CAMPUS ITM: Av.
Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com  
  1  
SYSTEMS OPERATION  
966G Series II Wheel Loader and 972G Series II 
Wheel Loader Power Train   
GENERAL INFORMATION   
I llustration 1: Location of Power Train Components  
(1) Diesel engine  
(2) Torque converter  
(3) Transmission  
(4) Output transfer gears   
(5) Rear final drives  
(6) Rear drive shaft  
(7) Front drive shaft  
(8) Front final drive  
Power from the diesel engine (1) is sent from the flywheel to torque converter (2). The 
torque  converter  is  splined  to  the  engine  flywheel.  The  torque  converter  is  fastened  to 
transmission  (3)  by  bolts.  Power  flows  directly  from  the  torque  converter  to  the 
transmission input shaft. The torque converter output gear is meshed to the transmission 
input gear.   
The transmission output shaft is connected to the input gear in output transfer gear case 
(4) by splines. Power is sent through the input gear to the output gear. The output gear 
sends  power  through  rear  drive  shaft  (6)  to  the  rear  differential.  The  output  gear  also 
sends  power  to  the  front  differential  through  front  drive  shaft  (7).  The  bevel  gear  and 
pinion  of  each  differential  sends  the  power  to  the  final  drives  through  the  differentials 
and through the sun gear shafts. Axle shafts transfer the power from final drives (5) and 
(8) to the wheels. An integral parking brake is mounted on the front of the transmission.   
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com  
  2      
I llustration 2: Block Diagram of the Power Train Electronic Control System  
(9) Position sensor (left pedal)  
(10) Transmission direction and speed 
control  
(11) ET service connector  
(12) CAT Data Link  
(13) Caterpillar Monitoring System  
(14) Caterpillar Monitoring System 
service connector  
(15) Power train electronic control 
module (ECM)  
(16) Auto/manual switch for the 
Autoshift control  
(17) Transmission neutralizer override 
switch  
(18) Variable shift control switch  
(19) Minimum engine speed setting  
(20) Engine  
(21) Engine speed sensor  
(22) Torque Converter  
(23) Torque Converter output speed 
sensor  
(24) Modulating valves (transmission 
clutch) (six)  
(25) Transmission oil temperature 
sensor  
(26) Transmission output speed sensors 
(two)  
(27) Differential  
(28) Transmission    
Six  hydraulically  activated  clutches  in  transmission  (28)  provide  four  forward  speeds 
and  four  reverse  speeds.  Speed  selections  and  direction  selections  are  made  manually 
with  transmission  direction  and  speed  control  (10).  The  autoshift  control  will  make 
speed selections if the machine is in automatic mode. The variable shift control uses the 
position  of  the  variable  shift  control  switch  and  the  engine  speed  in  order  to  provide 
alternate auto shift points.      
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  3  
The  power  train  electronic  control  system  electronically  controls  transmission  shifts. 
The  power  train  electronic  control  system  shifts  the  transmission.  In  order  for  the 
transmission  to  be  shifted  to  the  desired  speed  and  the  desired  direction,  power  train 
ECM  (15)  receives  the  operator  input  from  transmission  direction  and  speed  control 
(10)  and  the  left  brake  pedal  position  sensor.  The  power  train  ECM  signals  the 
modulating  valve  (transmission  clutch)  of  the  speed  clutch  that  is  selected.  The  power 
train  ECM  signals  the  modulating  valve  (transmission  clutch)  of  the  direction  clutch 
that  is  selected.  The  output  signal  energizes  the  solenoids  of  modulating  valves 
(transmission  clutch)  (24)  that  are  selected.  The  energized  modulating  valves 
(transmission  clutch)  electronically  modulate  the  oil  pressure  of  the  clutches  that  are 
selected. The power train ECM can request automatic shifts. The power train ECM uses 
the  following  input  signals  to  ensure  steady  engagement  of  the  clutches:  engine  speed 
sensor (21), torque converter output speed sensor (23), transmission speed sensors (26) 
and transmission oil temperature sensor (25).   
