Usage:
Remove Transmission And Transfer Gears (Power Shift)
start by:
a) remove seat and seat frame
b) remove brake pedal assembly
c) remove universal joint
d) remove transmission sequence relief valve
e) remove torque divider scavenge pump
f) remove torque converter outlet relief valve
g) remove transmission guard
1. Remove the control rods for the steering clutches and the brakes. Remove the oil from the bevel gear case.
2. Remove the control rods (1) and (3), vent line (4) and oil line (2).
3. Remove the oil line to the oil filter.
4. Install tool (A) on the transmission. Fasten a hoist to the transmission. Weight of the transmission is 1000 lb. (454 kg).
5. Remove nuts (6) and washers that hold the transmission (5) to the bevel gear case.
6. Move the transmission out of the bevel gear case. Remove the transmission from the machine.
Install Transmission And Transfer Gears (Power Shift)
1. Fasten a hoist to the tool (A) on the transmission (1).
2. Put the transmission in position in the bevel gear case.
| NOTICE |
|---|
Make sure the pinion on the transmission is in correct alignment with the bevel gear. |
3. Install the nuts (2) and washers that hold the transmission to the bevel gear case.
4. Connect the oil line to the oil filter.
5. Install oil line (3). Install vent line (6).
6. Connect the control rods (4) and (5) for the transmission.
7. Install the control rods for the steering clutches and brakes.
8. Fill the bevel gear case with oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.
end by:
a) install transmission guard
b) install torque converter outlet relief valve
c) install torque divider scavenge pump
d) install transmission sequence relief valve
e) install universal joint
f) install brake pedal assembly
g) install seat and seat frame
Disassemble Transmission And Transfer Gears (Power Shift)
1. Put the transmission on tool (A).
2. Remove the control lever from the case.
3. Remove cover (1) from the transmission case.
4. Remove the transmission hydraulic controls (Earlier Machines) as follows:
a) Remove tube (4) from the case.
b) Remove bolts (3) and pressure control valve (2).
c) Remove bolts (6) and valve assembly (5).
5. Remove the transmission hydraulic controls (Later Machines) as follows:
a) Remove bolts (7).
b) Remove pressure control valve (8).
c) Remove cover (11). Remove tube (10) from transmission case.
d) Remove bolts (9). Remove valve assembly (12).
NOTE: For the disassembly procedure of the transmission hydraulic control valves, see DISASSEMBLE TRANSMISSION HYDRAULIC CONTROL VALVES.
6. Remove all sleeves (14) that were not removed with valve assemblies.
7. Remove bolts (13) that hold transmission case to the input shaft bearing cage.
8. Remove bolts (15) that hold case to transfer gear case.
9. Install two 1/2" - 13 NC forged eyebolts in the top of the transmission case.
10. Fasten a hoist to the transmission case. Weight of the transmission case is 140 lb. (63.5 kg). Remove the transmission case.
11. Remove spring (17). Remove the nuts (16) and bolts that hold levers on the shaft.
12. Remove the shaft (18) from the transmission case and the levers (19) from the shaft.
13. Remove the seal (20) and bearing (21) from the transmission case.
14. Remove spring (23), lever (24), shaft (22) and lever (25) from transmission case.
15. Remove the two seals (26) and bearing from the transmission case.
16. Remove bolts (27) and locks (29) that hold bearing cage (28) for the input shaft to transmission.
17. Install two 3/8" - 16 NC forged eyebolts in the bearing cage. Fasten a hoist to the bearing cage. Remove bearing cage and input shaft as a unit. Weight of the unit is 60 lb. (27 kg).
18. Remove bolt (30). Remove washer (31) and flange (32).
19. Use tool (B) to remove seal (33) from bearing cage.
20. Remove the retainer ring that holds the bearing cage on the input shaft. Remove the bearing cage from the input shaft.
21. Inspect seal (34) and install a new seal if necessary.
22. Remove the two retainer rings, one on each side, that hold the bearing (36) in the cage.
23. Remove spacer (35) and bearing (36) from the cage.
24. Remove snap ring (37) that holds the bearing race (38) and two gears (39) on the shaft.
25. Use tooling (C) to remove two gears (39) and race (38) from shaft.
26. Remove the bearing cage from the shaft with a soft hammer.
27. Remove snap ring (40) that holds the bearing (41) in the cage.
28. Remove bearing (41) from cage.
29. Remove the bearing inner race from the shaft with tooling (D).
NOTE: Put identification on each of the clutch housings as to their order and location. The housings must be installed in the same location and reverse order that they were removed.
