RepairManual DIWA.5

DIWA.
5 Repair Manual
Version 06 / 06
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Table of contents
Table of contents
1 General notes 1
1.1 Safety notes 1
1.2 Signs 6
2 General 8
2.1 Checking and replacing parts 8
2.2 Cleaning 8
2.3 Suspension points 8
2.4 Hose lines 9
2.5 Storage 9
3 Tools 10
3.1 Standard tools 10
3.2 Special tools 12
3.3 Tools 20
3.4 Measuring tools 23
4 Dismounting the hydrodamp 25
4.1 Dismounting 25
4.2 Checking the oil level 26
4.3 Wear check at the hub 27

© 2006 Voith Turbo GmbH & Co. KG
5 Draining the transmission oil 28

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Table of contents Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
6 Disassembling the transmission into assemblies 31
6.1 Dismounting the heat exchanger 31
6.2 Dismounting the control blocks 33
6.3 Dismounting the cable harness 36
6.4 Dismounting the oil pan 38
6.5 Dismounting the output assembly 40
6.6 Dismounting the turbine transmission 43
6.7 Dismounting the drive unit 45
6.8 Dismounting the suction screen 46
6.9 Dismounting the gear pump 47
6.10 Dismounting the converter outlet valve 48
6.11 Dismounting the operating pressure valve 50
6.12 Dismounting the pump brake 52
7 Dismounting and mounting assemblies 53
7.1 Dismounting the input differential 53
7.2 Dismounting the planet carrier 63
7.3 Mounting the planet carrier 64
7.4 Mounting the input differential 65
7.5 Dismounting the pump brake 80
7.6 Mounting the pump brake 85
7.7 Dismounting the stator - turbine wheel 92

7.8 Mounting the stator - turbine wheel 94
7.9 Dismounting the turbine transmission 99

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7.10 Mounting the turbine transmission 102

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7.11 Dismounting the output and reverse gear 104
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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Table of contents
7.12 Dismounting the TB-RB disk carrier 105
7.13 Mounting the TB-RB disk carrier 108
7.14 Mounting and dismounting the operating pressure valve 111
7.15 Dismounting and mounting the gear pump 115
7.16 Mounting and dismounting the converter outlet valve 119
7.17 Repairing control blocks 122
8 Assembling the transmission 125
8.1 General 125
8.2 Mounting the screw plug 125
8.3 Mounting the pump brake 126
8.4 Mounting the operating pressure valve 129
8.5 Mounting the converter drain valve 131
8.6 Mounting the gear pump 133
8.7 Mounting the drive unit 135
8.8 Mounting the stator - turbine wheel 136
8.9 Mounting the turbine transmission 139
8.10 Mounting the reverse gear into the output unit 142
8.11 Measure and adjust the disk clearance of the reverse gear. 143
8.12 Mounting the output unit 145
8.13 Mount the oil pan. 149
8.14 Mounting the cable harness 150
8.15 Mounting the control blocks 154

8.16 Mounting the control block cover 155
8.17 Mounting the heat exchanger 156

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9 Mounting the hydrodamp 157
iii
Table of contents Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
10 Measuring pressures 158
11 DIWA.5 tightening torques 162

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iv
General notes
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Safety notes
General notes
1 General notes
Safety notes
1.1 Safety notes
General
Operation, maintenance and repair of the transmission are always subject to the
relevant local safety regulations and accident prevention regulations.
These regulations can, for example, concern handling of hazardous materials,

provision and wearing of personal protective gear or motor vehicle regulations.
Anyone operating the transmission or any persons involved in installation, repair or

maintenance have to familiarize themselves with the warning notes and precautions
described in this document.
Any person involved in operation, installation, repair or maintenance of the

transmission must exercise utmost diligence in making sure that his or her own
personal safety or the safety of other persons is not in danger.
State of the art
This transmission is designed and constructed according to the state of the art in
technology and acknowledged safety regulations. Nevertheless, operation, installation,
repair and maintenance of the transmission can involve the risk of injury and death of
persons or damage the transmission and other material assets if:
• the transmission is put to different use than prescribed,

• the transmission is operated, serviced or repaired by unqualified staff,
• the transmission is modified or reconstructed improperly and/or
• the safety notes are not observed.
Proper use
The proper use of the DIWA transmission is its application as an automatic drive for
busses.
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General notes
Safety notes Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Any use other than the one described above is considered improper. Voith Turbo
GmbH & Co. KG does not assume any liability for improper use. In this case, the risk
lies solely with the user.
The persons in charge, in particular the staff engaged in operation and maintenance,
must by all means heed the guidelines for the proper and correct use of the
transmission.
Conditions for usage
The transmission may only be operated:
• in technically flawless condition,

• for its intended purpose,
• with respect to the safety instructions and the dangers involved and in compliance
with the technical manual and other technical documents.
Malfunctions that impair the safety must be eliminated immediately.
Staff qualification
Work on the transmission may only be carried out by staff that is properly trained,
instructed and authorized by the operator. The legally prescribed minimum age must
be observed.
Maintenance and repair require special knowledge and training (e.g. a Voith repair
training) and may only be carried out by accordingly qualified personnel.
Personnel that is currently being trained, instructed, broken in or undergoes a general

training, may work on the transmisson only under the permanent supervision of a
person assigned to this purpose.
Responsibilities
The responsibilities of the personnel working on the transmission must be clearly

defined and complied with.
Only such personnel as is explicitly ordered to do so may work on the transmission.
Work on the chassis, brakes or steering systems may only be conducted by

accordingly qualified personnel.
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General notes
Unsafe instructions
The personnel working on the transmission must refuse unsafe instructions of third
parties.
Hoisting devices
Use only appropriate and technically immaculate hoisting devices and load
suspension devices with sufficient load capacity.
When replacing transmission, assemblies or individual parts, these must be carefully

attached to hoisting devices and secured such that they do not present any risk.
Never stay or work under suspended loads.
Risk of burning
The oil can become very hot - in extreme cases up to 130 °C.
Improper handling may cause burns of the skin.
Therefore, let the transmission cool down to approx. 60 °C before changing the oil.
Further risks of accidents due to oil
Oil that escapes through lines, gaskets or O-rings which were not installed correctly or
which have become leaky after prolonged time in operation, can cause accidents.
The hydraulic oil can be under high pressure in pipes and conduits as well as in the
converter.
Shut off the drive motor before conducting maintenance work or repairs.
Spare parts
Use only original spare parts for repairs since they only can guarantee that the
transmission complies with the road safety regulations and the technical state on
delivery.
When replacing parts, it is crucial to observe the notes in the spare parts catalogue.
Original spare parts are designed especially for the Voith transmission. We would like
to point out that original spare parts which are not supplied by Voith are neither tested
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nor approved by Voith. The installation and/or use of non-original spare parts might
affect the specified features of the transmission and thus impair safety.
3
General notes
Safety notes Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
In case of any damage due to the use of non-original spare parts, Voith does not
assume any liability.
Work on the transmission
Prior to peforming maintenance or inspection operations on the installed transmission

and during installation and removal of the transmission, the engine of the bus must be
secured against starting.
Prior to performing maintenance or inspection operations on the installed transmission

and during installation and removal of the transmission, the bus must be secured such
that it cannot be put in motion, neither deliberately nor accidentally (slope!).
The prescribed service work must be carried out regularly, on time and with the
intended fuels and fluids.
The work must be performed in accordance with Voith provisions, e.g. the customer
service information which describes improvements and modifications to the
transmission, so that no parts and tools take damage.
Performing work on the transmission requires a suitable workshop equipment.
After having worked on the transmission, all transmission oil lines must be checked for
leaks, loose connections, chafing and damage. Any defects must be eliminated
immediately.
After having worked on the transmission, all joints must be checked for leakage.
All screwed connections loosened during work on the transmission must be

retightened to the tightening torques indicated in the technical documents on the
transmission.
Cleaning the transmission
Before cleaning the transmission with water or steam jet (high-pressure cleaner) or
other cleaning agents, any openings into which no water, steam or cleaning agent
must penetrate for reasons of safety and functioning must be sealed.
After cleaning, remove all covers/adhesives completely.
Conversion or modification of the transmission

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Any modifications, attachments or rebuildings of the transmission must not be

implemented without approval from Voith Turbo GmbH & Co. KG.
4
General notes
Disposal
Fluids and auxiliary substances (e.g. used oil) and disassembled parts must be
disposed of in a safe and environmentally sound manner.
The local regulations and laws on environmental protection and disposal of hazardous
materials must be observed.
Towing
Shift the transmission to idle gear (N key).
Unplug the connecting cable between control and transmission from the control unit.
If the transmission is damaged: Dismount the cardan shaft or stub shaft of the rear
axle.
If no transmission damage is detected, the vehicle can also be towed with the cardan
shaft:
• max. permissible distance: 10 km

• max. permissible speed: 30 km/h.
For transmissions with angle drives it is in any case necessary to remove the cardan
shaft or stub shaft of the rear axle.
If this is not possible, please contact the Voith customer service.

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General notes
Signs Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Signs
1.2 Signs
DANGER
DANGER
indicates imminent danger for life and health of people.

The non-compliance with this note results in serious
damage to your health as well as life-threatening injuries.
WARNING
WARNING
indicates possible danger for life and health of people.

The non-compliance with this note might result in serious
damage to your health as well as life-threatening injuries.
CAUTION
CAUTION
indicates a potentially dangerous situation.

The non-compliance with this note might result in minor
injuries or property damage.
NOTE
Note
indicates information on the proper handling of the

gearbox. It does not indicate dangerous situations.
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General notes
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Signs
ENVIRONMENT
Environment
indicates a potentially harmful situation for the environment

owing to operation, maintenance or repair of the
transmission.
Î Meaning: an activity to be performed.

