Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 1P-2420 | Transmission Repair Stand | 1 |
B | 395-1590 | Lifting Eye Assembly | 2 |
C | 1P-1863 | Retaining Ring Pliers | 1 |
D | 1P-0520 | Driver Group | 1 |
E | FT-0833 | Clamp | 2 |
F | 395-1590 | Lifting Eye Assembly | 3 |
G | 136-1452 | Internal Pliers | 1 |
H | 1P-1861 | Internal Retaining Ring Pliers | 1 |
K | 395-1591 | Lifting Eye Assembly | 2 |
L | 395-1099 | Lifting Eye Assembly | 2 |
M | 1P-7404 | Eyebolt | 2 |
N | 395-1099 | Lifting Eye Assembly | 3 |
P | 1P-0510 | Driver Group | 1 |
R | FT-0834 | Clutch Testing Nozzle | 1 |
S | - | 3/8-16 NC x 5 Guide Bolt | 2 |
T | - | 1/2-13 NC x 4 Guide Bolt | 2 |
- Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary.
- Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.
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Illustration 1 g03328001 - If necessary, install dowel (156). Install the end of the dowel
1.00 ± 0.13 mm (0.039 ± 0.005 inch) above the bearing surface on the housing. - If carrier (155) was removed from the housing, heat the new carrier (155) to a temperature of
135°C (275.0°F) . Install the carrier on the housing assembly. Align the small groove in the carrier with the pin hole in the housing assembly. Install pin (154).Show/hide tableIllustration 2 g00491967 - Position housing assembly (124) on Tooling (A), as shown.
- Put shaft assembly (152) in position in housing assembly. Install retaining ring (151) with Tooling (C) (not shown).
- Install seal ring (153) in housing assembly (124).
- If the dowels were removed from housing (124), install the dowels to a depth of
7.50 ± 0.50 mm (0.295 ± 0.020 inch) .Show/hide tableIllustration 3 g03328037 - Install seal extension ring (150) into the groove in clutch piston (149).
- Attach Tooling (E) to clutch piston (149). Install clutch piston (149) in housing assembly (124).
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Illustration 4 g00491964 - If the dowel was removed from gear assembly (140), install the dowel. Position the dowel
2.04 ± 0.13 mm (0.080 ± 0.005 inch) above the surface of gear (140). - Install seal ring (147) in gear assembly (140).
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Illustration 5 g03328065 - Install seal extension ring (146) in balance piston (145).
- Position balance piston (145) on gear assembly (140). Align the notch in ball bearing (144) with the pin in gear assembly (140). Install ball bearing (144).
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Illustration 6 g03328066 - Use Tooling (C) (not shown) to install retaining ring (143) that holds ball bearing (144) to the gear.
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Illustration 7 g03328067 - Install twelve retainer springs (148) in clutch piston (149). Install gear (140) in housing assembly (124).
- Install six bolts (not shown) under housing assembly (124) in order to secure gear assembly (140).
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Illustration 8 g03327774 - Install three friction discs (141) and two plates in housing assembly (124). Install a friction disc on the bottom of the stack. Install the friction discs and plates in alternating order. Start with a friction disc (141) and end with a friction disc (141).
- Install seal ring (142) on gear (141).
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Illustration 9 g03328078 - Install bearings (133) and (137) in planetary gears (134) and (138). Install planetary gears and thrust discs (132), (135), (136), and (139) in position in carrier assembly (127).
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NOTICE The spring pins must be replaced with new parts during the assembly of the carrier assembly.
Failure to use new spring pins could result in damage to the carrier assembly.
- Install planetary shaft (130) in position in the carrier assembly. Align the hole in the planetary shaft with the hole in the carrier assembly. Install new spring pin (131).
- Repeat Steps 20 and 21 for the remaining five gears.
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Illustration 10 g00491959 - Install ring seal (129) into the groove in carrier assembly (127).
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Illustration 11 g03328082 - Use Tooling (D) in order to install bearing (128) in carrier assembly (127). The inside diameter of bearing (128) must be
112.547 ± 0.078 mm (4.4310 ± 0.0031 inch) after assembly.Show/hide tableIllustration 12 g03327115 - Attach Tooling (L) to carrier assembly (127). Put carrier assembly (127) on housing assembly (124). Rotate carrier assembly (127) in order to align carrier assembly (127) with housing assembly (124). Put carrier assembly (127) on the dowels. Install bolts (126) that hold carrier assembly (127). The weight of carrier assembly (127) is approximately
30 kg (66 lb) .Show/hide tableIllustration 13 g00493875 The photo shows the correct method to make new seal rings ready for installation. Note: Use the following procedure in order to make the seal rings ready for installation: Pull one end of the seal ring past the other end of the seal ring. Refer to Illustration 13. Use care to keep the seal ring circular. This makes an even bend all the way around the seal ring. When the seal ring is in the groove, the ends must contact each other. The seal ring must not contact the edge of the bore.
