Maintenance and Service Manual T20000 Powershift Transmission 3SPEED INTERMEDIATE DROP 31228.246TOWING OR PUSHING Bolore towing the vehicle, bo Sure to lit the rear wheels off the ground oF disconneat the driveline to avoid damage to the transmission during towing A Note: Ir THE TRANSMISSION HAS 4 WHEEL DRIVE, DISCONNECT SOTH FRONT AND REAR OAIVELINES. BECAUSE OF THE DESIGN OF THE HYDRAULIC SYSTEM, THE ENGINE CANNOT EE STARTED Y PUSHING OF TONG. Copyright DANA CORPORATION 1880. Unpublished material At tgs reserved Limited Distribuion. No part of this work may be reproduced in any form under any means without cirect writen permission of the DANA CORPORATION. Tee000 1D aosFOREWORD This manual has been prepared to provide the customer and the maintenance persennel with information and instructions on the maintenance and repair of the SPACER OFF-HIGHWAY product, Exireme 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 pravide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times. in low cast operation and trouble tree service. In order to become familiar with the varius parts of the praduct, its principle of eperation, troubleshooting and adjustments, it is urged that the mechanic 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 OFF-HIGHWA Y spproved paris as listed in the applicable parts manual shoukl be used, Use of *willfit or non-approved parts may endanger proper operation and performance: of the equipment. SPICER OFF-HIGHWA Y does not warrant repair or replacement parts, nor failures: resulting from the use of parts which are not supplied by or approved by SPICER OFF-HIGHWAY. ZX moonranr Atnrs FURNISH THE DISTRIBUTOR WET" THE SERLAL AND MODEL MAWES HMM GROEAING PARTS. 20000 3 1D antWITHOUT INTERNAL DISCONNECTTable of Contents 1. SAFETY PRECAUTIONS CLEANING, INSPECTION AND LEGEND SYMBOLS 2.1 CLEANING ...... a so 2.1.1 Bearings 2.1.2 Housings. 2.2 INSPECTION, 2.2.1 Bearings 222 Oil Seals, Gaskets, Ete 2.2.9 Goars and Shafts 2.2.4 Housing, Covers, ete. 2.9 LEGEND SYMBOLS...... 3. TECHNICAL SPECIFICATIONS 3.1 IDENTIFICATION OF THE UNIT 3.2 WEIGHT, DIMENSIONS, OL CAPACITY... 3.3. TIGHTENING TORQUES .. 8.8.1 Torque specications for lubriated or plated scvew treads 9.8.2. Elastic stop nut torque... 3.33 ‘O-ring port plug torque chart 3.3.4 Pipe plug torque chart... 3.5 Permanent metric plug torque chat... 9.3.6. Goll and cartridge torque .. 3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS .. 3.5 ELECTRICAL SPECIFICATIONS... 3.68 HYDRAULIC COOLER AND FILTER LINE SPECIFIGATIONS 4, MAINTENANCE 4.) OIL SPECIFICATION. 4.1.41 Rlecommended lubricants... 4.2 MAINTENANCE INTERVALS 4.2.1 Daily... 4.2.2 Normal drain period .. 4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL. Tee000 1D own bist 52 5g 54 61 62 og 64 OPERATION OF THE TRANSMISSION INSTALLATION DETAILS CONVERTER DRIVE COUPLING. TRANSMISSION TO ENGINE INSTALLATION PROCEDURE _. EXTERNAL PLUMBING. . 5.3.1 Optional: remote filter 5.2.2 Cooler & filter lines specifications... SPEED SENSOR INSTALLATION ..occecccensoeennnviteninnnnetn THE TRANSMISSION ASSEMBLY 6.1.1 The converter, pump drive section and pressure regulating valve .. 6.1.2 The input shaft and directional clutehes.......c0nccns seen 6.1.8 The range clutches oo nnn 6.1.4 The output section... 6.1.5 The transmission controls (refer to hydreulic diagram)... ELEGTRIG SOLENOID CONTROLS «0... eee POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT 6.2.1 Neutral and Srd clutch engaged ... 6.3.2 Forward Ist speed enn 6.3.3 Forward 2nd speed ccm 6.3.4 Forward Grd speed cen 635 Reverse 1st speed GEAR AND GLUTGH LAYOUT «concern 7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION 7 72 73 74 75 T2G000 TRANSMISSION soscssssse — esse TROUBLESHOOTING PROCEDURES 7.24 Stall Test 7.2.2 Transmission pressure checks 7.2.3 Mechanical ang electrical checks .. 7.24 Hydraulic check TROUBLESHOOTING GUIDE 7.21 Low cluteh pressure coco se sn 7.22 Low charging pump Outpt soc. 7.23 Overheating ...... vee TBA NOISY CONVERER esses sses in TAS LACK Of POWER neste sns ites CHECK POINTS no SPEED SENSOR - STATIC STANDALONE TEST cn ores cv vsnensnavnenscneanne TOP 20000 3 1D oat ui§. SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP - CONVERTER HOUSING o.oo GROUP - TRANSMISSION CASE AND REAR COVER GROUP - TURBINE SHAFT GROUP - DRIVE PLATE GROUP - TORQUE CONVERTER .... GROUP - AUXILIARY PUMP DRIVE... GROUP - PUMP DRIVE GROUP - FORWARD SHAFT GROUP - REVERSE AND 2ND SHAFT. GROUP - REVERSE IDLER GROUP - LOW SPEED SHAFT.. GROUP - SRD SHAFT... GROUP - OUTPUT SHAFT (FRONT & REAR CUTPUT) . GROUP - OUTPUT SHAFT [REAR QUTPUT)..... GROUP - OUTPUT SHAFT {INTERNAL DISCONNECT) GROUP - INTERNAL DISCONNECT (AIA - HYD. ACTUATED). GROUP - GHARGING PUMP & FILTER 0000 - GROUP - CONTROL VALVE (MECHANICAL) ..... GRQUP - GONTROL VALVE ASSEMBLY (MECHANICAL) . GROUP - ELECTRIC CONTROL VALVE MOUNTING GROUP - ELECTRIC CONTROL VALVE ASSEMBLY....... GRQUP - MODULATOA VALVE 9. ASSEMBLY INSTRUCTIONS 10, DISASSEMBLY AND REASSEMBLY 720000 INLINE TRANSMISSION 11. OPTIONS: 11.1 PARKING BRAKES: 11.1.1 Mechanical Brake 11.1.4.1 Sectional views and parts identification .. TAA. Adjustment and rebuild criteria co 11.1.1. Replacing friction pads... se 114.14 Disassembly ne 11-2 12 We? nz 11-8 11.4,1.5 Cleaning and inspection ... vnivnsninneetn one AB 111.1.6 Assembly 414.4.7 Replacing mou no cme 118) vn No ushings 11.1.8 Servicing rotor assembly ~ 11.1.2. Spring applied hydraulic released brake (high pressure) wan. 11-10 44.4.2.4 Sectional views and parts identification ... 414-10 11.1.22 Operation . 11-15. 11.1.2.3 Adjustment and rebuild criteria... somes HTB 11.1.2.4 Replacing trietion pads 411-15, 14.1,2.8 Disassembly 11418. 