ª Meaning: the result of an activity.
Meaning: please note.
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General
Checking and replacing parts Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
General
2 General
Checking and replacing parts

2.1 Checking and replacing parts
Check ball bearings, roller bearings and needle bearings, replace if necessary.
Replace all sealing elements, hose lines and internal disks.
Before installation, immerse internal disks in oil.
Check TB internal disks and external disks for wear. Replace disks if you detect any
signs of overheating or deformation.
Cleaning
2.2 Cleaning
If the transmission is very dirty, clean [Ö Page 4] it before repair.
After disassembly, clean all parts.
Suspension points
2.3 Suspension points
1 1
Fig. 1
Î Use only the suspension points (eyebolts M12, 1) to attach the transmission to an
appropriate lifting device [Ö Page 3] that assures an even weight distribution.

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General
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Hose lines
Fig. 2
Î The eyebolts may only be subjected to vertical upward stress.

The maximum allowed to be attached to the eyebolts is the transmission with heat
exchanger and angle drive.
It is not permitted to lift any additional loads at the eyebolts.
Hose lines
2.4 Hose lines
Even if they are stored properly and not stressed beyond the allowed limits, hoses and
hose lines are subject to a natural ageing process. Their service life is therefore
limited.
DIN 20066: The service life of a hose line including storage must not exceed 6 years.
Storage
2.5 Storage
If a transmission is stored after repair without a test run, it has to be protected against
corrosion.
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Tools
Standard tools Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Tools
3 Tools
Standard tools
3.1 Standard tools
Fastener for screwdriver socket
Order number H02.011204
Fig. 3 Fastener for screwdriver socket
Screwdriver socket
Fig. 4 Screwdriver socket
Design Order number
B-K 5x11 H02.011186
K-5 long H02.007820
B-K 6x11 H02.011187

B-K 8x11 H02.011188
B-K 10x11 H02.011183
B-K 12x11 H02.011190

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Tools
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Standard tools
Other
Torque wrench
Torque wrench 0-150 Nm
Forcing screw
• Forcing screw 2x M6

Pliers
Pliers for interior locking rings:
• Pliers J1 for locking rings ø 8-25 mm

Pliers for exterior locking rings:
• Pliers A1 for locking rings ø 10-25 mm

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Tools
Special tools Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Special tools
3.2 Special tools
Tool for loosening the cable plugs from the solenoid coils
Fig. 5 Tool for loosening the cable plugs from the solenoid coils
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Tools
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Special tools
Tool for inserting the cable plugs at the solenoid coils
Order number 150.00014510
Fig. 6 Tool for inserting the cable plugs at the solenoid coils
• 1 – soldered
• 2 – 150.00014410
• 3 – screwdriver DIN 5265-C-A 0, 8x4, tip removed
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Tools
Tool for loosening the cable plugs from the cable harness
Fig. 7 Tool for loosening the cable plugs for the temperature sensor from the cable harness
• 1 – soldered
• 2 - pliers DIN 5254-A40-gl
Tool for inserting the cable plugs in the cable harness
Fig. 8 Tool for inserting the cable plugs for the temperature sensor at the cable harness
• 1 – soldered
• 2 - pliers DIN 5256-C40-gl

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Tools
Tool for installing the radial shaft sealing ring into the output cover
Fig. 9 Tool for installing the radial shaft sealing ring into the output cover
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Tools
Tool for installing the radial shaft sealing ring into the input cover
Fig. 10 Tool for installing the radial shaft sealing ring into the input cover

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Tools
Puller for input cover
Fig. 11 Puller for input cover
• 1 – made of M16x100 DIN EN ISO 4017

• 2 – welded 30x30
Forcing screw M10
Order number: H58.274011

Fig. 12 Forcing screw M10
• Threaded bolt AM10 4.6 DIN 976-1, hardened

• Hexagon nut M10 8 A3C DIN934
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Tools
Tool for disassembling and assembling the EK/DK piston carrier
Plate
Fig. 13 Tool for disassembling and assembling the EK/DK piston carrier sheet plate
Base plate
Fig. 14 Tool for disassembling and assembling the EK/DK piston carrier base plate
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Tools
Tool for installing the turbine transmission
Fig. 15 Tool for installing the turbine transmission

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Tools
Tools Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Tools
3.3 Tools
Sleeve for mounting the input shaft bearing
Fig. 16 Sleeve for mounting the input shaft bearing
Sleeve for mounting the EK multi-disk carrier bearing
Fig. 17 Sleeve for mounting the EK multi-disk carrier bearing

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Tools
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Tools
Sleeve for mounting the turbine and pump brake bearings
Fig. 18 Sleeve for mounting the turbine and pump brake bearings
Disk for pulling off the external crown of the input differential
Fig. 19 Disk for pulling off the external crown of the input differential
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Tools
Tools Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Tool for mounting the inner race and roller bearing on the turbine shaft
Fig. 20 Tool for mounting the inner race and roller bearing on the turbine shaft
Tool for mounting the needle sleeve into the gear pump housing
Fig. 21 Tool for mounting the needle sleeve into the gear pump housing
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Tools
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Measuring tools
Measuring tools
3.4 Measuring tools
Measuring cover
Fig. 22 Measuring cover
1 WR 7 Operating pressure
2 Converter pressure 8 DK
3 TB 9 EK
4 RG 10 PB
5 RK 11 WP
6 SK
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Tools
Measuring tools Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Measurement connection

Quantity 9
Sealing ring

Quantity 9

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Dismounting the hydrodamp
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting

4 Dismounting the hydrodamp
Dismounting
4.1 Dismounting
Fig. 23
CAUTION
Danger of damaging the hydrodamp
The hydrodamp is manufactured with tight tolerances on

the inside. External damages can cause failure of the
hydrodamp.
Î Do not place the hydrodamp on its hub during
transport, storage or exchange.
Î Store or dispatch the hydrodamp in its original packing
only.
Î In case of repair, replace hydrodamp only as a whole.
Î Unscrew two opposite screws M10 out of the external pitch circle of the
hydrodamp (1).
Î Insert stud bolts, length 100 mm, into these places.
Î Unscrew ten screws out of the external pitch circle (2).
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Do not remove the hex. head screws in the clutch.

Î Press off the hydrodamp using the press-off screws [Ö Page 17] .
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Checking the oil level Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
There may be an intermediate ring on the flywheel. This can become loose while
removing. If this is the case, push the ring back to its position.
Checking the oil level

4.2 Checking the oil level
If oil traces are detected in the area of the hub, check the oil level in the hydrodamp.
Fig. 24
WARNING
Risk of burning through hot oil
Hot oil can escape from the hydrodamp. This can cause
burning.
Î Make sure that the temperature in the hydrodamp is
below 50°C.
Î Wear personal protection gear when removing and
working on the hydrodamp.
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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Wear check at the hub
ENVIRONMENT
Environmental hazard due to escaping oil
The oil from the hydrodamp must not enter the

environment. Any oil that has escaped must be disposed of
in accordance with the local regulations.
Î Turn the hydrodamp so that the check bores (1) and (2) are perpendicular above
each other.
Î Wait for three minutes.
Î Unscrew the upper screw plug (1).
Î Turn the hydrodamp clockwise by 40° to 45° around the hub axis.
If oil escapes the bore while doing so:
The oil level is ok.

Î Seal the bore (1) using a screw plug M10x1 and a new copper sealing ring
10.5x16x2 VGN3019 (special dimensions, no DIN design).
Tightening torque 18 Nm
Î Screw in the screw plug with type 243 Loctite.
If no oil escapes the bore:
Oil does not reach the minimum oil level. This may be due to the hydrodamp having a
leak.
Î Replace the hydrodamp.
Wear check at the hub

4.3 Wear check at the hub
To do so, check the backlash between the input shaft and hub of the hydrodamp.
Î Plug the hydrodamp onto a new transmission input shaft.
If the backlash at the bolt hole circle diameter of approx. 410 mm is greater than
2mm, replace the entire hydrodamp.
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Draining the transmission oil Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Draining the transmission oil

5 Draining the transmission oil
Î Shut off the engine.
Î Check the transmission oil temperature.
NOTE
Conditions
Drain the oil at operating temperature only (at least 60 °C).

Otherwise, too much oil will remain in the transmission.
The cooling water temperature indicator in the vehicle can

be used to determine the transmission oil temperature
since transmission oil and cooling water temperature are
almost identical.
Î If the transmission oil temperature is below 60 °C,
warm up the engine to operating temperature.

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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Draining the transmission oil
Fig. 25 1 - Drain plug in the oil pan
Î Unscrew the drain plug (1) in the oil pan with an Allen wrench.
WARNING
Risk of scalding through hot oil
Direct contact of the hot transmission oil with the skin can
cause severe scalding injuries.
Î Take appropriate safety precautions for handling hot
oil.
Î Drain the oil.

Width across flats 12.
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Draining the transmission oil Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 26 2 - Drain plug for the oil in the converter
Î Remove the drain plug (2) for the oil in the converter and drain the oil.
The drain plug (2) is accessible through the oil pan drain hole.
Î Screw in the drain plug (2) with a new copper sealing ring.
Î Tighten the drain plug (2).
Tightening torque 50 Nm.
Î Screw in the drain plug (1) in the oil pan with a new copper sealing ring.
Î Tighten the drain plug (1).

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Disassembling the transmission into
assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the heat exchanger
6 Disassembling the transmission into
Disassembling the transmission into assemblies

assemblies
Dismounting the heat exchanger

6.1 Dismounting the heat exchanger
WARNING
There may still be some hot oil in the heat exchanger that
can escape. This can cause burning.
Î Wear personal protection gear when removing the heat
exchanger.
ENVIRONMENT
Environmental hazard due to escaping oil
The oil from the heat exchanger must not enter the
environment. Any oil that has escaped must be disposed of
in accordance with the local regulations.
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assemblies
Dismounting the heat exchanger Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 27
Î Loosen and remove the two hex. head nuts (1).

