20-547792 en
20-547792 en
20-547792 en
GEAR BOX /
CONVERTER
TABLE OF CONTENTS
T12000 TRANSMISSION ASSEMBLY
HOW THE UNITS OPERATE
SECTIONAL VIEWS AND PARTS IDENTIFICATION
Transmission Case and Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. A
Converter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. B
Forward - Reverse and 1st - 2nd Clutch Group . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. C
High - 3rd and Output Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. D
Control Valve GroupDual Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. E
Control Valve GroupSingle Modulation,
Mechanical Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. F
Assembly Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. G, H, I, J, K
DISASSEMBLY OF TRANSMISSION
REASSEMBLY OF TRANSMISSION
60
78
79
80
81
82
83
84, 85
86
87
TROUBLESHOOTING GUIDE
88
89
DESCRIPTION
91
T12000
TRANSMISSION ASSEMBLY
The transmission and hydraulic torque converter portion of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to
fisrt understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system. It
is necessary to consider both units in the study of their function and operation.
The electric shift control valve is located in the vehicle's operator compartment. The function of the control is
to energize the selected solenoid valves thus directing the oil under pressure to the selected directional and range
(gear) clutches. The purpose of the range or directional clutches is to direct the power flow through the gear train
to provide the desired speed range and direction.
An axle disconnect is optional and is located on the output shaft. The drive to the front axle can be disconnected or connected by manual, pneumatic, or hydraulic shifting.
When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through
the direction selector solenoid to the oil sump. The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with slots and a bore to receive a hydraulically
actuated piston. The piston is "oil tight" by the use of sealing rings. A steel disc with external tangs is inserted into
the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs are
alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring.
A hub with O.D. splines is inserted into a splines of discs with teeth on the inner diameter. The discs and hub are
free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, the electric shift control lever is placed in the desired position. This energizes the selected direction and range (gear) solenoids allowing the oil under pressure to flow through tubes and passages to the
selected clutch shafts. Oil sealing rings are located on the clutch shaft. These rings direct oil under pressure
through a drilled passageway in the shaft to a desired clutch. Pressure of the oil forces the piston and discs against
the heavy back-up plate. The discs with tangs on the outer diameter clamping against discs with teeth on the inner
diameter enables the hub and clutch shaft to be locked together and allows them to drive as a unit.
There are bleed balls in the clutch piston or clutch drum which allow quick escape for oil when the pressure to
the piston is released.
Figure A
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
25
26
Oil Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spacer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27
Pipe Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
28
29
30
31
Transmission Case . . . . . . . . . . . . . . . . . . . . . 1
32
Filler Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33
10
Diverter Sleeve . . . . . . . . . . . . . . . . . . . . . . . . 1
34
11
Pipe Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
35
12
13
14
15
38
16
Air Breather . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39
17
40
18
Pipe Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
41
19
42
20
43
21
Dipstick Housing . . . . . . . . . . . . . . . . . . . . . . . 1
22
Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23
24
Figure B
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
40
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
42
43
44
45
Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . 1
46
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
47
Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
48
10
Charging Pump . . . . . . . . . . . . . . . . . . . . . . . 1
49
"O" Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11
50
Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12
51
13
52
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14
53
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15
54
16
17
Filter Assembly . . . . . . . . . . . . . . . . . . . . . .
55
18
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
56
19
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
57
20
Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
58
21
Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22
59
23
24
60
25
61
26
62
27
63
28
64
29
65
30
66
31
Stator Support . . . . . . . . . . . . . . . . . . . . . . .
67
Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
32
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ; 1
68
33
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
69
34
70
35
71
Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
72
Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
73
Converter Housing . . . . . . . . . . . . . . . . . . .
38
74
Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
V.
RE
D.
W
F
d
2n
t
1s
Figure C
DESCRIPTION
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
1
1
5
1
1
1
1
1
1
1
1
1
5
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
ITEM
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
DESCRIPTION
QUANTITY
H
HIG
4th
3rd
BRAKE OPTION
Figure D
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
32
33
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . .
34
35
36
37
Outer Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
7*
38
Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
8*
39
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
9*
40
41
11* Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
43
13* Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
45
46
47
Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . .
48
49
50
51
52
53
54
55
56
Output Flange . . . . . . . . . . . . . . . . . . . . . . .
57
Flange Plug. . . . . . . . . . . . . . . . . . . . . . . . .
58
59
60
61
Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . .
62
63
29
30
31
T12000
ELECTRIC CONTROL GROUP
DUAL MODULATION
Figure E
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
22
23
Stop Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
24
Spring Inner . . . . . . . . . . . . . . . . . . . . . .
2
25
Spring Middle . . . . . . . . . . . . . . . . . . . . .
2
26
2
27
2
28
2
29
Regulator Spool . . . . . . . . . . . . . . . . . . . . .
2
30
10
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Spring Retainer . . . . . . . . . . . . . . . . . . . . . .
31
12
32
13
33
14
Accumulator Spool . . . . . . . . . . . . . . . . . . .
34
15
Spring Outer . . . . . . . . . . . . . . . . . . . . . .
35
16
17
Cover Screw . . . . . . . . . . . . . . . . . . . . . . . .
36
18
Protective Cover . . . . . . . . . . . . . . . . . . . . .
37
Solenoid Coil. . . . . . . . . . . . . . . . . . . . . . . .
19
38
20
39
21
Solenoid Coil. . . . . . . . . . . . . . . . . . . . . . . .
SINGLE MODULATION
MECHANICAL INCHING
Figure F
ITEM
T12000
CONTROL VALVE GROUP WITH SINGLE MODULATION, MECHANICAL INCHING
(Figure F)
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
26
27
Stop Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Inching Sleeve . . . . . . . . . . . . . . . . . . . . . .
Spring Inner . . . . . . . . . . . . . . . . . . . . . .
29
Spring Middle . . . . . . . . . . . . . . . . . . . . .
30
Inching Spool . . . . . . . . . . . . . . . . . . . . . . .
Spring Outer . . . . . . . . . . . . . . . . . . . . . .
31
Accumulator Spool . . . . . . . . . . . . . . . . . . .
32
Cover Screw . . . . . . . . . . . . . . . . . . . . . . . .
33
Protective Cover . . . . . . . . . . . . . . . . . . . . .
Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
10
35
11
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
Solenoid Coil. . . . . . . . . . . . . . . . . . . . . . . .
12
Regulator Spool . . . . . . . . . . . . . . . . . . . . .
37
13
Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
Valve Cartridge . . . . . . . . . . . . . . . . . . . . . .
14
39
15
Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
16
41
17
Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . .
42
18
Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . .
43
19
44
20
Shuttle Spool . . . . . . . . . . . . . . . . . . . . . . .
45
21
Shuttle Sleeve. . . . . . . . . . . . . . . . . . . . . . .
46
22
Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
23
Inching Housing . . . . . . . . . . . . . . . . . . . . .
48
24
49
25
50
Valve Cartridge . . . . . . . . . . . . . . . . . . . . . .
3 SPEED
ASSEMBLY INSTRUCTION
Oil filter
REVERSE IDLER
VIEW H
View T
View K
REV.
View F
FWD.
View H
3rd
Expander
Piston ring
VIEW T
1st 2nd
SECTION A-A
(See reference Figure K)
Figure G
4 - 6 SPEED
ASSEMBLY INSTRUCTION
Oil filter
View F
View T
REV.
FWD.
View K
View H
4th/
3rd
HL
VIEW F
Enlarged view of seal
1st
2nd
VIEW K
SECTION A-A
(See reference Figure K)
Figure H
ASSEMBLY NOTES :
Use Permatex and Loctite only where specified.
