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Service Manual - Dana Corporation

1. T40000 LD 03 98 9 1 Assembly instructions 9 ASSEMBLY INSTRUCTIONS coNriNUED All lead in chamfers for oil seals piston rings and 05 must be smooth and free from burrs Inspect as assembled Prelube before assembly All piston ring grooves and O rings with Multi purpose grease Grade 2 Apply thin coat of Loctite 638 colour green to outside diameter of all oil seals bore plugs and bores they are to be installed into before assembly Use extreme care not to allow sealant to come into contact with seal lip material Apply thin coat of Loctite 270 colour green to all through hole stud threads which do not have pre applied sealant Apply thin coat of Vibra Seal 516 colour burnt orange to all pipe thread fittings which do not have pre applied sealant If grease is required for positioning gasket during assembly use Multi purpose grease Grade 2 After assembly of parts using Loctite there must not be any free excess material which might enter the oil circuit Only use Loctite where specified General bearing installation procedure If a thermal assembly aid is used expanding by heating 135 14 275 25 a check must be made after mating parts have reached the same temperature within 11 C 20 of ambient to be sure t
2. T40000 LD 03 98 10 54 Disassembly impeller cover and turbine assembly Figure 278 Figure 281 Block impeller cover and turbine assembly as shown Hemove turbine hub bolts and lock tabs Remove turbine hub to front bearing retainer ring Figure 279 Remove turbine hub bearing washer Figure 280 Tab turbine hub from front bearing T40000 LD 03 98 10 55 Reassembly impeller cover and turbine assembly Figure 282 Align holes in turbine with holes in turbine Position lock tabs and install turbine to turbine hub bolts Tighten bolts to specified torque See torque chart Bend a corner of the lock tab over a flat of the bolt heads Figure 285 Install bearing retaining ring Figure 283 Center impeller cover over turbine hub Install impeller cover bearing in impeller cover and over turbine hub Tap bearing into place Figure 284 Install bearing washer T40000 LD 03 98 10 56 Disassembly pump drive gear Figure 286 Remove bearing and support retaining ring
3. 7 4 34 le LUBE 4375 20 SAE RING PORT PORT 41 m CHECK PORT 1ST CLUTCH PRESSURE d 4375 20 SAE 0 RING PORT ag J 1 g FULL OIL LEVEL CHECK PORT 1 4 NPT LOW OIL LEVEL CHECK PORT 1 4 NPT LEFT SIDE VIEW PORT 31 CLUTCH PRESSURE PORT 36 4375 20 SAE CONVERTER MET PRESSURE RING PORT 4375 20 SAE RING PORT LIFTING EYE OIL FILL HOLE 75000 10 UNC 2B THDS 3 4 NPT 1 1250 28 57 DEEP FRONT LIFTING EYE LOCATION 7500 10 UNC 2B THDS 1 1250 28 57 DEEP BREATHER 3 4 NPT TOP VIEW T40000 LD 03 98 Troubleshooting guide 7 4 CHECK POINTS CONTINUED PORT 11 CONVERTER OUTLET TO COOLER 1 3125 12 SAE O RING PORT T40000 LD RIGHT SIDE VIEW 03 98 SPEED SENSOR PUMP DRIVEN GEAR PORT 45 CHECK PORT FWD CLUTCH PRESSURE 4375 20 SAE O RING PORT PORT 12 FROM COOLER 1 3125 12 SAE RING PORT SPEED SENSOR CLUTCH DRUM GEAR PORT 34 LUBE 4375 20 SAE RING PORT 7 6 Troubleshooting guide 7 5 ELECTRICAL WIRING BATTERY IGNITION STARTER ENGINE STARTER 28
4. T40000 LD 03 98 10 22 Disassembly of forward clutch Figure 118 Figure 121 Remove clutch shaft oil sealing rings piston rings Remove clutch gear outer bearing retaining ring Figure 119 Figure 122 Remove front bearing retaining ring Remove clutch gear and outer bearing cone Figure 120 Figure 123 Hemove front bearing inner race Remove clutch gear inner bearing cone T40000 LD 03 98 10 23 Disassembly of forward clutch A St G Figure 124 Figure 127 Remove clutch gear inner bearing cone retaining Remove inner and outer clutch discs ring Figure 125 Figure 128 Remove end plate retaining ring Compress piston return spring Hemove spring retaining ring Figure 126 Figure 129 Remove end plate Remove spring retainer T40000 LD 03 98 10 24 Disassembly of forward clutch Figure 130 Figure 133 Remove piston return spring Remove clutch shaft rear bearing Figure 131 Remove clutch piston Figure 132 Hemove clutch shaft rear bearing retaining ring T40000 LD 03 98 10 25 Reassembly forward clutch Figure 134 Warm bearing to 110 C 230 F Install clutch shaft rear bearing Note bearing outer retainer ring groove must
5. 0 0 0 936 0 934 0 932 0 930 0 928 0 926 0 924 0 922 0 920 0 918 0 916 0 914 0 912 0 910 0 908 0 906 0 904 0 902 0 900 0 898 0 896 0 894 0 892 23 774 100 23 724 23 673 23 622 23 571 23 520 23 470 23 419 23 368 23 317 23 266 23 216 23 165 23 114 SHIM GAP IN INCHES mm 23 063 THIS CHART IS FOR PLOTTING USE 23 012 22 962 22 911 22 860 22 809 22 758 22 708 22 657 11 3 90 10 2 80 9 0 10 7 9 60 6 8 50 5 6 40 4 5 30 3 4 20 2 3 1 1 0 0 0 936 0 934 0 932 0 930 0 928 0 926 0 924 0 922 0 920 0918 0 916 0 914 0 912 0 910 0 908 0 906 0 904 0 902 0 900 0 898 0 896 0 894 0 892 23 774 23 724 T40000 LD 23 673 23 622 23 571 23 520 23 470 23 419 23 368 23 317 23 266 23 216 23 165 23 114 GAP IN INCHES mm 03 98 23 063 23 012 22 962 22 911 22 860 22 809 22 758 22 708 22 657 N m N m 9 7 Assembly instructions 9 3 CONTROL VALVE BOLT TIGHTENING SEQUENCE DIAGRAM F 1 D 4 7 l _ 8 __ 4 NON MODULATION MODULATION 1 il E ON Jt 2 1 34 2 13 4 Or X 2
6. Figure 242 Hemove idler shaft gear T40000 LD 03 98 10 46 Reassembly idler shaft Figure 244 Install idler shaft gear retaining ring Figure 247 Install idler shaft front bearing inner race Figure 245 Figure 248 Install idler shaft gear with long hub down Install idler shaft front bearing outer race Tr j lh W AR Uu AN D Ki i M V URB M M Figure 246 Figure 249 Install idler shaft gear retaining ring Install 4th clutch disc hub T40000 LD 03 98 10 47 Reassembly idler shaft Figure 250 Install clutch disc hub retaining ring T40000 LD 03 98 10 48 Disassembly of turbine shaft Figure 251 Figure 254 Hemove turbine shaft piston ring Pry front bearing from shaft Figure 252 Remove turbine shaft front bearing retaining ring Figure 253 Remove front bearing washer T40000 LD 03 98 10 49 Rea
7. ISSIOn Operation of the transm 6 3 1 Neutral and 4th clutch engaged Continued NWA E 3NWA 3NWA NOLLVINGON NOLLYINGOW NOLLWINGOW N 55 IONOS QION3108 QION3108 QION310S 053105 CIONSTOS e NOT WNOILdO 3su3Aau WNOLLdO Que ON 15 WNOILdO 472 591 JAVA HOLVINDSY 3unss3ud H3LH3ANOI ISOH 431009 3S0H 3nouoL C 2 gt 2 194 O H i 1 ONDOVED 90 11 68 3NWA AL33vS HOdwo3Ho gt X O 391 9 3onv9 e X 3ufiSS3ud 03395 E aa5v5N3 HILNTO ANV IN3WLHVANON HOLVH3dO NOISSINSNVHL 00007 ission Operation of the transm 6 3 2 Forward 1st speed 1st SPEED FORWARD POWERFLOW 2nd H N N 2 7 N A 2 u 7 7 1st SPEED FORWARD ACTIVATED SOLENOIDS 1st SPEED FORWARD ACTIVATED SPOOLS 6 9 03 98 T40000 LD ission Operation of the transm 6 3 2 Forward 1st speed Continued HOLATO 917207 gt leq INWA NOLLYINCON N omg 41001 TNOLLdO HOLATO 3533 33 gt req S JAVA NOIL
8. 8 16 GROUP SPEED CLUTCH SHAFT 8 18 GROUP REVERSE AND 2ND CLUTCH SHAFT tr 8 20 GROUP LOW 1ST SPEED CLUTCH SHAFT ete 8 22 GROUP 4TH SPEED CLUTCH SHAFT ttt 8 24 GROUP IDLER SHAFT cecsescessecsecsecceccecsecsescecsucsuccucsecsecsucsucsecsucsucsacsarsecsecsacsassersetsecsetsecseeee 8 26 GROUP OUTPUT tette ttt ttt ttt 8 28 GROUP PRESSURE REGULATING VALVE amp CHARGING PUMP 8 30 GROUP ELECTRIC CONTROL VALVE ettet tt 8 32 T40000 LD 03 98 9 ASSEMBLY INSTRUCTIONS 9 1 9 2 9 3 9 4 LOW 1ST CLUTCH TAPER BEARING enne 9 4 9 1 1 General bearing installation proce REENEN 9 4 Taper bearing adjustment gege 9 4 LOW 1ST CLUTCH TAPER BEARING ADJUSTMENT PLOTTING CHARTS 9 7 CONTROL VALVE BOLT TIGHTENING SEQUENCE DIAGRAM 9 8 SPEED SENSOR BUSHING INSTALLATION arte a ocio 2 2 aa 9 8 10 DISASSEMBLY AND REASSEMBLY OF THE T40000 TRANSMISSION 11 OPTIONS 11 1 T40000 LD REC eee 11 1 11 1 1 Sectional views and parts identification 11 1 PR Wl TE e le td ee 11 4 11 1 3 Disassembly Section 11 5 11 1 4 Reassembly 11 7 03
9. Not used on all models T40000 LD 03 98 Quantity OO 07 KH P P 1 Only used with total neutra 8 33 9 ASSEMBLY INSTRUCTIONS
10. From cooler to transmission lube distributor RIGHT SIDE VIEW FRONT VIEW Filter type B From filter To filter 5 heo REAR SIDE VIEW 5 3 1 Cooler lines specifications Minimum 31 7 mm 1 25 inch internal diameter for lines and fittings Suitable for operation from ambient to 120 C 248 continuous operating temperature Must withstand 20 bar 290 psi continuous pressure and with 40 bar 580 psi intermittent surges e Conform SAE J1019 and SAE 517 100 T40000 LD 03 98 5 3 6 OPERATION THE TRANSMISSION 6 1 THETRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies 1 DJ converter pump drive section and pressure regulating valve 2 P he input shaft and directional clutches The range clutches 4 ES The output section 5 E The transmission control valve T40000 LD 03 98 6 1 Operation of the transmission 6 1 1 The converter pump drive section and pressure regulating valve Engine power is transmitted from the engine flywheel to the impeller through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be compared to a centrifugal pump in that it picks up fluid at its centre and discharges it at the outer diameter The torque converter turbine is
11. Figure 287 Remove bearing and support T40000 LD 03 98 10 57 Reassembly pump drive gear Figure 288 Press support in bearing Press bearing and support assembly in gear Figure 289 Install bearing retaining ring T40000 LD 03 98 10 58 Reassembly convertor housing Figure 290 Position pump drive gear and bearing assembly in converter housing Figure 293 From front of housing install turbine shaft bearing locating ring Tap shaft until bearing locating ring shoulders in groove in housing Figure 291 Align holes in pump drive gear bearing support with holes in converter housing Install bolts and washers and tighten to specified torque Figure 292 From the rear of the housing Tap turbine shaft and bearing in converter housing Tap shaft until gear shoulders against converter housing T40000 LD Figure 294 Install new sealing ring on support Position support on turbine shaft Turn suppor
12. lt gt SPICER Off Highway Products Service Manual Powershift Transmission T40000 Long Drop TSM 0116 March 1998 TOWING PUSHING Before towing the vehicle be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing Note IF THE TRANSMISSION HAS 4 WHEEL DRIVE DISCONNECT BOTH FRONT AND REAR DRIVELINES BECAUSE OF THE DESIGN OF THE HYDRAULIC SYSTEM THE ENGINE CANNOT BE STARTED BY PUSHING OR TOWING Copyright Dana Corporation 1998 Unpublished material All rights reserved Limited Distribution No part of this work may be reproduced in any form under any means without direct written permission of the Dana Corporation T40000 LD 03 98 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER CLARK HURTH product Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjustments it is urged that the mechan
13. 1st speed clutch taper bearing adjustment T40000 LD 11 97 10 67 Reassembly of transmission Figure 341 Figure 344 Install reaction member spacer Install turbine locating ring on turbine shaft Note This is the thinnest of the two turbine to turbine shaft snaprings Figure 342 Figure 345 Install reaction member Position new on impeller cover X Figure 343 Figure 346 Install reaction member retainer ring Install impeller cover and turbine assembly on 1 turbine shaft T40000 LD 11 97 10 68 Reassembly of transmission WS x Figure 347 Figure 350 Install impeller cover to impeller bolts and Position flex plates Install flex plates mounting lockwashers Tighten bolts to specified torque screws See converter drive coupling Figure 348 Figure 351 Install turbine retaining ring If used install pump hole covers and pump Note this is the thickest of the two rings adaptors torque cover screws to specified torque Figure 349 Figure 352 o Position a new impeller cover Position new O rings on pressure bearing cap install bearing cap regulator valve Install pressure regulating valve and charging pump on housing T40000 LD 11 97 10 69 Reassembly of transmission Figure 353 Figure 356 Install regulating valve to housing bolts and Position new control valve gasket on housing X lockwashers Tighten bolts to specified torque Fi
