Usage:
END VIEW
SIDE VIEW
TOP VIEW
Remove Transmission Hydraulic Controls
NOTE: The transmission does not have to be removed to remove the transmission hydraulic controls. The transmission was removed for illustration purposes only.
1. Lift the body of the truck and put FT1437 Body Support in position. See INSTALL AND REMOVE BODY SUPPORT on Page 7.
2. Make sure the area around the transmission hydraulic controls is clean and free of dirt before any parts are removed.
3. Remove four tubes (1), (2), (3) and (4) from the sequence and pressure control valve and the transmission.
4. Remove bolts (6) and washers that fasten cover (5) to the transmission case.
5. Install two 3/8"-16 NC forged eyebolts in cover (5) and fasten a hoist as shown. Remove the cover and gasket from the transmission case.
6. Remove two bolts (7) and washers. Remove accumulator group (8) and four sleeves (6) from the transmission case and the governor cut-off valve group.
NOTE: Put a mark on the side of the hydraulic control valve stack for assembly.
7. Remove twenty-seven bolts (9) and washers. Remove governor cut-off valve (10) from the automatic selector valve.
| NOTICE |
|---|
Valve spool (12) is free to slide out of the body when the valve is removed. |
8. Remove automatic selector valve (11) from the plate.
9. Remove plate (13) from the shift pressure valve.
10. Remove shift pressure valve (14) from the plate and rod (15). Remove the rod from the transmission case.
11. Remove bolts (16) and washers that fasten plate (17) to the pressure control valve.
12. Remove pressure control valve (18) from the manifold.
13. Remove six bolts (19) and washers that fasten manifold (20) to the selector valve.
| NOTICE |
|---|
Four valve spools (21) are free to slide out of selector valve (23) when the valve body is removed. |
14. Install 1/4"-20 NC forged eyebolts (22) and (24) in the dowels that hold the selector valve in position. Use the eyebolts to pull the dowels out of the accumulator group. Remove the selector valve from the plate.
15. Remove plate (25) from the accumulator group.
16. Pull five tubes (28), (29) and (30) out of accumulator valve and the transmission case. Remove the retainer ring from tube (27) and push the tube into the transmission case. Remove five bolts (31) and washers that fasten accumulator valve (26) to the manifold. Remove the accumulator valve from the manifold. Remove tube (27) from the case.
17. Remove bolts (32) and lockwashers that fasten cover (33) to the case. Remove the cover and gasket from the case.
18. Remove springs (34) and (35) from the pins and detent assemblies. Remove bolts (36) and (37) and remove detent assemblies (38) and (39).
19. Remove two pins (40) and (43) from the shaft. Make a mark on shaft (45) on the left side of lever (41) and lever assembly (42) for assembly purposes. Remove two nuts (44), washers and pins with tapers from the lever and the lever assembly.
20. Remove shaft (45) from the transmission case, cam (46), washers (47) and levers (41) and (42).
21. Remove two bearings (48) from cam (46).
22. Remove bolts (50) and lockwashers that fasten cover (49) to the switch base. Remove the cover and gasket from the switch base.
NOTE: The wires do not have to be disconnected from the switch.
23. Remove four bolts (51) that fasten base (52) to the transmission case. Remove the base and switch from the transmission.
24. Use tool (A) to remove retainer ring (53) from gear (55). Remove washer (54) from the gear and remove gear (55) from the inside of the transmission case.
25. Remove two lip type seals (58) from the transmission case. Use tooling (B) to remove three bearings (56), (57) and (59) from the transmission case.
Install Transmission Hydraulic Controls
1. Be sure all parts are clean and free of dirt and foreign material.
2. Inspect the condition of all O-ring seals and make replacements if necessary.
3. Use tooling (A) to install the bearing in the left side of the case. Install the bearing until it is 1.05 in. (26.7 mm) below the outside surface of the transmission case.
4. Use tooling (A) to install bearing (1) in the right side of the case. Install the bearing until it is .66 in. (16.8 mm) below the outside surface of the transmission case. Use tooling (A) to install bearing (2) until it is even with the inside of the case.
5. Put 7M7260 Liquid Gasket Material on the seal bore surfaces of the case and let dry. Install two lip seals on the right side of the case with tooling (A). Install the seals with the seal lip toward the inside of the case. Put a thin layer of SAE 30 oil on the seal lips.
