Usage:
Torque for two pump mounting studs in case and frame ... 30 ± 4 N·m (22 ± 3 lb ft)
(1) Torque for four bolts to hold cage to cover ... 30 ± 4 N·m (22 ± 3 lb ft)
(2) Put 7M7260 Liquid Gasket Material on plug (2) and install below flange surface to a depth of ... 1.25 ± 0.25 mm (.05 ± .010 in)
NOTE: Pump must turn freely by hand before and after assembly to the case of the case and frame.
(3) Clearance between gears and cover (section C new) ... 0.104 ± 0.043 mm (.0041 ± .0017 in)
(4) Clearance between gears and body (section B new) ... 0.104 ±0.043 mm (.0041 ± .0017 in)
(5) Clearance between gears and cover (section A new) ... 0.107 ± 0.021 mm (.0042 ± .0008 in)
(6) Diameter of shafts (new) ... 31.742 ± 0.005 mm (1.2497 ± .0002 in)
(7) Bore of bearings (new) ... 31.786 ± 0.008 mm (1.2514 ± .0003 in)
Torque Divider
(1) Diameter of planet shaft (new) ... 26.439 ± 0.005 mm (1.0409 ± .0002 in)
(2) Inside diameter of plant gear (new) ... 34.399 ± 0.010 mm (1.3543 ± .0004 in)
(3) Torque for bolts to hold retainer to housing ... 55 ± 7 N·m (41 ± 5 lb ft)
(4) Torque for bolts to hold stator to carrier ... 40 ± 5 N·m (30 ± 4 lb ft)
(5) Torque for bolts to hold impeller to housing ... 30 ± 5 N·m (22 ± 4 lb ft)
(6) Torque for bolts to hold carrier to impeller ... 55 ± 7 N·m (41 ± 5 lb ft)
(7) Torque for bolts to hold torque divider to housing ... 50 ± 7 N·m (37 ± 5 lb ft)
(8) Torque for bolt to hold yoke to shaft ... 45 ± 7 N·m (33 ± 5 lb ft)
(9) Outside diameter of new shaft (in bearing area) ... 44.437 ± 0.013 mm (1.7495 ± .0005 in)
Inside diameter of new bearings (after installation) ... 44.501 ± 0.013 mm (1.7520 ± .0005 in)
Relief Valve For Converter Outlet
(1) 4B5270 Washer: (earlier)
Thickness of washer ... 2.11 ± 0.64 mm (.083 ± .025 in)
Outside diameter of washer ... 22.4 mm (.88 in)
One washer will change pressure approximately ... 19 kPa (2.7 psi)
5M9623 Spacer: (later)
Thickness of one spacer ... 0.90 mm (.035 in)
Outside diameter ... 20.62 ± 0.25 mm (.812 ± .010 in)
One spacer will change pressure approximately ... 16.55 kPa (2.4 psi)
(2) 7M1297 Spring (Outer):
Length under test force ... 50.8 mm (2.00 in)
Test force ... 175.9 ± 14.1 N (39.54 ± 3.16 lb)
Free length after test ... 75.7 mm (2.98 in)
Outside diameter ... 22.35 mm (.880 in)
9W5595 Spring (Inner):
Length under test force ... 43.3 mm (1.70 in)
Test force ... 98.3 ± 4.9 N (22.09 ± 1.1 lb)
Free length after test ... 56.2 mm (2.21 lb)
Outside diameter ... 15.88 mm (.625 in)
Screen Group
(1) Torque for nuts ... 30 ± 5 N·m (22 ± 4 lb ft)
(2) Assemble the end of screen with part number and note in this position.