14. 80 9 0 70 79 60 6 8 50 5 6 lbf in 40 4 5 30 3 4 20 2 3 10 1 1 0 Le 0 0 0 936 0 934 0 932 0 930 0 928 0 926 0 924 0 922 0 920 0 918 0916 0914 0912 0910 0908 0 906 0 904 0 902 0 900 0 898 0 896 0 894 0 892 23 774 23 673 23 571 23 470 23 368 23 266 23 165 23 063 22 962 22 860 22 758 22 657 3 724 23 622 23 520 23 419 3 317 23 216 23 114 23 012 22 911 22 809 22 708 SHIM GAP IN INCHES mm T40000 LD 03 98 9 5 Assembly instructions 9 1 2 Taper bearing adjustment Continued The Best fit straight line through the data points where the line crosses zero is 23 419 0 922 Subtract average A and B dimension 22 149 0 872 D This is 1 270 0 050 F shim gap No preload no endplay To this F 0 050 shim gap add 0 0254 0 006 0 001 inch Final shim pack 1 40 1 44 0 055 0 057 This is an example only See page 9 7 for plotting charts T40000 LD 03 98 9 6 Assembly instructions 9 2 LOW 1ST CLUTCH TAPER BEARING ADJUSTMENT PLOTTING CHARTS Ibf in Ibf in 100 THIS CHART IS FOR PLOTTING USE 11 3 90 10 2 80 9 0 10 7 9 60 6 8 50 5 6 40 4 5 30 3 4 20 2 3 1 1
15. A Note THE TRANSMISSION FLUID MUST BE AT OPERATING TEMPERATURE OF 82 93 C 180 200 To OBTAIN CORRECT FLUID LEVEL AND PRESSURE READINGS Do NOT ATTEMPT TO MAKE THESE CHECKS WITH COLD OIL To raise the oil temperature to this specification it is necessary to either operate work the vehicle or run the engine with converter at stall Refer to 7 2 1 Stall test CAUTION BE CAREFUL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND CONVERTER AT STALL RPM 14000010 03 98 Troubleshooting guide 7 3 TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles 7 3 1 Low clutch pressure CAUSE 1 Low oil level 2 Clutch pressure regulating valve stuck open 3 Faulty charging pump 4 Broken or worn clutch shaft or piston sealing rings 7 3 2 Low charging pump output CAUSE 1 Low oil level 2 Suction screen plugged 3 Defective charging pump 7 3 3 Overheating Cause 1 Worn oil sealing rings 2 Worn charging pump 3 Low oil level 4 Dirty oil cooler 5 Restriction in cooler lines 7 3 4 Noisy converter Cause 1 Worn charging pump 2 Worn or damaged bearings 7 3 5 Lack of power Cause 1 Low engine RPM at converter stall 2 See Overheating and make same checks REMEDY 1 Fill to proper level Clean valve spool and housing Replace pump po m Replace sealing rings R
16. Snap ring Seal Pump drive shaft oil Plug Ring Retaining Spring Wave Assembly Thrust plate and bearing Assembly Thrust plate and bearing Assembly Pump drive shaft Assembly Pump driven shaft Seal Pump shaft 03 98 Quantity PO NNN sch N sch HH sch sch M NM sch sch sch 8 31 GROUP ELECTRIC CONTROL VALVE T40000 LD 03 98 8 32 GROUP ELECTRIC CONTROL VALVE Item c PS GO Description Housing Solenoid control Assembly Spool type solenoid cartridge Cartridge Spool type cartridge cartridge cartridge cartridge to coil Coil Solenoid O ring Coil to nut Nut Solenoid Plug Solenoid Solenoid plug Solenoid plug Gasket Solenoid housing to control valve housing Screw Solenoid housing to control valve housing Lockwasher Solenoid housing to control valve housing Housing Control valve Plug Pipe Spool Forward and reverse Spring Forward and reverse spool Spool 2nd speed Spool Range Spool 1st and 3rd speed Spring Spool Spring Spool Valve housing plug Valve housing plug Gasket Control valve housing to converter Screw Valve mounting Screw Valve mounting Lockwasher Valve mounting screw
17. Converter housing to front cover screw lockwasher Input shaft bearing Front cover Input shaft oil seal Input shaft flange Input shaft flange O ring Input shaft flange washer Input shaft flange nut Front cover drainback hose adapter Front cover drain back hose Drain back hose to transmission fitting Fitting O ring 03 98 Quantity sch Disassembly Section 11 1 3 Disassembly MHR Section Figure 1 Figure 4 Overall view of the transmission Remove bolts and lockwashers securing converter housing front cover to converter housing Figure 2 Figure 5 Remove input flange nut washer and O ring Hemove converter housing front cover Figure 3 Figure 6 Hemove drain hose from front cover as shown Remove input shaft support bearing T40000 03 98 11 5 Disassembly Section Figure 7 Remove input shaft mounting bolts Figure 8 Input shaft removed T40000 03 98 11 6 Reassembly Section 11 1 4 Reassembly Section Reassemble transmission following step by step procedures as explained in the T40000 LD section up to an
18. IGNITION RELAY SPEED ENERGISED WIRES Ri ELEM cr T40000 LD 03 98 3 R4 Be si 3 ome 7 7 8 SECTIONAL VIEWS AND PARTS IDENTIFICATION T40000 LD 03 98 8 1 8 2 03 98 GROUP CONVERTER HOUSING T40000 LD GROUP CONVERTER HOUSING Item Description Quantity 1 Assembly Converter housing and tube 1 2 Plug port 7 3 O ring 7 4 Plug Oil lube return 1 9 O ring 1 6 Assembly Forward pressure tube 1 7 Tube 3rd pressure 1 8 Tube 4th pressure 1 9 Clip Tube 3 10 O ring 3 11 Screw Tube retaining 3 12 Lockwasher Retaining screw 3 13 Tube Valve oil supply 1 14 Sleeve Tube 2 15 Sleeve Converter housing Forward and Low 1 16 Sleeve Converter housing Reverse and 2nd 1 17 Sleeve Converter housing 3rd amp 4th clutch 1 18 Lock Converter housing sleeve 19 Screw Sleeve lock 3 20 Lockwasher Sleeve lock screw 3 21 Plug 1 22 Seat Safety valve 1 23 Plunger Pressure relief valve 1 24 opring Pressure relief valve 1 25 Retainer Valve seat 1 26 Washer 1 27 Ring Retaining 1 28 Assembly Modulator bypass tube 1 29 Pin Converter housing to transmission case dowel 2 30 Screw Converter housing to transmission case 14 31 Screw Converter housing to transmission c
19. 00007 Operation of the transmission 6 4 GEAR AND CLUTCH LAYOUT Input Shaft Forward Reverse and 2nd EE Ist Output Section T40000 LD 03 98 6 19 7 TROUBLESHOOTING GUIDE FOR THE T40000 TRANSMISSION The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and correct functioning of the other components of the group Therefore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid charging pump torque converter transmission assembly oil cooler filter connecting lines and controls including the engine as a complete system By analyzing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system 7 1 T40000 TRANSMISSION 140000 power shift with torque converter transmission troubles fall into three general categories 1 Mechanical problems 2 Hydraulic problems 3 Electrical problems In addition to the mechanical and electrical components all of which must be in the proper condition and functioning
20. 10 inch lbs increment The difference between dimension A and B must not exceed 0 1270 mm 0 005 inch If variation greater than 0 1270 mm 0 005 inch occurs start seating procedure over beginning at bearing installation procedure Plot on the bearing record chart the average measurement of A and B at each 1 13 N m 10 inch Ibs increments Draw a Best fit straight line through the data points plotted on the record chart The gap value where the line crosses Zero torque minus the average of previously recorded A and B is the no endplay no preload shim gap To this gap add 0 1524 0 0254 mm 0 006 0 001 inch to equal final shim gap Establish the shim pack using a micrometer measure each shim to obtain the total shim pack compliment Measure the total shim pack to check if it equals exactly the total sum of each shim If the pack compliment does not equal the total sum then repeat the shim pack selection process from the beginning After proper low 1st speed clutch taper bearing adjustment is made remove bearing cap and install a new clutch shaft oil sealing ring new O rings on clutch pressure sleeve lube sleeve and bearing Install pressure and lube sleeve Install bearing cap with proper shim pack Install stud nut lockwashers and stud nuts and tighten to 55 6 61 0 N m 41 45 108 ft Rotate output shaft to seat bearings and recheck stud nut torque EXAMPLE 100 11 3 90 10 2
21. 3 4 x 4 3 4 0 5 5 Tighten control value mounting screw to 31 33 8 N m 23 25 161 ft 9 10 13 7 I Geh LI Tighten cartridge to 22 27 N m 16 20 Ibf ft _____ cartridge nuts to 5 7 N m 4 5 Ibf ft 9 4 SPEED SENSOR BUSHING INSTALLATION 1 390 0 007 35 3 0 18 o OL 10 D a 9 7 1 060 0 007 26 9 0 18 SHIM TYPE BUSHING Assemble Speed Sensor Bushing with shims Clean thread on bushing and housing with Loctite cleaner Use Loctite No 270 or No 262 on both bushing and housing Tighten bushing Q to 45 50 Ibf ft 61 68 N m torque T40000 LD 03 98 9 8 Disassembly 40000 LD transmission 10 DISASSEMBLY AND REASSEMBLY OF THE T40000 TRANSMISSION Figure 1 Figure 4 oide view Remove impeller cover bearing and O ring Figure 2 Figure 5 Hemove flexplate mounting screws Remove turbine shaft outer retainer ring Figure 3 Figure 6 Remove flexplates Remove impeller to impeller cover mounting screws T40000 LD 03 98 10 1 Disassembly 40000 LD transmission Figure 7 Figure 10 Using pry slots provided pry impeller cover and Remove reaction member retainer ring turbine from turbine shaft Figure 8 Figure 11 Hemove impeller cover and tu
22. FORWARD oS SUPPLY eg Me ER JH A E LES 7 RN REVERSE A en at E P PO Hn E NB TEM Y MM R 2 3 I R 2 3 ard SPEED FORWARD ACTIVATED SOLENOIDS ard SPEED FORWARD ACTIVATED SPOOLS T40000 LD 03 98 6 13 ission Operation of the transm 91907 leq NOLLYINAON 3583 33 req Ou JAVA NOLLYINAON WNOILdO 6 3 4 Forward 3rd speed Continued 1804 WOH 31 1804 COU 39085394 HOLNTO BI ANV QHVMHOJ HOLATO req 93 JAVA NOLLYINAON WNOILdO 3S0H req NL 4 1083105 8 100 OV 8 1002 6 14 HOLM HOLM HOLNTO ONE 15 gt gt gt 199 199 199 4405 10 N d3H1V388 Pic 1 3AWA SSVdAd LL ie 77 L OZ 991 Te JAVA 3uiss3ud 2 C bod Do req C EI 9 N 9 1 34055384 98071 68 JAWA AL34VS Sen er 03395 t Q IN3SWIHYdNON HO1VH3dO NVHSVIA NOISSINSNVHL 00007 S oO e ission Operation of the transm 6 3 5 Forward 4th speed 4th SPEED FORWARD POWERF
23. GROUP PUMP DRIVE 2 x 2 7 2 2 p D x iR 2 DS ie 2 75 47 Be De p SCH 7 s P id e e 2 e E Pd Dos 2 7 In a gt 7 y baeo S M NR Meet NN M ue IE M cS Sus 25 d l VW AWA N NON N IH 7 FR 2 SN z 4 12 N f AE DUE B ON S pp Td 25 dp 11 o SC ed 377 NE 2 pou Ae 4 4 2 M DECHE KA xt 72 1 i 1 E7 7 4 2 ge f 22 y A amp PA D E ez d LA E Ou ul 17 45 dux Lu 6 1 ft MM ER 03 98 14000010 GROUP PUMP DRIVE Item c PS CH 14000010 Description Support Pump drive bearing Screws Bearing support O ring Bearing support screw Washer Flat Lockwasher Bearing pump screw Screw Bearing support Bearing Pump drive gear Snap ring Pump gear Gear Auxiliary pump drive RH Gear Auxiliary pump drive LH Gear Charge pump drive Gear Impeller hub Snap ring Impeller hub gear 03 98 Quantity CO 0 8 15 GROUP FORWARD CLUTCH SH
24. Solenoid and solenoid cartridge torque 2 3 3 3 4 PRESSURE AND TEMPERATURE SPECIFICATIONS 3 4 35 ee ana 3 5 3 6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS 3 5 4 MAINTENANCE EE 4 1 2 1 1 Recommended dee 4 1 Eh NEE TER RE 4 2 RE 4 2 4 2 2 Normal drain 4 2 4 3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL 4 3 5 INSTALLATION DETAILS D CONVERTER DRIVE COUPLING eu ae he 5 1 5 2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 5 2 EXTERNAL PLUMEING eege 5 3 5 3 1 Cooler lines specifications ee en eier len rn 5 3 T40000 LD 03 98 l i 6 OPERATION OF THE TRANSMISSION 6 1 6 2 6 3 6 4 THE TRANSMISSION ASSEMBLY att on int 6 1 6 1 1 The converter pump drive section and pressure regulating valve 6 2 6 1 2 The input shaft and directional clutches uisus iubeo hind atado Pup Ee Dd dag cup o 6 3 6 1 3 The range te 6 4 6 1 4 Eeer 6 4 6 1 5 The transmission controls refer to hydraulic diagram 6 5 ELECTRIC SOLENOID CONTROLS at ds teu moenium 6 6 POWER FLOWS ACTIVATED SOLENOIDS SPOOLS AND
25. TAP AND CLEANED WITH SOLVENT DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION gt Select the thickest of the clutch gear retaining rings that can be installed into the retaining ring groove to assure proper bearing tightness Tighten oil screen assembly 13 20 N m 10 15 ft bel 9 1 LOW 1ST CLUTCH TAPER BEARING ADJUSTMENT gt 9 1 1 General bearing installation procedure If a thermal assembly aid is used expanding by heating up to 135 14 275 F 25 F a check MUST be made after mating parts have reached the same temperature within 11 C 20 F of ambient to be sure bearings are positioned solidly against their respective shoulders before bearing adjustment can be made This check must be made when installing the front and rear bearings on the low 1st clutch shaft and before clutch assembly is installed in the transmission housing 9 1 2 Taper bearing adjustment Build up transmission as explained in assembly section of the service manual through converter housing installation on transmission housing Place transmission assembly in a horizontal position with low 1st clutch vertical low clutch rear taper bearing up If the clutch shaft rear bearing cap was temporarily installed remove bearing cap This bearing adjustment must be made with the bearing cap O ring clutch pressure sleeve lube sleeve and clutch shaft rear oil sealing ring removed Measure thickness of bearing cap D with a micr
