TH350B, TH355B, TH360B, TH460B and TH560B Telehandlers Power Train Caterpillar

Assembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Bracket	2
B	1U-7262	Telescoping Magnet	1
C	1U-8241	Lifting Sling	1
D	1P-2320	Combination Puller	1
E	138-7573	Link Bracket	3
F	1P-1857	Retaining Ring Pliers	1
G	156-7100	Slide Hammer Puller Gp	1
H	1P-0510	Driver Gp	1
I	1P-1856	Retaining Ring Pliers	1
J	1P-2321	Combination Puller	1
K	4C-8359	Eyebolt (M12)	1
L	1P-1860	Retaining Ring Pliers	1
M	8B-7550	Push-Puller Leg	1
	8H-0663	Bearing Puller Gp	1
N	1P-0074	Slide Hammer Puller Gp	1

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 1	g00900310

1. Install O-ring seals (277) and (278) onto pressure regulator valve (276) .

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Illustration 2	g00899489

2. Install pressure regulator valve (276) into transmission housing (21) .

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Illustration 3	g00900314

3. Install O-ring seals (274) and (275) onto torque converter relief valve (273) .

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Illustration 4	g00899490

4. Install torque converter relief valve (273) into transmission housing (21) .

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Illustration 5	g00903008

5. Use a suitable drift in order to remove core plug (279) from transmission housing (21) .

   Note: It is necessary to remove the core plug in order to shim the forward/reverse shaft.

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Illustration 6	g00899492

6. Use Tooling (H) in order to install seal (264) that is shown in Illustration 14 into cover (263) .

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Illustration 7	g00901654

7. Install O-ring seals (64) and (65) onto valve spool (63) . Install the spool into modulating valve (58) .

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Illustration 8	g00901655

8. Install solenoid (62) , washer (61) , and nut (60) . Install O-ring seals (59) onto modulating valve (58) .

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Illustration 9	g00901649

9. Install O-ring seals (32) and (33) onto the valve spool of solenoid (31) .

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Illustration 10	g00901651

10. Install solenoid (31) , locking plate (30) , and allen head screw (29) onto actuator (20) .

11. Repeat Step 9 and Step 10 in order to install solenoid (34) onto actuator (20) .

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Illustration 11	g00901652

12. Install O-ring seals (25) and (26) onto neutralizing piston (23) and actuator piston (24) . Then install the two pistons into actuator (20) .

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Illustration 12	g00901653

13. Repeat Step 12 in order to install neutralizing piston (27) and actuator piston (28) .

14. Install O-ring seals (22) onto actuator (20) .

15. Repeat Steps 9 through 14 in order to assemble the actuator for the second and fourth speeds.

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Illustration 13	g00899524

16. Refer to Step 7 for details of installing the O-ring seals on the spools of solenoids (258) and (259) .

17. Install the two spools and solenoids (258) and (259) into valve housing (43) . Install nuts (256) and washers (257) in order to secure the solenoids to the spools.

18. Refer to Step 9 for details of installing the O-ring seals on the spool of solenoid (255) .

19. Install solenoid (255) , locking plate (254) , and allen head screw (253) onto valve housing (43) .

20. Install O-ring seals (252) into valve housing (43) .

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Illustration 14	g00899601

21. Install cover (263) and bolts (262) onto transmission housing (21) .

22. Install valve housing (43) and bolts (251) onto transmission housing (21) .

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Illustration 15	g01040680

23. Install Tooling (E) onto transmission housing (21) . Use Tooling (E) and a suitable lifting device in order to turn the transmission housing so that the bell housing is facing downward. Lower the transmission housing onto suitable cribbing. The weight of the transmission housing is approximately 135 kg (298 lb).

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Illustration 16	g00899635

24. Install bearing cups (260) , (261) , (264) , and (265) into transmission housing (21) .

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Illustration 17	g00899636

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Illustration 18	g00899638

25. Use Tooling (H) and a suitable mallet in order to install needle bearing (240) for the pump drive shaft. The needle bearing must be installed 5 mm (0.197 inch) below the edge of transmission housing (21) .

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Illustration 19	g00900218

26. Install annulus (227) for scavenge pump (223) . Ensure that the chamfered edge of the annulus is facing downward.

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Illustration 20	g00900355

27. Install rotor (226) of the scavenge pump. Ensure that the chamfered edge of the rotor is facing downward.

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Illustration 21	g00900366

28. Install back plate (225) of the scavenge pump. Ensure that the bolt holes are correctly aligned.

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Illustration 22	g00900382

29. Use a suitable allen wrench in order to install allen head screw (224) that secures the back plate to the scavenge pump.