All lead in chamfers for oil seals, piston rings, and
"O" rings must be smooth and free from burrs.
Inspect before assembly.
Lubricate all piston ring grooves and "O" rings
with oil before assembly.
Apply a thin coat of grease between seal lips on
lip type seals prior to assembly.
version only.
15 Solenoid cartridge to be assembled and tightened to
Figure I
M10
M12
GRADE 10.9
COARSE THREAD
lbfft
[nm]
44-48
[60-65]
74-81
[110-110]
lbfft
[Nm]
1/16-27
1/8-27
1/4-18
3/8-18
1/2-14
3/4-10
5-7
7-10
15-20
25-30
30-35
40-45
[7-9]
[9-14]
[20-27]
[34-41]
[41-47]
[54-61]
lbfft
25-30
45-50
[Nm]
[34-41]
[61-68]
Figure J
Section B - B
s
ed
e
sp n
or p t i o
f
o
ing
sh
u
tb
tpu
u
O
s
en
or-
uto
sh
ift
Filter plug
Breather
Soleniod bore
plug
1,397 (35,48)
43T
1,383 (35,13)
1,067 (27,10) 46T
1,053 (26,75)
REAR VIEW
GRADE 5
FINE THREAD
lbfft
.2500
.3125
.3750
.4375
.5000
.5625
.6250
.7500
9-11
16-20
26-29
41-45
64-70
91-100
128-141
223-245
[Nm]
[12-15]
[22-27]
[35-39]
[56-61]
[87-95]
[123-136]
[174-191]
[302-332]
GRADE 8
COARSE THREAD
lbfft
8-10
12-16
23-25
37-41
57-63
82-90
113-124
200-220
[Nm]
[11-14]
[16-22]
[31-34]
[50-56]
[77-85]
[111-122]
[153-168]
[271-298]
Figure K
FINE THREAD
lbfft
11-13
28-32
37-41
58-64
90-99
128-141
180-198
315-347
[Nm]
[15-18]
[38-43]
[50-56]
[79-87]
[122-134]
[174-191]
[224-268]
[427-470]
COARSE THREAD
lbfft
9-11
26-30
33-36
52-57
80-88
115-127
159-175
282-310
[Nm]
[12-15]
[35-41]
[45-49]
[71-77]
[108-119]
[156-172]
[216-237]
[382-420]
and reassemble.
CAUTION : Cleanliness is of extreme importance
and an absolute must in repair and overhaul of this
unit. Before attempting any repairs, the exterior of
the unit must be thoroughly cleaned to prevent the
possibility of dirt and foreign matter entering the
mechanism.
DISASSEMBLY
Figure 1
Side view of T12000 short drop transmission.
Figure 3
Remove drive plate attaching capscrews and
washers. Remove drive plate and backing ring.
Figure 2
Rear view showing disc brake and electric control.
Figure 4
Remove torque converter plug retainer ring.
-1-
Figure 5
Remove plug and "O" ring.
Figure8
Remove torque converter to shaft locating ring.
Figure 6
Remove torque converter to turbine shaft retainer
ring.
Figure 9
Remove filter assembly.
Figure 7
Remove torque converter assembly.
Figure 10
Remove pressure regulator and regulator sleeve.
NOTE : Special tool can be fabricated. (See Figure
388A).
-2-
Figure 11
Remove charging pump permanent pump hole
cover. (Not used when auxiliary pump is used.)
Figure 14
Remove converter housing and gasket.
Figure 15
Remove impeller hub gear.
Figure 12
Remove pump mounting bolts and washers.
Remove pump and gasket.
Figure 16
Remove solenoid valve cartridge retainer nut and
"O" ring.
Figure 13
Remove converter housing to transmission case
bolts and washers.
-3-
Figure 20
Remove bore plug and "O" rings. This plug is used in
the middle bore position in the 3 speed version only.
Figure 17
Remove solenoid coil and "O" ring.
Figure 21
Remove spacer plate bolts and washers.
Figure 18
Loosen solenoid valve cartridge.
Figure 22
Pry spacer plate away from transmission case at
dowel pin holes. Remove spacer plate and gasket.
Note aligning studs to facilitate spacer removal.
Figure 19
Remove valve. Repeat procedures Figures 16
through 19 for remaining solenoid valves. See figure
20.
-4-
Figure 23
Remove 1st and 2nd clutch assembly.
Figure 26
Remove 3rd speed clutch shaft pilot bearing.
Figure 24
Remove forward and reverse clutch assembly.
Figure 27
Remove oil baffle capscrew and washer.
Figure 25
Remove 3rd clutch assembly.
NOTE : A 4 and 6 speed transmission will have a
4th-high clutch on the clutch shaft also.
Figure 28
-5-
Figure 29
Remove oil supply tube "O" ring.
Figure 32
Remove 1st and 2nd clutch shaft rear roller bearing.
Remove 3rd gear roller bearing.
Figure 30
Remove supply tube and screen assembly.
Figure 33
Remove roller bearing locating ring.
Figure 34
Remove inner case set screw plug. Remove clutch
shaft distributor sleeve set screw.
Figure 31
Remove 3rd clutch gear and output shaft.
-6-
Figure 38
Remove inner, middle, and outer valve springs and
valve stop pin.
Figure 35
Use a hammer puller (or any suitable puller) as
shown to remove distributor sleeve and shaft pilot
bearing.
Figure 36
Pilot bearing and distributor sleeve removed.
Figure 39
Remove accumulator spool.
FOR SINGLE MODULATION AND MECHANICAL
INCHING SEE PAGE 70.
Figure 40
Remove modulation housing sleeve and "O" ring.
Figure 37
Remove dual modulator housing sleeve and "O"
ring.
-7-
Figure 41
Remove diverter sleeve.
NOTE : Diverter sleeve has a 5/16-24 threaded hole
in end of it. A threaded rod screwed into end of it will
facilitate removal of diverter sleeve.
Figure 44
Remove output flange to bearing retainer ring.
Figure 45
Tap output flange from rear bearing.
Figure 42
Remove parking brake caliper assembly bolts from
brake and housing.
NOTE : Brake is an option and will not be on all
units.
Figure 42
Remove brake caliper assembly.
Figure 46
Remove output flange and brake disc.
-8-
Figure 50
Remove bearing locating ring.
Figure 47
Remove output seal sleeve retainer ring.
DISASSEMBLY
LOW (1ST) BEING DISASSEMBLED
Figure 48
Remove seal sleeve, seal and "O" ring.
Figure 51
Remove clutch shaft oil sealing rings.
Figure 52
Remove front bearing retainer ring.
Figure 49
Remove output flange bearing.
-9-
Figure 56
Clutch gear and bearings removed.
Figure 53
Remove front bearing.
Figure 54
Remove outer thrust washer, bearing, and inner
thrust washer.
Figure 57
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 55
Remove clutch gear and disc hub.
Figure 58
Remove clutch disc end plate retainer ring.
- 10 -
Figure 59
Remove clutch disc end plate.
Figure 62
Remove retainer ring retainer.
Figure 60
Remove inner and outer clutch discs.
Fogure 63
Remove disc springs.
Note : See page 77.
Figure 61
Compress disc springs and remove retainer ring.
Figure 64
Remove clutch piston wear plate.
- 11 -
Figure 68
Remove gear from shaft.
Figure 65
Turn clutch over and tap clutch shaft on a block of
wood to remove clutch piston.
Figure 66
Using a gear puller as shown, remove gear and rear
bearing inner race.
Figure 69
Remove gear locating ring from shaft.