26. Tighten screws to specified torque T40000 LD 11 97 10 62 Reassembly of transmission Figure 311 Figure 314 From the rear install output gear retaining ring Install rear bearing cap nuts and lockwashers Tighten nuts to specified torque See torque chart Figure 312 Figure 315 Install rear taper bearing cone with large diameter of Tap and rotate output shaft to seat taper bearings loosen rear bearing cap nuts Using an inch Ib torque wrench determine the rolling torque of the taper In output shaft and record Tighten rear bearing cap nuts to specified torque Check rolling torque with nuts tight Torque must 4 to 10 inch 05 0 46 1 1 Nm more than when bearing cap nuts were loose Add or omit shims on the rear bearing cap to achieve the proper preload 8 m Figure 313 x Figure 316 Coat outer diameter of oil seal with Loctite 638 From the front position the forward clutch and press seal in the output shaft bearing cap assembly into housing with lip of seal in Using new O ring install rear Push clutch shaft rear bearing through housing bore output bearing cap and shims on transmission case From the rear open rear bearing snap ring tap clutch shaft till snap ring is in bearing groove T40000 LD 11 97 10 63 Reassembly of transmission Figure 317 Figure 320 From the rear install 3rd speed clutch T Install idler shaft rear bearing Retaining ring asse
27. V ES zen 0 227 M d 177 Ww pus e 22 A NES Ad E LAVA A N N 7 7 2 MM RE LEE 2 l y 2 T 17 n 7 ve Kack SS see gt V ere yo Cu E NS Xn tT mp d Ux CO Ta TTT 177 Wf Btn e Fil s tur cl X e 7 7 7 d 5 1 1 4 AUN ZN 2 207 NN E EC pe IN 7 7 SE aN 4 Wee m a ar Fr NNNM Ve why gt 2 Wu ner D Sex 27 Ge N Ay ui 27 77 7 N e y 7 l KE e 7 7 bu je _ 7 E et ory Foy det Ft 5 j P 2272 Cz N T jte cea N we 4 7 p A en 1 MD go ue aw Vg IA we N Me 7957 7 un pu E d Hu NI lt uw p WS ur DERE Mc ML gt m er T40000 LD 03 98 8 28 GROUP OUTPUT SHAFT Item c PS 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Description Shaft Output Cup Front bearing Cone Front bearing Ring Output gear retaining Cup Rear bearing Cone Rear bearing Seal Bearing cap oil O
28. ring Rear bearing cap Stud Rear bearing cap Lockwasher Rear bearing cap stud Nut Rear bearing cap stud Shim Rear bearing cap Cap Rear bearing Cap Front bearing Front bearing cap Cap screw Front bearing cap Lockwasher Bearing cap screw Plug Bearing cap bore O ring Output flange Washer Output flange Nut Output flange Flange Output front Flange Output rear Gear Output shaft AR As required T40000 LD 03 98 Quantity gt po O Ss ll H HAH AH 9 29 GROUP PRESSURE REGULATING VALVE amp CHARGING PUMP 8 30 03 98 T40000 LD GROUP PRESSURE REGULATING VALVE amp CHARGING PUMP Item c PS 14000010 Description Assembly Regulator valve and charging pump O ring Regulator valve pilot O ring Clutch pressure supply screw Valve to converter housing Lockwasher Valve to converter housing screw Tube Suction pump Gasket Retainer Coupling Fitting Pump suction adapter Pump suction adapter Housing Pressure regulator valve Gasket Valve body to pump Housing Charging pump Screw Valve to pump Screw Valve to pump Lockwasher Valve to pump screw Spool Valve regulator Spring Valve inner Spring Valve outer Cup Valve spring retainer Piston Safety valve Spring Safety valve piston Retainer Piston spring
29. with steam cleaner CAUTION CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS 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 fillings contaminated oil or lapping compound 2 2 INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date 2 2 1 Bearings Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further 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 14000010 03 98 2 1 Cleaning inspection and legend symbols 2 2 2 Oil Seals Gaskets Etc Replacement of spring load oil seals O rings metal sealing rings gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particularly when being installed Cutt
30. 03 98 10 14 Disassembly reverse and 2nd clutch Figure 83 Remove piston return spring Figure 84 Hemove clutch piston T40000 LD 03 98 19 19 Disassembly 2nd clutch Figure 85 Figure 88 Remove end plate retaining ring Compress piston return spring Remove return spring retainer ring Figure 86 Figure 89 Remove end plate Remove spring retainer Figure 87 Figure 90 Remove inner and outer clutch discs Remove piston return spring T40000 LD 03 98 10 16 Disassembly 2nd clutch Figure 91 Remove spring retainer Figure 92 Remove clutch piston T40000 LD 03 98 10 17 Reassembly 2nd clutch Figure 93 EN Figure 96 Make sure clutch piston bleed valve is clean and Install clutch piston return spring free of foreign material Install inner seal ring Install piston outer piston ring Lock piston ring joint securely P Grease ring t
31. 1 IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number 3 2 WEIGHT DIMENSIONS OIL CAPACITY MHR HR Weight dry 850 kg 1870 Ib Maximum length 1141 4 mm 44 94 1026 1 mm 40 40 Maximum width Modulated 740 3 mm 29 14 740 3 mm 29 14 Standard 693 8 mm 27 31 693 8 mm 27 31 Maximum height 1186 2 mm 46 70 1186 2 mm 46 70 Oil capacity 45 12 US Gallon without cooler and hydraulic lines Consult operators manual on applicable machine for system capacity T40000 LD 03 98 3 1 Technical specifications 3 3 TIGHTENING TORQUES 3 3 1 Torque specifications for lubricated or plated screw threads GRADE 5 C FINETHREAD COARSE THREAD LB FT N m LB FT N m 7500 223 245 302 332 200 220 271 298 6250 108 141 1 4 191 113 124 153 168 9625 91 100 1234 135 5 82 90 111 2 122 0 2500 9 11 123 149 8 10 GRADE 8 FINE THREAD COARSE THREAD LB FT N m LB FT N m 2500 11 13 15 0 17 6 9 11 3 3 2 Elastic stop torque 150 20 2034 2714 5000 64 70 06 8 94 9 57 63 77 3 85 4 200 250 2712 338 9 REN 300 350 406 8 474 5 VA 18 400 450 042 4 610 1 T40000 LD 03 98 3 2 3 3 3 ports plug torque THREAD SIZE THREAD SIZE 1 4 18 1 2 14 3 4 10 3 3 5 Suction screen torque 13 20 Nm 10 to 15 ft Ibs 3 3 6 Solenoid and solenoid cartridge torque Solenoid nut 5 7 Nm 4 5 ft 16 Sole
32. 120 110 100 n 4 90 80 70 60 50 40 Y 30 20 10 0 a 20 4 Y 30 40 50 Y Y 0 1 CONOCO high performance synthetic motor oil Spec No 6718 A Note 20 30 40 50 TEMPERATURE RANGES 2 AND 3 MAY BE USED TO LOWER AMBIENT TEMPERATURES WHEN SUMP PREHEATERS ARE USED EMPERATURE RANGE SHOULD BE USED ONLY IN AMBIENT TEMPERATURE RANGE SHOWN PREFERRED OIL VISCOSITY SELECT HIGHEST OIL VISCOSITY COMPATIBLE WITH PREVAILING AMBIENT TEMPERATURES AND OIL APPLICATION CHART ANY DEVIATION FROM THE ACCOMPANYING ILLUSTRATION MUST HAVE WRITTEN APPROVAL OF THE APPLICATION DEPARTMENT or SPICER CLARK HURTH ENGINEERING AND MARKETING DEPARTMENT T40000 LD 03 98 4 1 Maintenance 4 2 MAINTENANCE INTERVALS 4 2 1 Daily Check oil level daily with engine running at idle 600 RPM and oil at 82 93 C 180 200 Maintain oil level at full mark 4 2 2 Normal drain period Normal drain period and oil filter element change are for average environment and duty cycle condition Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterioration and contamination For extreme conditions judgement must be used to determine the required change intervals Every 500 hours Change oil filter element Every 1000 hours Drain and refill system as follows Drain with oil at 65 93 C 150 200 F 1 Drain
33. 90 7 16 20 mm 6 Intermediate drive plates e 16 875 428 625 mm diameter 1 Backing plate Kit No 802609 7 16 20 e 17 00 431 800 mm diameter Kit No 802593 10 1 Instruction sheet e 17 00 431 800 mm diameter A Note A Dimension Bolt circle diameter 16 00 406 400 mm diameter Kit No 802594 W O nuts Each kit will include the following parts 14 Drive plate mounting cap screws Kit No 802562 7 16 20 mm Each kit will include the following parts WITHIN A 15 MINUTE PERIOD FROM START OF ASSEMBLY OF FLEXPLATES MUST BE COMPLETED e 5 Intermediate drive plates 1 Drive plate assembly 1 Backing plate 14 Drive plate mounting cap screws 1 Instruction sheet 7 1 pc Drive plate mounting spacer is included in Kit No 802609 SCREW INSTALLATION IF THE SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED THE ADHESIVE LEFT IN THE TAPPED HOLES MUST BE REMOVED WITH THE PROPER TAP AND CLEANED WITH SOLVENT DRY THE HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION Position drive plate and weld nut assembly on impeller with weld nuts toward converter Align intermediate drive plates and backing plate with holes in impeller cover A Note Two DIMPLES 180 APART IN BACKING PLATE HOLLOW SIDE TOWARD THE CONVERTER INSTALL CAP SCREWS TIGHTEN CAP SCREWS TORQUE 70 4 77 1 52 57 FT LBS T40000 LD 03 98 Installation detai
34. 98 1 SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instruction must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced by a spare part which has the same part number or with a equivalent part Do not use a spare part of lesser quality The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a spare part service procedure or tool which is not recommended by SPICER CLARK HURTH must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the spare part service procedure or tool selected IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS CAUTIONS AND NOTICES THAT MUST BE CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE 15 ALSO IMPORTANT TO UNDERSTAND THAT THESE CAUTIONS AND NOTICES ARE NOT EXHAUSTIVE BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL THE POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE TO FOLLOW T
35. AFT T40000 LD 03 98 8 16 GROUP FORWARD CLUTCH SHAFT Item Description Assembly Clutch piston Seal Clutch piston outer Seal Clutch piston inner Disc Clutch inner Disc Clutch outer Plate Clutch disc backing Ball End plate retaining Spring End plate retaining Snap ring Backing plate opring Piston return Retainer Spring Snap ring Spring retainer Bearing Clutch driven gear Cone Bearing Clutch driven gear Cup Ring Bearing clutch drive gear locating Ring bearing retaining inner Ring Forward clutch gear tap bearing retainer Bearing Forward shaft front Ring Forward shaft front bearing retainer Bearing Forward shaft rear Snapring Forward shaft rear bearing Ring Forward shaft rear bearing retainer Ring Forward shaft piston Gear Forward clutch driven Assembly Forward shaft and drum Not used on all models Variable thickness retainer rings Select one at assembly to assure proper bearing tightness T40000 LD 03 98 Quantity 10 Standard 14 Modulation 10 Standard 14 Modulation LL 1 Only used with modulation 1 Only used with modulation A eck eck 8 17 GROUP 3RD SPEED CLUTCH SHAFT Vee ECH ANS u T40000 LD 03 98 8 18 GROUP 3RD SPEED CLUTCH SHAFT Item
36. AFT Item c PS Description Assembly Clutch piston Seal Clutch piston outer Seal Clutch piston inner Disc Clutch inner Disc Clutch outer Plate Clutch disc backing Snap ring Backing plate Retainer Spring Spring Clutch piston return Retainer Spring Ring Spring retaining Spacer 1st speed gear Bearing 1st speed gear Bearing 1st speed gear Ring 1st speed gear bearing locating Washer 1st speed gear bearing thrust Bearing 1st speed clutch shaft pilot Spacer 1st speed clutch shaft front bearing Ring 1st speed clutch shaft front bearing retaining Ring 1st speed clutch shaft piston Cap 1st speed clutch shaft rear bearing Plug Bearing cap lube and clutch pressure O ring Plug O ring Bearing Shim Bearing Bearing cap Lockwasher Bearing cap stud Nut Bearing cap stud Cone 1st speed clutch shaft front bearing Cup 1st speed clutch shaft front bearing Assembly 1st speed clutch shaft rear bearing Gear 3rd speed driven Gear 1st speed Assembly 1st speed clutch shaft and drum AR As required T40000 LD 03 98 Quantity 8 23 GROUP 4TH SPEED CLUTCH SHAFT 8 24 03 98 T40000 LD GROUP 4TH SPEED CLUTCH SHAFT Item c PS LL zech lE JO P CH 14000010 Description Assembly Clutch piston Seal Clutc