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Illustration 23	g00900399

30. Invert scavenge pump (223) . Install the scavenge pump onto transmission housing (21) in the orientation that is shown in Illustration 23.

31. Install suction pipe (224) onto scavenge pump (223) .

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Illustration 24	g00900406

32. Install bolts (222) in order to secure suction pipe (224) and scavenge pump (223) to transmission housing (21) .

    Note: The two bolts that secure the suction pipe are longer than the other two bolts.

33. Install baffle plate (221) into transmission housing (21) .

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Illustration 25	g00900415

34. Use a suitable allen wrench in order to install allen head screw (217) and washer (218) . Install bolt (219) and washer (220) .

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Illustration 26	g00900417

35. Install O-ring seals (215) and oil tube (214) .

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Illustration 27	g00900418

36. Use a suitable allen wrench in order to install four allen head screws (213) that secure oil tube (214) to the inside of transmission housing (21) .

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Illustration 28	g00900445

37. Install needle bearings (179) and third gear (178) onto output shaft (132) .

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Illustration 29	g00900447

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Illustration 30	g00900449

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

38. Install springs (176) , steel balls (177) , and energizers (175) around the edge of the inner sprocket for the synchronizer for the third speed and fourth speed. At the same time install outer ring (174) around the inner sprocket.

39. Install outer cone (173) so that the three lugs on the outer cone are aligned with the three energizers.

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Illustration 31	g00900531

40. Install plate (172) for the synchronizer.

41. Turn the synchronizer onto the other side and repeat Step 39 and Step 40.

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Illustration 32	g00900532

42. Install synchronizer (171) for the third speed and fourth speed onto output shaft (132) .

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Illustration 33	g00900533

43. Use Tooling (L) in order to install circlip (170) that secures synchronizer (171) to output shaft (132) .

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Illustration 34	g00900534

44. Install spacer (169) and needle bearings (168) onto output shaft (132) .

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Illustration 35	g00900535

45. Install fourth gear (167) onto output shaft (132) .

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Illustration 36	g00900536

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Illustration 37	g00900537

46. Install washer (166) between spacer (163) and tachometer drive (162) . Use a suitable press and Tooling (L) in order to install circlip (165) .

    Note: The spacer in Step 46 is replaced by a fifth gear for transmissions that are equipped with five speeds.

47. Install the tachometer drive onto the output shaft. The components on the output shaft of a transmission with five speeds are different to the components on the output shaft of a transmission with four speeds.
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    Illustration 38	g00900538
    Output Shaft of a Transmission with Four Speeds

    1. Install tachometer drive (162) and spacer (163) onto output shaft (132) .
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    Illustration 39	g00900539
    Output Shaft of a Transmission with Five Speeds

    2. Install tachometer drive (162) and fifth gear (164) onto output shaft (132) .

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Illustration 40	g00900540

48. Use a suitable press in order to install taper roller bearing (161) onto output shaft (132) .

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Illustration 41	g00900541

49. Install needle bearings onto the other end of output shaft (132) .

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Illustration 42	g00900542

50. Install second gear (159) onto output shaft (132) .

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Illustration 43	g00900543

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

51. Begin the assembly of the synchronizer for the first speed and second speed by positioning springs (157) , springs (158) , and energizers (156) around the edge of inner sprocket (155) . Install outer ring (154) over the inner sprocket at the same time as holding the locating pins, springs, and energizers in position.

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Illustration 44	g01883395

52. Install ring (152) so that the three lugs on the outer cone are aligned with the three connecting blocks that are beside the energizers.

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Illustration 45	g00900554
Example of Damaged Inner Cone (150) and Damaged Friction Ring (151)

53. Check the surfaces of inner cone (150) and friction ring (151) . Replace the inner cone of the friction ring with a new part if any of the following damage is found:
    • Scuffing

    • Burn marks.

