Usage:
Disassemble Transmission
start by:
a) remove transfer gears
b) remove power take off drive group
c) remove transmission hydraulic group
1. Install tooling (A) on the transmission case as shown. Fasten a hoist to tooling (A) and put the transmission in position on tool (B) as shown. The weight of the transmission is 1950 lb. (883 kg).
2. Install tooling (A) on manifold (2) and fasten a hoist as shown. Remove bolts (3) that fasten the manifold to the case. Do not remove bolts (1) and (4) at this time. Remove the No. 1 and No. 2 clutch assembly from the transmission. The weight of the assembly is 350 lb. (158 kg).
3. Remove bolts (1), (4), (5) and (6). Use two 3/8"-16 NC forcing screws to make a clutch separation of the manifold and the No. 1 clutch housing (7).
| NOTICE |
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Keep the clutch discs for the individual clutches in their original sequence and with their respective clutch housings. The original clutch discs are made with different friction material for different clutches and can not be mixed. |
4. Remove ten springs (8), five pins (10), three discs (9) and two plates from the No. 1 clutch housing.
5. Remove the No. 1 clutch piston (11) from housing (7). Remove the seal ring from the piston.
6. Remove housing (7) from the gear assembly. Remove seal ring (12) from the housing.
7. Use a hammer and punch to push two pins (14) into carrier (13). Put the retainer ring that holds the carrier in gear (15) under compression and remove the retainer ring.
8. Install two 3/8"-16 NC forged eyebolts in the carrier and fasten a hoist as shown. Remove three bolts and retainer. Remove the carrier assembly from the gear.
9. Remove retainer ring (16) and bearing (17) from carrier (13).
10. Disassemble the carrier as follows:
a) Use a hammer and punch to push the lockpin into shaft (18).
b) Remove shaft (18) from the carrier.
c) Remove gear (20) and two thrust washers (19) from the carrier.
d) Remove bearing (22) from the gear.
e) Remove lockpin (21) from shaft (18).
11. Remove gear (15) from the carrier.
12. Remove bolts (24) and washers that fasten carrier (23) to hub (25). Use two persons to remove the carrier from the shaft. The weight of the carrier assembly is 66 lb. (30 kg).
13. Use tool (C) and a press as shown to remove gear assembly (26) from carrier (23).
14. Remove retainer ring (27) and bearing (28) from carrier (23).
15. Disassemble the carrier as follows:
a) Use a hammer and punch to push the lockpin into shaft (29).
b) Remove shaft (29) from the carrier.
c) Remove gear (31) and two thrust washers (33) from the carrier.
d) Remove two bearings (30) from the gear.
e) Remove lockpin (32) from the shaft.
16. Remove shaft (35) and hub (34) from the No. 2 clutch assembly. Remove the hub from the shaft.
17. Remove retainer ring (36) from hub (34).
18. Remove five plates (37) and four discs from hub (25).
19. Remove six bolts (38) and remove piston (39) from the housing. Remove the seal ring from the piston. Remove the twelve springs from below the piston.
20. Remove retainer ring (42) and manifold (41) from the housing. Remove piston (40) from the hub and housing. Remove the seal ring from the piston.
21. Remove two seal rings (45) from carrier (43) on manifold (41).
NOTE: Carrier (43) must be destroyed to be removed. If the carrier must be removed, use a hammer and chisel to break the carrier. Remove the carrier and pin (44) from the manifold.
22. Remove bolts (46) and washers that fasten hub (25) to housing (47). Remove the housing from the hub.
23. Remove seal ring (49) and bearing (48) from housing (47).
24. Install tooling (A) on transmission case (50) as shown. Remove the bolts that fasten the case to No. 7 clutch housing (51). Remove the case. The weight of the case is 480 lb. (216 kg).
25. Install tooling (D) as shown to hold the No. 3 clutch piston in position. Remove bolts (53) that fasten housing (52) to the manifold (54). Remove the housing from the manifold.