30. Remove the nine bolts (42) that hold the clutch housings together.
31. Install tooling (E) to keep the No. 1 clutch piston in the No. 1 clutch housing. Remove the other three bolts.
32. Install two 1/2" - 13 NC forged eyebolts in the housing. Fasten a hoist to the housing. Weight of the housing is 55 lb. (25 kg). Remove No. 1 clutch housing and its piston as a unit.
33. Turn the No. 1 clutch housing over. Remove tooling (E). Remove piston (43). Remove the two rings from the piston and No. 1 clutch housing.
34. Remove the five pins (44) and ten springs (45).
35. Install two 3/8" - 16 NC forged eyebolts in the No. 1 carrier. Fasten a hoist to No. 1 carrier. Weight of No. 1 carrier is 50 lb. (22.7 kg). Remove No. 1 carrier (46).
36. Remove shafts (48), gears (49), and washers (50) from No. 1 carrier. There is a washer on each side of the gears. Remove the bearings from the gears.
| NOTICE |
|---|
Use caution when removing shafts (48) to prevent loss of balls (47). |
37. Remove bolts (54), locks (51) and plates (53). Remove gear (52) from No. 1 carrier.
38. Put No. 1 carrier in position on its side. Remove shafts (56) and tubes (57) from No. 1 carrier.
| NOTICE |
|---|
Use caution when removing shafts (56) to prevent loss of balls (55). |
39. Remove gears (60) and washers (59).
40. Remove bearings (58) from gears (60).
41. Remove bearing (61) from carrier No. 1.
42. Remove ring gear (62), three clutch disc assemblies (63), two plates (65) and plate (64).
43. Install two 1/2"-13 NC forged eyebolts in No. 2 clutch housing. Fasten a hoist to No. 2 clutch. Weight of No. 2 clutch is 55 lb. (25 kg). Remove No. 2 clutch.
44. Remove ten springs (66).
45. Remove ring gear (67), clutch disc assemblies (68) and plates (69) from No. 2 clutch housing. Remove piston from housing and seal rings from housing and piston.
46. Remove bolts (70), locks and plates that hold the No. 3 clutch housing in position.
47. Install two 1/2"-13 NC forged eyebolts in No. 3 clutch housing. Fasten a hoist to No. 3 clutch housing. Weight of No. 3 clutch housing is 55 lb. (25 kg). Remove No. 3 clutch housing.
48. Remove the five pins (71) and ten springs (72) from No. 4 and No. 5 clutch housings.
49. Remove ring gear (73), clutch disc assemblies (74), plate (75) and piston from clutch housing. Remove seal rings from piston and clutch housing.
50. Install tooling (E) to keep the No. 4 and No. 5 clutch pistons in the clutch housing.
51. Install two 1/2"-13 NC forged eyebolts in No. 4 and No. 5 clutch housing. Fasten a hoist to No. 4 and No. 5 clutch housing. Remove the clutch housing and piston as a unit. Weight of the unit is 65 lb. (29.5 kg).
52. Remove the ten springs (80), clutch disc assemblies (81), ring gear (83), and plate (82) from transfer gear case.
53. Remove ring gear (76), clutch disc assemblies (77), and plate (78) from clutch housing.
54. Turn the clutch housing over. Remove tooling (E). Remove piston (79). Remove rings from piston and housing.
55. Remove bolts (84) and locks that hold No. 2 carrier (85) to the transfer gear case.
56. Install three 3/8"-16 NC forged eyebolts in No. 2 carrier. Fasten a hoist to No. 2 carrier. Weight of No. 2 carrier is 50 lb. (22.7 kg). Remove No. 2 carrier.
57. Put No. 2 carrier on its side. Pull shafts (89) part of the way out and remove gear (93) and washers (92). Remove bearings (90) from gear (93).
NOTE: There is a washer (92) on each side of gear (93).
