SEBE9027-01
January 8, 2005
(Revised February 2005)
U-10
A-9
D-9
O-10
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| Priority |
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING
THE TORQUE CONVERTER SLEEVE BEARINGS AND RELATED PARTS ON CERTAIN 725,
AND 730 ARTICULATED TRUCKS
|
| 4800
3150 3127 3030 3101 3065 3073 3167 |
PI30747
|
NOTE: This Program must be administered as
soon as possible. When reporting the repair, use "PI30747" as the Part
number and "7751" as the Group Number, "56" as the Warranty Claim Description
Code and "T" as the SIMS Description Code. Exception: If the repair is
done after failure, use "PI30747" as the Part Number, "7751" as the Group
Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS
Description Code.
NOTE: The information supplied in this service
letter may not be valid after the termination date of this program. Do
not perform the work outlined in this Service Letter after the termination
date without first contacting your Caterpillar product analyst.
NOTE: This Revised Service Letter replaces
the January 8, 2005 Service Letter. Changes have been made to the Affected
Product.
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COMPLETION DATE
|
TERMINATION DATE
|
| July 31, 2005 |
January 31, 2006 |
PROBLEM
The torque converter sleeve bearings and related
parts need to be replaced in the transmissions of certain 725 and 730 Articulated
Trucks. The surface finish on the mating transmission center shaft can
cause the sleeve bearing to fail.
AFFECTED PRODUCT
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| Model |
Identification Number |
| 725 |
AFX00074, 75, 78, 82, 87, 96, 103, 105, 107,
118, 120, 129, 146, 173, 184-186, 194, 196-198, 203, 219, 220, 227, 232,
233, 238, 281-286, 304, 306, 312, 314, 329, 332, 335, 338, 340, 347-349,
354, 363, 370, 377, 414, 417, 419, 422, 424, 426, 428, 429, 433, 435, 450,
454, 463, 465, 481, 484, 490, 491, 501, 511, 515, 517, 521-525, 527, 533,
536, 541, 545, 549, 553, 560, 562, 563, 566, 568, 570, 574, 576, 579, 584,
585, 588, 592, 601, 609, 613, 615, 652, 690, 691, 783-786
|
| 730 |
AGF00175, 176, 179, 180, 184, 189, 191, 203,
205, 258, 263, 267, 268, 282, 293, 339, 350, 351, 358, 361, 363, 364, 369,
370, 374, 378, 384, 391, 395, 400, 406, 409, 411, 419, 435, 437-439, 458,
469, 471, 474, 477, 491, 494, 496, 502, 506, 510, 518, 522, 539, 542, 550,
551, 553, 555, 556, 562, 563, 566, 569-571, 574, 575, 578, 580, 583, 585,
590, 592, 595-597, 600, 602, 605, 606, 612, 632, 634, 654, 701, 742
|
PARTS NEEDED
Dealers will need to order parts for this Program.
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|
Quantity
|
Part Number
|
Description
|
| 12 |
8E8300 |
DISC-THRUST |
| 8 |
8E8304 |
DISC-THRUST |
| 8 |
8E8306 |
DISC-THRUST |
| 1 |
8E8313 |
DISC-THRUST |
| 1 |
2P1692 |
SEAL-O RING |
| 14 |
3S2708 |
PIN-SPRING |
| 1 |
1T0736 |
BEARING-THRUST |
| 5 |
3P7566 |
SPRING |
| 1 |
1387034 |
HUB-CLUTCH (Only If
Required) |
| 1 |
1391537 |
ELEMENT AS.- |
| 1 |
1401855 |
GASKET |
| 1 |
2156432 |
HUB AS (Only If Required) |
| 1 |
2362601 |
SFWR GP-A500 |
| 3 |
2225203 |
DISC FRICTION |
| 5 |
2237519 |
DISC FRICTION |
| 1 |
2246952 |
BEARING-SLEEVE |
| 2 |
2278380 |
RACE-SPL THRUST |
| 1 |
2303166 |
RELIEF VALVE |
| 1 |
2443114 |
VALVE GP-MDL |
ACTION REQUIRED
Obtain latest software part number 2362601 from
SIS Web.