The  power  train  ECM  also  controls  the  following  functions:  neutral  start,  ride  control, 
backup  alarm,  auto  shift  control,  variable  shift  control,  secondary  steering,  speed 
limiter, parking brake interlock and transmission neutralizer.                                 
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  4  
TORQUE CONVERTER AND PUMP DRIVE HOUSING  
I llustration 3: Torque Converter and Pump Drive Housing  
(1)  Torque  converter  housing.  (2)  Transmission  and  hydraulic  implement  pump  drive 
gear.  (3)  Pump  drive  flange.  (4)  Transmission  oil  pump.  (5)  Torque  converter.  (6) 
Transmission housing. (7) Torque  converter output gear.  (8) Drive  gear. (9)  Input  gear 
for planetary transmission.  
Transmission  oil  pump  (4)  and  the  hydraulic  implement  pump  are  mounted  on  torque 
converter  housing  (1).  Torque  converter  housing  (1)  is  between  the  engine  flywheel 
housing and transmission housing (6).   
Gear  (8)  turns  drive  gear  (2)  for  the  transmission  oil  pump  and  for  the  hydraulic 
implement  pump.  Pump  drive  flange  (3)  is  connected  to  transmission  oil  pump  (4)  by 
splines. The hydraulic implement pump is fastened to transmission oil pump (4). Torque 
converter output gear (7) sends power to input gear (9) for the planetary transmission. 
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  5  
TORQUE CONVERTER           
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  6  
TORQUE CONVERTER   
The  torque  converter  is  located  at  the  input  end  of  the  transmission.  The  torque 
converter  housing  is  bolted  to  the  flywheel  housing.  Output  torque  from  the  torque 
converter enters the planetary transmission through either the Number 1 sun gear or the 
Number  2  sun  gear.  The  gear  that  receives  the  output  is  dependent  upon  the  direction 
clutch that is engaged.   
Oil  for  the  operation  of  the  torque  converter  is  supplied  by  the  transmission  oil  pump. 
Oil from the transmission oil pump flows to the torque converter housing. The oil flow 
is  divided  in  the  torque  converter  housing.  The  transmission  hydraulic  control  relief 
valve and the clutch solenoid modulating valves receive the oil flow that is divided. The 
transmission hydraulic control relief valve regulates P3 converter inlet oil to flow to the 
torque  converter  at  a  nominal  pressure  of  550  kPa  (80  psi).  The  torque  converter  inlet 
relief valve limits the oil flow to the torque converter to a maximum pressure of 900  
70  kPa  (130    10  psi).  The  torque  converter  inlet  relief  valve  is  located  in  the  torque 
converter  housing.  The  transmission  hydraulic  control  relief  valve  is  located  above  the 
torque converter inlet relief valve.   
The torque converter outlet pressure is 415 kPa (60 psi).   
TORQUE CONVERTER  
                    I llustration 4: Torque Converter
(1) Rotating housing  
(2) Impeller  
(3) Gear  
(4) Inlet port  
(5) Output shaft  
(6) Turbine  
(7) Stator  
(8) Adapter  
(9) Carrier assembly  
(10) Outlet port   
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  7  
Rotating  housing  (1),  impeller  (2),  and  oil  pump  drive  gear  (3)  are  driven  by  the 
flywheel. These components rotate as a unit at the engine speed.   
P3  converter  inlet  oil  enters  the  torque  converter  through  inlet  port  (4)  in  carrier 
assembly  (9).  The  oil  is  directed  to  the  inlet  port  by  a  passage  in  the  torque  converter 
housing.  From  inlet  port  (4),  the  oil  flows  through  carrier  assembly  (9)  and  through  a 
passage in impeller (2).   
As impeller (2) rotates, the impeller acts as a pump in order to direct the oil to turbine 
(6).  The  turbine  is  fastened  to  the  hub  assembly  with  bolts.  The  hub  assembly  is 
connected to output shaft (5) by splines. The turbine directs oil to stator (7) that is held 
stationary. The stator is connected to adapter (8) with splines. Adapter (8) is connected 
to  carrier  assembly  (9)  with  splines.  Carrier  assembly  (9)  is  bolted  to  the  torque 
converter housing.   