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Illustration 46	g00900589

54. Install friction ring (151) for the synchronizer.

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Illustration 47	g00900595

55. Install inner cone (150) for the synchronizer.

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Illustration 48	g00900596

56. Install plate (149) for the synchronizer.

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Illustration 49	g00900544

57. Turn the synchronizer onto the other side and install connecting blocks (153) .

58. Repeat Steps 52 through 56 for the second side of the synchronizer.

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Illustration 50	g00900603

59. Install synchronizer (148) for the first speed and second speed onto output shaft (132) .

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Illustration 51	g00900853

60. Use Tooling (L) in order to install circlip (147) that retains synchronizer (148) for the first speed and second speed.

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Illustration 52	g00900854

61. Install needle bearings (146) onto output shaft (132) .

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Illustration 53	g00900856

62. Install first gear (143) and thrust washer (144) onto output shaft (132) and then use a suitable press in order to install taper roller bearing (145) onto the output shaft.

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Illustration 54	g00991732

63. Use a suitable press in order to install taper roller bearing (205) onto the first gear end of countershaft (136) .

64. Install the components onto the other end of the countershaft. The components on the countershaft of a transmission with five speeds are different from the components on the countershaft of a transmission with four speeds.
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    Illustration 55	g00900432
    Countershaft of a Transmission with Four Speeds

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    Illustration 56	g00991739

    1. Install spacer (207) onto countershaft (136) . Then use a suitable press in order to install taper roller bearing (206) onto the countershaft.
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    Illustration 57	g00900857
    Countershaft of a Transmission with Five Speeds

    2. Install needle bearings (211) and fifth gear (208) .

    3. Repeat Step 38 and Step 40 for the synchronizer for the fifth speed.
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    Illustration 58	g00900858

    4. Turn the synchronizer onto the other side and install circlip (212) .
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    Illustration 59	g00900859

    5. Install synchronizer (209) for the fifth speed and then use a suitable press in order to install taper roller bearing (210) .

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Illustration 60	g00991740

65. Use a suitable press in order to install taper roller bearings (203) onto reverse idler shaft (135) . Invert the shaft and install taper bearing (204) (not shown).

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Illustration 61	g00900860

66. Install piston (196) into the forward clutch assembly.

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Illustration 62	g00900861

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Illustration 63	g00900862

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

67. Install piston spring (193) , support (194) for the piston spring, and spring retainer (195) into the clutch assembly. Use a suitable press in order to compress the spring. Then use Tooling (L) in order to install circlip (192) .

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Illustration 64	g00900863

68. Install clutch plate (191) and friction plate (191) .

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Illustration 65	g00902087

69. Use forward primary gear (184) in order to align the clutch plate and the friction plate.

70. Repeat Step 68 and Step 69 until the six clutch plates and six friction plates are installed.

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Illustration 66	g00900864

71. Install top plate (189) into the clutch assembly.

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Illustration 67	g00900865

72. Use a suitable screwdriver in order to install snap ring (188) .

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Illustration 68	g00900866

73. Install thrust washer (187) , needle bearings (185) , spacer (186) , and forward primary gear (184) .

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Illustration 69	g00900867

74. Install thrust bearing (183) onto the top of forward primary gear (184) .

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Illustration 70	g00900868

75. Install input drive gear (133) and spacer (181) onto forward/reverse shaft (134) . Ensure that the boss of the input drive gear is facing downward.

76. Use a suitable press in order to install taper roller bearing (182) onto forward/reverse shaft (134) .

77. Turn the forward/reverse shaft onto the opposite end and repeat Steps 66 through 72 for the reverse clutch assembly.

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Illustration 71	g00900869

78. Install thrust washer (202) and needle bearings (201) onto forward/reverse shaft (134) .

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Illustration 72	g00900870

79. Install reverse primary gear (200) onto forward/reverse shaft (134) .

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Illustration 73	g00900871

80. Install thrust bearing (199) and thrust washer (198) onto forward/reverse shaft (134) .

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Illustration 74	g00991741

81. Heat taper roller bearing (197) to a maximum of 135 °C (275 °F). Install the bearing onto forward/reverse shaft (134) . Reset the bearing with a suitable driver after the mating parts have reached a uniform temperature.

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Illustration 75	g00900872

82. Install split seals (180) onto forward/reverse shaft (134) .

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Illustration 76	g00900907

83. Use a suitable hammer to install pin (142) in order to install fork (137) onto shift rail (139) for the first speed and second speed.

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Illustration 77	g00900908

84. Use a suitable hammer to install pin (141) in order to install fork (138) onto shift rail (140) for the third speed and fourth speed.