Figure 67
Remove inner race from shaft.
Figure 70
Remove thrust bearing and clutch gear retainer ring.
- 12 -
Figure 74
Remove clutch disc end plate retainer ring.
Figure 71
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 75
Remove end plate.
Figure 72
Remove clutch gear and hub and gear bearings.
Figure 73
Remove outer thrust washer, thrust bearing and
inner thrust washer.
Figure 76
Remove clutch discs.
- 13 -
Figure 80
Remove clutch piston wear plate.
Figure 77
Compress disc springs and remove retainer ring.
Figure 81
Remove clutch piston.
Figure 78
Remove retainer ring retainer.
Figure 82
Two bleed valves in clutch drum must be clean and
free of any foreign material.
Figure 79
Remove disc springs.
Note : See page 77.
- 14 -
Figure 86
Position clutch piston wear plate on piston.
Figure 83
Install clutch piston outer seal ring.
Figure 84
Install clutch piston inner seal ring. Note : Ring must
be sized before installing in clutch drum. Sizing is
best accomplished by rotating piston while holding a
round object against the new seal ring. Rotate piston
until seal ring is flush with outer diameter of piston.
Figure 87
Install piston return disc springs. First spring with
large diameter of bevel toward wear plate. Alternate
seven (7) springs.
Note : See page 77.
Figure 85
Position piston in low clutch drum as shown. Use
caution as not to damage inner and outer piston sealing rings.
Figure 88
Position return spring retainer on clutch shaft.
- 15 -
Figure 89
Start ring on shaft with snap ring pliers.
Figure 92
Install first friction (inner) clutch disc. Alternate steel
and friction until ten (10) steel and ten (10) friction
discs are in position.
Figure 90
Use a sleeve with the proper inner diameter to fit
over shaft and against retainer ring. A sharp blow
with a soft hammer will compress springs and seat
retainer ring. Be sure ring is in full position in groove.
Figure 93
Install clutch disc end plate.
Figure 91
Install first steel (outer) clutch disc.
Figure 94
Install end plate retainer ring.
- 16 -
Figure 98
Install outer thrust bearing washer against bearing.
Figure 95
NOTE : Low (1st) clutch pack must be checked for
clutch disc clearance.
With the clutch assembly on end, the clutch discs will
fall to the piston.
Measure the distance between the clutch end plate
and end plate retainer ring by inserting a feeler
gauge or taper gauge through the slots in the clutch
drum.
The required clearance is .080-.135 [2,03-3,43 mm].
If the clearance is greater than .135 [3,43 mm], add
one steel disc under the end plate.
Figure 99
Press bearings in clutch gear and disc hub, being
certain bearings are pressed flush with face of gear
on both sides.
Figure 96
Position thrust bearing inner washer on clutch shaft.
Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs.
Be sure the clutch hub is in full position in the clutch
assembly. Do not force this operation.
Figure 97
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
Figure 100
Position inner thrust washer on shaft.
- 17 -
Figure 104
Install front bearing retainer ring.
Figure 101
Position thrust bearing on shaft.
Figure 105
Install clutch shaft oil sealing rings. Grease rings to
facilitate reassembly into front housing.
Figure 102
Position outer thrust washer on shaft.
Figure 103
Install clutch shaft front bearing.
NOTE : Bearing has a shield in it. This shield must
be up.
Figure 106
Install inner and outer clutch piston seal rings. Size
inner ring as explained in Figure 84.
- 18 -
Figure 110
Position return spring ring retainer on clutch shaft.
Figure 107
Position piston in clutch drum, using caution as not
to damage piston sealing rings.
Figure 11
Start ring on shaft with snap ring pliers. Use a sleeve
with the proper inner diameter to fit over shaft and
against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring. Be
sure ring is in full position in groove.
Figure 108
Install clutch piston wear plate.
Figure 109
Install piston return disc springs. First spring with
large diameter of bevel toward wear plate. Alternate
five (5) Springs.
Note : See page 77.
Figure 112
Install first steel (outer) clutch disc.
- 19 -
Figure 113
Install first friction (inner) clutch disc. Alternate steel
and friction until five (5) steel and five (5) friction
discs are in position.
Figure 116
Position thrust bearing inner washer on clutch shaft.
Figure 117
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
Figure 114
Install clutch disc end plate.
Figure 118
Install outer thrust bearing washer against thrust
bearing.
Figure 115
Install end plate retainer ring.
- 20 -
Figure 122
Install outer thrust bearing washer against bearing.
Figure 119
Press needle bearings in clutch gear and disc hub,
being certain bearings are pressed flush with face of
gear on both sides. Install the clutch gear in the clutch
assembly by aligning the clutch hub teeth with the
clutch inner discs. Be sure the clutch hub is in full
position in the clutch assembly. Do not force this
operation.
Figure 123
Install thrust washer retainer ring.
Figure 120
Position thrust bearing inner washer on clutch shaft.
Figure 121
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
Figure 124
Install clutch shaft gear locating ring.
- 21 -
Figure 125
Install clutch shaft gear on clutch shaft with long hub
of gear down.
Figure 128
Remove clutch shaft oil sealing rings.
Figure 129
Using a gear puller as shown, remove clutch gear
and front bearing.
Figure 126
Install rear bearing inner race on clutch shaft with
bearing race shoulder down.
Figure 130
Remove clutch gear locating ring. For 3 speed
models proceed to Figure 144.
Figure 127
Position rear bearing on bearing race.
- 22 -
Figure 134
Remove bearings and spacer from clutch gear.
Figure 131
Remove outer thrust washer retainer ring.
Figure 132
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 135
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 133
Remove clutch gear and disc hub.
Figure 136
Remove end plate retainer ring.
- 23 -
Figure 140
Remove retainer ring retainer.
Figure 137
Remove end plate.
Figure 141
Remove disc springs.
Note : See page 77.
Figure 138
Remove clutch discs.
Figure 142
Remove clutch piston wear plate.
Figure 139
Compress disc springs and remove retainer ring.
- 24 -
Figure 143
Remove clutch piston.
Figure 146
Remove end plate.
Figure 144
Remove thrust washer retainer ring. Remove outer
thrust washer, thrust bearing, and inner thrust
washer.
Figure 147
Remove clutch discs.
Figure 145
Remove end plate retainer ring.
Figure 148
Compress disc springs and remove retainer ring.
- 25 -
Figure 152
Remove clutch piston.
Figure 149
Remove retainer ring retainer.
Figure 150
Remove disc springs.
Note : See page 77.
Figure 153
Clutch piston bleed ball must be clean and free of
any foreign material.
Figure 154
Install inner and outer clutch piston seal rings. Size
inner ring as explained in Figure 84. Install clutch
piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 151
Remove clutch piston wear plate.
- 26 -
Figure 155
Install clutch piston wear plate.
Figure 158
Start ring on shaft with snap ring pliers.
Figure 156
Install piston return disc springs. First spring with
large diameter of bevel toward wear plate . Alternate
five (5) springs.
Note : See page 77.
Figure 159
Use a sleeve with the proper inner diameter to fit
over shaft and against retainer ring. A sharp blow
with a soft hammer will compress springs and seat
retainer ring. Be sure ring is in full position in groove.
Figure 157
Position return spring ring retainer on clutch shaft.
Figure 160
Install first steel (outer) clutch disc.
- 27 -
3rd
Gauge
4th
Figure 161
Install first friction (inner) clutch disc. Alternate steel
and friction until six (6) steel and six (6) friction discs
are in position
Figure 163A
NOTE : 4th (high) clutch pack must be checked for
clutch disc clearance.