11.7.2'8 Cleaning and inspection 11-16 1-16 wt? rsntcsneie TAT 11.4.2.7 Assembly 11.1,2.8 Installation 11.1.2.9 Torque specs Tee000 1D own Li11, OPTIONS (Conmuen) 14.1.2. Spring applied hydraulic released brake (law pressure) 1118 11.1.8.1 Sectional views and parts identiication fv fone AB 11.1.3.2 Operation... : 7 1428 11.1.8. Adjustment and rebuild erteria 11-23 11.1.3.4 Replacing friction pads 11-28 144.35 Disassembly coco 14-23 14.1.8.6 Cleaning and inspection 124 FAB? Assembly cnn 11-34 11A.3.8 IStallation con nt ene fovnnes TUBS: 11,1.3,9 Torque specs: 11-25 12. SERVICE TOOLS: 12.1 REVERSE IDLEA SHAFT NUT SOCKET (TG 1904 - $4)... a re A 12,2 OIL SEALING RING SIZING TOOL soins soionnsnisianninnnnnnmennanne BD 20000 3 1D oat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. It replacement parts are raquited the part must be replaced by a spare part which has the same part number or with an equivalent part, Do not use a spare part of lesser quality. The service procedures recommended in this manual are effective methods for periarming service and repair. Some of these procedures require the use of tools specifically designed fer the purpose. ‘Accordingly, anyona who intends to use a spare part, servioe prooadura or tool, Which is net recommended by SPICER OFF-HIGHWA Y, mus! frst determine that neither his salsty nor the sale operation af the machine will be jeopardized by the spare part, service procedure or tool selected A\ suvonanr Tris neostanr To nore THAT THIS MANUAL Contam vaRaUs CAUTIONS’ awa ‘NOTES! THAT MUST BE CAREFULLY O28ERVED IV ORDER TO REDUCE THE RISK OF PERSONAL MURTY URNG SERVICE (OF REPAIR, OF THE POSSIBILITY THAT MPROPER SERVICE OA AEPAIN MAY DAMAGE THE UNIT OR RENDER (7 UNSAFE, Ts A150 RPORTANT TO UNDERSTAND THET THESE ‘CAUTIONS ano ‘NOTES’ ARE NOT EXHAUSTIVE, BECAUSE IT 1S IMPOSSELE TO WARN ABOUT ALL THE POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT POM FAILURE 10) FOLLOW THESE INSTRUCTIONS. Tee000 1D aos 1CLEANING, INSPECTION AND LEGEND SYMBOLS. 2.1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid, itis recammended that parts be immersed in Cleaning fluid and moved up and down stowiy until all ol lubricant and foreign material is dissolved and parts are thoroughly cleaned ZN CAUTION (CARE SHOULD RE EXERCISED TO AVON SieN RASHES. FF HAZARDS, ANDY BIALATION OF VAPOURS WHEN USING 2.4.1 Bearings Flemove bearings from cleaning fluid and sive flat against.a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush aut particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-tree compressed air, Be careful to direct air straam across bearing fo avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process. 2.1.2 Housings lean interior and exterior of housings, bearing caps, ete... thoroughly. Gast parts may be cleaned in hat solution tanks with mild alkali solutions providing these parts do not have graund or polished surfaces. Parts should remain in solution long enough ta be tharoughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in sclution tanks must be tharaughly rinsed with clean water to remove: all traces of alkali, Cast parts may also be cleaned with steam cleaner, AN CAUTION (CARE SHOULD HE EXEROISED TO AVOID INHALATION OF WAPOURE AND SKIN SASHES WHEN USIMGS ALKAL] CLEANESS, Allparts cleaned must be thoraughly dried immediately by using moisturé-free compressed airar soft, lintless absorber wiping rags free of abrasive materials such as metal lings, contaminated all, or lapping compound 2.2 INSPECTION The importance of careful and thorough inspection of all paris cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures ata later date, 22.1 Bearings Garetuity inspect all rollers: cages and cups for wear, chipping, oF nicks to determine fitness of bearings for further use, Oo not replace a bearing cane or cup individually without replacing the mating cup oreone al the same time. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or apor to protect them until instalied, 20000 3 1D ant a4Cleaning, inspection and legend symbols 2.2.2 Oil Seals, Gaskets, Etc. Replacementof spring loadoll seals, “O"rings, metal sealing rings, gaskets, and snap rings ismore econontical when unit is disassembled than premature overhaul to replace these paris 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 bo handled caretully, particularly when being installed. Cutting, 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 theit grooves for ease of assembly of mating members, Lubricate all O"-rings and seals with recommended type Automatic Transmission Fluid before assembly. 2.2.3 Gears and Shafts IW magna-flux process is available, use process to check parts. Examine teeth on all gears earatully for wear, pitting, chipping, nicks, eracks, or scores, f gear teeth show spots whare case hardening is worn through oF Cracked, replace with new gear. Small nicks may be removed with suitable hone, Inspect shaits and quills to make eerlain they are nol sprung, bent, or splinas twisted, and that shafts are true 2.2.4 Housing, Covers, ete, Ingpect housings, covers and bearing caps to ensure that they are thoroughly clean and that mating surtaces, bearing bores, ete... are tree fram nicks or burrs. Check all parts caretully far evidence of eracks or conditions Which would cause subsequent ail leaks or failures, 2.3 LEGEND SYMBOLS CS. % Soo Ce) otro Dronama ae BE oer cers nmn a ‘eee aoe rata GP rocmcmnnaons ferarhtaneaihie pig. | cmureapemnanrnos [yy orem enone BEF teat erormteatentatcttnnsdeosens] | EP | canner acannon ee enon, eens ecirto ‘aha pri a antag (risen om eters sary, sare asi wren rsa Cerne mpitses cose meses (Ce aeteg tegatana pratt Caria erro ok: ee Fring -opcng tng oR Smee Taateeen pect Pash Tespecallaol =Page ‘rare a, bears ete rte orton ‘Cerne esi conte unit ornate mcraacintct Cc4+0H62 ‘osnapeten oy eae bao arate iu Everiminene icin scet ence ce aoe oa Pome seca, ee etry Be | mm Rm ho ee Tee000 1D aos 223. TECHNICAL SPECIFICATIONS 3.1 IDENTIFICATION OF THE UNIT 1. Model and type af the unit 2. Serial number. 