Priority Valve
(1) 4M2381 Spring:
Length under test force ... 12.2 mm (.48 in)
Test force ... 2.30 ± 0.18 N (.517 ± .041 lb)
Free length after test ... 22.6 mm (.89 in)
Outside diameter ... 7.62 mm (.300 in)
(2) 7T8556 Spring:
Length under test force ... 36.6 mm (1.44 in)
Test force ... 580 ± 29 N (130.4 ± 6.5 lb)
Free length after test ... 45.7 mm (1.80 in)
Outside diameter ... 21.4 mm (.84 in)
(3) 5M9622 Spacer:
Thickness of one spacer ... 1.60 mm (.063 in)
Outside diameter ... 20.62 ± 0.25 mm (.812 ± .010 in)
One spacer will change pressure approximately ... 505 kPa (73.0 psi)
5M9623 Spacer:
Thickness of one spacer ... 0.90 mm (.035 in)
Outside diameter ... 20.62 ± 0.25 mm (.812 ± .010 in)
One spacer will change pressure approximately ... 293 kPa (42.7 psi)
5M9624 Spacer:
Thickness of one spacer ... 0.25 mm (.010 in)
Outside diameter ... 20.62 ± 0.25 mm (.812 ± .010 in)
One spacer will change pressure approximately ... 81 kPa (12.0 psi)
Selector And Pressure Control Valve
(1) 4M2381 Spring:
Length under test force ... 12.2 mm (.48 in)
Test force ... 2.30 ± 0.18 N (.517 ± .041 lb)
Free length after test ... 22.6 mm (.89 in)
Outside diameter ... 7.62 mm (.300 in)
(2) 7G4842 Spring (outer with two red stripes)
First test:
Length under test force ... 62.5 mm (2.46 in.)
Test force ... 32.3 ± 1.6 N (7.26 ± .36 lb.)
Second test:
Length under test force ... 36.3 mm (1.43 in.)
Test force ... 142.3 ± 4.3 N (31.99 ± .97 lb.)
Free length after test ... 68.45 mm (2.695 in.)
Outside diameter ... 27.79 mm (1.094 in.)
(3) 9P3041 Spring (inner with two red stripes)
First test:
Length under test force ... 110.0 mm (4.33 in.)
Test force ... 72.6 ± 3.6 N (16.32 ± .81 lb.)
Second test:
Length under test force ... 85.5 mm (3.37 in.)
Test force ... 240.3 ± 7.2 N (54.02 ± 1.62 lb.)
Free length after test ... 117.40 mm (4.622 in.)
Outside diameter ... 21.21 mm (.835 in.)
(4) 5M9622 Spacer:
Thickness of one spacer ... 1.60 mm (.063 in)
Outside diameter ... 20.62 ± 0.25 mm (.812 ± .010 in)
One spacer will change pressure approximately ... 98 kPa (14.2 psi)
5M9623 Spacer:
Thickness of one spacer ... 0.90 mm (.035 in)
Outside diameter ... 20.62 ± 0.25 mm (.812 ± .010 in)
One spacer will change pressure approximately ... 57 kPa (8.2 psi)
5M9624 Spacer:
Thickness of one spacer ... 0.25 mm (.010 in)
Outside diameter ... 20.62 ± 0.25 mm (.812 ± .010 in)
One spacer will change pressure approximately ... 16 kPa (2.3 psi)
(5) Tighten three bolts to a torque of ... 30 ± 7 N·m (22 ± 5 lb ft)
(6) 6P9784 Spring (outer with yellow stripe):
Length under test force ... 56.39 mm (2.220 in)
Test force ... 130 ± 7 N (29.3 ± 1.5 lb)
Free length after test ... 88.60 mm (3.488 in)
Outside diameter ... 16.26 mm (.640 in)
(7) 6P9783 Spring (inner with yellow stripe):
Length under test force ... 56.39 mm (2.220 in)
Test force ... 62 ± 3 N (13.9 ± .7 lb)
Free length after test ... 88.60 mm (3.488 in)
Outside diameter ... 11.02 mm (.434 in)
(8) 6P9785 Spring (yellow stripe):
Length under test force ... 19.48 mm (.767 in)
Test force ... 23.5 ± 1.2 N (5.28 ± .27 lb)
Free length after test ... 32.00 mm (1.260 in)
Outside diameter ... 14.83 mm (.584 in)
(9) 7S4607 Detent Assembly (four):
(A) Maximum free length ... 30.86 mm (1.215 in)
(B) A force of 32 ± 3 N (7.2 ± .7 lb) must hold the ball at ... 29.97 mm (1.180 in)
(C) A force of 45 ± 4 N (10.1 ± 1.0 lb) must hold ball at ... 27.69 mm (1.090 in)
Transmission Hydraulic Controls