Stand the clutch assembly on end. The clutch discs
on the bottom will fall to the end plate.
Measure the distance between the clutch piston and
the first steel disc by inserting a feeler gauge or
taper gauge through the slots in the clutch drum.
The required clearance is .048-.108 [1,22-2,74 mm].
Figure 162
Install clutch disc end plate.
Figure 163
Install end plate retainer ring.
Figure 164
Position thrust bearing inner washer on clutch shaft.
- 28 -
Figure 165
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
Figure 168
Position inner thrust washer on shaft.
Figure 166
Install outer thrust bearing washer against bearing.
Figure 169
Position thrust bearing on shaft.
Figure 167
Press one bearing in clutch gear. Install bearing spacer
next to bearing. Press second bearing in gear, being
certain bearings are pressed flush with face of gears on
both sides. Install the clutch gear in the clutch assembly
by aligning the clutch hub teeth with the clutch inner
discs. Be sure the clutch hub is in full position in the
clutch assembly. Do not force this operation
Figure 170
Position outer thrust washer on shaft.
- 29 -
Figure 174
Install clutch shaft front bearing.
NOTE : Bearing has a shield in it. This shield must
be up.
Figure 171
Install thrust washer retainer ring.
Figure 175
Install clutch shaft oil sealing rings. Grease rings to
facilitate reassembly into front housing.
Figure 172
Install clutch shaft gear locating ring.
Figure 176
Clutch piston bleed ball must be clean and free of
any foreign material.
Figure 173
Position gear on clutch shaft.
- 30 -
Figure 180
Position return spring ring retainer on clutch shaft.
Figure 177
Install inner and outer clutch piston seal rings. Size
inner ring as explained in Figure 84. Install clutch
piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 181
Start ring on shaft with snap ring pliers.
Figure 178
Install clutch piston wear plate.
Figure 182
Use a sleeve with the proper inner diameter to fit
over shaft and against retainer ring. A sharp blow
with a soft hammer will compress springs and seat
retainer ring. Be sure ring is in full position in groove.
Figure 179
Install piston return disc springs. First spring with
large diameter of bevel toward wear plate. Alternate
five (5) springs.
Note : See page 77.
- 31 -
Figure 183
Install first steel (outer) clutch disc.
Figure 186
Install end plate retainer ring.
Figure 184
Install first friction (inner) clutch disc. Alternate steel
and friction until five (5) steel and five (5) friction
discs are in position.
Figure 187
Position thrust bearing inner washer on clutch shaft.
Figure 188
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
Figure 185
Install clutch disc end plate.
- 32 -
Figure 189
Install outer thrust bearing washer against thrust
bearing. Install thrust washer retainer ring.
Figure 192
Remove clutch gear and disc hub.
Figure 190
Install 3rd clutch pilot bearing on clutch shaft. A coat
of high quality grease will hold pilot bearing in position.
Figure 194
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 191
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
- 33 -
Figure 195
Remove end plate retainer ring.
Figure 198
Compress disc springs and remove retainer ring.
Figure 196
Figure 199
Remove retainer ring retainer.
Figure 197
Remove clutch discs.
Figure 200
Remove disc springs.
Note : See page 77.
- 34 -
Figure 201
Remove clutch piston wear plate.
Figure 204
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 202
Remove clutch piston.
Figure 205
Remove clutch gear and disc hub.
Figure 206
Remove bearings and spacer from clutch gear.
Figure 203
Remove clutch shaft oil sealing rings.
- 35 -
Figure 207
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 210
Remove clutch discs.
Figure 208
Remove end plate retainer ring.
Figure 211
Compress disc springs and remove retainer ring.
Figure 209
Figure 212
Remove retainer ring retainer.
- 36 -
Figure 213
Remove disc springs.
Note : See page 77.
Figure 216
Clutch piston bleed orifice must be clean and free of
any foreign material.
Figure 214
Remove clutch piston wear plate.
Figure 217
Install inner and outer clutch piston seal rings. Size
inner ring as explained in Figure 84. Install clutch
piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 215
Remove clutch piston.
Figure 218
Install clutch piston wear plate.
- 37 -
Figure 219
Install piston return disc springs. First spring with
large diameter of bevel toward wear plate . Alternate
five (5) springs.
Note : See page 77.
Figure 222
Use a sleeve with the proper inner diameter to fit
over shaft and against retainer ring. A sharp blow
with a soft hammer will compress springs and seat
retainer ring. Be sure ring is in full position in groove.
Figure 220
Position return spring ring retainer on clutch shaft.
Figure 223
Install first steel (outer) clucth disc.
Figure 221
Start ring on clutch with snap ring pliers.
Figure 224
Install first friction (inner) clutch disc. Alternate steel
and friction until six (6) steel and six (6) friction discs
are in position.
- 38 -
Figure 225
Install clutch disc end plate.
Figure 227
Position thrust bearing inner washer on clutch shaft.
Figure 226
Install end plate retainer ring.
REV.
FWD.
Gauge
Figure 226A
NOTE : Forward clutch pack must be checked for
clutch disc clearance.
Stand the clutch assembly on end. The clutch discs
on the bottom will fall to the end plate.
Measure the distance between the clutch piston and
the first steel disc by inserting a feeler gauge or
taper gauge through the slots in the clutch drum.
The required clearance is .048-.108 [1,22-2,74 mm].
Figure 228
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
- 39 -
Figure 229
Install outer thrust bearing washer against thrust
bearing.
Figure 232
Position thrust bearing on shaft.
Figure 230
Press one bearing in clutch gear, flush with face of
gear. Install bearing spacer next to bearing. Press
second bearing in gear, flush with face of gear.
Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs.
Be sure the clutch hub is in full position in the clutch
assembly. Do not force this operation.
Figure 233
Position outer thrust washer on shaft.
Figure 234
Install clutch shaft oil sealing rings. Grease rings to
facilitate reassembly into front housing.
Figure 231
Position inner thrust washer on shaft.
- 40 -
Figure 235
Clutch piston bleed orifice must be clean and free of
any foreign material.
Figure 238
Install piston return disc springs. First spring with
large diameter of bevel toward wear plate. Alternate
five (5) springs.
Note : See page 77.
Figure 236
Install inner and outer clutch piston seal rings. Size
inner ring as explained in Figure 84. Install clutch
piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 239
Position return spring ring retainer in clutch shaft.
Figure 240
Start ring on shaft with snap ring pliers.
Figure 237
Install clutch piston wear plate.
- 41 -
Figure 244
Install clutch disc end plate.
Figure 241
Use a sleeve with the proper inner diameter to fit
over shaft and against retainer ring. A sharp blow
with a soft hammer will compress springs and seat
retainer ring. Be sure ring is in full position in groove.
Figure 245
Install end plate retainer ring.
REV.
FWD.
Figure 242
Install first steel (outer) clutch disc.
Gauge
Figure 245A
NOTE : Reverse clutch pack must be checked for
clutch disc clearance.
Stand the clutch assembly on end. The clutch disc
on the bottom will fall to the end plate.
Measure the distance between the clutch piston and
the first steel disc by inserting a feeler gauge or
taper gauge through the slots in the clutch drum.
Figure 243
Install first friction (inner) clutch disc. Alternate steel
and friction until six (6) steel and six (6) friction discs
are in position.
- 42 -
Figure 246
Position thrust bearing inner washer on clutch shaft.
Figure 249
Press one bearing in clutch gear, flush with face of
gear. Install bearing spacer next to bearing. Press
second bearing in gear, flush with face of gear.