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Illustration 78	g00900922

85. Install selector forks (137) and (138) and shift rails (139) and (140) onto output shaft (132) .

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Illustration 79	g00900938

86. Install Tooling (K) on the end of output shaft (132) and use a suitable lifting device to lift the output shaft, shift rails, and selector forks into transmission housing (21) . The weight of the output shaft is approximately 28 kg (62 lb). Move the output shaft into position but do not lower the output shaft fully into the bearing sleeve.

87. Install forward/reverse shaft (134) into transmission housing (21) . The weight of the forward/reverse shaft is approximately 20 kg (44 lb).

88. Install countershaft (136) into the position for the reverse idler shaft. The weight of the countershaft is approximately 14 kg (31 lb).

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Illustration 80	g00900953

89. Place a pinch bar under input drive gear (133) of forward/reverse shaft (134) . Use the pinch bar in order to raise the forward/reverse shaft slightly. Keep the forward/reverse shaft and output shaft (132) raised and move countershaft (136) into the position that is shown in Illustration 80.

90. Maintain forward/reverse shaft (134) and output shaft (132) in a slightly raised position and install reverse idler shaft (135) . Ensure that the threaded end of the reverse idler shaft is facing downward.

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Illustration 81	g00900958

91. Lower output shaft (132) and forward/reverse shaft into the bearing cups. Then remove the pinch bar and Tooling (K) . Ensure that the bearings on the bottoms of the following shafts are properly seated in the bearing cups:
    • Output shaft (132)

    • Countershaft (136)

    • Reverse idler shaft (135)

    • Forward/reverse shaft (134)

92. Ensure that the ends of shift rails (139) and (140) are properly located in transmission housing (21) .

93. Transmissions with five speeds are equipped with a shift rail and a fork for the fifth speed.
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    Illustration 82	g00900974

    1. Install O-ring seal (131) onto shift rail (129) , and slide selector fork (130) onto the shift rail.

    2. Install shift rail (129) into the hole in transmission housing (21) . At the same time engage selector fork (130) with synchronizer (209) for the fifth speed.
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    Illustration 83	g00900979

    3. Install guide rail (127) into transmission housing (21) and use a suitable hammer in order to install pin (128) .

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Illustration 84	g00900993

94. Use a suitable press in order to install drive gear (126) onto pump drive shaft (118) .

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Illustration 85	g00900995

95. Use Tooling (I) in order to install circlip (125) onto pump drive shaft (118) .

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Illustration 86	g00900998

96. Install thrust washer (124) and needle bearings (123) onto pump drive shaft (118) .

97. Install O-ring seal (119) onto pump drive shaft (118) .

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Illustration 87	g00901004

98. Install idler gear (120) and thrust washer (121) onto pump drive shaft (118) . Use a suitable press in order to install bearing carrier (122) onto the pump drive shaft.

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Illustration 88	g00901011

99. Install pump drive shaft (118) into the transmission. Ensure that the tangs on the rotor of scavenge pump (223) are aligned with the slots on the pump drive shaft.

    Note: The gear on the end of the pump drive shaft may be at a slightly lower level than the gears that are on the ends of the other shafts. This difference in levels will be automatically corrected when the transmission cover is installed.

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Illustration 89	g00901257

100. Use a suitable press in order to install drive gear (116) and taper roller bearing (117) onto fan drive shaft (108) .

     Note: Ensure that the boss of drive gear (116) faces the middle of fan drive shaft (108) .

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Illustration 90	g00901824

101. Install thrust washer (115) onto fan drive shaft (108) . Ensure that the pin on the fan drive shaft engages with the slot in the thrust washer.

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Illustration 91	g00901259

102. Install needle bearing (114) onto fan drive shaft (108) .

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Illustration 92	g00901258

103. Install idler gear (111) and thrust washer (112) and then use a suitable press in order to install taper roller bearing (113) .

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Illustration 93	g00901260

104. Install split seal (110) onto fan drive shaft (108) .

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Illustration 94	g00901261

105. Install bearing cup (109) for the fan drive shaft into transmission housing (21) .

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Illustration 95	g00901262

106. Install fan drive shaft (108) into transmission housing (21) .

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Illustration 96	g00901263

107. Install roller bearing (107) for the input shaft into transmission housing (21) .

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Illustration 97	g00901264

108. Use a suitable press in order to install bearing carrier (106) onto input shaft (102) .

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Illustration 98	g00901265

109. Install split seal (105) onto input shaft (102) .

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Illustration 99	g00901266

110. Install gear (104) onto input shaft (102) , and use Tooling (I) in order to install circlip (103) .

     Note: Ensure that the boss of gear (104) is at the same side as circlip (103) .