The oil flows through a passage in carrier assembly (9) to outlet port (10). From outlet 
port (10), oil is directed to the torque converter oil cooler. The temperature of the oil is 
lowered in the torque converter oil cooler. From the torque converter oil cooler, the oil 
flows  to  the  transmission.  The  oil  cools  the  internal  components  of  the  transmission. 
The oil lubricates the internal components of the transmission.   
TORQUE CONVERTER (FREEWHEEL STATOR)  
                                I llustration 5 
(1) Rotating housing  
(2) Impeller  
(3) Gear  
(4) Inlet port  
(5) Output shaft  
(6) Turbine  
(7) Plate  
(8) Stator  
(9) Race  
(10) Carrier 
assembly  
(11) Outlet port   
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  8   
I llustration 6 
(9) Race  
(12) Cam  
(13) Spring  
(14) Slot  
(15) Cam surface  
(16) Roller   
Rotating  housing  (1),  impeller  (2),  and  oil  pump  drive  gear  (3)  are  driven  by  the 
flywheel. These components rotate as a unit at the engine speed.   
P3  converter  inlet  oil  enters  the  torque  converter  through  inlet  port  (4)  in  carrier 
assembly (10). The oil is directed to the inlet port by a passage in the torque converter 
housing. From inlet port (4), the oil flows through carrier assembly  (10)  and through a 
passage in impeller (2).   
As impeller (2) rotates, the impeller acts as a pump in order to direct the oil to turbine 
(6).  The  turbine  is  fastened  to  the  hub  assembly  with  bolts.  The  hub  assembly  is 
connected  to  output  shaft  (5)  with  splines.  The  turbine  directs  oil  to  stator  (8)  that  is 
held stationary.   
Stator (8) is connected to freewheel cam (12) with splines. Stator (8) and freewheel cam 
(12)  rotate  together.  Freewheel  race  (9)  is  held  stationary.  Springs  (13)  are  inserted 
between  cam  (12)  and  rollers  (16).  Race  (9)  is  connected  to  carrier  (10)  with  splines. 
Carrier (10) is fastened to the cover that is around the torque converter. Carrier (10) and 
race  (9)  do  not  rotate.  The  carrier  helps  to  support  the  rotating  components  of  the 
converter.  The  carrier  also  contains  the  oil  flow  passages  for  the  operation  of  the 
converter.   
The oil flows through a passage in carrier assembly (10) to outlet port (11). From outlet 
port (11), oil is directed to the torque converter oil cooler. The temperature of the oil is 
lowered in the torque converter oil cooler. From the torque converter oil cooler, the oil 
flows  to  the  transmission.  The  oil  cools  the  internal  components  of  the  transmission. 
The oil lubricates the internal components of the transmission.  
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  9  
TRANSMISSION HYDRAULIC SYSTEM     
I llustration 7: Schematic for the Transmission Hydraulic System  
(1) Transmission hydraulic control relief valve  
(2) Torque converter  
(3) Torque converter outlet relief valve (if equipped)  
(4) Transmission oil filter  
(5) Modulating valve (transmission clutch) for the Number 1 clutch  
(6) Modulating valve (transmission clutch) for the Number 4 clutch  
(7) Modulating valve (transmission clutch) for the Number 2 clutch  
(8) Modulating valve (transmission clutch) for the Number 5 clutch  
(9) Modulating valve (transmission clutch) for the Number 3 clutch  
(10) Modulating valve (transmission clutch) for the Number 6 clutch  
(11) Transmission oil pump  
(12) Torque converter inlet relief valve  
(13) Suction screen and magnet  
(14) Oil sump  
(15) Transmission lubrication  
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  10 
(16) Oil cooler  
(A) Pump pressure tap  
(B) P3 Torque converter inlet pressure tap  
(C) Torque converter outlet pressure tap  
(D) Sampling valve for the transmission oil  
(G) Number 1 clutch pressure tap  
(H) Number 4 clutch pressure tap  
(J) Number 2 clutch pressure tap  
(K) Number 5 clutch pressure tap  
(L) Number 3 clutch pressure tap  
(M) Number 6 clutch pressure tap  
(N) Transmission lubrication pressure tap   
The transmission hydraulic system consists of the following components: suction screen 
and  magnet  (13),  transmission  oil  pump  (11),  transmission  oil  filter  (4),  transmission 
hydraulic control relief valve (1), modulating valves (transmission clutch) (5-10), torque 
converter (2), torque converter inlet relief valve (12), torque converter outlet relief valve 
(3) and oil cooler (16).   