6. Put gear (3) in position in the case and install washer (4) on the end of the gear. Install the retainer ring that holds the gear in the case with tool (B).
7. Install gasket (6) between base (7) and the case. Put the base in position and install but do not tighten two bolts (5) to hold the base in position. Install switch (8) with four bolts. Be sure the chamfer on the square shaft of the switch is in alignment with chamfer in square hole in gear (3). Remove the two bolts (5).
8. Install gasket (10) and cover (9) on the base with four bolts and lockwashers.
9. Use tooling (A) to install two bearings in cam (11). Install the bearings until they are even with the surface of the cam.
10. Install cam (15) on the shaft. Install the pin with a taper washer and nut that fasten the cam to the shaft. Tighten the nut to a torque of 25 ± 3 lb.ft. (35 ± 4 N·m). Install spacer (12) on shaft (16). Install the shaft in the case. Install washers (17), levers (13) and (14) and cam (11) on the shaft.
11. Be sure timing marks (18) on cam (11) and gear (3) are in alignment.
12. Install the pins with a taper, washers and nuts (21) that fasten the levers to shaft (16). Do not tighten the nuts at this time. Install pins (19) and (20) that hold the shaft on location in the case.
13. Install two detent assemblies (24) and (25) on the case with bolts, nuts and washers. Install two springs (22) and (23) on the detent assemblies and the case.
14. Install an O-ring seal on each end of tube (27). Install the tube in the case. Install six O-ring seals (29) on the manifold and three O-ring seals (28) on accumulator valve (26). Put the accumulator valve in position on the manifold.
15. Install five bolts (33) and washers that fasten the accumulator to the manifold. Tighten the bolts to a torque of 35 ± 3 lb.ft. (45 ± 4 N·m). Install O-ring seals on each end of tubes (30), (31) and (32). Install the tubes in the accumulator valve and case. Slide tube (27) into the accumulator valve and install the retainer ring that holds the tube in position.
16. Put plate (34) in position on the accumulator valve.
| NOTICE |
|---|
Valve spools (36) are free to slide out of the selector valve. |
17. Put selector valve (37) in position on the plate. The links on the valve spools must be over pin (35).
18. Use 1/4"-20 NC forged eyebolts (39) and (40) to install dowels that hold the selector valve on location. Push shaft (16) toward the right side of the case. Put lever (13) in position on the shaft so there is .09 in. (2.3 mm) clearance between the lever and the link (38) on the spool. Tighten nuts (21) to a torque of 25 ± 3 lb.ft. (35 ± 4 N·m).
19. Use this procedure to adjust the valve spools in the selector valve:
a) Turn shaft (16) until detent assembly is in the third notch of cam (15). This is first speed notch and has a "1" on it.
b) Loosen the nuts that fasten the links to the valve spools. Adjust the position of the valve spools until they are even with the surface of the valve body.
c) After the spools have been adjusted, tighten the nuts to a torque of 25 ± 5 lb.ft. (35 ± 7 N·m).
20. Put manifold (41) in position on the selector valve. Install the six bolts and washers that fasten the plate to the accumulator valve. Tighten the bolts to a torque of 22 ± 3 lb.ft. (28 ± 4 N·m).
21. Put pressure control valve (42) in position on the manifold.
22. Put plate (43) in position on the pressure control valve. Install the bolts and washers that fasten the plate to the accumulator valve. Tighten the bolts to a torque of 22 ± 3 lb.ft. (28 ± 4 N·m).
23. Inltall rod (45) in the shift pressure control valve. Put shift pressure control valve (44) in position on the plate. Move the retainer ring on the rod until the retainer ring is .06 in. (1.5 mm) from the inside surface of the case.
24. Put plate (46) in position on the shift pressure control valve.
| NOTICE |
|---|
Valve spool (48) is free to slide out of the automatic selector valve. Put automatic selector valve (47) in position on the plate. Be sure the links on the valve spools are over the pins on cam (11) and lever (14). |
26. Put governor cut-off valve (49) in position on the automatic selector valve. Install the bolts and washers that fasten the governor cut-off valve to the plate. Tighten the bolts to a torque of 22 ± 3 lb.ft. (28 ± 4 N·m).
