Usage:
Start By:
a. remove cab
b. remove hydraulic tank
1. Drain the oil from the transmission into a suitable container for storage or disposal. The capacity of the transmission is 53 liters (14 U.S. gal).
2. Remove eight bolts (3) from hydraulic tank bases (2). Remove hydraulic tank bases (2) from both sides of machine. Remove firewall (1).
3. Position the transmission jack to support belly guard (5) as shown. Remove bolts (4) and belly guard (5).
4. Position the transmission jack to support front belly guard (7) as shown. Remove bolts (6) and front belly guard (7).
5. Remove four bolts (8) and cover plate (9).
6. Remove four bolts (10) and ladder (11).
7. Remove four bolts (12) and cover plate (13).
8. Remove two bolts (16) and remove transmission oil fill tube (14).
9. Remove two bolts (not shown) and remove transmission dip stick tube (15).
10. Remove four bolts (18), straps (19), and disconnect rear drive shaft (17) from the transmission.
11. Remove four bolts (20), straps (21) from each end of front drive shaft (22). Remove front drive shaft (22).
12. Remove two bolts (24) and clamps, that hold heater hoses (23) in position.
13. Disconnect hydraulic hose assemblies (25) and (26).
14. Disconnect three electrical connectors (27).
15. Disconnect hydraulic hose assembly (28).
16. Remove bolts (not shown) and disconnect hydraulic hose assembly (29).
17. Remove tube assembly (30).
18. Remove bolts (not shown) and disconnect hydraulic hose assembly (31).
19. Disconnect three hydraulic hose assemblies (32).
20. Remove tube assembly (33).
21. Remove bolts (34) and tube assembly (35).
22. Remove bolts (37) and tube assembly (36).
23. Remove bolts (38) and disconnect hose assembly (39).
24. Remove bolt (40) and the clamp. Remove bolts (41) and disconnect hose assembly (42).
25. Remove tube assembly (43).
26. Remove bolt (45) and bracket (44). Remove bolts (46) and valve with bracket (47).
27. Remove tube assembly (48). Disconnect two hydraulic hose assemblies (49)
28. Disconnect two tube assemblies (50). Remove two bolts (51) and reposition valve (52) out of the way.
29. Remove bolts (54) and disconnect hydraulic hose assembly (53).
30. Remove bolts (55) and disconnect hydraulic hose assembly (56).
31. Attach hoist to the rear lifting eye of the engine. Use the hoist to keep the rear of the engine in position when the transmission is removed.
32. Attach Tooling (A) and (B) to transmission as shown.
33. Remove twelve bolts (57) that hold the transmission to the flywheel assembly.
34. Remove mounting bolt (60). Remove four bolts (58) and remove mounting bracket (59).
35. Remove transmission (61) from the machine. The weight of the machine is 772 kg (1700 lb).
NOTE: The following steps are for the installation of the transmission.
NOTE: Check the condition of the O-ring seal used on the transmission housing. If the seal is worn or damaged, use a new part for replacement.
36. Attach Tooling (A) and (B) to transmission as shown. Align the gears of the transmission up with the flywheel housing. Install transmission (61) into machine. The weight of the transmission is 772 kg (1700 lb).