(1) Torque for 26 bolts ... 30 ± 4 N·m (22 ± 3 lb ft)
(2) Torque for 4 bolts ... 48 ± 4 N·m (35 ± 3 lb ft)
(3) 3T4403 Spring (blue stripe):
Quantity ... 2
Length under test force ... 38.6 mm (1.52 in)
Test force ... 262.4 ± 13.1 N (59.00 ± 2.95 lb)
Free length after test ... 52.83 mm (2.080 in)
Outside diameter ... 32.54 mm (1.281 in)
Oil Filter Group
Bypass valve setting ... 262 ± 21 kPa (38 ± 3 psi)
(1) 9M1986 Spring:
Length under test force ... 25.4 mm (1.00 in)
Test force ... 111 ± 9 N (24.9 ± 2.0 lb)
Free length after test ... 47.2 mm (1.86 in)
Outside diameter ... 12.7 mm (.50 in)
(2) Torque for nut ... 15.0 ± 5.4 N·m (11 ± 4 lb ft)
Transmission
(1) Thickness of four new disc assemblies and three new plates for the No. 1 (reverse) and No. 2 (forward) clutches ... 37.36 ± 0.56 mm (1.471 ± .022 in)
Thickness of one new 9P7390 Disc Assembly ... 5.59 ± 0.08 mm (.220 ± .003 in)
Thickness of one new 8P2051 Plate ... 5.00 ± 0.08 mm (.197 ± .003 in)
(2) Thickness of three new discs and two new plates for the No. 3 clutch ... 26.77 ± 0.46 mm (1.054 ± .018 in)
Thickness of one new 7G3129 Disc (earlier) ... 5.59 ± 0.10 mm (.220 ± .004 in)
Thickness of one new 6Y5911 Disc (later) ... 5.59 ± 0.10 mm (.220 ± .004 in)
Thickness of one new 8P2051 Plate ... 5.00 ± 0.08 mm (.197 ± .003 in)
(3) Thickness of two new discs and one new plate for the No. 4 clutch ... 16.18 ± 0.28 mm (.637 ± .011 in)
Thickness of one new 7G3129 Disc (earlier) ... 5.59 ± 0.10 mm (.220 ± .004 in)
Thickness of one new 6Y5911 Disc (later) ... 5.59 ± 0.10 mm (.220 ± .004 in)
Thickness of one new 8P2051 Plate ... 5.00 ± 0.08 mm (.197 ± .003 in)
(4) Thickness of four new discs and three new plates for the No. 5 clutch ... 31.80 ± 0.64 mm (1.251 ± .025 in)
Thickness of one new 9P1861 Disc (earlier) ... 4.95 ± 0.10 mm (.195 ± .004 in)
Thickness of one new 6Y5912 Disc (later) ... 4.95 ± 0.10 mm (.195 ± .004 in)
Thickness of one new 8P1964 Plate ... 4.00 ± 0.08 mm (.157 ± .003 in)
(5), (6) Torque for 10 bolts ... 115 ± 7 N·m (85 ± 5 lb ft)
(7) 4M9592 Spring:
Quantity ... 20
Length under test force ... 34.93 mm (1.375 in)
Test force ... 117 ± 6 N (26.2 ± 1.3 lb)
Free length after test ... 44.7 mm (1.76 in)
Outside diameter ... 14.27 mm (.562 in)
(8) 3K2511 Dowel:
Quantity ... 10
Length ... 176.23 mm (6.938 in)
Outside diameter ... 12.637 ± 0.013 mm (.4975 ± .0005 in)
(9) Diameter of shafts (new) for planet gears ... 26.439 ± 0.005 mm (1.0409 ± .0002 in)
(10) Inside diameter of planet gears (new) ... 34.399 ± 0.010 mm (1.3543 ± .0004 in)
(11) Diameter of shafts (new) for planet gears ... 35.255 ± 0.008 mm (1.3880 ± .0003 in)
(12) Inside diameter of planet gears (new) ... 43.221 ± 0.010 mm (1.7016 ± .0004 in)
(13) 7H7658 Spring:
Quantity ... 10
Length under test force ... 105.56 mm (4.156 in)
Test force ... 187 ± 15 N (42.0 ± 3.3 lb)
Free length after test ... 140.5 mm (5.53 in)
Outside diameter ... 14.2 mm (.56 in)
(14) Inside diameter of planet gears (new) ... 47.653 ± 0.010 mm (1.8761 ± .0004 in)
(15) Diameter of shafts (new) for planet gears ... 38.095 ± 0.005 mm (1.4998 ± .0002 in)
Linkage For Transmission Controls
Torque for 1/4 in. locknuts (10) on cable assemblies (1) and (2) that hold the rod ends in place ... 8 ± 2 N·m (6 ± 1 lb ft)
Torque for 3/8 in. locknuts (7) on rod assembly (8) ... 12 ± 4 N·m (9 ± 3 lb ft)
Torque for all 5/8 in. and 9/16 in. jam nuts ... 38 ± 7 N·m (28 ± 5 lb ft)
Assembled length of rod assembly (8) ... 202.0 ± 1.5 mm (7.95 ± .06 in)
