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Table of Contents

01/2018 Rev. 1

EA(B)O-6X06

Table of Contents

3. Disassembly and Assembly .................. 41

Transmission Disassembly ................ 42
Front Case ......................................... 54
Rear Case ......................................... 56
Shift Yokes and Rails ......................... 59
Synchronizers .................................... 66
Input Shaft ......................................... 69
Mainshaft ........................................... 71
Countershaft ...................................... 93
Transmission Assembly ..................... 95
End Play Adjustment ....................... 110

4. Electro-Hydraulic Control Unit ............ 114

Characteristics and Operation ......... 114
Hydraulic Diagram ........................... 126

Connector Identification

................... 127

Troubleshooting ............................... 128
Disassembly and Assembly............. 132

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Содержание EABO-6106

Страница 1: ...EA B O 6X06 January 2018 Rev 1 Eaton Transmission Service Manual...

Страница 2: ...1 General Information 5 Introduction 5 Warnings and Precautions 6 Characteristics and Identification 7 Gear Ratio 9 Lubrication 10 Tightening Torques and Sealants 12 Precautions 15 Special Tools 18 E...

Страница 3: ...Case 54 Rear Case 56 Shift Yokes and Rails 59 Synchronizers 66 Input Shaft 69 Mainshaft 71 Countershaft 93 Transmission Assembly 95 End Play Adjustment 110 4 Electro Hydraulic Control Unit 114 Charac...

Страница 4: ...operation and functioning Tips for the Driver Power Flow and Troubleshooting 3 Disassembly and Assembly This section contains procedures for disassembling assembling and adjusting the transmission com...

Страница 5: ...time without notice Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalen...

Страница 6: ...sors installed in the electro hydraulic control unit and in the transmission that send signals to the TCU to perform the management of the general operation of the electro hydraulic control system and...

Страница 7: ...tified by the model designation and serial number This information is stamped on the identification plate fixed to the transmission case Forward speeds Design level Nominal torque capacity x100 N m WA...

Страница 8: ...gear set 44 29 1 52 1st speed ratio M C 1st speed x 1 52 input gear set 49 12 x 1 52 6 19 This means that the 1st speed gear ratio is 6 19 1 or in other words with the transmission shifted into the 1s...

Страница 9: ...ission in use As a general guide the following chart provides lubricant oils and maintenance interval recommendation for oil level check and oil change CAUTION Always follow the vehicle manufacturer m...

Страница 10: ...r shift lever housing cover etc Correct Oil Level Incorrect Oil Level Electro Hydraulic Control Unit The oil level of the electro hydraulic control unit may be checked either on the vehicle or removed...

Страница 11: ...2 15 9 11 59 Screw 12 14 9 10 62 M5 x 0 8 x 10 Screw 12 15 9 11 64 M8 x 1 25 x 20 Screw 19 26 14 19 Shift Yokes and Rails 82 M8 x 18 5 Torx Screw 38 44 28 32 Apply Loctite 262 onto thread 102 M14 x 1...

Страница 12: ...Corning 780 sealant onto the contact face 131 M8 x 1 25 x 16 Screw 19 26 14 19 132 M8 x 1 25 x 45 Screw 19 26 14 19 Apply Dow Corning 780 sealant onto the contact face 133 Ball stud 110 120 81 88 138...

Страница 13: ...l Wait for the alcohol to dry on the screw and apply compressed air into the hole to dry it completely Apply adhesive threadlocker on the screw thread in the central area that will be housed into the...

Страница 14: ...tion until the bearings are thoroughly clean Never drive the air jet directly to bearings in order to rotate them in high speed That can damage bearings Synchronizer assemblies Avoid bad handling of s...

Страница 15: ...d areas to determine whether they are suitable for reuse or replacement After inspection dip the needle roller bearings in an oil bath and then wrap them in a lint free cloth or paper so as to protect...

Страница 16: ...sembled than a premature overhaul to replace these parts in a future time An oil leakage through a worn seal may result in failures of other more expensive components of the transmission The sealing e...

Страница 17: ...edures are performed using special tools specifically recommended for this purpose These special tools are required for properly servicing the transmission and its use will prevent damages to the tran...

Страница 18: ...133 Puller countershaft 3rd speed gear Ref Tool Description EEA 17134 Puller countershaft bearings use with EEA 17103 EEA 17135 Puller support mainshaft rear bearing cup use with EEA 17136 EEA 17136 P...

