n `A HYDRAULIC TRANSMISSION
Contents
1. 8 13 Assembly of main shaft assembly bearing retainer coupling and main shaft nut in reduction housing PU pies 14 Assembly of reduction housing ring gear and main shaft assembly to the forward and reverse transmission e nnn us 15 BOLT TORQUE SPECIFICATIONS 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 16 GENERAL hh 85 8 8 8 sank aha a ananas 16 SOLIS 2 duree SEAGGA att pnm 150 uo f 6 28 2 454 30 78 62 2 AA HY C22 E E PUES ON SEN FLUSH 3262 Cri MOUS ME 2 EA us y y Do N NS E SAS SEN ni 4 EZIZ a EN i D D ILSED ca N N MOLE MAMAA RECOMENDED NE 44 5 ODE RATING TEMPERATUR rese L4 won 2 17986 M i cage ERES 22 fO SECTION A bo pe 2 Fig Cross Section of AS3 70C Transmission DIM FROM FRONT FACE QF CASE E TCH CYLINDER 0 754 iini appui2. Fig 3 Cross Section of ASI3 72C Transmission Fig 4 Rear View of Model 70C amp 71C Transmissions Fidi E Rede Womar Model 720 Transmission e 9 Fig 6 Parts Display for Forward amp Reverse section of the AS3 70C ransmission Only Those Parts Different from the ASI 70C Assembly illustrated TRANSMISSION CASE I 2 NAVE PLATE 3 BAFFLE 4 OIL STRAINER ASSEVBLY 5 ANNULAR GASKET OIL DRAIN PLUG SELECTIVE THRUST WASHER THRUST WASHER PINION CAGE amp OUTPUT SHAFT ASS Y o O 3 Fig 7 Parts up for Forward amp Reverse Secti Only Those Par TRANSMISSION CASE NAVE PLATE BAFFLE OIL STRAINER ASSEVBLY ANULAR GASKET OIL DRAIN PLUG SELECTIVE THRUST WEFER ts Different from the ASI 7 DE NO f the AS3 7IC Transmission ssembly are Illustrated 0 O5 DO X PART NO THRUST WASHER PINION CAGE 5 OUTPUT SHAFTASSY DOWEL PIN REVERSE CLUTCH PLATE QUTER CLUTCH PLATE Fig 8 Parts Display for Forward amp Reverse Section of the ASI3 72C Transmission Only Those Parts Different from the ASII 72C Assembly are Illustrated INDEX PART PART NAME TRANSMISSION CASE NAVE PLATE OIL STRAINER ASSEMBLY OIL DRAIN PLUG THRUST WASHER PINION CAGE amp OUTPUT SHAFT r SELECTIVE THRUST WASHER DOWEL PIN 72 A66B REVERSE CLUTCH PLATE OUTER CLUTCH PLATE NN O0
3. SES 179840 d 394 454 450 ur ETT 6 28 ascenso rese 154 50 773 LING s 2 5 Jesse 2 P229 05322 D 179860 ez AESI SEM SER IL ATA HOUSING 454785 y ants 4 6 146 LT P 4 O LL Ih NOST D YA SY AY NS 4 ARES ox jw i VN Meza OEIL L krl an M zx ib 52 5515 eo QA 135 SZ 475605 NE QIE RECOMENDED OUA ORERATING TEMPERATURE 907 2 yid N 79868 i rm TELA 2 N pesi OVERALL MATOS 207 N fe section DY D D ate i558 cad PE s y mi Cross Section of AS3 71C Transmission pra LEONTE of 4 ife mE fece 1940 lt Y 4340000 i 4482 154 30 YA b ale A lt cp 7 a z Sl PITE ZU p LL zz 2 A V NS ER e 2 ot d se un ae Z ES ANE E ACTA S RASO HAD NOS AA ALL PRICES MAR IVA SSI WW PFE D gt LA VS SV d S SC e RK aa E A 0 auna y if a VA Is T Ab UNS 3 7 S e Aor pL UT
4. Lift rear bearing cone from its cup The outer race and front cone can be pressed from reduction housing on an arbor press Press on rear face of front bearing cone while reduc tion housing is supported on its rear face on a clean flat surface DISASSEMBLY OF FORWARD amp REVERSE TRANSMISSION Follow disassembly procedures given in Service Manual Velvet Drive Hydraulic Transmission either Model 70 71 or 72 as required for dis assembly of forward and reverse transmission Fig 12 Transmission on stand INSPECTION AND GENERAL INSTRUCTIONS Cleanliness is absolutely necessary during assembly to insure proper functioning of transmission Trans mission case passages should always have plugs removed to allow for thorough cleaning When available use compressed air to dry parts be fore they are assembled Do not wipe parts with rags to clean or dry them as lint from the cloth may cause erratic valve action Inspect all parts for damage or wear Replace defective parts All gaskets oil seals and rubber sealing rings should be replaced except in relatively new units Judgement should then be exercised as to the need for replacing these parts Oil seals and bearings are best in stalled by using an arbor press suitable fixtures and tools to properly align parts being assembl ed Hammering seals and bearings into position can severly damage parts Automatic transmission fluid type A suffix