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Illustration 100	g00996881

111. Install input shaft (102) into transmission housing (21) .

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Illustration 101	g00901268

112. Install thrust washer (101) and thrust bearing (100) onto the end of input shaft (102) .

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Illustration 102	g00902088

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Illustration 103	g00902089

113. Use Tooling (H) in order to install seals (91) and (92) into transmission cover (10) .

     Note: Install the seals from the top side of the cover.

114. Turn the transmission cover onto the other side and install the oil tube into the transmission cover. The position of the oil tube in a transmission with five speeds is different to the position of the oil tube in a transmission with four speeds.
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     Illustration 104	g00901269
     Cover of a Transmission with Four Speeds

     1. Install an O-ring seal at both ends of oil tube (97) . Install the oil tube and four allen head screws (96) onto the transmission cover.
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     Illustration 105	g00901270
     Cover of a Transmission with Five Speeds

     2. Install an O-ring seal at both ends of oil tube (99) . Install the oil tube and four allen head screws (98) onto the transmission cover.

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Illustration 106	g00901271

115. Install an O-ring seal at both ends of oil tube (95) . Install the oil tube and four allen head screws (94) onto the transmission cover.

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Illustration 107	g00901273

116. Install bearing carrier (93) for the input shaft into the transmission cover.

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Illustration 108	g00901289

117. Use Tooling (F) in order to install circlip (90) and then install bearing sleeve (88) .

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Illustration 109	g00901298

118. Install bearing sleeves (84) , (85) , (86) , and (87) into the transmission cover.

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Illustration 110	g00901299

119. Install O-ring seals (81) onto transmission housing (21) .

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Illustration 111	g01040681

120. Install Tooling (E) to the three 10 mm holes in transmission cover (10) . Use a suitable lifting device and Tooling (E) in order to lift the transmission cover. The weight of the transmission cover is approximately 42 kg (93 lb).

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Illustration 112	g01040683

121. Use Tooling (E) and the suitable lifting device in order to lower transmission cover (10) onto transmission housing (21) . On transmissions with four speeds, shift rails (139) and (140) will engage with the transmission cover first. On transmissions with five speeds, the shift rail for the fifth speed will engage with the transmission cover first.

122. Use the suitable lifting device to fully lower transmission cover (10) onto transmission housing (21) . Ensure that the two locating pins that are between the interface of the transmission cover and the transmission housing are engaged.

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Illustration 113	g00901337

123. Install supports (79) for the harness and 22 bolts (80) in order to secure the transmission cover to the transmission housing.

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Illustration 114	g00901648

124. Install fan drive (46) , O-ring seal (45b) , washer (45a) , and bolt (44) on the end of fan drive shaft (108) .

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Illustration 115	g00902415

125. Install Tooling (P) and place a suitable screwdriver between fan drive (46) and transmission cover (10) in order to check the float on the fan drive shaft. The float must be between 0.0254 mm (0.001 inch) and 0.0762 mm (0.003 inch). If the float is not within these parameters you must complete the following procedure:

     1. Remove the components that were installed in Step 124 and Step 123. Then Refer to Step 121 in order to remove the transmission cover from the transmission housing.
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     Illustration 116	g00902508

     2. Turn over transmission cover (10) and remove bearing sleeve (88) . Install the required thickness of shims against circlip (90) and then install the bearing sleeve on top of the shims.

     3. Repeat Steps 121 through 125.

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Illustration 117	g00901340

126. Make sure that shift rail (76) and shift rail (77) are in the neutral position, and install detent balls (78) into the cavity.

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Illustration 118	g00901343

127. Install cap (75) into transmission cover (10) .

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Illustration 119	g00901353

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Illustration 120	g00901355

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

128. Install O-ring seals (74) onto spring retainers (71) . Install detent balls (73) , springs (72) , and spring retainers (71) into transmission cover (10) .

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Illustration 121	g00901656

129. Position modulating valve (58) and install bolts (57) onto transmission cover (10) .

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Illustration 122	g00901784

130. Use a suitable press in order to install bearing (69) onto idler (67) . Then use the press in order to install mounting flange (70) on the bearing. Install snap ring (68) that secures the bearing inside the mounting flange.