27. Use this procedure to adjust the valve spools in the automatic selector valve:
a) Turn shaft (16) until the detent assembly is in the sixth notch of cam (15). This is fourth speed notch and has a "4" on it.
b) Loosen the nuts that fasten the links to the valve spools. Adjust the position of valve spool (50) until it is even with the surface of the valve opposite the link end of the valve spool.
c) Move cam (11) until the detent assembly is in the third notch of the cam. This is first speed notch and has a "1" on it.
d) Adjust the position of valve spool (48) until it is even with the surface of the valve opposite the link end of the valve spool.
e) After the valve spools have been adjusted, tighten nuts (51) to a torque of 25 ± 5 lb.ft. (35 ± 7 N·).
28. Install gasket (52) and cover (53) on the case with seven bolts and lockwashers.
29. Install O-ring seal on each end of four sleeves (54). Install the sleeves in accumulator valve (55).
30. Put accumulator valve (55) in position on the case and in the governor cut-off valve. Install the two bolts and washers. Tighten the bolts to a torque of 35 ± 3 lb.ft. (45 ± 4 N·m).
31. Install two 3/8"-16 NC forged eyebolts in cover (56) and fasten a hoist as shown. Install a new gasket and the cover on the case. Install the bolts and washers that fasten the cover to the case.
32. Install two O-ring seals on sleeve (58) and one O-ring seal on plug (57). Install the sleeve in the cover and the shift pressure valve. Install the plug in the cover.
33. Install four tubes (59), (60), (61) and (62) on the case and the sequence and pressure control valve.
Disassemble And Assemble Transmission Hydraulic Controls
ACCUMULATOR VALVE
start by:
a) remove transmission hydraulic controls
1. Disassemble the accumulator valve as follows:
a) Remove plugs (3) and (6). Remove piston (1), slug (5), piston (4) and spring (7) from accumulator valve body (2).
b) Remove plugs (8) and (12). Remove slug (9), stop (10) and spring (11) from the body.
2. Assemble the accumulator valve as follows:
a) Inspect the condition of all O-ring seals and make replacements if necessary.
b) Install O-ring seals on plugs (3), (6), (8) and (12). Install slug (9) and plug (8) in the body.
c) Install stop (10), spring (11) and plug (12) in the body.
d) Install slug (5) in piston (1). Install piston (1) and plug (3) in the body.
e) Install piston (4), spring (7) and plug (6) in the body.
3. Disassemble the governor cut-off valve as follows:
a) Remove plug (14) from governor cut-off valve body (13).
b) Remove O-ring seal (16) from the plug.
c) Remove spring (15) and governor cut-off valve spool (17) from the valve body.
d) Remove the other plug from the valve body and remove the O-ring seal from the plug.
NOTE: Before the parts are assembled, clean all parts with a cloth that is free of loose material (lint). Put a thin layer of transmission oil on all of these parts.
4. Assemble the governor cut-off valve as follows:
a) Install the O-ring seals (16) on both plugs.
b) Install plug (13) in governor cut-off valve body (14).
c) Install spring (15) on governor cut-off valve spool (17).
d) Install the spring and valve spool in the valve body.
e) Install plug (18) in the other end of the valve body.
f) Tighten both plugs to a torque of 30 ± 5 lb.ft. (40 ± 7 N·m).
5. Disassemble the automatic selector valve as follows:
a) Remove manual selector valve spool (21) from automatic selector valve body (19).
b) Remove bolt and washer (23) and remove hydraulic shift valve spool (20) with its retainer.
c) Remove the bolts that hold retainer strip (22) in position and remove the strip from the body.
d) Loosen two nuts (27) on each valve spool. Remove two links (26) and their nuts from the spools.
e) Remove valve spool retainer (25) from the valve spool.
f) Install a 1/4"-20 NC eyebolt in each of three stops (24).
g) Remove stops (24) with a 1/4"-20 NC forged eyebolt.
| NOTICE |
|---|
The automatic selector valve spools and the valve spool bores in the body have a letter identification. Two valve spools (28) with the letter "R" must be assembled in bores (29) with the letter "R". One valve spool (30) with the letter "T" must be assembled in bore "T". Make a note of the direction in which the valve spools are installed, also. |
h) Remove the three valve spools from the valve body.
j) Remove two slugs from each of the valve spools.
