Maintenance and Service Manual 6000 Powershift 8 Transmission & 4 SPEED i SPICER OFF-HIGHWAY PRODUCTS DIVISION i srz1s.208 suse ssTOWING OR PUSH STARTING Belore towing the vehicle, be sure to lift the rear wheels NOTE: If ihe transmission has 4 whee! tive, disconnect off the ground or disconnect the driveline to avod beth front and rear drivelines, Because of the design of Gamage fo the ransmession during towing ‘the hydraulic system, the engine Cannot be started by pushing or towing, ‘© Copyright DANA SPICER OFF-HIGHWAY PACDUCTS DIMS.ON 1999 ‘inpubiened materia “al ants reserved Cire Burin No part ot the work may be reproduced in any form under “any meane without seact written peemission of DANA SPICER OF F-HIGHWAY PRODUCTS DIVISION.FORWARD This manual has been prepared to provide the customer and the maintenance personne! with information and instructions on the mainten- ance and repair of the DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION product. Extreme care has been exercised in the design, selection of materials and manu- facturing 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 law cost operation and trouble free service. In order to become familiar with the various parts of the product, its Principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION approved parts as listed in the applicable parts manual should be used. Use of “wilkfit’ or non-approved parts may endanger proper operation and performance of the equipment. DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by DANA SPICER OFF-HIGHWAY PRODUCTS. DIVISION. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS ASSEMBLY INSTRUCTION 00.0.2 20 0000 c cece eee eee eeee teen HOW THE UNITS OPERATE... 00.00.04 ceed SHAFT AND CLUTCH IDENTIFICATION. ...0. 0.00000 8 SECTIONAL VIEWS AND PARTS IDENTIFICATION Transmission Case and Internal Tubing... 0-6... wT input (Forward) and Reverse Clutch Group... ..sesceeseeeeeereeeeereeeer ee st and 2nd — 3rd and &th Clutch Group... 2.56.2 eee 10 Transmission Clutch and Gear Group... 6... cece AZ BTE ‘Control Cover Assembly... cee : 18 Modulator Wale. 20.260 oce ec ceevveeeseeeseeeessees 218 Disconnect ASSEMBIY 6... eevee eee cece eee 218 Exemal Gil Flow — Converter and Transmission ..........2600cseeeeeseeee 20 DISASSEMBLY OF THE TRANSMISSION |... 2.000000 0 0c cece eee eeee BI CLEANING AND INSPECTION. 0020000000 :cccceccceens cee REASSEMBLY OF TRANSMISSION... 32 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL ©0000-2000 0000000000651 SPECIFICATION AND SERVICE DATA... 2... 000000 000 ee ccc veeeeeeeeee rere ee BB LUBRICATION... vite 152 TROUBLE SHOOTING GUIDE AND TABLE OF TORQUE LIMITS .......5..000005-59) PRESSURE AND OIL FLOW CHECK SPECIFICATIONS «0.0.0... 200 oe eee NOTE: Metric Dimensions Shown in Brackets [ J.NOTESNore: 41 Libre all pion rings and 0" rings a assembly 2, Use Porton and Cre Sealer ony where soscitec, | Apply vary ight coat of ot auals belors azeecne opi High cot al Crane Saaine fall pe pups. tar sssombiy of pars, using Peemites or Grane Seale, Inara mutt be na ee frie te cre Torguesnuts 150.975 Loe. FL PORa oT? Nt Piste Font Searing OW Butta Muah wih oe oe 9 Bh, Teo steno tart aie "inna graph pstae raph pla 8 springs ded 8 pins one a reat agarat pian tooth find ond plas tet 6420 SERIES ASSEMBLY INSTRUCTIONS: Fed and Fes sasam (pienvog} andy Bui doug qn om “xo Nouatuos3a z- t t ATSW3SSW NOISSIWSNVHL 0009 B-aneworee —u--4—dog anien Mayes & sorwnboy seeds J2UIRIY 189g BAIA AIDES + funds sae, daajeg (68 OA\eA ADIOS wag anjen Ares: saul - Buds anyon zoreinBoy = *4an09 [On1U09, Ma10§ 12ND OF BPI + 48yBENIO 48A0D OF MEI = aneid Jang |oU0 ~ Buudg yddog . “sea wadddog * Buuids yoods anje Ho anys: ~doig 1oods enn HO ius vores qoods aaien soawnBey Bury .0., dog aa1eA HO NYS doig ane, s038)nB9y “Bury .0.. dors one, Bury deug dang on soysemn dows one, oss gaoeds ene; ane soraajag asianay 9 pieeng “USIND - A/G, 101998/05, ‘ALD NOlldIudSa0 re RK NNN eR eee ee eee ROR Re ee BRSSSPSIPSPSRSRs wall ATSINASSW H3A09 TOHLNOD joy doig onien Aiojeg @ anjen sorEinbay ++ ud IO 2nNeA s199}95 * Uld HOY foods GAIEA YO INYS wedded yaumg jeune = Bnjg 1u810g FEM Grid 1U919q, “Buyds wusreg weddog Ud ~saysemn dog anion, soos Bury deug doig anien, sreseereaeeceney 15S HO 8A J0198185 18UU} Jaysem doig anien, “1885 1 Bujy deus doig aajen “yoods aAleA HO anus ooo foIOH enIBA yo anys) Enjg odig ss yaing - Buds anje, s01e/nBoy “Bully .0., dors Arayes ene, s0yenBey Nold!¥9S30 sz ee zz te 6. aL ab aL 7MODULATOR VALVE ASSEMBLY DESCRIPTION cory. Aecumuletor Valve... ‘Accumulator Stop Pin...... ‘Accumulator Spring - Inner - Accumulator Spring - Middle. ‘Accumulator Spring - Outer. Spool Stop Plug “O" Ring . Spool Stop Plug « Regulator Spring. Regulator Spool... Modulator Valve Housing Plug se Modulator to Cover Screw Lockwasher sess Modulator to Cever Serew . sieieteese Modulator to Cover Screw . Modulator to Cover Sotew...... Modulator to Cover Serew Lockwasher vee SONS URINNAR ANN NNN MECHANICAL DISCONNECT DESCRIPTION ary. Shift Hub. Lock Serow Shift Fork, 0... Disconnect Shaft... Housing “O" Ring .......6 Housing Plug ...