26. Remove three discs (55) and two plates from gear (57). Remove fifteen springs (56) and five pins (58).
27. Remove piston (59) from housing (52).
28. Remove two seal rings (60) from piston (59).
29. Push plug (61) into housing (52).
30. Remove retainer ring (62) from plug (61) and remove the plug from the housing. Remove the seal from plug.
31. Install tooling (A) on the manifold and fasten a hoist as shown. Remove bolts (63) that fasten plate (64) to No. 7 clutch housing (51). Use two 3/8"-16 NC forcing screws to make a separation of the plate and housing. Remove the No. 4, No. 5 and No. 6 clutch assemblies from the No. 7 clutch. The weight of the assembly is 670 lb. (302 kg).
32. Remove three plates (66) and three discs from the No. 7 clutch housing. Remove twelve springs (67) and six pins (65) from the housing.
33. Remove piston (68) from the housing. Remove the seal rings from the piston and the housing.
34. Install No. 4, No. 5 and No. 6 clutch assemblies on tool (B). Remove retainer ring (69) and gear (70) from carrier (71).
35. Remove retainer ring (73) from shaft (72).
36. Install tooling (A) on carrier assembly and fasten a hoist as shown. Remove the carrier from the No. 6 clutch. The weight of the carrier assembly is 140 lb. (63 kg).
37. Remove retainer ring (74) and remove bearing (75) from the carrier.
38. Bend locks (76) and remove bolts (77) that fasten slinger (78) to the carrier. Remove the locks and slinger from the carrier.
39. Disassemble the carrier as follows:
a) Use a hammer and punch to push the lockpin into shaft (79).
b) Remove shaft (79) from the carrier and remove lockpin (84) from the shaft.
c) Remove two gears (81) and (83) from the carrier. Remove four thrust washers (80) and (82) from the carrier.
d) Remove two bearings (85) and spacer (86) from gear (81). Remove two bearings (87) from gear (83).
e) Use a hammer and punch to push the lockpin into shaft (88).
f) Remove shaft (88) from the carrier and remove lockpin (91) from the shaft.
g) Remove two thrust washers (89) and gear (90) from the carrier.
h) Remove two bearings (92) from the gear.
40. Remove bolts (93) and washers that fasten plate (64) to the No. 6 clutch housing. Install two 3/8" 16 NC forged eyebolts in the plate and fasten a hoist as shown. Remove the plate from the housing.
41. Remove ten springs (95) and five pins (94) from the housing. Remove five discs (96) and four plates from the housing.
42. Remove piston (97) from the housing. Remove the seal rings from the piston and housing.
43. Bend locks (99). Remove eight bolts (101), four locks (99) and four plates (100) from the carrier and gear (98). Remove gear (98) from the carrier.
44. Install tooling (D) to hold the No. 5 piston in position in the housing. Install two 3/8"-16 NC forged eyebolts in the housing and fasten a hoist as shown. Remove the housing from the manifold. The weight of the housing is 80 lb. (36 kg).
45. Remove piston (102) from the housing. Remove the seal rings from the piston and housing.
46. Remove dampers (103) from the housing.
47. Remove ten springs (104), three discs (105) and two plates from the No. 5 clutch assembly.
48. Remove ring gear (106) from carrier (107).
49. Install two 1/2"-13 NC forged eyebolts in plate (108) and fasten a hoist as shown. Remove the plate from manifold (54).
50. Put support (109), 1.5" (3.8 cm) square steel bar stock 14" (35.6 cm) long, in position under shaft (72) as shown.
51. Use tool (E) to remove retainer ring (110) from shaft (72). Remove gears (111) and (112) from the shaft.
52. Install two 3/8"-16 NC forged eyebolts in carrier (107) and fasten a hoist as shown. Remove bolts (113) and washers that fasten the carrier to the No. 4 clutch housing. Remove the carrier from the housing.
53. Disassemble the carrier as follows:
a) Use a hammer and punch to push the lockpin into shaft (114).
b) Remove shaft (114) from the carrier and remove lockpin (117) from the shaft.
c) Remove two thrust washers (115) and gear (116) from the carrier.
d) Remove bearing (118) from the gear.
54. Remove five springs (119), five pins (122) and thirty springs (121). Remove three discs (120) and two plates from the No. 4 clutch housing.