Install the clutch gear in the clutch assembly by alig
ning the clutch hub teeth with the clutch inner discs.
Be sure the clutch hub is in full position in the clutch
assembly. Do not force this operation.
Figure 247
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
Figure 250
Position inner thrust waher on shaft.
Figure 248
Install outer thrust bearing washer against bearing.
Figure 251
Position thrust bearing on shaft.
- 43 -
REASSEMBLY
(See Cleaning and Inspection Page.)
Figure 255
Install pressure regulator valve spring and regulator
valve piston as an assembly into regulator valve
sleeve.
Figure 252
Position outer thrust washer on shaft.
REGULATOR VALVE
DISASSEMBLY AND REASSEMBLY
DISASSEMBLY
Figure 256
Compress valve spring and valve and install pin into
regulator valve sleeve.
Figure 253
Tap pin from regulator valve sleeve. Use caution as
valve spool is under spring pressure.
Figure 257
Remove inner, middle, and outer spring and stop pin
from modulation housing sleeve. Reference Figure 38.
Figure 254
Remove regulator valve piston and pressure regulator valve spring.
- 44 -
Figure 258
Remove accumulator spool. Reference Figure 39.
Figure 261
Remove regulator spool.
Figure 262
Remove 2nd sleeve pin.
NOTE : This pin is the longer of the two sleeve pins.
Figure 259
Remove cross pin from sleeve.
NOTE : This pin is the shortest of the two sleeve
pins.
REASSEMBLY
(See Cleaning and Inspection Page)
Figure 260
Remove regulator spool spring, retainer spring, and
spacer spring from housing sleeve.
Figure 263
Install the longer of the two pins in the end hole of
housing sleeve.
- 45 -
Figure 264
Check orifice in regulator spool to be free and clear
of any foreign material. Insert spool in sleeve housing with orifice end against cross pin.
Figure 267
Position accumulator spool in sleeve as shown.
Figure 265
Install spring spacer in spring retainer. Install spring
in spring retainer against spacer. Install spring retainer, spring, and spacer in housing sleeve and into
regulator spoool.
Figure 268
Install outer accumulator spring.
Figure 266
Compress regulator spool and spring in sleeve far
enough to install cross pin.
NOTE : This pin is the shortest of the two housing
sleeve pins. Install pin.
Figure 269
Install middle spring.
- 46 -
Figure 270
Install inner spring.
Figure 273
Install new "O" ring on modulator housing sleeve.
Figure 271
Install stop pin in inner spring.
Figure 274
If charging pump or pump drive gear are to be replaced, remove retainer ring and drive gear.
Figure 272
Install new "O" ring on modulator valve housing.
- 47 -
Figure 275
Remove reverse idler gear end plate capscrew and
washer.
Figure 275
Remove reverse idler gear end plate capscrew and
washer.
Figure 279
Remove idler gear tanged thrust washer.
Figure 276
Remove end plate and dowel pin.
Figure 280
If reverse idler shaft is to be replaced, support spacer plate around idler shaft opening and press idler
shaft from spacer. Do not drive on idler shaft as
doing so may cause damage to spacer plate.
Figure 277
Remove reverse idler gear.
- 48 -
Figure 281
Idler shaft and locating ring removed.
Figure 284
Remove pump drive idler shaft and thrust washer.
Figure 282
Remove locating ring from idler shaft.
Figure 285
Remove stator support oil sealing ring. Remove sealing ring expander ring.
Figure 286
The stator support is held in place by two (2) retaining rings. Remove converter end retainer ring from
groove.
Figure 283
Tap pump drive idler shaft from spacer plate.
- 49 -
Figure 287
Remove thrust washer.
Figure 290
If support bushing is to be replaced, remove from
stator support. NOTE : Bushing must be removed
from same end as needle bearing.
Figure 291
If support bearing is to be replaced, remove from
stator support.
Figure 288
Push support toward transmission side far enough to
expose retainer ring. Remove retainer ring.
Figure 292
Compress converter safety valve spring and remove
retaining washer.
Figure 289
From converter end, remove stator support.
- 50 -
Figure 293
Remove safety valve spring.
Figure 296
Turn spacer over and position safety valve spring on
poppet. Compress spring and install poppet retaining
washer. NOTE : End of spring must go in recessed
side of washer.
Figure 294
Turn spacer plate over and remove safety valve poppet.
Figure 297
If stator support bushing was removed, install
bushing in support. Install needle bearing in stator
support.
Figure 295
From transmission side of spacer plate, position
converter safety valve poppet in bore in spacer.
Figure 298
Install stator support in spacer plate.
- 51 -
Figure 302
Install support oil sealing ring expander ring. Install
oil sealing ring on expander ring. NOTE : Expander
spring gap to be 180 degrees from sealing ring hook
joint.
Figure 299
Install support locating ring.
Figure 300
Push support back through spacer until locating ring
shoulders in support bore. Turn spacer plate over
and position impeller hub gear washer on support.
Figure 303
Install locating ring on reverse idler shaft.
Figure 304
Support spacer plate and press idler shaft into position and tight against locating ring.
Figure 301
Install support retainer ring.
- 52 -
Figure 305
Turn spacer plate over and position tanged thrust
washer on shaft, being certain tang in washer is in
notch in spacer plate.
Figure 308
Position idler gear end plate and roll pin on idler
shaft, aligning roll pin with hole in idler shaft.
Figure 309
Install end plate capscrew and washer. Tighten to
specified torque. See torque chart.
Figure 306
Position idler gear needle bearing on shaft. Lubricate
bearing.
Figure 307
Position idler gear on bearing and shaft.
Figure 310
Position pump drive idler shaft washer on spacer
plate.
- 53 -
Figure 311
Install pump drive gear shaft through washer and
into spacer plate aligning shaft roll pin with hole in
spacer plate.
Figure 314
Install idler gear thrust washer on shaft, aligning hole
in washer with roll pin in shaft.
Figure 313
Position idler gear on bearing.
Figure 315
Remove check valve ball assembly.
- 54 -
Figure 316
Remove torque converter bearing.
Figure 319
Remove converter housing plug. (3rd Clutch shaft on
3 speed and High and 3rd on 4 and 6 speed.)
Figure 317
Remove oil distributor and "O" rings.
Figure 320
Remove oil distributor sleeve set screw.
Figure 318
Remove converter oil seal.
Figure 321
Using a puller as shown, remove oil distributor sleeve. (3rd and High clutch shaft.)
- 55 -
Figure 322
Remove converter housing plug. (1st and 2nd clutch
shaft.)
Figure 325
Install 1st and 2nd clutch shaft oil distributor sleeve
in converter housing, with inside diameter chamfer
up, and the notch in the distributor aligned up with
the retaining set screw hole in the converter housing.
Figure 323
Remove oil distributor sleeve set screw.
Figure 326
Apply Loctite #243 to threads of sleeve set screw.
NOTE : This set screw has a hole in it. Use caution
as not to allow any Loctite to plug hole. Install set
screw in converter housing and in oil distributor.
Figure 324
Using a puller as shown, remove oil distributor sleeve. (1st and 2nd shaft.)
Figure 327
Install set screw plug.
- 56 -
Figure 328
Install 3rd and High clutch shaft oil distrisbutor sleeve in converter housing with inside diameter chamfer
up, and the notch in the distributor aligned up with
the retaining set screw hole in the converter housing.
Figure 331
Apply a very light coat of Permatex #2 to the outer
diameter of the converter housing oil seal. Press
seal in housing with lip of seal in.