-..-00.. Disconnect Housing... Shift Rails... Detent Ball... Detant Spring... . Oil Seal... Cotter Pin Nut... ‘Washer. Flange "0" Ring... Disconnect Flange. Deflector ‘Olt Seal Bearing Snap Ring. Bearing... .e.cecvesee Mousing to Case Screw. Housing to Case Screw Lockwasher . —19—CHECK POINTS. CUUTCH PRESSURE CONVERTER INLET CONVERTER OUTLET CONVERTER TEMPERATURE CONNECTION LUBE PRESSURE COOLER INLET PRESSURE COOLER OUTLET PRESSURE COOLER OUTLET TEMPERATURE 5 Sf xz Om mone > MURET LOWEST coms, OR ae DRAVITY BRAIN EY MRARSGUISHON =OVERHAUL OF TRANSMISSION ASSEMBLY ‘The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence th: Would normally be followed after the unit has been removed from the machine and is to be completely overhauled, It must siso be understood that this is» basic 6000 series wansmiasion with many options. Control covers, clutch eovers, companion flanges and evtput shat with and without disconnect assemblies mey vary on CAUTION: Cleanliness is of extreme importanct ‘absolute must in the repair and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism, DISASSEMBLY OF THE TRANSMISSION Figure 1 Input side view of the 6000 series transmission. Figure 2 Position transmission on a sturdy trensmission bench or ‘cart, Remove sump pan bolts. Figure 4 Remove sump screen and baffle assembly bolts. Remove: sump screen and garkat. —1—Remove control cover bolts. NOTE: Aligning studs ware used to facilitate cover removal. igure 9 Remove input flange nut, washer, “O" ring and flanga. Romove reverse shaft nut and bearing spacer. Figure 10 Remove input shett bearing cap bolts end bearing cop. Figure 7 Remove clutch caver 2Figure 11 Remove output flange nut, washer, “O" ring and output flange on both front and raar of wansmission. Hf axle connect is used remove disconnect ax an assembly. Figure 12 Remove output shaft basring cap bolts. Remove bearing cap and shime. Figure 13 Remove rear eutput shaft bearing cap. CLUTCH DISASSEMBLY NOTE: 1st, 2nd, 3rd and 4th clutehes arecisassembled in & similar manner, The | etand 2nd clutches: are larger than the Sed and th clutehes and the lstand 2adeluteh drumsheve 2 removable and replaceable cluteh drum hub gear. Clutch being disassembled ie the 2nd spead clutch, Figura 14 Depress and plata and remove end plate retainer ting. Figure 16 Ramove clutch piston return springs and pins. BeFigure 17 Remove clutch disc hub retainar ring and elutah Throadiad holes are incorporated in the dise hub to fa removal Figure 18 Remove innar and outer clutch discs, NOTE: ALL CLUTCH PARTS REMOVED FROM THIS POINT ON MUST BE KEPT TOGETHER. THE CLUTCH RETAINER RING, WASHER, TAPER BEARINGS, ORUM AND CLUTCH SUPPORT MUST BE KEPT TOGETHER FOR PROPER REASSEMBLY, MARK EACH PART REMOVED TO MATCH WITH THE CLUTCH SUPPORT. THESE PARTS MUST BE REASSEMBLED ON THE SAME SUPPORT THEY WERE REMOVED FROM. IF TAPER BEARINGS, CLUTCH SUPPORT OR CLUTCH DRUM ARE TO BE REPLACED, REASSEMBLE WITH NEW PARTS AS EXPLAINED LATER IN THIS TEXT. Figure 19 Remove clutch drum retainer ring and washer, Remove clutch drum and taper bearing. Figure 20 Ramove clutch support oil sealing ring and sealing ring expander spring Figura 21 Remove clutch suppart bolts and support, Seo note aftor Fig. 18. Digsssamble the 1st. 3rd and 4th clutches as ‘explained in figures 14 thru 21. 4INPUT (FORWARD) AND REVERSE GLUTCH DISASSEMBLY Squeeze ends at end plate ring retainer plate snap ring. Remove ring retainer piste. Sae following line drawings, Figure 25 Remove clutch disc hub, Figure 28 Remove inner and outar clutch discs. Figure 23 Remove end plate. ‘See note after figure 18; —26—re") Figure 30 Remove clutch drum, 58s Fig. 109 & 110 for belleville washer disassembly and reassembly. Figue 27 Remave elutch drum retainer rig. Figure 31 Remove clutch support oil sealing rings. Figure 32 Remove clutch drum outer taper, bearing, Remove clutch support bolts and supports. —26—Figure 33 Figura 36 Remove the idler gear retaining plate bolte, retaining plate Lock transmission gears with a soft bar to prevent shaft and shims. from turing. Remove the outer bearing jam nut, the nut lock and the tearing innar lock nut. Figure 34. Figure 37 Remove idler gear. Remove idler shaft crossaver lube plate bolts and plate Figure 38 Figure 35 Press output shaft rom transmission housing. Output shaft Straighten tangs an bearing nut lock. may be removed from sither eis, =<27-DISASSEMBLY OF CONTROL COVER Figure 39 Remove the 1st, 3rd, 2nd snd th clutch shafts ag shawn. (2nd