Argo Service Manual Cover 05-06
Contents
1. A2556 3 dog teeth Photo TR 50 Orient the the High Gear Pinion with the dog teeth facing up 4 Install the second Thrust Washer to the top of the High Gear Pinion Photo TR 51 5 Install the 107 10 retaining ring to secure the second thrust washer Photo TR 52 6 Slip the 34 103 Dog Clutch 4 Tooth prior to serial A2856 or 34 127 Dog Clutch 3 tooth from serial A2856 to the Input Shaft Photo TR 53 IMPORTANT The Dog Clutch needs to be oriented correctly when assembled to the Input Shaft The dogs on one side of the clutch have a small machined shoulder These dogs will engage with the Low Gear Pinion so they face away from the previously installed High Gear Pinion Photo TR 53 Dog Clutch 7 Install the 34 106 Low Gear Pinion 4 Tooth prior to serial A2856 or 34 129 3 tooth from serial A2856 with the dogs facing towards the previously installed Dog Clutch Photo TR 54 8 Press the 34 107 Reverse Gear Pinion on to the Input Shaft and up against the Low Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 15A Transmission Argo Service Manual Gear Pinion Orient the Reverse Gear Pinion with the chamfered teeth facing up Photo TR 55 Reverse Gear Pinion h f Mi i D ais e En gt 1 fe rr 55 od 9 Secure the Reverse Gear Pinion with a 107 12 Retaining Ring Photo TR 56 10 Press a 101 01 bearing to the end of the Input Shaft with2. PH 519 662 2840 FAX 519 662 2421 TR 47 di A PL pa N A wolf a Transmission Argo Service Manual 59 Press the inner Oil Seal to the Output Shaft Seat it to the Retaining Ring that was previously installed in the Housing in step 29 Do not over press Photo TR 179 180 amp 181 60 Install a Retaining Ring to the top of the Oil Seal Photo TR 182 amp 183 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 48 Argo Service Manual Transmission 61 Press the outer Sealed Bearing into the Side Cover and seat it to the Retaining Ring Photo TR 184 185 amp 186 62 Rotate the transmission assembly and repeat steps 59 61 to the Housing side 63 Place the transmission back into the rotating fixture and thread the output shaft puller on to the Output Shaft Photo TR 187 64 While holding the Output Shaft with the specialized tool holder thread the hex head bolt into the Output Shaft and tighten it down until the shaft has been pulled towards the outside of the Housing Pull the shaft far enough to install the Shim Washer and Retaining Ring to the machined groove of the Output Shaft Photo TR 188 189 190 amp 191 following Pages IMPORTANT Output Shaft Shims come in two thicknesses Generally the 040 Shim Washer is installed on the cover side and the 020 Shim Washer is installed on the Housing Side However there may be cases when only the thin
3. amp Gear Limited TR 18A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission 10 Wipe down the 2 34 98 Output Shaft and assemble to the Gear Plate using the same method as described for the Aluminum Cage Photo TR 71 72 73 11 Orient the 2 34 14 Sun Gear as in instruction 8 and install and secure it with a 107 04 Retaining Ring using the same method as described for the Aluminum Cage in instruction 10 Photo TR 74 75 76 amp 77 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 19A Transmission Argo Service Manual 12 Set the assembled 34 122 Aluminum Cage into an assembly stand Photo TR 78 13 Install 3 105 23 Hollow Dowl Pins into the mounting holes of the aluminum cage Photo TR 79 14 Install 6 34 13 Pinions into the Oilite Bushings of the Aluminum Cage alternating the Pinions in an up and down manner as shown in Photo TR 80 amp 81 Ontario Drive amp Gear Limited TR 20A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission 16 Assemble the Gear Plate to the Aluminum Cage Align the top of the Pinions in the Cage with the Oilite Bushings in the Gear Plate Photo TR 82 amp 83 17 Seat the Gear Plate to the Aluminum Cage using a soft faced mallet Photo TR 84 18 Apply Red 271 LOCTITE to each of the 3 112 143 fasteners Photo TR 85 and tighten down to 35 FT LBS Photo T
4. Assembly securing 1t with a 107 05 Retaining Ring Photo TR 136 137 amp 138 36 Install the 113 01 O ring to the 34 65 Shifter Assembly Photo TR 139 amp 140 following page 37 From the inside of the Housing slip the Shifter Assembly through the Oilite Bushing at the top of the Housing Photo TR 141 following page Any transmission being serviced and rebuilt between Serial Numbers CB17471 CB19432 RB17525 RB19441 BF11917 BF 13347 SN11905 SN13349 or S11906 SI3350 would benefit from having this new 108 74 shim washer installed at the time of the rebuild Even though this may not have been an issue it will be a good precautionary measure for the future Photo TR 142 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 39 aria 6x6 Vorlc com Transmission Argo Service Manual TR 141 38 Orient and secure the Shift Lever Holder to the Shift Shaft using 2 Roll Pins as shown in Photo TR 143 Be sure to support the shaft from below with a piece of metal stock when hammering the pins through the Holder Photo TR 144 ns i n AE eae 4 A A TR 143 E z _ LA a jo f eps b B r i a Pn da Ma na i a de roa E LA J a Phi e Li n gt LI R a A n A A risa a i E al EN Pier a a n mi A peers onl Y Pl 3 FEE r E pe a h i Ontario Drive amp Gear Limited TR 40 www odg com PH 51