3.2 WEIGHT, DIMENSIONS, OIL CAPACITY Weight (dry): +280 kg (618 Ib.) Temode! Maximum length: 810.9 mm (97.80) Maximum width: 555.1 mm (21.86") Maximum height: 728.8 mm (28.69") Ol capacity 416.01 {4.3 US Gallon) without cooler and hydraulic ines. Consult eporator’s manual on applicatle machine lor system capacity: 20000 3 1D ant atTechnical specifications 3.3 TIGHTENING TORQUES 3.3.1 Torque specifications for lubricated or plated screw threads NOM, SIZE craves €) NETHRERD ‘COARSE THREAD ar -FT arr Nn 200 en 8-10 ess ry 6-2 2-18 [ne -22 7 pel BS 25 t-a5 sea 500 om (5) ae rts) 5625 1-100 (23-136) 82-90 [unt - 123) 2 TRH [74 191} 113-124 1153-168) 7500. 23-25 [302-382] 20-200 [et -298) NOM, SIZE craves GD FINETHREAD ‘COARSE THREAD Ue FT Ni aF-ft Wn 250 ne fm ai pe tas ew p89 0 ea a0 ara 0-8 2.8 15) 8 s-6 va 51 mi-7m 520 38 jee 3 2.88 [r= 5825 we 144 ee 115-007 [s6=178 es 1-18 pes 29] 19-15 Bl6-207 i 6-37 or 7 20-310 e242 NOM, SIZE GRADES or 88 GRADE 109 COARSE THREAD (COARSE THREAD ar -FT sc LaF Wn 3 6-2 pa 2-8 po-8] m0 0-80 ee boa) Miz [es 78) 74-81 (100-110) 20000 SD oa: oeTechnical specifications 3.4.2 Elastic stop nut torque THREAD SIZE LB-FT IN.m) 1-20 150-200 eon4- 271.11 Te 0-20 Tia saa] 300-380 [206.8 74.5) 18818 00-480 [24-6101] 333 THREAD SIZE LBF - FT [N.m} 18-18 12-15 116-29) e168 20-5 [EE 9.3.4 Pipe plug torque chart THREAD NPTF TORQUE UF FT el mee BT 7-4 8-27 7-10 p-14) 18-18 15-2 (a-2i ae a0 [ae] wl 30-36 ia] a-10 0-45 (56-611 Ti 38-80 (68-781 tH 0-88 eo 3.35 Permanent metric plug torque chart ‘THREAD SIZE UBF FT [r} Mg 15 BH 35.20 peat] A 550 (64) 20000 3 1D antTechnical specifications 3.3.6 Coll and cartridge torque A tighten eartridge to 22-27 Nom (16-20 LBF-FT) B: tighten cartridge nuts to 5-7 N.m (4-5 LBF-FT) Te0000 SID avoTechnical specifications 34 PRESSURE AND TEMPERATURE SPECIFICATIONS * Normal operating temperature 70 - 120 "C (188 - 248 F) measured at temperature check port ‘conwerter out {port 71 = + Maximum allowed transmission temperature 120 °C (248 F). + Transmission regulator pressure (*) - (neutral) - port 31 (°*) ~ At 600 RPM min. 12.4 bar (180 PSI) minimum, = At 2200 RPM: 15.2 bar (220 PSI} maximum. + Pump tiow (*) +A 1800 RPM in neutral: 54.9 Winin, minimum (14.5 GPR). * Clutch pressures (7 = st clutch: port 41"). = Bnd clutch: part 42 = Bed clutch: port 43 ("). ~ Forward sluten: port 45 (°°) Reverse cluteh: port 46 (*"). ‘At 2000 RPM +124 - 18.2 bar (180 - 220 PSI clutch activated, 0-02 bar (0. 3 PSI clutch released, © Filter bypass valve set at 1. - 1.7 bar(*) (22 - 24 PSI). © Lube pressure (*) (port 33) 0.7 - 1.4 bar (10 - 20 PSI) at $4.9 min. (14.5 GPM) pump flow (£1800 APM), + Safety valve: cracking pressure (*) 8.2 - 12.1 bar (120 - 175 PSI). * Converter out pressure (*} (part 22) 1.7 bar min. (25 PSI) at 2000 RPM and max. 4.8 bar (70 PSI} at no load governed speed. (*) All pressures ang flows to be measured with oil temperature of 82-98 °C (180-200 F). (") eter to section 7 *Troublashooting’ for check port identification. 20000 3 1D ant 353.5 ELECTRICAL SPECIFICATIONS + Solenoid (forward, reverse, tstand 2nd) Coil resistance: 12V.9.79.0 £0.50, 2AVI99.9.0 220, ‘+ Speed sensor: + Type: magneto resistive sensor. Sensing distance: 0 - 1.8 mm (0" - 0.077) + Sensor signal: generates a square current with a fixed amplitude changing between 7 and 14 mA. 3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS + Minimum 19 men (.75") intemal diameter for lines and fittings. ‘= Suitable for operation from ambient to 120 °C (248 F) continuous operating temperature. ‘© Must withstand 20 bar (290 PSI} continuous pressure and with 40 bar {580 PSI) intermitient surges, = Conform SAE J1019 and SAE J517, 100R!I Te0000 SID aosMAINTENANCE 4.1 OIL SPECIFICATION 4.1.1. Recommended lubricants 1. Caterpillar TO-4, 2. Jahn Deere 20 0, D. 3. Military MIL-PRF.2104G, 4. Alison C4 5. Dexran* ll Equivalent - See note below, LN sow (Dexmon” || coUIvALErr &$ ACCEPTABLE; HOWEVER IT NOT COMMBKTELE WTIe TORQUE CONVERTERS OR TRANSINISSIONS EQUIPPED WITH GRAPHIC: FRICTION MC LN causes Dexnon’ II], Enoive ov on GL-8 ous ane NOT RECOMMENDED. tL CLUTCH PLATES, PREFERRED OIL VISCOSITY It is racommendad that the highest viscosity manograde lubricant available be used for the anticipated ambient temperature. Typically this will be a GAT TO-4 qualified lubricant, When large swings. in ambient temperature are probable, J20 C, D multigrades are recommended, Multigrade lubricants should be applied al the lewer viscosity rating tor the prevailing ambient temperature, ie. a 10W20 shaultt be used where a 1OW monagrade is used, If a C-4 multigrade is: used in stead of J20 lubricant it is recommended that the viscosity span no more than 10 points, Le. 10W20. A cout SYNTHETIC LUBRICANTS ARE APPRQVED 1 QUALIED BY-ONE OF THE ABOVE SPECIFICATIONS, (Oi Wiscasmry GUIDELINES APPLY, AUT SYATHETIG MULNGRADES WAY SPRN MORE THAN 10 POINTS, Fon PRE RESISTANT FLUID RECOMMENDATIONS PLEASE contact SPICER OFF-HIGHWA ¥. ex Gnd Pati erg tae Femme Re & ae . s 20000 3 1D ant a4SUMP PREHEATERS Preheat the transmission fluid tothe minimum temperature for the oll viscosity used betore engine start up. NORMAL OIL CHANGE INTERVAL Drain and refil system every 1000 hours for average envirenmental and duty cycie conditions. Severe or Sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination. Judgement must be Used to determine the required change intervals tor extreme conditions. EXTENDED OIL CHANGE INTERVAL Extended oil service lite may resuil when using synthetic fluids. Appropriate change intervals should ba determined fer each transmission