and 4th removed.) Figure 42 Remove bolts from oil circuit plate. Remove oil cireuit plate CAUTION: De not lose detent springs. Figure 40 Flomove the reverse and input shaft (forward) as shawn. Figure 43 (Input shaft baing removed) Remove spaad selector valve assembly retainer ring, Figure 44 ‘opposite end of speed aslactor valve. Valve will come out tagether. Figure 41 Remove idler shelt »s shown.Figure 48 Romove shut-off vaive spring, GAUTION: When remeving roll gins, itis recommended « press be used to depress valve stop. valve and spoot springs Figure 45 Remove forward and reverse selector valve ratainer ring. Figure 46 of forward and reverse selector | will come out together. Figure 49° Depress regulating valve spring stop and spring. Remove roll pin. Tap lightly on opposit valve. Valve and valve oi Figure 60 Figure 47 Release press slowly. Springs will push spring stop fram Remove shut-off valve plug and “O" ring. Remove shut-off contol housing, Remove spring stap and inner and outer . spring. —2—Figure 51 Remove roll pi on opposite end. Depressing w: pis Rot negassary 5 the springs ware removed in Figure 49. Figure: 52 Remove regulating valve stop and valve from control housing. Figure 53. Depress safety valve pring and spring stop. Figure 54 Remove safety valve spring stop, valve spring, and safety ball valve. TRANSMISSION INTERNAL TUBING ‘These tubes ete nat to be removed unless damaged, They should, however, be cleaned and checked for leaks when transmission is disassembled. The tubes are divided inte twa groups. The high pressure or clutch pressura lines and the low or lubricating prassure lines. When necessary to replace any tubss, tool CE-805. is required. The procedure for using tool is a8 follows: 1, Install tubing in housing with end flush with ease 2. Slida collar over end of tube and press into bore ofTurn mandrel with hand until tool le firmly eestad in tube, Using 2 3/8” wrench, turn mandrel as far as possible. (Use this procedure to instal! all tubes in housing. Principle of Too! Toot has roller which expands when mandcal is inserted. ‘As mandrel istumed, the rollers expand against ths internal bare of tubing, This forces tube to expand ageinst collar which has @ groove on inside diameter: When tube is ‘expanded into this groove it is locked into pasition, Cleaning and Repair of Toot This tao! isa precision instrument and must be treated a8 such. Aftar aach use, remove mandrel and rollars anc flush tool with cleaning solvern. inspect rollers and mandeel for chips and flaking. H rollers of mandrel need to bbe replaced, they may be purchased from Air Tool Division, Dresser Industres, ine, 302 S. Center St, Springfield, Ohio 45601, Phone 513-329-4981. Atte: Onter Dept. CLEANING AND INSPECTION CLEANING Clean all parts theroughly using solvent type cleaning fluid. this recommended that parts be immersed in cleaning fluid and slushed up and down slowly until all old lubricant end foreign materie| i dissolved and parts ara thoroughly cleaned. CAUTION: Care shauld be exercised to avoid skin rashes, fire hazards end inhalation of vepors when using solvent type cleaners. Bearings Remove bearings from cleaning fluld end strike larger side of cone flat ageinst a black of wood to dislodge solidified particles of lubricent. Immarse again in cleaning fluid to flush out particles. Repeat sbove operation until bearings are thoroughly clean. Dry bearings using moisture-free comprossad air, Be carsful to direct air stream across bearing to avoid spinning. Bo not spin bearings wnen drying. Bearings may be rotatad slowly by hand to facilitate drying process, Housings Claan interior and exterior of housings, bearing ete,, thoroughly. Cast parts may be cleaned in hot solution tanks with mild skal solutions providing thers parte de not hava ground of polished surtscas, Parts ahould remain in solution lang enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse watat. Pars cleaned In solution tanks must ba thoroughly rinsed with clean water te remove as of alkali, Catt parts may siso be cleaned with steam cleaner CAUTION: Core should be exercised to avoid iahelation of vepors and skin rashes when using alkali cleaners. All pacts clasned must be thoroughly dried immediately by using moisture-free compressed oo soft, lntiass absorbent wiping rags frae of abrasive materials such as ‘matal filings, contaminated oil or lapping compound INSPECTION The importance of careful and tharough inspection ofa parts cannot be averstressad. Replacement af all pans ‘showing indication of wear or sivas will eliminate costly ‘and avoidable failures at » latar date. Bearings Carefully inspect all rollers, cages and cups for wear, chipping oF nicks to determine fitness of bearings for further use, Do not roplace a bearing cone or cup indivi