fit the steel plate in the sequence indicated:

Add the pressure plate Use the special tool to secure the
pack of discs

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Pressure side

Oil and insert the seal rings

See figure alongside

Position the piston springs Add the piston, complete with springs,
using grease to the preassembled clutch pack.

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Compress the piston, making sure that the Fit the plugs with Loctite 270
gear teeth of both components are centred
Fit the circlip

Pressure side

Fit the seal ring (see drawing)

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Check the clearance 6.7 – 0.4

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Dimension “ A “ …………239.40 Dimension “ B “ ………….206.40

Example "C"
Dimension “ A “ ………… 239.40 mm ‐
Dimension “ B “ …… 206.40 mm ‐
Dimension “ C “ ………… 31.00 mm ‐
Clearance       ………… 0.30 mm ‐

Thickness =                     1.70 mm  

Dimension “ C “ ………….31.00

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ROLLING TORQUE 0.7 Nm

END FLOAT 0.03 mm ASSEMBLY OF PISTON

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CHECKING THE FRICTION DISC CLEARANCE = 3.7+/‐0.25

PUSH THE PACK OF DISCS DOWNWARDS AND
MEASURE THE DISTANCE BETWEEN DISC AND HOUSING
MEASUREMENT “ I “ E.G. …………7.60mm

EXAMPLE CALCULATION:
MEASUREMENT “I” ………….  7.60 mm
MEASUREMENT “II” ………. – 3.85 mm LOCATE THE ENDMOST DISC IN CONTACT WITH THE CIRCLIP
AND MEASURE THE DISTANCE BETWEEN HOUSING AND DISC
DIFFERENCE =             3.75 mm   MEASUREMENT “II” E.G. ………… 3.85   
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FORMULA:  S = 5.14 ‐ A – (+ /‐ X)

FORMULA / TOLERANCE ON PINION E.G. + 0.05 mm
S=  5.14 – A – 0.05
Formula / TOLERANCE ON PINION E.G. – 0.05 mm
S= 5.14 – A + 0.05

S = THICKNESS
5.14 = DISTANCE FACTOR
A = DISTANCE MEASURED
X = PINION TOLERANCE (185.1 THEORETICAL ASSEMBLY DISTANCE) 

DIMENSION “A” ………… 2.00 mm

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EXAMPLE "C" 
S = 5.14 ‐ A – (+ /‐ X)
S = 5.14 – 2.00 – 0.05 
S = 3.09  

DIMENSION “ X “ ………………. + 0.05

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04433972 0.25 mm 2 notches
04433973 0.20 mm 1 notch

Crownwheel / Pinion backlash
0.18 – 0.23 mm

Theoretical crown wheel assembly distance
with theoretical tolerance +/‐ 0.045 mm 

185.1 Theoretical
Pinion assembly distance 

Measure distance between face of Diff housing and centre of Crown wheel (C)

Se = a 190.000 – 190.035 gasket with 1 notch
Se = a 190.695 – 190.000 gasket with 2 notches

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P.T.O. SHAFT REAR

6 splines

Z = 6 (1  3/4) Z = 6 (1  3/8)
P/n = 04452772 P/n = 04452907

20/21 splines

Z = 20 (1  3/4) Z = 21 (1  3/8)
P/n = 0.010.3800.2 P/n = 04452908

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