Î Loosen and remove the six hex. head screws (2).
Î Remove the heat exchanger with fastener (3).
Fig. 28
Î Pull out the two plug-in tubes (1).

Î Remove the two gaskets (2).
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assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the control blocks
Dismounting the control blocks

6.2 Dismounting the control blocks
Fig. 29
Î Loosen the 20 hex. head screws (1) and remove them together with
the washers (2).
Î Remove the cover (3).
Î Remove the gasket (4).
Fig. 30
Î Remove the protective cover for cables (1).

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assemblies
Dismounting the control blocks Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 31
CAUTION
The cable-plug connection can be damaged.
When removing the cable plug (1), the connection between

cable (2) and cable plug (1) can be damaged.
Î Use the special tool (3) [Ö Page 12] to remove the
cable plug (1) from the solenoid coils.
Î Never pull out cable plugs (1) by tugging at the cables
(2).

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assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the control blocks
Fig. 32
CAUTION
The speed sensor can be damaged.
Î Never use an impact screwdriver to disassemble the
speed sensor.
Î Pull the plugs of speed sensors N1 (1), N2 (3) and N3 (2).

Î Loosen the screws at speed sensors N1, N2 and N3.
Î Remove speed sensors N1, N2 and N3.
Fig. 33
Î Loosen and remove the six cheese-head screws M8 (2).

Î Loosen and remove the six cheese-head screws M8 (4).

Î Take off the control blocks (1) and (5).
Î Pull out the connecting tube (3).
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assemblies
Dismounting the cable harness Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the cable harness

6.3 Dismounting the cable harness
Fig. 34
Î Use special tool (7) [Ö Page 14] to loosen the plug connection between cable
harness and oil sump temperature sensor (5).
Î Loosen the plug connection between cable harness and converter oil temperature
sensor (6).
Î Loosen the hex. head screw (2).

Î Loosen the hex. head screw (3).
Î Take out the cable duct (4).
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Î Dismount the pipe for oil level check with fastener (1).
36
assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the cable harness
Fig. 35
Î Loosen the four cheese-head screws (1).

Î Pull the cable harness (2) carefully out of the housing.
Fig. 36
Î Unscrew the converter oil temperature sensor (3).

Î Use a screw M12 to pull the plug-in tubes (1) out of the housing.
Î Dismount the WR pipe (2).
Î Use a screw M10 to pull the plug-in tube (4) out of the housing.
Fig. 37
Î Loosen and remove the screw plug (1).

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Î Remove the washer (2) and insert (3).

Î Release the screw (4).
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assemblies
Dismounting the oil pan Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the oil pan

6.4 Dismounting the oil pan
WARNING
The transmission may overturn.
Risk of injury and risk of damages to the transmission.

Î Wear personal protection gear.
Î Secure the transmission against overturning.
Î Set up the transmission with the main drive pinion facing upwards.
Fig. 38
Î Loosen and remove the oil drain plug (1).

Î Unscrew the oil filter cover (2).
Î Remove the oil filter. © 2006 Voith Turbo GmbH & Co. KG
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assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the oil pan
Fig. 39
Î Loosen and remove the 28 hex. head nuts (4).

Î Remove the 28 washers (3).
ENVIRONMENT
Environmental hazard due to oil.
Oil may continue to flow when removing the oil pan.
The oil must not enter the environment and must be

disposed of in accordance with the local regulations.
Î Remove the oil pan (2).

Î Remove the gasket (1).
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assemblies
Dismounting the output assembly Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the output assembly

6.5 Dismounting the output assembly
Transmission with angle drive

Î Dismount the angle drive (⇨ repair manual for the angle drive)
Transmission without angle drive
Fig. 40
Î Loosen and remove the three hex. head screws (1).

Î Remove the output flange (2) with washer, shim rings and O-ring.
Fig. 41
Î Loosen and remove the 12 hex. head screws (4).

Î Use an appropriate lifting device (1) to lift off the output cover (2) at two eyebolts
M10 (3) with the help of a crane.
Î Remove the gasket under the output cover.
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40
assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the output assembly
Fig. 42
Î Take out the R external and internal disks (1).

Î Dismount the parallel key (2).
Fig. 43
Î Unscrew the screw-in socket (2).

ª The hose line (1) is loose.
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assemblies
Dismounting the output assembly Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 44
Î Pull out the RG planet carrier (3) with a special tool [Ö Page 17] .
Î Dismount the R external crown (2).
Î Dismount the RG-TB multi-disk carrier (1).

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42
assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the turbine transmission
Dismounting the turbine transmission

6.6 Dismounting the turbine transmission
Fig. 45
CAUTION
The turbine transmission can get jammed at the planet
carrier shaft.
The toothing of the planet carrier shaft can be damaged.

Î Carefully pull out the turbine transmission.
Î If the turbine transmission is jammed, loosen it by
carefully shaking it.
Î Pull out the turbine transmission (1) with a special tool (2) [Ö Page 17] .
Fig. 46
Î Take out the TB disks (1).

Î Take out the planet carrier shaft (2).
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assemblies
Dismounting the turbine transmission Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 47
Î Loosen and remove the four cheese-head screws (1).

Î Take out the supporting ring (2).
Î Take out the washer (3).
Î Take out the disk spring (4).
Î Take out the disk spring (5).
Î Take out the brake piston (6).
Fig. 48
Î Loosen the 12 cheese-head screws (1) and remove them together with the
washers (2).
Î Press off the stator with turbine wheel and turbine shaft (3) using a special tool
[Ö Page 17] and remove them.
Î Place the transmission on its output side.
CAUTION
Pipes can be damaged.

Î Fasten the oil pan provisionally to the housing by
means of two nuts.
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assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the drive unit
Dismounting the drive unit

6.7 Dismounting the drive unit
Fig. 49
Î Loosen and remove the 13 hex. head screws M10.

Î Press off the cover with the special tool [Ö Page 17] .
Î Lift off the cover with input differential using an appropriate lifting device.
Î Dismount the gasket under the input cover.
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45
assemblies
Dismounting the suction screen Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the suction screen

6.8 Dismounting the suction screen
Fig. 50
Î Loosen and remove the two hex. head screws (2).

Î Take out the suction screen (1).

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46
assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the gear pump
Dismounting the gear pump

6.9 Dismounting the gear pump
Fig. 51
Î Loosen and remove the four hex. head screws M10 (1).
Î Take out the plug-in tube (2).
Î Take out the gear pump (3).
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assemblies
Dismounting the converter outlet valve Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the converter outlet valve

6.10 Dismounting the converter outlet valve
Fig. 52
Î Loosen the hollow screws (1) and (6).

Î Remove the pipe (4).
Î Loosen the screwed connection (2) and hollow screw (5).
Î Loosen the hollow screw (7), hex head screw (12) and screwed connection (17).
Î Loosen the screwed connection (10) and hollow screw (16).
Î Loosen the hollow screws (8) and (15).

Î Loosen the hollow screw (14).
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48
assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the converter outlet valve
Fig. 53
Î Loosen and remove the five cheese-head screws (2).

Î Take out the converter outlet valve (1).
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49
assemblies
Dismounting the operating pressure Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
valve
Dismounting the operating pressure valve

6.11 Dismounting the operating pressure valve
Fig. 54
Î Loosen and remove the three hex. head screws M10 (2).
Î Loosen and remove the four hex. head screws M8 (3).
Î Take out the valve shim (1).
Fig. 55
Î Loosen and remove the hollow screw (1).

Î Pull out the plug-in tubes (2) (3).
Î Take out the operating pressure valve (4).
Î Dismount the oil sump temperature sensor (5).

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assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the operating pressure
valve
Fig. 56
Î Dismount the pipes (1) (2) (4) (5) (6).

Î Take out the pipe line for oil sump temperature sensor (3).
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assemblies
Dismounting the pump brake Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the pump brake

6.12 Dismounting the pump brake
Fig. 57
Î Loosen and remove the cheese-head screw M10 (1).

Î Dismount the gear wheel (2).
Î Dismount all pipes.
Fig. 58
Î Loosen and remove the eleven hex. head screws M10 (1).
Î Press off the pump brake (3) with the special tool [Ö Page 17] (two forcing screws
M10) and take it out.
Positions for screwing in the forcing screws (2).
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Dismounting and mounting assemblies
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the input differential
7 Dismounting and mounting

assemblies
Dismounting the input differential

7.1 Dismounting the input differential
Fig. 59
Î Remove the locking ring (3).

Î Pull off the input cover with the special tools (1) [Ö Page 17] and (2) [Ö Page 17] .
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Dismounting the input differential Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 60

Î Dismount the input shaft (3).
Fig. 61

Î Press off the EK disk carrier (4) evenly using two screws M12 (1).
Î Take out the ring (3).
Î Take out the EK disks.

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Fig. 62
Î Pull off the external crown (5) with auxiliary tool (3) [Ö Page 21] , special tool (2)
[Ö Page 17] and two screws M10 (1).
ª Doing so, the spacer ring (4) is also pulled off.
Î Lift off the entire EK/DK piston carrier (6).
Fig. 63
Î Take out the entire planet carrier (1) including the DK disk unit (2).
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Fig. 64
Î Take out the cover disk (1).

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Fig. 65
CAUTION
The disk carrier is under spring tension.
Î Evenly unscrew the hex. head screws M10 (1)
crosswise.
Î Carefully remove the SK disk carrier (2).
Fig. 66
Î Take out all SK disks (1).

Î Take out the springs (2) and spring sleeves (3).
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Fig. 67
Î Take the pistons (1) out of the piston carrier (3).