ually without replacing the mating cup orcone at the same time, After inspection, dip bearings in Automatic Tranemis- sion Fluid and wrap in clean lintless cloth or paper to protect them until installed. Git Seale, Gaskets, Etc. Replacement of spring load eil geals, “O" rings, metal seeing rings, gaskets and snep rings is more economical when unit ig disagzembled than premature avarhaul to replace these parte at a future time. Further lose of lubricant through & worn seal may feault in failure of other more ‘expensive parts of the assembly. Sesling members should be hendled carefully, perticularly when bei Cutting, scratching, oF curling under ef lip af seal seriously impairs its efficiency. Apply a thin coataf Parmatex No. 2.07 the outer diemeterof the oil seal to assure an oil tight it the retainer. When assembling new metal typ rings, same should be lubricated with coat of chassis greese to stabilize rings in their grooves for ease of ‘assembly of mating members. Lubricate ail “O" rings and seals with Automatic Transmission Fluid before assembly. Gears and Shatts lf magna-flux process is available, use process to check parts, Examine teeth on all gears carefully for wear, pitting chipping, nicks, cracks or scoras. Ifgearteeth show spots where case hardaning is worn through ar crecked, replace with new gear, Small nicks may be ramoved with suitable hone. Inspect shafts and quills to make certain they ara not ‘sprung, bert, dr splines twisted, and that shafts are true, ing caps 10 be certain they are thoroughly cleaned and that mating surfaces, bearing bores, ote,, are free from nicks or burrs. Chack ail parts carefully for evidence of cracks or condition which would couse subsequent oil leaks er failures. aREASSEMBLY OF TRANSMISSION Instructions given below on reassembly of components of transmission assembly are given in the sequence that Must be followed in rebuilding. Principle of operations cited and views shown are similarand parallel on all shafts. The verious drive shslts are sssembled in the following order 1. tler Shate — 2. Input Shaft — 3. Reverse Shalt — 4, First and Third Shaft — 5. Second and Fourth Shaft — 6. Output Shaft — REASSEMBLY OF IDLER SHAFT Figure 87 With oil baffles in position (See Figure 58} install idler shaft Oil, BAFFLE: (NOTE POSITION) Figure 58 Figure 59 With the large taper bearing pressed on the idlershaft next to the gear, position sheft and bearing in transmission housing from ths input side, Block idler shaft and from the: ‘opposite side tap taper bearing on shaft. Be sure taper bearing is fully seated. "ee Figure 60 Figure 61 Install idler shaft cross over lube plate and bolts, Tighten bolts 82 to 90 ft. bs. torque [111.2+122.0 Nm} —32—Figure 62 Position large idler gear on idler shaft. Be sure gear is tight against bearing. Figure 63 Using ® micrometer depth gauge. messure the distance from the hub of the gear ta the end of the idlerehaft, reeord this distance. Figure 64 Choose and check shim pack with micrometar. When the proper amount af shims as recorded in Figura 63 is achieved, ramove one .004 [1016 mm] shim. Figuee 65 Position shims and retaining plate on idler gear and shatt. Install retaining plate balts. Block idler gear to prevent suming and torque retainer plate bolte 113 to 124 ft. Ibs. torque [153,3-168.1 Nm Figure 66 torque is 6 t0-10 inch lbs. (0,7-1,1 Nm}, Add shims for less rolling torque, remove shims tor more rolling torque. REASSEMBLY OF FORWARD (INPUT) AND REVERSE SHAFTS Figure 67 Press roller bearing on thresdad end of input shatt, install shortspaceran shaft eppesite threaded end, Position input gear in cage with longer offset of gear to the rear. Install input shaft and bearing inte front casa hore andi through ingut gear. Push beering and shaft in case bore w snap ring shouldars against transmission case. Do not remove shaft pusher. Install large spacer an shaft sgainst input geer. Pasition rear bearing on shaft, Align bearing lock ball with notch in bearing bore. —33—Figure 68 Drive rear rallar in place, NOTE: Bearing mus tight. Check gear spacer on shaft. When spac: tumed by hand, stack up between input gear spacer and reer roller bearing is tight, DO NOT attempt to draw bearings up tight with bearing lock nuts, Remeve shett pusher, 2 Figure 71 With a new gasket in place, pasition bearing cap and ‘on shaft. Install bearing cap bolts ang tighten 57 ta 63 tt. Ibs. torque [77,3-85,4 N.m] ‘Assomble the reverse shatt.as explained in Figures 67 ond 8, Figure 70. Apply a thin cost of Permatex No. 2.0m the outerdiameter of ‘the input shaft oil seal. Press seal, lip of seal inward, into input shaft bearing ea. Figure 72 ‘On the reverse shaft install the frost beating specer andaut. 