37. D ACTIVATED SOLENOIDS 6 11 03 98 T40000 LD ission Operation of the transm 6 3 3 Forward 2nd speed Continued 912001 req JMA NOILVINGOW TYNOILdO HOLM HOLM HOLM 3SH3N34 gt gt gt 100 100 100 ou 93 Or z 100 100 E du dd JAVA NOLLYINAON WNOLLdO 1804 93H Do 1804 93H 39055994 req NL Z L Es JAVA s NOLLYINAON 2 due m ISOH 831009 en I gt H d HILNTO 6 12 HOLM HOT HOLD ang 151 Cc gt gt 199 199 199 2 2 all dNNS 110 u3H1V388 HIV qZ 21 SSVd Ad 105 EK 18 c 5 109 02 991 34156384 Y3LHJANO9 9o req 9 H 1 9 1 69 INA 1409 3onvo 3onvo 3419934 9345 t IN3SWIHY4NON HOLVHI4O NOISSINSNVHL 00007 SS Operation of the transmission 6 3 4 Forward 3rd speed ard SPEED FORWARD POWERFLOW F F 1 a e Odd
38. EMEDY 1 Fill to proper level 2 Clean suction pump 3 Replace pump Remedy 1 Remove disassemble and rebuild converter assembly Replace charging pump Fill to proper level Clean cooler dee dw Change cooler lines Remedy 1 Replace charging pump 2 Acomplete disassembly will be necessary to determine which bearing is faulty Remedy 1 Tune engine check governor 2 Make corrections as explained in Overheating T40000 LD 03 98 7 3 Troubleshooting guide 7 4 CHECK POINTS 1 3125 12 O RING PORT 7500 16 O RING PORT T40000 LD FRONT VIEW REAR VIEW 03 98 PORT 44 CHECK PORT 4TH CLUTCH PRESSURE 4375 20 SAE O RING PORT PORT 18 OPTIONAL DRAIN CONNECTION TO SUMP 1 875 12 SAE O RING PORT PORT 16 FROM FILTER 1 3125 12 SAE O RING PORT PORT 13 TO FILTER 1 3125 12 SAE O RING PORT PORT 71 TEMPERATURE PICKUP CONVERTER OUTLET 1 2 NPT PORT 32 PRESSURE PICKUP CONVERTER OUTLET 5625 18 SAE O RING PORT PORT 43 CHECK PORT 3RD CLUTCH PRESSURE 4375 20 SAE O RING PORT SUCTION SCREEN DRAIN 1 3125 12 THD O RING PORT TYP 2 PLACES 7 4 Troubleshooting guide 7 4 CHECK POINTS CONTINUED
39. HESE INSTRUCTIONS T40000 LD 03 98 1 1 2 CLEANING INSPECTION AND LEGEND SYMBOLS 2 1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES FIRE HAZARDS AND INHALATION OF VAPOURS WHEN USING SOLVENT TYPE CLEANERS 2 1 1 Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles 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 2 1 2 Housings Clean interior and exterior of housings bearing caps etc 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
40. HYDRAULIC CIRCUIT 6 7 6 3 1 Neutral and 4th clutch engaged eegene hd eegen 6 7 6 3 2 Forward TSLEBEEE 6 9 E WEEN 6 11 Forward E __________ ____ 6 13 639 Forward AI ENEE 6 15 EE 6 17 GEAR AND CLUTCH LAYOUT za a a a an 6 19 7 TROUBLESHOOTING GUIDE FOR THE T40000 TRANSMISSION 7 1 7 2 7 3 7 4 T40000 TRANSMISSION HE 7 1 TROUBLESHOOTING PROG E 7 1 TO Lee ee 7 1 7 2 2 ransmission pressure checks einziehen 7 2 7 2 3 Mechanical and electrical 7 2 7 22 WAV AUS CHECKS 7 2 TROUBLESHOOTING GUIDE ee ee 7 3 Pa LOW DIOR SONS EE TOT 7 3 732 LOW charging OUI Bt EE 7 3 OV AG e 7 3 7 3 4 Noisy converter aa 7 3 reo Lack of ee 7 3 e Te KREE 7 4 EIOS WIRING E 7 7 8 SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP CONVERTER HOUSING eet teret teret tt 8 2 GROUP TRANSMISSION CASE AND REAR COVER 8 4 GROUP TURBINE SHAFT STATOR SUPPORT amp OIL BAFFLE 8 8 GROUP WHEEL ttt ttt ttc 8 10 GROUP DRIVE PLATE 8 12 GROUP PUMP DRIVE 8 14 GROUP FORWARD CLUTCH SHAFT 22 4 0404
41. LOW 2nd a v i LU gt D D 1st ard 4th 22127 W H WEEN 277 222 77 EL GL DER oo dO zur gt u 4th SPEED FORWARD ACTIVATED SPOOLS 4th SPEED FORWARD ACTIVATED SOLENOIDS 6 15 03 98 74000010 ission Operation of the transm HOLATO 9120201 req INWA E NOLLYINCON N IER 4001 NOLO 6 3 5 Forward 4th speed Continued req HOT HOLATO 3SU3A34 quvMdo3 leq 100 93 or JAVA NOLLYINAON NL JAVA s NOLLYINAON 4 WNO LdO 1HOdX03H 2 1809 34095344 GION310S TWNOILdO 471009 194 gt Yq39V9N3 HILNTO ANV QHVMHOH 6 16 HOLM HOT HILMO ang 181 gt gt gt leq 199 199 21 dNNS 10 4 u3H1V388 HIV Pc 1 3AWA SSVdAd 0043108 OION3108 ang 181 D 94102 59 38159344 H3LH3ANOO Sieft C Jo 100 n 3ufisS3ud eq 11 68 JAVA AL3JVS 141457 IN3INLBVdINOO HOLYHJdO NOISSINSNVHL 0000 e Operation of the transmission 6 3 6 Revers
42. Remove low 1st clutch and idler shaft together from housing Figure 44 Figure 47 Remove idler shaft rear bearing retaining ring Remove idler shaft front bearing Figure 45 Figure 48 Remove idler shaft rear bearing Remove 3rd speed clutch assembly T40000 LD 03 98 10 8 Disassembly 40000 LD transmission Figure 49 Figure 52 opread forward shaft rear bearing retainer ring and Output shaft front bearing cap and removed tap clutch assembly from housing Figure 50 Figure 53 Remove forward clutch assembly output shaft rear bearing stud nuts and lockwashers Figure 51 Figure 54 Remove output shaft front bearing cap screws and Output shaft rear bearing cap and shims lockwashers removed T40000 LD 03 98 10 9 Disassembly 40000 LD transmission Figure 55 Figure 58 Remove output shaft rear bearing cone From the rear side Remove output shaft gear Figure 56 Figure 59 Remove output shaft gear retaining ring Remove oil baffle mounting screws and lockwashers Figure 57 Figure 60 From the front side Remove output shaft and bearing Oil baffle removed cone as an assembly T40000 LD 03 98 10 10 Disassembly 40000 LD transmission Figure 61 Figure 64 Dipstick and dipstick housing removed Suction tube O ring and retainer removed Figure 62 Figure 65 Dipstick tube clip and screw removed Remove low c
43. Remove spring retaining ring i E Figure 161 Figure 164 Remove clutch gear inner bearing Remove spring retainer T40000 LD 03 98 10 31 Disassembly low clutch 1st NE Figure 165 Figure 168 Remove piston return spring Using a gear puller remove gear and taper bearing from clutch shaft Figure 166 Hemove spring retainer Figure 167 Remove clutch piston T40000 LD 03 98 10 32 Reassembly 1st low clutch Figure 169 Position clutch shaft gear on clutch shaft with long hub of gear up F i TS 14 Le m Figure 170 Position rear taper bearing on shaft with small diameter of taper up Press bearing into position Note If thermal assembly aid is used expanding by heating 275 25 F 135 C 14 C a check must be made after mating parts have reached the same temperature within 20 F 11 C of ambient to be sure the bearings are positioned solidly against their respective shoulders before bearing adjustment can be made Figure 172 Install spring retainer Figure 173 Install piston return spring Figure 171 Make sure clutch drum bleed valve is clean and free of foreign material Install inner seal ring Install piston outer piston ring Lock piston joint securely x Grease
44. See note below figure 337 Figure 330 Figure 333 Install output flange O ring flange washer X Install turbine shaft rear bearing outer race and flange nut Secure flange to prevent turning Tighten flange nut See elastic stop nut torque chart Tu CG ze Le ER Figure 331 Figure 334 Position the 2 speed clutch disc hub on the low Position new transmission housing gasket and 9 6 1st clutch shaft Install disc hub retainer ring O rings Note the use of alignment studs Install retainer ring retainer Install ring retainer ring will facilitate housing to housing assembly see figure 332 T40000 LD 11 97 10 66 Reassembly of transmission Figure 335 Figure 338 Position clutch shaft pilot bearings 2nd and 4th Install impeller and oil baffle assembly clutch shafts A high quality grease will hold bearings in position during assembly Figure 336 Figure 339 Install alignment studs and position converter Install impeller hub bearing inner race housing on studs Note turn output shaft to align clutch disc hub in clutch and final assembly Figure 337 Figure 340 Install converter housing to transmission housing bolts and Install oil baffle retainer ring lockwashers and tighten screws to specified torque Caution Bolts are not to be used to pull converter housing to transmission housing Note See assembly instructions for low
45. VINGOW TYNOILdO N 1409 1HOdwosHo 34055344 HOLATO gt gt 199 193 AL leq T NL s NOLLWINGOW p 1053105 TYNOILdO 350 831002 09 1 Yq39V9N3 HILNTO 151 ANV QHVMHOJ HOLATO HOLATO HOLM que NC 151 Sa Gi dns 10 4 u3H1V388 HIV i 092 1 NE SS lt gt 9 JAYA SSVe A8 QION3108 0048108 0048105 K 191 94102 59 7 HOLYINOEH Nu SEHR HALHSANOO 3SOH INOYOL C e 9 1 N 3ufiss3ud 11 68 3NWA 133 5 391 9 39nvo IESSE INAWLYVdNOO 30199340 13345 NOISSINSNVHL 00007 6 10 03 98 74000010 ission Operation of the transm 6 3 3 Forward 2nd speed 2nd SPEED FORWARD POWERFLOW 2nd 1st 3rd 0 2225 Se DA 9555555 22 UJ LE EG GL GG S 1771 Ve O is gt H N N N 5 2 A 2 A 2 and SPEED FORWARD ACTIVATED SPOOLS and SPEED FORWAR
46. an and free of Install spring retainer foreign material Install inner seal ring Install piston outer piston ring Lock piston ring joint securely QD Grease ring to stabilize in ring groove Position piston in clutch drum use caution as not to damage A the inner and outer piston seal rings Figure 230 Figure 233 Install spring retainer Compress return spring Install retainer ring in groove Figure 231 Figure 234 Install clutch piston return spring Install one steel disc Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel last disc installed is friction T40000 LD 03 98 10 44 Reassembly 4th speed clutch Figure 235 Figure 238 Install clutch disc end plate Install bearing retaining ring Figure 236 Figure 239 Install end plate retainer ring Install clutch shaft oil sealing rings piston rings Figure 237 Warm bearing to 110 C 230 F Install clutch shaft front bearing Note bearing outer retainer ring groove must be up T40000 LD 03 98 10 45 Disassembly of idler shaft Figure 240 Figure 243 Remove idler shaft front bearing inner race Remove idler shaft gear retaining ring Figure 241 Remove idler shaft gear retaining ring
47. aring Note this bearing has a shield in it this shield must be up T40000 LD 03 98 10 40 Reassembly 3rd speed clutch Figure 214 Figure 217 Install outer bearing retaining ring Install clutch shaft rear oil sealing ring piston ring Figure 215 Warm bearing to 110 C 230 F Install clutch shaft rear bearing Note bearing outer retainer ring groove must be up Figure 216 Install rear bearing retaining ring T40000 LD 03 98 10 41 Disassembly 4th speed clutch Figure 218 Figure 221 Remove clutch shaft oil sealing rings piston rings Remove end plate retainer ring Figure 219 Figure 222 Hemove Ath shaft front bearing retaining ring Remove plate Figure 220 Figure 223 Hemove Ath shaft front bearing Remove inner and outer clutch discs T40000 LD 03 98 10 42 Disassembly 4th speed clutch Figure 224 Compress piston return spring Remove return spring retainer ring Figure 227 Hemove spring retainer Figure 225 Figure 228 Remove spring retainer Remove clutch piston Figure 226 Remove piston return spring T40000 LD 03 98 10 43 Reassembly 4th speed clutch Figure 229 FTN Figure 232 Make sure clutch piston bleed valve is cle
48. ase 9 32 Lockwasher Converter housing to transmission case screw 23 33 Gasket Converter housing to transmission case 1 34 Bushing Reducing 1 35 Breather 1 36 Cap 1 37 Gasket 1 38 Plug Fill 1 39 Plug Converter out pressure 1 40 O ring 1 41 Plug Converter out temperature 1 42 Bushing 1 43 Washer Shim AR 44 Plug speed sensor bushing 1 45 O ring 1 AR As required T40000 LD 03 98 GROUP TRANSMISSION CASE AND REAR COVER T40000 LD 03 98 8 4 GROUP TRANSMISSION CASE AND REAR COVER Item c PS Description Assembly Transmission case and tube Tube 1st speed clutch pressure Tube Low shaft rear bearing lube Tube 3rd speed clutch pressure Sleeve Tube Sleeve Lockup piston ring Washer Lockup sleeve retainer Screw Lockup sleeve retainer Lockwasher Lockup sleeve retainer O ring 1st and 3rd clutch rear bearing pressure tube Transfer tube 1st speed clutch pressure and bearing lube O ring Pressure transfer tube Cover Rear Plug Rear cover 1st and reverse bearing lube supply Pin Transmission case to rear cover dowel Screw Rear cover to transmission case Stud Rear cover to transmission case Screw Rear cover to transmission case Stud Rear cover to transmission case Nut Rear cover to transmission case stud Lockwasher Rear cover to transmission case stud Gasket Rear