Страница 19: ...7406 Support mainshaft end play measurement EEA 17501 Driver Ref Tool Description EEA 17503 Device to block mainshaft output yoke EEA 17504 Device to block mainshaft output flange use with EEA 17503 E...

Страница 20: ...48 2A Side shield 2B Screw 2C Top shield 2D M8 x 25 Torx screw 2E Lifting plate 2F Clamp 2G M8 x 1 25 x 25 screw 50 Bracket lower 51 M8 x 30 screw 52 Grounding strap 53 TCU and software assy 54 M6 x...

Страница 21: ...O ring 14 Recirculation breather filter 15 Repair kit position sensor pwm 16 Cable harness 17 Repair kit recirculation tube includes item 18 18 Recirculation tube clamp 19 Repair kit motor cover incl...

Страница 22: ...item 35 35 Hydraulic pump screw 36 Motor pump coupling 37 Repair kit clutch actuator tube includes item 36 38 Nylon clamp 39 Repair kit proportional flow valve 40 Repair kit proportional pressure val...

Страница 23: ...yoke includes item 80 80 Shift yoke pad 81 Gear selector 82 M8 x 1 0 x 18 5 Torx screw 83 Main shift rail 84 Shift and selection block 85 Shift rail rear support 86 5th 6th Shift rail 87 5th 6th Shif...

Страница 24: ...6 5 Socket screw 121 M8 x 1 5 x 25 Screw 122 Adapter plate 123 M6 x 1 0 x 25 Allen screw 124 Cover 125 M6 x 1 0 x 14 Screw 126 Oil drain plug 127 Inspection cover 128 Expansion plug 129 Clutch releas...

Страница 25: ...r 146 Spring 147 Shift actuator plug 148 M8 x 1 25 x 45 Screw 149 Oil seal 150 Output yoke 151 Washer 152 M16 x 1 5 x 55 Bolt 153 Threaded plug 154 Bracket explo006 18 155 Reverse idle gear shaft reta...

Страница 26: ...g 183 Snap ring 184 Ball 185 Thrust washer 186 4th Speed gear 187 Needle roller bearing 188 Snap ring 189 4th Speed synchronizer cone 190 Synchronizer ring 191 3rd 4th synchronizer assy includes item...

Страница 27: ...im 0 050 0 070 mm 210 Shim 0 087 0 113 mm 210 Shim 0 175 0 225 mm 210 Shim 0 275 0 325 mm 210 Shim 0 362 0 438 mm 210 Shim 0 462 0 538 mm 210 Shim 0 560 0 640 mm 210 Shim 0 660 0 740 mm 210 Shim 0 760...

Страница 28: ...0 070 mm 226 Shim 0 087 0 113 mm 226 Shim 0 175 0 225 mm 226 Shim 0 275 0 325 mm 226 Shim 0 362 0 438 mm 226 Shim 0 462 0 538 mm 226 Shim 0 560 0 640 mm 226 Shim 0 660 0 740 mm 226 Shim 0 760 0 840 m...

Страница 29: ...ve gear 4 5th 6th speed synchronizer assy 5 Mainshaft 6th speed gear 6 Mainshaft 4th speed gear 7 3rd 4th speed synchronizer assy 8 Mainshaft 3rd speed gear 9 Mainshaft 2nd speed gear 10 1st 2nd speed...

Страница 30: ...aft what allows both shafts to rotate at different rotation speeds ESO 6106 6206 fluxo4 3 22 7 21 14 6 4 The torque along the countershaft 22 is transmitted to all the gears of the mainshaft 14 assemb...

Страница 31: ...32 2 Operation 01 2018 Rev 1 EA B O 6X06 ESO 6106 6206 fluxo1 ESO 6106 6206 fluxo2 Power Flow 1st Speed 2nd Speed...

Страница 32: ...33 EA B O 6X06 01 2018 Rev 1 2 Operation ESO 6106 6206 fluxo3 ESO 6106 6206 fluxo4 Power Flow 3rd Speed 4th Speed...

Страница 33: ...nation is due to the fact that in this speed the input shaft although it drives the countershaft together transfers the engine torque directly to the mainshaft without any gear reduction The coupling...

Страница 34: ...the second reduction 16 and 15 gear set of this speed and finally the torque is transferred from the reverse idle gear 15 to the mainshaft reverse gear 12 performing the third reduction 12 and 15 gear...

