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1. v 03395 t 03345 t PIE PUS pug 151 A3H 03395 9 PIE iH OM 19 151 S3HOLfTIO 43345 9 GION330S Mo 1043105 2 L a 5 3 GION310S 03345 9 H91N193G ONIHONI 8 NOHWINGOW ATONIS 4 4 9 ON HOLO3NNOO HOIO3NNOO OL SHIM OL 2043106 GION310S 04 19 09 HOLIMS 410 NO WNOILdO HOLIMS 440 qdf19201 IWNOILdO Date Apr 2000 104100 WNWIXVA 108 B31HVIS OL ve 85 NMOUS 1 9 L N3349 H MOTI3A 13100 Ov ig 31IHM 3002 40109 2 ama 9 3000 Y01709 3ulM JOHLINOO gVO 20 902 28 HOI DANKE 20 6 SalON310S 24 82 HO OCA SL 20 6 3OVLIOA HLIM SWALI AlddNS LON Maintenance amp Servic
2. 1 24 Output Shaft Sleeve Ring 4 BUSHING tee alas A dace 1 25 Output Shaft Bearing Snap Ring 5 Output Shaft Bearing Snap Ring 1 26 Output Shaft and Brake Flange 6 Seal Sleeve Ring 1 27 Piston Stop Nut 7 Output Shaft Oil 1 28 Piston Stop Nut Ring 8 Oil Seal Sleeve 1 29 Rod Locknut 9 Output Shaft Bearing 1 30 Disconnect Piston 10 Output Shaft Bearing Snap Ring 1 31 Piston 11 Flange Retaining Ring 1 32 Piston External Ring 12 Disconnect Shift Hub 1 33 Piston Internal Ring 13 Gear Retaining Ring 1 34 Disconnect Spring 14 Output Shaft Gear 1 35 Disconnect Rod Stop Sieeve 15 Disconnect Detent Ball 1 36 Disconnect Shift Fork Rod 16 Disconnect Detent Spring 1 37 Disconnect Shift Fork Lockscrew 17 Disconnect Overshift Stop 1 38 Disconnect Shift Fork 18 Detent Plug Ring 1 39 Disconnect Shift Fork Rod Seal 19 Disconnect Detent Plug 1 40 Disconnect Shift Fork Rod
3. 2 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD 3 SPEED ASSEMBLY INSTRUCTIONS ne 37 VIEW Enlarged View of Seal rT PEPER ET NI Som OD EE Es SECTION C C 17 5 32 VIEW K Figure H Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD 4 6SPEED ASSEMBL Y INSTRUCTIONS OIL FILTER REVERSE IDLER VIEW H Figure Date Apr 2000 Maintenance amp Service Manual A A Assemble oil filter and tighten to 20 25 Ibf ft 27 34 N m Teflon seals must be sized prior to assembly 10 outer steel plates 10 inner plates Alter nately assemble starting with outer steel plate 6 outer steel plates 6 inner plates Alternately assemble starting with outer steel plate 5 outer steel plates 5 inner plates Alternately assemble starting with outer steel plate Shield bearing assemble with shield as shown Fwd Rev 2nd 3rd and 4th High clutch return disc springs Concave side of first disc spring to be placed against clutch piston wear sleeve Remaining four springs to be stacked alternately as shown Low clutch return disc springs concave side of first disc spring to be placed against clutch piston wear sleeve Remaining six springs to be stacked alter nately as shown Clearance between clutch piston and steel separator plate to be 048 108 1 22 2
4. 2 OIL FROM COOLER ee ee 2 ponr 5 CLUTCH PRESSURE some CHECK PORT REVERSE CLUTCH PRESSURE RIGHT SIDE VIEW 89 CHECK PORT CLUTCH PRESSURE 3 SPEED 4 SPEED 6 SPEED FWD 5TH 6TH REV port 2 CHECK PORT CLUTCH PRESSURE 4 SPEED FWD 4TH 6 SPEED FWD HI Ses Pages 94 through 97 for Hydraulic Diagram LEFT SIDE VIEW 79 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearing to avoid spinning Do not spin bearings when drying Bearings may be rotated slowly by hand to facilitate drying process Housings Clean interior and exterior of housings
5. 5000 34705 20491 DON HUM SWIL 418 LON 4 8 Date Apr 2000 1712000 3 4 6 Speed LD Maintenance amp Service Manual 2 S H 5 5 4 L Zid d iH N 4 2 3 54 94 SdION310S NOISSINSNVHL SATVA NOISSI QO31VALDOV 03345 9 ANY v GION3 OS 91419373 11 01 HEOL S LOL 9 1 SE LEOL 11 01 Ekt 51 LL OL 7 S L L 1 1 I 101 1 0 61119 L L L D 9 9 0 9 9 L L L N ld 4 93 94 S3HIM NOILISOd 435019 SLOVLNOD 1 3OH1NO2 BvD aaads 9 SNOILISOd TIY NI SNJdO 11 0 LOVLNOO 1 LOL Ob 9 ld 11 01 24 1 4 LOL Ebb 91 bd WSNVHL 3NYA TOHLNOD PIE pug pug 151 Add 151 S3HIM N33M138 0350712 SLOVLNOD NOILISOd TOYLNOS BVO TOYLNOD 8V9 03345 p PIE Ulp Up Pug ISL QMA 151 3395
6. 174 191 153 168 180 198 224 268 159 175 156 172 216 237 302 332 271 298 Figure L 315 347 427 470 282 310 382 420 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD PARKING BRAKE AND DISC ON DROPPED OUTPUT OPTION v DROPPED OUTPUT WITH BRAKE OPTION DROPPED OUTPUT SECTION VV GROUND DRIVEN EMERGENCY STEERING PUMP DRIVE OPTION Figure M Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD MAINTENANCE AND SERVICE The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence that would normally be foliowed after the unit has been removed from the machine and is to be completely overhauled It must also be understood that this is a basic T12000 3 4 and 6 speed long drop output transmission with many options The units are very similar to troubleshoot disassemble repair and reassemble CAUTION Cleanliness is of extreme importance and an absolute must in repair and overhaul of this unit Before attempting any repairs the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism DISASSEMBLY Figure 1 Side view of T12000
7. 20 Output Shaft Bearing Snap Ring 1 41 Disconnect Shift Fork Lockscrew 21 Output Shaft Bearing 1 42 Disconnect Shift Fork Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T12000 ELECTRIC CONTROL GROUP DUAL MODULATION Figure F Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T12000 CONTROL VALVE GROUP DUAL MODULATION ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION QUANTITY 1 Modulator Valve Housing 2 22 Coil to Cartridge O Ring 2 Modulator Housing Ring 2 23 Valve Cartridge 2 Way Used at Rev and Fwd Incl Items 24 25 26 3 SOP cse be kk 2 24 Cartridge Ring 4 Spring 2 25 Cartridge Ring 5 Spring Middle 2 26 Cartridge Ring 6 Sleeve Ring 2 27 Cartridge Ring 7 Modulation Housing Sleeve 2 28 Cartridge Ring 8 Modulation Housing Sleeve Snap Ring 2 29 Cartridge Ring 9 Regulator Spool 2 30 Solenoid Bore Plug Used at Fwd High 10 Spring 2 and Fwd Low Incl Items 27 28 29 Bore Plug U
8. 1 MODULATION ES VALVE gt Re 5 LJ _ _ OPERATOR COMPARTMENT 7 TEMPERATURE PRESSURE mood GUAGE GUAGE 1 ties a VIL 109 PRESSURE per REGULATOR BEN D DE psi psi 109 si Qu T FWD LO gt SAFETY 19 hee psi FWD HI COOLER S2 z pores TORQUE gt CONVERTER 1 FILTER 4 one 121 lt gt 2 3 2 63 Go T 109 psi ZX E psi 2ND HOSE 1 L 2 em EUER BREATHER D oN pst L 1ST OIL SUMP Ne se FILTER AIR HYDRAULIC DISCONNECT OPTION SPEED SHIFT DIAGRAM 6 m FORWARD 611213111213 VIEW V REMOTE FILTER OPTION gt gt Date Apr 2000
9. 1 61 End Plate 1 62 Inner Disc 5 63 5 64 Retainer Snap Ring 1 65 Snap Ring Retainer l a uaaa aaa 1 66 Disc Spring Assembly 5 67 Clutch Piston Wear Plate 1 68 Clutch Piston 1 69 Clutch Piston Seal Outer 1 70 Clutch Piston Seal Inner 1 71 High and 3rd Shaft Drum and Plug Assembly 1 72 Clutch Piston Seal Inner 1 73 Clutch Piston Seal Outer 1 74 Clutch Piston 1 75 Clutch Piston Wear Plate 1 76 Disc Spring Assembly 5 77 Snap Ring Laaa 1 78 Retainer Snap Ring 1 79 Outer Disc 1st Clutch 6 80 Inner Disc 1st Clutch 6 81 End Plate 82 Plate Snap Ring 1 83 Clutch Gear Thrust Washer 1 84 Clutch Gear Thrust Washer Bearing 1 85 Clutch Gear Thrust Washer 1 86 4th Clutch Gear 1 87 Bearing usse ert s 1 88 Bearing 1 89 Bearing 1 90 Clutch Gear Thrust Washer 1 91 Clutch Gear Thrust Washer Bearing 1 92 Clutch Gear Thrust Washer 1 93 Gear Hu
10. 1 34 Hydraulic Inching Upper Piston Seal 1 2 Modulator Housing Ring 1 35 Hydraulic Inching Lower Piston 1 5 tO Pince ow 1 36 Hydraulic Inching Body Snap Ring 1 4 Spring Inner 1 37 Hydraulic Inching Body Seal 1 5 Spring Middle 1 38 Hydraulic Inching Ring 1 6 Spring Outer 1 39 Hydraulic Inching Body 1 7 Accumulator 1 40 Hydraulic Inching Body to Case Ring 1 8 Modulation Housing Sleeve 1 41 Hydraulic Inching Actuator Rod 1 a tt Uti era 1 42 Hydraulic Inching Return Spring 1 10 Regulator Spool Stop 1 43 Hydraulic Inching Regulator Spring 1 11 SPRING RR 1 44 Hydraulic Inching 8 1 12 Regulator Spool 1 45 Hydraulic Inching Sleeve 1 nbn ete 1 46 Hydraulic Inching Ring 1 14 Regulator Spool Sleeve 1 47 Cover 2 AS Spas uen ot tet e e Lune 1 48 Cover Screw Lockwasher 2 16 Spool Sleeve Ring 1 49 Protective 1 17 Snap 1 50 Valve Cartridge Retainer Nut
11. 61 1 67 7 Nem 2555 4 157140 2960 38 78 20 VE FILLET WELD Figure 389A T12000 3 4 amp 6 Speed LD Figure 390 Install oil filter on regulating valve Tighten filter to 20 25 Ibf ft 27 34 N m INSTALLATION OF DUAL MODULATION For single modulation and mechanical inching see page 86 Figure 391 Install modulation diverter in transmission case 68 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 395 Install housing over sleeve and spring assembly and tighten securely Figure 392 Position a new ring on lower end of the modu If parking brake is not used proceed to Figure 400 lation valve sleeve and spring assembly Install O ring on other valve sleeve Figure 396 Position parking brake disc on output flange Install capscrews and washers and tighten to specified Figure 393 torque See torque chart Install valve or valves in transmission case Figure 394 Figure 397 Position a new O ring on modulator valve housing Position caliper brake assembly on brake disc Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 398 Install brake mounting screw through brake assembly and through locknut Apply Loctite 262 to threads and install screw in transmission case Figure 400 See special section on page 74 for drive plate installation Figure 399 M
12. 4 18 Snap Ring 1 51 Nut to Coil Ring 4 19 Sleeve Ring 1 52 Solenoid Coil 4 20 Shuttle Spool 1 53 Coil to Cartridge O Ring 4 21 Shuttle Sleeve 1 54 Valve Cartridge 2 22 cedi 1 55 Cartridge O Ring 2 23 Inching Housing 1 56 Cartridge Ring 2 24 Inching Housing Ring 1 57 Cartridge Ring 2 25 Inching Return Spring 1 58 Cartridge O Ring 1 26 Inching Actuator Rod 1 59 Cartridge Ring 1 27 Inching Regulator Spring 1 60 Cartridge Ring 1 28 Inching Spool 1 61 Solenoid Bore Plug Used with 3 Speed Only 1 29 Inching Sleeve Ring 1 62 Cartridge Ring 2 30 Inching Sleeve 1 63 Cartridge Ring 2 31 Hydraulic Inching Cover 1 64 Cartridge Ring 2 32 Hydraulic Inching Cover Plug 3 65 Cartridge Ring 2 38 Hydraulic Inching Upper Piston 1 66 Valve Cartridge
13. 3RD CLUTCH Figure 145 Remove bearing Figure 146 Figure 143 Remove outer thrust washer thrust bearing and inner Remove clutch piston thrust washer 95 Date Apr 2000 Maintenance 8 Service Manual T12000 3 4 amp 6 Speed LD gt 74 Figure 147 Figure 150 Remove 3rd gear and gear bearings Remove end plate gt e i 53 148 Remove outer thrust washer thrust bearing and inner thrust washer Figure 151 Remove clutch discs Figure 149 Figure 152 Remove end plate retainer ring Compress disc springs and remove retainer ring 26 Date Apr 2000 Maintenance amp Service Manual Figure 153 Remove retainer ring retainer 45 Figure 154 Remove disc springs NOTE See page 71 m Figure 155 Remove clutch piston wear plate gt T12000 3 4 amp 6 Speed LD Figure 156 Remove clutch piston REASSEMBLY OF 4TH HIGH CLUTCH See cleaning and inspection page For 3 speed proceed to Figure 177 E Figure 157 Clutch piston bleed ball must be clean and free of any foreign material Figure 158 Install inner and outer clutch piston seal rings Size inner ring as explained in Figure 91 Install clutch piston in clutch drum Use caution as not to damage Sealing rings Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 159 Install clutch piston wear plate Figure 162 Start ring on shaft wit
14. Service Manual T12000 3 4 amp 6 Speed LD lt REVERSE CLUTCH REASSEMBLY Figure 232 Clutch piston bleed orifice must be clean and free of any foreign material Figure 229 Press one bearing in clutch gear flush with face of gear Install bearing spacer next to bearing Press second bearing in gear flush with face of gear Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Be sure the clutch hub is in full position in the clutch assembly Do not force this operation Figure 233 Install inner and outer clutch piston seal rings Size inner ring as explained in Figure 91 Install clutch piston in clutch drum Use caution as not to damage sealing rings Figure 230 Position inner thrust washer on shaft Position thrust bearing on clutch shaft against inner thrust bearing washer Position outer thrust washer on shaft Figure 231 Install clutch shaft oil sealing rings Grease rings 1o Figure 234 facilitate reassembly into front housing Install clutch piston wear plate 2000 Maintenance amp Service Manual Figure 235 Install piston return disc springs First spring with large diameter of bevel toward wear plate Alternate five 5 springs NOTE See page 71 Figure 236 Position return spring ring retainer on clutch shaft Figure 237 Start ring on shaft with snap ring pliers T12000 3 4 amp 6 Speed LD a F
