Usage:
Upper Housing
Removal
1. Remove oil pump (7), oil filter (1), control valve (2), oil manifold (6), oil manifold (8), oil cooler (3) and magnetic strainer (9). See the covering topics.
2. Remove bolts (4) and lift cover (5) from the top housing. Inspect the gasket and replace if necessary.
3. Remove the bolts (11) securing the upper housing to the lower housing.
4. Disconnect oil line (13) at position indicated.
5. Bend locks and loosen bolts (14) and also the locks and bolts securing the rear retainers (15).
NOTE: Before saddle bolts (12) are loosened, place two four inch wooden blocks under the clutch end of the shaft between the drive ring and the lower housing. The clutch end of the shaft is over-balanced and will drop into the lower housing unless it is supported.
6. Loosen and remove saddle bolts (12).
7. With the aid of four forcing screws, separate the upper housing from the lower housing and lift the upper housing off as shown.
PREPARING TO REMOVE UPPER HOUSING
1-Oil filter. 2-Control valve. 3-Oil cooler. 4-Bolts (twenty-six). 5-Top cover. 6-Oil manifold. 7-Oil pump. 8-Oil manifold. 9-Magnetic strainer.
REMOVING UPPER HOUSING
10-Upper housing. 11-Bolts (sixteen). 12-Saddle bolts (four). 13-Oil lubrication line. 14-Retainer bolts (nine). 15-Rear retainers (two).
REMOVING UPPER HOUSING
Upper Housing Installation
1. Clean and dry the mating surfaces of the upper and lower housings.
2. Apply 7M7260 Liquid Gasket Material to the lower housing.
3. Lower the upper housing (10) onto the lower housing, aligning the dowels in the lower housing with mating holes in the upper housing.
4. Install bolts (11) securing the upper housing to the lower housing.
5. Insure that the front bearing retainers are tight.
6. Tighten bolts (14) securing rear bearing retainers (15) in place.
7. Install and initially tighten saddle bolts (12) in a C-B-D-A sequence to 150 lb. ft. (20,7 mkg). Tighten the bolts in the same sequence to 265 ± 35 lb. ft. (36,6 ± 4,8 mkg).
TIGHTENING UPPER HOUSING SADDLE BOLTS
8. Connect line (13) to fitting on saddle.
9. Install the gasket and top cover (5) using bolts (4).
Upper Shaft
Removal
1. Remove the upper housing. See the covering topic.
PREPARING TO REMOVE UPPER SHAFT
1-Front retainer. 2-Front retainer. 3-Rear retainer. 4-Bolts (five). 5-Bolts (four). 6-Rear retainer.
2. Install a 1/2" forged lifting eye and attach a hoist to the shaft group.
3. Remove bolts (4) and (5) securing rear retainers (3) and (6).
REMOVING UPPER SHAFT
4. Attach one end of a nylon sling to the hoist and hook the other end over the end of the small shaft. Adjust the sling so a minimum of weight is transferred to the small shaft.
Upper Shaft Installation
UPPER SHAFT INSTALLATION
7-FT836 Bearing Cap.
NOTE: Before installing the shaft group in the lower housing, be sure the front retainers (1) and (2) are tight and rear retainers (3) and (6) are loose. This will allow the shaft to be lowered into its correct position.
Place the upper shaft in the lower housing and, with the shaft supported by the hoist, place FT836 Bearing Cap (7) over the bearings as illustrated. This will insure that all of the top shaft bearings are properly seated.
Install the upper housing. See the covering topic.
Clutch Disassembly
REMOVING CLUTCH SPIDER
1-Bearing retainer nuts (six). 2-Stud nuts (twelve). 3-Clutch spider.
1. Place the upper shaft group in a vertical position by blocking up under the plate assembly as illustrated.
2. Remove all but two of the bearing retainer nuts (1) leaving the remaining two accessible to a wrench.
FT840 RETAINING BRACKET
4-FT840 Retaining Brackets. 5-Plate assembly.