Страница 35: ...aged Replace yoke Instructions in the yoke vehicle s manual Warped or Repair or replace Requires specific unbalanced drive drive shaft procedure shaft Low lubricant level Fill with recommended Lubrica...

Страница 36: ...Instructions in this shaft or manual countershaft Hard shifting Malfunction of Verify and adjust Instructions in the clutch not clutch driving system vehicle s manual releasing Worn or damaged Replace...

Страница 37: ...ed parts Instructions in the flywheel bushing vehicle s manual or bearing Incorrect idle Adjust idle speed Instructions in the speed adjustment vehicle s manual Worn or damaged Replace rings Synchroni...

Страница 38: ...ening Torques not properly sealant and tightening and Sealants in this tightened or lack torque manual of sealant Cracked housing Replace or repair Requires specific or covers damaged parts procedure...

Страница 39: ...01 2018 Rev 1 EA B O 6X06 Troubleshooting Problem Probable cause Possible solution Reference Double shifting Double gear Reassemble system Instructions in this shifting interlock manual system assemb...

Страница 40: ...ring service for example shafts gears etc protect the jaws with an aluminum angle or other soft material to prevent damage to the part During assembly lubricate the following parts using the same lubr...

Страница 41: ...ctro hydraulic control unit shield 4 Disconnect the electrical connector from the TCU 6936 2 Remove the top electro hydraulic control unit shield CAUTION Make sure that the Electro Hydraulic Control U...

Страница 42: ...n screws securing the TCU to the bracket and remove the TCU Transmission Disassembly 0002 18 1 Unlock 2 Disconnect axially 3 Do not tilt the connector when disconnecting 1 2 3 6946 6 Unscrew the two s...

Страница 43: ...Unscrew the ground strap retaining screw and remove the strap and both the upper and lower TCU brackets 8 If necessary remove the four screws securing the TCU upper bracket to the lower bracket and r...

Страница 44: ...leeve 15 With a T40 Torx wrench remove the six retaining Torx screws securing the electro hydraulic control unit to the transmission and remove the control unit NOTE To break the seal and make easy to...

Страница 45: ...pecial tool EEA 17503 with tool EEA 17504 to block the mainshaft Figure B 22 With a sliding T handle and 24mm hex socket remove the output yoke or flange depending on the transmission model retaining...

Страница 46: ...emove the shift actuator 5974 6961 25 With a 27mm hex socket remove the speedometer sensor 6962 26 On the stand set the transmission vertically with the rear case facing up 27 With an 11mm hex socket...

Страница 47: ...en above Figure A and three from underneath Figure B the flange 6963 29 With an 11mm hex socket remove the reverse idle gear shaft retaining bolt and plate 30 Install the tool EEA 17141 with adapter E...

Страница 48: ...aring from falling underneath 33 With an 11mm hex socket remove retaining screws and the PTO cover NOTE With a soft hammer gently tap on the cover to break the seal 6968 34 Prior removing the transmis...

Страница 49: ...speedometer rotor 6988 37 With a 13mm hex socket remove the two pivot pins of the 5th 6th shift yoke one at each side of the case 6989 6981 38 With a T40 Torx wrench remove the retaining Torx screws f...

Страница 50: ...il when it is pulled up Hold the blocks to prevent them from falling as the shift rail is being removed 6986 42 With a pin punch remove two roll pins from the reverse shift yoke 43 Remove the reverse...

Страница 51: ...er the shafts fitting the input shaft and countershaft into their housings in the device 6482 47 After shafts and shift rails assembly is supported on the device EEA 17505 cut the strap used to hold t...

Страница 52: ...emove the 5th 6th shift yoke 6485 49 Remove the shift rails rear support 6497 50 Detach shift rails and yokes from the mainshaft and countershaft 51 Remove the mainshaft countershaft and input shaft f...

Страница 53: ...17107 and EEA 17144 not shown remove together the oil baffle installed underneath the input shaft front bearing cup and the input shaft front bearing cup 2 NOTE The oil baffle will be damaged during d...

Страница 54: ...ools EEA 17032 and EEA 17006 not shown assemble the countershaft front bearing cup 3 NOTE Do not install shims under countershaft or input shaft mainshaft front bearing cups End play adjustment is don...

Страница 55: ...ear case with its internal side facing up 2 Using special tools EEA 17136 and EEA 17137 1 remove the rear bearing cup from the countershaft and remove the end play shims 3 Using special tools EEA 1713...

