ZF WSK 400 WSK 440 16 S Repair Manual PDF Download

Description

WSK 400/440 Coverage for 16 S Applications

The ZF WSK 400/440 repair manual identifies WSK 400 for 16 S 151 and 16 S 221, including versions without/with NMV, and WSK 440 for 16 S 251. Its content runs from removal and installation through converter, clutch, control, retarder, pressure-measuring and functional-test work, backed by a dense register of exact settings and tightening torques.

Assemblies and Variants Documented

The document identifies the following applicability or named equipment:

• WSK 400 for 16 S 151
• WSK 400 for 16 S 221
• WSK 400 without/with NMV
• WSK 440 for 16 S 251

Repair Chapters and Test Sections

The manual is organised around these top-level sections and repair groups:

• Preface
• Important notes
• Repair notes
• Tightening torques
• Consumables
• Register data
• Spring table
• Special tools
• 1 — WSK/engine removal and installation
• 2 — Transmission support
• 3 — Central wiring, WSK 400/440
• 4 — Oil tank, WSK 400/440
• 5 — NMV
• 6 — Clutch cylinder, WSK 400/440
• 7 — WSK/transmission, WSK 400/440
• 8 — Engagement clutch, WSK 400/440
• 9 — Torque converter, WSK 400/440
• 10 — Turbine shaft, WSK 400/440
• 11 — Oil filter, WSK 400/440
• 12 — Radiator switching valve
• 13 — Control, WSK 400/440
• 14 — Retarder, WSK 400/440
• 15 — NMV gear pair
• 16 — Converter housing, WSK 400/440
• 17 — Pressures and measuring points for WSK 400, WSK 440 and NMV
• 18 — KD functional test of WSK system

Measurements, Torques and Setup Work

Across those sections, the work is centred on the following systems and service subjects:

• engine-flanged and engine-separated WSK versions
• gearbox support and central wiring
• oil tank and NMV assemblies
• clutch cylinder and WSK-to-transmission interface
• engagement clutch
• torque converter disassembly and assembly on WSK 440
• turbine shaft and oil filter
• radiator switching valve, direct and indirect NMV versions
• WSK controls with and without NMV
• retarder and NMV gear pair
• converter housing, oil-supply flange, gear pump and wiring harness
• pressure measuring points and KD functional testing
• tightening torques, consumables, spring data and special tools

Practical tasks supported by the procedures include:

• remove and install the WSK with engine-flanged or engine-separated arrangements
• set torque-converter installation dimensions and tapered-roller-bearing axial play
• check inductive-sensor distances for engine/turbine speed sensing
• disassemble and assemble the WSK 440 torque converter
• service the engagement clutch, turbine shaft, filter, switching valve and control units
• service retarder and NMV-related parts
• use the register-data tables for tightening values, clearances, installation dimensions and temperatures
• check WSK 400/440/NMV pressure points and carry out the KD functional test

Selected Register Data

Among the measurable values and reference points printed in the manual are:

• Converter installation dimension C: WSK 400 80.7 ±0.20 mm; WSK 440 81.6 ±0.20 mm
• Inductive transducer distance “n Motore”: 0.50 to 0.80 mm
• Tapered roller bearing axial play: 0.05–0.15 mm
• M12x1.5 adapter ring/converter tightening torque: 83 Nm
• Converter expansion screw tightening torque: 190 Nm
• WSK/engine installation dimension: 83.15 ±0.65 mm
• Diaphragm thickness: WSK 400 2.4 ±0.14 mm; WSK 440 1.5 ±0.07 mm
• Converter piston/lamella clearance: 0.70–1.70 mm
• Converter check dimension: 149.8 -0.2 mm
• Outer bearing ring/oil-supply flange heating temperature: approx. 100 °C
• M45x1.5 converter plug tightening torque: 140 Nm