5. Do not install this 101 01 Bearing to the end of the shaft if the differential assembly has the high ratio 3 3 Gear Plate This bearing should be installed to the housing at the same time as the 101 03 Bearing step 16 of Assembling Transmission Components to Housing pg TR 25 Interference between this Bearing and Gear Plate teeth will be apparent later on when installing along side the differential assembly if this is not observed Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 13A Transmission Argo Service Manual Assembling the Input Shaft Transmissions built prior to A5883 For transmissions built from_A5883 see Pages TR 35 for revised Input Shaft Assembly guidance 1 Install the 107 02 Retaining Ring to the 34 104 Input Shaft Photo TR 48 IMPORTANT Remember to do the comparison check of this retaining ring as described on page TR 9 2 Slip a 108 79 Thrust Washer on to the Input Shaft and up against the previously installed retaining ring Photo TR 49 3 Slip the 34 105 High Gear Pinion with 4 dog teeth or 34 128 High Gear Pinion with 3 dog teeth up against the Thrust Washer Photo TR 50 See Note Regarding number of teeth on following page Ontario Drive amp Gear Limited TR 14A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission NOTE Transmissions manufactured prior to serial A2856 utilize 4 dog teeth and from
6. Manual Transmission 12 13 14 Remove the Shifter Assembly Locate the Plug Plate on the Housing side and with a hammer and punch knock the Plug Plate through at the center until the Shifter Assembly is freed from the Bearing Photo TR 21 If the 101 01 Bearing has remained on the Input Shaft it will be necessary to remove it using a gear puller Photo TR 22 amp 23 Slip the Reverse Idler gear from the Y2 Dowel Pin Photo TR 24 15 16 ie Remove the Input Shaft s Oil Seal Photo TR 25 Remove the Input Shaft s Retaining Ring Photo TR 26 Remove the Shim installed below the Retaining Ring Photo TR 27 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 13 Transmission Argo Service Manual NOTE Some transmissions may have 2 Shims instead of 1 In rare cases there may be none used In any case when reassembling use the same amount as were used originally 18 Using a soft faced hammer tap the Input Shaft out of the Housing Photo TR 28 19 Place the Housing in the assembly fixture to remove all Bearings Retaining Rings Seals and the Plug Plate 20 Remove the old Cover Gasket Photo TR 29 21 Knock the outer Bearing from the Housing using a hammer and drift punch Tap around the perimeter of the Bearing through the backside of the housing to ensure that it will not bind Photo TR 30 22 Knock out the Housing Plug Plate Photo TR 31 Ontario
7. the Housing Photo TR 166 54 Install the Cover Gasket to the sealing edge of the Housing Photo TR 167 55 Apply the same gasket compound to the lower edge of the Side Cover as well Photo TR 168 following page 56 Install the Cover to the Housing and press to fit Photo TR 169 170 amp 171 When applying pressure to the cover at the press use a soft faced mallet to tap the top end of the cover at the same time to ensure that the cover 1s not installed crooked Photo TR 172 amp 173 following page Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 45 Transmission Argo Service Manual Ontario Drive amp Gear Limited TR 46 www odg com PH 519 662 2840 FAX 519 662 2421 aaa MankhLeam Argo Service Manual Transmission 57 Secure the Cover using 1 Cap Screw 4 Bolts and 4 Lock Washers Apply LOCTITE Silver Grade anti seize to the cap screw before installing to the lower end of the transmission assembly Photo TR 174 amp 175 Silver Gra Anti Seize Y TR 174 o ca wit i 58 Secure the Cover and torque to specifications Photo TR 176 amp 177 NOTE Tighten down all fasteners in a cross corner sequence l A TR 176 NOTE Apply a little gear oil to the inner lip of the Oil Seal to ease assembly around the Output Shaft and prevent any deformity during ARG installation Photo TR 178 gt SS A E TR 178 Ontario Drive amp Gear Limited
8. the Retaining Ring is properly seated to the machined groove of the Output Shaft Photo TR 82 Press the Output Shaft from the inside of the cage to seat the Retaining Ring snuggly against the Sun Gear Photo TR 83 o 4 _ i a S RT ue ee w Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 29 Transmission Argo Service Manual 10 Wipe down the 2 Output Shaft and assemble to the Gear Plate using the same method as described for the Aluminum Cage Photo TR 84 85 amp 86 11 Orient the 2 Sun Gear as in instruction 8 and install and secure it with a 107 04 Retaining Ring using the same method as described for the Aluminum Cage in in struction 10 Photo TR 87 88 89 amp 90 Ontario Drive Gear Limited PH 519 662 2840 FAX 519 662 2421 1R 30 Argo Service Manual Transmission 12 Set the assembled Aluminum Cage into an assembly stand or an aluminum jawed vise Photo TR 91 13 Install 6 Pinions into the Oilite Bushings of the Aluminum Cage alternating the Pinions in an up and down manner as shown in Photo TR 92 amp 93 14 LOCTITE the 3 threaded holes of the Aluminum Cage with Red 271 LOCTITE Photo TR 94 15 Assemble the Gear Plate to the Aluminum Cage Align the top of the Pinions in the Cage with the Oilite Bushings in the Gear Plate Photo TR 95 amp 96 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 31 aa on