The  bottom  of  the  output  transfer  gear  case  contains  oil  sump  (14).  Transmission  oil 
pump  (11)  is  a  one-section  gear  type  pump.  Transmission  oil  pump  (11)  is  a  positive 
displacement  pump.  Transmission  oil  pump  (11)  supplies  oil  to  the  transmission 
hydraulic  system.  Transmission  oil  pump  (11)  pulls  oil  from  oil  sump  (14).  The  oil 
flows  through  the  suction  screen  and  magnet  (13).  Oil  is  supplied  to  the  pump  inlet 
through  a  tube  that  is  mounted  to  the  pump  inlet  and  the  output  transfer  gear  case. 
Pressurized  oil  exits  the  pump  outlet  and  flows  to  externally  mounted  transmission  oil 
filter (4). Pressurized oil flows from transmission oil filter (4) through an external hose 
to the torque converter housing. Pressurized oil then flows through internal passages in 
the  torque  converter  housing.  Transmission  hydraulic  control  relief  valve  (1)  receives 
some  of  the  pressurized  oil  flow.  Modulating  valves  (5-10)  receive  some  of  the 
pressurized oil flow.   
Modulating valves (5-10) are mounted on the top of the transmission under the cab. The 
six transmission clutches have an individual modulating valve (5-10). In order to move 
the machine, a direction clutch solenoid and a speed clutch solenoid must be energized. 
The modulating valves (5-10) are used to directly modulate the oil pressure that is sent 
to each individual clutch. The leakage oil from the clutches and the  return oil flows to 
the  bottom  of  the  transmission.  The  nonenergized  modulating  valves  (5-10)  return  the 
oil  flow  to  the  bottom  of  the  transmission.  The  oil  then  flows  to  oil  sump  (14)  in  the 
bottom of the output transfer gear case.   
Transmission hydraulic control relief valve (1) controls the pressure of the oil that flows 
to  modulating  valves  (5-10).  Oil  flows  into  transmission  hydraulic  control  relief  valve 
(1) at a maximum pressure of 2930 kPa (425 psi). The oil pressure overcomes the spring 
force  of  transmission  hydraulic  control  relief  valve  (1).  Torque  converter  inlet  oil  then 
flows to torque converter (2) at 550 kPa (80 psi).   
Torque  converter  inlet  relief  valve  (12)  limits  P3  torque  converter  inlet  oil  to  a 
maximum pressure of 900  70 kPa (130  10 psi). Torque  converter inlet relief valve 
(12)  is  located  in  the  torque  converter  housing.  Transmission  hydraulic  control  relief 
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  11 
valve (1) is located above the torque converter inlet relief valve. Transmission hydraulic 
control relief valve (1) must be removed in order to attain access to the torque converter 
inlet relief valve.   
The outlet oil from torque converter (2) flows to torque converter outlet relief valve (3). 
Torque  converter  outlet  relief  valve  (3)  (if  equipped)  maintains  the  oil  pressure  inside 
the  torque  converter  at  a  specific  rate.  Torque  converter  outlet  relief  valve  (3)  (if 
equipped) maintains the oil pressure inside the torque converter at 415  140 kPa (60  
20 psi). The oil flows from the torque converter outlet relief valve to oil cooler (16).   