Î Take off the piston rings.
Î Remove the six O-rings (2).
Fig. 68
Î Take the circlip (1) out of the groove of the SK planet carrier.
Î Check whether the seal bushing has shrunk.
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Fig. 69
Î Press off the SK planet carrier (4) from the disk carrier (5) using auxiliary tool (3)
[Ö Page 21] and special tool (2) [Ö Page 17] and special tool (1) [Ö Page 17] .
Fig. 70
Î Apply the special tool (2 and 4) [Ö Page 18] .

Î Loosen two toothed plate rings each at once by turning the forcing screws (1)
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[Ö Page 17] .
59
Fig. 71
CAUTION
Risk of injury due to springs under tension.
Springs can bounce out.

Î Carefully remove the toothed plate rings (2) using the
special tool (1).
Î Take out the springs, spring sleeves, rods and guide disk.
Fig. 72
Î Dismount the pistons (1) and (6) from the EK/DK piston carrier (3).
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Î Remove the piston rings (2) and (5).

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Î Take out the four O-rings (4).
60
Fig. 73
Î Check the cylindrical sieves (1) on the EK/DK side for soiling.
Î Replace the cylindrical sieves if necessary.
Fig. 74
Î Dismount the locking ring (1).

Î Dismount the grooved ball bearing (2) from the supporting washer (3).
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Fig. 75
Î Dismount the circlip (2) and supporting washer with driving pin (1) from the
external crown (3).

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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the planet carrier
Dismounting the planet carrier

7.2 Dismounting the planet carrier
NOTE
The following instruction applies accordingly to all planet
carriers in the DIWA.5 transmission.
Fig. 76
Î Dismount the roll pin (1).

Î Dismount the axle (2).
Î Dismount the planet wheel (5).
Î Dismount the lateral washers (3).
Î Dismount the needle collars (4) from the planet wheel.
Check all parts for wear, replace them if necessary.
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63
Mounting the planet carrier Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the planet carrier

7.3 Mounting the planet carrier
Fig. 77
Î Insert the new oiled needle collars (4) into the planet wheel (5).
Î Mount the planet wheel (5) with the new lateral washers (3).
Î Press the axle (2) into the right position and secure it with the new roll pin (1).

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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the input differential
Mounting the input differential

7.4 Mounting the input differential
NOTE
The following instruction applies accordingly to the
insertion of all piston rings in the DIWA.5 transmission.
Î Slightly stretch the inner piston rings before inserting
them.
Î Look for damages of the piston bearing surface,
retouch if necessary.
Fig. 78
Î Insert the new piston rings (4) into the SK piston (1) of the SK piston carrier (3)
with the groove facing the oil pressure side.
Grease the bearing surfaces in the piston carrier.
Î Mount the pistons.
Î Insert 6 greased O-rings 9x2 (2) into the piston carrier.
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Mounting the input differential Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 79
Î Place the circlip (1) on the SK disk carrier (3).

Î Check and mount the grooved ball bearing (2).

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Fig. 80
WARNING
The circlip may become jammed.
Î Make sure that the circlip does not become jammed.
Î Mount the SK planet carrier (1) on the grooved ball bearing.
CAUTION
When turning over the assembly, the planet carrier can
drop out of the grooved ball bearing.
Risk of injury and risk of damages to the transmission.

Î Secure parts against dropping out when turning them
over.
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Fig. 81
Î Insert the circlip (1) into the groove of the SK planet carrier.
Fig. 82
Î Insert the eight new SK disks in the following order:
• Outside disk 2 mm thick

• Inside disk
• Outside disk 3.5 mm thick
• Inside disk
• Inside disk
• Inside disk
Î Align the disks.
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Fig. 83
Î Mount the four rods (1) with the cylindrical pressures springs (3), spring retainers
(2) and guide disk (4) at two opposite sides.
Fig. 84
Î Place the SK piston carrier (1) on the guide disk.

Mind the position of the guide pin.
Î Secure the SK piston carrier with two screws M10x30-8.8 (2).
Do not tighten the screws.
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Fig. 85
Î Mount the 12 spring sleeves (1) and 12 springs (2).

Î Screw the disk carrier together with the SK piston carrier with 12 hex. head screws
M10x30-8.8 with B10.5 washers underneath.
Tightening torque 46 Nm
CAUTION
Risk of injury due to springs under tension.
NOTE
Î Make sure that the disks run smoothly.
Î Make sure that the SK piston fits correctly.

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70
Fig. 86
Î Mount the external crown (2).

Î Place the planet carrier (1).
Fig. 87
Î Insert the 8 new DK disks in the following order:
• Outside disk 2 mm thick

• Inside disk
• Inside disk
• Inside disk
• Inside disk
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Î Place the EK/DK planet carrier with mounted external crown (1) on the assembly.
71
Fig. 88
Î Insert the new piston rings (2) and (5) into the EK piston (1) and the DK piston (6)
with the groove facing the oil pressure side.
Î Grease the bearing surfaces in the EK/DK piston carrier (3).
Î Mount both pistons (1) and (6) into the piston carrier.

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Fig. 89 Position of the DK pistons
72
Fig. 90 Position of the EK pistons
Mind the correct position of the pistons.
Fig. 91
Î Insert the four new greased O-rings 9x2 (1) into the piston carrier.
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73
Fig. 92
Î Put on the outside disk (5) and mount it as follows:
• Mount the rods (6), tapering on the O-ring side.

• Mount the spring sleeves (5).
• Mount the cyl. pressure springs (3).
• Mount the toothed plate rings (2) with locking washers (1).
Î Hold tight the rods and guide disk.
Î Turn over the piston carrier.
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74
Fig. 93
Î Put on the outside disk (3).

Î Mount the spring sleeves, cyl. pressure springs and toothed plate rings with
locking washers on the already mounted rods.
Î Apply the special tools (1), (2) and (4) to the already mounted rods.
Î Use special tools (2) and (4) [Ö Page 18] to press the cyl. pressure springs down
and mount the toothed plate rings with locking washers.
Î Mount the remaining rods, spring sleeves, cyl. pressure springs and toothed plate
rings with the special tools.
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Fig. 94
Î Place the EK/DK piston carrier (1) on the SK piston carrier (2).
Î Mind the position of the guide pin.
Fig. 95
Î Mount the external crown (1).

Î Insert the 8 new EK disks in the following order:
• Inside disk
• Inside disk
• Inside disk
• Inside disk
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Î Align the disks.
76
Fig. 96
Î Mount the EK disk carrier (2)

Î The spacer ring (1) is to be glued in with Loctite 270.
Î Screw the disk carrier (2) together with the EK/DK piston carrier (4) using 12
screws M10x150-10.9 (3).
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Fig. 97
CAUTION
When overturned, the input differential can start to roll.
Risk of injury and risk of damages to the input differential.

Î Secure the differential against rolling.
Î Turn over the input differential by 90°.

Î Press on the bearing until the planet carrier sits close. Use the auxiliary tool
[Ö Page 20] for that.
Î Insert the new locking ring 62x3 (1).
Î Set up the input differential.

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78
Fig. 98
Measuring the input shaft:

Î Measure the tooth profile of the shaft at the wear points using balls or rollers ø 4
mm.
If the measure is below 53.85 mm, replace the input shaft.
Î Place the input shaft on the input differential and screw it tight using 12 hex. head
screws M12x30-10.9 with B12 spring washers underneath.
Î Insert the new O-ring.
Î Mount the complete input cover on the input shaft with a new ball bearing 6210C3,
new locking ring 90x3 and new shaft sealing ring A60x78x10 using the auxiliary
tool [Ö Page 20] .
Fig. 99
Î Mount the bushing (1) greased on the inside and outside and the new locking ring
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50x2 (2).
Mind the mounting position of the bushing.
79
Dismounting the pump brake

7.5 Dismounting the pump brake
Fig. 100

Î Dismount the guide ring (2).
Î Lift off the pump wheel (3).
Î Take off the washer (4).
Î Loosen and remove the three cheese-head screws M8 (5).

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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the pump brake
Fig. 101
CAUTION
The disk carrier is under spring tension.
Î Lift off the pressure plate (2) from the piston carrier.
Î Lift off the PB disks (3) from the piston carrier.
Î Dismount the springs (5).
Î Dismount the spring sleeves (6).
Î Lift off the guide disk (7).
Î Remove the sealing ring (1).
Î Lift off the internal PB disk carrier (4) from the piston carrier.
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Fig. 102
Î Pull the PB piston (2) out of the piston carrier using two screws M8 (1).
Î Loosen and remove the six cheese-head screws.
Î Dismount the piston carrier with a plastic hammer or press.

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82
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the pump brake
Fig. 103

Î Lift off the piston ring carrier (2) from the pump shaft (4).
Î Remove the square section rings (3).
NOTE
To remove the square section rings, press one end
inwards and unhook.
Î Dismount the cylindrical roller bearing.
NOTE
Two bores are provided for dismounting the cylindrical
roller bearing.
Î Clean all parts carefully, check them for wear and replace them if necessary.
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Fig. 104
Î Dismount the double ring (5) out of the pump shaft (2).
Î Dismount the bushing (4) out of the pump shaft.
Î Dismount the two square section rings (3) out of the pump shaft.
NOTE
Dismount the Teflon bushing (1) if it is damaged (worn or
scratched).

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84
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the pump brake
Mounting the pump brake

7.6 Mounting the pump brake
Fig. 105
Î Install the two new square section rings (3).

Î Install the bushing (4).
Mind the mounting position of the bushing (4).
Î Mount the double ring (5).
NOTE
If the Teflon bushing (1) has been removed, press a new
Teflon bushing flush into the pump shaft.
Î The Teflon bushing has to be dry when installed.
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85
Mounting the pump brake Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 106
Î Install the two new square section rings (3) into the piston ring carrier (2).
Î Push the piston ring carrier (2) over the pump shaft (4); press the square section
rings (3) together while doing so.
Î Insert the new locking ring (1).