NOTE: Before removing stud nuts (2) and the remaining two nuts (1), install two FT840 Brackets as illustrated to prevent shaft from sliding out of the clutch pack.
3. Remove the stud nuts (2), retainer nuts (1) and remove the clutch spider (3), being careful not to damage the clutch studs.
REMOVING CLUTCH SPIDER
REMOVING ASTERN CLUTCH DRIVE RING
NOTE: If the old plates are to be reused, mark the clutch plates in a manner so they will be assembled in the same order. This will accommodate any wear pattern.
REMOVING ASTERN CLUTCH
6-Driven plate. 7-Drive plate. 8-Cylinder assembly.
4. Remove the ahead clutch drive ring (9) and the ahead clutch plates in the same manner as in the astern clutch.
REMOVING CLUTCH CYLINDER ASSEMBLY
8-Cylinder assembly. 9-Ahead clutch drive ring. 10-Plate assembly.
5. Inspect the ahead and astern clutch plates and replace if worn or damaged. The clutch plates are installed alternately, beginning with a sintered bronze plate.
REMOVING PLATE ASSEMBLY
PREPARING TO REMOVE ASTERN PISTON
11-Retainer rings. 12-Ahead piston. 13-Astern piston.
NOTE: The astern piston can also be removed by lifting the cylinder assembly off the piston after the retaining rings (11) have been removed. The cylinder assembly will then have to be turned over in order to remove the retainer rings on the ahead piston.
REMOVING ASTERN PISTON
12-Ahead piston. 13-Astern piston. 14- Springs. 15-Washers. 16-Pins. 17-Retainer rings. 18-Washers. 19-Springs.
6. After the retainer rings (11) have been removed, turn the cylinder over so that the astern piston (13) is on top.
| NOTICE |
|---|
Use care in turning over cylinder assembly as the astern piston may fall out if not held in place. |
7. Lift off astern piston (13) being careful not to damage the pins (16).
8. Remove retainer rings (17), washers (18), springs (19) and lift off cylinder assembly from ahead piston (12).
Clutch Assembly
1. Lift cylinder assembly (8) and set it on the ahead piston (12). Install springs (19), washers (18) and retainer rings (17).
2. Install springs (14) and washers (15) into place and set astern piston (13) into the cylinder.
3. Turn the cylinder assembly (8) over, holding astern piston (13) in place. Install retaining rings (11).
4. Install plate assembly (10) on main shaft and bolt FT840 Bracket in place.
5. Install ahead clutch drive ring (9) on plate assembly (10).
6. Install the clutch plates alternately beginning with a sintered bronze plate.
7. Install cylinder assembly (8) on ahead clutch drive ring (9).
8. Install astern clutch drive ring and clutch plates in the same sequence as for the ahead clutch.
9. Install the clutch spider (3), being careful not to damage the clutch studs, and install stud nuts (2).
10. Install bearing retaining nuts (1).
Dump Valve Removal and Installation
PREPARING TO REMOVE DUMP VALVE BODY
1-Retainer ring.
The clutches contain two dump valves.
REMOVING VALVE BODY
1. Remove the valve body using a 5F7344 Block, two 1D4719 Nuts, two L1329 Bolts, two 8B2377 Bolts, two 4B4280 Washers and two 4B4276 Washers.
REMOVING DUMP PISTON FROM BODY
2-Dump piston. 3-Valve body.
NOTE: When installing, be sure the arrow on the dump valve is pointing outward from the clutch cylinder as illustrated. The solid end of the dump valve piston marked "OUT" must also be positioned as illustrated.
Clutch Drive Spider and Oil Pump Drive Shaft
Disassembly
NOTE: The oil pump drive shaft is splined to the spider and can be removed by lifting it straight up from the spider after the four bolts securing the retainer, cover and coupling are removed.