Страница 56: ...e the mainshaft rear oil seal from the outside of the case or hit the seal from inside NOTE The rear oil seal will be damaged during disassembly Replace it with a new one during assembly The oil seal...

Страница 57: ...ly of the gear box during the measurement of the end play After measurement the correct quantity of shims should be installed by removing and re installing the bearing cup 4 Using special tools EEA 17...

Страница 58: ...hift rails that once disassembled should be reassembled very carefully to guarantee its proper functioning Identification of balls in the pictures for identification of the shift rails see Exploded Vi...

Страница 59: ...st remove the 3rd 4th gear shift rail 4 Remove the 1st 2nd gear shift rail 6 Remove balls pins and springs that are still inside the rails support 7 Once the shift rails are disassembled if necessary...

Страница 60: ...mbled later when the transmission is mounted to the stand after installation of the shafts and rails assembly to the front housing NOTE The correct side of assembly of the shift rails front support is...

Страница 61: ...ear shift rail while maintaining the balls in their housings with your finger in the position of the 3rd 4th gear shift rail Push the rail until the interlock ball snaps to the notch on the rail NOTE...

Страница 62: ...h a pin punch through the hole on the 3rd 4th gear shift rail 12 Install the 3rd 4th gear shift rail ensuring that the notches on its end are properly facing the positioner plug and interlock balls Pu...

Страница 63: ...in the hole that connects this rail to the previously installed interlock NOTE Use grease to keep the balls in their housings 16 Install one 7 9 mm ball in the 5th 6th gear shift rail on the transvers...

Страница 64: ...balls in their housings 18 After installing the spring insert the third 7 9 mm diameter ball Using a pin punch through the hole on the 5th 6th gear shift rail push and press the ball inside its housin...

Страница 65: ...gear Synchronizer with single synchronizer ring one for each gear used in the 3rd 4th 5th and 6th speed gears NOTE In case of repair of a synchronizer set do not replace parts separately Always replac...

Страница 66: ...4 Sliding clutch synchronizer sleeve Synchronizer cones The synchronizer cone of the 4th 5th and 6th speed gears on which the respective synchronizer ring works is removable and mounted on splines Th...

Страница 67: ...shaft Figures show the 6th speed gear without the cone exposing the splines and with the cone assembled EFM II coating EFM II Eaton Friction Material is a special coating used in some synchronizer rin...

Страница 68: ...isassembly 1 Remove the 5th gear synchronizer cone 1 2 Remove the oil baffle 2 from inside its housing NOTE The oil baffle will be damaged when disassembled Replace it with a new one during assembly 3...

Страница 69: ...h press with the front end facing up 2 Install the front bearing cone using the special tool EEA 17004 NOTE If needed heat the bearing to 120 C to facilitate the installation 3 Install a new oil baffl...

Страница 70: ...onizer cone 2 Remove the pocket bearing snap ring 4 Place the mainshaft in vertical position on a work bench with the pocket end facing up and the rear yoke end supported on the special tool EEA 17506...

Страница 71: ...A 17131 supported in the lower face of the 6th speed gear synchronizer cone remove together the cone the 6th speed synchronizer ring the 5th and 6th speed synchronizer hub and the pocket bearing cone...

Страница 72: ...0 Mainshaft 9 Remove the thrust washer and the positioning ball 10 Remove together the 4th speed synchronizer ring the synchronizer cone and the 4th speed gear 12 Remove the 3rd and 4th speed synchron...

Страница 73: ...g the special tool EEA 17131 supported in the lower face of the reverse speed coupling hub remove together the hub and the rear bearing cone 16 Remove the reverse speed gear 14 Place the protecting de...

Страница 74: ...assembly and Assembly 6096 6093 6092 6094 17 Remove the double needle bearing of the reverse speed gear 18 Remove the thrust washer snap ring 20 Remove the 1st speed gear 19 Remove the thrust washer a...

Страница 75: ...eedle bearings of the reverse speed gear 23 Remove the 1st and 2nd speed synchronizer assembly snap ring 24 Remove the sleeve and the three keys of the 1st and 2nd speed synchronizer NOTE Pay attentio...

Страница 76: ...nchronizer ring tricone assembly and the 2nd speed gear CAUTION Hold the shaft from underneath the press so it does not fall 27 Invert the position of the mainshaft in the press and place it now with...

Страница 77: ...snap ring 29 Place the mainshaft on the work bench once again with the pocket end facing up and supported on the special tool 30 Remove the double needle bearing of the 3rd speed gear 32 Remove the t...