For buyers comparing this manual with a shorter overview, the depth comes from the way its named sections connect to real workshop subjects. Preface is part of the documented coverage, alongside engine-flanged and engine-separated WSK versions. Important notes is part of the documented coverage, alongside gearbox support and central wiring. Repair notes is part of the documented coverage, alongside oil tank and NMV assemblies. Tightening torques is part of the documented coverage, alongside clutch cylinder and WSK-to-transmission interface. Consumables is part of the documented coverage, alongside engagement clutch. Register data is part of the documented coverage, alongside torque converter disassembly and assembly on WSK 440. Spring table is part of the documented coverage, alongside turbine shaft and oil filter. Special tools is part of the documented coverage, alongside radiator switching valve, direct and indirect NMV versions. 1 — WSK/engine removal and installation is part of the documented coverage, alongside WSK controls with and without NMV. 2 — Transmission support is part of the documented coverage, alongside retarder and NMV gear pair. 3 — Central wiring, WSK 400/440 is part of the documented coverage, alongside converter housing, oil-supply flange, gear pump and wiring harness. 4 — Oil tank, WSK 400/440 is part of the documented coverage, alongside pressure measuring points and KD functional testing. 5 — NMV is part of the documented coverage, alongside tightening torques, consumables, spring data and special tools. 6 — Clutch cylinder, WSK 400/440 is part of the documented coverage, alongside engine-flanged and engine-separated WSK versions. 7 — WSK/transmission, WSK 400/440 is part of the documented coverage, alongside gearbox support and central wiring. 8 — Engagement clutch, WSK 400/440 is part of the documented coverage, alongside oil tank and NMV assemblies. 9 — Torque converter, WSK 400/440 is part of the documented coverage, alongside clutch cylinder and WSK-to-transmission interface. 10 — Turbine shaft, WSK 400/440 is part of the documented coverage, alongside engagement clutch. 11 — Oil filter, WSK 400/440 is part of the documented coverage, alongside torque converter disassembly and assembly on WSK 440. 12 — Radiator switching valve is part of the documented coverage, alongside turbine shaft and oil filter. 13 — Control, WSK 400/440 is part of the documented coverage, alongside radiator switching valve, direct and indirect NMV versions. 14 — Retarder, WSK 400/440 is part of the documented coverage, alongside WSK controls with and without NMV. 15 — NMV gear pair is part of the documented coverage, alongside retarder and NMV gear pair. 16 — Converter housing, WSK 400/440 is part of the documented coverage, alongside converter housing, oil-supply flange, gear pump and wiring harness. 17 — Pressures and measuring points for WSK 400, WSK 440 and NMV is part of the documented coverage, alongside pressure measuring points and KD functional testing. 18 — KD functional test of WSK system is part of the documented coverage, alongside tightening torques, consumables, spring data and special tools. The coverage is therefore not limited to a single repair operation; it follows the document’s own section structure and keeps related inspection, adjustment and reference material in the same PDF.

The procedures also show the kinds of jobs for which the manual can be kept open beside the equipment. A technician can use the manual for remove and install the WSK with engine-flanged or engine-separated arrangements. A technician can use the manual for set torque-converter installation dimensions and tapered-roller-bearing axial play. A technician can use the manual for check inductive-sensor distances for engine/turbine speed sensing. A technician can use the manual for disassemble and assemble the WSK 440 torque converter. A technician can use the manual for service the engagement clutch, turbine shaft, filter, switching valve and control units. A technician can use the manual for service retarder and NMV-related parts. A technician can use the manual for use the register-data tables for tightening values, clearances, installation dimensions and temperatures. A technician can use the manual for check WSK 400/440/NMV pressure points and carry out the KD functional test. These are the actual work areas represented in the document, so the buyer can use the manual to move from component identification into the relevant removal, inspection, adjustment, test or installation material without substituting an unrelated model reference.

Reference values matter most when a repair reaches the checking stage. The reference data includes Converter installation dimension C: WSK 400 80.7 ±0.20 mm; WSK 440 81.6 ±0.20 mm. The reference data includes Inductive transducer distance “n Motore”: 0.50 to 0.80 mm. The reference data includes Tapered roller bearing axial play: 0.05–0.15 mm. The reference data includes M12x1.5 adapter ring/converter tightening torque: 83 Nm. The reference data includes Converter expansion screw tightening torque: 190 Nm. The reference data includes WSK/engine installation dimension: 83.15 ±0.65 mm. The reference data includes Diaphragm thickness: WSK 400 2.4 ±0.14 mm; WSK 440 1.5 ±0.07 mm. The reference data includes Converter piston/lamella clearance: 0.70–1.70 mm. The reference data includes Converter check dimension: 149.8 -0.2 mm. The reference data includes Outer bearing ring/oil-supply flange heating temperature: approx. 100 °C. The reference data includes M45x1.5 converter plug tightening torque: 140 Nm. The figures belong to the same manual as the procedures above, which makes them useful for verifying the documented setup, limit, clearance, pressure, dimension, torque or operating condition where that type of value is supplied.

Document Details

• Manual type: Service / Workshop / Repair
• Brand / model: ZF — WSK 400 / WSK 440
• Language: Italian
• Page count: 101
• File format: PDF
• Document number: 4130 751 403b
• Publication / issue: Edition: 2011-07
• Revision: Index b / 10.2010 change status shown

Bring the WSK Dimensions and Torques to the Bench

WSK work quickly becomes measurement-sensitive: converter installation dimensions, sensor gaps, axial play and tightening torques all have to land on the stated value. This manual gives the procedure chapters and the register data needed to assemble, adjust, test and check WSK 400/440 units against the correct figures. The PDF is available immediately after payment with no shipping delay, ready for phone, tablet, laptop or workshop PC use and printable at the bench.