15. Speed LD Figure 220 Position return spring ring retainer on clutch shaft Figure 221 Start ring on clutch with snap ring pliers Figure 222 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress springs and seat retainer ring Be sure ring is in full position in groove Date Apr 2000 Maintenance amp Service Manual Figure 223 Install first steel outer clutch disc Figure 224 Install first friction inner clutch disc Alternate steel and friction until six 6 steel and six 6 friction discs are in position Figure 225 Install clutch disc end plate 259 T12000 3 4 amp 6 Speed LD Figure 226 Install end plate retainer ring a Figure 227 NOTE Forward clutch pack must be checked for clutch disc clearance Stand the clutch assembly on end as shown Measure the distance between the clutch end plate and the end plate retainer ring by inserting a feeler gauge or taper gauge through the slots in the clutch drum The required clearance is 048 108 1 22 2 74 If the clearance is greater than 108 2 74 add one steel disc under the end plate Figure 228 Position thrust bearing on clutch shaft against inner thrust bearing washer Position thrust bearing inner washer on clutch shaft Install outer thrust bearing washer against thrust bearing Date Apr 2000 Maintenance amp
16. engine at idle 400 to 600 R P M 8 1 690 kPa outlet pressure with engine shift thru direction and speed clutches All clutch operating at no load governed speed pressure must be equal within 5 P S I 34 5 kPaJ CONTROLS If clutch pressure varies in anyone clutch more than Speed Selection Electric 5 P S I 34 5 kPa repair clutch CLUTCH TYPE Multiple discs hydraulically actuated spring Normal operating pressure 240 280 P S I released automatic wear compensation and no 1654 8 1930 5 kPa at 2000 R P M adjustment clutches oil cooled and lubricated NOTE Never use service brakes while making CLUTCH clutch pressure checks Units having brake ac INNER DISC Friction tuated declutching in torward and or reverse will CLUTCH not givea true reading OUTER DISC Steel ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS LUBRICA RECOMMENDED LUBRICANTS FOR CLARK HURTH POWER SHIFTED TRANSMISSION AND TORQUE CONVERTERS Prevailing Ambient Temperature TYPE OF OIL See Lube Chart m 140 60 CAPACITY Consult Operator s Manual on applicable machine mt model for system capacity Torque Converter m nt Temperature 1 b C 3 Grade 30 Transmission and allied hydraulic system must be i il E d 09 Range c Engine Oil Grade 30 considered as a whole to determine capacity M API CD SE or CD SF CHECK PERIOD Check oil level DAIL Y with engine running at 500 600
17. of the Clark Hurth Components Engineering and Marketing Department Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission torque converter and its allied hydraulic system are important links in the driveline be tween the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and con necting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a degree of judgment must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for cleaning 3 Replace oil filter elements cleaning out filter cases thoroughly 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler If necessary cooler assembly should be removed from machine for
18. 03345 3NIDN3 000 21 red sz ONILVH3dO WELLMAN NI NOISSINSNVELL 2 10 01 29 3 022 081 710 H31002 OL 1 1831 Vi31SAS NOUVOIHANT NOISSINSNYEL JHL 40 WOVE ONY SANIT H39NYHOX3 1V3H H3ONVHOX3 40 19101 JHL 51 03 38155344 4H31002 01 1831 31H21H3 TWWHON GSYNSVaW 38 LSNW 31002 OL 26 1809 0 4 008 19 121 3 082 INN 12 121 28 3 052 081 TVWHON 5 412345 WO I1N3NIHYdINOO NI 9317201 38 OL SI H31002 OL SNOUVII41934S NOUVOIHANT 3214438 335 10 Q310N ss31Nn 01106118 SONU 1 4 SANIT ISOH 11 5 NOISSINSNVHJI DV H3diN31 HHH 51531 61017 2348 01 WHOINOS LSNW 0350 53 1 ISOH 71 NOI1V214I23dS 380H OITwHOAH 1400 115 ON 3YS SIOWNS 16191154 009 HLIM 384089384 5902 154 006 ONVLSHLIM LSNN ONILVH3dO SNONNILNOD 2 121 3 092
19. 74 If over 108 2 74 clearance add one steel outer disc under end plate Clearance between clutch piston and steel separator plate to be 080 135 2 03 3 43 If over 135 3 43 clearance add one steel outer disc under end plate Tighten regulator sleeve to 45 50 Ibf ft 61 68 N m Use solenoid bore plug in middle position for 3 speed version only Solenoid cartidge to be assembled and tightened to 16 20 22 27 N m Assemble speed sensor bushing to specifications shown with a max of 3 shims Apply Loctite No 577 and torque bushing 45 to 50 Ibf ft 61 68 N m M10 Screw M10 Screw M8 Screw M8 Screw Figure J T12000 3 4 amp 6 Speed LD A M10 Screw aw N M8 Screw crew 8 Screw rew M10 Screw rew AN M8 Nut M8 Nut M10 Nut IAN Tighten cartridge nuts to 4 5 Ibf ft 5 7 ASSEMBLY NOTES Use Permatex and Loctite only where specified All lead in chamfers for oil seals piston rings and rings must be smooth and free from burrs Inspect before assembly Lubricate all piston ring grooves and rings with oil before assembly Apply a thin coat of grease between seal lips on lip type seals prior to assembly Apply a thin coat of Permatex No 2 or Loctite No 641 to O D of all oil seals before assembly Apply a thin coat of Loctite No 592 or No 506 Dryseal to all pipe plugs Where precoated pipe plugs are not used apply a thi
20. Figure 32 Figure 35 Tighten inching housing to specified torque See Install accumulator spool in housing sleeve as shown assembly instruction drawing Figure 33 Figure 36 Position shuttle spool in shuttle sleeve Install spool and Install stop pin inner middle and outer springs in ac sleeve in modulator valve bore cumulator and housing sleeve 4 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 37 Figure 38 Position a new ring on modulator valve housing Tighten modulator valve housing to specified torque Thread housing into valve bore See assembly instruction drawing NOTES Date Apr 2000 1712000 3 4 amp 6 Speed LD Maintenance amp Service Manual GIONDIOS X IX D D A LA La d WYuOvIO 131HS 03345 181 T HRP sd 3 TRF e sd T HIKE 6 eee C S ann 123550250 SLOWS 31CW3u 154 sd y OTO PANGS Ted ovi aowno 38055384 JUNAJN 20 6 pue 8 5 995 NOILVINGOW HLIM 45 O3NH3AO09 GVO ON 8 131100 069 tsd 00 30 ONY
21. Install clutch piston outer seal ring Figure 88 Figure 91 Remove clutch piston Install clutch piston inner seal ring NOTE Ring must be sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a REASSEMBLY OF LOW 1ST AND round object against the new seal ring Rotate piston 2ND CLUTCH ASSEMBLY until seal ring is flush with ring groove in piston See Cleaning and Inspection Page 2ND CLUTCH BEING REASSEMBLED m Figure 89 Figure 92 Two bleed valves in clutch drum must be clean and Position piston in clutch drum using caution as not to free of any foreign material damage piston sealing rings 16 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Install clutch piston wear plate Figure 96 Start ring on shaft with snap ring pliers Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress springs and seat retainer ring Be sure ring is in full position in groove 1 Figure 94 Install piston return disc springs First spring with large diameter of bevel toward wear plate Alternate tive 5 springs NOTE See page 71 Figure 97 Install first steel outer clutch disc 98 d Install first friction inner clutch disc Alternate steel Figure 95 and friction until five 5 steel and five 5 friction discs Position return spring ri
22. Service Manual T12000 3 4 amp 6 Speed LD Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD 12000 48 6 SPEED HYDRAULIC DIAGRAM WITH DUAL MODULATION MODULATION MODULATION VALVE VALVE irs a Sea da eum ont 7 ae Seale s SS ae OPERATOR COMPARTMENT 1 1 1 TEMPERATURE PRESSURF 1 GUAGE GUAGE E ER 2242 2048 i PRESSURE psi REGULATOR REV D DLO psi psi y psi Qv FWD LO 7 Y psi FWD HI VALVE 4TH COOLER 1 TE i psi TORQUE HA 3RD 2 CONVERTER FILTER EUR A 199 gt o y 69 PUMP Y psi i ZLA ps 2ND 1 4 HOSE UBRICATION 2 FILTER 4 BREATHER psi L D 1ST OIL SUMP 3 SPEED SHIFT DIAGRAM 1121314111213111213 FILTER sn VIEW V REMOTE FILTER OPTION AIR HYDRAULIC DISCONNECT OPTION B C X D X X X X SOLENOID ENGAGED 6 SPEED SHIFT DIAGRAM 2 neo 12121 B X X XIXIXIXIXIX XIXIX X x X X X X X X SOLENOID ENGAGED Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD 12000 486 SPEED HYDRAULIC DIAGRAM WITH MODULATION AND INCHING INCHING
23. and at all connecting points The controls are actuated electrically Check the wiring and electrical components Be sure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and trans mission Air clean the radiator if necessary The engine must be operating correctly Be sure that it is correctly tuned and adjusted to the correct idle and maximum no load governed speed specifications Hydraulic Check Also before checking the transmission clutches torque converter charging pump and hydraulic circuit for pressure and rate of oil flow it is important to make the following transmission fluid check Check oil level in the transmission The transmission fluid must be at the correct fulllevel All clutches and the converter and its fluid circuit lines must be fully charged filled at all times See NOTE below NOTE The transmission fluid must be at operating temperature of 82 93 C 180 200 F to obtain correct fluid level and pressure readings DO NOT ATTEMPT TO MAKE THESE CHANGES WITH COLD OIL To raise the oil temperature to this specification it is necessary to either operate work the vehicle or run the engine with converter at stall CAUTION Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall R P M Date Apr 2000 Maint
24. bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION Care should be exercised to avoid inhalation of vapors and skin rashes when using alkali cleaners All parts cleaned must be thoroughly dried im mediately by using moisture free compressed air or soft lintless absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping com pound INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date Bearings Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time After inspection dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed Oil Seals Gaskets Etc Replaceme
25. d MIL L 2104C Grade R P M and oil at 180 to 200 82 2 30 e MIL L 2104D 93 3 C Maintain oil level to FULL port gii 30 NORMAL Every 1000 hours change oil filter E a 21056 eT ayem eS follows t 0 Temperature 2 MIL L 21040 Grade 10 rain with oil at to 65 6 93 3 b afi Range C 2 Grade 10 a Drain transmission 4 C 3 Grade 10 n Engine Oil Grade 10 x b Oil filter remove and discard Install new oil filter API CD SE CD SF c Refill transmission to LOW port t Quintolubric 822 220 Non 4 Phosphate Ester Fire d at 500 600 R P M to prime con e Resistant Ei id Ede 2 Temperature 3 4 Dexron R P M and add oil to bring level to LOW port When oil temperature is hot 180 200 82 2 93 3 C make final oil level check BRiNG OIL LEVEL TO FULL PORT NOTE it is recommended that oil filter be changed after 50 and 100 hours of operation on newand rebuilt or repaired units Normal drain periods and oil filter change intervals are for average environmental and duty cycle conditions Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause acclerated deterioration and contamination For extreme conditions judgment must be used to determine the r
26. disc springs NOTE See page 71 S Figure 71 Remove clutch piston wear plate T12000 3 4 amp 6 Speed LD Figure 72 Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston 2ND CLUTCH DISASSEMBLY Figure 73 Using a gear puller as shown remove gear and rear bearing inner race Figure 74 Remove inner race and 3rd clutch driven gear NOTE Clutch shaft rear bearing was removed in Figure 29 9355 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 75 78 Remove output drive gear from shaft Remove outer thrust washer thrust bearing and inner thrust washer Li Figure 76 Remove gear locating ring from shaft Figure 79 Remove clutch gear and hub and gear bearings Figure 80 Figure 77 Remove outer thrust washer thrust bearing and inner Remove thrust bearing and clutch gear retainer ring thrust washer c3 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 84 Compress disc springs and remove retainer ring Cho Figure 81 Remove clutch disc end plate retainer ring Figure 82 Remove end plate Figure 85 Remove retainer ring retainer Figure 83 Figure 86 Remove clutch discs Remove disc springs NOTE See page 71 is Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 87 Figure 90 Remove clutch piston wear plate