Flash software into transmission ECM using
Winflash.
See the attached procedure in order to carry
out inspection and rework of the transmission.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached
Owner Notification.
SERVICE CLAIM ALLOWANCES
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|
Caterpillar
|
Dealer Suggested
|
Customer Suggested
|
|
Parts
|
Labor Hrs.
|
Parts
|
Labor Hrs.
|
Parts
|
Labor Hrs.
|
|
100%
|
65
|
0
|
0
|
0
|
0
|
|
NOTE: This is a 65-hour job.
|
PARTS DISPOSITION
NOTE: All dealers are to make sure the outside
of the shipping container is marked PI30747.
***** U.S. and Canadian Dealers *****
Return all of the removed races, bearings,
and a copy of the claim to:
Caterpillar Inc.
Attn: Randy Gallinger PI30747
Service Claims Room
8201 N. University
Peoria, IL 61615
Handle all other parts in accordance with your
Warranty Bulletin on warranty parts handling.
***** All Other Dealers *****
Handle the parts in accordance with your Warranty
Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM
AS SOON AS POSSIBLE.
Attach. (1-Owner Notification)
(2-Rework Procedure)
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation3240 Arrow DriveAnywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR
REPLACING THE TORQUE CONVERTER SLEEVE BEARINGS AND RELATED PARTS ON CERTAIN
725, AND 730 ARTICULATED TRUCKS
MODELS INVOLVED - 725, AND 730 ARTICULATED TRUCKS
Dear Caterpillar Product Owner:
The torque converter sleeve bearings and related
parts need to be replaced in the transmissions of the products listed below.
The surface finish on the mating transmission center shaft can cause the
sleeve bearing to fail.
Contact your local Caterpillar dealer immediately
to schedule this service. The dealer will advise you of the time required
to complete this service. Please refer the dealer to their Service Letter
dated January 8, 2005 when scheduling this service. You will not be charged
for the service performed.
We regret the inconvenience this may cause
you, but urge you to have this service performed as soon as possible to
prevent unscheduled downtime.
Identification #(s)
Attached to January 8, 2005 Service Letter
REWORK PROCEDURE
Refer to media number RENR3448 to: remove transmission,
separate torque converter group from planetary, and disassemble planetary.
TORQUE CONVERTER HOUSING-REMOVE
Start By:
a. Remove the transmission oil filter. Refer
to Disassembly and Assembly, "Transmission Oil Filter - Remove and Install"
for the removal procedures.
b. Remove the bypass valve. Refer to Disassembly
and Assembly, "Bypass Valve - Remove and Install" for the removal procedures.
c. Remove the transmission oil temperature
sensor. Refer to Disassembly and Assembly, "Temperature Sensor (Transmission
Oil) - Remove and Install" for the removal procedures.
d. Remove the 193-0421 Speed Sensor. Refer
to Disassembly and Assembly, "Speed Sensor (Transmission) - Remove and
Install" for the removal procedures.
e. Remove the torque converter outlet relief
valve. Refer to Disassembly and Assembly, "Relief Valve (Torque Converter
Outlet) - Remove and Install" for the removal procedures.
1. Mount the transmission assembly on 1P2420 repair
stand with the torque converter assembly downward.
Illustration 1
2. Disconnect hydraulic tube (1) from fittings
(2). Then remove the hydraulic tubing.
Illustration 2
3. Remove bolts (3) in order to remove gasket
(4) and access plate (5) from the planetary transmission housing.
Illustration 3
4. Remove bolt (6) and the washer in order
to remove torque converter pump suction tube (7). Carefully remove the
torque converter pump suction tube from the torque converter housing.
Note: The suction tube is removed through
the opening in the planetary transmission housing.
Illustration 4
5. Remove O-ring (8) from torque converter
pump suction tube (7).