by measuring oil oxidation and wear metals, over time, 10 determine & baseline, Wear metal analysis ean provide useful information but a transmission should not be removed from service based solely on this analysis. FILTERS Service oil filters slement every 500 hours under normal environmental and duty cycle conditions “Dexron is a registered trademark of GENERAL MOTORS CORPORATION Tee000 1D aos a24.2 MAINTENANCE INTERVALS 42.1 Daily Chock oll level daily witn engine running at idle (600 RPM) and oll Maintain oil tevet at full mark. 1 82 - 93 °C (180-200 F), 4.2.2 Normal drain period Normal drain period and oll fiter element change are for average environment and duty cycle conditien, ‘Sovore ar sustained high operating temperature of 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 Ghange ail fiter element. Every 1000 hours Drain and refil system as follows (Drain with oil at 65 - 95.°C: (150 - 200 F)) 4.0 transmission 2, Remove and discard filter. Install new filter. 8, Relill ansmission to FULL mark, 4, Run engine al 500 - 600 RPM to prime corwertor and lines, 8, Recheck level with engine running at 500 - 600 IPM and add oil to bring level to LOW mark ‘When ail temperature is hat 82.2 » 93.3 °C (160> 200 F) make final oi! level Check andl adjust it necessary 10 bring ail level te FULL mark, A we Iris neconmennen re OIL rierEst REBUILT OF PREPARED U OuNGED AFTER 100 HOURS OF ORERETION ore NEN, 20000 3 1D ant 43Maintenance 4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL ‘The transmission, torque converter, andits allied hydraulic system are important links in the driveline betwoen the engine and the wheels. The proper operation oj either unit depends greatly on the cendition and aperation of the other. Therefore, whenever repair or overhaul af one unit is performed, the balance of the system must be considered batore the jen can he cansidered complate, ‘After the overhauled er repaired transmission has baén installad in the machine, the oil coalar, and connecting hydraulle system must be thoroughly.cleaned, This can be accomplished in several manners and adegrae-of judgement must be exercised as fo the method employed. The following are considered the minimum steps te be taken: 1, Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed frarh machine: ‘or cleaning. 9, Replace oil titer ebement. 4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed" with oil and compressed air until all foreign material has Deen removed, Flushing in diréction of narmal ol eww will not adequately lean the cooler. If necessary, ceoler assembly should be removed from machine for cleaning, using oil, compressed ait, and steat cleaner for that purpose. AN IMPORTANT DO NOT Use FLussinia coupHUNDS FOR CLEANING PURPOSE: 5, Reassembie all components and use only type oll (See chapter 4.1.1 “Recommendad lubricants") Fill the transmission through tiller opening until fluid cames up to FULL mark gn transmissign dipstick + Flemove tiller plug and til oil until FULL mark, + Flun engine two minutes at 00 - 600 RPM to prime torque convertor and hydraulie lines. * Recheck level of fluid in transmission with engine running at idle (500 - 600 RPM). + Add quantity necessary tc-bring fluid level io LOW mark cn dipstick, "Recheck with hot cil 82.2 - 93.3 °C (180 - 200 F). + Adjust oil Ievel to FULL mark on dipstick, 6. Recheck all drain plugs, lines, cannections, ele...., for leaks and lighten Where necessary. Tee000 1D aos at5. INSTALLATION DETAILS 5.1. CONVERTER DRIVE COUPLING Measure the “AT dimension (bolt circle diameter) and order drive plate kit listed below Nota thrae (3) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Thea (3) kits with three intermediate drive plates. Cberenvenuce ewe ures sokeionn fh InTEPREDUTE ORE ALTER Dimension (Bolt circle diameter) + 11.980" (288.900 mm) diameter Kit No. 814978, + 19,125" (833.98 mm) diameter Kit No. 814977. ‘+ 13.500" (342,90 mm) diameter Kit No. 814975. Each kit will include the following parts: + 2 Intermediate drive plates 4 Drive plate and weld nut assembly. 1 Backing ring. + 6 Mounting sorews., 6 Lockwashors: | Instruction sheet “A™ Dimension (Bolt circle diameter) + 17.280" (288.900 mm) diameter Kit No. 814979, * 18.125" (833.48 mm) lamater Kit No. 814960, * 13.800" (342.90 mm} diameter Kit No, 814961, Each kit will include the follwing parts: + Gintermediate drive plates. #4 Backing ring * 6 Mounting screws, * G Lockwashers. * 1 Instruction sheet. Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter. Align intermediate drive plates and backing plate with holes in torque converter assembly. A wor Two DiMeLes 180° APART mF BACKING FING MUST RE OUT TOMARD: ENGINE FLYWHEEL (SOLLOW SIDE FACING TOROUE CONVERTER ASSEMELY). INSTALL CAP SCREWS AND LOCKWASHERS. Tiare cap ScReves TORQUE 401+ 50 Nau. (90 » 37 uae. 20000 3 1D BtInstalfation details 5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1. Remove all burs from flywheel mounting face and nose pilot bore, Clean drive plate surlaoe with solvent, 2. Check engine flywheel & housing toe conformance tostandard SAE No. 3 per SAE J927 and J1033 tolerance specifications. tor pilot Dore size, pilot bore runout and mounting lace flainess, Measure land record engine crankshaft end play (Fig. 1) Install two 63,50 mm (2.50) lang transmission to flywheel housing guide studs in the engine flywheel housing as shown. Rotste the engine fiywhee!ta align a drive plate mounting screw note with the flywheel housing access hole {Fig.2) “4. Install a 101,60 mm (4.00% lang drive plate locating stud 3750-24 fine thread in adrive plate nut. Align the locating stud in the drive plate with the Ilywheel drive plate mounting screw hole positioned in step No.3. 