Usage:
Start By:
a. install body retaining pins
1. Remove the four bolts that hold guard assembly (1) to the transmission, and remove the guard assembly.
2. Remove the bolts that hold clips (3) and (4) to the transmission, and move the wire harness and clips (3) and (4) away from the transmission.
3. Remove the bolts that hold clip (5) to the transmission, and move the hose and clip (5) away from the transmission.
4. Put identification marks on electrical connectors (6) for correct installation. Disconnect the electrical connectors from the two valves.
5. Remove the bolts that hold clips (7) to the transmission, and move the hoses and clips (7) away from the transmission.
6. Remove the bolts, cover assembly (2) and the gasket from the transmission.
7. Remove three plugs (8) from the switch manifold.
8. Remove the lockwire from wire harness connector (9), and disconnect the wire harness connector from the switch manifold.
9. Remove the bolts, cover (10) and the gasket from the switch manifold.
10. Disconnect wire harness (12) from switch (11).
11. Remove the two bolts, bushings and O-ring seals that hold switch (11) to the switch manifold, and remove the switch.
12. Move sleeves (13) from the actuator group, and remove them through switch manifold (15). Remove the O-ring seals from the sleeves.
13. Move sleeve (14) out of the actuator group and into the switch manifold. Remove four bolts (16), and remove switch manifold (15) from the transmission and coupling assembly.
14. Remove sleeve (14) from switch manifold (15). Remove the O-ring seals from the sleeve.
15. Remove coupling assembly (17) from the rotary selector spool.
16. Remove five 3/8" bolts (20) and five 5/16" bolts (21), and remove valve group (18) and cover (19).
17. Fasten a hoist to valve group (22). Remove the bolts and valve group (22) from the transmission. The weight of the valve group is 25 kg (56 lb).
18. Remove bolt (23) and plate (24).
19. Remove the four bolts that hold manifold assembly (27) to the side of the transmission, and remove the manifold assembly.
20. Remove sleeves (25) from manifold (26). Remove the O-ring seals from the sleeves.
21. Remove manifold (26) from the transmission and sleeves (28) and (29).
22. Remove sleeves (28) and (29) from the transmission. Remove the O-ring seals from the sleeves.
Install Transmission Hydraulic Control Valves
1. Put the O-ring seals in position on sleeves (1) and (2). Put clean SAE 30 oil on the O-ring seals. Put sleeves (1) and (2) in position in the transmission.
2. Put manifold (3) in position in the transmission and on sleeves (1) and (2).
3. Put the O-ring seals in position on sleeves (4). Put clean SAE 30 oil on the O-ring seals. Put sleeves (4) in position in manifold (3).
4. Put the O-ring seals and manifold assembly (7) in position on the side of the transmission, and install the four bolts.
5. Put plate (6) in position on the manifold, and install four 3/8 " - 16 NC x 5" bolts (8) to align the plate and manifold. Install bolt (7). Tighten bolt (7) to a torque of 30 ± 4 N·m (22 ± 3 lb ft). Remove four 3/8 " - 16 NC bolts (8).
6. Fasten a hoist to valve group (9), and put the valve group in position in the transmission. Install 12 bolts (10) and bolt (11). Tighten the bolts to a torque of 30 ± 4 N·m (22 ± 3 lb ft). The weight of the valve group is 25 kg (56 lb).
7. Put valve group (12) and cover (13) in position in the transmission, and install five 3/8" bolts (14) and five 5/16" bolts (15). Tighten bolts (14) to a torque of 48 ± 4 N·m (35 ± 3 lb ft). Tighten bolts (15) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
8. Install coupling assembly (16) in the transmission. The groove in the coupling assembly must be aligned with the pin in the bore of the rotary selector spool.
9. Put the O-ring seals in position on sleeves (17) and (18). Put clean SAE 30 oil on the O-ring seals. Position sleeve (18) in the switch manifold.
10. Put the O-ring seals in position in switch manifold (19). Position the switch manifold over the coupling assembly and on the transmission. Install sleeves (17) in the switch manifold. Install four bolts (20) that fasten the switch manifold to the transmission. Tighten the four bolts to a torque of 48 ± 4 N·m (35 ± 3 lb ft).