58. Remove shafts (89), gear (91) and washers. Remove the bearings from gear (91).
NOTE: There is a washer on each side of gear (91).
| NOTICE |
|---|
Use caution to prevent loss of balls (88) when removing shafts (89). |
59. Remove shafts (86), gear (87) and washers. Remove the bearings from the gear.
NOTE: There is a washer on each side of the gear.
| NOTICE |
|---|
Use caution to prevent loss of balls when removing shafts (86). |
60. Remove cage (94), retainer ring (96) and output shaft (95) from transfer gear case.
61. Remove dowel (98) from cage with a 6-40 screw. Remove bearing (97) from cage.
62. Remove cage (99) with three 1/2"-13 NC forcing screws. Remove bearing (100) from cage (99).
| NOTICE |
|---|
Use caution to prevent loss of ball (102) when cage is removed. |
63. Inspect piston ring type seals (101) and install new seals if necessary.
64. Remove plate assembly (103) from transfer gear case.
65. Remove bolts (104) and locks (105) that hold case assembly (106) to transfer gear case (107).
66. Remove the dowels that hold case assembly in position on transfer gear case with 1/2"-13 NC bolts 3 in. long. Remove case assembly (106).
67. Remove bolts (108) and lock. Remove retainer (109) that holds the pinion in the transfer gear case.
68. Remove the pinion from the transfer gear case.
69. Remove bearings (110) from the pinion with tooling (F).
70. Remove the transfer gear from the transfer gear case.
71. Remove bearings (112) from transfer gear (111) with tooling (G).
72. Remove plugs and dowels (114) that hold the bearing races in the transfer gear case. Use a 6-40 screw to remove the dowels.
73. Remove the races (113) from the transfer gear case.
74. Remove the plugs and dowels (116) that hold the races in the case assembly. Use a 6-40 screw to remove the dowels.
75. Remove the races (116) from the case assembly.
TRANSMISSION (POWER SHIFT)
Assemble Transmission And Transfer Gears (Power Shift)
1. Lower the temperature of race (2) and install it in case (1) with tooling (A). Install the race with the hole in the race in alignment with the hole in the case.
2. Install the dowel and plug that hold the race in position in the case.
3. Lower the temperature of the bearing race and install it in the case with tooling (B). Install the bearing race with the hole in alignment with the hole in the case.
4. Install the dowel and plug that hold the bearing race in the case.
5. Lower the temperature of bearing race (3) and install it in case (4) with tooling (A). Install the bearing race with the hole in the race in alignment with the hole in the case.
6. Install the dowel and plug that holds the race in position in the case.
7. Lower the temperature of bearing race (5) and install it in the case with tooling (A). Install the race with the hole in the race in alignment with the hole in the case.
8. Install the dowel and plug that holds the race in position in the case.
9. Heat bearings (8) to a temperature of 275°F (135°C) and install on each end of transfer gear (9). Install transfer gear in case.
10. Heat bearings (6) to a temperature of 275°F (135°C) and install on each end of pinion gear (7). Install pinion gear in case.
11. Install washer, lock, and bolts that hold pinion in the transfer case.
12. Put case (1) in position on transfer case (4). Install the three dowels that hold case (1) in position on case (4).
13. Install locks (11) and bolts (10) that hold the two cases together.
14. Turn transfer case over and install plate (15).
15. Lower temperature of bearing (13) and install in cage (14).
16. Inspect piston ring type seals (12), and install new seals if necessary. Put clean grease on the seals.
17. Put ball (16) in position and install cage (14).
| NOTICE |
|---|
Do not cause damage to piston ring type seals (12). |
18. Lower temperature of bearing and install it in cage (17) with tooling (B). Install bearing with hole in bearing in alignment with hole in cage.
19. Install the dowel and plug that hold bearing in cage.
20. Put the output shaft (18) in position in the transfer case. Install retainer ring (19) and bearing cage.
21. Install bearings (24) in gears (25), (21), and (27). Put clean oil on the bearings.
22. Put shafts (20) in position in the carrier.
| NOTICE |
|---|
Make sure the balls (22) are in the shaft. |
23. Put gears (21) and washers (26), one washer on each side of gears, in carrier and install shafts (20) through the gears into carrier.
24. Put shafts (23) in position in carrier.
| NOTICE |
|---|
Make sure balls (22) are in the shafts. |
25. Put gears (25) and (27) and washers (26), one on each side of gear, in position in the carrier. Install shafts (23) through the gears and into the carrier.