55. Remove five plates (125) from piston (123) and piston (124). Remove gear (126) from the shaft.
56. Remove two seal rings (127) from gear (126).
57. Remove piston (124) from the No. 4 clutch housing. Remove the seal ring from the piston.
| NOTICE |
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Shaft (72) is free to fall when manifold (54) is removed. Install two 1/2"-13 NC forged eyebolts in the manifold and fasten a hoist as shown. Use tool (F) to remove retainer ring (128) from the shaft. Remove the manifold from the shaft. The weight of the manifold is 100 lb. (45 kg). |
59. Remove seal ring (130) and retainer ring (131) from cage (129).
60. Install tooling (A) on the housing and fasten a hoist as shown. Remove the piston and housing from the manifold.
61. Remove housing (132) from piston (123).
62. Remove seal rings (135) from housing (132). Remove retainer ring (133) and bearing (134) from the housing.
63. Bend locks (136) and remove six bolts (137) from gear (138). Remove the gear from the cage.
64. Remove retainer ring (141) from cage (129). Use two 3/8"-16 NC forcing screws to remove plate (139) and bearing (140) from the cage.
65. Bend locks (142) and remove six bolts (143) that fasten cage (129) to manifold (54).
66. Use two 3/8"-16 NC forcing screws (144) to remove the cage from the manifold.
67. Remove seal rings (145) from cage (129).
NOTE: Carrier (146) must be destroyed to be removed.
68. If the carrier must be removed, use a hammer and chisel to break the carrier. Remove the carrier and pin (147) from the cage.
69. Use tooling (G) to remove bearing (148) from the cage.
Assemble Transmission
1. Be sure all parts of the transmission are clean and free of any foreign material.
2. Use tooling (A) to install the bearing in cage (1). Install the bearing until it makes contact with the shoulder in the cage.
3. If carrier (2) was removed from cage (1), heat the new carrier to a temperature of 275° F (135° C). Install the carrier on the cage so the part number on the carrier can be seen after it is installed. Also install the carrier with one of the grooves in the carier in alignment with the pin hole in the cage. Install pin (4) that holds the carrier in position on the cage.
4. Install two seal rings (3) on the carrier.
5. Install two 3/8"-16 NC guide pins (5) in manifold (6). Install the cage assembly in the manifold. Remove the guide pins and install the locks and bolts that hold the cage in place.
6. Put plate (8) in position on the cage with the counterbore up.
7. Install bearing (7) on the cage with the notch in the bearing in alignment with the dowel in the cage. Install the retaining ring to hold the bearing in position.
8. Install two 3/8"-16 NC guide pins (9) in plate (8). Install gear (10) on the plate. Install the locks and bolts that fasten the gear to the plate.
9. Install bearing (13) in No. 4 clutch housing (11) with the notch in the inner race of the bearing down. Install retainer ring (12) that holds the bearing in the manifold.
10. Install O-ring seal (14) on housing (11). Put SAE 30 oil on the O-ring seal. Install the housing in piston (15) with the openings in the housing in alignment with the openings (slots) in the piston.
11. Install tooling (B) on the housing and fasten a hoist as shown. Install the housing and piston in manifold (6). Be sure the notch in bearing (13) is in alignment with the dowel in cage (1).
12. Install retainer ring (16) that holds the housing on the cage. Install seal rings (16 and 17) and put SAE 30 oil on the seal rings.
13. Install two 1/2"-13 NC forged eyebolts in the manifold and fasten a hoist as shown. Put support (19) in position on tool (C) as shown. Put shaft (18) in position on the support and install the manifold assembly on the shaft. The weight of the manifold assembly is 100 lb. (45 kg).
14. Use tool (D) to install retainer ring (21) on the shaft. Install seal ring (22) on piston (20). Put SAE 30 oil on the seal. Install the piston in the housing.
15. Install two seal rings (23) on gear (24).
16. Install gear (24) on the shaft. Install five plates (25) on piston (20) and in piston (15).
NOTE: A clutch disc has friction material on both sides. A clutch plate is a smooth steel plate and does not have friction material on either side. Put clean transmission oil on all clutch discs and clutch plates before assembly.