Show/hide tableIllustration 14 g00493876 The photo shows an incorrect method to make new seal rings ready for installation. Show/hide tableIllustration 15 g00491956 - Invert the housing. Place the housing assembly on a flat surface.
- Install two seal rings (125) in housing assembly (124).
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Illustration 16 g03327207 - Position the housing assembly onto Tooling (A) (not shown). Attach Tooling (B) and a suitable lifting device to center manifold (121). Install center manifold (121) on the housing assembly. The weight of center manifold (121) is approximately
50 kg (110 lb) . - Position baffle assembly (120) on center manifold (121). Install the two bolts.
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Illustration 17 g03328175 - Align the notch in ball bearing (123) with dowel (156). Install ball bearing (123) in the center manifold. Use Tooling (C) to install retaining ring (122).
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Illustration 18 g03328181 - If dowel (157) was removed, install dowel (157) in manifold assembly (118). Position dowel (157)
2.043 ± 0.13 mm (0.0804 ± 0.005 inch) above the bearing surface of manifold assembly (118). - Install two seal rings (119) into the grooves in manifold assembly (118).
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Illustration 19 g03328184 - Install Tooling (S) in center manifold (121). Align the ports in manifold assembly (118) with the ports in center manifold (121). Install manifold assembly (118). Install the six bolts that hold manifold assembly (118) to center manifold (121).
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Illustration 20 g03328245 - Install seal ring (117) into the groove in housing assembly (110).
- Install seal extension ring (116) in clutch piston (115).
- Install clutch piston (115) in housing assembly (110).
- If the dowels were removed from housing assembly (110), install the dowels in housing assembly (110). Install the dowels to a depth of
7.5 ± 0.5 mm (0.30 ± 0.02 inch) .Show/hide tableIllustration 21 g03327382 - Attach Tooling (N) and a suitable lifting device to housing assembly (110). Install the clutch piston and housing assembly (110) in center manifold (121). The weight of the clutch piston and housing assembly (110) is approximately
26 kg (57 lb) . - Install 16 retainer springs (114) in the clutch piston.
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Illustration 22 g03328260 - Use Tooling (D) to install ball bearing (112) in balance piston (109). Install retaining ring (111) with Tool (H) (not shown).
- Install ring (113) into the groove in balance piston (109).
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Illustration 23 g03328262 - Install Tooling (S) in balance piston (109). Align the notch in the ball bearing in balance piston (109) with the dowel in the carrier. Install balance piston (109).
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Illustration 24 g03328298 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Remove Tooling (S). Install the bolts. Tighten the bolts evenly in order to prevent binding of balance piston (109) in the housing assembly.
- Install metal seal ring (107) in manifold assembly (118).
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Illustration 25 g03328336 Show/hide tableIllustration 26 g03327386 - If dowel (158) was removed from balance piston (109), install dowel (158) in balance piston (107). Position dowel (158)
2.043 ± 0.13 mm (0.0804 ± 0.005 inch) above the bearing surface of the balance piston. - Install metal seal ring (106) in balance piston (109).
- Install sun gear assembly (105) and metal seal ring (106).
- Install two clutch plates and two friction discs (108) on balance piston (109). Install the clutch plates and the friction discs in alternating order. Start with a clutch plate and end with a friction disc.
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Illustration 27 g00491930 - Position bearing (101) in planetary gear (102). Install planetary gear (102), thrust disc (103), and thrust disc (104) in carrier assembly (98).
- Install planetary shaft (99) in carrier assembly (98).
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NOTICE The spring pins must be replaced with new parts during the assembly of the carrier assembly.
Failure to use new spring pins could result in damage to the carrier assembly.
- Align the hole in planetary shaft (99) with the hole in carrier assembly (98). Install spring pin (100).
- Repeat Steps 49 through 51 for the remaining three gears.