Procedure for Adjustment
1. Loosen bolts (4) that hold cover (6) to the housing.
2. Loosen locknut (5) for the cable that needs to be adjusted. Turn cover (6) for the cable that needs to be adjusted.
NOTE: To move transmission control lever (9) to either side (right or left), adjust directional cable (2). An adjustment of speed cable (1) will move control lever (9) to the front or rear.
3. Adjust control lever (9) so that it does not make contact with the guide (3) in any forward or reverse gear or in neutral.
Parking Brake Control
 |
To prevent possible personal injury do not make any adjustments to the control linkage with the engine running unless necessary and then let only approved personnel on the machine. Keep other personnel off the machine and in clear view of the service personnel. |
 |
Torque for 3/8 in. locknuts ... 12 ± 4 N·m (9 ± 3 lb ft)
(1) Torque for three screws ... 30 ± 4 N· (22 ± 3 lb ft)
(2) 7G1251 Spring:
Length under test force ... 124 mm (4.9 in)
Test force ... 318 ± 25 N (71.5 ± 5.6 lb)
Free length ... 105.00 mm (4.13 in)
Outside diameter ... 22.22 mm (.875 in)
(4) Adjust neutral start switch to dimension A (later machines only) ... 29.0 ± 1.0 mm (1.14 ± .04 in)
Torque for nut ... 25 ± 7 N·m (18 ± 5 lb ft)
Contacts ... normally open
(5) Assembled length of rod assembly ... 290 ± 2 mm (11.4 ± .08 in)
(6) Assembled length of rod assembly ... 482 ± 2 mm (19.0 ± .08 in)
NOTE: Make all rod assembly measurements in a straight line between the centerlines of the rod end mounting holes.
Procedure to Adjust Parking Brake Linkage
1. Install adjusted rod assemblies (5) and (6).
2. Move parking brake lever (3) down to the Brake ON position.
3. Install a 0 to 4000 kPa (0 to 600 psi) pressure gauge on the right or left brake pressure tap.
4. Start the engine and run it at maximum rpm.
5. The pressure gauge must read 0 kPa (0 psi). If the pressure is not 0 kPa (0 psi), make rod assembly (6) longer and check the pressure again.
6. Move parking brake lever (3) up to the Brake OFF position. The pressure gauge must read 2750 ± 70 kPa (400 ± 10 psi). If the pressure reading is low, make rod assembly (6) shorter and check the pressure again.
7. Stop engine and remove the test equipment.
Drive Shaft
(1) Torque for eight bolts that hold bearing to flange ... 55 ± 10 N·m (40 ± 7 lb ft)
(2) Torque for eight bolts that hold bearing to yokes ... 55 ± 10 N·m (40 ± 7 lb ft)
Transmission Mounting Group
(1) Torque for four mounting bolts ... 270 ± 40 N·m (200 ± 30 lb ft)
(2) Torque for 22 mounting bolts ... 135 ± 20 N·m (100 ± 15 lb ft)
Bevel And Transfer Gear Group
(1) Torque for six bolts ... 135 ± 20 N·m (100 ± 15 lb ft)
(2), (8) Use shims as needed to get an end play of ... 0.10 ± 0.05 mm (.004 ± .002 in).