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86
Fig. 107
Î Check the grooved ball bearing (4), replace it if necessary.

Î Place the new gasket (1) on the piston ring carrier (2).
Î Mount the PB piston carrier (3) on the piston ring carrier (2).
NOTE
The bores (5) must face in the same direction while doing
so.
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87
Fig. 108
Î Tighten the six cheese-head screws M8x20-10.9 with washers B8 (1) crosswise.
NOTE
Î Grease the bearing surfaces of the piston rings.
Î Insert the new piston rings (4) into the PB piston (2) with the groove facing the oil
pressure side.
Î Mount the PB piston (2) into the PB piston carrier (3). © 2006 Voith Turbo GmbH & Co. KG
150.00024110_EN
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88
Fig. 109
Î Insert the inside PB disk carrier (2) into the piston carrier (3).
Î Grease, center and mount the new sealing ring (1).
Î Insert the new guide disk (7) into the piston carrier.
Î Insert ten spring sleeves (5) and ten cyl. pressure springs (4).
NOTE
Î Align the external disks with the guide disk.
Î Insert the disks (6) in the following order:
• 1 new inside disk

• 2 new outside disks, 3.5 mm thick
• 1 new inside disk
Î Install the pressure plate (3).
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89
Fig. 110
Î Place the PB disk carrier (1) on the piston carrier.
NOTE
Î Mind the position of the bore for the dowel pin (2) and
the correct fit of the spring seats.
Î Screw the disk carrier tight using three cheese-head screws M8x20-10.9 (2).
NOTE
Î When tightening the screws, make sure that the disks
do not become jammed when inserting them into the
guide brackets.

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90
Fig. 111
Î Mount the washer (4).

Î Mount the pump wheel (3).
Î Mount the guide ring (2).
Î Mount the new locking ring (1).
NOTE
Do not open the locking ring more than necessary.
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91
Dismounting the stator - turbine wheel Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the stator - turbine wheel

7.7 Dismounting the stator - turbine wheel
Fig. 112
Î Take the two circlips and the locking ring (1) out of the turbine wheel (2).
Î Take off the turbine wheel (2) and the stator from the turbine shaft.
Fig. 113
NOTE
Î If the stator is damaged, replace it as a whole.
Î Do not dismount the core ring (1).
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92
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the stator - turbine wheel
Fig. 114
Î Press the turbine shaft (2) out of the grooved ball bearing (4) and inner ring (3).
Î Take the double ring (7), ring (6) and seal bushing (5) out of the shaft.
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93
Mounting the stator - turbine wheel Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the stator - turbine wheel

7.8 Mounting the stator - turbine wheel
Fig. 115
Î Check that stator bushing (2) and roll pin (1) sit tightly.
The inside diameter of the stator bushing must not exceed 68.200 mm.
Fig. 116
Î Mount the new seal bushing (2) into the turbine shaft (1).
Î Mount the ring (3).
Î Mount the double ring (4).
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94
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the stator - turbine wheel
Fig. 117
Î Press the new grooved ball bearing (2) with inserted double ring (1) and inner ring
(5) on the turbine shaft (4) using the auxiliary tool [Ö Page 22] .
Î Place the spacing ring (3) on the grooved ball bearing.
Fig. 118
Î Place the stator (3) and turbine wheel (2) on the turbine shaft.
Î Secure it with a locking ring A58x2 and two circlips B73 (1).
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95
Assembly instructions for the locking ring for turbine wheel on the turbine shaft
NOTE
These instructions only apply for the installation of the
locking ring of the new 150.0085811 series on the turbine
shaft of the new 150.00101811 series together with the
turbine wheel H64.154310 without any bores for shim
rings. The device 151.00198410 is required for that.
Fig. 119 © 2006 Voith Turbo GmbH & Co. KG

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Fig. 120 Device 151.00198410
Î Slip the locking ring on the mandrel.

Î Press the sleeve with tenons (long side 1 to the sleeve) open manually.
ª The locking ring is moved to shortly before edge A.
CAUTION
The locking ring must not be mounted with pliers. Danger
of overexpansion.
Fig. 121
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Fig. 122
Î Mount the turbine wheel with turbine shaft 150.0010811 into the stator.
Î Place the mandrel with locking ring and sleeve on the turbine shaft.
Î Insert the tenon into the sleeve with the short end 2 and press the locking ring in
the groove intended for that by pressing the tenon.
Fig. 123
Î Install the two locking rings 150.00086010 in such a way that the openings of the
locking rings are not positioned on top of each other.
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98
Dismounting the turbine transmission

7.9 Dismounting the turbine transmission
Fig. 124
Î Loosen and remove the six hex. head screws (1).

Î Dismount the double ring (2).
Fig. 125
Î Press off the sun gear (2) from the planet carrier using the special tool (1)
[Ö Page 17] .
Î Take off the T-external crown (3).
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Dismounting the turbine transmission Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 126
Î Remove the spacer plate (1).

Î Take out the ring (2).
Fig. 127
Î Press off the retainer washer (3) and ball bearing (2) evenly from the planet carrier
(4) using two forcing screws M8 (1).
The forcing screws must not press on an axle.
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100
Fig. 128
Î Check the grooved ball bearing (1), replace it if necessary.
If the grooved ball bearing has to be replaced:

Î apply Loctite 270.
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101
Mounting the turbine transmission Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the turbine transmission

7.10 Mounting the turbine transmission
Fig. 129
Î Place the retaining washer (2) with turned groove facing upwards on the planet
carrier (1).
Î Mount the grooved ball bearing (4) with locking ring (3) on the planet carrier (1)
using the auxiliary tool [Ö Page 22] .
Î Mount the spacer ring (6), locking ring A80x2.5 (7) and spacer plate (5).
Fig. 130
Î Place the sun gear (1) on the external crown (2).

Î Mount the double ring (3), replace it if necessary.
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102
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the turbine transmission
Fig. 131
Î Screw the sun gear with mounted external crown on the planet carrier using six
hex. head screws M8x16 - 8.8 (1) with spring washers placed underneath.
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103
Dismounting the output and reverse gear Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Dismounting the output and reverse gear

7.11 Dismounting the output and reverse gear
Fig. 132
Î Loosen and remove the six cheese-head screws M8.
Fig. 133
Î Press off the supporting ring (1) using two forcing screws M8 (2).
Î Take off the disk spring (3), brake piston (4) and shim ring behind.
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104
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the TB-RB disk carrier
Dismounting the TB-RB disk carrier

7.12 Dismounting the TB-RB disk carrier
Fig. 134
Î Loosen and remove the four cheese-head screws (1).

Î Dismount the counter ring (2).
Fig. 135
Î Dismount the R planet carrier with external crown (1) from the TB-RB disk carrier
(2).
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105
Dismounting the TB-RB disk carrier Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 136
Î Take the external crown (1) off the planet carrier (2).
Fig. 137
Î Disassemble [Ö Page 63] the planet carrier (1).

Î Mount the new square section rings (2).

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106
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Dismounting the TB-RB disk carrier
Fig. 138
Î Loosen and remove the three cheese-head screws (1).

Î Dismount the thrust ring (2).
Fig. 139
Î Make sure that the thrust ring (1) sits tightly.

If the thrust ring is loose:
Î Fasten the thrust ring with the new rivets, replace the thrust ring if necessary.
Î Take out and clean the springs (2).
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107
Mounting the TB-RB disk carrier Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the TB-RB disk carrier

7.13 Mounting the TB-RB disk carrier
Fig. 140
Î Mount the springs (2).

Î Insert the thrust ring (1).
Î Set up the disk carrier.
Î Insert the three sleeves (3).
Î Screw tight with three screws M8x25 - 10.9 (5) with washers (4) underneath.
Fig. 141
Î Assemble [Ö Page 64] the planet carrier (1).

Î Mount the new square section rings (2).
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108
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the TB-RB disk carrier
Fig. 142
Î Place the external crown (1) on the planet carrier (2).
Fig. 143
Î Mount the R planet carrier with external crown (1) into the TB-RB disk carrier (2).
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109
Mounting the TB-RB disk carrier Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 144
Î Screw the counter ring (2) tight using four cheese-head screws M6x30 – 10.9 (1).

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Mounting and dismounting the operating
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual pressure valve
Mounting and dismounting the operating pressure valve

7.14 Mounting and dismounting the operating pressure valve
Fig. 145
NOTE
Do not dismount the threaded pin and thread insert (6) for
setting the operating pressure.
CAUTION
Risk of injury
The console (4) and the cover (12) are under spring
tension.
Î Loosen and remove the four hex. head screws (13).


Î Dismount the piston with the locking ring (11).
Î Dismount the piston (10).
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Î Dismount the piston actuator (9).

Î Dismount the pressure spring 2.0x15.5x76.5 (8).
111
pressure valve Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Î Loosen and remove the three cheese-head screws CV84 M6x20 (5).
Î Dismount the console (4).
Î Dismount the cyl. pressure spring 3.2x21.0x101 (7).
Î Dismount the washer (2).
Î Check the pistons and bores for damage, replace if necessary.
Make sure that the pistons are mounted in the correct position and run smoothly.
Fig. 146
Î Loosen and remove the two cheese-head screws CV84 M6x20 (7).
Î Dismount the pressure spring 3.0x20.0x31.6 (5).
Î Loosen and remove the two cheese-head screws CV84 M6x20 (3).
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112
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual pressure valve
Fig. 147
Î Check the piston and bores for damage, replace if necessary.

Fig. 148
Î Mount the washer (2).

Î Screw the console (4) tight using three cheese-head screws CV84 M6x20 (5).
Î Mount the cyl. pressure spring 3.2x21.0x101 (7).
Î Mount the cyl. pressure spring 2.0x15.5x76.5 (8).
Î Mount the piston actuator (9).
Î Mount the piston (10).