27. in the proper condition and functioning correctly the correct functioning of the hydraulic circuit is most important Transmission fluid is the life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components TROUBLESHOOTING PROCEDURES Stall Test Use a stall test to identify transmission con verter or engine problems Transmission Pressure Checks Transmission problems can be isolated by the use of pressure tests When the stall test indicates slipping clutches then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure In addition converter charging pressure and transmission lubrication pressure may also be measured Mechanical Checks Prior to checking any part of the system for hydraulic function pressure testing the following mechanical checks should be made There are only two mechanical linkages available on the transmission 1 Mechanical inching from brake pedal to inching valve on transmission 2 Linkage from axle disconnect to disconnect actuator Check the parking brake and inching pedal for correct adjustment and travel Be sure the pedal moves freely and returns fully Be sure all lever linkage is properly connected and ad justed in each segment
28. long drop transmission Figure 2 Rear view showing disc brake and electric control Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 6 Remove torque converter to turbine shaft retainer ring Figure 3 Remove drive plate attaching capscrews and washers Remove drive plate and backing ring Figure 7 Remove torque converter assembly Figure 4 Remove torque converter plug retainer ring Figure 5 Figure 8 Remove plug and O ring Remove torque converter to shaft locating nng Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 12 Remove pump mounting bolts and washers Remove pump and gasket Figure 9 Remove oil filter assembly Figure 13 Remove converter housing to transmission case bolts and washers Figure 10 Remove pressure regulator and regulator sleeve NOTE Special tool can be fabricated See Figure 389A Figure 11 Remove charging pump permanent pump hole cover Figure 14 Not used when auxiliary pump is used Hemove converter housing and gasket 3 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 18 Remove solenoid valve cartridge retainer nut and Figure 15 ring Remove impeller hub gear SES Figure 19 A 4 Remove solenoid coil and ring Figure 16 Remove pump drive idler gear washer Figure 17 Remove pump drive gear a
29. new balls item 5 with high compres sion grease and place in ramps of new cam plates item 4 6 Install new cam plates item 4 in brake module item 7 making sure locking lugs are aligned properly in brake module item 7 7 Install piston item 13 in brake module item 7 making sure piston aligns properly on cam plates item 4 8 Install five 5 belleville springs item 10 and retainer item 11 on lever end of piston item 13 9 Depress retainer item 11 and install retaining ring item 12 in groove on piston item 13 1 0 Install brake module assembly item 7 on housing item 1 11 Position lever item 8 in a convenient location for actuation rod Install lever item 8 and lever retaining nut item 9 on brake module assembly item 7 Snug lever retaining nut item 9 12 Adjust brakes per instructions PARKING BRAKE ADJUSTMENT Mechanical Applied With the brake assembled on the transmission with a free floating operation of the caliper adjust caliper as follows NOTE Do not use operating lever item 8 as a means to turn the module body item 7 To use the lever will cause the piston to extend and cause a false setting Module capscrews item 14 must be loose before brake adjustment 1 Screw brake module item 7 in until linings contact disc Back module item 7 off until a flat on module lines up with capscrew item 14 Torque capscrews item 14 8 10 Ibf ft 11 14 N m 2 Remove lever ret
30. rail detent spring plug and O ring Remove brake disc to output flange capscrews Caution Plug is under spring pressure Figure 35 m Remove brake disc NOTE front disconnect is Figure 38 not used proceed to Figure 41 Remove detent spring ball and overshift stop pin 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 39 Figure 42 Remove shift fork Remove flange bearing and seal assembly Figure 40 Figure 43 Remove disconnect shift hub used on models with disconnect only Figure 41 Remove front output flange retainer ring from ring groove Carefully pry flange and seal assembly from Figure 44 bearing bore Remove front bearing locating ring Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 45 Remove output gear to shaft retainer ring Figure 48 Remove rear bearing locating ring T bas Figure 46 Remove rear output flange retainer ring from ring groove Carefully pry flange and bearing assembly Figure 49 from bearing bore and output gear Remove output shaft gear Figure 47 Figure 50 Remove flange bearing and seal assembly Remove oil supply tube clip screw and clip Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 51 Remove supply tube and screen assembly Figure 54 Remove valve spring stop pin and accumulator spool Figure 52 Remove m
31. ritiro Fig I J K L M DISASSEMBLY OF TRANSMISSION REASSEMBLY OF TRANSMISSION 58 CLUTCH ENGAGEMENT POWER FLOW 3 SPEED 72 CLUTCH ENGAGEMENT POWER FLOW 4 AND 6 SPEED 73 DRIVEPLATEINSTALLATION ees cr dS 74 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 75 SPECIFICATIONSANDSERVICEDATA 76 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL ene 77 EXTERNAL PLUMBING AND PRESSURE CHECK 78 79 GLEANINGANDINSPEQGTION 4 ete tt ec eR HA EC E ec EAE ds 80 5 81 TROUBLESHOOTINGGUIDE ts rt e et e rte gutta e EL n reete ed ndun 82 CONVERTERSTALLPROGEDURE 3 nh her a ia Pe d eee Pri he 83 ELECTRIC SOLENOID CONTROL WIRING DIAGRAM NOTE Metric Dimensions Shown in Brackets Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T12000 TRANSMISSION ASSEMBLY The transmission and hydraulic torque converter portion of the power train enacts an important role in transmitting engine power to the driving wheels In order to properly maintain and service these units it is important to first understand their function and how they operate The transmission and tor
32. 00 1712000 3 4 amp Speed LD Maintenance amp Service Manual Figure A Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T12000 TRANSMISSION CASE AND PLATE GROUP ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION QUANTITY 1 Sensor Port Plug 1 23 Speed Sensor Plug 2 Sensor Port Plug Washer 1 24 Level Plug 3 Sensor Adjusting Bushing 1 25 Plug Ring 4 Sensor Bushing Shim AR 26 Tube and Screen Assembly 5 Spacer 1 27 Supply Tube Seal Ring 6 Pipe Plug sis men 1 28 Retainer Clip annaa aLaaa 7 Outlet Temperature Port Plug 1 29 Retainer Clip Screw Lockwasher 8 Plate to Transmission Case Gasket 1 30 Oil Supply Tube Retainer Clip 9 Plate to Transmission Case Dowel Pin 1 31 Magnetic Drain Plug 10 Transmission 1 32 Drain Back Port Plug 11 cFiller Pl g c5 ee t 1 33 Plate to Transmission Case Dowel 12 Diverter 1 34 Plate to Transmission Case Screw Lockwasher 13 Pipe Plug oA iii 1 35 Plate to Transmission Case Screw 14 Auto Shift Sensor Port Plug 1
33. 01 LNSIGW 318 11 5 SINN 3HNSSIHd 9 KLIMA 133HS 1404 H93H9 AlddNS LON SHNSS3Yd ONY JHL NO IWYS ONOdS3HHOI SiNIOd ONY SLNIOd WVH9vIQ 45 00021 1 94 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD 12000 SPEED HYDRAULIC DIAGRAM WITH 9i ees gt gt gt 3 gt MODULATION pr VALVE E NEUTRAL AGRAM GAGED INCHING 7 1 TEMPERATURE PRESSURE GUAGE 5 r lth psi 2n REGULATOR GULAT SS psi TORQUE CONVERTER FILTER gt 123 XX da REMOTE FILTER AIR HYDRAULIC DISCONNECT OPTION VIEW REMOTE FILTER OPTION v pagg OZE gZ a 201 OzcRsZO b 00 205902 Poss tz 85 38 8 482 45 HP 5 22 48 35 5 25 d d iz iu 000 f 8 560 ZZ BH amp 0 5 Fe ON 94 95 Date Apr 2000 ENGINE OUTLET Maintenance amp
34. 1 50 Clutch Gear Thrust Washer 11 Clutch Gear Thrust Washer Bearing 1 51 2nd Clutch Gear Hub Snap 12 Clutch Gear Thrust Washer 1 52 Output Drive Gear 13 Bearing ER EE EL MEE 1 53 3rd Driven TET ASLAN 1 54 Rear Bearing 15 1st Clutch Gear Bearing 1 16 Clutch Gear Thrust Washer 1 56 Output Flange 17 Clutch Gear Thrust Washer Bearing 1 18 Clutch Gear Thrust Washer 1 2 5 AUUE ANER 19 End Plate Snap Ring 1 seeiis 20 1 59 Output Shaft Oil Seal 21 Inner Disc Tet Clutch coc ios ems 10 60 Oil Seal Sleeve 22 Outer Disc 1st Clutch 10 61 Output Shaft Bearing 23 Retainer Snap Ring 1 62 Output Shaft Bearing Snap Ring 24 Snap Ring Retainer 1 63 Flange Retaining Ring 25 Disc Spring Assembly 7 64 Gear Retaining Ring 26 Clutch Piston Wear Plate 1 65 Output Shaft 27 Clutch Piston 1 66 Output Shaft Gear Bearing Snap Ring 28 Clutch Piston Seal Outer 1 67 Output Shaft Bearing 29 Cl
35. 36 Plate to Transmission Case Screw 15 Sensor Port Plug 1 37 Plate to Transmission Case Screw 16 Sensor Adjusting Bushing 1 17 Sensor Bushing Shim AR 38 Poppet Retainer uu 18 Air Breather 1 39 Safety Valve Spring 19 Pipe Plug 2 40 Safety Valve 20 Sensor Bushing Shim 41 Seat Snap Ring 21 Sensor Adjusting Bushing 1 42 Safety Valve 22 Sensor Port Plug Ring 1 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure B Date Apr 2000 Maintenance amp Service Manual ITEM ON OO A 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 T12000 3 4 amp 6 Speed LD T12000 CONVERTER GROUP DESCRIPTION QUANTITY Pump Drive Idler Thrust Washer 1 Idler Gear Bearing 1 Pump Drive Idler 1 Pump Drive Idler and Pilot Shaft 1 Pump Drive Idler and Pilot Shaft Dowel 1 Pump Drive Idler Thrust Washer 1 Pump Drive Gear Retainer Snap Ring 1 Pump Drive Gear 1 Charging P
36. 8 GRADE 10 9 COURSE THREAD COURSE THREAD N m N m 15 18 20 25 22 26 30 35 30 37 40 50 44 48 60 65 50 55 65 75 74 81 100 110 PIPE PLUG TORQUE CHART THREAD NPTF TORQUE N m PERMANENT PLUG METRIC THREAD SIZE TORQUE Ipf ft 25 30 45 50 M18 X 1 5 6H M26 X 1 5 6H SECTION B B Figure K Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Charging Pump SAE A Input sensor location for Auto shift Plug 1 397 35 48 1 383 35 13 1 067 27 10 1 053 26 75 T Charging Pump SAE B Optional Shipping Plug and Bushing for Speedometer Speed Sensor Option Charging Pump Optional REAR VIEW TORQUE SPECIFICATION 9 LUBRICATED PLATED SCREWS AND GRADE 5 GRADE 8 FINE THREAD COARSE THREAD Nm TE 15 FINE THREAD THREAD lbf 11 14 11 13 1848 _ 9 11 15 __ 22 297 16 22 28 32 38 43 26 30 85 41 35 39 31 34 37 41 50 56 33 36 45 49 56 61 50 56 58 64 79 87 52 57 71 77 87 95 77 85 90 99 122 134 80 88 108 119 123 136 _ 111 122 128 141 174 191 115 327
37. 88 900 mm Diameter Kit No 802543 13 125 1333 38 mm Diameter Kit No 802426 13 500 342 90 mm Diameter Kit No 802427 Kit will include the following parts 3 Intermediate Drive Plates 1 Backing Ring 6 Mounting Screws 6 Lock Washers 1 Instruction Sheet 1 Instruction Sheet TO FACILITATE ASSEMBLY ALIGN SMALL HOLES IN DRIVE PLATES SEE ILLUSTRATION ABOVE ALIGNMENT HOLES Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter Align intermediate drive plates and backing ring with holes in torque converter assembly NOTE Two dimples 180 apart in backing ring must be out toward engine flywheel Install capscrews and washers Tighten 26 to 29 ft lbs torque 35 39 N m Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1 Remove all burrs from flywheel mounting face and nose pilot bore Clean drive plate surface with solvent Puy wie 2 Check engine flywheel amp housing for conformance to standard SAE No 3 per SAE J927 and J1033 tolerance specifications for pilot bore size pilot bore runout and mounting face ENGINE flatness Measure and record engine crankshaft end play M FLYWHEEL _ 3 Install two 2 50 63 500 mm long transmission to flywheel housing guide studs in the engine flywheel housing as shown Rotate the engine flywheel to align a drive plate mounting s