37. Install twelve bolts (57) that hold transmission to bell housing.
38. Install bolts (58) and mounting bracket (59). Install mounting bolts (60).
39. Remove Tooling (A) and (B) from transmission.
40. Remove hoist from rear of engine.
41. Connect hydraulic hose assembly (56) and install bolts (55).
42. Connect hydraulic hose assembly (53) and install bolts (54).
43. Position valve (52) and install two bolts (51). Connect two tube assemblies (50).
44. Connect two hydraulic hose assemblies (49). Install tube assembly (48).
45. Install bolts (46) and valve with bracket (47). Install bolts (45) and bracket (44).
46. Install tube assembly (43).
47. Connect hose assembly (42) and install bolts (41). Install bolt (40) and clamp.
48. Connect hose assembly (39) and install bolts (38).
49. Install tube assembly (36) and bolts (37).
50. Install tube assembly (35) and bolts (34).
51. Install tube assembly (33).
52. Connect three hydraulic hose assemblies (32).
53. Connect hydraulic hose assemblies (31) and install bolts (not shown).
54. Install tube assembly (30).
55. Connect hydraulic hose assembly (29) and install bolts (not shown).
56. Connect hydraulic hose assembly (28).
57. Connect three electrical connectors (27).
58. Connect hydraulic hose assemblies (25) and install bolts (26).
59. Reposition heater hoses (23) and install two bolts (24) and clamps.
60. Install front drive shaft (22) install four bolts (20) and straps (21) to each end of front drive shaft (22).
61. Connect rear drive shaft (17). Install straps (19) and four bolts (18).
62. Install transmission dip stick tube (15) and install two bolts (not shown).
63. Install transmission oil fill tube (14) and install two bolts (16).
64. Install cover plate (13) and four bolts (12).
65. Install ladder (11) and four bolts (10).
66. Install cover plate (9) and four bolts (8).
67. Position transmission jack to support front belly guard (7) as shown. Install front belly guard (7) and bolts (6).
68. Position transmission jack to support belly guard (5) as shown. Install belly guard (5) and bolts (4).
69. Install firewall (1). Install hydraulic tank bases (2) to both sides of machine. Install bolts (3).
70. Fill the transmission with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedures.
End By:
a. install hydraulic tank
b. install cab
Disassemble Transmission Pump
1. Remove two bolts (1) and cover (2).
2. Remove seven bolts (3). Check O-ring seal (4) for damage or wear and replace if necessary.
3. Install two forcing screws as shown.
4. Use Tool (A), chains and a suitable lifting device to remove gear pump group (5).
5. Remove six bolts (6).
6. Remove shaft (7).
7. Use Tool (B), to remove retaining ring (8).
8. Remove gear (9) and ball bearing (10) as a unit.
9. Use a suitable press to remove ball bearing (10) from gear (9).
10. Remove five bolts (11).
NOTE: Only one of these bolts marked (X) has a washer.
11. Turn gear pump group (5) over and remove one bolt (12).
12. Separate pump cover assembly (13) from gear pump group (5).
13. If necessary, remove two bushings (14).
14. Check O-ring seal (15) for damage or wear and replace if necessary.
15. Remove two oil pump gears (16). Mark these gears and their location for assembly purposes.
16. Check the condition of two dowels (17) and replace if necessary.
17. Check the condition of two dowels (18) and replace if necessary.
18. If necessary, remove two bushings (19).
Assemble Transmission Pump
1. If removed, install two bushings (19).
2. Install two oil pump gears (16).
3. Check the condition of two dowels (17) and replace if necessary.
4. Check the condition of two dowels (18) and replace if necessary.
5. If removed, install two bushings (14).
6. Check O-ring seal (15) for damage or wear and replace if necessary.
7. Turn gear pump group (5) over and install one bolt (12).
8. Connect pump cover assembly (13) to gear pump group (5).
9. Install five bolts (11).
NOTE: Only one of these bolts marked (X) has a washer.
10. Heat bearing (10) to 135°C (275°F) and install in gear (9).
11. Install gear (9) and bearing (10) as a unit.
12. Use Tool (B) to install retaining ring (8)
13. Install shaft (7).
14. Install six bolts (6).
15. Use Tool (A), chains and a suitable lifting device to install gear pump group (5).
16. Install seven bolts (3). Check O-ring seal (4) for damage or wear and replace if necessary.
17. Install two bolts (1) and cover (2).
Separation & Connection Of Torque Converter From Transmission
Start By:
a. remove transmission
1. Thoroughly clean the outside of the transmission prior to disassembly.
2. Drain the transmission fluid into a suitable container.
3. Mark all parts and components for assembly purposes.
4. Install Tool (A), chains and a suitable lifting device to transmission (1) as shown. The weight of the transmission is 700 kg (1545 lb).
5. Move the transmission to a clean safe work area and install on Tool (B) as shown.
6. Install Tooling (C), chains and a suitable lifting device to transmission cover (2) as shown.
NOTE: Use a bubble level to get the cover as level as possible.
7. Remove twenty seven bolts (3).
8. Slowly and carefully lift the transmission cover straight up far enough to clear input shaft (4). The weight of the transmission cover is 200 kg (440 lb).
NOTE: Install in the reverse order.
NOTE: Use 6V-6640 Gasket Maker on mating surfaces of the torque converter and the transmission.
9. Tighten twenty seven bolts (3) to the torque of 55 ± 10 N·m (40 ± 7 lb ft).
End By:
a. install transmission