11. Install sleeves (17) and (18) into the holes in the actuator group.
12. Put switch (21) in position on the coupling assembly, and install the two bolts, bushing and O-ring seals that hold the switch in place.
13. Connect wire harness (22) to switch (21).
14. Install the gasket and cover (25) on the switch manifold.
15. Connect wire harness (24), and install the lockwire to hold the connector in place.
16. Install three plugs (23) in the switch manifold.
17. Put the gasket and cover (26) in position on the transmission, and install the bolts.
18. Put the wire harness and clips (27) and (29) in position, and install the bolts.
19. Connect electrical connectors (30) to the two valves.
20. Put the hoses and clips (28) and (31) in position on the transmission, and install the bolts.
21. Install guard assembly (32).
22. Test and adjust the transmission hydraulic controls. See the topic "Transmission Hydraulic System Tests" in the Testing And Adjusting module, Form No. SENR5640.
End By:
a. remove body retaining pins
Disassemble Transmission Hydraulic Control Valves
Start By:
a. remove transmission hydraulic control valves
1. Remove six O-ring seals (1) from switch manifold (2).
2. Put identification marks on coil assemblies (3) for correct installation. Remove nuts (4), and remove coil assemblies (3) from the cartridge assemblies.
3. Remove plug (5) from the switch manifold, and remove the O-ring seals from the plug.
4. Remove cartridge assemblies (6) from the switch manifold.
5. Remove O-ring seals (7) and back-up rings (8) from each of the cartridge assemblies.
6. Remove two bolts (9), the cover and wire harness (10) from the switch manifold.
7. Remove lip-type seal (11) from the switch manifold.
8. Use tooling (A) to remove bearing (12) from the switch manifold.
9. Remove two plugs (14) from pressure control valve (13). Remove the O-ring seal from each plug.
NOTE: The pressure control valve for each clutch is identified on the pressure control valve body by a letter at location (15) on the valve body.
| NOTICE |
|---|
Do not at any time mix the components between valve groups during disassembly or assembly. |
NOTE: Valve group (A) is for clutch No. 3. Valve group (B) is for clutch No. 1. Valve group (C) is for clutch No. 2. Valve group (E) is for clutch No. 5. Valve group (F) is for clutch No. 4. Valve group (G) is for clutch No. 6. Valve group (H) is for clutch No. 7.
10. Use the following procedure to disassemble the valve groups.
a. Remove two screws (28) and body (26) from the valve body.
b. Remove two springs (20), shims (21) and two pistons (22) from body (26).
NOTE: There is no center plug (27) on valve group (H).
c. Remove spring (23), orifice (24), O-ring seal (25) and three plugs (27) from body (26).
d. Remove stop (19), spool (18) and spring (16) from the valve body.
e. Remove slug (17) from spool (18).
11. Use the following procedure to disassemble spools (18) from the valve groups.
a. Use tool (B) to remove snap ring (32) from the spool.
b. Remove retainer (31), spring (30) and ball (29) from the spool.
12. Remove bolt (34), washer (35) and piston (33) from the valve body.
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There is spring pressure against cover (36). To prevent personal injury, hold cover (36) while the bolts are removed. |
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13. Remove cover (36), spool (41) and spring (43) from the valve body.
14. Remove spiral ring (37), retainer (38), spring (39) and check valve (40) from spool (41).
15. Remove shims (42) from the end of the spool.
16. Remove cover (44), spool (46) and spring (47) from the valve body.
17. Remove O-ring seal (45) and the pin from cover (44).
18. Use the following procedure to disassemble spool (46).
a. Use tool (B) to remove snap ring (48) from the spool.
b. Remove seat (49), ball (51) and spring (52).
c. Remove O-ring seal (50) from seat (49).
19. Remove two bolts (53) and actuator (54).
20. Remove two bolts (55) and cover (56).
21. Use tooling (A) to remove bearing (57) from cover (56).
22. Remove rotor (58) from the actuator.
23. Remove two bolts (59) and vane (60).
24. Remove two plugs (61) from the actuator. Remove the valve that is under each plug. Remove the O-ring seal from each plug.