38. DIRECTION SPEED CLUTCH ee 2d 3d CLUTCH ENGAGEMENT FOR 6 SPEED T12000 POWER SHIFT TRANSMISSION FORWARD DIRECTION SPEED CLUTCH CLUTCH REVERSE SPEED CLUTCH CLUTCH om pw fc ad pow rac 73 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD DRIVE PLATE INSTALLATION Measure the dimension Bolt Circle diameter and order Drive Plate Kit listed below Note two 2 kits have two 2 intermediate drive plates and one 1 drive plate and weld nut assembly Two 2 kits with three intermediate drive plates ALIGNMENT HOLES 1 DRIVE PLATE AND 2 INTERMEDIATE DRIVE PLATES BACKING RING A Dimension Bolt Circle Diameter 11 380 1288 900 mm Diameter Kit No 802501 13 125 333 38 mm Diameter Kit No 802424 13 500 342 90 mm Diameter Kit No 802425 Each Kit will include the following parts 2 Intermediate Drive Plates 1 Drive Plate and Weld Nut Assembly 1 Backing Ring 6 Mounting Screws 6 Lock Washers WELD NUT ASSEMBLY 9 NJ 0 259 5 87 M CIRCLE 3 INTERMEDIATE DRIVE PLATES BACKING RING Dimension Bolt Circle Diameter 11 380 2
39. MBLY A bore plug is used in the center hole on 3 speed only Figure 367 Align hole in outer washer with pin in shaft and install washer gt Figure 370 Figure 368 install solenoid cartridges explained above Position impeller hub gear stator support C Fiqure 369 Position spacer to converter housing gasket on Figure 371 spacer A light coat of grease will hoid gasket in place Tighten cartridges 16 20 torque 21 7 27 1 N m 64 Date Apr 2000 Maintenance amp Service Manual Figure 372 Install new O rings on cartridges Figure 373 Position solenoid coil on cartridge Figure 374 With new ring in position install coil to cartridge nut 65 12000 3 4 amp 6 Speed LD Figure 375 Tighten cartridge nut per assembly instruction drawing Figure 376 The use of aligning studs will facilitate converter housing to spacer installation The transmission could be laid down to align the end of the clutch shafts into sealing ring sleeves in converter housing Do not force this operation Converter housing must be tight against transmission spacer NOTE Do not use bolts to pull converter housing in place Install converter housing to transmission case screws and lockwashers See Figures J and K for proper screw location and installation Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 380 Install converte
40. OVERNED SPEED PORT 31 CLUTCH PRESSURE IT IS RECOMMENDED THAT CLUTCH PRESSURE BE MONITORED BY A GAUGE LOCATED IN THE OPERATOR COMPARTMENT NORMAL OPERATING PRESSURE 240 280 PSI 1655 1930 kPa at 2000 RPM PORT 45 and 46 BACKUP WARNING THIS PORT IS PROVIDED FOR INSTALLATION OF BACK UP PRESSURE SWITCH FOR WARNING LIGHT OR HORN OIL TEMPERATURE GAUGE SPECIFICATIONS 1 NORMAL OPERATING TEMPERATURE 180 250 F 82 121 C 2 RED LINED TEMPERATURE 250 F 121 F fi 89 o CLUTCH PRESSURE FROM COOLER PRESSURE COOLER F b b K j 4 V AY 1 xT i ef M 7 FLLER KOLE 4 21 04 TO COR FF MEAT EXCHANGER AT MEAT LET TEMP RATURE mu J OUTLET AC 1 8 AUN o 7 MOAT EXCHANGER OUTLET TENPERATUME ponr 9 TOWARD CLUTCH PSE ACVENSE CLUTCH mESSUnE 7 O LEVEL LEVE 3 Je pe 4 71280 OPTION REMOTE FILTER Sep Pages 94 trough 87 for Hydravic Diagram Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD FRONT VIEW 3 4 amp 6 Speed PORT CHECK PORT CLUTCH PRESSURE 3 SPEED 1ST 4 SPEED 1ST 6 SPEED FWD 151 2ND REV 1ST som CHECK PORT CLUTCH PRESSURE 3 SPEED 2ND 4 SPEED 2ND 6 SPEED FWD 3RD 4TH REV 2ND
41. Remove disc springs NOTE See page 71 Remove clutch shaft oil sealing ring Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 205 Remove outer thrust washer thrust bearing and inner thrust washer Remove end plate retainer ring Figure 206 Remove bearings and spacer from clutch gear Figure 209 Remove end plate Figure 207 Remove outer thrust washer thrust bearing and inner Figure 210 thrust washer Remove clutch discs 36 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T Figure 214 Remove clutch piston wear plate Figure 211 Compress disc springs and remove retainer ring Figure 215 Remove clutch piston REASSEMBLY OF FORWARD CLUTCH See cleaning and inspection page Figure 212 Remove retainer ring retainer Figure 216 Clutch piston bleed orifice must be clean and free of Figure 213 any foreign material Install inner and outer piston seal Remove disc springs NOTE See page 71 rings Size inner ring as explained in Figure 91 Date Apr 2000 Maintenance amp Service Manual Figure 217 Install clutch piston in clutch drum Use caution as not to damage sealing rings Figure 218 Install clutch piston wear plate Figure 219 Install piston return disc springs First spring with large diameter of bevel toward wear plate Alternate five 5 springs NOTE See page 71 38 1712000 3 4 amp
42. Service Manual lt pana gt SPICER Off Highway Products Powershift Transmission 112000 3 4 amp 6 Speed Long Drop TSM 0023 April 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the Spicer Off Highway Product Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjustments it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Spicer Off Highway approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Spicer Off Highway does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied by or approved
43. aining nut item 9 Remove lever item 8 3 Reposition lever item 8 to desired angle of operation 4 Install retaining nut item 9 and tighten to 10 Ibfft torque 13 6 N m Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain com ponents Proper operation of the transmission depends on the condition and correct functioning of the other com ponents of the group Therefore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid charging pump torque converter transmission assembly oil cooler filter con necting lines and controls including the engine as a complete system By analyzing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system T12000 TRANSMISSION T12000 powershift with torque converter transmis sion troubles fall into two general categories mechanical problems and hydraulic problems In addition to the mechanical components all of which must be
44. b Snap Ring 1 94 Gear Hub Snap Ring 1 95 1st Drive Gear 1 96 Bearing and Seal Assembly 1 97 Piston 2 98 Oil Distributor Sleeve 1 99 Sleeve Locating Screw 1 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure D Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T12000 LOW 1ST 2ND AND OUTPUT SHAFT GROUP WITH BRAKES ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION QUANTITY Distributor Cap Mounting Screw 4 40 Plate eec v n Distributor Cap Mounting 41 End Plate Snap Ring Screw Lockwasher 4 42 Clutch Gear Thrust Washer 3 Distributor Cap Plug 2 43 Clutch Gear Thrust Washer Bearing 4 1st and 2nd Distributor Cap 1 44 Clutch Gear Thrust Washer 5 Distributor Cap O Ring 2 45 2nd Clutch Gear 6 Distributor Cap Gasket 1 46 7 Piston Ring 2 47 8 Bearing Retaining Snap Ring 1 48 Clutch Gear Thrust Washer 9 Bearing and Seal Assembly 1 49 Clutch Gear Thrust Washer Bearing 10 Clutch Gear Thrust Washer
45. by Spicer Off Highway IMPORTANT Always furnish the Distributor with the serial and model number when ordering parts TOWING OR PUSH STARTING Before towing the vehicle be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing NOTE If the transmission has 4 wheel drive disconnect both front and rear drivelines Because of the design of the hydraulic system the engine cannot be started by pushing or towing Copyright Dana Spicer Off Highway Products Division Unpublished Material All rights reserved Limited Distribution No part of this work may be reproduced in any form Under any means without direct written permission of Dana Spicer Off Highway Products Division Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD TABLE OF CONTENTS T12000 TRANSMISSION ASSEMBLY HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Transmission Case and Plate Group Fig A Converter Group dii eden e pet Fig B Forward Reverse 3rd and 4th High Clutch Group Fig C Low 1st 2nd and Output Shaft Group Fig D Output Shaft Group with Disconnect Fig E Control Valve Group Dual Fig F Control Valve Group Single Modulation Mechanical INCHING iioc eec earn te E L2 Fig G Assembly Instructions
46. ce Manual Figure 315 Oil seal sleeve and ring removed Figure 316 Remove oil seal from sleeve Figure 317 Remove oil seal retainer ring trom output flange T12000 3 4 amp 6 Speed LD REASSEMBLY See cleaning and inspection page Figure 318 Position bearing retainer ring on output flange Figure 319 Apply a very light coat of Permatex 2 to the outer diameter of the output flange oil seal Press oil seal in oil seal sleeve Oil seal must be flush with one side of face of oil seal sleeve and lip of seal must be in Figure 320 Install new ring on seal sleeve Position oil seal sleeve assembly on output flange NOTE Recessed portion of oil seal and sleeve must be up with lip of seal up This leaves a space between oil seal and output bearing Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 324 Remove converter oil seal Figure 321 Press bearing on output flange DISASSEMBLY AND REASSEMBLY OF CONVERTER HOUSING DISASSEMBLY Figure 325 Remove converter housing plug High and 3rd Clutch Shaft Remove oil distributor sleeve set screw Figure 322 Remove torque converter bearing Figure 326 Figure 323 Using a hammer puller as shown remove oil Remove oil distributor and O rings distributor sleeve High and 3rd 56 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD F
47. cleaning using oil compressed air and steam cleaner for that purpose DO NOT use flushing compounds for cleaning purposes Reassemble all components and use only type oil recommended for lubrication section Fill transmission through filler opening until fluid comes up to LOW port on transmission Remove LOWER check plug fill until oil runs from LOWER oil hole Replace filler and level plug Run engine two minutes at 500 600 R P M to prime torque converter and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 Add quantity necessary to bring fluid level to run freely from LOWER oil level check plug hole Install oil level plug Recheck with hot oil 1802000 F 182 2 93 3 C Bring oil level to FULL port to run freely from UPPER oil level plug hole 6 Recheck all drain plugs lines connections etc for leaks and tighten where necessary Date Apr 2000 Maintenance amp Service Manual PORT 71 TO COOLER TEMPERATURE PORT IS TO BE USED FOR OIL TO COOLER T12000 3 4 amp 6 Speed LD TEMPERATURE PICK UP GAUGE IS TO BE LOCATED IN THE OPERATOR COMPARTMENT SEE OIL TEMPERATURE GAUGE SPECIFICATION TEST CONDITIONS 1 TO COOLER OIL TEMPERATURE 180 220 F 82 104 C 2 TRANSMISSION IN NEUTRAL OPERATING SPECIFICATIONS 1 25 psi 173 kPa MINIMUM PRESSURE 2000 rpm ENGINE SPEED AND A MAXIMUM OF 100 PSI 690 kPa OUTLET PRESSURE AT NO LOAD G
48. crew hole with the flywheel housing access hole 4 Install a 4 00 101 60 mm long drive plate locating stud 3750 Dei 24 fine thread in a drive plate nut Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No 3 CONVERTER HOUSING 5 Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No 3 Locate transmission on flywheel housing Aligning drive plate to flywheel and transmission to flywheel housing guide studs install transmission to flywheel housing Screws Tighten screws to specified torque Remove transmission to engine guide studs Install remaining screws and tighten to specified torque T a 21 ALIGNING STUDS 6 Remove drive plate locating stud um FLYWHEEL HOUSING 7 Install drive plate attaching screw and washer Snug screw but do not tighten Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten A
49. e 1 Disc Spring Assembly 5 Snap Ring Retainer 1 Retainer Snap Ring 1 Outer 6 Inner Disc aci bene ee 6 End Plate ear une 1 End Plate Snap aaau 1 Clutch Gear Thrust Washer 1 Clutch Gear Thrust Washer Bearing 1 Clutch Gear Thrust Washer 1 Forward Clutch a na 1 Bearing ta Pook ue o REN 1 Spacet Cd eR e oues bes ce ded 1 Bearing 1 Clutch Gear Thrust Washer 1 Clutch Gear Thrust Washer Bearing 1 Clutch Gear Thrust Washer 1 Turbine Shaft Rear Bearing 1 Piston 0 3 Oil Distributor Sleeve 1 Retainer Screw 1 Rear Bearing Retaining Snap Ring 1 Rear Bearing 1 T12000 3 4 amp 6 Speed LD T12000 FORWARD REVERSE 3RD AND 4TH HIGH CLUTCH GROUP ITEM DESCRIPTION QUANTITY 51 Clutch Gear Thrust Washer 1 52 Clutch Gear Thrust Washer 1 53 Clutch Gear Thrust Washer 54 3rd Clutch Gear 1 55 Bearing 1 56 Bearing 1 57 Clutch Gear Thrust Washer 1 58 Clutch Gear Thrust Washer Bearing 1 59 Clutch Gear Thrust Washer 1 60 End Plate Snap Ring