Figure 332
Install new "O" rings on converter housing oil distributor. Install oil distributor in converter housing with
long hub toward oil seal.
Figure 329
Apply Loctite #243 to threads of sleeve set screw .
(NOTE : This set screw has a hole in it. Use caution
as not to allow any Loctite to plug hole.) Install set
screw in converter housing and in oil distributor.
Figure 333
Press converter bearing in housing against shoulder.
Figure 330
Install set screw plug.
- 57 -
Figure 337
Remove sleeve "O" ring.
REASSEMBLY
(See Cleaning and Inspection Page)
Figure 334
Position ball check valve assembly in converter housing as shown.
Fugure 338
Install a new "O" ring on oil seal sleeve.
Figure 335
Tap check valve assembly in position.
Figure 339
Apply a very light coat of Permatex #2 to the outer
diameter of the output flange oil seal. Press oil seal in
oil seal sleeve. Oil seal must be flush with one side of
face of oil seal sleeve and lip of seal must be in.
Figure 336
Press output flange oil seal from seal sleeve.
- 58 -
REASSEMBLY
(See Cleaning and Inspection Page)
Figure 342
If output flange plug was removed for any reason,
install new plug as follows : Apply a light coat of
Loctite #577 to outer edge of expansion plug. Install
plug in flange. NOTE : See Figure 342A for expansion plug installation tool fabrication.
Figure 340
If the output flange or brake disc is to be replaced,
remove brake disc capscrews and washers.
Figure 342A
NOTE : PARKING BRAKE DISC MUST BE REPLACED IF BRAKE PAD WEAR EXCEEDS .065 [1,65].
Brake disc thickness new is
.375 [9,52]
Maximum brake pad wear
.065 [1,65]
Min. thickness at brake pad wear .310 [7,87]
Figure 341
Remove brake disc.
Figure 343
Position bracke disc on output flange.
- 59 -
Figure 344
Install capscrew and washers. Tighten to specified
torque. See torque chart.
Figure 347
Install reverse and forward clutch shaft rear bearing
in transmission case.
REASSEMBLY OF TRANSMISSION
(See Cleaning and Inspection Page)
Figure 345
Install forward-reverse oil distributor sleeve in transmiision case with inside diameter chamfer out,
(toward front of transmission), and the notch in the
distributor aligned up with the retaining set screw
hole in the transmission case.
Figure 348
Install rear output bearing locating ring in transmission case.
Figure 346
Apply Loctite #243 and install set screw in transmission case and in oil distributor sleeve. Install set
screw plug.
Figure 349
Install output bearing against locating ring.
- 60 -
Figure 350
Position oil seal sleeve in transmission case with
recessed portion of oil seal toward output bearing.
This leaves a space between oil seal and output
bearing.
Figure 353
Install output flange to rear bearing retainer ring.
Figure 351
Install oil seal sleeve retainer ring.
Figure 354
Install 3rd gear shaft bearing locating ring.
Figure 352
Install output flange through oil seal and rear output
bearing. Use caution as not to damage seal.
Figure 355
Install 3rd gear shaft bearing.
- 61 -
Figure 359
Position oil baffle in transmission case.
Figure 356
Position 3rd gear and shaft through bearing and into
output flange.
Figure 360
Install oil baffle capscrews and tighten to specified
torque. See torque chart.
Figure 357
Position the oil suction tube and screen in transmission case.
Figure 361
Position the forward and reverse clutch assembly
shaft through the rear needle bearing and into the oil
distributor sleeve. Use extreme caution as not to
damage or break the clucth shaft oil sealing rings.
Figure 358
Push suction tube through opening in case and install "O" ring.
- 62 -
Figure 362
With the 3rd speed clutch shaft rear pilot bearing on
shaft, install 3rd clutch assembly in 3rd clutch gear
disc hub. Align splines on 3rd gear disc hub with
internal teeth of friction discs. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs. Use caution as not to
damage pilot bearing. NOTE : A 4 and 6 speed
transmission will also have a 4th High clutch on with
3rd clutch.
Figure 364
Position new transmission case to converter housing
gasket on transmission case. A light coat of grease
will hold gasket in position.
Figure 365
Install spacer plate assembly on transmission, aligning clutch shafts with opening in spacer plate. Use
caution as not to damage oil sealing rings. Spacer
plate must be tight against transmission case. Do not
use bolts to pull spacer plate and case together. Tap
spacer plate into position at dowel pins. Install spacer plate to transmission case capscrews.
Figure 363
With the rear clutch shaft roller bearing in position on
shaft, install the 1st and 2nd clutch assembly in
transmission case.
- 63 -
Figure 366
See "NOTE" on Figure I for proper capscrew installation and torque.
Figure 369
The use of aligning studs will facilitate converter housing to spacer installation. The transmission could be
laid down to align the end of the clutch shafts into
sealing ring sleeves in converter housing . Do not
force this operation. Converter housing must be tight
against transmission spacer.
NOTE : Do not use bolts to pull converter housing in place. Install converter housing to transmission case screws and lockwashers. See
Figures I and J for proper screw location and installation.
Figure 367
Position impeller hub gear on stator support.
Figure 368
Position spacer to converter housing gasket on spacer. A light coat of grease will hold gasket in place.
Figure 370
Tighten bolts to specified torque. See "NOTE" in
Figure 369. See Figures I and J for proper screw
location and installation.
- 64 -
Figure 371
Install converter locating ring on turbine shaft.
Figure 374
With new "O" ring in place, install bore plug in
converter assembly.
Figure 372
Position converter assembly on stator support and
turbine shaft.
Figure 373
Install converter assembly retainer ring.
Figure 375
Install bore plug retainer ring.
- 65 -
Figure 376
With new "O" rings in position on the solenoid cartridges, install cartridges as explained above. The
3.100 [78,74 mm] length cartridges go in the top two
holes, the 4.100 [104,14 mm] length cartridges go in
the two (2) or three (3) bottom holes depending on
speed of transmission.
Figure 379
Install coil and wire lead assembly on cartridge.
Figure 380
With new "O" ring in position, install coil to cartridge
nut.
Figure 377
Tighten cartridges to specified torque. See assembly
instruction drawing.
- 66 -
Figure 384
With new lower end "O" ring on modulation valve
sleeve, install sleeve and spring assembly in transmission case.
Figure 381
Tighten cartridge nut per assembly instruction drawing.
Figure 385
With new "O" ring in position, install modulator valve
housing over spring and sleeve assembly.
Figure 382
On 3 speed transmission only, position new "O"
rings on the center hole bore plug. Install plug and
tighten to specified torque.
Figure 386
Tighten modulator valve housing 60-65 lbfft [81-88 Nm].
Figure 383
Install modulation diverter in trans mision case.
- 67 -
Figure 387
Install regulator valve assembly in converter housing.
Figure 388A
Figure 388
A special tool can be fabricated to tighten the regulator valve (See Figure 388A). Tighten valve assembly
sleeve 45-50 lbfft [61,1-67,7 Nm].
Figure 389
Install oil filter assembly on regulating valve. Tighten
filter 20-25 lbfft [27-34 Nm].
- 68 -
Figure 390
With new gasket in place, install charging pump in
converter housing.
Figure 393
Install caliper brake mounting screw through brake
assembly and through locknut. Apply Loctite #262 to
threads and install screw in transmission case.
Figure 391
Install charging pump to converter housing bolts and
washer and tighten to specified torque. See torque
chart.
Figure 394
Mounting screws to be installed to allow free movement of caliper pads to disc. Tighten jam nut. See
torque chart. See page 87 for brake information.