25. Use tooling (A) to remove bearing (62) from the actuator.
26. Remove two bolts (63). Remove retainers (66) and springs (64).
27. Remove bolt (67), the washer and rotary selector spool (65).
28. Remove pin (70), cam (68) and the screen from the rotary selector spool.
29. Remove pin (69).
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Support (71) holds a spring under compression. To prevent personal injury, hold support (71) when bolts (73) are removed. |
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30. Remove bolts (73) and support (71). Remove two dowels (72) from the support if a replacement is necessary.
31. Remove spool (74) and spring (76) from the valve body.
32. Remove shims (75) from spool (74).
33. Use tool (B) to remove snap ring (77) from spool (74).
34. Remove slug (78), spring (79) and ball (80) from the spool.
35. Remove cap (84), spring (83) and valve (81) from the valve body. Remove spacer (82) from the valve.
36. Remove body (85). Remove the O-ring seal from the body.
Assemble Transmission Hydraulic Control Valves
1. Install O-ring seal (2) on body (3). Install body (3) in selector control valve (1). Tighten body (3) to a torque of 41 ± 7 N·m (30 ± 5 lb ft).
2. Put clean transmission oil on the outside diameter of valve (7). Install spacer (6) in valve (7).
3. Install valve (7), spring (5) and cap (4) on the selector control valve. Tighten cap (4) to a torque of 41 ± 7 N·m (30 ± 5 lb ft).
4. Put clean SAE 30 oil on slug (9). Install ball (11), spring (10) and slug (9) in spool (12). Use tool (A) to install snap ring (8).
5. Put clean SAE 30 oil on spool (12). Install shims (15) in the end of spool (12).
6. Install spring (14) and spool (12) in selector valve (13) as shown.
7. Install two dowels (16) on the top and bottom of support (17). Install the dowels so they extend 6.50 ± 0.25 mm (.256 ± .010 in) above the surface.
8. Put support (17) in position on selector valve (13). Install the two bolts that hold it in position.
9. Install the screen in rotary selector spool (19). Tighten the screen to a torque of 6.1 ± 0.7 N·m (54 ± 6 lb in). Install cam (18) in the rotary selector spool, and install pin (22) that holds the cam in place. Install the pin until it is 0.80 ± 0.25 (.032 ± .010 in) below the surface of the rotary selector spool.
10. Install pin (21). Install the pin with the head of the pin up as shown when two holes (20) are in the position shown.
11. Put clean SAE 30 oil on rotary selector spool (19). Install the rotary selector spool in the valve body.
12. Install bolt (28) and washer (25) that hold the rotary selector spool in position.
13. Install two springs (24) and (30), two retainers (25) and (27) and bolts (23) that hold the springs in position on the support. Make sure the side of each spring is 4.5 ± 0.5 mm (.18 ± .02 in) from the side of the selector valve body.
14. Loosen bolts (29) enough to make sure the rollers in springs (24) and (20) are in the center of the notches in the cam. Tighten bolts (29).
15. Use tooling (B) to install bearing (31) in actuator body (32). Install the bearing so that it extends 3.00 ± 0.50 mm (.118 ± .020 in) above the surface.
16. Put O-ring seal (34) in position on plug (33). Put clean SAE 30 oil on the O-ring seal and on valve (35).
17. Install valves (35) in the actuator body. Make sure the flat end of the valve is installed first. Install plug (33).
18. Install vane (36) and two bolts (37) in the actuator body. Do not tighten bolts (37) at this time. Make sure notch (38) on the vane is in the position shown.
19. Put clean SAE 10 oil on all surfaces of the rotor. Install rotor (39) in the actuator.
20. Use tooling (B) to install bearing (40) in cover (41). Install the bearing so it is 1.30 ± 0.25 mm (.051 ± .010 in) below surface (42).
21. Install cover (41) on the actuator body. Install two bolts (43) that hold the cover in position. Tighten bolts (43) to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
22. Tighten bolts (37) (see Step 18) to a torque of 15 ± 3 N·m (11 ± 2 lb ft).
23. The rotor must turn freely through 300 degrees of rotation.
24. Install the actuator on the selector valve body. Make sure the larger groove (slot) (44) in rotor (39) is in alignment with the head on the pin on rotary selector spool (19).
25. Install the two bolts that hold the actuator in position on the selector valve. Tighten the bolts to a torque of 30 ± 4 N·m (22 ± 3 lb ft).