50. e 58 Figure 336 Install set screw in transmission case and in oi distributor sleeve Install set screw plug Figure 337 Install reverse and forward clutch shaft rear bearing in transmission case Figure 338 Position supply tube and screen assembly in transmission case sump Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 339 Figure 342 Push supply tube through opening in case and install Install output shaft inner bearing locating ring in rear O ring of transmission case Figure 340 Install supply tube clip and screw and lockwasher in case and tighten to specified torque See torque chart Figure 343 Install rear bearing in case against locating ring Figure 341 Position output gear in transmission case with long Figure 344 hub of gear toward front of case Install new ring on rear oil seal sleeve 59 Date Apr 2000 Maintenance amp Service Manual Figure 345 very light of Permatex 2 to the diameter of the output flange oil seal Press oil seal in oil seal sleeve Oil seal must be fiush with one side of face of oil seal sleeve and lip of seal must be in Position oil seal sleeve in transmission case with recessed portion of oil seal toward output bearing This leaves a space between oil seal and output bearing Figure 346 Install oil seal sleeve retainer ring Figure 347 Install rear output flange and s
51. e amp Service Manual T12000 3 4 amp 6 Speed LD REASSEMBLY See Cleaning and Inspection Page Figure 22 Install sleeve retainer ring Figure 19 Install a new ring on regulator spool sleeve Position check ball in sleeve Figure 23 Install housing sleeve pin Figure 20 Install check ball retainer pin Figure 21 Figure 24 Position sleeve and ball assembly in regulator spool Install regulator spool stop spring and regulator spool with check ball retainer pin up and sleeve assembly in housing sleeve gg Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 25 Figure 28 regulator spool spring and install retainer ring install inching regulator spool spring Figure 26 Position new ring on modulation sleeve Figure 29 SINGLE MODULATION AND Install inching actuator rod over spring MECHANICAL INCHING INSTALLATION Figure 27 Install a new O ring on inching sleeve Install inching spool in sleeve Install spool and sleeve in inching control Figure 30 bore install inching return spring fib Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 31 Figure 34 With new actuator rod oil seal in position and new With new ring in position install modulation housing ring on inching housing install housing over actuator sleeve assembly in bore rod and thread into inching bore
52. e Capscrew 1 End Plate Capscrew Washer 1 End Plate to Shaft Roll LL 1 Reverse Idler Gear Bearing 1 Thrust Washer 1 Spring dcus eee ERES 1 EE 1 Ball Check Valve l u a uaaa naaa 1 OPO RING rria VEE 1 Less ee 1 Regulator Pressure Port Plug 1 utes isa us 1 Pl g one s testes te vede s 1 Converter Housing to Plate Screw Lockwasher 6 Converter Housing to Plate Screw 6 Converter Housing to Plate Screw Lockwasher 1 Converter Housing to Plate Screw 1 Converter Housing to Transmission Case Screw Lockwasher 10 Converter Housing to Transmission Case Screw 10 Turbine Hub Snap Ring 1 Torque Converter Assembly 1 Turbine Hub Snap Ring 1 Torque Converter Plug O Ring 1 Torque Converter Plug 1 Plug Snap Ring 1 Drive Plate Weld Nut Assembly 1 Drive Plate 2 Drive Plate Backing Ring 1 Drive Plate Mounting Screw Lockwasher 5 Drive Plate Mounting Screw 5 Pl g codo ttr 1 1 Converter Housing 1 eerte neue Seau 1 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 a
53. e Manual T12000 3 4 amp 6 Speed LD SINGLE MODULATION AND MECHANICAL INCHING REMOVAL Figure 4 Remove inching spool Figure 1 Remove inching valve housing Figure 5 Remove modulator valve housing and O ring Figure 2 Remove inching return spring actuator rod and regu lator spring Figure 6 Figure 3 Remove modulator valve outer middle and inner springs Remove inching sleeve and ring and spring stop 00 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 7 Figure 10 Remove modulation housing sleeve and accumulator Remove modulator valve outer middle and inner springs spool and spring stop Figure 8 Remove shuttle sleeve and spool DISASSEMBLY AND REASSEMBLY OF 11 SINGLE MODULATOR VALVE ASSEMBLY DISASSEMBLY Figure 9 Figure 12 Remove modulator valve body ring Remove modulator sleeve pin B7 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 13 Figure 16 Remove regulator spool assembly retainer ring Remove regulator spool sleeve assembly Remove O ring 14 Figure 17 Remove regulator stop spring and spring Remove sleeve check ball retainer pin sleeve assembly 15 18 Remove regulator spool sleeve retainer ring Remove check ball Date Apr 2000 Maintenanc
54. eeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch To engage the clutch the electric shift control lever is placed in the desired position This energizes the selected direction and range gear solenoids allowing the oil under pressure to flow through tubes and passages to the selected clutch shafts Oil sealing rings are located on the clutch shaft These rings direct oil under pressure through a drilled passageway in the shaft to a desired clutch Pressure of the oil forces the piston and discs against the heavy back up plate The discs with tangs on the outer diameter clamping against discs with teeth on the inner diameter enables the hub and clutch shaft to be locked together and allows them to drive as a unit There are bleed balls in the clutch piston or clutch drum which allow quick escape for oil when the pressure to the piston is released Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD HOW THE UNITS OPERATE With the engine running the transmission charging pump draws oil from the transmission sump through the oil suction tube and screen and directs it through the pressure regulating valve and oil filter The pressure regulating valve maintains pressure to the transmission solenoid valves for actuating the direction and speed clutches This regulator valve consists of a hardened valve spo
55. enance amp Service Manual T12000 3 4 amp 6 Speed LD CONVERTER STALL PROCEDURE 1 Put the vehicle against a solid barrier such as a wall and or apply the parking brake and block the wheels 2 Put the directional control lever in FORWARD REVERSE as applicable 3 Put the speed control lever in 3rd 3 speed HIGH or 6th 6 speed With the engine running slowly increase engine speed to approximately one half throttle and hold until transmission converter outlet oil temperature reaches the operating range CAUTION Do not operate the converter at stall condition longer than 30 seconds at one time shift to neutral for 15 seconds and repeat the procedure until desired tempera ture is reached Excessive temperature 120 C 250 F maximum will cause damage to transmission clutches fluid converter and seals TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles CAUSE REMEDY LOW CLUTCH PRESSURE 1 Low oil level 2 Clutch pressure regulating valve stuck open 3 Faulty charging pump 4 Broken or worn clutch shaft or piston sealing rings 5 Clutch piston bleed valve stuck open 1 Fill to proper level 2 Clean valve spool and housing 3 Replace pump 4 Replace sealing rings 5 Clean bleed valves thoroughly LOW CHARGING PUMP OUTPUT 1 Low oil level 2 Suction screen plugged 3 Defective charging pu
56. equired change intervals See Caution Below Temperature 4 a MIL L 46167 Range b MIL L 46167 A Temperature 5 a Conoco High Performance Range Synthetic Motor Oil Spec No 6718 Dexron is a registered trademark of Generai Motors Corporation PREFERRED VISCOSITY Select highest oil viscosity compatible with prevailing ambient temperatures and oil application chart Temperature ranges 2 and 3 may be used to lower ambient temperatures when sump preheaters are used Temperature range 4 should be used only in ambient temperature range shown MODULATED TRANSMISSIONS T12000 18000 24000 28000 amp 32000 series transmissions with modulated shift use only C 3 or temperature range 3 items a amp b Dexron Dexron D SEE CAUTION BELOW 3000 4000 5000 6000 8000 16000 8 34000 series transmission with modulated shift use only C 3 or temperature range 3 item a only Dexron Do NOT use Dexron D SEE CAUTION BELOW CAUTION Dexron is not compatible with graphitic clutch plate friction materiai UNLESS iT MEETS THE APPROVED C 3 SPECIFICATIONS Dexron D cannot be used in the 3000 4000 5000 6000 8000 16000 or 34000 series power shift transmissions or the HR28000 amp HR32000 series having converter lock up or the C270 series converter having locKJP UNLESS iT MEETS THE APPROVED C 3 SPECIFICATIONS Any deviation from tnis cnart must nave written approval from tne application department
57. fter all eight 8 screws are installed torque each one 26 to 29 Ibf ft torque 35 39 N m This will require tightening each screw and rotating the engine flywheel until the full amount of eight 8 screws have been tightened to specified torque SPECIAL STUD WASHER AND SELF LOCK NUT FURNISHED BY ENGINE MANUFACTURER 22 C E FLY WHEEL F HOUSING FLYWHEEL 8 Measure engine crankshaft end play after transmission has been completely installed on engine flywheel This value must be within 001 0 025 mm of the end play recorded in step No 2 Does not apply to units having 3 intermediate drive plates See Fig 4 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD SPECIFICATIONS AND SERVICE DATA POWER SHIFT TRANSMISSION AND TORQUE CONVERTER TRANSMISSION With transmission outlet oil temperature 180 OUT PRESSURE 200 82 3 93 3 C and transmission in NEUTRAL Operating specifications e Recheck level with engine running at 500 600 OIL FILTRATION Full flow oil filter safety by pass also strainer screen in sump at bottom of transmission case CLUTCH 185 P S I 1275 5 kPa minimum With parking Range b Dexron Il D Fanrenneit Cutis 25 P S I 173 kPa minimum pressure at 2000 PRESSURE brake set see note oil temperature 180 200 F R P M engine speed AND a maximum of 100 182 27 93 3 C
58. h snap ring pliers Figure 160 Install piston return disc springs First spring with large diameter of bevel toward wear plate Alternate Figure 163 five 5 springs NOTE See page 71 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress springs and seat retainer ring Be sure ring is in full position in groove Figure 161 Figure 164 Position return spring ring retainer on clutch shaft Install first steel outer clutch disc 28 Date Apr 2000 Maintenance amp Service Manual Figure 165 Install first friction inner clutch disc Alternate steel and friction until six 6 steel and six 6 friction discs are in position Figure 166 Install clutch disc end plate Figure 167 Install end plate retainer ring T12000 3 4 amp 6 Speed LD sS 4 Figure 168 NOTE 4th high clutch pack must be checked for clutch disc clearance With the clutch assembly on end the clutch discs will fall to the piston Measure the distance between the clutch end plate and the end plate retainer ring by inserting a feeler gauge or taper gauge through the slots in the clutch drum The required clearance is 048 108 1 22 2 74 If the clearance is greater than 108 2 74 add one steel disc under the end plate Figure 169 Position thrust bearing inner washer on clutch shaft Position thrust bearing on clutch shaft Install outer
59. haft through output oil seal Align splines on shaft with splines on output gear Install shaft through gear Use caution as not to damage oil seal Tap shaft into position 60 12000 3 4 amp 6 Speed LD Figure 348 Install output shaft to output gear retainer ring NOTE disconnect to the front is not used proceed to Figures 350 and 351 Figure 349 Position shift hub on output shaft Figure 350 Install front output shaft bearing locating ring Date Apr 2000 Maintenance amp Service Manual Figure 351 Position front output flange and bearing assembly on output shaft Using Snap ring pliers as shown squeeze snap ring ends together and tap flange assembly into case until snap ring can seat in snap ring groove transmission is less disconnect proceed to Figure 358 Figure 352 Apply Permatex 2 to outer diameter of shift rail oil seal Install seal in case with lip of seal in Figure 353 Position shift fork in shift hub on output shaft Install shift rail through oil seal Align fork and rail T12000 3 4 amp 6 Speed LD Figure 354 Install shift fork to rail lockscrew Tighten securely and lockwire to prevent loosening Figure 355 Position detent ball spring and overshift pin as shown Figure 356 With new ring in position install detent plug Date Apr 2000 Maintenance amp Service Manual Figure 357 Tighten plug securely Figure 358 Position 4th