3(On the input shaft install the input flanges, flange: washer and flange nut. Biock input and reverse shafts to prevent tuming. Tighten input flange nut and reverse shaft nut 150 to 175 ft. Ibs. ‘torque (203,4-237.2 Nem}, install nut catters. Figure 76 With new gasket in placs position reversa shaft bearing cap fon shaft. ingtall bearing cap bolts and tighten 87 to 63 ft Ibe. torque [77,3-85,4 N.m. REASSEMBLY OF Ist & ard & 2nd & 4th SHAFTS Figure 77 1 Press the double taper bearing assembly on she: Vest & rd ‘shaft tight egainst shoulder on shatt. CAUTION: These bearings are im matched sats and under no circumstances ‘eam any of tha four (4} parts be changed or mixed up with anothir bearing. Position the Ist & Srd gear in tha transmission case with long Pub of gear towerd the input side of the eaee. Insert shatt into shalt bore and through the ‘ist & Sed gest. Align double taper bearing lack pin with notch in Bearing bore, Figure 78. Puth heft aesembly in case until taper besring shoulders ‘are against locating ring in bore: of case. De net ramove shaft pusher. ‘On opposite end of shalt, position long spaceron shaft and "the gaar. Instell bearing spacer (washer) against Chock lang spacer en shalt, When spacer can not be turned by hand, stack up between the front and rear bearing is tight, D0 NOT attemptte drew bearing up tight with bearing lock nut, Remove shaft pusher. This was left on only to hold shaft while installing roller beeingFigure 81 ross the dovble taper bearing assembly on tha 2nd & ath shaft tight against shoulder on shaft CAUTION: Thess bearings aro in matshad sets and under no circumstances gan any of the tour (4) parts be changed or mixed up with another bearing Install the long spacer on the 2nd & 4th shaft against the double taper bearing. Position the 2nd & ath gear in the transmission ease with the lang hub of the gear toward the input side of the case. Insert shaft into shaft bore and through the 2nd and th gear. sAlign double bearing lock in with noteh in bearing bore. (See Figure 77) Use shatt pusher as shaven in Figure 78. Push shaft assembly in case Until taper bearing shouldersin bare af case, Bo not remove shaft pusher. On opposite end of the shaft instal! besring soucer {washer} againat the gear. Drive rear bearing tight agsinat washer. NOTE: Bearings must be driven in tight. Check long spaceron shett. When spacercan not be turned by hand, stock up betwaen the front and rear bearing is tight, BO NOT attempt to draw bearing up tight with beoring Fock mut as at — Shr Figure 82 Figure 83 Lock gears using 8 soft ber, énd install bearing inner lock nist {00 notel, Tigiten lock nuts 178 to 200 h. Ibs. torque 1297,2.271,1 Nim], lostall nut locks and outer lock nuts. Tighten ‘outer lock ruts 178 to 200 ft Ibs. torque 1273,3271.1 Numi. NOTE: On the dre & 4th cluteh, eorne units will have a double locknut with a tanged washer & some units wil have a single slastic locknut — the tightaning toraus is the sama on froth style nuts. Bend e portion of the nut lack over one fiat of the inner lock nut, Bend a portion of the nut lock ever one flat of the outer lock nut. OUTPUT SHAFT REASSEMBLY There are two types of output halts, One shalt (threaded on bath ends) is used far continuous 4 wheal drive or 2 wheel ‘drive with one side capped, see Figure 87. This is the type ‘of shaft being assembled in the following photas. The ather shaft is thraedad on one end and. pilet Dearing pocket on the other used with a axle disconnect, See Figure 92. —36—Pross taper bearing (large dismater of taper inward) aver threaded end of output shaft against shoulder on shatt Position targe output gear in tranamission case to the input side (front) with longer offset ef gear hub to the from. Position smell output gear in transmission case to the rear with longer offsat of gear hub to the front. Insert output shaft through the rear bore of case and through small and large output gears, Figure 87 shows proper etack up of (oars, install tapar bearing cup ovar rear basring. Apply & very ight coatof Permatex No. 2 to the outer diameter of the output oil seal, Press seal in output bearing cap to depth shown in Figure 86. Position a New “Q” ring on bearing cap. Position bearing cap assembly on output shaft. Install bearing cap bolts and tighten 57 to-63 ft Ibs. torque [77,3 85,4 Num} Figure 87 Figure 88. Block output shaft and install front taper bearing (large meter of taper inward) on output shaft until bearing shoulders against Jarge output goar. install bearing cup cover front bearing. Figure 9. Apply # thin coat of Permatex No. 2 on the outer diametar of the output shaft oll seal, Press oil sesl, lip of seal inward, Inte output shaft bearing cap. See Figure 86, lastall a new "0" ring on output shaft bearing cap. Lubricate ring with automatic tranemission fluid. Install bearing cap and shims, Do net tighten bearing eap batts. Figura 20 torque wrench on the output flange rmount of torque required to tun geer ‘Using an inch poun fut, determine the train =—7-Figure 83 Insert lock ballin clutch piston ring outer race, Prass outer race and ballin clutch drum. Install the innerand outer taper bearing cups ia the clutch drum. Figure 91 Tighten output shaft bearing cap bolts 57 to 63 ft, Ibe. torque [77,3-85.