k) Remove the bolt and washer that holds valve spool retainer (31) on the opposite side of the valve body. Remove the valve spool retainer from the body.
l) Remove the bolts that hold retainer strip (38) in position on the opposite side of the automatic selector valve.
m) Use a 1/4"-20 NC eyebolt and remove three stops (35) from the body.
| NOTICE |
|---|
Valve spool (34) with letter identification "S" must be assembled in bore (32) with letter identification "S". Valve spool (37) with letter "R" must be assembled in bore (36) with letter "R". Valve spool (39) with letter "T" must be assembled in bore "T". Make a note of the direction in which the valve spools are installed, also. |
n) Remove the three valve spools from the valve body.
p) Remove two slugs from each of the valve spools.
q) Remove three dowels (33) from the valve body.
r) Remove the three middle stops that are held in place by the dowels.
6. Assemble the automatic selector valve as follows:
NOTE: Clean all parts with a cloth that is free of loose material (lint). Put a thin layer of transmission oil on all of these parts.
a) Lower the temperature of middle stops (40).
b) Install the three middle stops in automatic selector valve body (19) so the hole in the stops will be in alignment with the holes in the valve body.
c) Install dowels (33) in the valve body and through the holes in each of the stops. Make sure the dowels are below the surface of each face of the valve body.
| NOTICE |
|---|
Make sure the slugs are installed in the correct valve spools and the spools are installed in the correct bores. |
d) Install two slugs in each of the valve spools.
e) Install six valve spools (28), (30), (34), (37) and (39) in their respective bores and in the direction shown.
f) Install two retainer strips (22) and (38) on the valve body. Install the bolts that hold each strip in place.
g) Install valve spool retainer (31) in the valve body.
h) Install valve spool retainer (25) on hydraulic shift valve spool (20) in the direction shown.
j) Install a nut (27) and link (26) on each of the valve spools.
k) Install valve spool (20) in the valve body and install the bolts and washers that hold its retainers in place.
l) Install manual selector valve spool (21) in the valve body.
m) Tighten all of the bolts in the valve body to a torque of 22 ± 3 lb.ft. (28 ± 4 N·m).
7. Disassemble shift pressure valve as follows:
| NOTICE |
|---|
Make a note of the direction, sequence and location in which all of the parts are removed from the valve body. The springs have different lengths and wire diameters and must be assembled in their original positions. |
a) Remove the bolts that hold cover (42) in position.
b) Remove the cover from shift pressure valve body (41).
c) Remove wiper (48) from the cover.
d) Remove two spacers (45), spring (47) and thick spring (44) from the body.
e) Remove valve seat assembly (49), spring (46) and priority valve assembly (43) from the valve body.
f) Disassemble the valve seat assembly as follows:
Step 1) Remove screw (52), spring (51) and valve (53) from valve seat (50).
g) Disassemble the priority valve assembly as follows:
Step 1) Remove spiral snap ring (56), retainer (58), spring (55) and valve (57) from valve spool (54).
h) Remove the bolts that hold cover (63) in position.
j) Remove the cover from the valve body.
| NOTICE |
|---|
Make a note of the number of turns it takes to remove each adjustment bolt so that it can be installed in its original position. |
k) Remove two adjustment bolts (60) from covers (42) and (63). Remove the plug, spacer and spring from behind each bolt.
l) Remove two spacers (62), long spring (59), with a yellow stripe and spring (61) from the body.
m) Remove the bolts that hold cover (66) in position on the opposite side of the valve body.
n) Remove the cover from the valve body and remove the two seals from the cover.
p) Remove piston (68) for hold valve, spring (67) and downshift reducing valve spool assembly (64) from the body.
q) Remove O-ring seal (65) from the piston.
r) Disassemble the downshift reducing valve spool assembly as follows:
Step 1) Remove snap ring (71), retainer (73), spring (70) and plunger (72) from valve spool (69). Use tool (A) to remove the snap ring.
s) Remove the bolts that hold retainer strip (76) in place.
t) Remove the retainer strip from the valve body.
u) Remove three upshift reducing valve spools (77) from the body.
v) Remove one slug (75) from each valve spool.
w) Remove dowel (74) from the valve body and remove the middle stop that the dowel holds in place.