17. Install five pins (27) and five springs (29) in the housing. Install thirty springs (28), three discs (26) and two plates for the No. 4 clutch.
| NOTICE |
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Be sure the plugs are in the end of shafts (31) before assembly. Be sure the rubber in the pins (33) that hold the shafts in the carrier is not damaged. If the rubber is damaged, a replacement of the pins must be made. |
18. Put SAE 30 oil on bearing (34) and thrust washers (32). Install the bearing in gear (35). Install the gear in No. 5 planet carrier (30) with a thrust washer on each side of the gear.
NOTE: Be sure lockpin hole (36) in the shaft is in alignment with hole (37) in the carrier.
19. Install the shaft in the gear and carrier. Install lockpin (33) in the shaft and carrier. Install the lockpin until it is even with the surface of the carrier.
20. Install two 3/8"-16 NC forged eyebolts in the No. 5 planet carrier and fasten a hoist as shown. Put the number five planet carrier (30) in position on the number four clutch housing. Be sure all the springs are engaged in the holes in the carrier. Install the bolts that hold the carrier to the housing.
21. Install gears (39) on the shaft as shown. Use tool (E) to install retainer ring (38) that holds the gears on the shaft.
22. Install two 1/2"-13 NC forged eyebolts in plate (40) and fasten a hoist as shown. Put the plate in position on the manifold.
23. Put ring gear (41) on the No. 5 planet carrier.
24. Install ten springs (43) in the manifold. Install three No. 5 clutch discs (42) and two plates on the carrier. Start and stop with a disc.
25. Install eighteen dampers (45) in No. 5 and No. 6 clutch housing (44).
26. Install seal rings (47) on the No. 5 clutch piston (46) and housing (44). Put SAE 30 oil on the seals.
27. Install tooling (F) as shown to hold the No. 5 piston in place. Install two 3/8"-16 NC forged eyebolts in the housing and fasten a hoist as shown. Install the housing on the plate. Be sure springs (43) are in position in the housing. The weight of the housing is 80 lb. (36 kg).
28. Install two bolts (49) that hold the housing to the manifold. Install ring gear (48) on the No. 5 planet carrier with the plates, locks and bolts.
29. Install seal rings (51) on No. 6 piston (50) and housing. Put SAE 30 oil on the seals. Install the piston in the housing.
30. Install five pins (54) in the housing and plate (40). Install ten springs (53) on the No. 6 piston. Install five discs (52) and four plates in the housing. Start and stop with a disc.
31. Install two 3/8"-16 NC forged eyebolts in plate (55) and fasten a hoist as shown. Put the plate in position on the housing. Be sure springs (53) are in position in the plate. Install the sixteen bolts and washers that fasten the plate to the manifold. The weight of the plate is 60 lb. (27 kg).
| NOTICE |
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Be sure the plug is in the end of shaft (57) before assembly. Be sure the rubber in pins (59) and (69) that hold the shafts in carrier is not damaged. If the rubber is damaged, a replacement of the pins must be made. |
32. Put SAE 30 oil on bearings (60) and thrust washers (58). Install the bearings in No. 7 outer planetary gear (61). Install the gear with a thrust washer on each side in No. 6 and No. 7 planet carrier (56).
NOTE: Be sure hole (62) in the shaft is in alignment with hole (63) in the carrier.
33. Install the shaft in the carrier and gear. Install lockpin (59) in the shaft and carrier.
34. Put SAE 30 oil on bearings (66) and (68) and thrust washers (65) and (67). Install bearings (72) in No. 6 planetary gear (68). Install bearings (70) with spacer (71) between them in No. 7 inner planetary gear (66). Put a thrust washer on each side of both gears and put the gears in position in the planet carrier.
NOTE: Be sure hole (73) in the shaft (64) is in alignment with the hole in the carrier.
35. Install the shaft (64) in the carrier and the gears. Install lockpin (69) that holds the shaft in the carrier until the lockpin is even with the surface of the carrier.
