Perform actuator test
Call the button "Actuator test" (1) in ALADIN under the "Service" button.
Order number H68.1535xx
Tool for loosening the cable connectors from the solenoid coils
Order number 150.000145xx
Tool for plugging the cable connectors into the solenoid coils
1. Hard-soldered
2. Insert for assembly tool
Order number 150.000144xx
3. Screwdriver DIN 5265-C-A 0,
8x4, tip removed
In the future, the modified cable guard of the DIWA.6 transmission will be used in DIWA.5 transmissions. If the cable guard in a DIWA.5 transmission has to be replaced, then only the new version of the cable guard is available as a spare part. If the cable guard has to be replaced, then the new version of the cable tray must also be used since only the new versions or the previous versions can be installed together. A mixed installation is not possible. |  |
Cable guard
1. Previous version
2. New version
Remove the cable guard
Remove the cable guard (1)
NOTICE
The connection between the plug and cable can be damaged.
To loosen the cable connectors from the solenoid coils, use the special tool.
Never pull on the cables.
Removing control blocks
Pull off cable plug (1) from the solenoid coils.
Use the special tool (→ 1).
Removing control blocks
Loosen and remove the 12 socket head screws M8x50 (2).
Remove the spring washers 8 (12x) underneath these.
Remove control blocks (1 and 4).
Pull out connecting tube (3).
Take apart the input-side control block
Release 5 hexagon bolts (1) and remove cover (2).
Loosen all screw plugs M10 (12) and remove them with the sealing rings (11).
Otherwise, the pistons cannot be dismantled.
Dismount the following parts from the housing (8):
4 pistons (5)
4 control pins (4)
4 pressure springs (3)
Pistons (7)
Pressure spring (6)
Loosen 10 socket head screws M 5 x 20 – CV84 (13) and remove
5 solenoid coils (14).
Dismounting the output-side control block
Release 4 hexagon bolts (1) and remove cover (2).
Loosen all screw plugs M10 (15) and remove them with the sealing rings (16).
Otherwise, the pistons cannot be dismantled.
Dismount the following parts from the housing (17):
Pistons (3, 18)
Control pin (4, 19)
2 pressure springs (5)
2 pistons (6)
2 pressure springs (7)
Dismount the insert (9), 2 O-rings (8), ball (10), valve body (11) and locking ring (12).
Loosen the 8 socket head screws M 5 x 20 (13) and dismount 4 solenoid coils (14).
Check the valves for smooth running.
If necessary, make the valves run smoothly (e.g. polish, hone...) or replace them.
NOTICE
Risk of mounting the pistons incorrectly!
If the pistons are mounted incorrectly, transmission malfunctions may occur during operation.
Make sure that spools are mounted in the correct position and run smoothly.
Assembling the input side (drive side) control block
Use 10 socket head screws M 5 x 12 - CV84 (13) to screw the 5 solenoid coils (14) tight.
Tightening torque 5 Nm.
The connections must be on top.
Mount the following parts in the housing (8) again:
4 pistons (5)
4 control pins (4)
4 pressure springs (3)
Pistons (7)
Pressure spring (6)
Screw the cover (2) tight using 5 hexagon bolts (1) M6 x 12 - 8.8.
Tightening torque 9 Nm.
Screw in 5 screw plugs WP M10 x 1 (12) with sealing rings (11).
Tightening torque 15 Nm.
Assembling the output-side control block
Use 8 socket head screws M 5 x 12 - CV84 (13) to screw the 4 solenoid coils (14) tight.
Tightening torque 5 Nm.
The connections must be on top.
Mount the following parts in the housing (18) again:
Pistons (3, 18)
Control pin (4, 19)
2 pressure springs (5)
2 pistons (6)
2 pressure springs (7)
Mount the insert (9), 2 O-rings (8), ball (10), valve body (11) and locking ring (12).
Screw the cover (2) tight using 4 hexagon bolts M6 x 12 - 8.8 (1).
Tightening torque 9 Nm.
Screw in 5 screw plugs WP M10 x 1 (15) with sealing rings (16).
Tightening torque 15 Nm.
Mounting control blocks
Fix the control block (2) with 6 socket head screws M8 x 50 (1).
Plug 5 cable connectors (4) into the solenoid coils using the special tool (→ 1).
Mounting control blocks
Use a special tool (1) (→ 1) to insert the cable plugs (3) into the
solenoid coils.
Mount the connecting tube (2) with new O-rings 12 x 2.
Fix the control block (4) with 6 socket head screws M8 x 50 (5).
Tighten 12 socket head screws M8 x 50.
Tightening torque 20 Nm.
Remove the cable guard
Remove the cable guard (1)
NOTICE
The connection between the plug and cable can be damaged.
When unplugging the cable connectors → 1(1), the contacts between the cable connectors → 1/(1) and cables → 1/(2) can be damaged.
Unplugging the cable connectors
Unplug cable connector (2) from the solenoid coil (3).
Use special tool (1) (→ 1).
Unplug all cable connectors from all solenoid coils.
All cable connectors on the solenoid coils unplugged
Unplug connectors from the N1 sensor (1).
Carefully pull line (2) out of the holder (3).
Unplugging the cable harness
Unplug connector (1) from the N2 sensor.
Unplug connector (2) from the N3 sensor.
Unplug connector (3) from the IM.
Removing control blocks
Loosen and remove the 12 socket head screws M8 x 50 (3).
Remove the spring washers 8 (12x) underneath these.
Pull the control block (1) carefully in the direction of the output until the connecting tube (2) comes out of the control block (1).
Carefully lift out the control block (1).
Pull out the connector tube.
Carefully lift out the control block (4).
Take apart the control blocks (→ Taking apart the control blocks.).
Check valves (→ Checking valves).
Assemble the control blocks (→ Assembling the control blocks).
Mounting control blocks
Fix the control block (1) with 2 socket head screws M8 x 50 (2).
Install the connecting tube (3) with two new O-rings 12 x 2.
Plug the cable connector (4) into the solenoid coils (5) with the special tool (3) (→ 1).
Mounting control blocks
Plug in all six cable connectors (1).
Mounting control blocks
Plug four cable connectors (1) into the solenoid coils (3) using the special tool (2) (→ 1).
Mounting control blocks
Fix the control block (2) with two socket head screws M8 x 50 (1).
Mounting control blocks
Tighten 12 socket head screws M8 x 50 (1).
Tightening torque 20 Nm.
Inserting the cable harness
Insert the cable (1) into the holder (2).
Insert the plug for the speed sensor N1 (3).
Plug in the connector on the EO valve (4) with the auxiliary tool (→ 1).
Mounting control blocks
Mount the cable guard (1).