49. be up N AN Figure 137 Position piston in clutch drum use caution as not to damage the inner and outer piston seal rings Figure 135 Install rear bearing retaining ring Figure 138 Install clutch piston return spring Figure 136 Make sure clutch piston bleed valve is clean and free of foreign material Install piston inner seal ring Install piston outer piston ring Lock piston ring joint securely Grease ring to stabilize in ring groove T40000 LD Figure 139 Install spring retainer 10 26 Reassembly forward clutch Figure 140 Figure 143 Compress return spring Install end plate retainer ring Install retainer ring in groove Figure 141 Figure 144 Install one steel disc Install one friction disc Install clutch gear inner bearing cone retaining ring Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel last disc installed is a friction disc Figure 142 Figure 145 Install clutch disc end plate Install clutch gear inner bearing cone with small diameter of taper up T40000 LD 03 98 10 27 Reassembly forward clutch Figure 149 Install clutch shaft front bearing inner race Figure 146 Being sure clutch gear bearing cups and locating rings are installed Install clutch gear and hub into clutch drum Align splines on clutch hub with internal teeth of friction discs Tap gear into
50. c PS ND PO PO PO POP SH 14000010 Description Assembly Clutch piston Seal Clutch piston outer Seal Clutch piston inner Disc Clutch inner Disc Clutch outer Plate Clutch disc backing Snap ring Backing plate Retainer Clutch piston return spring Spring Clutch piston return Retainer Clutch piston return spring Snapring Spring retaining Bearing 3rd speed gear Bearing 3rd speed gear Ring 3rd speed bearing locating Ring 3rd speed bearing retaining Ring 3rd speed shaft piston Bearing 3rd speed shaft rear O ring Rear bearing cap transfer tube Cap 3rd speed shaft rear bearing Snap ring 3rd speed rear bearing O ring Bearing Plug Bearing cap plug Stud Bearing cap Lockwasher Bearing cap stud Nut Bearing cap stud Gear 3rd speed Assembly 3rd speed clutch shaft and drum 03 98 Quantity 8 19 GROUP REVERSE AND 2ND CLUTCH SHAFT 8 20 03 98 T40000 LD GROUP REVERSE AND 2ND CLUTCH SHAFT Item c PS Description Assembly Clutch piston Seal Clutch piston outer Seal Clutch piston inner Retainer Spring Spring Clutch piston return Retainer Spring Snap ring Spring retainer Disc Clutch inner Disc Clutch outer Plate Clutch disc backing Snap ring Ba
51. cking plate Assembly Clutch piston Seal Clutch piston inner Seal Clutch piston outer Disc Clutch inner Disc Clutch outer Plate Clutch disc backing Ball End plate retaining Spring End plate retaining Snap ring Backing plate opring Piston return Retainer Spring Snap ring Spring retainer Bearing Clutch driven Cone Bearing Clutch driven Cup Ring Clutch driven gear locating Ring Bearing retainer inner Ring Reverse clutch gear tap bearing retainer Bearing Reverse and 2nd shaft front Ring Reverse and 2nd shaft front bearing retaining Ring Reverse and 2nd shaft front bearing retainer Hub 2nd clutch disc Snap ring 2nd clutch disc hub retainer Retainer 2nd clutch disc hub retaining ring Ring 2nd clutch disc hub retaining Ring Reverse and 2nd shaft piston Gear Reverse clutch driven Assembly Reverve amp 2nd shaft drum Not used on all models Variable thickness retainer rings Select one at assembly to assure proper bearing tightness T40000 LD 03 98 Quantity eck eck CO ech sch sch ol 10 Standard 14 Modulation 10 Standard 14 Modulation LL 1 Only used with modulation 1 Only used with modulation A eck eck eck c 8 21 GROUP LOW 1ST SPEED CLUTCH SHAFT 8 22 03 98 T40000 LD GROUP LOW 1ST SPEED CLUTCH SH
52. correctly the correct functioning of the hydraulic circuit is most important Transmission fluid is the life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components 7 2 TROUBLESHOOTING PROCEDURES 7 2 1 Stall Test A stall test to identifies transmission converter or engine problems Use following procedure 1 Put the vehicle against a solid barrier such as a wall and or apply the parking brake and block the wheels 2 Put the directional control lever in FORWARD or REVERSE as applicable 3 Select the highest speed With the engine running slowly increase engine speed to approximately one half throttle and hold until transmission converter outlet oil temperature reaches the operating range CAUTION 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 MAXIMUM WILL CAUSE DAMAGE TO TRANSMISSION CLUTCHES FLUID CONVERTER AND SEALS 14000010 03 98 7 1 Troubleshooting guide 7 2 2 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 det
53. cover to transmission case Plug Drain back Plug Oil level Plug Drain Plug Auxiliary drain Assembly Screen and plug Gasket Screen assembly Bushing Sensor Washer Bushing shim Plug Speed sensor Plug Lockup supply hole Tube Suction Clip Suction tube to transmission case Screw Suction tube to transmission case Lockwasher Suction tube to transmission case Flange Tube O ring Suction tube assembly Washer Suction tube assembly retainer Screw Retainer washer Assembly Baffle mounting plate Baffle Oil Screw Baffle to mounting plate Washer Baffle to mounting plate screw AR As required T40000 LD 03 98 Quantity 8 5 GROUP TRANSMISSION CASE AND REAR COVER T40000 LD 03 98 8 6 GROUP TRANSMISSION CASE AND REAR COVER Item 61 62 Description Screw Oil baffle to rear of transmission case Lockwasher Baffle to rear of transmission case Screw Oil baffle to transmission case Washer Oil baffle to transmission case Tube Dipstick Clip Dipstick tube Lockwasher Screw Dipstick tube clip Housing Dipstick Dipstick housing Dipstick Plug AR As required Not used on all models T40000 LD 03 98 Quantity c c c eh M ND PO 8 7 x 7
54. crew FLYWHEEL HOUSING BY ENGINE MANUFACTURER but do not tighten Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten After all eight 8 screws are installed Tighten each cap screw to the following torque 78 86 N m 58 64 ft Ibs for a 7 16 cap screw and 65 75 48 55 ft Ibs for an M10 cap screw This will require rotating the engine flywheel until the full amount of eight 8 screws have been tightened FLYWHEEL IMPELLER COVER INTERMEDIATE DRIVE PLATES PLATES TO BE INSTALLED WITH CONCAVE SIDE TOWARD ENGINE FLYWHEEL 8 Measure engine crankshaft end play after transmission has been completely installed on engine flywheel This value must be within 0 025 mm 0 001 of the end play recorded in step No 2 T40000 LD 03 98 5 2 Installation details 5 3 EXTERNAL PLUMBING u To cooler from converter En mn mu rmn mn o I dL Transmission cooler 3
55. d including Install turbine retaining ring Figure 9 Figure 11 Position new on input shaft Install input shaft bearing on shaft Figure 10 Figure 12 Install input shaft on impeller cover Tap input shaft bearing in place Install input shaft bolts tighten 37 41 ft lbs torque 50 2 55 5 N m T40000 03 98 11 7 Reassembly MHR Section Figure 13 Figure 16 Apply a light coat of Loctite 515 between the Connect drain hose to front cover convertor housing and front cover Press seal in front cover with lip of seal in Figure 14 Install bolts and lockwashers and tighten 37 41 ft lbs torque 50 2 55 5 Figure 15 Install input flange O ring washer nut and flange Tighten nut to specified torque see elastic stop nut torque chart T40000 03 98 11 8
56. e 1st speed R 2 3 T st SPEED REVERSE ACTIVATED SOLENOIDS T40000 LD 1st SPEED REVERSE POWERFLOW C g 2nd FORWARD EN Lafe p d Ei ON NN Bier a We E S A 3rd d ON UU REVERSE LAO P om E LJ LJ m gd 0 1 1st SPEED REVERSE ACTIVATED SPOOLS 03 98 6 17 ission Operation of the transm HOLATO 9120201 INWA ES NOLLYINCON N IER 4001 NOLO 6 3 6 Reverse 1st speed Continued 3Su3A3u req Ou JAVA NOLLYINAON TVNOILdO 1HOdX03H 9 3n vedi 1809 19 Junss3ud X 19 151 ANV 3S83 A3H HOLATO 087 gt leq 93 NOLLYINAON JAVA req WNOILdO 350 100 or 831002 D 6 18 HILMO HOLMIO HILMO ang 181 gt gt gt Jeq Jeq Jeq 9 21 dNNS 10 4 u3H1V388 HIV 100 1 JAWA 5690 48 0048108 0048108 181 D 94112 59 HOLYINOSH JUNSSIUd U3IU3ANO2 30080 C 9 req C ES 9 1 e i 3unss3ud ONIMOWHO eq 1 68 JAVA 5 3ony5 3onv5 3un1vu3dWaL 34195949 03395 t 90194940 NOISSINSNVHL
57. e is clean and free of foreign material Install piston inner seal ring Install clutch piston outer piston ring Lock piston ring securely Grease ring to stabilize in ring groove Position piston in clutch drum use caution as not to damage the inner and outer piston seal Figure 205 Install outer spring retainer Figure 203 Figure 206 Install inner spring retainer Compress return spring Install retainer ring in groove Figure 204 Figure 207 Install clutch piston return spring Install one steel disc Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel last disc installed is friction T40000 LD 03 98 10 39 Reassembly 3rd speed clutch Figure 208 Figure 211 Install clutch disc end plate Install clutch gear inner bearing Note this bearing does not have a shield in it Figure 209 Figure 212 3 Install end plate retainer ring Being sure clutch gear bearing retaining ring is installed Install clutch gear and hub into clutch drum Align splines on clutch hub with internal teeth of friction discs Tap gear into position Do not force this operation Gear splines must be in full position with internal teeth of all friction discs ch m 1 F T 1 M 1 E u 1 Figure 210 Figure 213 Install clutch gear inner bearing locating ring Install clutch gear outer be
58. e of oil when the pressure to the piston is released As an option the engagement of the directional clutches can be modulated This means that clutch pressure is built up gradually This will enable the unit to make forward reverse shifts while the vehicle is still moving and will allow smooth engagement of drive The modulation is done hydraulically m THE INPUT AND DIRECTIONAL CLUTCHES T40000 LD 03 98 6 3 Operation of the transmission 6 1 3 The range clutches Once a directional clutch is engaged power is transmitted to the range clutches 1st 2nd 3rd or Ath Operation and actuation of the range clutches is similar as the directional clutches The engagement of the range clutches is not modulated 6 1 4 The output section With a range clutch engaged power is finally transmitted to the output shaft Output rotation is the same as the engine rotation when the forward clutch is engaged An axle disconnect is optional and is located on the output shaft The drive to the front or rear axle can be disconnected or connected by manual shifting Ey THE RANGE CLUTCHES py THE OUTPUT SECTION T40000 LD 03 98 6 4 Operation of the transmission 6 1 5 The transmission controls refer to hydraulic diagram The transmission is controlled by the control valve The control valve assembly may be mounted directly on the side of the convertor housing or front transmission cover or remote mounted and connected to the transmission by mean
59. e turbine shaft driven from the turbine transmits power to the forward or reverse clutches These clutches consists of a drum with internal splines and a bore to receive a hydraulic actuated piston The piston is oil tight by the use of sealing rings The steel discs with external splines and friction discs with internal splines are alternated until the required total is achieved A back up plate is then inserted and secured with a retainer ring A hub with outer diameter splines is inserted into the 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 control valve will direct oil under pressure through tubes and passages to the selected clutch shafts Oil sealing rings are located on the clutch shafts These rings direct the oil through a drilled passage in the shaft to the desired clutch Pressure of the oil forces the piston and discs against the back up plate The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit When the clutch is released a return spring will push the piston back and oil will drain back via the control valve the bleed valve or holes in the clutch piston into the transmission sump These bleed valve will only allow quick escap