60. high and 3rd clutch assembly in center bore in transmission case NOTE 3 speed trans mission will only have 3rd clutch Figure 359 Position 1st and 2nd clutch assembly in bottom bore in transmission casa 62 1712000 3 4 amp 6 Speed LD Figure 360 Position forward and reverse clutch in top bore Figure 361 Position new transmission case to converter housing gasket on transmission case A light coat of grease will hold gasket in position NOTE The use of aligning Studs will facilitate spacer plate to transmission case installation Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 364 With roll pin in position in pump idler shaft install inner washer and shaft in spacer aligning pin with hole in washer and spacer Figure 362 Install spacer plate assembly on transmission aligning clutch shafts with opening in spacer plate Use caution as not to damage oil sealing rings Spacer plate must be tight against transmission case Do not use bolts to pull spacer plate and case together Tap spacer plate into position at dowel pins Install spacer plate to transmission case capscrews Figure 365 Position needle bearing on shaft Figure 363 See NOTE on Figure J for proper capscrew Figure 366 installation and torque Install idler gear on bearing 63 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD ELECTRIC CONTROL VALVE REASSE
61. igure 238 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress springs and seat retainer ring Be sure ring is in full position in groove Figure 239 Install first steel outer clutch disc Figure 240 Install first friction inner clutch disc Alternate steel and friction until six 6 steel and six 6 friction discs are in position 41 Date Apr 2000 Maintenance amp Service Manual Figure 241 Install clutch disc end plate Figure 242 Install end plate retainer ring Figure 243 NOTE Reverse clutch pack must be checked for clutch disc clearance Stand the clutch assembly on end as shown Measure the distance between the clutch end plate and the end plate retainer ring by inserting a feeler gauge or taper gauge through the slots in the clutch drum The required clearance is 048 108 1 22 2 74 If the clearance is greater than 108 2 74 add one stee disc under the end plate T12000 3 4 amp 6 Speed LD Figure 244 Position thrust bearing inner washer on clutch shaft Position thrust bearing on clutch shaft against inner thrust bearing washer Install outer thrust bearing washer against bearing Figure 245 Press one bearing in clutch gear flush with face of gear Install bearing spacer next to bearing Press second bearing in gear flush with face of gear Install the clutch gear in the c
62. igure 330 Install new rings on converter housing oil distnbutor Install oil distributor in converter housing REASSEMBLY OF CONVERTER HOUSING with long hub toward seal See cleaning and inspection page Sleeve removed Figure 331 Press converter bearing in housing against shoulder Figure 328 Make sure pressure regulator check ball assembly is clean and free of foreign material Figure 332 Figure 329 Install high 3rd clutch shaft oil distributor sleeve in Apply a very light coat of Permatex 2 to the outer converter housing with inside diameter chamfer up diameter of the converter housing oil seal Press seal and the notch in the distributor aligned up with the in housing with lip of seal in retaining set screw hole in the converter housing Bp Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 333 Apply Loctite 243 to threads of sleeve set screw NOTE This set screw has a hole in it Use caution as not to allow any Loctite to plug hole Install set screw in converter housing and in oil distributor Figure 334 Install set screw plug REASSEMBLY OF TRANSMISSION See cleaning and inspection page Figure 335 Install forward reverse distributor sleeve in transmission case with inside diameter chamfer out toward front of transmission and the notch in the distributor aligned up with the retaining set screw hole in the transmission cas
63. ition outer thrust washer on shaft DISASSEMBLY 125 Install clutch shaft front bearing NOTE Bearing has Figure 128 a shield in it This shield must be up Remove clutch shaft oil sealing rings 20 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD ATH CLUTCH HIGH DISASSEMBLY Figure 129 Figure 132 Using a gear puller as shown remove front bearing Remove outer thrust washer retainer ring S Figure 130 Figure 133 Remove clutch gear Remove outer thrust washer thrust bearing and inner thrust washer Pd Figure 131 Figure 134 Remove clutch gear locating ring For 3 speed Remove clutch gear and disc hub Remove bearings models proceed to Figure 144 and spacer from clutch gear 23 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD 4 Figure 135 Remove thrust washer thrust bearing and inner thrust washer 3 Figure 138 Remove clutch discs Remove end plate retainer ring Figure 139 Compress disc springs and remove retainer ring Figure 137 1 Remove end plate Figure 140 Remove retainer ring retainer 24 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 141 Figure 144 Remove disc springs NOTE See page 71 Remove 3rd clutch rear bearing retainer ring Figure 142 Remove clutch piston wear plate DISASSEMBLY OF
64. its will have two cross pins the same length Some units will have two pins of different lengths The longest pin goes in the bottom hole Figure 255 Remove regulator spool spring retainer spring and spacer spring from housing sleeve 44 1712000 3 4 amp 6 Speed LD REASSEMBLY See cleaning and inspection page Figure 256 Install spring spacer in spring retainer Figure 257 Install spring in spring retainer Figure 258 Check orifice in regulator spool to be free and clear of any foreign material Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 259 Figure 262 Install spring retainer spring and regulator valve in From opposite end position accumulator spool in Sleeve against inner cross pin sleeve as shown Figure 260 Compress regulator spool and spring in sleeve far enough to install cross pin Figure 263 Install outer accumulator spring Figure 261 Figure 264 Install cross pin See note after Figure 254 Install middle spring 45 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD DISASSEMBLY AND REASSEMBLY OF SPACER PLATE DISASSEMBLY Figure 265 Install inner spring Figure 268 Remove reverse idler gear end plate capscrew and washer Figure 266 Install stop pin in inner spring Figure 269 Remove end plate and dowel pin Figure 267 charging p
65. lutch assembly by aligning the clutch hub teeth with the clutch inner discs Be sure the clutch hub is in full position in the clutch assembly Do not force this operation Figure 246 Position inner thrust washer on shaft Position thrust bearing on shaft Position outer thrust washer on shaft Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD REGULATOR VALVE DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 250 Install pressure regulator valve spring and regulator valve piston as an assembly into regulator sleeve Figure 247 Tap pin from regulator valve sleeve Use caution as valve spool is under spring pressure Figure 251 Compress valve spring and valve and install pin into regulator valve sieeve DISASSEMBLY AND REASSEMBLY OF DUAL MODULATED VALVE ASSEMBLY Figure 248 For single modulation and mechanical inching see Remove regulator valve piston and pressure regulator oce 86 valve spring pag 1 DISASSEMBLY REASSEMBLY See cleaning and inspection page Figure 249 Figure 252 Position pressure regulator valve spring into regulator Remove inner middle and outer spring and stop pin valve piston from modulation housing sleeve Reference Figure 53 43 Date Apr 2000 Maintenance amp Service Manual Figure 253 Remove accumulator spool Reference Figure 54 Figure 254 Remove cross pin from sleeve NOTE Some un
66. mp OVERHEATING 1 Worn oil sealing rings 2 Worn charging pump 3 Low oil level 4 Dirty oil cooler 5 Restriction in cooler lines NOISY CONVERTER 1 Worn charging pump 2 Worn or damaged bearings LACK OF POWER 1 Low engine R P M at converter stall 2 See Overheating and make same checks 1 Fill to proper level 2 Clean suction pump 3 Replace pump 1 Remove disassemble and rebuild converter assem bly 2 Replace 3 Fill to proper level 4 Clean cooler 5 Change cooler lines 1 Replace 2 Acomplete disassembly will be necessary to deter mine what bearing is faulty 1 Tune engine check governor 2 Make corrections as explained in Overheating Date Apr 2000 1712000 3 4 amp Speed LD Maintenance amp Service Manual 03345 QION31OS 91419373 104100 INSHHND OION310S HOLN1930 HOF HOLIMS 330 TIVNOLLdO HOLIMS 330 WNOLIdO Nan aon 9 319NIS BOF X08 SNOILISOd 31VIG3 H31NI TIY SN3dO 80 LOVINOD 84 EL OL f BL LE 8 44184 70H1NO BVO 2 04 2 0 4 252 1 XOS 130 20 82 20 6 SQION31OS DAA rZ HOS
67. mp 6 Speed LD Figure C Date Apr 2000 Maintenance amp Service Manual ITEM NN 0 ARERR ER PR CG ND D IN ND ND amp D amp D N Oo 0 D JO DESCRIPTION QUANTITY Turbine Shaft Front Bearing 1 Clutch Gear Thrust Washer 1 Clutch Gear Thrust Washer Bearing 1 Clutch Gear Thrust Washer 1 Bearing ee 1 SPACE wpe tee wach Shoe 1 Bearing 213 1 Reverse Clutch Gear 1 Clutch Gear Thrust Washer sens 4 Clutch Gear Thrust Washer Bearing 1 Clutch Gear Thrust Washer 1 End Plate Snap Ring 1 End Plate eed 1 Inner Disc 6 Outer Disc 6 Retainer Snap Ring 1 Snap Ring Retainer 1 Disc Spring Assembly 5 Clutch Piston Wear Plate 1 Clutch Piston 1 Clutch Piston Seal Outer 1 Clutch Piston Seal Inner 1 Turbine Shaft Drum and Plug Assembly 1 Clutch Piston Seal Inner 1 Clutch Piston Seal Outer 1 Clutch Piston 1 Clutch Piston Wear Plat
68. n coat of Loctite No 592 or 506 Dryseal to pipe plugs After assembly of parts using Loctite or Permatex there must not be any free or excess material which might enter the oil circuit Clean mounting surfaces and tapped holes with solvent Dry thoroughly being certain tapped holes are dry and clean Install components and special self locking screws Tighten screws to proper torque per chart NOTE Assembly of components must be completed within a fifteen minute period from start of screw installation The special screw is to be used for one installation only If the screw is removed for any reason it must be replaced The epoxy left in the tapped holes must be removed with the proper tap and cleaned with solvent Dry holes thoroughly and use a new screw for reinstallation If special capscrews are not available clean epoxy away from threads and dry thoroughly Apply Loctite 262 thread locker to threads Install capscrews in the proper locations and tighten to specified torque See Torque Chart Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD NOTE The Torque For The Bolts Of Trans Case and Conv Housing 15 To Be Obtained In Two Steps Step 1 Torque To 30 41 N m With Pneumatic Pistol Step 2 Torque To 55 75 N m Both Steps Starting At The Center Ending At The Outer Side TORQUE SPECIFICATION FOR LUBRICATED OR PLATED SCREWS AND NUTS GRADE 8 8 or 9
69. nd bearing Remove gear Figure 20 and washer Loosen solenoid valve cartridge mov Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD P Figure 21 Remove valve Repeat procedures Figures 18 through 21 for remaining solenoid valves NOTE A 3 speed Figure 24 will have a bore plug in the center bore Remove bore Remove distributor gasket plug Figure 22 Figure 25 Remove 1st and 2nd clutch oil distributor capscrews Remove spacer plate bolts and washers Figure 26 Pry spacer plate away from transmission case al Figure 23 dowel pin holes Note aligning studs to facilitate Remove oil distributor and rings spacer removal 5 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 30 Remove forward and reverse clutch assembly Figure 27 Remove spacer plate and gasket Figure 31 Remove high and 3rd clutch assembly NOTE 3 speed will only have 3rd clutch Figure 28 Remove 1st and 2nd clutch assembly Figure 32 Remove parking brake caliper assembly bolts from Figure 29 brake and housing NOTE Brake is an option and will Remove clutch shaft rear bearing not be on all units Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 33 Remove brake caliper assembly Figure 36 Remove shift fork to shift rail lockscrew Figure 37 Figure 34 Remove shift