Î Mount the piston with locking ring (11).
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Î Screw the cover (12) tight using four hex. head screws M6x45-8.8 with four spring
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washers B6 (13) placed underneath.
113
pressure valve Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 149
Î Screw the cover (2) tight using two cheese-head screws CV84 M6x20 (3).
Î Mount the pressure spring 3.0x20.0x31.6 (5).
Î Screw the cover (6) tight using two cheese-head screws CV84 M6x20 (7).

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114
Dismounting and mounting the gear
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual pump
Dismounting and mounting the gear pump

7.15 Dismounting and mounting the gear pump
Fig. 150
Î Loosen and remove the seven hex. head screws M8 (1).

Î Pull the two cylindrical pins (2) out of the housing (10).
Î Dismount the cover (3).
Î Dismount the gear wheel with axle (5) from the housing.
Î Loosen and remove the hex. head nut (13).
Î Remove the washer (12).
Î Remove the gear wheel (11).
Î Pull the gear wheel with pump shaft (8) out of the housing.
Î Press the needle sleeves (4) and (7) out of the cover (3).
Î Press the needle sleeves (6) and (9) out of the housing (10).
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115
pump Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 151
Î Press the needle sleeves (6) and (9) into the housing (10) using the auxiliary tool
[Ö Page 22] .
Î Press the needle sleeves (4) and (7) into the cover (3) using the auxiliary tool
[Ö Page 22] .
Î Mount the gear wheel with pump shaft (8) into the housing.
Î Mount the gear wheel with axle (5) into the housing.
Î Fix the cover (3) at the housing (10) using two cylindrical pins.
Î Screw the cover (3) to the housing (10) using seven hex. head screws M8 (1).
Î Screw the gear wheel (11) with washer (12) tight using a hex. head nut (13).
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116
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual pump
Disassembling the intermediate gear
NOTE
It is also possible to replace the gear wheel as a whole.
Fig. 152
The rivets (6) must be destroyed for disassembling the gear wheel.
Î Dismount the rivets (6).
Î Remove the washers (3) and (5).
Î Press the supporting ring (1) out of the gear wheel.
Î Press the grooved ball bearing (2) out of the gear wheel.
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pump Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Assembling the intermediate gear
Fig. 153
Î Mount the new grooved ball baring (2) into the gear wheel (4).
Î Mount the supporting ring (1).
Î Put on the washers (3) and (5).
Î Fasten them with the new rivets (6).

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118
Mounting and dismounting the converter
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual outlet valve
Mounting and dismounting the converter outlet valve

7.16 Mounting and dismounting the converter outlet valve
Fig. 154
Î Loosen and remove the four cheese-head screws M6x30 – 8.8 (15).
Î Loosen and remove the three cheese-head screws M6x55 - 8.8 (12).
Î Dismount the pressure spring 0.9x10.5x31 (8).
Î Dismount one piston (17).
Î Loosen and remove the two cheese-head screws M6x16 - 8.8 (11).
Î Remove cover (10).
Î Dismount the two pressure springs 0.9x10.5x31 (8).
Î Dismount two pistons (7).
Î Loosen and remove the three cheese-head screws M6x16 – M8.8 (11).
Î Dismount the cover (4).
Î Loosen and remove the two cheese-head screws M6x50 - 8.8 (13).
Î Remove the plate (2).
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119
outlet valve Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 155
Î Check the pistons for wear, replace them if necessary.

Î Check the bores for pistons in the housing (1) for wear, replace the housing if
necessary.
Fig. 156
Î Screw the plate (2) tight using two cheese-head screws M6x50 – 8.8 (13).

Î Mount the two pistons (7).
Î Mount the two pressure springs 0.9x10.5x31 (8).
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Î Screw the cover (4) tight using the three cheese-head screws M6x16 – 8.8 (11).
Î Tightening torque 9 Nm.
120
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual outlet valve

Î Screw the cover (6) tight using the four cheese-head screws M6x30 – 8.8 (15).
Î Screw the cover (10) tight using the three cheese-head screws M6x55 – 8.8 (12).
Î Install the pressure spring 0.9x10x5x31 (8).
Î Screw the cover (16) tight using the three cheese-head screws M6x55 (12).
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121
Repairing control blocks Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Repairing control blocks

7.17 Repairing control blocks
Input-end control block
Fig. 157 Input-end control block
Dismounting the input-end control block

Î Loosen the 5 hex. head screws (1) and dismount the cover (2).
Î Dismount the 3 pistons (5), 3 control pins (4) and 3 pressure springs (3) from the
housing (8).
Î Loosen all screw plugs M10 (12) and remove them with the washers (11).
Otherwise the pistons cannot be dismounted.
Î Dismount the piston (7) and the pressure spring (6).
Î Loosen the 8 cheese-head screws M 5x20-CV84 (13) and dismount the 4 solenoid
coils (14).
Mounting the input-end control block

Î Use the 8 cheese-head screws M 5x20-CV84 (13) to screw tight the 4 solenoid
coils (14).
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The connections must be on top.
122
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Repairing control blocks
Î Mount the piston (7) with the pressure spring (6).

Î Mount the 3 pistons (5), 3 control pins (4) and 3 pressure springs (3).
Î Screw the cover (2) tight using the five hex. head screws (1) M6x12-8.8.
Î Screw in the screw plugs WP M10x1 (12) with sealing rings (11).
NOTE
Mounting the pistons
If the pistons are mounted incorrectly, transmission

malfunctions may occur during operation.
Î Make sure that the pistons are mounted in the correct
position and run smoothly.
Output-end control block
Fig. 158 Output-end control block
Dismounting the output-end control block

Î Loosen the 5 hex. head screws (1) and dismount the cover (2).
Î Loosen all screw plugs M10 (15) and remove them with the washers (16).
Otherwise the pistons cannot be dismounted.

Î Dismount the pistons (3), control pins (4) and pressure springs (5) from the
housing (17).
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Î Dismount the pistons (6) and pressure springs (7) from the housing (17).
123
Repairing control blocks Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Î Dismount the insert (8), O-rings (9), ball (10), valve body (11) and locking ring
(12).
Î Loosen the 10 cheese-head screws M 5x20 (13) and dismount the solenoid coils
(14).
Mounting the output-end control block

Î Use the 10 cheese-head screws M 5x20-CV84 (13) to screw tight the 5 solenoid
coils (14).
The connections must be on top.
Î Mount the piston (6) with the pressure spring (7).
Î Mount the pistons (3), control pins (4) and pressure springs (5).
Î Mount the insert (8), O-rings (9), ball (10), valve body (11) and locking ring (12).
Î Screw the cover (2) tight using the five hex. head screws (1) M6x12-8.8.
Î Screw in the screw plugs WP M10x1 (15) with sealing rings (16).
NOTE
Mounting the pistons
If the pistons are mounted incorrectly, transmission

malfunctions may occur during operation.
Î Make sure that the pistons are mounted in the correct
position and run smoothly.
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124
Assembling the transmission
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual General

8 Assembling the transmission
General
8.1 General
Check the bearing surfaces of the piston rings for grooves, polish slight grooves if
necessary.
Stretch the inner piston rings before inserting them.
Insert piston rings generally with the groove facing the oil pressure side.
Grease all piston rings and O-rings before mounting.
Grease bearing surfaces of radial sealing rings.
Do not open locking rings more than necessary during assembly.
Mounting the screw plug

8.2 Mounting the screw plug
Fig. 159
Î Mount the insert (3).

Î Insert the washer (2).
Î Mount the screw plug (1) into transmission housing.
Screw in the screw plug at least until it is flush with the housing.
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125
Mounting the pump brake

8.3 Mounting the pump brake
Fig. 160
Î Place the transmission housing on its output side.

Î Insert the new O-ring 275x2.65 (1) into the housing groove.
Stretch and grease the O-ring before mounting.
Fig. 161
Î Mount the pump brake assembly (1) using the special tool [Ö Page 17] .
Î Align the pump brake with the centering pin (3).
Î Screw the pump brake tight with the nine hex. head screws M10x65-8.8 (2) with
the nine B1 spring washers placed underneath.
The positions 4 and 5 remain empty.
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126
Fig. 162
Î Screw the line (1) tight with the hex. head screw (2) M10x65.
Î Insert and fasten the line (3).
Î Insert and fix the pipe with the cable (4).
Fig. 163
Î Screw the plate (6) with the temperature sensor (4) to the housing using the hex.
head screws M 10x20 – 8.8 (7).

Î Screw the pipe with the cable (3) and oil line (2) to the housing using the hex.
head screw M10x20 – 8.8 (1).
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Î Insert the cable (5) at the temperature sensor (4).
127
Fig. 164
NOTE
Put greased O-rings on all plug-in tubes before mounting.
Use new O-rings.
Î Mount the plug-in tubes (1) (2) (3) with the thread facing upwards – O-rings
29.3x3.
Î Mount the pipe (4) – O-rings 12x2.
Î Screw the pipe (4) tight using the hex. head screw M10x65 – 8.8 (6) and the
spring washer.
Î Screw the pipe (5) tight with the hollow screw M16x1.5x28 (7).

Î Fasten the pipe H68.0766.. (8).
Î Screw tight pipe H68.0766.. (10) and pipe H68.3158.. (11) with hollow screw
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M14x1.5x32 (9).
128
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the operating pressure valve
Mounting the operating pressure valve

8.4 Mounting the operating pressure valve
Fig. 165
CAUTION
Risk of injury from dropping part
When the operating pressure valve is re-installed, it is not

secured by screws at first. It can drop and cause injury.
Î Wear appropriate protection gear.
Î Insert the operating pressure valve (2).

Î Fasten the line (1).
Î Mount the plug-in tubes (3) and (4).
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129
Mounting the operating pressure valve Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 166
1 Pipe 68.3153...
2 Pipe 68.0766...
3 Pipe 68.3034...
Î Fasten the pipe (1) at the operating pressure valve using a hollow screw.
Î Mount the valve shim.
Only fasten the valve shim, do not tighten the screws.