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Illustration 123	g00901795

131. Install allen head screws (66) through mounting flange (70) in order to install idler (67) for the fan drive.

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Illustration 124	g00901657

132. Install O-ring seal (56) onto speed sensor (55) .

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Illustration 125	g00901658

133. Install bolt (54) and speed sensor (55) .

134. Install temperature sensor (53) into transmission housing (21) .

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Illustration 126	g00901659

135. Install roller bearing (52) onto the end of pump drive shaft (118) and use Tooling (F) in order to install circlip (82) .

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Illustration 127	g00901660

136. Install washer (50) , and bolt (49) onto the end of pump drive shaft (118) .

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Illustration 128	g00901661

137. Install bolts (47) and access panel (48) onto transmission cover (10) .

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Illustration 129	g00902784

138. Install Tooling (A) and use a suitable lifting device in order to lift the transmission. The weight of the transmission is approximately 350 kg (772 lb). Rotate the transmission to the orientation that is shown in Illustration 130 and then lower the transmission.

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Illustration 130	g00902785

139. Install Tooling (C) and a suitable lifting device in order to lift the transmission. The weight of the transmission is approximately 350 kg (772 lb). Rotate the transmission so that the bell housing is facing upward. Position a piece of cribbing that measures at least 10 cm (3.9 inch) by 5 cm (2 inch) under each end of the transmission and then lower the transmission onto the cribbing.

140. Remove the plug from valve housing (43) .

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Illustration 131	g00902807

141. Install an M12 bolt that is at least 80 mm long into the end of the reverse idler shaft. Use the bolt in order to rotate all of the shafts for several revolutions. This rotation will ensure that the bearings are seated before the floats on the shafts are checked.

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Illustration 132	g00902808

142. Install Tooling (P) and place a suitable pinch bar between the bolt head and valve housing (43) in order to check the float on the reverse idler shaft. The float must be between 0.0254 mm (0.001 inch) and 0.0762 mm (0.003 inch).

143. Install a hose fitting onto the lube port of valve housing (43) . Insert a 60 mm long M12 bolt into the end of the fitting.

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Illustration 133	g00902826

144. Install Tooling (P) and pass a suitable screwdriver through the hole for the core plug. Use the screwdriver as a lever and check the float on the forward/reverse shaft. The float must be between 0.0254 mm (0.001 inch) and 0.0762 mm (0.003 inch).

145. If the float on the reverse idler shaft or on the forward/reverse shaft is not between 0.0254 mm (0.001 inch) and 0.0762 mm (0.003 inch), complete the following procedure:
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     Illustration 134	g00902832

     1. Remove bolts (251) in order to remove valve housing (43) from transmission housing (21) .
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     Illustration 135	g00902848

     2. Install shims or spacers for reverse idler shaft (135) and forward/reverse shaft (134) , as required.

     3. Add sealant to the mating surface of transmission housing (21) .

     4. Refer to Illustration 134 in order to install bolts (251) and valve housing (43) onto transmission housing (21) .

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Illustration 136	g00902915

146. Install an 80 mm long M12 bolt through cover (263) onto the end of the countershaft. Install Tooling (P) and pass a suitable screwdriver through the hole for the transmission speed sensor. Use the screwdriver as a lever and check the float on the countershaft. The float must be between 0.0254 mm (0.001 inch) and 0.0762 mm (0.003 inch).

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Illustration 137	g00902920

147. Install Tooling (P) and place a suitable pinch bar between the bottom of output shaft (132) and the bench in order to check the float on the output shaft. The float must be between 0.0254 mm (0.001 inch) and 0.0762 mm (0.003 inch).

148. If the float on the countershaft or on the output shaft is not between 0.0254 mm (0.001 inch) and 0.0762 mm (0.003 inch), complete the following procedure:
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     Illustration 138	g00902925

     1. Remove bolts (262) in order to remove cover (263) from transmission housing (21) .
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     Illustration 139	g00902930

     2. Install shims or spacers for countershaft (136) and output shaft (132) , as required.

     3. Add sealant to the mating surface of transmission housing (21) .

     4. Refer to Illustration 138 in order to install bolts (262) and cover (263) onto transmission housing (21) .

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Illustration 140	g00901702

149. Use a suitable press in order to install bearing (237) onto pump coupling (238) . Then use Tooling (I) in order to install circlip (239) that secures the bearing to the pump coupling.