5. Rotate the transmission torque converter to align the Incating stud in the ceive plate with the thwnee drive plate mounting screw hole posilonedin sep Na. 3. Locate transmission on flywheel housing, ‘Aligning drive plate to flywheel and transmission to flywheel housing guide studs. Install transmission to flywheel housing screws. Tighten ‘screws to specified torque. Remave transmission to engine guide studs. Install remaining screws. and ughien to specified torque. “6. Remove drive plate locating stud. 7. Install drive plate attaching sorew and washor ‘Snug screw but do not tighten, Some angina flywheel housings have a hole located on the flywheel housing circumference in ina with the drive plate screw access Mole. A scremdriver or pry bar used te hold the drive plate against the flywheel willfaciitate installation ofthe drive plate sscrows, Rotate the engine flywhee!| andinstall the remaining seven (7) flywheel to drive plate ataching serows. Snug sorews butde not tighten, Alter all eight (8) screws are installed. ‘Torque each one35 19:39 N.m, (26- 291K ibs.) This will require tightening each sceaw and rotaiing the ‘engine flywheel unbl the full amount of eight (3) ‘screws have been lightened to specified torque. 8. Measure engine crankshait end play after ‘eansmission has been completely installed on engine flywheel. This value must be within 0,025 mm (0.007") of the end play recorded in stop No. 2 * Does notapply to unitshaving 3 intermediate drive plates. See Fig.4. Tee000 1D aos Rs : eh 525.3 EXTERNAL PLUMBING roe sl 5.3.1 Optional: remote filter abneaoetrammee hen ree 5.3.2 Cooler & filter lines specifications + Minimum 19 mm (.75 inch) internal diameter for lines and ttings. + Suitable for operation from ambient ta 120 °C: (248 F} continuous operating temperature. += Must withstand 20 bar (280 psi) continuous pressure and with 40 bar (580 psi} intermittent surges. * Conform SAE J1019and SAE S17, 100A. 20000 3 1D antInstalfation details 5.4 SPEED SENSOR INSTALLATION a on he sensor body her i msl este Want peso in ‘Make sure the position sign on the sensor points as shown below Inte ecient ie mover! he geaou eet atone hot nai. ea ote SF Uff es er A e\ \e\ é ae aA, set sr tein “ute peedenerhctoe Tee000 1D aos54 SPEED SENSOR INSTALLATION (conminuen) e ©™ | Le Pin 49 (oy ts The magneto resistiva sensor generates a square wave current with a fixed amplitude changing between 7 mA and 14 mA, ‘The sensor has an integrated AMP superseal 2 pin cennector. The two pins are numbered 7 and 2. Following table shaws the rolatian between wire colaur, pin number and cannection, COLOUR PINMUMBER | FUNCTION CONNECTION BaCHi 1 Cures input Hot wte BLE 2 ‘Curent euput Ground wire A sw THE SENSOR WRES HAVE & POLARITY. Be SuNE To CORRECTLY OMSESWE SENEON FOLARIES, AS WIIORG CONNECTIONS WILL DEACIIVATE THE SEN5OH | 20000 3 1D ant 556. OPERATION OF THE TRANSMISSION 6.1 THE TRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies: 1, 1 The converter, pump drive section and pressure regulating valve. 2, HEED The input shalt and directional clutches, 3, MMM The ranga clutches. 4. ESSE The output section. 5, EEE The transmission control valve, Teo000 SID avo erQperation of the transmission 6.1.1 The converter, pump-drive section and pressure regulating valve Engine power is transmitted from the engine flywheel te the impeller through the impeller cower. 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 toa centrifugal pump, that picks up fluid at its Centre and discharges it at the outer diameter. The torque converter turbine is 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 impelier and turbine elements, Its function is te take the fluid which is exhausting from the inner portion of the turbine and change its direction ta allow correct entry for recirculation inta the impeller element This recirculation will make the converter to mutipi torque. The torque muipication is function of the blading (impeller, turbine.and reaction member} and the converter output speed (turbine speed) The converter will multiply engine torque toits designed maximum multiplication ratio when the turbine shatt is at zero RPM (stall). ‘Theretore we can say that as the turbine shall is decreasing in speed, the torque multiplication is increasing. The hydraulic pump is connected with the pump drive gear. This pump drive gearis driven by the impeller hub gear. Since the impeller hub gear ts connected with the: impeller cover, the pump speed is in diract relation with the engine speed ZV soe ‘TWE PRESSURE REGULATOR VALVE AND SAFETY NALYE ARE MOUNTED BEND (NC THE PIETER ADAPTER HOUSING, aren, (= THe COWERTER PUMP OANE SECTION AND PRESSURE REGULATING VALVE 20000 3 1D ant 62Operation of the transmission 6.1.2 The input shatt and directional clutches ‘The turbine shaft diiven from the turbine transmits power to the forvraid or reverse clutch These clutches consist of a drum with internal splines and a bare to receive a hydraulic actuated piston. The piston is oil tight by the use of sealing rings. The steo! discs with extemal splines, and friction disos with internal splines, are alternated until the required total is achieved ‘A back-up plate is then inserted and seoured with a retainer ring. & 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 89000 ar rotate in the opposite direction as lang as no pressure Is present in that specitic clutch, To engage the clutch, the solenoid will direct oil under pressure through tubes and passages ta the selected clutch shafts, il. sealing rings are located on the clutch shafts, These rings direct the oil through a drilled passage in the chaft to the desired clutch, Pressure of the oil foroes the piston and discs against the back-up plate, The disas with splines on the outer diameter clamping against discs with testh on the inner diameter enabies the drum