Страница 78: ...79 EA B O 6X06 01 2018 Rev 1 3 Disassembly and Assembly 6119 34 Remove the 1st and 2nd speed synchronizer hub snap ring Mainshaft...

Страница 79: ...to protect the bearing seat 4 Now invert the shaft position and place this end with the protecting device in the tool on the bench placing the shaft with the rear yoke end facing up Heat the 1st and 2...

Страница 80: ...Install the 1st speed synchronizer ring tricone outer ring with the teeth side facing up matching the ridges on the ring to the slots on the hub 7 Install the 1st speed synchronizer ring tricone midd...

Страница 81: ...the elongated holes in the hub 10 Install the two needle bearings of the 1st speed gear NOTE Lubricate the bearings with oil for the gearbox 11 Install the 1st speed gear with the cone side facing the...

Страница 82: ...ball of the 1st speed gear thrust washer 14 Install the 1st speed gear thrust washer aligning the slot on the washer with the positioning ball 15 Install the thrust washer snap ring 16 Install the dou...

Страница 83: ...40 C and with special tool EEA 17029 and a hammer mount the hub in its position in the shaft until the hub touches the snap ring 19 With the special tool EEA 17027 and a hammer install the rear bearin...

Страница 84: ...slots on the hub 22 Install the 2nd speed synchronizer ring tricone outer ring with the teeth side facing up matching the ridges on the ring to the slots on the hub 23 Install the 2nd speed synchroni...

Страница 85: ...with oil for the gearbox 27 Install the 2nd speed gear with the cone side facing the synchronizer hub 28 Turn the gear until the tabs on the tricone synchronizer ring snap onto the elongated holes in...

Страница 86: ...washer snap ring 32 Install the double needle bearing of the 3rd speed gear NOTE Lubricate the bearings with oil for the gearbox 33 Install the 3rd speed gear with the cone side facing up 34 Install...

Страница 87: ...align and fit the slots on the hub to the ridges on the synchronizer ring 36 Install the 3rd and 4th speed synchronizer hub snap ring 37 Install the three keys and the 3rd and 4th speed synchronizer...

Страница 88: ...ings of the 4th speed gear NOTE Lubricate the bearings with oil for the gearbox 40 Install the 4th speed gear with the cone side facing the synchronizer hub 41 Install the positioning ball of the thru...

Страница 89: ...washer snap ring 44 Install the two needle bearings of the 6th speed gear NOTE Lubricate the bearings with oil for the gearbox 45 Install the 6th speed gear with the cone side facing the synchronizer...

Страница 90: ...align and fit the slots on the hub to the ridges on the synchronizer ring 48 With the special tool EEA 17026 and a hammer install the front bearing cone NOTE If needed heat the bearing to 120 C to fac...

Страница 91: ...92 3 Disassembly and Assembly 01 2018 Rev 1 EA B O 6X06 Mainshaft 6292 51 Install the 5th speed synchronizer ring with the teeth side facing up matching the ridges on the ring to the slots on the hub...

Страница 92: ...ar bearing cone 3 Place the countershaft vertically in a press with the front end facing up Supporting the countershaft by the lower face of the drive gear 1 press the shaft down and remove the drive...

Страница 93: ...t side facing the 3rd speed gear 6th speed gear 2 with the prominent side facing up Countershaft drive gear 1 with the prominent side facing the 6th speed gear 3 Using a tubular device EEA 17004 press...

Страница 94: ...input shaft gear with the cone side facing up 3 Position the mainshaft over the input shaft and fit the pocket bearing into its housing Make sure that the mainshaft is properly fitted and check if the...

Страница 95: ...hafts and shift rails assembly to the correct position on the front case After that remove for adjusting the assembly in the case and then reinstall NOTE Disengage all gears putting them in neutral po...

Страница 96: ...they do not come loose during its moving and installation into the front transmission case 9 Install the eye bolt EEA 17505 into the threaded bore at the end of mainshaft for lifting shafts and shift...

Страница 97: ...case with at least three capscrews 12 With a hoist lift shafts and shift rails assembly from the special base and position the assembly over the front case 14 After seating the shafts and rails assemb...

Страница 98: ...talled making the rail to pass through their holes Fit the lower end of the rail into the front support 18 Install and tighten selection lever 1 and gear selector 2 Torx screws to the specified torque...