5. SERVICE MANUAL VELVET ORME HYDRAULIC TRANSMISSION REDUCTION GEAR ASSEMBLY 2 100 1 RATIO WARNER GEAR N enu BORG WARNER Muncie Indiana DIVISION OF 8086 WARNER CORPORATION ym PRICE 1 50 fm SERVICE MANUAL WELVET DWE HYDRAULIC TRANSMISSION REDUCTION GEAR ASSEMBLY 2 100 1 RATIO Service Manual Supplement for 2 100 to 1 Reduction Units for either right hand or left hand rotation units This manual to be used in conjunction with models 70 71 and 72 Service Manuals which will have slight variations as noted in this supplement WARNER GEAR transmissions BORG J WARNER Muncie Indiana DIVISION OF BORG WARNER CORPORATION TABLE OF CONTENTS CROSS SECTION ASSEMBLY DRAWINGS peo a VG QU V voe oer bY et De a pa qos Sow iere C ES 3 PARTS DISPLAY AND INFORMATION va 232 x8 Rus A RUF POR E AE Bene CR S Ros R Rae RR 5 DESCRIPTION 1 8 nsns 6 DISASSEMBLY OF TRANSMISSION oo ce hr hmmm ree rn ens 9 Removal of reduction housing ring gear and main shaft assembly ehh ehh hehehe eer ran 9 Removal cof pinion cage assembly socerdegue Oe se oa VD we Oe Yos ON 9 Removal of reduction unit adapter and sun gear assemblyeseeeseesseenuuhennuennueuHhesshtsisutessassssesnueaspuessut 9 Disassembly of ring gear main shaft coupling and bearing from reduction H
6. 8 BOLTS AND LOCKWASHERS Fig 27 Installing the Six 7 16 Hex Head Bolts and Lockwashers Fig 28 Installing the Reduction Housing Gasket Rear Fig 29 Installing Reduction Housing Retaining Bolts OUTPUR SHAFT NUT COUPLING Fig 30 Installing Output Shaft Nut A gt Tm gt TORQUE SPECIFICATIONS PART TORQUE NUMBER DESCRIPTION APPLICATION LBS FT 179840 3 8 16 x 1 1 4 REDUCTION ADAPTER TO HEX HEAD BOLT REDUCTION HOUSING 21 32 179860 7 16 14 x 1 1 4 BEARING RETAINER TO HEX HEAD BOLT REDUCTION HOUSING 42 50 179864 7 16 14 x 1 3 4 REDUCTION HOUSING AND HEX HEAD BOLT ADAPTER TO CASE 42 50 4853 7 16 14 x 1 HEX REDUCTION ADAPTER HEAD BOLT LOCKING TO CASE 42 50 4775L 1 20 NUT OUTPUT SHAFT NUT 100 200 4 GENERAL INFORMATION wu MBIGHT LBS TRANGMISSION OLD CAPACITY QUART MODEL EMPTY AS3 70C or CR 1 AS3 71C or CR 1 AS13 72C or CR 153 NOTE OIL CAPACITY DOES NOT INCLUDE CAPACITY NEEDED FOR TRANSMISSION COOLER AND OIL LINES C 16 H 4 MARINE TRANSMISSION STANDARD WARRANIY TO ENGINE MANUFACIURERS Seller guarantees its products against defective material or workmanship for a period of 12 months or 400 hours which ever occurs first from date of delivery to the first owner operator Seller s obl
7. A should be used to lubricate parts as they are assembl ed Petroleum jelly may be used on gaskets or other parts that must be held in position during assembly All rubber parts will slide mores freely if lubricated Tighten all bolts and screws evenl to the recommended torque see page 16 All pinion cage service instructions are covered in the Service Manual Velvet Drive Hydraulic Trans mission under Pinion Cage Service Instruction sheets ASSEMBLY OF TRANSMISSION ASSEMBLY OF PINION CAGE amp OUTPUT SHAFT IN THE TRANSMISSION CASE Place the reduction housing on its forward face and then set the transmission case so that its rear face is supported on the rear face of the reduction housing This will provide proper support for the transmission case during the assem bly of the forward and reverse unit when the pinion cage and output shaft assembly protrudes from the rear of the case Coat steel back of thrust washer with petroleum jelly Install thrust washer on inside thrust sur face of case with washer tang pos itioned in case groove as shown in Fig 13 d Install pinion cage and output shaft flush against thrust washer as shown in Fig 14 Avoid rotation of pinion cage and output shaft during assembly as it tends to unseat washer tang from its groove NOTE Pinion cage and output shaft assembly 72 1A2B is now being supplied with three oil grooves around the large shaft diameter as shown in