and hub to be locked together and alles them to drive as one unit. When the clutch is released, a return spring will push the piston back and oil willdeain back via the shit spool, the bleed vaive er holes in the elutch piston into the transmission stump. ‘These bieed valves wil only allow quick escape of oll when the pressure ta the piston is released ‘As an option the engagement of the directional cluiches ean be modulated. This means that clutch pressure is bu up gradually. This will enable the unit to make forward, reverse shits while the vehicle is still moving and will allow smooth engagement of drive. The modulation is done hydraulically. (GERRI THE INPUT SHAFT AND DIRECTIONAL CLUTCHES: Tee000 1D aos 63Operation of the transmission .3. The range clutches (Ones a directional cluteh ie engaged power is transmitted te the range clutches (1st, 2nd or ard). Operation and actuation of the range cluiches is similar to the directional clutches. ‘The engagement ot the range clufohes are nat modulated. 6.1.4 The output section With a range elutch engaged, power is finally transnvtted te the output shaft. utput rotation is opposite as the engine rotation when the forward clutch is engaged. A front and/or rear axle disconnect is optional and is located on the output shaft. The drive to the front ancl or rear axle can be disconnected or connected by manual shifting. 20000 3 1D ant 64Operation of the transmission 6.1.5 The transmission controls (refer te hydraulic diagram) ‘The transmission is contvalled by the control vahve, The control valve assembly is mounted directly an the side of the converter housing, The function of the eontral valve assembly is to direct oil under pressure to the dasirad directional and speed clutch. A provision is made on certain madels fer inching ar deciutch whan the brakes are apaliad, This is accomplished through use of a brake actuated valve, Operation of the valve Forward can be selected by activating the forward solenoid, The forward soleneid will then allow pilot pressure to move the forward shift spool, ue to this movement of the shift spool, the farward cluteh is ted with oil prassure. When the reverse solencid is activated, pilot pressure will mova the reverse shift spool The reverse clutch will be fed with oll 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. fomard sinsad Fwese sand Sanson TR THE TRANSMISSION CONTROLS Selection of range I the range solenoids 1st and 2nd are activaled, regulated pressure Is fed thraugh the shift spools to the Ist cluten, It the range solenoid 2nd is activated, regulated pressure Is fed through the shift spools to the 2nd clutch. Ino range solenoids are activated, the requiated pressure is fed to the Srd clutch. Tee000 1D aos 65Qperation of the transmission 6.2 ELECTRIC SOLENOID CONTROLS ‘Transmission gear Activated solenaids Activated clutches Forward S Forward Forward, Sra Forward 2 Forward, and Forward, 2nd Forward 1 Forward, 1st, 2nd Forward, 1st Neutral 3 - rd Neutral 2 end 2nd Neutral 1 fst, 2nd ist averse 3 Reverse Reverse, Srd Fleverse 2 Reverse, and Reverse, 2nd Fleverse 1 Reverse, tat, 2nd Reverse, ist 20000 3 1D antOperation of the transmission 6.3 POWERFLOWS, ACTIVATED SQLENOIDS AND HYDRAULIC CIRCUIT 6.3.1 Neutral and 3rd clutch engagedQperation of the transmission 6.3.1. Neutral and 3rd clutch engaged (continued) (earasnt= a0) ‘03 9¥9N3 HOLD CHCONY TWELNSN sent ai dOU0 SUVIOaMLLM NOISSIRSNYHL O23eS 6 DanIEvnN09 YOUVE) INYO IO NNYHOAH MOISSINSNNHL OOOTEL ant 20000 3 1DOperation of the transmission 6.3.2 Forward ist speedQperation of the transmission 6.3.2 Forward ist speed (continued) OQ» 2 ac => => ae 6 a we _ ~ a 4 pe 3 a be al } 3 dl atl aude a JNAVaNOO WoL ‘G@DYSNa HOLT LSE ONY GHYINUOE 40U0 SLVICRIIWELNI NOISSINSNYUL OB3dS & NYHOYIC ONNWWOAH- WOSSINSNNEL OO0ZL 6410 ant 20000 3 1DQperation of the transmission 6.3.3 Forward 2nd speed (continued) sam (1) om @ JNAVaNOO WoL ‘o39vONa HOLTD aNE ONY CBYINKOS 40U0 SLVICRIIWELNI NOISSINSNYUL OBRUS & NYHOYIC ONNWWOAH- WOSSINSNNEL OO0ZL 612 ant 20000 3 1DFORWARD Sr jasTHteD SOUENOIS ANDLSFOOLS)Qperation of the transmission 6.3.4 Forward 3rd speed (continued) Q o> o> o> 6 6 & é ae 3 3 3 a jl _ ta = mf) at éL él “ 2 mas =e NBC WOLKE ‘O3DvOKG HOLMNTO CE ANY OHNO 4OU0 BLVICHINWELN NOWSSWISH YUL 03345 ¢ res OMNYIOAH NOISSINSHINE COON eta ant 20000 3 1DOperation of the transmission Reverse 1st speed6.3.5 Reverse 1st speed (continued) Qperation of the transmission Isstieri= man are re GBO WON HOLITIO 181 ONY 3SeHNH seme see 4040 BLVIGaIIWaLM NOISSWISN UL 93345 € {NUE BOLWEREO NYO OMEGA NOSSIRSHVEL CoODeL 6416 ant 20000 3 1DOperation of the transmission 6.4 GEAR AND CLUTCH LAY-OUT EE owes CE te meimene (ES Pownsiter sa C2) ovpteecin Teo000 SID avo er?TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION The following informatian 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 compenents of the group. Therefore, to property diagnose @ Suspected problem in the transmission, itis necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oll cooler, filter, connecting lines, and centrols, including ihe engine, as a complete system, By analysing the principles of operation tegether with the Information in this section, it should be possible to identify and correct any malfunction which may eccur in the system, 7.1 720000 TRANSMISSION 20000 (power shift with torque converter transmission) troubles fall into three general categoria 1. Mechanical problems. 