Страница 99: ...ntact surfaces Tighten capscrews to the torque of 19 26 N m 14 19 Lb ft 6934 6988 21 Install the two pivot pins of the 5th 6th shift yoke one at each side of the case Use a 13mm hex socket NOTE Apply...

Страница 100: ...its retaining screws Perform the end play measurement and determine the number of shims required for adjustment see End Play Adjustment in this manual Otherwise proceed to the next step 25 Apply a con...

Страница 101: ...ex socket 27 Install the two retaining capscrews of the shift rails rear support Use an 11mm hex socket NOTE Aply Dow Corning 780 sealant onto the capscrews contact face Tighten to the torque of 19 26...

Страница 102: ...ul to prevent the needle roller bearing from falling underneath 6433a 5985a 5991a 31 Install the reverse idle gear cover and the eight retaining bolts Use an 9mm hex socket NOTE Apply Dow Corning 780...

Страница 103: ...to the torque of 14 20 N m 10 15 Lb ft 6961 6956 5974 34 Heat the output yoke to a temperature of 110 C to 120 C and position the yoke over the mainshaft rear spline Using a proper tubular device and...

Страница 104: ...ite 570 Eaton E677 threadlocker onto the plug thread Tighten to the torque of 20 34 N m 15 25 Lb ft 40 Install the clutch release fork fitting pivot points on the ball studs 6923 6926 If removed durin...

Страница 105: ...to the control unit contact surface with the transmission 6970 6949 46 Install the adapter plate 3 between the transmission front case and the clutch actuator cylinder flange 2 securing the actuator c...

Страница 106: ...with two retaining screws 6946 51 Install the third retaining screw securing the TCU lower bracket together with one end of the ground strap 48 With a 13mm open end wrench install the clutch actuator...

Страница 107: ...ith four Allen screws Secure the other end of the ground strap as shown in the figure using one of the TCU retaining screws 2 53 Connect the electrical connector 3 to the TCU 6939 CAUTION Observe the...

Страница 108: ...109 EA B O 6X06 01 2018 Rev 1 3 Disassembly and Assembly 55 Install the top electro hydraulic control unit shield 6936 Transmission Assembly...

Страница 109: ...e electro hydraulic control unit installed in the transmission 1 Place the transmission in the vertical position with the rear case facing up 2 Install the output yoke bolt and washer or use the speci...

Страница 110: ...ershaft end play or go back to the transmission assembly and continue from the point where the assembly was stopped Otherwise determine the shim pack thickness needed to adjust the mainshaft end play...

Страница 111: ...tool EEA 17403 on the countershaft 4th speed gear with the three magnets facing down positioning the device so that the projecting tab stay out of the PTO opening as shown in the figure The device sh...

Страница 112: ...r 7 If the countershaft end play reading in the dial indicator is within the specified limits go back to the transmission assembly and continue from the point where the assembly was stopped Otherwise...

Страница 113: ...transforming electrical energy into hydraulic energy through a DC electric motor and the oil pump It also maintains stable hydraulic pressure required for system operation where the working pressure...

Страница 114: ...anaged by an electronic unit TCU Transmission Control Unit The electro hydraulic control unit used on the EA B O 6X06 transmission is of LSC Linear Selection Control type The LSC system consists of tw...

Страница 115: ...positions and is controlled by two solenoid valves Position 1 Rest neutral position Position 2 Engagement of even gears Position 3 Engagement of odd gears Characteristics and Operation The components...

Страница 116: ...he oil pump It also maintains stable hydraulic pressure required for system operation where the working pressure ranges from 40 to 60 bar at 20 C Main Components 1 Pressure sensor 2 Oil recirculation...

Страница 117: ...ection of all electro hydraulic control unit components 0086 18 1 1 High pressure circuit channels in red 2 Actuating circuit channels in yellow 3 Return circuit channels in blue 4 Air breather and oi...

Страница 118: ...trol Unit Characteristics and Operation Oil Pump Even after the electric motor is shut down this circuit remains pressurized and the oil being pushed due to the work of the oil accumulator 0088 18 1 1...

Страница 119: ...chamber cover 4 Gear shift piston 5 Gear selection piston 6 Electrovalve EV 0 Actuates the clutch actuator 7 Electrovalve EV 1 Actuates the engagement of odd gears 8 Electrovalve EV 2 Actuates the eng...

Страница 120: ...cteristics and Operation 0091 18 1 Shift piston 2 Selection piston 1 2 Gear selection is performed by controlling the oil flow in one side of the piston by means of a spring in the opposite side 0092...