Illustration 5
6. Remove bolts (9) that secure planetary
transmission assembly (10) to torque converter housing (11).
Illustration 6
7. Install 138-7575 link bracket (B) and
attach a suitable hoist in order to separate planetary transmission housing
(10) from torque converter housing (11).
Note: The weight of the planetary transmission
housing is 386 kg (850 lb).
Illustration 7
8. Remove the supply tube (12) from either
planetary transmission housing (10) or torque converter housing (11) (not
shown).
RETARDER AND NUMBER 1 CLUTCH REMOVE
Illustration 8
9. Remove the o-rings from the torque converter
housing at position (X).
Illustration 9
10. Perform the following procedure in order
to separate the retarder from the torque converter:
a. Remove eight bolts (58) that secure the
retarder in position.
b. Remove two allen head screws (59) that secure
the retarder in position.
Illustration 10
-
Use 4C8359 eyebolts and a suitable hoist to remove
retarder (57) from the center shaft of the torque converter. The weight
of the retarder is 48 kg (105 lb). Set retarder with #1 clutch assembly
aside in preparation for Step 54.
RETARDER SUPPLY TUBE INSPECTION
Illustration 11
It is necessary to inspect that the retarder
supply tube is correctly retained within torque converter housing
Illustration 12
11. Inspect the tube by looking into the port
described below.
12. Measure the distance from the spot-face
in the case to the end the tube. The distance should not exceed 6 mm.
Illustration 13
13. If the distance exceeds 6mm, then the
retarder supply tube needs to be reinstalled.
14. Apply salvage technique SEBF8147 to this
end of the tube if the tube has not been installed correctly. Follow steps
15 to 21 to remove the torque converter, in order to gain access to the
retarder supply tube.
TORQUE CONVERTER REMOVE
Illustration 14
15. Remove eight allen head screws (56) and
the washers from the torque converter housing.
Illustration 15
16. Remove four bolts (55) from torque converter
housing (54) in order to release the separator plate.
17. Install three M-12 guide bolts, Tool (E),
to the torque converter housing. Install three 4C8359 eyebolts, Tool (F),
into the carrier assembly.
18. Use Tool (F) and a suitable hoist to raise
the torque converter housing approximately 5 mm (0.1969 inch) from the
torque converter. The weight of the torque converter housing is 159 kg
(350 lb).
Insert the soft drift in hole (Z).
Illustration 16
19. Use a hammer and a suitable soft drift
to tap the separator plate from the torque converter housing. This will
enable the separator plate to remain with the torque converter.
Illustration 17
20. Take care when removing the separator
plate (52) from the torque converter assembly; try not to catch the lip
seal on the gear. Remove tool E from the carrier assembly.
Illustration 18
21. Remove and inspect O-ring seal (53).
Inspect 135-3198 Lip Seal (51) for damage. If the lip seal shows any sign
of wear or damage, replace the lip seal with a new item.
TORQUE CONVERTER SHAFT - REMOVE
The torque converter shaft needs to be removed
in order to allow inspection and rework of the torque converter shaft and
the torque converter stator carrier.
Illustration 19
22. Remove six bolts (49) that secures flywheel
pilot (48).
Illustration 20
23. Install two 8T4182 bolts, Tool (D), into
threaded extraction holes to remove flywheel pilot (48) and O-ring seal
(50) (not shown).
Illustration 21
24. Remove the following components in order
to remove the center shaft: three bolts (45), retainer (46), washer (47).
Caution: If bolts (45) are being removed
while the converter is in the converter housing, the converter will fall
out. Make sure that the converter is properly supported.
Illustration 22
25. Carefully remove torque converter shaft
41 from the center of the carrier. The thrust bearing and two thrust races
can be removed to expose the converter stator carrier.
TORQUE CONVERTER STATOR CARRIER REWORK PROCEDURE
The thrust bearing surface on the torque converter
stator carrier needs to be reworked in order to ensure that the surface
is within the flatness limits.