70. ng retainer on clutch shaft are in position Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD 0 NX Figure 102 Press needle bearings in clutch gear and disc hub being certain bearings are pressed flush with face gear on both sides Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with Figure 99 the clutch inner discs Be sure the clutch hub is in full Install clutch disc end plate position in the clutch assembly Do not force this operation 1 Figure 100 Figure 103 Install end retainer ring Position thrust bearing inner washer on clutch shaft Position thrust bearing on clutch shaft against inner thrust bearing washer Install outer thrust bearing washer against bearing Figure 101 Position thrust bearing inner washer on clutch shaft Install outer thrust bearing washer against thrust bearing Position thrust bearing on clutch shaft Figure 104 against inner thrust bearing washer Install thrust washer retainer Date 2000 Maintenance amp Service Manual Figure 105 Install clutch shaft gear locating ring Figure 106 Install clutch shaft output drive gear on clutch shatt with long hub of gear up 4 Figure 107 Install 3rd driven gear on clutch shaft with long hub of gear up T12000 3 4 amp 6 Speed LD Figure 108 Install rear bearing inner race on clutch shaft with bearing race sho
71. nt of spring load oil seals 0 rings metal sealing rings gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling under of lip of seal seriously impairs its efficiency Apply a thin coat of Permatex No 2 on the outer diameter of the oil seal to assure an oil tight fit into the retainer When assembling new metal type sealing rings same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members Lubricate all 0 rings and seals with recommended type Automatic Transmis sion Fluid before assembly Gears and Shafts If magna flux process is available use process to check parts Examine teeth on all gears carefully for wear pitting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or splines twisted and that shafts are true Housing Covers etc Inspect housings covers and bearing caps to be certain they are thoroughly clean and that mating surfaces bearing bores etc are f
72. odulator valve housing NOTE For single Figure 55 modulation and mechanical inching see page 86 Remove modulator housing sleeve and regulator spool assembly Figure 56 Figure 53 Remove oil sleeve distributor lockscrew plug Remove Remove inner middle and outer springs lockscrew 10 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 57 Use hammer puller as shown to remove distributor sleeve and pilot bearing Figure 60 Remove front bearing retainer ring Figure 58 Pilot bearing and oil distributor sleeve removed DISASSEMBLY AND REASSEMBLY OF LOW 1ST AND 2ND CLUTCH Figure 61 Remove front bearing DISASSEMBLY LOW 1ST BEING DISASSEMBLED XQ Figure 62 Figure 59 Remove outer thrust washer bearing and inner thrust Remove clutch shaft oil sealing rings washer oo Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 66 Remove clutch disc end plate Figure 63 Remove clutch gear and disc hub Remove clutch gear bearings Figure 67 Remove inner and outer clutch discs Figure 64 Remove outer thrust washer thrust bearing and inner thrust washer Figure 65 Figure 68 Remove clutch disc end plate retainer ring Compress disc springs and remove retainer ring Date Apr 2000 Maintenance amp Service Manual Figure 69 Remove retainer ring retainer 1 Figure 70 Remove
73. ol operating in a closely fitted bore The valve spool is spring loaded to hold the valve in the closed position When a specific pressure is achieved the valve spool works against the spring until an exhaust port is exposed along the side of the bore This sequence of events provides the proper system pressure This requires a small portion of the total volume of oil used in the system The remaining volume of oil is directed out through an external oil cooler and into the lube inlet port From the lube inlet port oil goes through the forward reverse shaft lubricating the forward and reverse clutches with the remainder going to the torque converter After entering the converter the oil is directed through the converter blade cavity and exits in the passage between the turbine shaft and impeller hub The oil then lubes the impeller hub bearing with the remainder going to the 3rd 4th clutch shaft and 1st 2nd clutch shaft to lubricate those clutches and shaft bearings The oil then gravity drains to the transmission sump The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be com
74. ounting screws 10 be installed to allow free movement of caliper pads to disc Tighten jam nut See torque chart See page 81 for brake information Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Note The disc spring packs are to be used as complete assemblies and care should be taken not to intermix the individual disc springs with disc springs in another clutch or disc spring pack Service replacement assemblies are banded together and must be replaced as assembly Date Apr 2000 Maintenance amp Service Manual CLUTCH ENGAGEMENT CLUTCH ENGAGEMENT FOR 3 SPEED 712000 POWER SHIFT TRANSMISSION FORWARD SHIFT DIRECTION SPEED SPEED CLUTCH CLUTCH ist A REVERSE SHIFT DIRECTION SPEED ist zd sa T12000 3 4 6 Speed LD 72 181 LE Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD CLUTCH ENGAGEMENT CLUTCH ENGAGEMENT FOR 4 SPEED T12000 POWER SHIFT TRANSMISSION FORWARD SPEED CLUTCH CLUTCH 2nd Cap CLUTCH REVERSE SHIFT
75. pared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter This element receives fluid at its outer diameter and discharges at its center Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque The reaction member of the torque converter is located between and at the center of the inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at zero R P M Therefore we can say that as the output shaft is decreasing in speed the torque multiplication is increasing With the engine running and the electric shift control lever in neutral position oil pressure from the regulating valve is blocked at the solenoid control valves and the transmission is in neutral Movement of the control lever will energize the forward or reverse solenoid valves and selected range gear solenoid directing oil under pressure to the selected direction and range gear clutches Date Apr 20
76. que converter function together and operate through a common hydraulic system It is necessary to consider both units in the study of their function and operation The electric shift control valve is located in the vehicle s operator compartment The function of the control is to energize the selected solenoid valves thus directing the oil under pressure to the selected directional and range gear clutches The purpose of the range or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction An axle disconnect is optional and is located on the output shaft The drive to the front axle can be disconnected or connected by manual pneumatic or hydraulic shifting When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector solenoid to the oil sump The same procedure is used in the speed selector The direction or speed clutch assembly consists of a drum with slots and a bore to receive a hydraulically actuated piston The piston is oil tight by the use of sealing rings A steel disc with external tangs is inserted into the drum and rests against the piston Next a friction disc with splines at the inner diameter is inserted Discs are alternated until the required total is achieved A heavy back up plate is then inserted and secured with a snap ring A hub with O D splines is inserted into the splines of discs with t
77. r locating ring on turbine shaft Figure 377 Tighten bolts to specified torque See Figures J and K tor proper screw location and installation Figure 381 Position converter assembly on stator support and Figure 378 turbine shaft Position new rings and gasket on the 1st and 2nd clutch shaft oil distributor cap Figure 379 Install distributor cap on clutch shaft Use caution as not to damage clutch shaft oil sealing rings Install capscrews and washers Tighten to specified torque Figure 382 See torque chart Install converter assembly retainer ring 66 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 383 Figure 386 With new O ring in place install bore plug in Install charging pump to converter housing bolts and converter assembly washers and tighten to specified torque See torque chart Figure 384 Install bore plug retainer ring Figure 387 If auxiliary pump is used it is not necessary to install the permanent pump hole cover With new gasket in place install pump hole cover on charging pump Install bolts and washers and tighten to specified torque See torque chart Figure 385 With new gasket in place install charging pump in Figure 388 converter housing Install regulator sleeve assembly in converter housing 267 Date Apr 2000 Maintenance amp Service Manual Figure 389 Using a special tool as shown in Figure 389A tighten sleeve to 45 50
78. ree from nicks or burrs Check all parts carefully for evidence of cracks or condition which would cause subsequent oilleaks or failures Date Apr 2000 Maintenance amp Service Manual 7 2 2 f 2 v r 227027 CL 5 AA SM GR T12000 3 4 amp 6 Speed LD CALIPER BRAKE ASSEMBLY ITEM DESCRIPTION QUANTITY 1 HOUSING 1 2 LINING repete 2 9 7 ie RE DM 1 4 Cam eo o ERU Red 1 MEN ren a minis 1 6 aussen adire cdd er e DC A Feet dvi gne 1 1 BodyModule rtc Sr e 1 T12000 ITEM DESCRIPTION QUANTITY 8 aii a eis entera rt rit 1 9 NU en eie e e d eere cedes 1 10 BellevilleSpring iet 1 11 Retalfier nci e em eee 1 12 Retainer Ring inier es 1 195 eC 1 14 1 PARKING BRAKE LINING AND PISTON REPLACEMENT PROCEDURE DISASSEMBL Y 1 Loosen and remove lever retaining nut item 9 from brake module and piston assembly item 13 Remove lever item 8 2 Depress retainer item 11 and remove retaining ring item 12 from lever end of brake module item 7 3 Remove retainer item 11 and five 5 belleville springs item 10 from piston item 13 4 Remove piston item 13 two cam plates item 4 and three balls item 5 from brake module item 7 REASSEMBLY 5 Lubricate three
79. ring Position idler gear on bearing 50 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD FRONT OUTPUT FLANGE DISASSEMBLY AND REASSEMBLY FLANGE USED WITH FRONT DISCONNECT DISASSEMBLY NOTE Unless disconnect front and rear flange bushings are to be replaced DO NOT remove bushing or expansion plug Figure 295 Position idler gear end plate and roll pin on idler shaft aligning roll pin with hole in idler shaft Figure 298 Remove flange to bearing retainer ring Figure 296 Install end plate capscrew and washer gt Figure 297 Tighten capscrew to specified torque See torque Figure 299 chart Using a bearing puller as shown remove bearing siia Date Apr 2000 Maintenance amp Service Manual Figure 300 Bearing removed Figure 301 Oil seal sleeve and O ring removed Figure 302 Remove oil seal from sleeve 52 T12000 3 4 amp 6 Speed LD Figure 303 Remove oil seal retainer ring from output flange Figure 304 expansion plug from flange See note at top of page 51 Na A Figure 305 Remove output bushing See note at top of page 51 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD REASSEMBLY See cleaning and inspection page r 22 56 Apply Loctite 577 or Loctite HVV 571 To Plug Prior To Installation Remove Excess Material Chamfer Of Plug Must Be In Mu
80. sed with 3 Speed Only 11 Spring Retainer 2 31 Cartridge Ring 12 Spring Retainer Snap Ring 2 32 Cartridge Ring 13 Accumulator Spool Snap Ring 2 33 Cartridge Ring 14 Accumulator 2 34 Cartridge Ring 15 Spring Outer 2 35 Valve Cartridge 4 Way Used at 16 Cover Screw Lockwasher 2 1st and 2nd 3rd Incl Items 31 32 33 34 Li AR naa A 17 Cover 2 36 Coil to Cartridge Ring 18 Protective 1 37 Solenoid Coil 19 Valve Cartridge Retainer Nut 2 38 Nut to Coil 20 Nut to Coil Ring 2 39 Valve Cartridge Retainer Nut 21 Solenoid Coil 2 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD SINGLE MODULATION MECHANICAL INCHING AIR OR HYDRAULIC ACTUATED INCHING Figure G Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T12000 CONTROL VALVE GROUP WITH SINGLE MODULATION INCHING ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION QUANTITY 1 Modulator Valve Housing
