Usage:
Start By:
a. remove shuttle assembly and four-speed gearbox
1. Disconnect oil lines from the oil filter on control system (1).
2. Remove two bolts and lock washers securing control system (1) to control valve (2). Lift the control system away from the shuttle assembly.
3. Remove four bolts and star washers securing control valve (2) to the shuttle assembly.
4. Remove the control valve and gasket (3). Discard the gasket. This must be replaced with a new part during assembly.
5. Remove four bolts and washers securing pump (6) to the shuttle assembly. Discard the washers. These must be replaced with new parts during assembly.
6. Remove pump (6) and square-ring seal (5) from case (4). Discard the square-ring seal. This must be replaced with a new part during assembly.
7. Disassemble pump (6), if desired, by removing one screw. Tap with a rubber hammer to separate components. If parts are damaged or worn out, the entire pump assembly must be replaced with a new part.
8. Reassemble the pump. Replace seal (7) with a new part.
9. Remove eight bolts and lock washers securing pump cover (10) to case (4).
10. Remove sump cover (10) and screen (9). Remove and discard two gaskets (8). These must be replaced with new parts during assembly.
11. Remove two corks (11) from the pump side of the case, if used. Discard the corks. They do not need to be reinstalled.
12. Set case (4) on its side, as shown. Working from the pump side of the case, drive idler shaft (12) out of the case. Hold idler gear (14) and spacer tube (13) in place while removing the shaft.
13. Remove spacer tube (13), and idler gear (14) assembly from inside the case. Hold the idler gear by washers (15) and (16) to prevent the rollers from falling out.
14. Remove bronze washer (15), steel washer (16), two rows of rollers (18), and three spacer washers (17) from the idler gear. Keep these parts together for assembly. Discard bronze washer (15). This must be replaced with a new part during assembly.
15. Working from the pump side of case (4), drive counter shaft (19) out of the case.
16. Remove counter gear (20) assembly from inside the case. Hold the counter gear by washers (21) to prevent the rollers from falling out.
17. Remove two bronze washers (21), four rows of rollers (23), bearing spacer (24), and six spacer washers (22) from inside the counter gear. Keep these parts together for assembly. Discard bronze washers (21). These must be replaced with new parts during assembly.
18. Lift clutch stack (25) out of the case.
19. Remove relief valve components as follows:
a. Thread cap (26) out of the relief valve and case (4).
b. Remove block (28), spring (30), and spool (31).
c. Discard o-rings (27) and (29). These must be replaced with new parts during assembly.
20. Remove regulator valve components as follows:
a. Remove plug (37) securing high-pressure regulator valve components inside case (4).
b. Remove spring (34), pin (33), spool (32), and shims (35), if used.
c. Discard o-ring (36). This must be replaced with a new part during assembly.
d. Repeat steps a through c to remove components of low-pressure regulator valve (38).
NOTE: Keep components of each regulator valve separate. Parts must be installed in the bore they were removed from.
21. Clean all parts thoroughly in a suitable solvent. Remove any gasket material from the gearbox mounting face of the case.
22. Check bore (39) at the pump end of case (4). If this area is damaged or excessively worn, the case must be replaced with a new part.
23. Blow screen (9) out with clean compressed air. If the screen is torn or otherwise damaged, it must be replaced with a new part.
Assemble Case
1. Install regulator valve components as follows:
a. Make sure the orifice at the end of spool (32) is open.
b. Install pin (33) in spool (32). Make sure the pin moves freely in the spool.
c. Set spool and pin assembly in its bore in case. Move the spool in and out and rotate in the bore to make sure there is no binding.
d. Install a new o-ring (36) on cap (37).
e. Place shims (35), if used, inside cap (37). Set spring (34) inside the cap, on top of the shims.
f. Thread the cap and spring assembly into the bore in case (4). Spring (34) must fit inside spool (32).
g. Repeat steps a through f to install remaining regulator valve (38) components.
2. Install relief valve components as follows:
a. Install a new thin o-ring (27) in the counterbore of cap (26).
b. Insert the cap and o-ring assembly through block (28).
c. Install a new thick o-ring (29) on the cap threads, against block (28).
d. Install spring (30) and spool (31) into block (28). Spring (30) must fit inside the cap.
e. Thread the relief valve assembly into case (4). Orient the relief valve with fitting (40) facing up, as shown.
3. Install components into the idler gear as follows:
a. Set the long shoulder of idler gear (14) near the edge of a flat surface, as shown. Set a new bronze washer (15) under the gear bore.
b. Set one spacer washer (17) inside the idler gear.
NOTE: Idler shaft (12) and counter-shaft (19) look similar, but the diameter of the idler shaft is slightly smaller. If these shafts are switched, rollers will not be installed correctly in the following steps.
c. Install idler shaft (12) into the idler gear, through spacer washer (17) and bronze washer (15).
d. Install one row of 16 rollers (18) into the idler gear. Rotate the shaft to help rollers drop into place.
NOTE: A piece of wire is a helpful tool to move the rollers around to fit the last couple in place.
e. Slide a second spacer washer (17) over the idler shaft, on top of the rollers.
f. Install a second row of 16 rollers (18) into the idler gear.
g. Slide a third spacer washer (17) over the idler shaft, on top of the rollers.
h. Slide steel washer (16) over the idler shaft, onto the idler gear.
i. Remove the idler shaft from the gear. Carefully slide the gear to the edge of the surface. Pick the gear assembly up by the steel and bronze washers, and set aside.