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Illustration 141	g00901706

150. Use a suitable press in order to install bearing (237) and pump coupling (238) into cover plate (233) . Then use Tooling (G) in order to install circlip (236) that secures the bearing to the cover plate.

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Illustration 142	g00901713

151. Install rotor (234) and annulus (235) into the housing of charge pump (229) . Ensure that the chamfered edge of the rotor and the chamfered edge of the annulus are facing downward. Then fit cover plate (233) onto the housing of the charge pump.

     Note: Ensure that the bolt holes of the cover plate and the bolt holes of the housing are aligned.

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Illustration 143	g00901719

152. Turn the charge pump onto the other side, and install allen head screw (232) in order to secure cover plate (233) to the housing of the charge pump. Install O-ring seal (231) .

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Illustration 144	g00901730

153. Install O-ring seal (230) in the groove on transmission housing (21) .

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Illustration 145	g00901735

154. Use bolts (228) in order to install charge pump (229) onto transmission housing (21) . Tighten bolts (228) diagonally.

     Note: Ensure that the bolt holes in the charge pump are aligned with the bolt holes in the transmission housing.

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Illustration 146	g00900213

155. Install thrust washer (250) onto support (249) . Ensure that the rough side of the thrust washer is facing outward, and ensure that the small pin on the support is engaged with the hole in the thrust washer.

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Illustration 147	g00902090

156. Install support (249) into transmission housing (21) . Ensure that the oil galleries on the support are aligned with the holes in the transmission housing.

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Illustration 148	g00900214

157. Install support (249) onto transmission housing (21) with five allen head screws (248) .

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Illustration 149	g00900350

158. Install O-ring seal (246) onto pump drive gear (245) .

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Illustration 150	g00900215

159. Install pump drive gear (245) onto support (249) .

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Illustration 151	g00900216

160. Install thrust bearing (243) onto the rear of cover (242) for the pump drive gear. Ensure that the two small pins on the cover engage with the holes in the thrust bearing.

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Illustration 152	g00900217

161. Install cover (242) for the pump drive gear onto transmission housing (21) with bolts (241) . Tighten the bolts (241) in a diagonal pattern.

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Illustration 153	g00901662

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Illustration 154	g00901663

162. Install drive yokes (41) and (42) , washers (39) and (40) , and bolts (37) and (38) onto both ends of the output shaft.

     Note: Ensure that drive yokes (41) and (42) are installed with the same phase angle.

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Illustration 155	g00901664

163. Install actuator (36) and bolts (35) onto transmission cover (10) .

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Illustration 156	g00901665

164. Install actuator (20) and bolts (19) onto transmission cover (21) .

165. Transmissions with five speeds have additional components that need to be assembled and installed.
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     Illustration 157	g00901666

     1. Install O-rings (17) on actuator (9) and install O-ring seal (18) on piston (16) . Then install the piston into the actuator.

     2. Install O-ring seals (14) and (15) onto the valve spool of solenoid (13) .
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     Illustration 158	g00901667

     3. Install solenoid (13) , locking plate (12) and allen head screw (11) onto actuator (9) . Position actuator (9) onto transmission cover (10) and install bolts (8) .
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     Illustration 159	g00901668

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     Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

     4. Install detent ball (7) and spring (6) into the cavity of transmission cover (10) .
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     Illustration 160	g00901669

     5. Use a suitable allen wrench in order to install cap (5) onto transmission cover (10) .
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     Illustration 161	g00901670

     6. Install sensor (4) for the shift rail and allen head screws (3) onto transmission cover (10) .

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Illustration 162	g00903009

166. Use a suitable drift in order to install core plug (279) into transmission housing (21) .

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Illustration 163	g00900315

167. Install O-ring seals (272) onto speed sensors (268) , (269) and (271) .

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Illustration 164	g00899491

168. Install speed sensors (268) , (269) , and (271) into transmission housing (21) . Install allen head bolts (267) and bolt (270) in order to secure speed sensors (268) , (269) , and (271) to the transmission housing.

     Note: The speed sensors differ from each other, and each one must be installed in the correct location that is shown in Illustration 164.

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Illustration 165	g00901672

169. Use allen head screws (1) in order to install position sensors (2) onto transmission housing (21) .

End By:

1. Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Assemble".
2. Install the transmission. Refer to Disassembly and Assembly, "Transmission - Install".