Страница 121: ...sor 1 2 3 4 3 Magnet 4 Spring chamber In both cases the positioning of the piston is monitored by a magnet and a position sensor where the magnet is attached to the piston and sends a magnetic field t...

Страница 122: ...engagement of odd gears EV 2 Actuates the engagement of even gears EV 3 Actuates the gear selection 0094 18 Actuating Circuit The high pressure circuits in red and the actuating circuits in yellow ar...

Страница 123: ...or gear shifting and clutch control There is no communication between the high pressure circuit and the oil return circuit which always works at low pressure EV 3 EV 2 EV 1 EV 0 0097 18 Oil Return Cir...

Страница 124: ...unction of allowing the passage of atmospheric air into the oil reservoir when the electric motor is turned on It allows the air to escape when the electric motor is turned off and the oil is returnin...

Страница 125: ...linder 2 Shift Piston 3 Selection Piston 4 Safety Valve 5 Pressure Sensor 6 Piston Accumulator 7 Check Valve 8 Filter 9 Hydraulic Pump 10 Reservoir 1 2 3 4 5 6 7 8 9 10 EV 0 Proportional Flow Valve EV...

Страница 126: ...lve EV3 Selection J05 Electrovalve EV2 Engagement Shifting J06 Electrovalve EV1 Engagement Shifting J07 Electrovalve EV0 Clutch J08 Selection Position Sensor J09 Shifting Position Sensor J13 Clutch Po...

Страница 127: ...oubleshooting manual Instructions in the troubleshooting manual Does not make clutch learning Learning conditions not respected Incorrectly assembled clutch Contaminated dirty clutch Clutch actuator f...

Страница 128: ...ontrol Unit Check DTC evaluation instructions in Troubleshooting Make the missed learning Check for correct TCU P N Instructions in this manual Instructions in the troubleshooting manual and in this m...

Страница 129: ...s in the troubleshooting manual and in this manual Instructions in the troubleshooting manual and in this manual Instructions in the troubleshooting manual and in this manual Instructions in the troub...

Страница 130: ...adjustment of the Electro Hydraulic Control Unit Check DTC evaluation instructions in Troubleshooting Instructions in the troubleshooting manual and in this manual Instructions in the troubleshooting...

Страница 131: ...n an environment free of dust and impurities and using an equally clean tray to support the unit and collect any oil leaks Where not expressly indicated in this manual there is no need to drain the sy...

Страница 132: ...ir Kit Replacement 142 Reservoir Replacement 144 Electric Motor Replacement 146 Hydraulic Pump Replacement 148 Non Return Valve Replacement 150 Selection Piston and Repair Kit Replacement 151 Coupling...

Страница 133: ...wivel stand 2 Secure the Electro Hydraulic Control Unit in a U support with two bolts and washers interposing a soft material between the parts to avoid damages 4 Install a plastic film on the reservo...

Страница 134: ...ted in this manual there is no need to exhaust the system oil Simply sealing the reservoir cap before replacing the parts see Preparation Before Disassembly operations 3 and 4 Remember that this is a...

Страница 135: ...the position of the connectors and clamps different diameters in order to avoid its inversion in the assembly 1 Loosen the electrical connections of the selection and coupling sensors 2 To release the...

Страница 136: ...fied torque 6 Using a Torx T20 wrench loosen the bolts from the three clamps which attach the harness to the housing and remove the complete harness 2 Apply 0 4g of Nyogel on pressure sensor and conne...

Страница 137: ...ssembly and Assembly 5 Apply 0 5g of Nyogel to each of selection and coupling electrical connectors and mount then on 3 Apply 0 4 g of Nyogel to each of the solenoid valves connectors and mount them o...

Страница 138: ...nd tighten them into the specified torque 2 Using a Torx T20 wrench loose the two sensors bolts 0022 18 0023 18 0021 18 ATTENTION The sensors have a guide pin that fits into a hole in the housing Ther...

Страница 139: ...ydraulic Control Unit Disassembly and Assembly 2 Using a 24 mm spanner release the pressure sensor and remove it 2 Apply 0 5g of Nyogel to the connector and plug it on Pressure Sensor Replacement Disa...

Страница 140: ...l Unit Disassembly and Assembly Assembly 1 Install the new o ring on the sensor moistened wid oil itself and mount it in its seat 0027 18 0028 18 2 Using a 24 mm spanner tighten the pressure sensor wi...