Oil cooler (16) is located on the right side of the engine.  After the oil has been cooled, 
the  oil  flows  to  the  transmission.  The  oil  provides  lubrication  to  the  transmission  and 
cooling to the transmission. The oil flows through internal passages in the transmission 
to  the  bearings,  the  gears  and  the  clutches.  The  oil  then  flows  to  the  bottom  of  the 
transmission.  The  oil  then  flows  to  oil  sump  (14)  in  the  bottom  of  the  output  transfer 
gear case.    
TRANSMISSION OIL PUMP     
I llustration 8: Torque Converter and Pump Drive Housing  
(1) Torque converter 
housing. 
(2) Transmission 
and hydraulic pump 
drive gear. 
(3) Pump drive 
flange. 
(4) Transmission oil 
pump.  
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  12              
I llustration 9: Location of the transmission oil pump  
Transmission  oil  pump  (4)  is  mounted  on  the  left  side  of  torque  converter  housing  (1) 
under the cab.   
Transmission oil pump (4) is a positive displacement type pump. The one-section  gear 
pump  is  bolted  to  the  torque  converter  housing  (1).  The  following  pumps  are  mounted 
on  the  transmission  oil  pump  (4)  and  driven  by  the  transmission  oil  pump:  steering 
pump, implement pump and pilot/brake pump.   
The pump drive gear is fastened to the torque converter impeller. The pump drive gear 
drives  transmission  and  hydraulic  pump  drive  gear  (2).  Transmission  and  hydraulic 
pump  drive  gear  (2)  is  fastened  to  pump  drive  flange  (3).  Pump  drive  flange  (3)  is 
connected to transmission oil pump (4) by splines. The splined shaft of the transmission 
oil pump drives the transmission oil pump.   
I llustration 10: Transmission oil pump  
The  main  components  of  the  transmission  oil  pump  are  (5)  cover  assembly,  (6)  body 
assembly, (7) manifold assembly, (8) drive gear, and (9) gear. 
(4) Transmission oil 
pump.  
(5) Cover assembly.  
(6) Body assembly.  
(7) Manifold 
assembly.  
(8) Drive gear.  
(9) Gear.  
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  13  
OIL FILTER (POWER TRAIN)     
I llustration 11: Location of the power train oil filter  
The power train oil filter (1) is mounted on the left side of the machine frame under the 
cab.  
The  externally  mounted  oil  filter  has  a  bypass  valve.  If  there  is  a  restriction  in  the  oil 
filter or if the oil viscosity is high, the bypass valve in the filter housing will open.   
If the inlet pressure to the oil filter is 248  21 kPa (36  3 psi) greater than the outlet 
pressure,  the  bypass  valve  will  open.  When  the  oil  does  not  flow  through  the  filter 
element, the debris in the oil could cause damage to other components in the hydraulic 
system.   
Correct  maintenance  recommendations  must  be  followed  in  order  to  ensure  that  the 
element does not fill with debris. If the element is full of debris, the flow of clean oil to 
the hydraulic system stops.   
TRANSMISSION OIL COOLER   
I llustration 12: Location of Transmission Oil Cooler 
(1) Power train oil filter.  
Coolant  from  the  engine 
enters  the  end  of  the  oil 
cooler.  The  coolant 
flows  through  the  many 
long tubes that are in the 
oil  cooler.  The  coolant 
then  exits  the  opposite 
end of the oil cooler and 
the coolant returns to the 
engine  cylinder  block. 
The  coolant  is  then 
cooled  by  the  cooling 
system of the engine.  
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  14    
I llustration 13: Schematic of Transmission Oil Cooler  
Transmission  system  oil  with  a  high  temperature  comes  from  the  relief  valve  for  the 
torque converter outlet. Transmission system oil enters the oil cooler inlet. The flow of 
oil is around the tubes and along the tubes inside the oil cooler. In this process, heat that 
is removed from the oil is given to the engine coolant. After the oil flows through the oil 
cooler  tubes  the  oil  flows  through  the  bottom  outlet  with  a  lower  temperature.  The 
components in the transmission are then cooled and lubricated by the oil.   