8. C1 Rw o 4775L 4547BA 4547AY 3 62 179860 103322 L4 7 Lu 147 X3372 L5 LU 146 4853 am OUTPUT SHAFT NUT COUPLING FCR 70 4 71 MODELS COULING FOR 72 MODEL OIL SEAL 7 16 14x1 1 4 HEX HEAD E 7 t6 LOCKWASHER BEARING RETAINER BEARING RETAINER GASKET BEARING REDUCTION HOUSING REDUCTION HOUSING GASKET REAR LOCK BOLT Fig Epe b 14 15 16 7 18 9 20 21 22 114607 L5 A2 L3 6 57560 13 24 L5 1A150 L5A 1 AI 50 5 L5 8 4766A Lu 155 7 16 LOCKWASHER MAIN SHAFT RING GEAR RING GEAR SNAP RING THRUST WASHER PLANETARY ASSEMBLY AJTOVOTI VE ROTATION PLANETARY ASSEMBLY NN AUTOMOTIVE ROTATION SN GEAR REDUCTION UNIT ADAPTER SNAP RING REDUCTION UNIT ADAPTER GASKET FRONT MN u TYYY YT 12 G 9 Parts Display for 2 100 to Reduction Unit INDE Nene no PART NAN um NO 23 24 25 26 2000 O voo 23 25 LLLED 26 179864 103322 103321 179840 7 16 14x1 3 4 FEX HEAD BOLT N n5 7 16 LOCKWASHER 3 8 LOCKWASHER 6 3 8 16x1 1 8 HEX HEAD LT DESCRIPTION The 2 100 to 1 reduction gear box Location of several transmission operates in conjunction with any of details are shown in Figures 10 and the following models Model 70 TOR 11 as follows 70C 70CR 71 718 71C 71CR 72 728 72C and 72CR A Oil Filler Plug The reduction gear box co
9. Fig 15 This new shaft can be used to replace earlier shafts However the earlier shafts without the grooves must not be useda with the latest forward and reverse y PINION CAGE AND OUTPUT transmission cases supplied without SHAFT ASSEMBLY e 71 28R bushings 4 Complete forward and reverse trans mission assembly by following instructions given in either Service Manual for Model 70 71 or 72 Velvet Drive Hydraulic Trans mission as required SELECTION OF PROPER THRUST WASHER FOR SATISFACTORY END CLEARANCE 5 Forward and reverse unit end clear ameer swouldi be checked by placing Fig 1 Installing Pinion Cage and an indicator on either input shaft Output Shaft or output shaft as shown in Fig 16 Shove all parts to front of case set indicator on zero and then move all parts to rear of case NEW SHAFT by pushing on drive gear End clearance should read between 004 and 043 inch 6 Replace selective thrust washer if necessary to bring end play within above limits NOTE End play checked during dis assembly permits selection of correct washer during reassembly Fig 15 Late and Early Model Pinion Cage and Output Shafts OUTPUT SHAFT THRUST INDICATOR WASHER Fig 13 Thrust Washer with Tang and Fig 16 Checking End Play Groove Aligned TRANSMISSION CASE GASKET Fig 17 in iction Unit Adapter Gasket Front ASSEMBLY OF SUN GEAR AND REDUCTION UNIT ADAPTER ON FORWARD amp REVERSE T
10. OUSING 8 aas ssa 5 Disassembly of Forward amp Reverse A SdHOTIa te e bi m cm a a Da ny aai Ge Rr aT E aS a oaths imu e ah c e ai Stan ua Oath 9 INSPECTION AND GENERAL INSTRUCTIONS 8 8 8 8 8 8 8 8 8 8 8 10 ASSEMBIY OR TBANSMESSION xX x xis a m am m cae 8 LR 8 RUE E M UN 8 OR CE DR NE ER JR RR RR RT 8 8 8 10 Assembly of pinion cage amp output shaft in the transmission case Son ace e ek 10 Selection of proper thrust washer for satisfactory end clearance o oo 4 4 4 4 46 eee teen eee en hh 54 nn 11 Assembly of sun gear and reduction unit adapter on forward amp reverse E sg ion CASEN RR Dm a a T Ca ce Ca Cu CR RR BU Nt a Tw sw a Mie 182 wow Elm ee e Assembly of pinion cage assembly to transmlsSSlOD s 2 73 4 5 5 s non wn wm n m m m m m EA 8 n E m M 8 M 888 m m 12 Assembly of ring gear to main shaft ar mure Ee esq ers 13 Assembly of bearing into the reduct ion housing BOR OR OR HOA HOA
11. RANSMISSION CASE Support Forward and Reverse trans mission on its front face or place it upright on bench with an inch block under back of transmission to give clearance needed for assembling reduction unit parts trans mission stand may also be used as described in the disassembly section of this manual Coat rear face of case with petrol eum jelly and install reduction unit adapter gasket front on rear face of transmission case as shown in Fig 17 REDUCTION UNIT ADAPTER Fig 8 Installing Sun Gear Snap Ring 10 11 12 13 14 15 16 Slide sun gear splines into reduct ion unit adapter splines until gear bottoms on shoulder of adapter Support reduction unit adapter and sun gear on rear face of sun