8. Assemble shift pressure valve as follows:
NOTE: Clean all parts with a cloth that is free of loose material (lint). Put a thin layer of transmission oil on all of these parts.
a) Install inner stop (78) in valve body (41) so the hole in the stop will be in alignment with the holes in the body.
b) Install dowel (74) in the valve body and through the stop. Make sure the dowel is below the surface of each face of the body.
c) Assemble priority valve assembly (43) as follows:
Step 1) Install the valve, spring, retainer and snap ring into the valve spool.
d) Install spring (46) in the other end of the priority valve assembly.
e) Install the priority valve spool assembly in the body against the inner stop as shown.
f) Assemble valve seat assembly (49) as follows:
Step 1) Install the valve, spring and screw in the valve seat.
g) Install the valve seat assembly in the valve body and spring (46) as shown.
h) Install the wiper in cover (42) and install the cover and the bolts that hold it in place.
j) Install cover (63) and the bolts that hold it in position on the valve body.
k) Install the spring, spacer and plug in each of the four holes in covers (63) and (42). Start with a spring and stop with a plug.
l) Install four adjustment bolts (60) in the two covers first far enough to hold the springs, spacers and plugs in place.
m) Assemble downshift reducing valve spool assembly (64) as follows:
Step 1) Install the plunger, spring, retainer and snap ring in the valve spool. Use tool (A) to install the snap ring.
n) Install a spacer, thick spring (44) and the downshift reduction valve spool in the valve body.
p) Install the O-ring seal on piston (68).
q) Install spring (67) and the piston in the valve body.
r) Install two seals (79) on cover (66).
s) Install the cover on the valve body and the bolts that hold it in position.
t) Install three spacers, long spring (59) with a yellow stripe and the other two springs into the valve body as shown.
u) Install one slug (75) in each of three upshift reducing valve spools (77).
v) Install the three valve spools in the valve body as shown.
w) Install retainer strip (76) on the valve body and install the bolts that hold it in position.
x) Tighten all of the twelve point head bolts in the valve body to a torque of 22 ± 3 lb.ft. (28 ± 4 N·m).
y) Turn all of the four adjustment bolts into their original positions.
9. Disassemble the pressure control valve as follows:
| NOTICE |
|---|
Make a note of the direction, sequence and location in which all of the parts are removed from the valve body. Keep a record of the number and thickness of the spacers in the pressure control valve for assembly purposes. |
a) Remove four bolts from cover (80) and remove the cover from the body assembly.
b) Remove screw (81) and check valve ball (86) from the body assembly.
c) Remove O-ring seal (89) from the screw.
d) Remove O-ring seal (84) from the cover.
e) Remove load piston (83), spacers (82) and relief valve spool (88) from the body assembly.
f) Remove spring (85), spacers (87) and slug (90) from the relief valve spool.
g) Remove the bolt that holds body assembly (93) in place. Remove the body assembly from pressure control valve body (94).
h) Remove the O-ring seals (96) from the body assembly.
j) Remove retainer (92), two springs (91), small spring (95), check valve plunger (97) and stop (99) from the valve body.
k) Remove two O-ring seals (98) from the stop.
l) Remove the bolts that hold opposite side cover (106) in position. Remove the cover from the valve body. Remove seals (110) from cover.
m) Remove spring (103), flow control valve plunger (101), modulating relief valve spool assembly (104), sleeve (102), retainer (105), safety valve spool assembly (109) and spring (108) from the valve body.
| NOTICE |
|---|
Make a note of dowel (107) in the bore of the valve body. This dowel must be in alignment with the notch in sleeve (102) for correct assembly. |
n) Remove two dowels (100) from the valve body and the two stops that the dowels hold in place.
p) Disassemble the modulating relief valve spool assembly as follows:
Step 1) Remove spiral snap ring (113), retainer (115), spring (112) and poppet (114) from valve spool (111).
q) Disassemble the safety valve spool assembly as follows:
Step 1) Remove spiral snap ring (118), retainer (120), spring (117) and poppet (119) from valve spool (116).