NOTE: See Procedure to Adjust Lower Transfer Gear Bearings
(3) Torque for six bolts ... 135 ± 20 N·m (100 ± 15 lb ft)
(4) Torque for 12 bolts ... 270 ± 40 N·m (200 ± 30 lb ft)
NOTE: Torque for four bolts that hold the transmission mounting brackets is ... 270 ± 40 N·m (200 ± 30 lb ft)
(5) Torque for bolt ... 270 ± 40 N·m (200 ± 30 lb ft)
(6) Torque for six bolts ... 135 ± 20 N·m (100 ± 15 lb ft)
(7) Torque for six bolts ... 55 ± 10 N·m (40 ± 7 lb ft)
(9) Put 5P3931 Anti-Seize Compound on threads and tighten the nut to a torque of ... 612 ± 68 N·m (451 ± 50 lb ft)
(10) Torque for six bolts ... 135 ± 20 N·m (100 ± 15 lb ft)
(11) Use shims as needed to adjust backlash (free play) between pinion and bevel gear to ... 0.30 + 0.12 - 0.10 mm (.012 + .005 - .004 in)
NOTE: See Procedure To Adjust End Play Of Bevel Pinion Bearings
NOTE: Use a 5/8 in. - 11 dog point set screw 102 mm (4 in) long through the case. Tighten the set screw until there is zero end play in the pinion. Position the bevel and transfer gear group so that the bevel gear shaft is in the vertical position with the bevel gear at the bottom. Add shims (11) to reduce backlash or remove shims to increase backlash.
| NOTICE |
|---|
Make sure the set screw that holds the pinion in place (for backlash checks) is removed when adjustments are complete. |
(12) Torque for 12 bolts ... 475 ± 60 N·m (350 ± 45 lb ft)
Procedure To Adjust Lower Transfer Gear Bearings
1. Use a 0.038 mm (.0015 in) shim stock or a standard feeler gauge to make sure the bearing cups and cones are seated correctly.
2. Assemble the input transfer in a vertical position in the case. Install the bearing cage without shims (2).
3. Install two bolts and washers 180 degrees apart.
4. Torque the bolts to 2.25 N·m (20.0 lb in).
5. Rotate the input gear three full turns.
6. Torque the bolts to 4.5 N·m (40 lb in) and repeat Step 5. Retorque the bolts to 4.5 N·m (40 lb in).
7. Measure the space between the case and the outside diameter of the bearing cage flange next to each bolt.
8. Add the dimension found in Step 7 and divide by two.
9. Add 0.23 mm (.009 in) to the dimension found in Step 8.
NOTE: If the shim thickness is determined in Step 9 or the bearing adjustment is questionable, repeat Steps 2 through 9. If the "repeat" shim thickness is within 0.05 mm (.002 in) of the original thickness, use the lesser of the two measurements.
10. Add enough shims (2) to equal the dimension found in Step 9.
11. Install the bearing cage, shims, bolts, and washers. Torque the bolts to 135 ± 20 N·m (100 ± 15 lb ft). Check end play with a dial indicator.
Procedure To Adjust End Play Of Bevel Pinion Bearing
1. Use a 0.038 mm (.0015 in) shim stock or a standard feeler gauge to make sure the bearing cups are seated against the shoulders in the case and that the bearing cones are seated against the shoulders of the pinion shaft.
2. With the pinion in a vertical position, install the (cup) cage in the case without shims (11).
3. Install two bolts and washers 180 degrees apart.
4. Torque the bolts to 4.5 N·m (40 lb in).
5. Rotate or oscillate the pinion the equivalent of three full turns.
6. Torque the bolts to 9.0 N·m (80 lb in).
7. Rotate or oscillate the pinion the equivalent of three full turns. Retorque the bolts to 9.0 N·m (80 lb in).
8. Measure the gap between the case and the outside diameter of the cage at the flange next to each bolt.
9. Add the measurements found in Step 8 and divide by two.
10. Add 0.43 mm (.017 in) to the dimension found in Step 8.
11. Install shims (11) that equal the dimension found in Step 10.
12. Install the bolts and washers. Torque the bolts to 135 ± 20 N·m (100 ± 15 lb ft). Check end play with dial indicator.