gear and install snap ring firmly into its groove as shown in Fig 18 Install adapter and sun gear over the transmission output shaft and locate pilot of adapter into bore provided in rear of transmission case Assemble the two 7 16 14 x 1 3 4 hex head bolts to insure correct align ment but do not tighten Install six NEW 7 16 14 x l nylock bolts and external tooth lockwashers shown in Fig 19 Tighten bolts evenly and torque to 42 50 pounds feet Remove the two 7 16 14 x 1 3 4 hex head bolts which were installed in step 6 ASSEMBLY OF PINION CAGE ASSEMBLY TO TRANSMISSION the thrust washer on hub of shown in Fig 20 Install sun gear as Engage pinion gears w
12. igation under this guarantee is limited to replacement or repair of any defective material when re turned f o b Seller s factory at Muncie Indiana and shall be subject to Seller s inspection and verification of claim Purchasers of engines or boats using our products should follow the procedure designatedinthe warranty policy supplied by the company from whom the product was purchased WARNER GEAR Division of Borg Warner Corporation Muncie Indiana DIVISI N OF BORG WARNER CORPORATION FORM 108A
13. ith sun gear teeth as planet cage assembly is slowly rotated to align pinion cage splines with output shaft splines then bottom cage against thrust washer on rear of sun gear Fig 19 Removing the Two us inch Bolts After Tightening the 6 Nylock Bolts 18 19 CAUTION Two planetary cage and pinion sub assemblies are available for the 2 100 1 ratio reduction units Selection of proper sub assembly is dictated by direction of transmission rotation Part numbers and matching direction of rotation are shown in Fig 9 Correct cage assembly must be used at all times The pinions are located differently in the two assemblies Install thrust washer on the hub of pinion cage as shown in Fig 21 1 ASSEMBLY OF RING GEAR TO MAIN SHAE T Install mainshaft into ring gear Assemble snap ring firmly into ring gear groove as shown in Fig 22 Assemble ring gear and mainshaft over pinion carrier rotating the ring gear to properly align gear teeth as the ring gear slides onto the pinion gears ASSEMBLY OF BEARING INTO THE REDUCT ION HOUSING Place the reduction housing on an arbor press resting the front face on a clean flat surface Install the first row of tapered bearing so that inner ring rests against the shoulder in the reduct ion housing The relationship of the bearing parts are shown in Fig 23 E AO MEAN E THRUST WASHER PINION CAGE Fig 21 Installing Pinio
14. ks or other damage which might cause leakage and replace if necessary Oil seal is pressed in flush with the rear re tainer face Assemble the bearing retainer onto reduction housing aligning the oil passages as shown in Fig 26 Install the six 7 16 14 x 1 1 4 hex head bolts and lockwashers and torque to 42 50 pounds feet as shown in Fig 27 14 28 29 30 314 32 ASSEMBLY OF REDUCTION HOUSING RING GEAR AND MAIN SHAFT ASSEMBLY TO THE FORWARD AND REVERSE TRANSMISSION Use petroleum jelly to hold reduct ion housing gasket rear in position as shown in Fig 2989 Assemble reduction housing and bear ing assembly over output shaft and position it against rear face of the reduction adapter Install the six 3 8 16 x 1 1 8 hex head bolts and lockwashers and the two 7 16 14 x 1 3 4 hex head bolts and lockwashers as shown in Fig 29 Torque the 7 16 bolts to 42 50 pounds feet and the 3 8 bolts to 27 32 pounds feet Inspect coupling sealing diameter to make sure that there are no burrs or sharp edges which might damage the oil seal or prevent proper sealing replace if damaged Lubricate the sealing diameter and internal Splines with automatic transmission fluid Align splines of coupling to those of the main shaft and press coupling down until contact with bearing inner race is made Assemble main shaft nut as shown in Fig 30 and tighten to 100 200 pounds feet 7 6 15 1