10. Assemble the pressure control valve as follows:
NOTE: Clean all parts with a cloth that is free of loose material (lint). Put a thin layer of transmission oil on all of these parts.
a) Install stops (121) and (122) in pressure control valve body (94) as shown. Make sure the holes in the stops are in alignment with the holes in the valve body.
b) Install one dowel in each of the holes in the valve body and through each of the stops. Make sure the dowels are below the surface of each face of the body.
c) Assemble safety valve spool assembly (109) as follows:
Step 1) Install the poppet, spring, retainer and snap ring (118) into the valve spool.
d) Assemble modulating relief valve spool assembly (104) as follows:
Step 1) Install the poppet, spring, retainer and snap ring (113) into the valve spool.
e) Install spring (108) in the safety valve spool assembly. Install the valve spool assembly into the valve body as shown.
f) Install the modulating relief valve spool assembly into the sleeve as shown.
g) Install sleeve (102) into the valve body. Put the notch in the sleeve in correct alignment with the dowel in the bore of the valve body.
h) Install spring (103) into flow control valve plunger (101). Install the plunger into the valve body as shown.
j) Install three O-ring seals (110) on cover (106). Install the cover on the valve body and the bolts that hold it in place.
k) Install retainer (105), two springs (91), retainer (92), small spring (95) and plunger (97) into the valve body.
l) Install two O-ring seals on stop (99) and install the stop into the valve body as shown.
m) Install the three O-ring seals on body assembly (93). Install the body assembly on the valve body and install one bolt in the body assembly to hold it in position.
n) Install the original amount of spacers (82) on load piston (83). Install the load piston in the body assembly.
p) Install the original amount of spacers, spring (85) and slug (90) in relief valve spool (88). Install the valve spool in the body assembly.
q) Install the O-ring seal on cover (80). Install the cover on body assembly and the four bolts that hold it in place.
r) Install O-ring seal on screw (81). Install check valve ball (86) and the screw in the body assembly.
s) Tighten all of the twelve point head bolts in the pressure control valve to a torque of 22 ± 3 lb. ft. (28 ± 4 N·m).
11. Disassemble the selector valve as follows:
| NOTICE |
|---|
Make a note of the location of each of the valve spools before they are removed from the valve body. Each of the bores in the body have a letter identification on the opposite face of the body. |
a) Remove all four valve spools (123), (124), (125), (126) from selector valve body (128).
b) Loosen nut (129) on each of the valve spools.
c) Remove link assembly (127) and the nut from each valve spool.
12. Assemble the selector valve as follows:
NOTE: Clean all parts with a cloth that is free of loose material (lint). Put a thin layer of transmission oil on all of these parts.
a) Install a nut on each link assembly (127). Install a link assembly on each valve spool.
b) Install valve spool (126) into bore (133) of the valve body.
c) Install valve spool (125) into bore (132), valve spool (124) into bore (130) and valve spool (123) into bore (131).
13. Disassemble the accumulator as follows:
| NOTICE |
|---|
Make a note of the direction, sequence and location in which all of the parts are removed from the valve body. |
a) Use a hammer and punch to push two pins (138) out of the manifold. Remove piston (134), pin (135) and three springs (136). Remove retainer (137) and pin (139) from the manifold.
b) Remove plug (142), spring (141) and valve spool (140) from the manifold.
c) Remove plug (143) and the valve assembly from the manifold.
d) Put spring (144) under compression and push the pin out of plug (143). Make a separation of the two pins (145), spring (144), valve (146) and plug (143).
e) Remove two bolts (147) and washers. Remove retainer (149) and three sleeves (148).
14. Assemble the accumulator as follows:
NOTE: Clean all parts with a cloth that is free of loose material (lint). Put a thin layer of transmission oil on each of these parts.
a) Install two O-ring seals on each sleeve (148). Install three sleeves in the manifold. Install retainer (149) that holds the sleeves in the manifold. Install the two bolts and washers that fasten the retainer to the manifold.
b) Install spring (144) on pin (145). Install pin (145) and valve (146) on pin (150). Push pin (150) into plug (143) and install pin (151) in the plug and pin (150).
c) Install plug (143) and valve assembly in the manifold. Tighten the plug to a torque of 18 ± 9 lb. ft. (25 ± 12 N·m).
d) Install O-ring seal on plug (142). Install valve spool (140), spring (141) and plug (142) in the manifold.
e) Install piston (139) and retainer (137) in the manifold. Install one of the pins (138) that holds retainer (137) in the manifold. Install three springs (136), pin (135) and piston (134) in the manifold. Put the springs under compression and install the last one of the pins (138) in the manifold.
end by:
a) install transmission hydraulic controls