60. engine two minutes at 500 600 RPM to prime torque convertor and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 RPM Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole Install oil level plug of dipstick Recheck with hot oil 82 2 93 3 C 180 200 Bring oil level to FULL mark on dipstick or runs freely from UPPER oil level plug 7 Recheck all drain plugs lines connections etc for leaks and tighten where necessary T40000 LD 03 98 4 3 5 INSTALLATION DETAILS 5 1 CONVERTER DRIVE COUPLING Measure the A dimension bolt circle diameter and order drive plate kit listed below AX Te DRIVE PLATE INTERMEDIATE XN E ANS ASSEMBLY DRIVE PLATES 6 DRIVE PLATES 5 ISP ANS e A 3 P NJ AN amp 5 I 2 K N N R 2 NS AN N SE NJ 5 Q 5 P P NS C oe 2 Ke y 9 A N e 9 9 BOLTCIRCLE lt MOSQ AT V BOLT CIRCLE MATO SoS d De TAPER pre d Q We EN ps EN Poe eh gt eh M No BACKING PLATE BACKING PLATE A Dimension Bolt circle diameter 15 00 381 000 mm diameter Kit No 802587 10 16 00 406 400 mm diameter Kit No 802558 10 mm 16 00 406 400 mm diameter Kit No 8025
61. er shaft bearing cap stud nuts and gasket and O rings lockwashers Figure 26 Figure 29 Remove 3rd shaft bearing cap stud nuts and Remove idler shaft bearing cap and O ring lockwashers Figure 27 Figure 30 Remove 3rd shaft bearing cap and O rings Remove low 1st clutch shaft bearing cap stud nuts and lockwashers T40000 LD 03 98 10 5 Disassembly 40000 LD transmission Figure 31 Figure 34 Hemove low 1st clutch shaft bearing cap and idler shaft rear bearing locating ring shims Figure 32 Figure 35 Remove low 1st speed clutch pressure and lube Remove output flange nut washer and O ring sleeve Hemove output flange Figure 33 Figure 36 Hemove 3rd shaft rear bearing locating ring Hemove rear cover bolts nuts and lockwashers T40000 LD 03 98 10 6 Disassembly 40000 LD transmission Figure 37 Figure 40 Using pry slots provided pry cover from Remove 4th clutch hub transmission housing tapping on idler shaft and 3rd clutch shaft to allow cover to be removed without shaft binding Figure 38 Figure 41 Hear cover and gasket removed Hemove 2nd clutch hub retaining ring retaining ring retainer and retainer snap ring Figure 39 Figure 42 Remove 4th clutch hub retaining ring Remove 2nd clutch hub T40000 LD 03 98 10 7 Disassembly T40000 LD transmission A Figure 43 Figure 46 T L Remove turbine shaft rear bearing outer race
62. ermine 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 7 2 3 Mechanical and electrical checks Prior to checking any part of the system for hydraulic function pressure testing the following mechanical and electrical checks should be made Check the parking brake for correct adjustment Besure all lever linkage is properly connected and adjusted in each segment and at all connecting points controls are actuated electrically Check the wiring and electrical components Be sure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission Air clean the radiator if necessary e he engine must be operating correctly Be sure that it is correctly tuned and adjusted to the correct idle and maximum no load governed speed specifications 7 2 4 Hydraulic checks 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 Check oil level in the transmission The transmission fluid must be at the correct full level All clutches and the converter and its fluid circuit lines must be fully charged filled at all times
63. ge 2 DR DEEN SN d DES RE ION vut St a Dee EN 25 WB 277 S NON RTL IP 4 7 oe E oe N AS sls gt 4k m A EK ee KH ee Ne Gef a BE 2 S 718 pA tt v SS SEN 7 Ly All RISE ANS gt 4 a SN NN EON dun x xS N gt W Gud ws NN ps ji SMES NND Wy LU Ww N Wyant lt ESS gt OA d o SS zw X 524 55 WA ZA OW 7 gt N ANN E Ww NS AN 7 UDAEN 2 ni Nae N NON x gt aly 7 Www N li Ka X SN y D M LI ld 96 Ay 2 M 27 7 4 22224 2 a 4 447 SCH _ ANN An x b ON SS 7 SES 4 i 8 8 GROUP TURBINE SHAFT STATOR SUPPORT amp OIL BAFFLE T40000 LD 03 98 GROUP TURBINE SHAFT STATOR SUPPORT amp OIL BAFFLE Item P gt ech sec Ll LX CH 14000010 Description Bearing Turbine shaft front Bearing Turbine shaft rear Washer Bearing Snap ring Bearing Ring Piston Assembly Stator s
64. gure 354 Figure 357 Install pump suction adaptor fittings X The use of alignment studs will facilitate valve O rings to housing assembly Position control valve on housing Figure 355 Figure 358 Install suction tube and couplings Install all valve to housing bolts and lockwashers in their specified locations see control valve bolts tightening sequence diagram Tighten bolts to 23 to 25 ft lbs torque 31 2 33 8 N m T40000 LD 11 97 10 70 11 5 11 1 MHR SECTION The information contained herein must be used in conjunction with a T40000 LD section The MHR model is the midship mounted T40000 series transmission with an integral convertor unit 11 1 1 Sectional views and parts identification Refer to following pages T40000 03 98 Section GROUP SECTION ww lr 2 2 1 7 e IS re Mu E d E a Ju SEY 2 VLL STE 2 12 11 97 T40000 Section GROUP SECTION c PS PO Vw eck HSH sch HS eck 2 2 2 P 140000 Description Input shaft screw Input shaft Turbine hub retainer ring Impeller cover bearing retainer ring Impeller cover bearing spacer Impeller cover bearing Impeller cover to impeller screw Impeller cover to impeller screw lockwasher Impeller cover Converter housing to front cover screw
65. h piston outer Seal Clutch piston inner Disc Clutch inner Disc Clutch outer Plate Clutch disc backing Snap ring Backing plate Retainer Spring Spring Piston return Retainer Spring Snap ring Spring retainer Bearing 4th speed shaft front Snap ring 4th shaft front bearing Ring 4th speed shaft front bearing retaining Hub 4th clutch disc Ring 4th clutch disc hub retaining Ring 4th speed shaft piston Assembly 4th clutch shaft and drum 03 98 Quantity eck eck eck cl eck OO sch 8 25 GROUP IDLER SHAFT T40000 LD 03 98 8 26 GROUP IDLER SHAFT Item Description c PS T40000 LD Shaft Idler Bearing Idler shaft pilot Bearing Idler shaft front Ring Idler gear retaining Bearing Idler shaft rear Ring Rear bearing retaining O ring Rear bearing cap Stud Bearing cap Lockwasher Bearing cap stud Nut Bearing cap stud Cap Rear bearing Gear Idler shaft 03 98 Quantity 8 27 GROUP OUTPUT SHAFT A Dee a ZEN ro pM EST Rare N a ES FEIERN SC gt 1 P y pu _ N gm ML 2 Y FL un Eo y QS T gt SS 7 Wi i tw pre P S p ys T E I e 2 pts 2 SEN P Bee WS wt eier eme S AVA pot prat SE
66. he bearings are positioned solidly against their respective shoulders gt Low 1st clutch taper bearing adjustment See 9 1 Shim output shaft bearings to produce 0 67 0 90 Nm 4 10 In lbs preload rolling torque See 3 3 2 Elastic stop nut torque opecial turbine shaft bearing 314 MG loading notches must be on same side as retaining ring Cast iron piston rings in outer piston ring location and Viton Rings at inner piston ring location speed versions all clutches 8 outer steel plates 8 inner friction plates alternately assemble starting with outer steel plate 12 outer steel plates 12 inner friction plates alternately assemble starting with outer steel plate Modulated Forward and Reverse clutches 14 outer steel plates 14 inner friction plates alternately VV e assembled starting with outer steel plate Non modulated Forward and Reverse clutches use 10 outer steel plates and 10 inner friction plates which are alternately assembled starting with outer steel plate Place bolts to be used at these locations V Requires special torque PLACE BOLT TORQUE LB FT TORQUE N m 0 4375 92207 11 TI 0 3750 33 36 45 49 T40000 LD 03 98 9 2 Assembly instructions 9 ASSEMBLY INSTRUCTIONS coNriNUED D Bend lock tabs at assembly after tightening cap screws to proper torque Tabs must be set against screw head flats or around corners as shown below All dowel pin
67. ic studies the instructions in this manual carefully and uses it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only SPICER CLARK HURTH approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment SPICER CLARK HURTH does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied by or approved by SPICER CLARK HURTH IN IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS T40000 LD 03 98 Table of Contents 1 SAFETY PRECAUTIONS 2 CLEANING INSPECTION AND LEGEND SYMBOLS a ae 2 1 le EE 2 1 21 2 seen andere E 2 1 22 gt M roe 2 1 INOS EE 2 1 22 2 Oil Seals Gaskets EE 2 2 EE 2 2 2 224 Housing OVENS E 2 2 293 LEGEND EE 2 2 3 TECHNICAL SPECIFICATIONS 3 1 25 e teda 3 1 92 WEIGHT DIMENSIONS aan ee 3 1 CSC Mie KR Ee 3 2 3 3 1 Torque specifications for lubricated or plated screw threads 3 2 3 2 3 3 3 O ring poris plug Ree 3 3 334 Fipe plug E 3 3 3 3 5 Suction sereen ENEE eege 3 3 3 3 6
68. ing scratching or curling under of lip of seal seriously impairs its efficiency When assembling new metal type sealing rings these should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members Lubricate all 05 and seals with recommended type Automatic Transmission Fluid before assembly 2 2 3 Gears and Shafts If magna flux process is available use process to check parts Examine teeth on all gears carefully for wear pitting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or splines twisted and that shafts are true 2 2 4 Housing Covers etc Inspect housings covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures 2 3 LEGEND SYMBOLS Smontaggio di sottogruppi Disassembly of assembly groups Montaggio di sottogruppi Reassemble to from assembly group Sostituire con ogni montaggio Renew at each reassembly Smontaggio di particollari ingombranti Remove obstruction parts Togliere mettere la sicura Unlock lock e g split pin locking pla
69. l friction discs Figure 183 Figure 186 Install clutch gear outer bearing Install clutch shaft sealing rings piston rings Note this bearing has a shield in it this shield must be up See figure 176 T40000 LD 03 98 10 35 Disassembly 3rd speed clutch Figure 187 Figure 190 Hemove clutch shaft rear oil sealing ring piston ring Turn clutch over and remove clutch gear retaining ring Figure 188 Figure 191 Remove clutch shaft rear bearing retaining ring Hemove clutch gear and outer bearing from clutch Figure 189 Figure 192 Hemove clutch shaft rear bearing Remove end plate retaining ring T40000 LD 03 98 10 36 Disassembly 3rd speed clutch Figure 193 Figure 196 Remove end plate Hemove inner bearing locating ring Figure 194 Figure 197 Remove inner and outer clutch discs Compress piston return spring Hemove spring retaining ring Figure 195 Figure 198 Remove clutch gear inner bearing Remove spring retainer T40000 LD 03 98 10 37 Disassembly 3rd speed clutch Figure 199 Remove piston return spring Figure 200 Remove spring retainer Figure 201 Remove clutch piston T40000 LD 03 98 10 38 Reassembly 3rd speed clutch Figure 202 Make sure clutch piston bleed valv
70. lic lines Where feasible hydraulic lines should be removed from machine for cleaning 3 Replace oil filter elements cleaning out filter cases thoroughly 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler If necessary cooler assembly should be removed from machine for cleaning using oil compressed air and steam cleaner for that purpose DO USE FLUSHING COMPOUNDS FOR CLEANING PURPOSES 5 On remote mounted torque convertors remove drain plug from torque convertor and inspect interior of convertor housing gears etc If presence of considerable foreign material is noted it will be necessary that the convertor be removed disassembled and cleaned thoroughly It is realised this entails extra labor however such labor is a minor cost compared to the cost of difficulties which can result from presence of such foreign material in the system 6 Reassemble all components and use only type oil See chapter 4 1 1 Recommended lubricants Fill the transmission through filler opening until fluid comes up to LOW mark on transmission dipstick A Note IF THE DIPSTICK IS NOT ACCESSIBLE OIL LEVEL CHECK PLUGS ARE PROVIDED Remove LOWER check plug fill until oil runs from LOWER oil hole Replace filler and level plug Run