2, Hydraulic problems, 3, Electrical problems. In addition to the machanical and electrical components, all af which must Be in the proper condition and functioning correctly, the correct functioning of the hydraulic circu is most important. Transmission fluid is the “fe blood” of the transmission, It must be supplied in an adequate quantity and delivered ta the system al the comect pressures to ensure converter operation, te engage and hold the clutches trom slipping, and to ool and lubricate the working components, 7.2 TROUBLESHOOTING PROCEDURES 7.21 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, andier apply the parking brake and black the whaeis, 2, Pul tha directional control lavar in FORWARD (or REVERSE, as applicable) 8, Select tha highest speed. ‘With the engine running, slowly increase engina speed to approximately one-halt thrattie and hold until ‘transmission (converter outlet) oil temperature reaches the operating range, AN CAUTION Do NOT GPERATE THE CONVERTER AT STALL CONDINON LONGER THAN 0 SEGONDS AT GNE TIME, SHIFT TO NEUTRAL Fron 18 SfCOMDS AND. RESCAT THE PROCCDURE UNTIL BCSIRED TEMPERATURE 18 REACHED, Excessive remmenarune 120°C (250 F] maximune Witt CAUSE OMMAGE TO TRANSMISSION CLUTCHES, FLUO, ‘CONVERTER, AND SEALS, 20000 3 1D ant rsTroubleshooting guide 7.2.2 Transmission pressure checks Transmission problems can be Kolaled by the use of pressure tests. When the stall test indicates slipping clutches, thon measure clutch pack pressure to determing ifthe slippage is due to low pressure or clutch plate friction material lalure In addition, converter charging pressure end transmission lubrication pressure can also be measured. 7.2.3 Mechanical and electrical checks Prior to checking any part af the system far hydraulic function (pressure testing), the following mechanical and electrical checks should be made: ‘= Check the parking brake and inching pedal for correct adjustment. + Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points. The 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. + The engine must be operating comectly. Be sure that itis 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 pressure and rate of ail flow, i is impartant to make the folowing (ransinissian 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 filed) at all umes, AN sex ‘The TANSWSGION FLUID MUST BE AF OPCRATING TEMPERUTURE OF BB = 93°C (180 « 200 F) ro onTAN (CORRECT FLUID LEVEL AND PRESSURE READINGS, Do No¥ ATTEMPT To WAKE THESE CHEEKS WATH COLD OIL. it for To raise the oil temperature to engine with converter at *stal LY cauvon Bir CAREFUL THAT THE VESDOLE DOES NOT OME Us (CONVERTER AT STALL BOM, is specification itis necessary to either operate (work) the vehicle or run the (Rotar to 7.2.1 "Stall test"). Tee000 1D aos 72Troubleshooting guide 7.4 TROUBLESHOOTING GUIDE later to the following troubleshooting guide for the diagnosis of typical transmission troubles. 7.3.1 Low clutch pressure Cause Remedy 1, Low oil level, 2, Clutch pressure regulating valve stuck open. 3, Faully charging pump. 4, Broken or wern clutch shalt or piston sealing rings. §. Clutch piston bleed valve stuck open. 7.3.2 Low charging pump output Cause 11, Fillto proper level, 2, Clean valve spool and housing. 3, Replace pump, 4, Replace sealing rings §. Clean bleed valves theroughly. Remedy 1. Low oil level 2. Suction screen plugged 3, Delective charging pump, 7.3.3 Overheating 1. Fill to proper level 2, Clean sustion pump. 8, Replace pump. Cause Remedy 1, Worn eil sealing rings, 2. Worn charging pump. 3, Low oil level 4. Dirty oil cooker. 5, Restriction in cooler lines, 7.3.4 Noisy converter Cause 1. Remove, disassemble, and rebuild converter assembly, 2. Replace charging pump. 8, Fill to proper level, 4, Clean cooler. 8, Change cooler lines, Remedy 1.Worn charging pump. 2, Worn or damaged bearings. 7.35 Lack of power Cause 1, Replace charging pump. 2. A complete disassembly will be necessary to determing which bearing is faulty, Remedy 1. Low engine RPM at converter stall, 2, See "Overheating" and make same checks, 1, Tune engine check governor. 2, Make corrections as explained in “Overheating”. 20000 3 1D ant 73‘Troubleshooting guide 7.4 CHECK POINTS Teo000 SID avo oyTroubleshooting guide 7.4 CHECK POINTS (conTiNvED) ott ech evar Seti miter nasi” LEFTSEVEW T2000 3 1D oat 7Troublesheating guide 7.4 CHECK POINTS (conTINUED) Tee000 1D TOP YEW aos 78Troubleshooting guide 7.8 SPEED SENSOR - STATIC STANDALONE TEST In onder to be-able to sense the currents, & series resistor of €.9. 200 Ohms must be used. This resistor is integrated in the controller, but when the sensor is to be tested, it must be connected externally. ‘The idea is to connect the sensor to an external power source and measure the DC voltage across the-series resistor. ‘The voltage reading should be either 1.2V-1.6V (for the 7MA & 1mA current level) or 2.6-3.0V (for the 1amA + 1mA current lewoly If the teeth can be moved slowly, distinet toggling between the two levels should be noticed. wre ‘m0 Ohm 1 et 20000 3 1D ant 78. SECTIONAL VIEWS AND PARTS IDENTIFICATION 20009 1D ain aGROUP - CONVERTER HOUSING Tea0e0 3 IDGROUP - CONVERTER HOUSING Hem Description Quantity 1 Housing - Converter 1 2 ‘Tube - Lube 1 3 Sleeve - Converter housing 1 4 Plug - Pipe i 5 Plug - Pipe 1 5 ‘Gasket - Converter housing te to transmission ase 1 7 Screw - Converter housing to transmission case 16 8 Lockwasher- Converter housing to transmissian case seravr 16 8 Pin - Converter housing to transmission case dowel 1 10 ‘Clip 1 " Screw - Clip 1 12 Lockwasher - Clip screw 1 13 Air - Broather 1 14 Plug 3 15 “Oring 3 16 Plug - Speed sensor port 1 17 *O!