1. Using an 8B7551 Bearing Pulling Attachment, an 8B7548 Push Puller, 8B7550 Legs, an 8B7560 Step Plate and an 9H684 Wrench, pull the top bearing assembly (1) from the clutch spider as illustrated.
REMOVING BEARING ASSEMBLY FROM CLUTCH DRIVE SPIDER
1-Bearing assembly. 2-Bearing assembly. 3-Spacer.
2. Remove the spacer (3) located between the two bearings.
3. Using the same pulling tools with two 91/2" legs in place of the 8B7550 Legs, remove bearing (2).
Clutch Drive Spider and Oil Pump Drive Shaft Assembly
1. Heat bearing assemblies (1) and (2) in oil to 200° - 240° F (104° - 115° C) Max. before installation.
2. Install bearing (2) on the clutch drive spider.
3. Replace the bearing spacer.
4. Install bearing assembly (1) with the grease seal facing away from the spider.
Main Shaft Disassembly
REMOVING ASTERN DRIVING GEAR AND REAR THRUST BEARINGS
1-Rear thrust bearing assembly. 2-Astern driving gear.
1. Using a 8B7548 Push Puller, 8B7549 Puller Legs, 7F9540 Hydraulic Puller, a 5F9886 Adapter and a suitable Hydraulic Pump Group, pull the rear thrust bearing assembly (1) and the astern driving gear (2) off the astern driving shaft.
REMOVING AHEAD DRIVE SHAFT ASSEMBLY
2. Using a 1H3107 Push Puller, 1H3109 Puller Legs, 1H3110 Bearing Pulling Attachment, 7F9540 Hydraulic Puller and a suitable Hydraulic Pump Group, remove the inner bearing race (3) from the astern drive shaft.
3. Using a 1H3107 Push Puller, 1H3110 Bearing Pulling Attachment, 5F7694 Plug, 7F9540 Hydraulic Puller and a suitable Hydraulic Pump Group, remove the double tapered thrust bearing (4) from the ahead drive shaft.
REMOVING BEARING INNER RACE FROM ASTERN DRIVE SHAFT
3-Inner race.
REMOVING DOUBLE TAPERED THRUST BEARING FROM AHEAD DRIVE SHAFT
4-Double tapered thrust bearings.
REMOVING AHEAD DRIVING GEAR
5-Outer race of front support bearing.
4. Using a 1H3107 Push Puller, 1H3108 Puller Legs, 7F9540 Hydraulic Puller, 5F7694 Plug and a suitable Hydraulic Pump Group, remove the ahead driving gear from the ahead drive shaft.
5. Remove the outer race (5).
REMOVING FRONT SUPPORT BEARING FROM AHEAD DRIVE SHAFT
6-Front support bearing. 7-Inner race.
PREPARING TO REMOVE INNER BEARING FROM AHEAD DRIVE SHAFT
8-Retainer.
REMOVING INNER BEARING AND SHIELD
9-Bearing. 10-Shield.
6. Using a 1H3107 Push Puller, 1H3108 Puller Legs, 1H3110 Bearing Pulling Attachment, 5F7694 Plug, 7F9540 Hydraulic Puller and a suitable Hydraulic Pump Group, remove bearing (6) and inner race (7).
7. Inspect all bearings and replace if worn or damaged.
Main Shaft Assembly
1. Install shield (10) and bearing (9) into the ahead drive shaft.
2. Install bolts securing retainer (8).
NOTE: Bearings and gears can be assembled on shafts by heating them in oil to 275° F (135° C) Max. then quickly slipping them on the proper shafts (seat the bearings with a soft hammer).
3. Install inner race (6) and bearing (7) on the shaft.
4. Install outer race of front support bearing (5).
5. Install the ahead driving gear on the ahead drive shaft.
6. Install double tapered thrust bearings (4) on the ahead drive shaft.
7. Install bearing inner race (3) on astern drive shaft.
8. Install ahead drive shaft assembly on the astern driving shaft.
9. Install astern driving gear (2) and rear thrust bearing assembly (1) on the astern driving shaft.