71. ls 5 2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1 Remove all burrs from flywheel mounting face FLYWHEELHOUSING MOUNT and nose pilot bore Clean drive plate surface with vicc solvent 2 Check engine flywheel amp housing for EE conformance to standard SAE No 1 per SAE J927 and 1033 tolerance specifications for pilot i FLYWHEEL bore size pilot bore runout and mounting face PILOT BORE flatness Measure and record engine crankshaft end play FLYWHEEL 3 Install two 88 90 mm 3 50 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 CONVERTER HOUSING 4 Install a 101 60 mm 4 00 long drive plate locating stud in a drive plate nut Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No 3 5 Locate transmission on flywheel housing Aligning drive plate to flywheel and transmission to flywheel housing Install transmission to flywheel housing screws Tighten screws to N DRIVE specified torque Remove transmission to engine Db Ba guide studs Install remaining screws and tighten to specified torque 2 ALIGNING STUDS 6 Remove drive plate locating stud SPECIAL STUD WASHER AND SELF LOCK NUT FURNISHED 7 Install drive plate attaching SCrew Snug s
72. lutch shaft front bearing cup baffle plate and retaining Figure 63 Remove suction tube mounting screw 3 T40000 LD 03 98 10 11 Disassembly of converter housing Figure 66 Figure 69 opread 4th clutch front bearing retainer ring and pry turbine shaft outer bearing retainer ring clutch assembly from converter housing Figure 67 t Figure 70 Spread reverse clutch front bearing retainer _ Tap turbine shaft and bearing from converter ring and pry reverse and 2nd clutch assembly housing from converter housing Figure 68 Hemove forward shaft front bearing outer race T40000 LD 03 98 10 12 Disassembly reverse and 2nd clutch Figure 71 Figure 74 Remove clutch shaft oil sealing rings piston rings Remove clutch gear outer bearing retaining ring Figure 72 Figure 75 Remove front bearing retaining ring Remove clutch gear and outer bearing cone Figure 73 Figure 76 Hemove front bearing Remove clutch gear inner bearing cone T40000 LD 03 98 10 13 Disassembly reverse and 2nd clutch Figure 77 Figure 80 Remove clutch gear inner bearing cone retaining Remove inner and outer clutch discs ring jl Figure 78 Figure 81 Remove end plate retainer ring Compress piston return spring Hemove spring retaining ring Figure 79 Figure 82 Remove end plate Remove spring retainer T40000 LD
73. mbly Figure 318 iE Figure 321 The low clutch 1st assembly and idler shaft Position new gasket and O rings 3 on X assembly must be installed together Be sure rear of transmission case clutch and idler are in full position in housing A Figure 319 Figure 322 Warm bearing to 110 C 230 Install idler shaft Install rear cover and tap cover into place rear bearing with snap ring groove to the rear side T40000 LD 11 97 10 64 Reassembly of transmission Figure 323 Figure 326 Install rear cover to case screws nuts and Position 3rd shaft rear bearing cap on studs lockwashers Tighten screws and nuts to specified Use caution as not to damage oil sealing ring torque Install stud nuts and lockwashers Tighten nuts to specified torque Figure 324 Figure 327 Install 3rd shaft rear bearing locating ring Install idler shaft rear bearing retaining ring Figure 325 Figure 328 Install new O rings on 3rd shaft rear Position new on idler shaft bearing X bearing cap cap Install bearing cap T40000 LD 11 97 10 65 Reassembly of transmission Disc hub retainer ring Low clutch shaft Retainer ring retainer 2nd Clutch disk hub Figure 329 Figure 332 Instal idler shaft bearing cap nuts and lockwashers Tighten nuts to specified torque Note Do not install low 1st clutch rear bearing cap at this time or install bearing cap temporarily
74. mounted opposite the impeller and is connected to the turbine shaft of the torque converter This element receives fluid at its outer diameter and discharges it at its centre The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation will make the converter to multiply torque The torque multiplication is function of the blading impeller turbine and reaction member and the converter output speed turbine speed The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM stall Therefore we can say that as the turbine shaft is decreasing in speed the torque multiplication is increasing The hydraulic pump is connected with the pump drive gear This pump drive gear is driven by the impeller hub gear Since the impeller hub gear is connected with the impeller cover the pump speed is in direct relation with the engine speed Note PRESSURE REGULATOR VALVE IS MOUNTED BETWEEN THE CONVERTER AND THE CHARGING PUMP 1 THE CONVERTER PUMP DRIVE SECTION AND PRESSURE REGULATING VALVE T40000 LD 03 98 6 2 Operation of the transmission 6 1 2 The input shaft and directional clutches Th
75. n impeller with impeller hub use caution Tap bearing into place as not to disrupt O ring Figure 269 Figure 272 Install impeller hub bearing retaining ring Position impeller hub screw backing ring Figure 270 Figure 273 o Position a new impeller to hub on 4 2 Clean hub mounting surface and tapped holes with solvent an Dry thoroughly being certain tapped holes are clean and dry Install backing ring impel ler hub and special self locking screws Tighten screws 58 64 ft Ibs 79 87 N m Note assembly of hub must be completed within a fifteen minute period from start of screw installation The special screw is to be used for one installation only If the screw is removed for any reason it must be replaced The epoxy left in the hub holes must be removed with the proper tap and cleaned with solvent Dry hole thoroughly and use a new screw for reinstallation If lock tabs are used bend lock tabs T40000 LD 03 98 10 53 Reassembly impeller and oil baffle Figure 274 Figure 277 Apply a light coat of loctite 638 to the outer diameter Install impeller hub gear retainer ring of the oil baffle oil seal press oil seal in baffle with lip of seal down Figure 275 Install a new oil baffle oil seal ring on oil baffle Position oil baffle on impeller assembly Figure 276 Install impeller hub gear
76. noid cartridge 22 27 Nm 16 20 ft Ibs T40000 LD 03 98 3 3 Technical specifications 3 4 PRESSURE AND TEMPERATURE SPECIFICATIONS 9 Normal operating temperature 70 120 158 248 measured at temperature check converter out port 71 Maximum allowed transmission temperature 120 C 248 Transmission regulator pressure neutral port 31 At 600 RPM min 16 5 bar 240 PSI minimum At 2000 RPM 20 7 bar 300 PSI maximum Pump flow 9 At 2000 RPM in neutral 143 8 l min minimum 38 GPM Clutch pressures 1st clutch port 41 2nd clutch not available 3rd clutch port 43 4th clutch port 44 Forward clutch port 45 Reverse clutch not available At 2000 RPM 16 5 20 7 bar 240 300 PSI clutch activated 0 02 bar 0 3 PSI clutch released Filter bypass valve set at 1 7 2 bar 25 30 PSI Lube pressure port 34 0 7 1 4 bar 10 20 PSI at 108 l min 28 5 GPM pump flow 1500 RPM Safety valve cracking pressure 8 9 11 7 bar 130 170 PSI measured at port 36 with convertor out shut off Converter out pressure port 11 1 7 bar min 25 PSI at 2000 RPM and max 4 8 bar 70 PSI at no load governed speed All pressures and flows to be measured with oil temperature of 82 93 C 180 200 Refer to section 7 Troubleshooting for check port identifica
77. nstall retainer ring in groove Figure 107 Install one steel disc Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel last disc installed is a friction disc 10 20 Reassembly reverse clutch Figure 108 Figure 111 Install clutch disc end plate Install clutch gear inner bearing cone witch small diameter of taper up Figure 109 Figure 112 Install end plate retainer ring Make sure clutch gear bearing cups and locating rings 7 are installed Install clutch gear and hub into clutch drum Align splines on clutch hub with internal teeth of friction discs Tap gear into position Do not force this operation Gear splines must be aligned with internal teeth of all friction discs Figure 110 Figure 113 Install clutch gear inner bearing cone retaining ring Install clutch gear outer bearing cone with small diameter of taper down T40000 LD 03 98 10 21 Reassembly reverse clutch Figure 114 Figure 117 Install clutch gear outer bearing retaining ring Install clutch shaft oil sealing rings piston rings gt Figure 115 Warm bearing to 110 C 230 Install clutch shaft front bearing Note bearing outer retainer ring groove must be down Figure 116 Install front bearing retainer ring
78. o stabilize in ring groove Figure 94 Figure 97 Position piston in clutch drum use caution Install spring retainer not to damage the inner and outer piston seal rings Figure 95 Figure 98 Install spring retainer Compress return spring Install retainer ring in groove T40000 LD 03 98 10 18 Reassembly 2nd clutch Figure 99 Install one steel disc Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel last disc installed is a friction disc Figure 100 Install clutch disc end plate Figure 101 Install end plate retainer ring T40000 LD 03 98 10 19 Reassembly reverse clutch Figure 102 Make sure clutch piston bleed valve is clean and free of foreign material Install inner seal ring Install piston outer piston ring Lock piston ring joint securely Grease ring to stabilize in ring groove Figure 103 Position piston in clutch drum use caution as DJ not to damage the inner and outer piston seal rings Figure 104 Install clutch piston return ring T40000 LD 03 98 Figure 105 Install soring retainer Figure 106 Compress return spring I
79. ometer at location A and B Add the two dimensions together and divide by two to get an average thickness and record Example A 22 123 0 871 22 174 0 873 ala 44 298 1 744 2 22 149 0 872 Average thickness Example only Lubricate taper bearing and bearing cap bore Be sure bearing cap Slip fits in bearing bore Install bearing cap on rear cover using all four 4 cap studs Install all four 4 stud nuts Rotate the output shaft flange to seat taper bearings and rap transmission rear cover adjacent to taper bearing while tightening stud nuts a crisscross sequence 20 3 27 0 N m 15 to 20 ft lbs torque Use a mechanical advantage a socket and extension on the output flange nut to rotate flange if needed T40000 LD 03 98 9 4 Assembly instructions 9 1 2 Taper bearing adjustment Continued After seating the bearings remove two 2 nuts 180 apart Remove the two 2 nuts that are not next to the raised machine surface Loosen the remaining two 2 nuts G until they are finger tight Using a micrometer depth gauge C set firmly against raised machined surface and B and using calibrated metric or equivalent inch 105 torque wrench tighten the two remaining nuts in 1 13 N m 10 inch Ibs increments from 113 N m 10 inch Ibs through 11 3 N m 100 inch 108 Rotate the output shaft flange while tightening the nuts Measure A and B at each 1 13
80. position Do not force this operation Gear splines mut be in full position with internal teeth of all friction discs Figure 147 Figure 150 Install clutch gear outer bearing cone with small Install clutch shaft front bearing outer race diameter of taper down Figure 148 Figure 151 Install clutch gear outer bearing retaining ring Install front bearing retaining ring T40000 LD 03 98 10 28 Reassembly forward clutch Figure 152 Install clutch shaft oil sealing rings piston rings T40000 LD 03 98 10 29 Disassembly low clutch 1st Figure 153 Figure 156 Remove clutch shaft oil sealing rings piston rings Hemove gear thrust washer Figure 154 Figure 157 Pry rear taper bearing up far enough to use a Remove low clutch gear and outer bearing bearing puller Figure 155 Figure 158 Hemove rear bearing Remove end plate retaining ring T40000 LD 03 98 10 30 Disassembly low clutch 1st Figure 159 Figure 162 Remove clutch disc end plate low gear spacer TE Figure 160 Figure 163 Remove inner and outer clutch discs Compress piston return spring
81. pressure is fed to the 4th clutch T40000 LD 03 98 6 5 Operation of the transmission 6 2 ELECTRIC SOLENOID CONTROLS Activated solenoids Activated clutches Forward 4 Forward Forward 4th Forward 3 Forward 3rd Forward 3rd Forward 2 Forward 2nd 3rd Forward 2nd Forward 1 Forward 1st 2nd 3rd Forward 1st Neutral 4 5 Neutral 4 th Neutral 3 3rd Neutral 3 rd Neutral 2 2nd 3rd Neutral 2 nd Neutral 1 1st 2nd 7 3rd Neutral 1 st Reverse 4 Reverse Reverse 4 th Reverse 3 Reverse 3rd Reverse 3 rd Reverse 2 Reverse 2nd 3rd Reverse 2 nd Reverse 1 Reverse 1st 2nd 7 3rd Reverse 1 st T40000 LD 03 98 6 6 ission Operation of the transm 6 3 POWER FLOWS ACTIVATED SOLENOIDS SPOOLS AND HYDRAULIC CIRCUIT 6 3 1 Neutral and 4th clutch engaged NEUTRAL POWERFLOW SUPPLY D i Bim Z Tr recs SON JE LEID MESSE Op p d 2 AQ 6 NEUTRAL ACTIVATED SPOOLS NEUTRAL ACTIVATED SOLENOIDS 6 7 03 98 T40000 LD 6 8 91 19 HOLATO HOI 91 19 HOLATO HOLATO H LNTIO 419907 3Su3A3u Que ONS 159 gt gt gt gt gt gt 199 194 109 leq leq leq 194 M ou 93 Or 5 9l dg 10 N33uos line 100 1 ANA SSVd Ad 1