Special Tools:
Illustration 31
Dial Indicator with flat bottom base capable
of measuring 0.00254mm (0.0001")
a. Mahr-Federal Gage Co. #C2-I dial indicator
(8S3158)
b. Mahr-Federal Gage Co. #AD-87 collet (3P1565)
c. Mahr-Federal Gage Co. #75P-53 base (5P4156)
d. Mahr-Federal Gage Co. #PYT-U-750-2 contact
Note: This inspection tool can also be found
as part of 6V7926 Dial Indicator Group.
Illustration 32
Scotch-Brite Roloc Surface Conditioning Disc
Illustration 33
Air or electric rotary tool that uses scotch-brite
disc
Illustration 35
26. Before the grinding operation on the
stator carrier, remove the 146-7447 seal rings on the torque converter
stator carrier. Tape a plastic bag over the housing with a hole large enough
for the stator carrier
Illustration 36
27. Place a tight bundle of paper towels
in the center of the stator assembly to protect the inside to the torque
converter from machining debris and blow out the stator surface.
Illustration 37
28. Measure the amount of raised material
around the ball plugs by: First, zero the dial indicator away from the
ball plugs on the stator race surface. Then, slide the indicator around
the ball plugs and measure the raised surface, especially the area between
the 2 closest ball plugs.
Illustration 38
29. Grind the raised areas down using the
tool with scotch-brite pad. Carefully and progressively remove a minimum
amount of material at a time and measure the amount of raised material.
Take care not to press too hard and remove too much material in one operation.
The areas around the ball plugs should be 0.000 mm or a maximum of 0.013
mm (0.0005 in) below the surface.
Illustration 39
30. Recheck the face for flatness. The variation
should be no more than 0.0025 mm (0.0001 in) around the circumference of
the bearing surface.
Illustration 40
31. When complete, the surface looks like
this. Carefully clean this surface and remove all debris generated by the
rework process.
32. Inspect the 146-7447 seal rings and replace
with new items if required.
TORQUE CONVERTER SHAFT INSPECTION
It is necessary to inspect the Pitch Line
Run Out between the splines and the bore for the sleeve bearing, and to
inspect the thrust bearing face on the torque converter shaft.
TORQUE CONVERTER SHAFT INSPECTION
Special tools:
..............3.175 mm dia magnetic inspection
pin
..............25-50 mm micrometer with anvil
tip
Illustration 41
33. Invert the shaft to inspect the face
that supports the sleeve-bearing race.
Good surface-Reuse shaft Unfinished surface-Replace
shaft
Illustration 42
34. If the surface is found to be unfinished,
replace the torque converter shaft with the new 226-0755 Shaft Assembly.
Illustration 43
35. Remove the three 3K1431 seals (40) from
the torque converter shaft (41) and inspect for excess seal wear. The side
of the seal may have a wear step.
Illustration 44
If this wear step is 0.25mm (0.010") or less
on all three seals, reuse the seals and converter shaft. If the wear step
is greater than 0.25mm (0.010") on any of the three seals then, replace
the converter shaft with the new 226-0755 shaft assembly and new seals.
Illustration 45
Lightly lubricate the seal rings with the oil
that is to be used in the transmission.
36. Remove the sleeve bearing from the converter
shaft assembly.
Illustration 46
37. Measure the Pitch Line Run Out (PLRO)
to ensure the shaft meets print. Mark 5 almost equally spaced places around
splines on the end of the shaft (~ every 10 teeth).
Illustration 47
38. Place the 3.175 mm dia magnetic pin in
spline and work up and down to ensure the pin is seated (no burrs or debris
is under pin).
Illustration 48
39. Measure the middle of the spline (on
the pin) to sleeve bearing bore and record.
40. Repeat for the other 4 locations marked
on the shaft. The spline PLRO is the difference between the high and low
numbers. If PLRO is greater than or equal to m
0.0080", then replace the shaft with a new 226-0755 Shaft Assembly. If
PLRO is less than 0.0080", and the thrust bearing surface is satisfactory,
the shaft can be reused.