26. Install O-ring seal (47) on seat (46). Put clean SAE 30 oil on the O-ring seal.
27. Install spring (49), ball (48) and seat (46). Use tool (A) to install snap ring (45).
28. Put the shims, spring (51) and neutralizer valve spool (50) in position in the selector valve body.
29. Put the O-ring seal and pin in position in cover (52). Put clean SAE 30 oil on the O-ring seal. Put the cover in position on the selector valve body, and install the bolts that hold it.
30. Install valve (57), spring (56), retainer (55) and spiral ring (54) in priority reducing valve spool (58).
31. Put shims (59) in position in the end of spool (58). Put clean SAE 30 oil on the outside diameter of spool (58).
32. Install spring (60), spool (58) and cover (53) on the selector control valve.
NOTE: Step 33 is the assembly procedure for the spools for valve groups.
33. Install ball (62), spring (63) and retainer (64) in spool (61). Use tool (A) to install snap ring (65) in the end of the spool.
NOTE: The pressure control valve for each clutch is identified on the pressure control valve body by a letter on the valve body.
| NOTICE |
|---|
Do not at any time mix the components between valve groups during disassembly or assembly. |
NOTE: Valve Group A is for clutch No. 3. Valve group B is for clutch No. 1. Valve group C is for clutch No. 2. Valve group E is for clutch No. 5. Valve group F is for clutch No. 4. Valve group G is for clutch No. 6. Valve group H is for clutch No. 7.
34. Use the following procedure to assemble the valve groups.
a. Put clean SAE 30 oil on all the surfaces of spool (61) and slug (67). Install slug (67) in the spool as shown.
b. Install spring (66), spool (61) and stop (68) in the pressure control valve.
NOTE: There is no plug (79) in valve group (H).
c. Make sure the O-ring seals are in position on plugs (78), (79) and (80). Install the plugs in the body.
d. Put clean SAE 30 oil on O-ring seal (76). Install O-ring seal (76), orifice (75) and spring (74) in body (77).
e. Put clean SAE 30 oil on all the surfaces of pistons (72) and (73). Install piston (72) in piston (73) as shown.
f. Install shims (71) and springs (69) and (70) in the end of piston (72).
g. Install piston (73) in body (77). Install body (77) on the pressure control valve. Install the two screws that hold the body in position.
35. Cut a 51 mm (2 in) section off of a 3/16 "allen wrench. Use this 3/16 " section (81) and a torque wrench to tighten the screws that hold the bodies in position to a torque of 6.1 ± 0.7 N·m (54 ± 6 lb in).
36. Put clean SAE 30 oil on piston (82). Install piston (82). Install piston (82) in the pressure control valve. Install the washer and bolt (83) that hold the piston in place.
37. Make sure O-ring seals (84) are in position on plugs (85). Install plugs (85) in the end of the pressure control valve.
38. Use tooling (B) to install bearing (86) in the switch manifold. Install the bearing so that it is maximum of 0.50 mm (.020 in) below surface (87).
39. Put 7M7260 Liquid Gasket Material on the bore in the switch manifold for the lip-type seal. Do not put the liquid gasket material on the lip seal case.
Let the liquid gasket material become dry before the seal is installed. Use tooling (B) to install lip-type seal (88) in the switch manifold. Install the seal with the lip of the seal in as shown. Put clean transmission oil on the lip of the seal.
40. Install wire harness (89) in the switch manifold. Make sure pin (91) in the wire harness is in the position shown. Install cover (90) and the bolts that hold the wire harness in position.
41. Install O-ring seals (92) and back-up rings (93) on both cartridge assemblies (94).
42. Install cartridge assemblies (94) in the switch manifold. Tighten the cartridge assemblies to a torque of 25 ± 5 N·m (18 ± 4 lb ft).
43. Make sure the two O-ring seals are in position on plug (95). Install plug (95) in the switch manifold.
44. Install coil assemblies (97) the cartridge assemblies, and install nuts (98). Tighten the nuts to a torque of 3.0 ± 0.5 N·m (27 ± 4 lb in).
45. Install six O-ring seals (99) on the switch manifold. Put clean SAE 30 oil on each seal.
End By:
a. install transmission hydraulic control valves