81. st be Secure And O Tight Figure 3078 Figure 306 Install new inner and outer flange bushings to dimensions shown in Figure 3078 NOTE Bushings used only with front disconnect Figure 308 Position retainer ring on output flange Figure 307 Apply a light coat of Loctite 577 to the outer edge of expansion plug Install plug in flange NOTE See Figure 307A for expansion plug installation tool fabrication It is imperative plug be installed properly to prevent oil leakage i 1 2302 304 T Figure 309 1 very light coat of Permatex 2 to the outer n diameter of the output flange oil seal Press oil seal in oil seal sleeve Oil seal must be flush with one side of Figure 307A face of oil seal sleeve and lip of seal must be in 53 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD REAR OUTPUT FLANGE DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 310 Install new O ring on oil seal sleeve Position oil seal sleeve assembly on output flange NOTE Recessed portion of oil seal and sleeve must be up with lip of seal up This leaves a space between oil seal and output bearing Figure 313 Using a bearing puller as shown remove bearing Figure 311 Press bearing on output flange Figure 312 Figure 314 Install bearing to flange retainer ring Bearing removed 2000 Maintenance amp Servi
82. support converter safety valve poppet in bore in Spacer 48 Date Apr 2000 Maintenance amp Service Manual Figure 283 Turn spacer over and position safety valve spring on poppet Compress spring and install poppet retaining washer NOTE End of spring must go in recessed side of washer Figure 284 If stator support bushing was removed install bushing in Support Figure 285 Install needle bearing in stator support 49 1712000 3 4 amp 6 Speed LD Figure 286 Install stator support through spacer plate Figure 287 Install stator Support locating ring T Figure 288 Push support back through spacer until locating ring shoulders in support bore Turn spacer plate over and install impeller hub gear washer and support retaining ring Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 292 Turn spacer plate over and position tanged thrust Figure 289 washer on shaft being certain tang in washer is in Install stator support oil sealing ring expander ring notch in spacer plate Install oil sealing ring on expander ring NOTE Expander spring gap to be 180 degrees from sealing ring hook joint Figure 290 Install locating ring on reverse idler shaft Figure 293 Position idler gear needle bearing on shaft Lubricate Figure 291 Support spacer plate and press reverse idler shaft into Figure 294 position and tight against locating
83. te retainer ring by inserting a feeler gauge or taper gauge through the slots in the clutch drum The required clearance is 080 135 2 03 3 43 3 Figure 118 the clearance is greater than 135 3 43 add one Install first friction inner clutch disc Alternate steel steal disc under the end plate and friction until ten 10 steel and ten 10 friction discs are in position Figure 122 Position thrust bearing inner washer on clutch shaft 5 Position thrust bearing on clutch shaft against inner Figure 119 thrust bearing washer Install outer thrust bearing Install clutch disc end plate washer against bearing 21 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD zp B 02 Figure 126 Install front bearing retainer ring certain bearings are pressed flush with face of gear on both sides Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Be sure the clutch hub is in full position in the clutch assembly Do not force this Figure 123 Press bearings in clutch gear and disc hub being 4 operation Figure 127 Install clutch shaft oil sealing rings Grease rings to facilitate reassembly into front housing DISASSEMBLY AND REASSEMBLY OF 3RD AND 4TH HIGH CLUTCH Figure 124 4TH CLUTCH USED ON Position inner thrust washer on shaft Position thrust 4 amp 6 SPEED MODELS ONLY bearing on shaft Pos
84. thrust bearing washer against thrust bearing Date Apr 2000 Maintenance 8 Service Manual T12000 3 4 amp 6 Speed LD 22 b Figure 172 Install thrust washer retainer ring Figure 170 Press one bearing in clutch Install bearing spacer next to bearing Press second bearing in gear being certain bearings are pressed flush with face of gears on both sides Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Be sure the clutch hub is in full position in the clutch assembly Do not force this operation a 173 Install clutch shaft gear locating ring Figure 171 Position inner thrust washer on shaft Position thrust bearing on shaft Position outer thrust washer over Figure 174 thrust bearing Position gear on clutch shaft 30 Date Apr 2000 Maintenance amp Service Manual Figure 175 Install clutch shaft front bearing NOTE Bearing has a shield in it This shield must be up Figure 176 Install clutch shaft oil sealing rings Grease rings to facilitate reassembly into front housing 3RD CLUTCH REASSEMBLY 2 X Ja Figure 177 Clutch piston bleed ball must be clean and free of any foreign material T12000 3 4 amp 6 Speed LD Figure 178 Install inner and outer clutch piston seal rings Size inner ring as explained in Figure 91 Install clutch piston in clutch drum Use ca
85. ulder down REASSEMBLY OF LOW 1ST CLUTCH See cleaning and inspection page Figure 109 Install clutch piston outer seal ring Figure 110 Install inner clutch piston seal ring Size inner ring as explained in Figure 91 Date Apr 2000 Maintenance amp Service Manual Figure 111 Position piston in low clutch drum as shown Use caution as not to damage inner and outer piston rings Figure 112 Position clutch piston wear plate on piston Figure 113 Install piston return disc springs First spring with large diameter of bevel toward wear plate Alternate seven 7 springs NOTE See page 71 20 12000 3 4 amp 6 Speed LD NBD Figure 114 Position return spring retainer on clutch shaft T Figure 115 Start ring on with snap ring pliers Figure 116 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress springs and seat retainer ring Be sure ring is in full position in groove Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD E g Figure 120 Install end plate retainer ring Figure 117 Install first steel outer clutch discs Figure 121 NOTE Low 151 clutch pack must be checked for clutch disc clearance Stand the clutch assembly on end as shown Measure the distance between the clutch end plate and the end pla
86. ump Gasket 1 Charging Pump 1 Pump Mounting Screw Lockwasher 1 Pump Mounting Screw 1 Pump Mounting Screw 1 Pump Mounting Screw Lockwasher 1 Pump Mounting Screw 4 Pump Mounting Screw Lockwasher 4 Filter 1 PISTON c eee tL mnt 1 SPiN 4s ote 1 Aa S RE tet tt 1 Lise ete n ERES SERIA ne 1 Converter Housing Oil Seal 1 Oil Distributor Ring Ring 1 Oil Distributor Ring 1 Oil Distributor Ring Ring 1 Torque Converter Bearing 1 Impeller Hub 1 Stator Support Snap Ring 1 Stator Support Piston Ring 1 Stator Support Piston Ring Expander 1 Stator Support 1 BUSHING at ELLE 1 Bearing 1 Impeller Hub Gear Washer 1 Idler Shaft Snap Ring 1 Idler and Pilot 1 Housing to Plate Gasket 1 Stator Support Snap Ring 1 Reverse Idler 1 ITEM 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 DESCRIPTION QUANTITY 1 Reverse Idler End Plat
87. ump or pump drive gear are to be Figure 270 replaced remove retainer ring and drive gear Remove reverse idler gear 46 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 274 idler shaft and locating ring removed Figure 271 Remove reverse idler gear bearing Figure 275 Remove locating ring idler shaft Figure 272 Remove idler gear tanged thrust washer Figure 273 If reverse idler shaft is to be replaced support spacer plate around idler shaft opening and press idler shaft Figure 276 from spacer Do not drive on idler shaft as doing so Remove stator support oil sealing ring and expander may Cause damage to spacer plate ring 47 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 280 If support bushing or bearing is to be replaced Figure 277 remove from stator support The stator support is held in place by two retaining rings Remove converter end retainer ring trom groove Remove thrust washer Figure 281 Compress converter safety valve spring and remove Figure 278 retaining washer Remove safety valve spring Turn Push support toward transmission side far enough to spacer over and remove safety valve poppet expose retainer ring Remove retainer ring REASSEMBLY OF SPACER PLATE See cleaning and inspection page Figure 282 Figure 279 From transmission side of spacer plate position From converter end remove stator
88. ust bearing Figure 191 Install clutch shaft rear bearing Figure 189 Press bearings in clutch gear and disc hub being certain bearings are pressed flush with face of gear on both sides Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Be sure the clutch hub is in full position in the clutch assembly Do not force this Figure 192 operation Install bearing retainer ring Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD DISASSEMBLY AND REASSEMBLY OF FORWARD AND REVERSE CLUTCHES NOTE 3 speed transmission will not have external gear teeth on the forward and reverse clutch drum REVERSE CLUTCH BEING DISASSEMBLED 4 Figure 196 Remove end plate retainer ring Figure 193 Remove outer thrust washer thrust bearing and inner thrust washer lt Figure 194 Remove end plate Remove bearings and spacer from clutch gear 3 Figure 195 Remove outer thrust washer thrust bearing and inner Figure 198 thrust washer Remove clutch discs 34 Figure 197 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 202 Remove clutch piston wear plate Figure 199 Compress disc springs and remove retainer ring Figure 203 Remove clutch piston Figure 200 Remove retainer ring retainer DISASSEMBLY OF FORWARD CLUTCH Figure 201 Figure 204
89. utch Piston Seal Inner 1 68 Oil Seal Sleeve 30 1st and 2nd Shaft Drum 69 Output Shaft Oil Seal Plug Assembly 1 31 Clutch Piston Seal Inner 1 SD UID SIGNS 32 Clutch Piston Seal Outer 1 shat Bearing Snap FANG esas 33 Clutch Piston md leo wh 1 220510 1 72 Output Shaft and Brake Flange 34 Clutch Piston Wear Plate 1 73 Caliper Assembly Capscrew Locking Nut 35 Disc Spring Assembly 5 74 Caliper Brake Assembly 36 Snap Ring Retainer 1 75 Caliper Assembly Mounting Capscrew 37 Retainer Snap Ring 1 76 Brake Disc i e 38 Outer Disc 2nd Clutch 5 77 Brake Disc Capscrew Lockwasher 39 Inner Disc 2nd Clutch 5 78 Brake Disc Capscrew Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure E Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD T12000 OUTPUT SHAFT GROUP WITH HYDRAULIC OR MECHANICAL DISCONNECT ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION QUANTITY 1 Flange Plug 1 22 Oil Seal Sleeve 25 BUSING 1 23 Output Shaft Oil Seal 3 Output
90. ution as not to damage sealing rings Figure 179 Install clutch piston wear plate Bm a p Figure 180 Install piston return disc springs First spring with large diameter of bevel toward wear plate Alternate five 5 springs NOTE See page 71 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 181 Position return spring ring retainer on clutch shaft Figure 184 Install first steel outer clutch disc Figure 182 Start ring shaft with snap ring pliers Figure 185 install first friction inner clutch disc Alternate steel and friction until five 5 steel and five 5 friction discs Bh are in position w Figure 183 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a 5 soft hammer will springs and seat retainer Figure 186 ring Be sure ring is in full position in groove Install clutch disc end plate 32 Date Apr 2000 Maintenance amp Service Manual T12000 3 4 amp 6 Speed LD Figure 187 Install end plate retainer ring e Figure 188 Position thrust bearing inner washer on clutch shaft Position thrust bearing against inner washer Install outer thrust washer on thrust bearing Figure 190 Position thrust bearing inner washer on clutch shaft Position thrust bearing on shaft against washer Install outer thrust bearing washer against thr

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