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130
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the converter drain valve
Mounting the converter drain valve

8.5 Mounting the converter drain valve
Fig. 167
Î Fasten the converter drain valve (14) using the five cheese-head screws M6x40
10.9 (13).
Do not tighten the cheese-head screws.
Î Fasten the pipe (12) at the converter drain valve (14) with the hollow screw (18)
and at the operating pressure valve with the union nut (10).
Î Fasten the pipe H68.3152.. (19) at the converter drain valve (14) with the hollow
screw (20) and at the operating pressure valve (4) with the hollow screw (6).
Î Fasten the pipes (1) H68.076310 and (11) at the converter drain valve (14) with
the hollow screw (17).
Î Fasten the pipe (1) H68.076310 at the operating pressure valve (4) using the
hollow screw (2).
Î Fasten the pipe (3) H68.0761.. at the converter drain valve (14) using the hollow
screw (15).
Î Fasten the pipe (9) at the converter drain valve (14) with the hollow screw (16) and
at the pipe 68.3153... with the hollow screw.
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Î Screw the pipe (7) to the housing with the hex. head screw M8x10 - 8.8 (8).
131
Mounting the converter drain valve Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Î Tighten all screws.

Tightening torques [Ö Page 162]

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132
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the gear pump
Mounting the gear pump

8.6 Mounting the gear pump
Fig. 168
Î Fasten the gear pump (2) at the housing with the three hex. head screws M10x45–
8.8 (4) with B10 spring washers underneath.
Î Fasten the pipe (1) to the housing using a new O-ring with the hex. head screw
M10x45–8.8 (3).
Î Tighten the hex. head screws (3) and (4).
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133
Mounting the gear pump Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 169
Î Screw the gear wheel (1) tight using the cheese-head screw M10x30–10.9 (3) with
the spring washer B10x18 (2) underneath.

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134
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the drive unit
Mounting the drive unit

8.7 Mounting the drive unit
Fig. 170
Î Place the new gasket (4) on the transmission housing.

Î Lower the input differential (2) by continuously turning the shaft (1) and align it with
the roll pin (3).
The gears of the driveline must mesh.
Î Screw the input cover tight using 13 hex. head screws M10 x 50 – 8.8 and 13 B10
spring washers.
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135
Mounting the stator - turbine wheel

8.8 Mounting the stator - turbine wheel
Fig. 171
Î Insert the stator with the turbine wheel and turbine shaft (1) into the transmission
housing using the special tool (2) [Ö Page 17] .
Fig. 172
The guide at the stator (1) and the groove at the housing (2) must be aligned to
each other.
Fig. 173
Î Insert the throttle (1) with the new O-ring 12x2 (2) in the bore of the transmission
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housing (control block side).

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136
Fig. 174
Î Mount the piston rings (4) and (5) with the groove facing the pressure side into the
T-piston (3).
Î Screw the stator (2) tight using 12 cheese-head screws M10x35 (1) and washers
B10.5.
Fig. 175
Î Insert the disk spring (6).

Î Insert the supporting ring (1).
Î Insert the four cheese-head screws M8x30– 10.9 (2) with Loctite 242 and tighten
them.

Î Insert the two disk springs (3) and (4).
Insert the disk springs in X-shape. .
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Î Insert the brass washer (5) into the supporting ring.
137
Fig. 176
Î Insert the planet carrier shaft (1) with the double ring (2).
Î Bring the planet carrier shaft into toothing by turning it.

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138
Mounting the turbine transmission

8.9 Mounting the turbine transmission
Fig. 177
The external disks (3) of the turbine transmission bear a special marking (5) that
allows them to be distinguished from the external disks of the reverse-gear
transmission.
Observe the marking to distinguish from reverse-gear disks.
Î Place four external disks with marking (3) and three inside disks (4) on the turbine
transmission on top of each other.
Begin with an external disk.
Î Align the disks.
Î Press the disks and turbine transmission together using the special tool (2)
[Ö Page 19] .
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139
Mounting the turbine transmission Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 178
Î Insert the turbine transmission (2) into the housing using the special tool (1).
Î Remove the special tool (1).
Fig. 179
Î Insert the RG-TB disk carrier (1) complete with external crown with thrust ring (2)
upwards and groove facing the parallel key groove.
NOTE
The disk carrier must not get jammed.
The disk carrier must sit on the stator.
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140
Fig. 180
Î Screw in the screw neck (1) with the hose line (2).
Î Screw the hose line to the converter drain valve using the hollow screw (3) and
sealing rings A10x16.
Fig. 181
Î Insert two new O-rings 12x3 (1).

Î Insert the parallel key (2).
Fig. 182
Î Mount six external and five internal disks (1) alternately.

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Begin with an external disk.
141
Mounting the reverse gear into the
output unit Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the reverse gear into the output unit

8.10 Mounting the reverse gear into the output unit
Fig. 183
Î Press the new oiled radial sealing ring (1) into the output cover (2).
NOTE
The radial sealing ring must lie 2 mm below the upper
edge of the input cover.
Fig. 184
Î Mount the ring (2).

Î Insert the brake piston (1).
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142
Measure and adjust the disk clearance of
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual the reverse gear.
Measure and adjust the disk clearance of the reverse gear.

8.11 Measure and adjust the disk clearance of the reverse gear.
Fig. 185
NOTE
Insert the brake piston without the piston rings into the
output cover. Disks and piston must sit close when
measuring.
Do not press the disks together.
Î Take measure A.
Î Take measure B.
ª A minus B provides the measured disk clearance.
• Example:
Measure A = 5.5 mm
Measure B = 1.0 mm
5.5 mm - 1.0 mm = 4.5 mm disk clearance.
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143
Measure and adjust the disk clearance of
the reverse gear. Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Defining the shim rings:
Shim rings are available in 0.5 mm, 1.0 mm and 1.5 mm thickness.
NOTE
The disk clearance must lie between 2.7 and 3.2 mm.
• Example:
4.5 mm measured disk clearance
minus 1.5 mm shim ring
yields a clearance of 3.0 mm.
Î Take the brake piston out of the output cover.
Î Insert the new piston rings with the groove facing the pressure side.
Î Insert the new piston ring without groove into the brake piston.
Î Insert the brake piston into the output cover.

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144
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the output unit
Mounting the output unit

8.12 Mounting the output unit
Fig. 186
Î Check the grooved ball bearing 6215 (1), replace it if necessary.
Fig. 187
Î Insert the new spring washer (2) and ring (1) into the output cover.
Î Screw the output cover tight using six cheese-head screws M8x30– 10.9 (3) and
six spring washers A8.
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145
Mounting the output unit Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 188
Î Slightly roughen the bearing surface of the gasket on the housing.

Î Place the new gasket (1) on the transmission housing.
Fig. 189
Î Mount the output cover (2) with the special tool (1) [Ö Page 17] .
When lowering the output cover, make sure that the ring gear does not become
jammed and the radial sealing ring is not damaged.
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146
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the output unit
Fig. 190
Î Fix the output cover and gasket with the special tool (2) [Ö Page 17] .
Î Insert the output flange (1).
Î Use a plastic hammer to knock on the output flange until the cover sits tight on the
transmission housing.
Î Screw the output cover tight using 12 hex. head screws M10 x 60 – 8.8 and 12
B10 spring washers.
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Mounting the output unit Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 191
Î Place the measuring device (2) on the shaft.

Î Screw the measuring device to the shaft using three hex. head screws M10x70 –
10.9 (1):
- Tighten the screws one after the other to a tightening torque of 50 Nm.
- Tighten the screws a second time to a tightening torque of 50 Nm one after the
other.
- Tighten the screws again subsequently to a tightening torque of 50 Nm.
Repeat this process three times.
Î Measure the distance between the planet carrier shaft (4) and the upper edge of
the measuring device (2) using a depth gauge.
ª The measured clearance is X = A - 30 mm.
The allowed clearance is 0.0 to 0.2 mm.

Î Loosen and remove the hex. head screws (1).
Î Remove the measuring device.
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Î Use the shim rings (3) where necessary to adjust the clearance.
148
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mount the oil pan.
Mount the oil pan.

8.13 Mount the oil pan.
Fig. 192
Î Put on the new gasket (1).

Î Screw the oil pan (2) tight using 28 hex. head nuts (4) and 28 washers (3).
Fig. 193
Î Insert the oil filter.

Î Screw in the oil filter cover (2).
Î Screw in the oil drain plug with sealing ring A26x34 (1).
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Mounting the cable harness Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the cable harness

8.14 Mounting the cable harness
Fig. 194
Î Insert the speed sensors N1(1), N2 (4) and N3 (3).
CAUTION
The speed sensor can be damaged.
Î Never use an impact screwdriver to assemble the
speed sensor.
Î Tighten the screws at speed sonsors N1(1), N2 (4) and N3 (3).

Î Screw in the converter oil temperature sensor (2).
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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the cable harness
Fig. 195
Î Screw the fastener tight with the hex. head screw M8x16 - 8.8 (1).
Î Screw the pipe tight with the hollow screw M10x1 (2).
Fig. 196
Î Insert the cable harness (1).

Î Tighten the four hex. head screws M6x40-A4-70 (2).
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Mounting the cable harness Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 197
Î Mount the protective cable cover (2).

Î Screw the cable protection tight with the hex. head screw M8x16 - 8.8 (1).
Fig. 198
Î Insert the connector to the oil sump temperature sensor (2) with the special tool
(1) [Ö Page 14] .
Fig. 199
Î Plug in the connector to the converter temperature sensor (1).

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Î Lay the cable and plug in the protective cable covering as shown in the picture.
152
Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the cable harness
Fig. 200
Î Plug in the connector to the speed sensor N1 (1).
Fig. 201
Î Insert the plugs to the speed sensors N2(1) and N3 (2).