-ring - Speed sensor 1 18 Screw Speed sensor 1 Tego & 1D aot eaGROUP - TRANSMISSION CASE AND REAR COVERGROUP “TRANSMISSION CASE AND REAR COVER, Hem Description Quantity 1 Gase ~Transmission 1 2 Assembly - Suction tube 1 8 Glip - Tube 1 4 "O"-ring - Suction tube assembly 1 5 ‘Tube - Low speed pressure 1 6 Sleeve - Gluten pressure tube 2 7 “Tube = Lube 1 8 Sleeve - Tube 1 8 Spacer -Tube clip 1 10 Screw - Tube clip 1 4 Lockwasher - Tube clip screw 1 12 Plug 2 13 “o4ing 2 14 Piug 1 15 "o-ring 1 10 Cover Rear 1 17 Plug 1 18 “o-ring 1 i Pin - Transmission case to rear caver dowel 1 20 Screw - Rear cover to transmission ease 20 21 Lockwasher - Rear cover to transmission case screw 20 2 “Oring - Clutch pressure tube 3 23 “Oring - Clutch pressure 2 24 Gasket - Transmission case to rear cover 1 25 Piug - Magnetic drain 2 28 Dipstick 1 27 Assembly - Dipstick tube 1 20 Cap - Low shait bearing 1 20 Plug 1 2 “onring 1 3t Plug - Speed sensor port 1 22 "O-ring - Speed sensor port plug 1 33 Screw - Speed sensor port plug 1 34 Plug 1 35 Plug - Dipstick hole 1 20009 1D ainGROUP - TURBINE SHAFT Hem Description Guantity 4 ‘Assembly - Turbine shaft & hub 2 ing - Retaining a Bearing - Ball a Snap sing - Bearing 5 Washer - Bearing support 8 ing - Bearing retaining 7 Ring - Piston 8 ‘Support - Stator 5 Screw - Stator support 10 Ring - Piston "1 Batlle - Oil 1B Seal - Ol battle 13 ing - Oil baffle seal 14 Fling - Oil battle retaining 20009 1D ain ose gasses arGROUP - DRIVE PLATE a8 Tea0e0 3 IDGROUP - DRIVE PLATE Hem Description Assambly - Drive plate Drive » Plate ing - Drive plate backing ‘Screw - Drive plate mounting Lockwasher- Drive plats mounting maw 20009 1D ain Guantity oases a9GROUP -TORQUE CONVERTERGROUP -TORQUE CONVERTER Hem Description Guantity Assembly -Torque converter Bearing - Impeller hub gear ing - External snap Plug - Torque converter *o%ring -Torque eanverter plug ing - Sra Ring - Turbine retaining Nenana 20009 1D ain pose esasGROUP - AUXILIARY PUMP DRIVE Tea0e0 3 IDGROUP - AUXILIARY PUMP: DRIVE Hem Description Guantity ‘Support - Pump drive bearing Serow - Bearing support Pin - Bearing support Bearing - Ball ing « Drive gear bearing retaining Gear - Auxiliary pump drive ‘Cover - Pump mouniing permanent Gasket - Shipping cover ‘Screw - Pump mounting permanent cover Lockwasher- Pump cover screw Seavenauns 20009 1D ain fomoasasaaeGROUP - FUMP DRIVE Hem Description Guantity 1 ‘Support - Pump drive bearing 2 Pin : Bearing support 3 ‘Screw - Bearing support 4 Bearing - Ball 5 ing « Drive gear bearing retaining 6 Gear - Charging pump drive 7 Gear - Pump dive idler 8 Shaft - Idler gear stub 8 Ball - Idler shail lock 10 Bearing - Ball 4 ing - idler gear bearing locatlon 12 Fing - Idler gear bearing retaining 20009 1D ain woes esasGROUP - FORWARD SHAFTGROUP - FORWARD SHAFT Hem Description Guantity 1 ‘Assembly - Forward shatt, drum and plug 1 2 Piston - Clutch 4 3 Seal - Clutch pistan (Outer) 1 4 Seal - Clutch pistan (Inner) i 5 (Disc - Clutch (Inver) 8 8 iso - Clutch (Outer) a 7 Spacer - Piston retum spring 1 8 Plate - Clutch disk basking 1 9 ‘Sap sing - Backing plate 1 10 Assembly - Dise spring 1 n ‘Snap ring - Spring retaining 1 12 Sleeve - Piston ring 1 3 Spring - Piston ring expand 4 14 ing - Piston 4 15 Bearing - Forward shat front 1 16 Snap ring 4 7 Bearing - Forward shaft rear 1 20008 8 1D sit Ba?GROUP - REVERSE AND 2ND SHAFT Hem Description Quantity 1 ‘Assembly - Reverse, 2nd shaft & drum 1 2 Fision « Clutch 1 3 Seal - Glutoh piston (Guten) 1 4 Seal - Clutch pistan (Inner) 1 5 Piston « Clutch 1 8 Seal - Clutch pistan (Guter) i 7 ‘Seal - Clutch pistan (Inner) 1 8 DDise - Gluten (Inver) 8 9 Disc - Clutch (Inner) 6 10 Disc - Gluten (Outer) 8 " Disc - Clutch (Outer) 8 12 ‘Spacer - Piston retum spring 1 13 Plate - Clutch dise backing 2 14 Snap ring - Backing plate 2 15 ‘Spring - Piston return 1 16 Retainer « Spring 1 7 ‘Assembly - Ds spring 1 18 ‘Snap ring - Spring retaining i 19 Bearing - Clutch driven gear 1 a0 Bearing - Clutch driven gear 1 21 Ring - Reverse clutch gear bearing 2 22 Bearing - Ball 1 23 Ring - Front bearing retaining 1 24 ‘Shap ting - Front bearing 1 25 Ring - Piston a 28 Snap sing - Spring retaining 1 ar Hub - 2nd cluten 1 28 Ring - 2nd clutch disc hub retaining 1 29 Bearing - Nesdie 1 30 ‘Spacer - Reverse clutch gear 1 31 ‘Gear - Fleverse clutch 1 Tego & 1D aot egGROUP - REVERSE IDLER Hem Description Guantity Shaft - Reverse idler Assomibly - Reverse idler bearing Washer Nut - Bearing retaining ‘Washer - Bearing retaining Lockball - Idler shaft Gear - Fleverse idler “O"ring - llr shat eVnnaens 20009 1D ain 2.21GROUP - LOW SPEED SHAFT : is ® 5sGROUP - LOW SPEED SHAFT Hem Description Guantity ‘Assembly - Low shatt drum Fision « Clutch Seal - Glutoh piston (Guten) Seal - Clutch pistan (Inner) (Disc - Clutch (Inver) Disc - Clutch (Outer) Plata - Clutch dise backing ling - Backing plate retaining Spring - Piston return Retainer - Spring Snap ring - Spring retainer Bearing - Low speed gear ing - Low speed gear bearing retainar Ring - Low speed gear bearing locating ing - Low shat piston Bearing - Low speed clutch shaft front ‘Spacer - Low speed shaft front bearing ‘Spacer - Low speed gear Bearing - Low speed shaft rear Washer -Flear bearing support Ring - Rear bearing retainer Stud - Bearing cap Lockwasher- Bearing cap stud Bearing cap stud ing » Rear bearing cap "Oring - Rear bearing cap 20009 1D ain oe eesti wees we isis 2.23GROUP - 3RD SHAFT eet ayo Teo090 3 IDGROUP - 3RD SHAFT Hem Description Quantity 1 ‘Assembly - Sra clutch shat and dram 1 2 ing » 3rd clutch goar and hub retaining 1 3 ling - See shaft piston 1 4 Bearing - 3rd shaft pilot 1 5 Piston » Gluten 1 8 Seal - Clutch pistan (Guten) i 7 ‘Seal - Clutch piston (Inner) 1 8 DDise - Gluten (inner) 5 8 Disc - Clutch (Outer) 6 10 Plata - Clutch dise basking 1 " ‘Shap sing » Backing piate 1 12 Spring - Piston return 1 13 Retainer Spring 1 14 Snap ring - Spring reisiner 1 15 Bearing - 3rd shaft rear 1 16 ing - 3rd shall rear bearing retaining 1 7 (Cap - Sra shaft rear bearing 1 18 ‘Gasket - 2rd shaft bearing cap 1 19 ‘Stud - Rear bearing cap 4 20 Lockwasher- Rear bearing cap stud nut 4 21 Nut - Rear bearing cap stud 4 22 Gear - ard ctutch 1 20009 1D ain 2.25