NOTE: With the steel and bronze washers holding the rollers in place, rollers will not fall out of the bore. If they do fall out, parts are damaged or badly worn. Idler gear and rollers will have to be replaced with new parts.
4. Install components into the counter gear as follows:
a. Set counter gear (20) near the edge of a flat surface, as shown. Set a new bronze washer (21) under the gear bore.
NOTE: A special tool is needed to install rollers in the following steps. Obtain a piece of round stock or wood, 42.8 mm (1.68 in.) long and 30 mm (1.18 in.) in diameter for this purpose.
b. Slide the special tool into the counter gear, on top of bronze washer (21).
c. Slide bearing spacer (24) into the counter gear, on top of the special tool.
d. Install counter shaft (19) into the counter gear assembly.
e. Slide a spacer washer (22) over the counter shaft, on top of bearing spacer (24).
f. Install one row of 17 rollers (23) inside the counter gear. Rotate the shaft to help rollers drop into place.
g. Slide a second spacer washer (22) over the shaft, on top of the rollers.
h. Install a second row of 17 rollers (23) into the counter gear.
i. Slide a third spacer washer (22) over the shaft, on top of the rollers.
j. Slide a new bronze washer (21) over the shaft, onto the counter gear.
k. Carefully slide the counter gear to the edge of the work surface. Pick the gear assembly up by the bronze washers. Remove the counter shaft and special tool, and turn the gear assembly over onto the work surface.
NOTE: With the bronze washers holding the rollers in place, rollers will not fall out of the bore. If they do fall out, parts are damaged or badly worn. Counter gear and rollers will have to be replaced with new parts.
l. Install counter shaft (19) back into the counter gear assembly.
m. Slide a spacer washer (22) over the shaft, on top of bearing spacer (24).
n. Install one row of 17 rollers (23) into the counter gear.
o. Slide a second spacer washer (22) over the shaft, on top of the rollers.
p. Install a second row of 17 rollers (23) into the counter gear.
q. Slide a third spacer washer (22) over the shaft, on top of the rollers.
r. Slide a new bronze washer (21) onto the counter gear. Remove the shaft from the gear assembly.
5. Set case (4), gearbox side up, at the edge of a table. Support the case to prevent it from falling.
6. Install clutch stack (25) into the case.
NOTE: Be sure to hold the bronze washer at the bottom of the counter gear during installation. Otherwise the rollers will fall out.
7. Install counter gear (20) assembly into the case. Small gear must be at the bottom, as shown. Teeth of the counter gear must engage gears of the clutch stack.
8. Slide a new bronze washer (21) into place between the counter gear and the case.
9. Install counter shaft (19) into the case and through the counter gear assembly. Make sure all washers are lined up correctly.
NOTE: One end of the counter shaft may be flared slightly from factory assembly. If the shaft does not seem to fit through the gear, try installing the opposite end of the shaft.
10. Drive the counter shaft into the case. The shaft must be below flush on the gearbox side of the case.
11. Set idler gear (14) assembly inside the case. The long shoulder of the gear must face down, and must rest on bronze washer (15). Steel washer (16) must be on top.
12. Set spacer tube (13) inside the case, on top of steel washer (16).
13. Install idler shaft (12) into the case, through the spacer tube and idler gear assembly. Make sure all washers are lined up correctly.
NOTE: One end of the idler shaft may be flared slightly from factory assembly. If the shaft does not seem to fit through the gear, try installing the opposite end of the shaft.
14. Drive the idler shaft into the case. The shaft must be below flush on the gearbox side of the case.
15. Install a new gasket (8) and screen (9) onto sump cover (10). Make sure gasket and screen are positioned so that pump supply holes (40) line up.
NOTE: Screen (9) must be set in place so that the magnetic strips face upward, into case (4).
16. Install a new gasket (8) onto the bottom of case (4). Position the gasket so that pump supply hole (41) lines up with the supply hole in the case.
17. Install sump cover (10) onto the case. Make sure the pump supply holes line up. Secure the sump cover with eight bolts and lock washers.
18. Install a new square-ring seal (5) into the pump side of the case.
19. Install pump (6) to the case and secure with four bolts and four new washers. Tighten the bolts to 19 N·m (14 lb. ft.).
20. Temporarily mount the four-speed gearbox to the shuttle assembly. Secure with five bolts and lock washers.
21. Attach a dial indicator to the end of the input shaft on the pump side of the shuttle assembly. Measure the end play of the clutch stack inside the shuttle assembly.
22. Total end play should be .38 to .76 mm (.015 to .030 in.).
23. If endplay is not correct, the shuttle assembly and gearbox must be separated. Remove adapter ring (42) from clutch stack. Adjust shim (43) thickness as follows:
a. If endplay exceeds maximum, shim thickness must be increased.
b. If endplay is less than minimum, shim thickness must be decreased.
c. Repeat steps 20 through 23 until endplay is correct.
24. When endplay is correct, remove bolts and separate the gearbox from the shuttle assembly.
25. Set a new gasket (3) in place on the shuttle assembly. Install control valve (2) and secure with four bolts and star washers.
26. Set control system (1) in place on the shuttle assembly. Secure with two bolts and lock washers.
27. Connect oil lines to the oil filter on control system (1).
End By:
a. install shuttle assembly and four-speed gearbox