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Transmissions ZF WG180 transmission: We have rebuilt a ZF WG180…

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We have rebuilt a ZF...
We have rebuilt a ZF WG180 transmission in an 18 tonne loader, replacing the 1st and 2nd clutch packs and had an auto electrician check all of the electrical wiring and said everything was ok. But the loader with a ZF WG180 transmission is having problems – when it is in forward gear it goes in reverse and when it is in reverse gear it goes forward and then freezes. Would you be able to advise where to look or what to fix. Is it likely to be a hydraulic problem?
Submitted: 6 years ago.Category: Construction and Road Equipment
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Answered in 6 hours by:
4/29/2016
Mechanic: Curtis B., Technician replied 6 years ago
Curtis B.
Curtis B., Technician
Category: Construction and Road Equipment
Satisfied Customers: 43,982
Experience: Technican turned service manager with multiple lines of equipment and rental units.
Verified
Electrical problem, with two solenoids trying to engage transmission at once. Check voltage to the f/r solenoids. May have bad shifter or diode in harness, letting voltage bleed back and power both solenoids at once. unplug one of the f/r solenoids and see if they work in the correct fashion with one out of the circuit.
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Customer reply replied 6 years ago
All of the electric circuitry to the solenoids has been checked and is all ok and all of the hoses from the valve bank to the front of the transmission are correct. We have pressure checked the clutch packs with a air line and they are all ok. But when in forward gear, the machine goes backwards and in reverse gear it goes forwards.
Mechanic: Curtis B., Technician replied 6 years ago
?? Why not swap the circuits for forward and reverse? At shifter or at the solenoids.
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Customer reply replied 6 years ago
All the electrics are ok. The loader is now going forward and backward in the correct gears, but only a little bit and then it seizes, maybe over-pressurizing? We have double-checked hoses on the front of the transmission and they are correct.
Mechanic: Curtis B., Technician replied 6 years ago
From all my experience this is caused when transmission goes into two gears at once!
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Customer reply replied 6 years ago
Ok, thanks, ***** ***** is picking up too many gears, why would it be doing that and can you advise how to fix it?
Mechanic: Curtis B., Technician replied 6 years ago
I would have thought it was solenoid problem, but you say all is good! Valve body gasket leaking over to another clutch pack?
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Customer reply replied 6 years ago
Hi Curtis,We have checked the oil pressures. The K3 clutch pack is making too much pressure.
Mechanic: Curtis B., Technician replied 6 years ago
?? Clutch pack just gets what is sent to it from the control valve. . It doesn't make pressure.
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Customer reply replied 6 years ago
We are wondering if it could be sucking in air around the ends of the transmission pump. The transmission is definitely making air pressure.
Mechanic: Curtis B., Technician replied 6 years ago
If there is air in the oil, it has to be at the pump or the suction to the pump!
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Curtis B.
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Category: Construction and Road Equipment
Satisfied Customers: 43,982
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