36. Put slinger (74) in position on the No. 6 and No. 7 planet carrier. Install the four locks and eight bolts that fasten the slinger to the carrier.
37. Install bearing (75) in the No. 6 and No. 7 planet carrier. Be sure the notch in the inner race of the bearing is down when installed.
38. Install tooling (B) on the carrier and fasten a hoist as shown. Install the carrier assembly on the shaft. Be sure the notch in bearing (75) is in alignment with the dowel on shaft (18). The weight of the carrier assembly is 140 lb. (63 kg).
39. Install retainer ring (76) that holds the carrier on the shaft.
40. Put governor drive gear (78) in position in the carrier. Install retainer ring (77) that holds the gear in the carrier.
41. Install seal rings (81) on No. 7 piston (79) and No. 7 clutch housing (80). Put SAE 30 oil on the seals. Install the piston in the housing.
42. Put ring gear (84) in position on the No. 7 housing. Install three discs (83) and three plates (82). Start with a disc and stop with a plate. Install six pins (86) in the housing. Put twelve springs (85) in position on the piston.
43. Install two 1/2"-13 NC guide pins (87) in No. 7 clutch housing. Install tooling (B) on the manifold and fasten a hoist as shown. Install the No. 4, No. 5 and No. 6 clutch assembly on the No. 7 clutch housing. Be sure the No. 7 outer planet gears are in alignment with the ring gear. Be sure the twelve springs are in position between the piston and plate (55). Install the bolts and washers that fasten the plate to the housing. The weight of the No. 4, No. 5 and No. 6 clutch assemblies is 670 lb. (302 kg).
44. Install seal (90) on plug (89). Put SAE 30 oil on the seal and push the plug into No. 3 clutch housing (88). Install the retainer ring that holds the plug in the housing.
45. Install two seal rings (92) on No. 3 clutch piston (91). Put SAE 30 oil on the seals.
46. Install No. 3 piston (91) in No. 3 clutch housing (88).
47. Install five pins (94) in the manifold. Install three discs (93) and two plates (95). Start and stop with a disc. Install fifteen springs (96) as shown.
48. Use tooling (F) to hold the piston in the No. 3 clutch housing. Install the housing assembly on the manifold. Be sure the springs are in position between the housing and the clutch plates. Install the bolts and washers that fasten the housing to the manifold.
49. Install O-ring seal (98) on the No. 7 clutch housing. Put SAE 30 oil on the seal. Install tooling (B) on case (97) and fasten a hoist as shown. Install the case on the No. 7 clutch housing. Install the four bolts and lockwashers that fasten the case to the housing. The weight of the case is 480 lb. (216 kg).
50. Install seal ring (101) on housing (99). Install bearing (100) in the housing. Be sure the notch in the inner race of the bearing is down.
51. Install housing (99) on hub (103). Install bolts (104) and washers that fasten the housing to the hub. Install seal ring (102) on the housing.
52. Install seal ring (106) on No. 1 piston (105) and put SAE 30 oil on the seal. Install the piston in the hub.
53. If carrier (108) was removed from manifold (107), heat the new carrier to a temperature of 275°F (135°C) and install it on the manifold. One of the grooves in the carrier must be in alignment with the pin hole in the manifold. Install pin (110) that holds the carrier on the manifold.
54. Install two seal rings (109) on the carrier.
55. Install two 1/2"-13 NC forged eyebolts in the hub and fasten a hoist as shown. Install the hub on the manifold. Be sure the notch in bearing (100) is in alignment with dowel (111) in the manifold.
56. Install retainer ring (112) that holds the manifold in the hub assembly.
57. Install seal ring (116) on piston (113) and put SAE 30 oil on the seal. Install twelve springs (115) in piston (105). Install two 3/8"-16 NC guide bolts (114) in the hub assembly as shown and put piston (113) in position in the hub assembly. Install the six bolts and washers that fasten the piston to the hub assembly.