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Illustration 28 g03328341 - If dowels (159) were removed from carrier assembly (98), install dowels (159). Position dowels (159) to a depth of
5.0 ± 0.5 mm (0.20 ± 0.02 inch) . - Attach Tooling (M) and a suitable lifting device to carrier assembly (98). Position carrier assembly (98) on the dowels of housing assembly (110). Install the 15 bolts that hold the carrier assembly in place.
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Illustration 29 g03328354 - If pins (95) and (160) were removed from plate (94), install three pins. Position two pins (95) to a depth of
10.0 ± 0.5 mm (0.39 ± 0.02 inch) . Install pin (160) in plate (94). - Align the pins in plate (94) with the holes in the center manifold. Install plate (94).
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Illustration 30 g03328356 - Position ring gear (96) on the carrier assembly. Install dowels (91) into the holes in plate (94).
- Install two friction discs (90) and clutch plate (93) on ring gear (96). Install a friction disc (90) on each side of clutch plate (93).
- Install ten springs (92) in plate (94).
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Illustration 31 g03328357 - Put seal extension ring (161) and ring seal (162) into the grooves in clutch piston (89).
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Illustration 32 g00491916 - Install clutch piston (89) in clutch housing (88).
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Illustration 33 g03326400 - Attach Tooling (E) in position in order to hold the clutch piston in clutch housing (88).
- Attach Tooling (B) and a suitable lifting device to clutch housing (88). Position clutch housing (88) on the dowels. Ensure that the springs in the plate assembly align with the holes in the clutch piston. The weight of clutch housing (88) and the clutch piston as a unit is approximately
24 kg (53 lb) .Show/hide tableIllustration 34 g03328362 - If dowels (86) were removed from clutch housing assembly (87), install four dowels (86). Position dowels (86) to a depth of
11.0 ± 0.5 mm (0.43 ± 0.02 inch) in housing assembly (80). - Attach Tooling (F) and a suitable lifting device to clutch housing assembly (87). Align dowels (86) in the bottom of clutch housing assembly (87) with the holes in clutch housing (88). Install clutch housing assembly (87).
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Illustration 35 g03328473 - Install seal extension ring (163) and ring seal (164) into the grooves in clutch piston (85).
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Illustration 36 g03328477 - Install clutch piston (85) in clutch housing assembly (87).
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Illustration 37 g03328481 - Use a screwdriver to install retaining ring (83) in ring gear (84). Install ring gear (84) with the ring on the bottom.
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Illustration 38 g03328483 - Install plate (82) onto dowels (165). Install the six bolts that hold plate (82).
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Illustration 39 g03328489 - Install metal seal ring (80) in plate (79).
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Illustration 40 g03328490 - Position plate (79) with the counterbore on top. If plate (79) is installed incorrectly, ball bearing (78) will not seat correctly.
- Align the notch in ball bearing (78) with dowel (158). Install ball bearing (78).
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Illustration 41 g00491874 - Install sun gear (76). Use Tool (C) (not shown) to install retaining ring (75).
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Illustration 42 g03328511 - Install bearings (71) in planetary gear (74). Position planetary gear (74) and thrust discs (73) and (72) in carrier assembly (57). Install (69) in carrier assembly (57).
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NOTICE The spring pins must be replaced with new parts during the assembly of the carrier assembly.
Failure to use new spring pins could result in damage to the carrier assembly.
- Align the hole in planetary shaft (69) with the hole in carrier assembly (57). Install spring pin (70).
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Illustration 43 g03328518 - Use a suitable press and Tooling (P) in order to install bearing (68) in carrier assembly (57). Position bearing (68)
9.5 ± 0.5 mm (0.37 ± 0.02 inch) below the surface of the end of the carrier assembly. The inside diameter of bearing (68) must be41.262 ± 0.039 mm (1.6245 ± 0.0015 inch) after assembly.Show/hide tableIllustration 44 g03328521 - Attach Tooling (M) and a suitable lifting device to carrier assembly (57). Align the planetary gears in carrier assembly (57) with ring gear (84). Install carrier assembly (57) and the bolts.
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Illustration 45 g00491858 - Position sun gear (65) in coupling hub (66). Use Tooling (C) in order to install retaining ring (67).
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Illustration 46 g03328531 - Put five dowels (45) in the housing assembly.
- Install four friction discs (62) and three clutch plates (64) in alternating order. Start with a friction disc and end with a friction disc.
- Install ten springs (63) on the clutch piston.
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Illustration 47 g03328538 - If dowels (61) were removed from clutch housing assembly (59), install dowels (61). Position dowels (61) to a depth of
11.0 ± 0.5 mm (0.43 ± 0.02 inch) . - Attach Tooling (K) and a suitable lifting device to clutch housing assembly (59).