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Mounting the control blocks Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the control blocks

8.15 Mounting the control blocks
Fig. 202
Î Fasten the control block (2) with six cheese-head screws M8x50 (1).
Î Insert the five cable connectors (4) with the special tool [Ö Page 13] at the
solenoid coils.
Fig. 203
Î Insert the cable connectors (3) with the special tool (1) [Ö Page 13] at the solenoid
coils.
Î Mount the connecting tube (2) with the new O-rings 12x2.
Î Fasten the control block (4) with six cheese-head screws M8x50 (5).
Î Tighten the 12 cheese-head screws M8x50.

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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the control block cover
Mounting the control block cover

8.16 Mounting the control block cover
Fig. 204
Î Insert the new gasket (4).

Î Screw the control block cover (3) tight using 20 hex. head screws M8x30–8.8 (1)
and washers B8.4 (2).
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Mounting the heat exchanger Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Mounting the heat exchanger

8.17 Mounting the heat exchanger
Fig. 205
Î Mount the plug-in tubes (1).

Î Put on two new gaskets (2).
Fig. 206
Î Attach the heat exchanger with fastener (3) to the transmission using six hex. ead
screws M12x40-8.8 (2) and two hex. head nuts M12 (1).
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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Mounting the hydrodamp
Mounting the hydrodamp

9 Mounting the hydrodamp
Fig. 207
Î Apply molybdenum disulphide (paste or spray) to the spline profile of the

hydrodamp.
Î Fix the hydrodamp at the external pitch circle at the engine flywheel in the
positions 2 and 10 o' clock by way of two assembly pins.
Î Push the hydrodamp into the centering.
Î Screw the hydrodamp to the engine flywheel with two screws.
Î Unscrew the assembly pins.
Î Insert the remaining screws.
Î Evenly tighten the 12 screws M10-8.8 crosswise.
The hydrodamp can also be fixed in the positions a and b at the engine flywheel using
two dowel pins.
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Measuring pressures Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Measuring pressures
10 Measuring pressures
Fig. 208 Measuring cover
1 WR 7 Operating pressure
2 Converter pressure 8 DK
3 TB 9 EK
4 RG 10 PB
5 RK 11 WP
6 SK
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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Measuring pressures
DANGER
Improper behaviour may result in severe injuries or

scalding.
Î Mount the measuring cover only with the engine dead.
Î Connect the pressure gauge only with the engine dead.
Operating pressure
Î Measure the operating pressure at measuring point 7 (see illustration).
• after shifting into second gear,

• at an engine speed of approx. 15001/min,
• at an oil temperature of 80-90 °C.
The setpoint for the operating pressure is pA = 8.5 bar. (± 0.2 bar).
If the operating pressure deviates from this value, it has to be re-adjusted. The
operating pressure may, for instance, deviate from the setpoint after
disassembling and assembling the operating pressure valve.
The adjustment bore in the housing allows the threaded pin with hexagon socket
at the operating pressure valve to be turned using a hexagon socket wrench a/f 5.
The threaded pin allows adjusting the preload of the spring in the operating
pressure valve.
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Measuring pressures Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Fig. 209 1 - Adjustment bore
Î Turn the threaded pin until an operating pressure of 8.5 bar is reached.
If the operating pressure is below the setpoint and can no longer be set to 8.5 bar, the
gear pump could be defective.
Î Check the gear pump, repair or replace it if necessary (see repair manual).
The setpoint at engine idle speed (500 -± 50 1/min) is pA ≥ 3.5 bar.
Î See the illustration for measuring points.

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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual Measuring pressures
Pressures at the solenoid valves
At the measuring points DK, EK, PB, WP and SK, the pressures must be identical to
the operating pressure.
NOTE
WR pressure
The WR oil pressure is cycled and therefore variable over

time. Its height depends on the operating status (braking or
reversing).
Therefore, simple pressure measurements by means of a
pressure gauge are not suitable for more thorough
troubleshooting at the WR valve.
NOTE
Exception for RBK pressure
The RBK pressure for braking in first gear is 1 bar.

In few cases the RBK pressure for braking in first gear is
max. 2 bar.
Converter pressure
Î Measure the converter pressure at measuring point 2.
pC ≥ 2 bar at
• oil temperature toil 80-90 °C

• with forward gear engaged,
• engine at idle speed (500 ± 50 1/min),
• and parking brake applied.
See the illustration for measuring points.

If this value is not reached, the converter sealing must be improved.

pW when converter filling control (CFC) pC= 0 bar is active.
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DIWA.5 tightening torques Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
DIWA.5 tightening torques

11 DIWA.5 tightening torques
Tightening torques for hex. head and cheese-head screws
Dimensions Property class Tightening torque Tightening torque

[Nm] [lb-ft]
M4 8.8 3 2
M4 10.9 4 3
M5 8.8 5 4
M5 10.9 8 6
M6 8.8 9 7
M6 10.9 14 10
M8 8.8 23 17
M8 10.9 33 24
M10 8.8 46 34
M10 10.9 67 49
M10x1 8.8 51 38
M10x1 10.9 75 55
M12 8.8 78 57
M12 10.9 115 85
M14x1.5 12.9 232 171
M16 10.9 281 208

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Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual DIWA.5 tightening torques
Special cases
Name Dimensions Tightening torque Tightening torque

[Nm] [lb-ft]
Control block M8x50 20 15
Input differential M10x150 55 41
Stator M10x35 50 37
Output flange* M10x50-10.9 SBE 72 53
M10x50-10.9 SBE- 66 49
R
Gear pump - M10x30-10.9 50 37

intermediate gear
Oil filter cover S110x3 25 18
Temperature M14x1.5 20-25 15-19

sensor
*Fastening the screws at the output flange

Î Tighten the device with 3 screws to 50 Nm each.
Î Measure the clearance.
Î Set the clearance to 0.1 ± 0.1.
NOTE
Tighten the screws at the output flange one after the other
in 3 complete tightening cycles to an appropriate tightening
torque (see table).
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DIWA.5 tightening torques Voith Turbo GmbH & Co. KG | DIWA.5 Repair Manual
Tightening torques for screw plugs and hollow screws with CU sealing rings
Dimensions Sealing Tightening torque Assembly Name

ring [Nm]
Steel/Al
Nm lb-ft oiled dry
M10x1.5 10x13.5 13 10 x Banjo bolt
M10x1 10x13.5 15 11 x Screw plug
M12x1.5 12x15.5 20 15 x Screw plug
M14x1.5 14x18 38 28 x Screw plug
M18x1.5 18x22 45 33 x Screw plug
M26x1.5* 26x34 100 74 x Screw plug
M30x1.5* 30x36 115 85 x Screw plug
M32x1.5* 32x38 130 96 x Screw plug
M38x1.5* 38x44 150 111 x Screw plug
M42x1.5* 42x49 190 141 x Screw plug
M48x1.5* 48x55 260 192 x Screw plug
NOTE
Sealing ring and screw of dimensions marked with * have
to be oiled slightly.
All other sealing rings and screws have to be dry for

mounting.
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Voith Turbo GmbH & Co. KG
Alexanderstraße 2
D-89522 Heidenheim
+49 7321 37 0
+49 7321 37 7618
[email protected]
www.voithturbo.com

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DIWA.

1.1 Safety notes 1

2.1 Checking and replacing parts 8

2.3 Suspension points 8

2.4 Hose lines 9

3.1 Standard tools 10

3.2 Special tools 12

3.4 Measuring tools 23

4 Dismounting the hydrodamp 25

4.2 Checking the oil level 26

4.3 Wear check at the hub 27

5 Draining the transmission oil 28

6 Disassembling the transmission into assemblies 31

6.1 Dismounting the heat exchanger 31

6.2 Dismounting the control blocks 33

6.3 Dismounting the cable harness 36

6.4 Dismounting the oil pan 38

6.5 Dismounting the output assembly 40

6.6 Dismounting the turbine transmission 43

6.7 Dismounting the drive unit 45

6.8 Dismounting the suction screen 46

6.9 Dismounting the gear pump 47

6.10 Dismounting the converter outlet valve 48

6.11 Dismounting the operating pressure valve 50

6.12 Dismounting the pump brake 52

7 Dismounting and mounting assemblies 53

7.1 Dismounting the input differential 53

7.2 Dismounting the planet carrier 63

7.3 Mounting the planet carrier 64

7.4 Mounting the input differential 65

7.5 Dismounting the pump brake 80

7.6 Mounting the pump brake 85

7.7 Dismounting the stator - turbine wheel 92

7.8 Mounting the stator - turbine wheel 94

7.9 Dismounting the turbine transmission 99

7.10 Mounting the turbine transmission 102

7.11 Dismounting the output and reverse gear 104

7.12 Dismounting the TB-RB disk carrier 105

7.13 Mounting the TB-RB disk carrier 108

7.14 Mounting and dismounting the operating pressure valve 111

7.15 Dismounting and mounting the gear pump 115

7.16 Mounting and dismounting the converter outlet valve 119

7.17 Repairing control blocks 122

8 Assembling the transmission 125

8.1 General 125

8.2 Mounting the screw plug 125

8.3 Mounting the pump brake 126

8.4 Mounting the operating pressure valve 129

8.5 Mounting the converter drain valve 131

8.6 Mounting the gear pump 133

8.7 Mounting the drive unit 135

8.8 Mounting the stator - turbine wheel 136

8.9 Mounting the turbine transmission 139

8.12 Mounting the output unit 145

8.13 Mount the oil pan. 149

8.14 Mounting the cable harness 150

8.15 Mounting the control blocks 154

8.16 Mounting the control block cover 155

8.17 Mounting the heat exchanger 156

9 Mounting the hydrodamp 157