26. Install three 3/8"-16 NC forged eyebolts in No. 2 carrier. Fasten a hoist to No. 2 carrier. Put No. 2 carrier in position on output shaft and remove hoist.
27. Install the bolts and locks that hold the No. 2 carrier to the transfer gear case.
28. Put the transfer gear case in position on tool (C).
29. Install the rings on piston (28) and in clutch housing (29). Put clean oil on the rings.
| NOTICE |
|---|
Do not cause damage to the rings on installation. |
30. Install tooling (D) on the clutch housing to keep pistons from falling off the housing. Turn housing over.
31. Install the gear (34) on the case. Install ten springs (31). Install clutch disc assemblies (33) and plate (35).
| NOTICE |
|---|
Make sure the disc assemblies are free from dirt and oil. Do not cause damage to the teeth of the discs. |
32. Install two 1/2"-13 NC forged eyebolts in the clutch housing. Fasten a hoist to the clutch housing. Install the clutch housing.
33. Install seal rings on piston (30) and housing. Put clean oil on rings.
| NOTICE |
|---|
Do not cause damage to seal rings. |
34. Install piston (30) in housing. Install clutch disc assemblies (32), plate, and ring gear in housing.
| NOTICE |
|---|
Make sure the disc assemblies are free from dirt and oil. |
35. Remove tooling (D).
36. Install the seal rings on the piston (39) and No. 3 clutch housing (40). Put clean oil on the rings. Install piston in housing.
| NOTICE |
|---|
Do not cause damage to seal rings when piston is installed. |
37. Install clutch disc assemblies (37) and plate (36) in housing. Install ring gear (38) in housing.
| NOTICE |
|---|
Make sure the clutch disc assemblies are free of dirt and oil. Do not cause damage to the teeth of the disc assemblies. |
38. Install five pins (42) and ten springs (41).
39. Install two 1/2"-13 NC forged eyebolts in the No. 3 clutch housing. Fasten a hoist to the eyebolts. Install housing on springs and pins.
40. Install plates, locks, and bolts that hold No. 3 clutch housing in position.
41. Install seal rings on the piston (47) and in No. 2 clutch housing (46). Put clean oil on the rings. Install piston in housing.
| NOTICE |
|---|
Do not cause damage to seal rings when piston is installed. |
42. Install clutch disc assemblies (44) and plates (45) in housing. Install ring gear (43) in housing.
| NOTICE |
|---|
Make sure the clutch disc assemblies are free of dirt and oil. Do not cause damage to the teeth of the discs. |
43. Install two 1/2"-13 NC forged eyebolts in the No. 2 clutch housing. Fasten a hoist to the eyebolts.
44. Install ten springs (48) and put the housing in position on springs. Remove hoist and eyebolts.
45. Put plate (49) in position on No. 2 clutch housing.
46. Install clutch disc assemblies (5) and plates (51) on plate (49). Install gear (52) on plate.
| NOTICE |
|---|
Make sure the clutch disc assemblies are free from dirt and oil. Do not cause damage to the teeth of the discs. |
47. Lower the temperature of the bearing for No. 1 carrier. Install the bearing in the carrier.
48. Install bearings (57) in gears (56) and install tubes (55) in shafts (54). Put shafts in position in No. 1 carrier. Install balls (53) in shafts (54). Put gears (56) and washers (58), one on each side of gears in position in No. 1 carrier. Install the shafts through gears and into No. 1 carrier.
| NOTICE |
|---|
Make sure balls (53) are in shafts when shafts are installed. |
49. Put gear (59) in No. 1 carrier. Install plates (62), locks (61), and bolts (60) in No. 1 carrier.
50. Install balls (63) in shafts (64). Install the bearings in gears (66). Put a washer (65) on each side of gears (66). Put the gears in position in No. 1 carrier and install shafts (64) as shown.