82. rbine as an assembly Hemove reaction member and spacer Remove impeller cover O ring Figure 9 Figure 12 Remove turbine locating ring from turbine shaft Remove oil baffle retainer ring T40000 LD 03 98 10 2 Disassembly 40000 LD transmission Figure 13 T Figure 16 1 An impeller removal tool like the shown L _ Hemove charging pump and pressure L can be fabricated to facilitate the removal of regulating valve assembly impeller and oil baffle Figure 14 Figure 17 Remove pump suction tube and suction tube If used remove pump hole covers coupling Figure 15 Figure 18 Remove pump suction adaptor fittings and O rings Remove control valve mounting screws m remove control valve and gasket T40000 LD 03 98 10 3 Disassembly 40000 LD transmission Figure 19 Figure 22 Remove stator support bolts Hemove pump drive gears Figure 20 Figure 23 Turn support to clear drive gear oupport converter housing with a chain hoist and Remove stator support strap Remove converter housing to transmission housing screws and lockwashers Figure 21 Figure 24 Hemove pump drive gear bearing support bolts Separate converter housing from transmission assembly Note reverse and 2nd and forward high and 4th clutch will remain in the converter housing T40000 LD 03 98 10 4 Disassembly 40000 LD transmission Figure 25 Figure 28 Remove converter housing to transmission housing Remove idl
83. ring to stabilize in ring groove Position piston in clutch drum use caution as not to damage the inner and outer piston seal rings T40000 LD 03 98 Figure 174 Install spring retainer 10 33 Reassembly 1st low clutch Figure 175 Compress piston return spring and install retainer ring IR Figure 176 Figure 178 Install one steel disc Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel Last disc installed is friction Oct Figure 179 Install clutch disc end plate Figure 177 Install bearing spacer being sure spacer is in full position over spring retainer ring See figure 176 T40000 LD Figure 180 Install clutch disc end plate retainer ring 10 34 Reassembly 1st low clutch Figure 181 Figure 184 Install clutch gear inner bearing Install clutch gear bearing washer Note this bearing does not have a shield unit See figure 176 Figure 185 Figure 182 Being sure clutch gear bearing locating ring is 7 Install rear taper bearing on clutch shaft with small installed Install clutch driven gear into clutch drum diameter of taper Up See note in figure 170 Align splines one clutch hub with internal teeth of friction discs Tap gear into position Do not force this operation Gear splines must be in full position with internal teeth of al
84. s must be installed transmission case before assembly of mating parts When installing clutch support piston ring centre the piston rings in the ring groove Must be loose internal fit bearings with a number 3 etched on the bearing Oil pump sleeve and coupling assembly Torque clamp bolt 10 12 N m 7 5 9 ft Ibs Bearing shield must face OUT on low and 3rd clutch Lube hole in converter support 1 17 1 24 mm 0 046 0 049 inch diameter must be checked prior to assembly Must be free of dirt and burrs V SS SS Lube hole in converter support 1 95 2 05 0 077 0 081 diameter must be checked prior to assembly Must be free of dirt and burrs T40000 LD 03 98 9 3 Assembly instructions 9 ASSEMBLY INSTRUCTIONS Impeller hub and turbine hub assembly with backing ring and special self locking screws 1 Clean hub mounting surface and tapped holes with solvent Dry thoroughly being certain tapped holes are clean and 2 Install backing ring and special self locking screws Tighten the screws to 122 134 N m 90 99 ft lbs for turbine and 79 87 N m 58 64 ft lbs for impeller A Note ASSEMBLY OF HUB MUST BE COMPLETED WITHIN A FIFTEEN MINUTE PERIOD FROM START OF SCREW INSTALLATION THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION ONLY IF THE SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED EPOXY LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER
85. s of flexible hoses The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutch A provision is made on certain models to neutralize the transmission when the brakes are applied inching or declutch This is accomplished through use of a brake actuated shutoff valve The control valve has 5 solenoids and 5 shift spools A control valve with optional neutral has an extra spool and solenoid Operation of the valve Forward can be selected by activating the forward solenoid The forward solenoid will then allow pilot pressure to move the forward shift spool Due to this movement of the shift spool the forward clutch is fed with oil pressure When the reverse solenoid is activated pilot pressure will move the reverse shift spool The reverse clutch will be fed with oil pressure The shift spools of forward and reverse are located opposite each other separated by a return spring This ensures that only one direction can be selected gs THE TRANSMISSION CONTROLS Selection of range If the range solenoids 1st 2nd and 3rd are activated regulated pressure is fed through the shift spools to the 1st clutch If the range solenoids 2nd and 3rd are activated regulated pressure is fed through the shift spools to the 2nd clutch If the range solenoid 3rd is activated regulated pressure is fed through the shift spool to the 3rd clutch If no range solenoids are activated the regulated
86. ssembly turbine shaft Figure 255 Install turbine shaft bearing with snap ring groove up m Figure 258 Install turbine shaft piston ring Figure 256 Install front bearing washer Figure 257 Install front bearing retaining ring T40000 LD 03 98 10 50 Disassembly impeller and oil baffle Figure 259 Figure 262 ob Hemove impeller hub gear retaining ring Remove hub bolts Note some units will have lock tabs instead of a backing ring straighten lock tabs Impeller and hub must reassembled as explained in figure 273 Figure 260 Figure 263 Remove impeller hub gear impeller hub screw backing ring Figure 261 Figure 264 Remove oil baffle from impeller Remove impeller from hub T40000 LD 03 98 10 51 Disassembly impeller and oil baffle Figure 265 Hemove impeller hub Figure 266 Remove impeller hub bearing retaining ring Figure 267 Hemove impeller hub bearing T40000 LD 03 98 10 52 Reassembly impeller and oil baffle Figure 268 Figure 271 Install impeller hub bearing Align holes i
87. t to clear pump drive gear Align support holes with converter housing Figure 295 Install stator support bolts and lockwashers Tighten bolts to specified torque 10 59 Reassembly convertor housing Figure 296 opread reverse clutch front bearing locating T ring and tap reverse and 2nd clutch assembly into converter housing Be certain locating ring is in full position in ring groove Figure 297 Install forward shaft front bearing outer race Figure 298 opread 4th speed clutch assembly front 1 bearing locating ring and tap clutch assembly into position Be certain locating ring is in full position in ring groove T40000 LD 03 98 10 60 Reassembly of transmission Figure 305 Figure 308 Install dipstick tube and dipstick as shown From the front of case insert output shaft cone and Install mounting screw and lockwasher and tighten gear retaining ring assembly through output gear screw to specified torque Figure 306 Figure 309 View of output shaft as it would be positioned in Position new O ring on front bearing X transmission case Install bearing cap Figure 307 Figure 310 From the rear position output gear in transmission Install front bearing cap screws and lockwashers case
88. te etc Montaggio di particollari ingombranti Reinstall remount parts which had obstructed disassembly Mettere la sicura incollare mastice liquido Lock adhere liquid sealant Attenzione indicazione importante Attention important notice Evitare danni ai materiali danni ai pezzi Guard against material damage damage to parts Controllare regolare p e coppie misure pressione etc Check adjust e g torque dimensions pressures etc Marchiari prima dello smontaggio per il montaggio Mark before disassembly observe marks when reasembl T Attrezzature speciali P Pagina T Special tool P Page Carricare riempire olio lubrificante Filling topping up refilling e g oil cooling water etc Rispettare direzione di montaggio Note direction of installation Scarricare olio lubrificante Drain off oil lubricant Controllare esaminare controllo visuale Visual inspection Tendere Tighten clamp tightening a clamping device Eventualimente riutilizzable sostituire se necessario Possibly still serviceable renew if necessary 03 98 Insere pressione nel circuito idraulico Apply pressure into hydraulic circuit Pulire To clean 2 2 3 TECHNICAL SPECIFICATIONS 2 9 SPICER CLARK HURTH TEN BRIELE 3 B 8200 BELGIUM C 3
89. tion T40000 LD 03 98 3 4 Technical specifications 3 5 ELECTRICAL SPECIFICATIONS Solenoid forward reverse 1st 2nd and 3rd Coil resistance 12V 9 79 0 20 C 68 24V 39 90 Q 20 C 68 F Speed sensor Type inductive sensor Sensing distance 0 0 6 mm 0 0 024 Coil resistance 1050 100 0 3 6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS e Minimum 32 mm 1 25 internal diameter for lines and fittings e Suitable for operation from ambient to 120 C 248 continuous operating temperature Must withstand 20 bar 290 PSI continuous pressure and with 40 bar 580 PSI intermittent surges Conform SAE J1019 and 5 517 100 T40000 LD 03 98 4 4 1 OIL SPECIFICATION 4 1 1 Recommended lubricants Temperature range 1 1 C 4 grade 30 2 C 3 grade 30 3 MIL L 2104C grade 30 Temperature range 2 1 MIL L 2104C grade 10 2 MIL L 2104D grade 10 3 C 4 grade 10 4 C 3 grade 10 Temperature range 3 1 3 DEXRON II D 2 C 4 DEXRON II D DEXRON is a registered trademark of the General Motors Corporation A Caution D is NOT COMPATIBLE WITH GRAPHITE CLUTCH PLATE MATERIAL UNLESS IT MEETS THE APPROVED C3 C4 SPECIFICATIONS Temperature range 4 1 MIL L 46167 A Temperature range 5 F PREVAILING AMBIENT TEMPERATURE 150 4 130
90. transmission and remove sump screen Clean screen thoroughly and replace using new gaskets 2 Remove and discard filter elements Install new elements 3 Refill transmission to LOW mark 4 Run engine at 500 600 RPM to prime convertor and lines 5 Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil temperature is hot 82 2 93 3 180 200 make final oil level check Bring oil level to full mark Note IS RECOMMENDED THAT OIL FILTER BE CHANGED AFTER 100 HOURS OF OPERATION NEW REBUILT OR REPAIRED UNIT 14000010 03 98 4 2 Maintenance 4 3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL The transmission torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other Therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and connecting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydrau
91. upport and sleeve Screw Stator support Lockwasher Stator support screw Ring Piston Baffle Oil Seal Baffle oil Ring Oil baffle seal Ring Oil baffle retainer Tube Converter inlet Shaft Idler 03 98 Quantity 8 9 GROUP WHEEL T40000 LD 03 98 8 10 GROUP WHEEL Item JO P NO PO PO HSH SH OD 10 P Go 14000010 Description Member Reaction Snap ring Reaction member hub opacer Reaction member Turbine Hub Turbine Snap ring Turbine hub Snap ring Turbine hub front Screw Turbine hub Locktab Turbine hub screw Impeller O ring Impeller to impeller cover Screw Impeller to impeller cover Lockwasher Impeller to impeller cover screw Hub Impeller Impeller hub Screw Impeller to hub Ring Impeller hub screw backing Bearing Impeller hub Snap ring Bearing Cover Impeller Bearing Turbine hub O ring Impeller cover to impeller cover hub Spacer Impeller cover hub bearing Snap ring Impeller cover hub bearing Hub Impeller cover 03 98 Quantity GROUP DRIVE PLATE T40000 LD 03 98 8 12 GROUP DRIVE PLATE Item Description 1 Assembly Drive plate when used weld nut 2 Plate Drive 3 Ring Backing 4 Mounting screw Drive plate T40000 LD 03 98 Quantity 5 8 13 8 14

Service Manual - Dana Corporation

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