TRANSMISSION HYDRAULIC CONTROL   
I llustration 14: Transmission Hydraulic Control    
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  15  
(1) Number 1 clutch modulating valve (Reverse)  
(2) Number 2 clutch modulating valve (Forward)  
(3) Number 3 clutch modulating valve (Fourth Speed)  
(4) Number 4 clutch modulating valve (Third Speed)  
(5) Number 5 clutch modulating valve (Second Speed)  
(6) Number 6 clutch modulating valve (First Speed)  
(A) Transmission hydraulic control relief valve  
(B) Modulating valves (transmission clutch)  
(C) Torque converter inlet relief valve  
(D) Torque converter outlet relief valve (if equipped)  
The  transmission  hydraulic  control  controls  the  oil  pressure  to  the  torque  converter,  to 
the  transmission  clutches,  and  to  the  lubrication  circuits.  The  transmission  hydraulic 
control also controls the flow of oil to the clutches. The transmission hydraulic control 
is installed on the top of the transmission planetary group and on the side of the torque 
converter  housing.  The  transmission  hydraulic  control  consists  of  the  following 
components: transmission hydraulic control relief valve (A), six modulating valves (B), 
torque converter inlet relief valve (C) and torque converter outlet relief valve (D).  
Pressurized  oil  for  the  operation  of  the  transmission  hydraulic  control  flows  from  the 
transmission oil pump to the transmission oil filter. The oil flows through a hose to the 
oil inlet in the torque converter housing. The oil flows through internal passages in the 
torque  converter  housing  in  order  to  supply  transmission  hydraulic  control  relief  valve 
(A) with oil. The oil also flows through internal passages in the transmission housing in 
order to supply the six modulating valves (B) with oil.   
The six modulating valves (B) are mounted on the top of the transmission under the cab. 
The  six  transmission  clutches  have  an  individual  modulating  valve  (B).  In  order  to 
move  the  machine,  a  direction  clutch  solenoid  and  a  speed  clutch  solenoid  must  be 
energized. The modulating valves (B) are used to directly modulate the oil pressure that 
is sent to each individual clutch.   
The  following  table  provides  the  combination  of  the  energized  solenoids  and  engaged 
clutches for each forward speed and for each reverse speed.   
TABLE 1 
Speed Range and Direction      Clutches and Solenoids that are Engaged     
Fourth Speed Forward      3 and 2     
Third Speed Forward      4 and 2     
Second Speed Forward      5 and 2     
First Speed Forward      6 and 2     
Neutral      3     
First Speed Reverse      6 and 1     
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  16 
Second Speed Reverse      5 and 1     
Third Speed Reverse      4 and 1     
Fourth Speed Reverse      3 and 1      
Transmission  hydraulic  control  relief  valve  (A)  controls  the  pressure  of  the  oil  that  is 
supplied  to  modulating  valves  (B).  The  oil  pressure  overcomes  the  spring  force  of  the 
transmission  hydraulic  control  relief  valve.  Torque  converter  inlet  P3  oil  then  flows  to 
the torque converter.   
Torque converter inlet relief valve (C) limits P3 torque converter inlet oil pressure to a 
maximum  of  900    70  kPa  (130    10  psi).  Torque  converter  inlet  relief  valve  (C)  is 
located in the torque converter housing. Transmission hydraulic control relief valve (A) 
is located above torque converter inlet relief valve (C). Transmission hydraulic control 
relief valve (A) must be  removed in order to  attain access to the torque converter inlet 
relief valve (C).    
TRANSMISSION HYDRAULIC CONTROL OPERATION    
I llustration 15: Transmission Hydraulic Control 
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  17       
Starting the Engine with the Transmission in the NEUTRAL position:  
When the engine is started, the transmission oil pump (11) pulls oil from oil sump (14). 