¢ Nam] |Add or vemove shims from bearing cap to adjust proload, When bearings are adjusted property, it will take 6 to8 inch Ibe. (0,68-0,90 Nem} more torque to tum gear train with cap bolts torque than when bolte were loose. Figure 94 Prass inner taper bearing on clutch support NOTE: The input (forward) and reverse clutch supports are different than the 3rd and 4th eupports. The 3rd and 4th supports have one) lube hola (see line drawing) and the Input (forward) and reverse aupports have two (2) lube holes (see line deawing). Figure 92 CLUTCH DRUM REASSEMBLY IFctutch drum taper bearings, clutch support, or clutch rum are to be replaced, reassemble with naw parts a oxplained in Figures 93 thre 101, NOTE: Do not install clutch support on transmission housing, Unit proper stack up of parts in the clutch drum is achieved Mark ail parts of sch set (clutch support, clutch drum taper beating, selected tangad washer and selected snap ring). Keep ll parte together.SEE PAGES 58 & 69 FOR PROPER SELECTION OF ‘VARIABLE THICKNESS TANG WASHER & SELECTED VARIABLE THICKNESS SNAP RING. Figure 95, Position clutch drum and cup assambly on clutch support Be sure the proper drum ia matehad to the proper support, See note following Figure 94, Figure 98 ‘Clutch chum retainer ving i= selected ot assembly for proper thickness. Vafable thickness rings are used in snap ting ‘grooves to assure proper taper bearing tightness, Check ring a8 shown for tight ring to bearing fit. [See pages 6B & 69 for [proper selaction of snap ring.) Figure 96 SNAP RING Figure 87 Pasition outer bearing rewiner washer on clutch support align ing tang on washer with notch on support. Soe pages 58 & 68 Figuee 99) for proper selection of washer). —39—Figure 102 Figuee 100 lnstall retainer ring, being certain ring is in full position in ring ‘groove. NOTE: Use ring that will give the tightasr ft between washer and snap ring groove as explained on pages BB & 68. Position clutch suppent and taper bearing assembly on transmission housing. See note following Figure 94. BEARING OUTER TAPER WASHER = SNAPRING == BEARING. Figure 103, INNER TAPER = CLUTCH = CLUTCH DRUM ASSEMBLY BEARING ‘SUPPORT Figure 101 CAUTION: After parts have been matched with each other do not mix with other ehatch parts Install twa lock type oil sealing rings on each clutch Remove reteines ring and washer, Remove drum assembly fear Support. Lock rings in position, Grease rings to facilitate slut rum support. ‘dium 10 support assert. -40—Figure 106. Install 8 new clutch piston outer aeeling ring. Position clutch piston in clutch drum, INPUT (FORWARD) & REVERSE CLUTCH REASSEMBLY {Reverse Clutch Being Assembled) Figure 107 Position belleville washers ogeiast the eluteh piston shawn in Figure 109, Concave sides against exch oth; Five (6) sats, totel of ten (10) washers in each clutch, input (forward) and reverse. Locate sasp ring retainer on belle- ville washers. Figure 108 Position snsp ring over cluteh hub. Compress snap ring retainer end belleville washers below snap ring groove, 12 Figura 109). Install s fing groove and release tension on ring retainer. Retainer ‘must fit all around snap ring, (See Figure 110). Figure 103 Figure 110 =<“Figure 114 ya Install seiacted clutch drum srap ring, being certain ing isin-tull Figure 111 1 position in ring groove. Check te make sure end play on cach Position clutch drum on suppor, | drum does not exceed specications .0000 fine 10 fine) to & matched with the support as explained In note following ‘maximum at 0040 loose fend ply Figure 18. Figure 118 install the clutch dise hub and hub retainarsing, Install one Figure 112 friction disc next to the piston, Install one steel disc. Position matched outer tapar babring in chitch drum and Alternate cluteh plates until a quantity of sixteen {16} inner ‘over clutch support jation plates and fifteen (15) outer steel plates installed. You start with a friction plate and endwith friction, Plate. Position clutch end plate against clutch plates. Figure Position matched retainer washer on clutch support aligning tang on washer with natsh in support, Figure 118 Inatall and plate eetainae slog, —a—With the retainer plate snap ring in place in the: clutch end plate, squeaze the ends of the snap ring together. install ing retainer plate oversnap ring and against the and plata. Release the snap ring in undercut of retainer plate. Be sure ‘ing is in full