- Align the ports in clutch housing assembly (59) with the ports in clutch housing assembly (87). Put clutch housing assembly (59) on dowels (45). Align springs (63) with the holes in clutch housing assembly (59).
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Illustration 48 g03328559 - Install seal extension ring (165) and ring seal (166) into the grooves of clutch piston (60).
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Illustration 49 g03328568 - Install clutch piston (60) in clutch housing assembly (59).
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Illustration 50 g00491853 - Install metal seal ring (58) on carrier assembly (57).
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Illustration 51 g00491848 - Install bearings (53) in planetary gear (56). Put the planetary gear and thrust discs (55) and (54) in planetary carrier (50).
- Install shaft assembly (51) in the planetary carrier.
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NOTICE The spring pins must be replaced with new parts during the assembly of the carrier assembly.
Failure to use new spring pins could result in damage to the carrier assembly.
- Align the hole in shaft assembly (51) with the hole in planetary carrier (50). Install spring pin (52).
- Repeat Steps 88 through 90 for the remaining three gears.
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Illustration 52 g03328587 - Attach Tooling (L) and a suitable lifting device to planetary carrier (50). Align planetary carrier (50) with the shaft assembly. Install planetary carrier (50). The weight of planetary carrier (50) is approximately
24 kg (53 lb) . - Position speed adapter (47) on planetary carrier (50). Install the four bolts that hold speed adapter (47) to the planetary shaft.
- Support the weight of planetary carrier (50) with the hoist. Install retaining ring (48) with Tooling (G).
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Illustration 53 g03328625 - Position ring gear (42) in position on planetary carrier (50).
- Install five friction discs (43) and four plates (46) on ring gear (42) in alternating order. Start with a friction disc (43) and end with a friction disc (43).
- Install ten springs (44) into the clutch piston.
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Illustration 54 g03328627 - Use a suitable press and Tooling (D) in order to install roller bearing assembly (40) and bearing cup (41) in end plate (29) as an assembly.
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Illustration 55 g03328631 - Use a suitable hydraulic press in order to install bearing cup (41). Install spacer (39). Install bearing cone (38).
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Illustration 56 g03328636 - Use Tooling (D) in order to install lip seal (37) in bearing retainer (36).
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Illustration 57 g03328641 - Install O-ring seal (167) on bearing retainer (36). Install bearing retainer (36) on end plate (29).
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Illustration 58 g03328647 Show/hide tableIllustration 59 g03328721 - Position end plate (126), as shown. Attach Tooling (B) and a suitable lifting device to end plate (29).
- Position end plate (29) over yoke assembly (33). The weight of end plate (29) is approximately
50 kg (111 lb) . - Position retainer plate (32) on the yoke assembly. Install four evenly spaced twelve point head bolts (31) around retainer plate (32). Do not tighten bolts (31) at this time.
- Use a feeler gauge in order to measure the gap between yoke assembly (33) and retainer plate (32). Measure the gap in four places. Find the average of the measurements.
- Remove four twelve point head bolts (31) and retainer plate (32). Install the shims with a thickness of
0.03 to 0.08 mm (0.0012 to 0.0031 inch) less than the average gap. - Position retainer plate (32) on the shims. Install twelve twelve point head bolts that hold retainer plate (32) to yoke assembly (33).
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Illustration 60 g03328728 - Attach Tooling (F) and a suitable lifting device to housing (29). Align the splines in yoke assembly (33) with the splines on the planetary carrier. Put the end plate on dowels (45). Ensure that springs (44) engage the holes in end plate (29). The weight of housing (29) is approximately
70 kg (154 lb) .Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install the 20 bolts that hold end plate (29) to the transmission planetary.
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Illustration 61 g03328738 - Attach Tooling (F) (not shown) and a suitable lifting device to the transmission planetary. Position the transmission planetary upside-down on Tooling (A). The weight of the transmission planetary is approximately
454 kg (1000 lb) . - If pins (27) and (168) were removed from plate assembly (28), install two pins. Install two pins to a depth of
10.0 ± 0.5 mm (0.39 ± 0.02 inch) . Install pin (138) in the plate assembly. - Position plate assembly (28) on the manifold.
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Illustration 62 g03328759 - Install five reaction dowels (22) in housing assembly (28).
- Install ring gear (26) on the carrier assembly.