The oil flows through the suction screen and magnet (13). Transmission oil pump (11) 
sends  pressurized  oil  through  transmission  oil  filter  (4).  Pressurized  transmission  oil 
flows from the transmission oil filter to the oil inlet in the torque converter housing. The 
pressurized oil flows through internal passages in the torque converter housing in order 
to  supply  transmission  hydraulic  control  relief  valve  (1)  with  oil.  The  pressurized  oil 
also  flows  through  internal  passages  in  the  transmission  housing.  The  pressurized  oil 
flows out of the internal passages in the transmission housing into modulating valves (5-
10).  Number  3  clutch  solenoid  (9)  is  energized  because  the  transmission  is  in  neutral. 
None  of  the  remaining  modulating  valves  (5),  (6),  (7),  (8)  and  (10)  provide  oil  to  the 
transmission clutches. The pressurized oil leakage drains to oil sump (14).   
The transmission hydraulic control relief valve (1) sends P3 converter inlet oil to torque 
converter (2). Torque converter outlet oil flows to oil cooler (16). After the oil cools, the 
oil flows to the transmission for transmission lubrication (15). After the transmission is 
lubricated and cooled the oil drains to the oil sump (14).   
Torque converter inlet relief valve (12) limits P3 torque converter inlet oil pressure to a 
maximum  of  900    70  kPa  (130    10  psi).  Torque  converter  inlet  relief  valve  (12)  is 
located in the torque converter housing. Transmission hydraulic control relief valve (1) 
must be removed in order to attain access to torque converter inlet relief valve (12).  
Shifting the Transmission to the FIRST SPEED FORWARD position:  
The  power  train  electronic  control  module  (ECM)  modulates  the  electrical  current  that 
is  sent  to  the  selected  modulating  valves.  Modulating  the  current  to  the  modulating 
valve controls the transmission clutch pressure.   
When  the  transmission  direction  and  speed  control  lever  (if  equipped)  is  moved  to  the 
FIRST SPEED FORWARD position, both Number 2 clutch solenoid (7) and Number 6 
clutch  solenoid  (10)  are  energized.  When  the  transmission  direction  control  switch  (if 
equipped)  and  the  transmission  upshift  switch  are  shifted  to  the  FIRST  SPEED 
FORWARD position, both Number 2 clutch solenoid (7) and Number 6 clutch solenoid 
(10) are energized.   
Number 2 clutch solenoid (7) is electronically modulated when the Number 2 clutch is 
filled.  Number  6  clutch  solenoid  (10)  is  electronically  modulated  when  the  Number  6 
clutch is filled. When the electrical current is modulated to the full current, the Number 
6 clutch and the Number 2 clutch are at full oil pressure.  
Modulating valves (5), (6), (8), and (9) are not energized. The leakage oil drains to oil 
sump (14).  
(AA) Pressure oil     (BB) P3 Torque Converter inlet pressure  
(CC) Torque converter outlet pressure     (DD) Lubrication pressure 
(EE) Return oil   
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  18  
Transmission in the FOURTH SPEED REVERSE position:  
The  power  train  electronic  control  module  (ECM)  modulates  the  electrical  current  that 
is  sent  to  the  selected  modulating  valves.  Modulating  the  current  to  the  modulating 
valve controls the transmission clutch pressure.   
When  the  transmission  direction  and  speed  control  lever  (if  equipped)  is  moved  to  the 
FOURTH SPEED REVERSE position, both Number 1 clutch solenoid (5) and Number 
3  clutch  solenoid  (9)  are  energized.  When  the  transmission  direction  control  switch  (if 
equipped)  and  the  transmission  upshift  switch  is  shifted  to  the  FOURTH  SPEED 
REVERSE  position,  both  Number  1  clutch  solenoid  (5)  and  Number  3  clutch  solenoid 
(9) are energized.   