Illustration 49
41. If the torque converter shaft is to be
reused, install the 224-6952 sleeve bearing. If a new 226-0755 Shaft assembly
is used, it is supplied with a new sleeve bearing already installed.
Illustration 50
42. Install new 227-8380 race then new 1T-0736
bearing and finally the second new race onto the torque converter shaft.
Lightly lubricate the bearing with the oil that is to be used in the transmission.
Illustration 58
43. Carefully install torque converter shaft
(41) into the center of the carrier. Rotate the shaft during installation
to help the seal rings align.
Illustration 59
44. Install the following components in order
to secure the center shaft in position: split race bearing half (41a),
washer (44), retainer (43), three bolts (42).
Note: Ensure the washer is turned such that
it holds the bearing inner race securely to prevent rotation. Tighten the
output shaft bolts (42) to a torque of 30 +/- 5 N.m (22 +/- 3 lb ft).
Illustration 60
45. Place O-ring seal (50) (not shown) in
position on the housing, use 1U-6396 O-Ring Assembly Compound.
46. Place flywheel pilot (48) in position over
the O-ring on the housing and install 6 bolts (49). Tighten the bolts to
a torque of 60 +/- 7 Nm (42 +/- 5 lb ft). Take care that O-ring (50) does
not come out of the groove upon assembly.
REWORK TRANSMISSSION PUMP GROUP
47. Follow instructions "Transmission Oil and
Scavenge Pump - Disassemble" to inspect and replace bearing as needed in
the pump body. The 8H9789 Bearing replaces the 1B4109 Ball Bearing. The
three needle bearings (142-3350) did not change.
48. Reassemble pump and reinstall into converter
housing by following instructions "Transmission Oil and Scavenge Pump -
Assemble" and "Transmission Oil and Scavenge Pump - Install".
INSTALLING THE TORQUE CONVERTER INTO THE TORQUE
CONVERTER HOUSING
Illustration 61
49. If a new lip seal is required, use 1P-0510
Driver Group to install Lip Seal (51) into separator plate (52). Apply
5P-3413 Pipe Sealant to the outside of the lip seal prior to installation.
50. Install O-ring seal (53) into the groove
around the outside diameter of the separator plate
Illustration 62
51. Install 217-9911 Seal Guide (G) (part
of 139-3158) over gear (J) to protect the lip seal from damage.
Illustration 63
52. Install separator plate (52) and remove
the seal guide. Install Tool (E) to the torque converter stator carrier.
Lubricate O-ring seal (53) and lip seal (51) with the lubricant that is
going to be used in the transmission.
Illustration 64
53. Install Tool (F) to torque converter
housing (54). Use Tool (F) and a suitable hoist to install the torque converter
housing onto the torque converter.
Note: The weight of the torque converter
housing is 159 kg (350 lb).
54. Install four bolts (55) in order to secure
the separator plate in position inside the torque converter housing.
Note: These bolts should be coated with Loctite
Studlock.
CLUTCH 1 PISTON REWORK PROCEDURE
It is necessary to machine slots in piston
seal grooves in order to allow oil pressure to move behind the seals and
to improve the sealing capability. Rework the number 1 clutch piston using
the following procedure.
Special tools:
........12.7 mm diameter flat bottom mill bit
and vertical mill
or......12.7 mm diameter die grinder
55. Go to the retarder and the number 1 clutch
that was removed from the torque converter housing group in step 9
56. Remove the number 1 rotating clutch hub.
Refer to RENR3448 "Retarder ? Disassemble - The No. 1 Rotating Clutch is
included".
57. Remove both the inner and outer piston seals
from clutch 1 piston.
Illustration 65
58. Add (4) slots to the outer diameter of
the piston through the edge of the piston seal groove. Use a 12.7 mm diameter
flat bottom mill bit at a 100.86 mm radius from the center of the part
to machine a slot 2.5 mm deep from the material edge. This should cut all
the way through the top edge of the piston seal groove.