position over retainer plate. (See line drawing) ard & 4th CLUTCH REASSEMBLY (4th Being Assembled) Figure 117 Position elvich drum en support, being sure the drum is matched with the suppact as explained in note following Figure 18. Position matched autor taper bearing in clutch drum and over clutch supper. Figure 118 Position matched retainer washer on clutch support, signing tang on wesher with notch in suppor. Install selected clutch drum snap ring being cerain ring is in full position in ring ‘groove. Check to make sure end play on clutch drum does nat ‘oncoed gpecifiestions. (See Figure 114.) Figure 119) Install the eluteh dise hub and hub retainer cing, ‘The outer disc has teeth missing on the outer diameter. This {sto allowpassege for the clutch release springs. Insert two ‘oF more raleasa springs in drum and againatthe taeth af the eluteh piston. —43—Figure 121 Install one friction disc next to the piston Install one stool disc, Alternate elutch plates until a quantity of ten (10) inner friction plates and nine (8) outer sta stallad. If assembly is correct each release s\@ tooth on the elutch piston and you start nar disc and nd with an inner disc! Insjall remaining clutch release springs and pins in open passages in the steal outer discs, Totel quéntity six (6) springs and six {8} pins. Figure 124 Position end plata against last friction disc. Compress end id plate recainer ring. Figure 125 Position new-clutch cover gaskat on transmission housing, ‘thin caat of chassis groase will hold the gaskat in place. Use oligning studs to hold elutch cover spacer in place. Figure 126 Position clutch cover on aligning stuss. install sil of the ‘cover bolts end washers. Remave aligning studs and inst remaining bolts and washers. “ueFigure 128 Position the 1st & 2nd eluteh supports on housing, install ‘support bolts and tighten BO to BB ft, Ibe. torque [103 119.3 Nm). Install naw clutch support sesling rings and ‘expander springs. Expander spring gup to be 180° from ‘seeling ring hook joint, Lock rings in position. Grease rings to facilitate drum to support assembly, NOTE: Oil sealing ring expander springs used under the oil sealing rings on the 1st and 2nd. supports only. REASSEMBLY OF ‘st & 2nd CLUTCHES (2nd Being Assembled} 3: Figura 129 Position clutch drum an support, baing sure the drum is, matched with the suppert as explained in note following Figure 18. Install new inner and outer clutch piston oil sealing rings. Figure 130 Position matched outer tapar bearing in cluteh drum and ‘ver support Figure 131 Position matched drum retainer washer en ehuich suport align ing tang on washer with notch in support. Install eeected clutch ‘drum snap ring, bein cemtsin ring is in full position in ting ‘groove. Chock to make: sura end play on cluteh drum does not ‘exceed specifications. (See Figure 114) Figure 132 Install clutch dise hub and hub retainer ring,=m Paietd The outerdise has teeth missing on the outer diameter. This isto allow peasage forthe clutch release springs. Insart wo ormore ralesee springs in deum and against the tasth oft passages in the stee! outer discs. Total quantity eight (8) ‘springs end sight (8) pins. Install ona inner clutch disc (spline teeth on innerdiometer) ‘on dist: hub and against the clutch piston, Figure 137 Pasition end plata against last friction disc. igure 135 Install one stee! outer disc, install next inner disc, alternate clutch diges, outeragainst inner, and always aligntha teeth on each outer dise with the tasth on the prec disc. If sssembly is correct each release spring i tooth on the clutch piston and you start with an inner disc andend with an inner disc, There are twalva (12) inner disoe and eleven (11) outer discs,Figure 142 position 8 naw ch toh over gasket " install new gasket on transmission sump pan. Set pan i on transi magnets over welded washars in sump pan, Secure pi housing. Use sligning studs to hold clutch cover in wah bette ced Letlodie west, position. Install all of the bolte and washers, Remove igning studs and install remaining bolts snd weshers. Figure 143 Tighten sump pan bolts 23 to 26 ft Ibs. torque [21,2-33,9 Nam] REASSEMBLY OF CONTROL COVER 16 for sequence: of parts and parts identification. ibricate all valves, eprings, “O" rings, sleaves and with a light cost of Figure 141 Install output flange, flenge "0" ving, washer end flange rut, Block output ahatt oF usa 6 soft bar to Bleek the gear train, tighton output flange nuts 250 tw 300 ft Ibs. torque [399.0-408,7 Nim]. Install new gasket on sump screen onaning, Install sump screen and battle assembly in housing and securewith bolts and lockwashers. Tighten 23 fing in position install spring stop on spring. 