Страница 141: ...Control Unit Disassembly and Assembly 2 Loosen the two Torx T20 bolts that secure the solenoid valve 0030 18 0031 18 SolenoidValve s RepairKitReplacement Disassembly 1 Release the connectors 0032 18 0...

Страница 142: ...he assembly use all the parts provided in the repair kit Start with the filters and then the o rings NOTES The solenoid valves are different and each one have a correct mounting position The letter P...

Страница 143: ...onnectors and plug it on 0037 18 0038 18 2 Tighten the electrovalve bolts with the specified torque 0039 18 Reservoir Replacement Disassembly 1 Loosen the upper screw 2 Turn the electro hydraulic unit...

Страница 144: ...into the coupling nozzles lightly lubricate the o rings with its own oil and fit the reservoir equally 2 Complete the assembly following the reverse order of dismantling respecting the specified torq...

Страница 145: ...e the motor first remove the oil reservoir see Reservoir Replacement always protecting with a container the possible oil drip from the compartment 2 Loosen the four bolts and remove the motor cap NOTE...

Страница 146: ...shaft housing 0050 18 0051 18 3 Use your finger to rotate the motor shaft to achieve the perfect fit with the plastic coupling sleeve 4 Mount the two bolts on the motor and apply the specified torque...

Страница 147: ...electro hydraulic unit upside down remove the two Torx T20 bolts securing the pump yellow arrows 5 Carefully mount the gasket on the cover and place it observing the three electrical contacts on the...

Страница 148: ...ling in the plastic coupling sleeve ensuring that the gasket and the pressure ring do not get out of their seats 3 Insert the two bolts and apply the specified torque Assembly 1 Fit the plastic coupli...

Страница 149: ...mbly but before inserting the valve moisten the new o rings with its own oil Non Return Valve Replacement Disassembly 1 Using lock pliers remove the locking ring 0061 18 3 With a hook remove the sprin...

Страница 150: ...assembly operations 3 and 4 release the two connectors of the solenoid valves to facilitate access to the piston cover bolts 2 Loosen only two Allen 5 mm bolts diagonally opposite on the piston cap le...

Страница 151: ...Remove the spring 3 Holding the cap with your finger due to the pressure of the spring and loosen the other two bolts 0068 18 5 Finish removing the bolts and remove the cover detail 4 Let the cover mo...

Страница 152: ...ing a thin layer of its own oil into the piston and o rings before assembling it Attach the camera cover observing that the chamfer should facing the same side of the solenoid valves 0102 18 7 With on...

Страница 153: ...see detail 2 Start by tightening equally two diagonally opposed bolts until the cover fits into its seat then other two bolts Apply the specified torque 0106 18 Coupling Piston and Repair Kit Replace...

Страница 154: ...ue pushing the piston until extract it completely 4 With the help of a extractor hook remove the two o ring and the fixed gasket CAUTION Make sure the correct positioning of the fixed gasket which sho...

Страница 155: ...on the valve see detail 2 Fit the valve and apply the specified torque 2 Proceed in the reverse order of disassembly passing a thin layer of its own oil into the piston before assembling it 0113 18 Ma...

Страница 156: ...UTION Make sure that the oil has been fully depressurised at the time of removal of the electrohydraulic unit from the vehicle oil drain into the reservoir NOTE It should be taken into account that a...

Страница 157: ...ssembly and Assembly 0117 18 Recirculation Breather Filter Replacement Disassembly 1 Using a 33 mm wrench loosen the recirculation breather and remove it 0119 18 2 Lubricate the gasket and Install the...

Страница 158: ...pping from the engine compartment 2 Then remove the hose together with the clamps Assembly 1 Mount the new repair kit and with the aid of a specific pliers crave new clamps 2 Mount the reservoir see R...

Страница 159: ...y to the end but not giving the final tightening 2 Install the plastic clamp observing the tube alignment 3 Apply the specified torque 0123 18 Air Purge of Brushless Motor Chamber If all the oil in th...

Страница 160: ...Hydraulic Control Unit Disassembly and Assembly 0125 18 0126 18 2 Loosen one motor cover bolt for a maximum of 4 turns using a Torx T20 wrench 3 Lift up the cover using a screwdriver holding it up unt...

Страница 161: ...ap remove it otherwise the system may be damaged or malfunction 2 Perform the oil reservoir level check procedure as instructed by the manufacturer and if necessary complete the level 2 1 4 Note that...

Страница 162: ...their customers vendors and distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modi cation...

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