- Install three friction discs (24) and two clutch plates (25) over the ring gear in alternating order. Start with a friction disc (24) and end with a friction disc (24).
- Install ten springs (23) in plate assembly (28).
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Illustration 63 g03328761 - Install seal extension ring (169) and ring seal (170) in the grooves of clutch piston (21).
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Illustration 64 g00491411 - Install clutch piston (21) into clutch housing (20).
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Illustration 65 g03328766 - Position Tooling (E) in order to hold the clutch piston in clutch housing (20).
- Attach Tooling (K) and a suitable lifting device to clutch housing (20). Position clutch housing (20) on dowels (22). Ensure that springs (23) engage the holes in clutch housing (20). The weight of clutch housing (20) and the clutch piston as a unit is approximately
28 kg (62 lb) .Show/hide tableIllustration 66 g00491407 - Install sun gear (14) in clutch hub assembly (11).
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Illustration 67 g03328772 - Install retainer ring (13) that holds the sun gear to clutch hub assembly (11).
- If dowel (171) was removed from clutch hub assembly (11), install dowel (171). Install the end of dowel (171)
2.403 ± 0.13 mm (0.0946 ± 0.005 inch) above the bearing surface of clutch hub assembly (11).Show/hide tableIllustration 68 g00491405 - Use Tooling (D) in order to install ball bearing (12) in bearing cage (9).
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Illustration 69 g03328777 - Align the notch in ball bearing (12) with the dowel in clutch hub assembly (11). Install ball bearing (12) and the bearing cage on clutch hub assembly (11) as an assembly.
- Use Tool (C) in order to install retainer ring (10) in clutch hub assembly (11).
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Illustration 70 g03328778 - Install manifold (8) onto bearing cage (9). Install four bolts (172) and the washers.
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Illustration 71 g03328798 - Attach Tooling (B) to bearing cage (9). Align clutch hub assembly (11) with carrier assembly (127). Install clutch hub assembly (11), bearing cage (9), and the manifold as an assembly.
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Illustration 72 g03328822 - Install five dowels (16) and ten springs (17) in the holes in clutch housing (20).
- Install two friction discs (19) and clutch plate (18) on clutch housing (20) in alternating order. Start with a friction disc (19) and end with a friction disc (19).
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Illustration 73 g03328832 - Install seal extension ring (173) and ring seal (174) into the grooves of clutch piston (15).
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Illustration 74 g03328837 - Install clutch piston (15) on dowels (16) and springs (17). Ensure that the springs engage the holes in clutch piston (15).
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Illustration 75 g03328838 - Install Tooling (T) in the manifold. Attach Tooling (K) to housing assembly (7). Position housing assembly (7) on the transmission planetary. The weight of housing assembly (7) is approximately
32 kg (70 lb) .Show/hide tableIllustration 76 g03329293 - Install eight bolts (175) that hold clutch housing assembly (7) to the manifold.
- Install two bolts (176) and eight bolts (6) that hold housing assembly (7) to the transmission planetary.
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Illustration 77 g03329354 - Remove transmission planetary (1) from Tooling (A). The weight of transmission planetary is
610 kg (1350 lb) . - Position case (4) on Tooling (A). The weight of case (4) is approximately
205 kg (450 lb) . - Install O-ring seal (177) on transmission planetary (1).
- Attach Tooling (B) and a suitable lifting device to transmission planetary (1). Position transmission planetary (1) in case (4). Install the bolts that fasten transmission planetary (1) to case (4). The weight of transmission planetary (1) is approximately
610 kg (1350 lb) .Show/hide tableIllustration 78 g03329370 - Position the spacer and bracket (3), as shown. Install the six bolts and the washer.
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Illustration 79 g03329372 - Use Tool (R) (not shown) in order to ensure that the clutch pistons are free in the clutch housings:
- Put dry shop air pressure into each of the seven oil passages. The shop air pressure must have a pressure of
690 to 1030 kPa (100.1 to 149.4 psi) . - If the clutch pistons do not move, put a small amount of clean SAE 30 oil in each oil passage. Check the clutch pistons for movement. If the clutch pistons do not move, the transmission planetary must be disassembled.
- Put dry shop air pressure into each of the seven oil passages. The shop air pressure must have a pressure of
End By:
- Install the transmission hydraulic control. Refer to Disassembly and Assembly, "Transmission Hydraulic Control - Remove".
- Connect the transfer gears to the transmission. Refer to Disassembly and Assembly, "Transmission Planetary and Transfer Gears - Connect".