Usage:
start by:
a) remove drive shaft (front)
b) remove drive shaft (rear)
1. Put the truck body in the up position. Install the two pins that lock the body in the up position and disconnect the lift cylinder linkage rods from lever (1).
2. Drain the oil from the transmission, brake and hoist hydraulic tank. The capacity of the tank is 44 U.S. gal. (166.5 liter).
3. Disconnect brake oil cooler return line (2) at flange (4). Remove the bolt that fastens clip (3) to the chassis.
4. Remove bolt and clip (5) from the filter manifold.
5. Put identification on lines (6), (7), (8) and (9). Disconnect the lines from the transmission.
6. Put identification on lines (12) and (13). Disconnect the lines from the transmission. Remove bolts (10) and (11) and clips from the transmission cover.
7. Remove the bolt that fastens clip (14) to the chassis.
8. Remove bolts (15) and (16) and clips from the transmission cover.
9. Disconnect electrical connectors (17), (18) and (22). Remove wire (21) from the filter housing. Remove bolts (2) that fasten filter housing (19) to the adapter. Remove the filter housing.
10. Remove four bolts (23), (24), (25) and (26) and wiring harness clips from the transmission.
11. Disconnect two wires (28) from transmission sensor assembly (29). Remove bolt (27) and wiring harness clip from the governor.
12. Loosen two clamps (30) and slide hose (31) toward the torque converter.
13. Remove line (33) from sequence and pressure control valve (32).
14. Remove line (34) from the hydraulic tank.
15. Install two 5/8"-11 NC forged eyebolts (35) in the transmission and fasten a hoist as shown.
16. Remove two transmission rear mounting bolts (36) and (37) and washers.
17. Remove two transmission mounting bolts (38), nuts and plate from each side of the transmission.
18. Remove the transmission and transfer gears as a unit from the vehicle. The weight of the transmission and transfer gears is 2500 lb. (1125 kg).
Install Transmission And Transfer Gears
1. Install two 5/8"-11 NC forged eyebolts in the transmission case and fasten a hoist as shown. Put the transmission in position in the chassis. The weight of the transmission and transfer gear is 2500 lb. (1125 kg).
2. Install two bolts (1) and (2) and washers that fasten the transmission to the rear support.
3. Install two bolts (3), nuts and plate that fasten each side of the transmission to the support.
4. Inspect the condition of all O-ring seals and make replacements if necessary. Install O-ring seal on line (4) and install the line on the hydraulic tank.
5. Install line (5) on sequence and pressure control valve (6).
6. Put hose (10) in position on tubes (8) and (9). Tighten clamps (7).
7. Put wiring harness (13) in position and install clips (11), (12), (14) and (15) that fasten the wiring harness to the transmission.
8. Install two wires (16) on transmission sensor assembly (18). Install clip (17) on the governor with a bolt and lockwasher.
9. Install two O-ring seals on filter base (20). Install the base on adapter (19).
10. Install wire (25) on switch (23). Connect three electrical connectors (21), (22) and (24). Install the lockwire that keeps the connectors tight.
11. Put line (26) in position and install two clips (27) and (28) on the transmission cover.
12. Put line (30) in position and install clip (29) on the chassis.
13. Put line (32) in position and install two clips (31) that fasten the line to the transmission cover. Install two hoses (33) and (34) on the fitting.
14. Install O-ring seal on line (35). Install lines (35), (36), (37) and (38) on the transmission.
15. Put line (40) in position and install clip (39) on the filter adapter with a bolt and lockwasher.
16. Install O-ring seal on line (41). Connect lines (41) and (42) together. Install clips (43) and (44) on the chassis with a bolt and lockwasher.
17. Fill the transmission, brake and hoist hydraulic tank with oil. See LUBRICATION AND MAINTENANCE GUIDE.
18. Remove the two pins that lock the body in the up position. Connect hoist cylinder control linkage rod (45) to lever (46). Lower the body of the truck.