Figure 392
If auxiliary pump is used, it is not necessary to install
the permanent pump hole cover. With new gasket in
place, install pump hole cover on charging pump.
Install bolts and washers and tighten to specified
torque. See torque chart.
Figure 395
See special section on page 80 for drive plate installation.
- 69 -
SINGLE MODULATION
AND MECHANICAL INCHING
Figure 396
Remove inching valve housing.
Figure 399
Remove inching spool.
Figure 397
Remove inching return spring, actuator rod, and
regulator spring.
Figure 400
Remove modulator valve housing and "O" ring.
Figure 398
Remove inching sleeve and "O" ring.
Figure 401
Remove modulator valve outer, middle, and inner
springs and spring stop.
- 70 -
Figure 402
Remove modulation housing sleeve and accumulator spool.
Figure 405
Remove modulator valve outer, middle, and inner
springs and spring stop. Reference Figure 401.
Figure 406
Remove accumulator spool. Reference Figure 402.
Figure 403
Remove shuttle sleeve and spool.
Figure 407
Remove modulator sleeve pin.
Figure 404
Remove modulator valve body "O" ring.
- 71 -
Figure 411
Remove regulator spool sleeve assembly. Remove
"O" ring.
Figure 408
Remove regulator spool assembly retainer ring.
Figure 409
Remove regulator spool stop, spring, and spool and
sleeve assembly.
Figure 412
Remove sleeve check ball retainer pin.
Figure 410
Remove regulator spool sleeve retainer ring.
Figure 413
Remove check ball.
- 72 -
REASSEMBLY
(See Cleaning and Inspection Page)
Figure 414
Install a new "O" ring on regulator spool sleeve.
Position check ball in sleeve.
Figure 417
Install sleeve retainer ring.
Figure 418
Install housing sleeve pin.
Figure 415
Install check ball retai,er pin.
Figure 416
Position sleeve and ball assembly in regulator spool
with check ball retainer pin up.
Figure 419
Install regulator spool stop, spring, and regulator
spool and sleeve assembly in housing sleeve.
- 73 -
Figure 423
Install inching regulator spool spring.
Figure 420
Compress regulator spool spring and install retainer
ring.
Figure 421
Position new "O" ring on modulation sleeve.
Figure 424
Install inching actuator rod over spring.
Figure 422
Install a new "O" ring on inching sleeve. Install
inching spool in sleeve. Install spool and sleeve in
inching control bore.
Figure 425
Install inching return spring.
- 74 -
Figure 426
With new actuator rod oil seal in position and new
"O" ring on inching housing, install housing over
actuator rod and thread into inching bore.
Figure 429
With new "O" ring in position, install modulation housing sleeve assembly in bore.
Figure 430
Install accumulator spool in housing sleeve as
shown.
Figure 427
Tighten inching valve housing to specified torque.
See assembly instruction drawing.
Figure 428
Position shuttle spool in shuttle sleeve.Install spool
and sleeve in modulator valve bore.
Figure 431
Install stop pin, inner, middle, and outer springs in
accumulator and housing sleeve.
- 75 -
Figure 432
Position a new "O" ring on modulator valve housing.
Thread housing into valve bore.
Figure 433
Tighten modulator valve housing to specified torque.
See assembly instruction drawing.
- 76 -
Note : The disc spring packs are to be used as complete assemblies and care should be taken not to
intermix the individual disc springs with disc springs
in another clutch or disc spring pack. Service replacement assemblies are banded together and must be
replaced as asembly.
NOTES
- 77 -
CLUTCH ENGAGEMENT
REV.
FWD.
3rd
DIRECTION
CLUTCH
SPEED
CLUTCH
1st
2nd
3rd
A
A
A
C
D
E
SHIFT
SPEED
DIRECTION
CLUTCH
SPEED
CLUTCH
1st
2nd
3rd
B
B
B
C
D
E
REVERSE
1st
- 78 -
2nd
CLUTCH ENGAGEMENT
DIRECTION
CLUTCH
SPEED
CLUTCH
1st
2nd
3rd
A
A
A
C
D
E
4th
DIRECTION
CLUTCH
SPEED
CLUTCH
B
B
B
C
D
E
REV.
FWD.
REVERSE
SHIFT
SPEED
1st
2nd
3rd
4th
1st
- 79 -
2nd
3rd
Measure the "A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below.
Note : two (2) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Two (2) kits
with three intermediate drive plates.
ALIGNMENT HOLES
Backing ring
Backing ring
Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter. Align
intermediate drive plates and backing ring with holes in torque converter assembly, NOTE : Two dimples 180
apart in backing ring must be out (toward the engine flywheel). Install capscrews and washers. Tighten 26 to 29
lbfft torque [35 - 39 Nm]
- 80 -
Flywheel
housing
Engine
3. Install two 2.50 [63,500 mm] long transmission to flywheel housing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align a
drive plate mounting screw hole with the flywheel housing access hole.
Flywheel
pilot bore
Flywheel
FIG 1
Converter
housing
Flywheel
4" stud
Flywheel housing
drive plate
FIG 2
Flywheel housing
Flywheel
Impeller cover
(3) intermediate drive
plates
FIG 3
- 81 -
FIG 4
SPECIFICATIONS AND SERVICE DATA POWER SHIFT TRANSMISSION AND TORQUE CONVERTER
TRANSMISSION OUT
PRESSURE
With transmission outlet oil temperature, 180 -200 F. [82,3 - 93,3 C] and transmission in NEUTRAL. Operating specifications :
60 P.S.I. [4 bar] minimum pressure at 2000 R.P.M. engine speed AND a maximum of
120 P.S.I. [8 bar] outlet pressure with engine operating at no-load governed speed.
CONTROLS
CLUTCH TYPE
Friction.
Steel.
OIL FILTRATION
Full flow oil filter safety by-pass, also strainer screen in sump at bottom of transmission case.
CLUTCH PRESSURE
185 P.S.I. [13 bar] minimum With parking brake set (see note), oil temperature
180 - 200 F. [82,2 - 93,3 C], engine at idle (775 R.P.M.), shift thru direction and
speed clutches. All clutch pressure must be equal within 5 P.S.I., [0,35 bar]. If clutch
pressure varies in any one clutch more than 5 P.S.I., [0,35 bar] repair clutch.
Normal operating pressure 240 - 280 P.S.I. [16 19 bar] at 2000 R.P.M.
Note : ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE
CHECKS.
- 82 -
LUBRICATION
TYPE OF OIL
CAPACITY
SHELL
DONAX TA
Temperature
range "3"
(a) Dexron
(b) Dexron II D
See caution
below.
Temperature
range "4"
(a) MIL-L-46167
(b) MIL-L-46167 A
Temperature
range "5"
- 82 A -
- 83 -
PRESSURE CHECK
1) Regulated clutch pressure :
(main pressure)
Adap. mark.64
Adap. mark.64
Adap. mark.65
Adap. mark.65
Adap. mark.65
Adap. mark.65
Adap. mark.66
Adap. mark.65
TOP VIEW
3
4
5
6
62
63
63
63
63
63
63
63
63
64
64
65
65
65
65
65
66
67
67
67
67
67
67
- 84 -
Procedure
Before carrying out the pressure check, lift up and wedge the lift truck, making sure the main
wheels are not in contact with the ground.
- Fix the adapters and the pressure gauge connection onto the check ports :
The adapters Mark 64 of the kit are to be fixed onto the points 1 and 2.
The adapters Mark 65 of the kit are to be fixed onto the points 3-4-5-6 and 8.