15. n Fig 12 may be built from one inch angle iron One piece is placed to hold the trans mission from sliding forward and a second angle is placed to support the case just forward of the reduc tion unit adapter The two angles may be welded to any suitable sup porting pieces Remove the two 7 16 bolts and lock washers which fasten the reduction housing and the reduction adapter to the forward and reverse transmission case and the 3 8 bolts which fasten the reduction adapter to the reduc tion housing Slide the reduction housing ring gear and main shaft assembly rearward off the trans mission REMOVAL OF PINION CAGE ASSEMBLY Remove thrust washer from rear of planet cage Slide planet cage assembly rearward from unit Remove thrust washer from rear of sun gear REMOVAL OF REDUCTION UNIT ADAPTER AND SUN GEAR ASSEMBLY Remove six lock bolts and lock washers that retain reduction unit adapter then remove adapter and sun gear assembly from forward and re verse transmission 8 10 11 12 13 14 Remove snap ring from sun gear then remove sun gear from reduction unit adapter DISASSEMBLY OF RING GEAR MAIN SHAFT COUPLING AND BEARING FROM REDUCTION HOUSING Remove main shaft nut and coupling and slide ring gear and main shaft from reduction housing Remove snap ring and main shaft from ring gear Remove bearing retainer after remov ing six hex head bolts and lock washers that retain it
16. n Cage Thrust Washer REDUCTION UNIT MAIN SHAFT ASSEMBLY REDUCTION nuusTNG Fig 23 Assembling Bearing into the Reduction Housing ARBOR PRESS BEARING OUTER RACF 2 34 Fig 24 Installing Outer Bearing Race BEARING 24 25 Fig 25 Installing Rear Inner Bearing Race 26 27 Fig 26 Installing Bearing Retainer and Gasket NOTE Bearings are received in matched sets and match marks should check One bearing cone will have a number with an suffix the other will have the same number without the A suffix The outer race will have the same number with the suffix A on one end and no number on the other end The parts with the A suffix should be placed together and the end of the outer race with no number should be placed with the bearing cone without the suffix Lubricate the outer diameter of the outer race with automatic trans mission fluid then using a suitable tool as shown in Fig 24 press race in until it is firmly seated against shoulder in the reduction housing Install the rear bearing cone into the outer race as shown in Fig 25 ASSEMBLY OF MAIN SHAFT ASSEMBLY BEARING RETAINER COUPLING AND MAIN SHAFT NUT IN REDUCTION HOUSING Place bearing retainer gasket on reduction housing aligning the slot with the passages as shown in Fig 26 Gasket may be coated with petroleum jelly for easier assembly Inspect rubber lip of the oil seal for cuts crac
17. nsists of a B Oil outlet Opening to Cooler planetary gear set which is always C Oil Inlet Opening from Cooler engaged and reduces the input revolu D Mountings Pads and Mounting Bolt Holes tion by a 2 100 to 1 ratio The E Shift Lever splined output shaft of the reduction F Oil Drain Cap gear box is coaxial with the input G Breather shaft of the main unit and with the H Drive Gear transmission operating in forward its I Valve Cover direction of rotation is the same as J Coupling 4 that of the engine rotation Lub K Q l Pump L ricating oil is supplied by the pump Reduction Gear Box in the main transmission and is returned to the main transmission by gravity and jet flow CAUTION NOTE Either item 17 or 18 on the preceding page is used depending upon the transmission rotation As can be seen by checking the two parts in Figure 9 the pinion placement is different for the two assemblies DO NOT USE THE WRONG ASSEMBLY Fig 10 Left Side of Transmission Fig Right Side of Transmission SA bo 6 DISASSEMBLY OF TRANSMISSION REMOVAL OF REDUCTION HOUSING RING GEAR AND MAIN SHAFT ASSEMBLY Place transmission right side up on a clean bench and loosen the main shaft nut Place an inch thick block under the rear of forward and reverse trans mission just forward of reduction unit adapter so that reduction unit will clear bench NOTE A transmission stand similar to the one shown i
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