58. Install retainer ring (117) in hub (118).
59. Put shaft (119) in position in hub assembly (103). Install hub (118) on the shaft.
60. Install five plates (120) and four discs (121) between hubs (103) and (118). Start and stop with a plate.
61. Put SAE 30 oil on bearings (124) and thrust washers (127). Install the bearings in gear (125). Put the gear with a thrust washer on each side in position in carrier (122).
| NOTICE |
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Be sure the plug is in the end of shaft (123) before assembly. Be sure the rubber in pin (126) that holds the shaft in carrier is not damaged. If the rubber is damaged, a replacement of the pins must be made. |
62. Install the shaft in the carrier and gear. Be sure hole (128) in the shaft is in alignment with hole (129) in the carrier. Install pin (126) until even with the surface of the carrier.
63. Install bearing (132) in the carrier. Be sure notch (131) in the inner race of the bearing is up. Install retainer ring (130) that holds the bearing in the carrier.
64. Install gear assembly (133) on the carrier. Be sure the pin in the gear is in alignment with the notch in bearing (131).
65. Use two persons to install the carrier and gear assembly on the hub. Install the bolts and washers that fasten the carrier to the hub. The weight of the carrier and gear assembly is 66 lb. (30 kg).
| NOTICE |
|---|
Be sure the plug is in the end of shaft (135) before assembly. Be sure the rubber in the pin (138) that holds the shaft in carrier is not damaged. If the rubber is damaged, a replacement of the pins must be made. |
66. Put SAE 30 oil on bearing (139) and thrust washers (136). Install the bearing in gear (137). Install the gear with a thrust washer on each side in carrier (134).
67. Install the shaft in the gear and carrier. Be sure hole (140) in the shaft is in alignment with the hole in the carrier. Install pin (138) in the carrier and shaft until the pin is even with the surface of the carrier.
68. Install bearing (143) in carrier (134). Be sure notch (142) in the inner race of the bearing is up. Install retainer ring (141) that holds the bearing in the carrier.
69. Install ring gear (144) on carrier (122).
70. Install two 3/8"-16 NC forged eyebolts in carrier (134) and fasten a hoist as shown. Install the carrier in gear assembly (133) and ring gear (144).
71. Install plate (146) on the end of shaft (18) with three bolts. The plate holds carrier (134) on the shaft. Install retainer ring (145) that holds ring gear (144) on the carrier. Install the two pins that hold the retainer ring in position until the pins are even with the top of the carrier.
72. Install seal ring (148) on No. 1 clutch housing (147) and put SAE 30 oil on the seal. Put the No. 1 clutch housing in position on ring gear (144).
73. Install seal ring (150) on No. 1 clutch piston (149) and put SAE 30 oil on the seal. Put the piston in position in the housing.
74. Install five pins (153) in the No. 1 clutch housing. Install three discs (151) and two plates (154) in the housing. Start and stop with a disc. Put ten springs (152) in position on the piston.
75. Install two 3/8"-16 NC guide pins (156) in manifold (107) and two 1/2"-13 NC guide pins (155) in the housing. Put manifold (157) in position on the No. 1 clutch housing and manifold (107).
76. Install six bolts (160) and washers that fasten manifold (157) to manifold (107). Tighten the bolts to a torque of 5 lb. ft. (7 N·m). Install bolt (161) and washer and tighten to a standard torque. Tighten bolts (106) again to standard torque. Install two bolts (158) and (159) and washers that fasten the manifold to the housing. Be sure the No. 1 clutch springs are in position between the manifold and the piston.
77. Install tooling (B) on the manifold and fasten a hoist as shown. Install two 1/2"-13 NC guide pins (162) in the transmission case. Put the No. 1 and No. 2 clutch assembly in position in the case. Install the fourteen bolts and washers that fasten the clutches to the case.
78. Check to make sure the pistons are free in their clutch housings with tool (G) as follows:
a) Put air (free of water) under a pressure of 100 to 150 psi (690 to 1030 kPa) into each of the seven oil passages.
b) If the pistons do not move, put a small amount of clean SAE 30 oil in each passage. Check for movement again. If the pistons still do not move, the transmission must be disassembled and the pistons checked.
end by:
a) install transmission hydraulic controls
b) remove power take-off drive group
c) remove transfer gears