0 25 ft. Ibs. torque [31,2-33,9 N.m} —47—Figuee 148 Install regulating valve spooliin valve-cover, instal new "0" ring on valve step, install valve step in cover andieatain with Figure 149 roll pin, Inestell shut-oft valve spring, Figure 147 At opposite end of regulating valve install inner and outer Figure 150 valve spring. Install new “O" ring on spring stop. Inst Install shut-off valve in housing. Depress velve end spring pring stop on springs. with valve plug, Tighten plug securely. —48—Figure 151 Figure 154 Install forward and reversa selector vaive in housing. Install Install speed selector valve In housing, Install selactor selector valve stop washer and on solectar valvo. valve stop washer and oil saa on valve. wt] Figure 155 ‘Apply a light coat of Permatex No. 2 on the outer diameter of a new selector valve oil seal. Instell oll sesl in housing. Apply 8 light coat of Parmatex No. 2.0n the outer diameter ‘of 3 new salector valve oil seal. Install oil seal in housing. lngtal olf geal ratainer ring.Figure 157 Install poppet balls end poppet springs in drilled porta in contral caver, Install control cover plete. Secure with bolts, sand external shake proof washers. Tighten 12 to 16 ft. Iba, Figure 160. torque [16.3-21.7 Num]. Install control cover bolts and washers, tighten 23 ta 26 1, Vs. torque [31,2-33,9 Nem]. Position: new control cover gasket and “O" rings on ‘ansmiseion housing. Aligning studs will hold gasket in place and facilitate cover installatian. Figure 169 Lorate control cover on aligning studs. —s0—SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and its alliod hydraulic aystem are important Tinks in the drive line between the engin and the wheels. The proper oper- ation of either unit depends greatly on the condition and operation of the other; therefore, whenever repair for overhoul of one unit is performed, the belonce of the system must be considered before the job can be comidered completed. After the overhauled or cépaired transmission has boon installed in the machine, the ail cooler, and con- necting hydraulic system must be thoroughly cleaned, ‘This can be accomplished in vaveral manners and a de- ‘of judgment must be exercised a+ to the method The fallewing ar be taken: considered the minimum steps to: 1, Drain entire system thorovahly 2. Disconnect and clean all hydraulic lines, Where feasible, hydraulic lines should be removed from machine for cleaning. 3. Replace oil filter elements, le ing out filter eases thoroughly, 4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oll and compressed air until all foreign material has been moved. Flushing in direction of normal oil flow ‘will not adequately clean the cooler, Hf nece sary, cooler assombly should be remaved from machine for cleaning, using oil, compressed air and steam cleaner for that purposs, DO NOT use flushing compounds for cleaning purposes. 5 On remate mounted torque converters remave drain plug from torque converter and inspect interior of converter housing, gears, etc. If presence of considerable for noted, will be necessary th disassembled and el lized this entails extra such labor is a minor cost compared to cost of difficulties which can result from presence of such foreign material in the system, Reastemble all components and use only type recommended in lubrication section. — Fill ransmission through filler opening uml fluid comes up fo LOW mark on transmission dipstick. NOTE: If the dipstick is not accessible oil level check ploge ere: provided. Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug. Run engine twa minutes at 500-600 RPM to prime torque converter and hydraulig check level of flvid in transmission with engine running at idle (500-600 RPM) Add quantity necessary te bring fluid level to LOW mark on dipstick or runs freely from LOWER cil level check plug hole. install oil level plug or dipstick. ‘Recheck with hot il (180-200" F.) (82, 2-93, 3° C). Being oil level to FULL mark on dips from UPPER oil level plug. kor Rochock all drain plugs, lines, connections, ate, for lasks and tighten where necessary. —st-ccouventen our assume connie ures Tere ou ieee (GUTEH QUTER bee TvFe oF on chee rene ‘Normal drain periods and filter change intervals are for average environment Severe of sustained high SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION ‘AND TORQUE CONVERTER om. FurRarion ‘Conner cate al sang. 180 «200° eyes * “Taran i NEUTRAL ‘Soeratng source ae 155 oo [S78 Fl mane pneu a 70200 REM. ‘engine speed AND 4 maurmar of TO pat [82.8 46a ‘Suter pressive wise engine opecring Ros ‘governed ape Forman end Paves — Meant ‘Seon Becton — Marea! Mug eos. hrraulealy ace peng eben, ‘chee ol rook ond as ain, Biel (CLUTCH PHESSURE LUBRICATION See lube Chart ‘GonrerterTrenenitton and sled hydral fyetem mutt be conwtered af» hale te detornine cxpacny ‘Check all eve! 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