Illustration 66
NOTE: Make sure the mill bit does not touch
the back edge of the piston seal groove! Scuffing the back edge of the
seal groove will reduce seal life.
Illustration 67
59. Add (4) slots to the inner diameter of
the piston through the edge of the piston seal groove. Use a 12.7 mm diameter
flat bottom mill bit at a 54.84 mm radius from the center of the part to
machine a slot 6.0 mm deep from the material edge. This should cut all
the way through the top edge of the piston seal groove.
NOTE: Make sure the mill bit does not touch
the back edge of the piston seal groove! Scuffing the back edge of the
seal groove will reduce seal life.
Illustration 68
60. Measure slot width on edge of piston.
Slot width should be 5 - 8 mm wide.
Slots added correctly to piston seal groove.
Illustration 69
61. Deburr edge of slot in piston seal groove
if necessary. Do not scuff back edge of seal groove while deburring slot.
62. Inspect the condition of the 8D-9738 and
6T-0257 piston seals. If the pistons seals are displaying wear, replace
with new items.
* Note: Piston can be reworked with a 12.7
mm diameter die grinder as long as care is taken not to damage the back
edge of the seal groove. A thin piece of steel may be inserted into groove
to protect back edge while machining by hand.
138-7034 Number 1 CLUTCH HUB INSPECTION AND REWORK
PROCEDURE
63. Inspect the external splines on the 138-7034
Clutch Hub. If wear steps are present on the external splines, replace
the clutch hub with a new item.
Before After
Illustration 70
The 138-7034 hub requires reworking to improve
the surface finish of the thrust disc face.
Special tools: Norton 400 grit paper or equivalent
Lubricant (stanisol, kerosene, or equivalent)
Illustration 71
Illustration 72
64. Lay 400 grit paper on flat surface such
as a Plexiglass sheet. Wet the paper liberally with lubricant.
Illustration 73
65. Lay the hub on the paper and polish each
end face by moving it in a circular or orbital pattern. Lap for approximately
1 minute.
Before After
Illustration 74
66. Examine the surface for final finish.
Surface appearance should be polished. Do not keep removing stock until
all blemishes are removed, just enough to remove the high spots.
67. Reassemble number 1 clutch. Refer to RENR3448
"Retarder-Assemble (The No. 1 Rotating Clutch is Included)" using the reworked
piston. Also replace five 134-8360 clutch discs with new part number 223-7519
clutch discs.
68. Perform the following procedure in order
to connect the retarder to the torque converter:
Illustration 75
a. Install 4C8359 eyebolts (G) and use a
suitable hoist to place retarder (57) in position over the output shaft
of the torque converter. Ensure that the bolt holes of the retarder are
properly aligned with the bolt holes of the torque converter housing.
Note: The weight of the retarder is 48 kg
(105 lb).
Illustration 76
b. Install eight bolts (59) that secure the
retarder in position. Tighten the bolts to a torque of 55 +/- 10 N.m (41
+/- 7 lb ft).
c. Install two allen head screws (58) that
secure the retarder in position. Tighten the bolts to a torque of 12 +/-
3 N.m (9 +/- 2 lb ft).
INSPECTION OF THE ECPC VALVES
It is necessary to determine the date code
of each of the ECPC valves that are used on the transmission. Also, the
ECPC valve for number 5 clutch needs to be replaced with the 216-5338 modulating
valve group. This is because the number 5 clutch could be more susceptible
to contamination.
69. Mark each ECPC valve with the clutch
number where it was removed. Inspect each ECPC valve to read the date code/serial
number stamped in the body at the location shown in the illustration below.
Illustration 77
If this serial number begins with 0046, replace
it with a new 216-5338 valve.
Replace number 5 clutch valve, even if the
date code is other than 0046.
TRANSMISSION INPUT SHAFT REWORK PROCEDURE
The transmission input shaft needs to be checked
and reworked in order to improve the surface finish of the shaft where
it runs in the sleeve bearing.