Number 1 clutch solenoid (5) is electronically modulated when the Number 1 clutch is 
filled.  Number  3  clutch  solenoid  (9)  is  electronically  modulated  when  the  Number  3 
clutch is filled. When the electrical current is modulated to the full current, the Number 
3 clutch and the Number 1 clutch are at full oil pressure.   
Modulating valves (6), (7), (8), and (10) are not energized. The leakage oil drains to oil 
sump (14).    
OUTPUT TRANSFER GEARS     
I llustration 16: Output Transfer Gears  
(1) Case.  
(2) Drive gear.  
(3) Shims.  
(4) Driven gear.  
(5) Shaft.  
(6) Yoke assembly.  
(7) Yoke assembly.    
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  19  
The  output  transfer  gears  are  at  the  output  side  of  the  transmission.  The  transmission 
output shaft is connected to drive gear (2) by splines.   
Drive gear (2) is engaged with driven gear (4). Driven gear (4) is connected to shaft (5) 
by  splines.  Yoke  assemblies  (6)  and  (7)  are  connected  to  shaft  (5)  by  splines.  Yoke 
assembly  (6)  is  connected  to  the  short  drive  shaft  that  is  connected  to  the  rear 
differential.  Yoke  assembly  (7)  is  connected  to  the  drive  shaft.  The  drive  shaft  is 
connected to the pillow block bearing and to the front differential.   
The flow of power in the output transfer  gears goes from the transmission output shaft 
to  drive  gear  (2).  The  power  then  flows  from  drive  gear  (2)  to  driven  gear  (4).  The 
power then flows from the driven gear to shaft (5).   
At shaft (5), the flow of power divides. Some of the power goes from yoke assembly (6) 
through  a  drive  shaft  to  the  rear  differential.  Some  of  the  power  goes  from  yoke 
assembly (7) through a drive shaft and through the bearing cage to the front differential.   
Shims (3) are used to adjust the end play of gear (2).   
MAGNETIC SCREEN   
I llustration 17: Magnetic Screen Assembly  
The  magnetic  screen  assembly  is  located  on  the  bottom  right  side  of  the  rear  of  the 
transfer  gear case. Oil from the bottom of the transfer  gear case  flows through an inlet 
passage.  As  the  oil  flows  through  the  screen,  foreign  particles  that  are  in  the  oil  are 
stopped by the screen. This keeps the foreign particles from going into the transmission 
hydraulic system.   
After the oil flows through the screen, the oil flows through the magnets. The magnets 
are installed on the tube assembly so that the same magnetic ends are next to each other. 
Smaller  metal  particles  that  go  through  the  screen  are  captured  by  the  magnets.  The 
magnets  will  not  allow  the  metal  particles  to  go  with  the  oil  through  the  transmission 
hydraulic system.   
Then, the oil flows through the tube assembly to the transmission pump. 
(1) Magnetic tube.  
(2) Screen.  
(3) Seal.   
                                                                                                                       CAMPUS ITM: Av. Ramn Castilla 1110 
                                                                                                                               Carretera Trujillo  Huanchaco 
                                                                                                                                  E-mail: itmaperu@yahoo.com 
  20  
DIFFERENTIAL   
I llustration 18: Typical I llustration            
A  differential  divides  the  power  that  is  sent  to  the  wheels  or  a  differential  causes  a 
balance of the power that is sent to the wheels. A differential allows one wheel to turn at 
a  slower  rate  than  the  other  wheel  on  an  axle.  For  example,  this  occurs  during  a  turn. 
During  a  turn,  the  differential  allows  the  inside  wheel  to  rotate  at  a  slower  rate  in 
relation  to  the  outside  wheel.  The  differential  still  sends  the  same  amount  of  torque  to 
each wheel.   
(1) Bevel pinion.  
(2) Bevel gear.  
(3) Ring gear.  
(4) Planetary gear.  
(5) Carrier.  
(6) Axle shaft.  
(7) Spider.    
(8) Differential case.  
(9) Pinion.  
(10) Side gear.  
(11) Brake piston.  
(12) Brake disc.  
(13) Reaction plate.  
(14) Sun gear.