51. Install three clutch disc assemblies, two plates (70) and ring gear (69).
52. Install two 3/8"-16 NC forged eyebolts in No. 1 carrier. Install No. 1 carrier (67).
53. Install new rings in piston (71) and No. 1 clutch housing (72).
54. Put a small amount of clean SAE 30 oil on the rings. Install the piston (71) in No. 1 clutch housing (72) as shown.
55. Install the five pins (73) and ten springs (74).
56. Use tool (D) to hold the piston in No. 1 clutch housing.
57. Install two 1/2"-13 NC forged eyebolts in No. 1 clutch housing. Fasten a hoist to No. 1 clutch housing and install it in the correct position shown.
58. Install the three of the bolts (75) evenly spaced that hold the clutch housing together. Tighten the bolts to a torque of 85 ± 5 lb.ft. (11.8 ± 0.7 mkg).
59. Install the other six bolts. Tighten the bolts to a torque of 85 ± 5 lb.ft. (11.8 ± 0.7 mkg).
60. Heat the race to a temperature of 275°F to (135°C). Install the race (76) on the shaft. Install the ring seal (77) on the race.
61. Install the bearing (78) in the cage. Install ring (79) to hold bearing in position.
62. Slide the shaft through the bearing and cage as shown. Use a soft faced hammer to install the cage on the shaft.
63. Slide the gears (82) on the shaft.
64. Heat the race (80) to a temperature of 275°F (135°C). Install the race on the shaft. Install ring (81) on the shaft.
65. Install the spacer (83) and bearing (84) in the cage. Install the two rings that hold the bearing and spacer in position.
66. Install a new seal (85) on the cage. Put a small amount of clean SAE 30 oil on the seal. Put the cage on the shaft.
67. Install the retainer ring (86) that holds the cage in position.
68. Install a new seal in the cage. Lubricate the lip of the seal with clean SAE 30 oil before installing the seal.
69. Install the flange (87), washer (88), lock and bolts (89). Tighten the bolts to a torque of 40 ± 5 lb.ft. (5.5 ± 0.7 mkg).
70. Install two 3/8"-16 NC forged eyebolts in the bearing cage. Fasten a hoist to the bearing cage.
71. Install the bearing cage and shaft.
72. Install the locks and bolts (91) that hold the bearing cage and shaft in position.
NOTE: Check to make sure the pistons are free in their clutch housings as follows:
a) Put air (free of water) under a pressure of 100 to 150 psi (690 to 1035 kPa) into the five oil passages with an FT834 Nozzle.
b) There must be .12 to .25 in. (3.0 to 6.4 mm) of travel for each piston.
c) If the pistons do not move the correct distance, put a small amount of clean SAE 30 oil in each passage. Follow the procedure in Step (a) again. If the pistons still do not move, the transmission must be disassembled and the pistons checked.
73. Use tooling (E) to install seals (92) in case.
74. Install the seals and bearing in the case with tooling (E). Put SAE 30 oil on the lips of the seals.
75. Install lever (96) and shaft (93). Install lever (94) and spring (95).
76. Slide shaft (97) into case. Slide levers (99) on shaft.
77. Install the bolts and nuts (100) that hold the levers in position on the shaft.
78. Install spring (98).
79. Install two 1/2"-13 NC forged eyebolts in case (101). Fasten a hoist to the case. Install the case (101) on the transmission.
80. Install the bolts that hold the transmission case to the transfer gear case.
81. Install the bolts (102) that hold input shaft bearing cage to transmission case.
82. Put lubricant on the seals on sleeves (103). Install the sleeves in the transmission.
| NOTICE |
|---|
Make sure seals are in position on transmission before installing hydraulic controls. Put a small amount of clean SAE 30 oil on the seals. |
NOTE: Use the following steps to install the transmission hydraulic controls (Later Machines).
83. Put the valve assembly (107) in position in the transmission. Install the three bolts (108).
84. Install tube (105) in transmission.
85. Install cover (106) and bolts.
86. Install seals (104) in valve assembly. Put a small amount of clean SAE 30 oil on the seals.
87. Install pressure control valve (109).
88. Install three bolts (110).
NOTE: Use the following steps to install the transmission hydraulic controls (Earlier Machines).
89. Put valve assembly (111) in the correct position in the transmission.
90. Install seals (112) in valve assembly. Put a small amount of SAE 30 oil on the seals.
91. Install pressure control valve (113). Install the three bolts that hold the pressure control valve in position.
92. Install gasket and cover (114). Install the bolts and washers that hold the cover in position.
end by:
a) install transmission