Special tools:
..........25-50 mm micrometer
..........40m
Precision Micro-finishing Film, made by Norton
..........Profilometer
70. Position transmission such that the input
shaft is positioned horizontally or vertically hanging down. Place plastic
over end of transmission and tape in position to ensure transmission remains
free of fine metal shavings removed during rework.
Illustration 78
71. Use a 25-50 mm micrometer to measure
the transmission input shaft diameter (measure at various depths to ensure
no taper exists). Use a portable profilometer to measure the axial surface
finish of the transmission input shaft. Record these results.
72. Polish the input shaft stub by hand in
order to improve the surface finish. Place several drops of oil on a 40m
Precision Micro-finishing Film, made by Norton. Loop the tape around the
shaft and pull the ends of the tape several times. Rotate around the entire
diameter of the shaft. Repeat until surface finish <0.1 mm.
Measure surface finish is in several areas around the shaft to ensure the
finish in consistent. Use a micrometer to measure the transmission input
shaft diameter in several locations. Make sure the shaft diameter is still
within print (31.066 +/- 0.013 mm). The goal is to just knock off the high
spots to improve surface finish, not to actually remove any material. Record
final surface finish and diameter measurements. If the planetary shaft
cannot be reworked and maintain print dimensions, replace with new shaft:
part no 231-3318.
TRANSMISSION PLANET GEARS REWORK PROCEDURE
The surface finish of the thrust disc faces
of all the planet gears within the transmission need to be reworked and
new thrust discs fitted.
Special tools: Norton 400 grit paper or equivalent
Illustration 79
Lubricant (stanisol, kerosene, or equivalent)
73. Refer to RENR3448 "Transmission Planetary-Disassembly"
to remove the three 140-2371 discs in the #4 clutch and to remove the planet
gears from each planet carrier.
74. Inspect, and use the following steps to
polish if necessary thrust disc surfaces on all planet gears.
Illustration 80
75. Lay 400 grit paper on flat surface such
as a Plexiglass sheet. Wet the paper liberally with lubricant.
76. Examine the gear faces. If the part number
is marked on the gear face and not on the teeth, then the planet gear must
be replaced with a new part.
Illustration 81
77. Lay the gear on the paper and polish
each end face by moving gear in a circular or orbital pattern. Lap for
approximately 1 minute and repeat for opposite face.
Before-dull, rough finish After-polished, smooth
finish
Illustration 82
78. Examine the gear faces for final finish.
Gear face appearance should be polished. Do not keep removing stock until
all blemishes are removed, just enough to remove the high spots.
REPLACING THE RETRACTION SPINGS IN THE NUMBER
5 CLUTCH
It is necessary to increase the #5 clutch piston
retraction forces. Installing new higher force springs is required.
Illustration 83
79. Remove five springs (43) and replace them
with five new 3P-7566 springs.
REPLACING CONVERTER OUTLET RELIEF VALVE
It is necessary to reduce converter outlet
pressure. Installing a new 230-3166 outlet relief valve is required
Illustration 84
80. Disconnect the wire connector from retarder
hydraulic control valve (1). Remove four bolts (2). Remove retarder hydraulic
control valve (1) and O-ring seal (3) (not shown) from the transmission.
Illustration 85
81. Remove torque converter outlet relief valve
(1) from the torque converter housing. Replace it with new part number
230-3166 relief valve. Reinstall retarder hydraulic control valve. The
test pressure for converter inlet pressure will increase to 72+/-10 PSI
at High Idle and 18+/-5 PSI at Low Idle.
TRANSMISSION REBUILD AND INSTALL
82. Install planet gears in carriers using new
thrust washers.
83. Refer to Follow "Transmission Planetary-Assemble"
to reassemble planetary. Install 3 x 222-5203 discs to the number 4 clutch.
84. Follow "Torque Converter Housing -Install"
to reassemble torque converter group to planetary.
85. Bench test transmission according to REHS1313.
86. Install the transmission in the machine.
Refer to RENR3448 "Transmission ? Install"