The adapters Mark 66 of the kit is to be fixed onto the point 7.
- Bring the box oil to a temperature : 82 to 104C .
- Check the pressure with an engine speed of 2000 rpm.
- Transmission in neutral for the pressures 1 and 2.
1) Main pressure :
16 to 19 bar
Minimum pressure of 13 bar
2) Converter pressure :
4 to 8 bar
3) Forward gear pressure
4) Reverse gear pressure
5) 1st gear
Same pressure as main pressure
6) 2nd gear
7) 3rd gear
8) 4th gear
8
5
3
7
4
- 85 -
CONVERTER TIMING
Engine
1004-4T
Box
T12000
Speed
Short Drop
The engine r.p.m. on timing represents 2090 rpm whatever the ratio.
- 85-2 -
INSPECTION
The importance of careful and thoroughinspection of
all parts cannot be overstressed. Replacement of all
parts showing indication of wear or stress will eliminate costly and avoiable failures at a later date.
BEARINGS
Carefully inspect all rollers : cages and cups for
wear, chipping, or nicks to determine fitness of bearings for futher use. Do not replace a bearing cone or
cup individually without replacing the mating cup or
cone at the same time. After inspection, dip bearings
in Automatic Transmission Fluid and wrap in clean
lintless cloth or paper to protect them until installed.
BEARINGS
Remove bearings from cleaning fluid and strike flat
against a block of wood to dislodge solidified partilcles of lubricant. Immerse again in cleaning fluid to
flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air
stream across bearing to avoid spinning. Do not spin
bearings when drying. Bearings may be rotated
slowly by hand to facilitate drying process.
HOUSINGS
Clean interior and exterior of housings, bearing caps,
ect., Thoroughly. Cast parts may be cleaned in hot
solution tanks with mild alkali solutions providing
these parts do not have ground or polished surfaces.
Parts Should remain in solution long enough to be
thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water.
Parts cleaned in solution tanks must be thoroughly
rinsed with clean water to remove all traces of alkali.
Cast parts may also be cleaned with steam cleaner.
CAUTION : Care should be exercised to avoid inhalation of vapors and skin rashes when using alkali
cleaners.
All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft,
lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping compound.
- 86 -
DESCRIPTION
QUANTITY
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body (module) . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
ITEM
8
9
10
11
12
13
14
DESCRIPTION
QUANTITY
Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belleville Spring . . . . . . . . . . . . . . . . . . . . . . .
Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . . .
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
- 87 -
T12000 TRANSMISSION
T12000 (powershift with torque converter transmission troubles fall into two general categories :
mechanical problems and hydraulic problems).
TROUBLESHOOTING PROCEDURES
Stall Test : Use a stall test to identify transmission,
converter, or engine problems.
Hydraulic Check : Also, before checking the transmission clutches, torque converter, charging pump, and
hydraulic circuit for pressure and rate of oil flow, it is
important to make the following transmission fluid
check :
Transmission Pressure Checks : Transmission problems can be isolated by the use of pressure tests.
When the stall test indicates slipping clutches, then
measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction
material failure. In addition, converter charging pressure and transmission lubrication pressure may also be
measured.
- 88 -
to approximately one-half throttle and hold until transmission (converter outlet) oil temperature reaches the
operating range.
CAUTION : Do not operate the converter at stall condition longer than 30 seconds at one time, shift to neutral
for 15 seconds and repeat the procedure until desired
temperature is reached. Excessive temperature ([120
C] 250 F maximum) will cause damage to transmission
clutches, fluid, converter, and seals.
TROUBLESHOOTING GUIDE
Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
REMEDY
3. Replace pump.
3. Replace pump.
OVERHEATING
1. Worn oil sealing rings.
2. Replace.
4. Clean cooler.
NOISY CONVERTER
1. Worn charging pump.
1. Replace.
LACK OF POWER
1. Low engine R.P.M. at converter shall.
- 89 -
- 91 -
MODEL DESCRIPTION
1101 T12 4 XX - XX
OUTPUT LOCATION AND RATIO
NUMBER OF SPEEDS
T12000 TRANSMISSION
CONVERTER
1106 F
F = FREE WHEEL
MANITOU MODEL:
1106 F : MLT
- 92 -
STANDARD
SPECIAL
10 - 19
50 - 59
20 - 29
40 - 49
60 - 69
90 - 99
T = HR MODEL
MT = MHR MODEL
S. D.
L. D.
I. D.
- 93 -
BOOST PUMP
EXTERNAL, LOCATED AT REAR SIDE OF TRANSMISSION
CHARGING PUMP
BOOST PUMP
46,2
ON TRANSMISSION
- 94 -
FILTER: SPIN-ON
MIN AT
1800
RPM
CONTROLS
SOLENOIDS ENERGIZED
FWD.
REV.
A, D, E
B, D, E
A, E
B, E
A, C
B
A
C
D
E
- ELECTRONIC SENSORS
3 - TURBINE SPEED SENSOR
- 95 -
MODULATION
MODULATION
- 96 -
DUAL VALVE
MODULATION
vent
REV - CLUTCH
FWD - CLUTCH
- 97 -
BAR
21
20
19
17
15,5
15
14
12
10
10
7
5
3,5
2
1,75
- 98 -
HYDRAULIC CIRCUIT
DUAL MODULATION
CLUTCH PRESSURE
REGULATOR VALVE
FILTER
COOLER
SAFETY
PUMP
CONVERT.
- 99 -
MODULATION
MODULATION
VALVE
HYDRAULIC DIAGRAM
DUAL MODULATION
MODULATION
MODULATION
OPERATOR COMPARTMENT
TEMP.
PRESSURE
GAUGE
GAUGE
CLUTCH
PRESSURE
REGULATOR
VALVE
REV
HOSE
FWD slow
SAFETY
VALVE
FWD high
4th speed
COOLER
TORQUE
3rd speed
FILTER
CONVERTER
PUMP
2nd speed
HOSE
LUBRICATION
FILTER
AIR
BREATHER
1st speed
OIL SUMP
4 SPEED SHIFT DIAGRAM
FORWARD
REVERSE NEUTRAL
X = SOLENOID ENGAGED
PRESSURE REGULATOR
VALVE
SAFETY VALVE
TORQUE
CONVERTER
CONTROL VALVE
VIBRATION
FREQUENCY
- 101 -
SPEED
INPUT
REV
FWD
FWD
ST
INPUT
HI
ND
FWD
FWD
FORWARD 3TH
FWD
OUTPUT
ST
HI
HI
RD
RD
OUTPUT
ND
FORWARD 2ND
REV
FWD
RD
FORWARD 1ST
INPUT
REV
ST
INPUT
HI
REV
FWD
RD
FWD
OUTPUT
ND
FORWARD 4TH
- 102 -
ST
ND
OUTPUT
ENTRE
REV
FWD
FWD
ST
INPUT
HI
ND
FWD
FWD.
FWD
OUTPUT
REVERSE 2ND
REV
ST
HI
FWD
RD
REVERSE 1ST
INPUT
REV
RD
OUTPUT
ND
REVERSE 3TH
- 103 -
ST
ND
HI
RD
OUTPUT
- 104 -
TO STARTER
SOLENOID
START
PREHEAT
DRIVE
DECLUTCH
REQUEST ON/OFF
(ON PEDAL)
g/n
REVERSE
RELAY
TURBINE
SPEED
g/n
2x21w
j/vt
j/vt
bl
n/s
ro
g/n
COILS
bl
g/n
n/s
j
ro
r
jvt
jvt