9. the housing finger tight then remove it to view the level 5 Inspect the oil level If the level indicated is not even with the mark on the dipstick go to step 6 Otherwise return the dipstick to the transmission Ontario Drive amp Gear Limited TR_4 www odg com PH 519 662 2840 FAX 519 662 2421 sx6Worlcicon Argo Service Manual Transmission 6 a Oil Level Above The Groove 1 Insert a vacu pump hose into the dipstick opening A CAUTION Do not insert the Vacu pump hose into the transmission if the gearbox oil is extremely hot Vacu pump components may melt 11 Draw out a small quantity of gear oil from the transmission 111 Remove the vacu pump from the transmission iv Repeat steps I to 5 6 b Oil Level is Below The Groove 1 Place a clean long spouted funnel into the oil fill dipstick hole 11 Add a small quantity of fresh clean oil as specified in the Recommended Oil Type on page TR 3 of this manual 11 Remove the funnel and replace the dipstick Apply a small amount of anti seize compound to the thread of the dipstick Older Models and retighten into the housing with a 3 8 opened end wrench Changing The Transmission Oil You may drain the transmission s oil through the oil fill dipstick by using a vacuum style pump such as the one available through your ARGO dealer part 638 02 or preferably at the drain plug located at the bottom of the transmission just behind the firewall Refer t
10. will indicate this process when the oil is changed for the first time The oil will appear very silvery and fine metal filings will be noticeable on the drain plug s magnet Abrasive Wear and Scratching Metal particles which flake off gears shafts and castings are carried in the lubricant and can cause uneven and premature wear to gear teeth Thorough cleaning of all components at disassembly and fresh transmission oil can normally prevent further wear of this kind Breakage Any gear or spline shaft with cracked broken or missing teeth should be replaced immediately The installation of a badly damaged gear or shaft will lead to premature wear of other components and other potential breakdowns Replace all badly worn broken or missing components immediately with genuine ARGO replacement parts If there is any doubt as to whether the transmission component needs replacing generally the best thing to do is to replace it while the job 1s at hand Aluminum Cage Inspect the aluminum cage for any hairline cracks especially at the shoulder where the inner bearing is seated Photo TR 68 Bearings Unless the ARGO technician has determined to his her own satisfaction that the bearings are suitable to reuse it is recommended that all bearings be replaced when rebuilding a transmission Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 24 o Argo Service Manual Transmission Argo Transm
11. 0 19 Remove the reverse and low gear from the input shaft at the arbor press Photo TR 21 20 Slip the dog clutch from the input shaft and remove the retaining ring amp Thrust Washer found above the High Gear Photo TR 22 21 Slip the high gear from the input shaft PhotoTR 22 and remove the thrust washer and Retaining Ring found below it Photo TR 23 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 5A Transmission Argo Service Manual 22 Remove the last ball bearing from the input shaft at the arbor press Photo TR 24 Disassemble the Spline Shaft Drive Gear Assembly 23 Remove the bearing and high gear from the spline shaft at the arbor press Photo TR 25 24 Remove low gear reverse gear drive gear and bearing from the spline shaft using the the arbor press Photo TR 26 Ontario Drive amp Gear Limited TR 6A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission 26 Press the differential from the housing at the arbor press Photo TR 28 NOTE The use of wood blocks beneath the housing prevents damage to the sealing edge of the casting as well as provides height for removing the differential 27 Disassemble the reverse shift shaft block by removing the roll pin securing 1t to the shaft Photo TR 29 amp 30 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 7A Transmissio
12. 19 662 2840 FAX 519 662 2421 6x6GWond com Argo Service Manual Transmission Transmission Assembly Assembling the Differential l Secure the Aluminum Cage to the base of the arbor press using a spacer and nut Photo TR 69 2 Install 6 Oilite Bushings into the Aluminum Cage Photo TR70 3 Repeat the process installing these bushings into the appropriate Gear Plate Photo TR 71 The 3 Gear Plates used are M Gear Plate H Gear Plate G Gear Plate 4 Blow all foreign debris from the Cage and Gear Plate Photo TR 72 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 27 Transmission Argo Service Manual 5 Install a Bearing into both Cage and Gear plate Photo TR 73 amp 74 6 Wipe the Output Shaft free of debris with a lint free rag Install this Output Shaft into the Aluminum Cage Photo TR 75 amp 76 NOTE See Transmission Component Changes chart on page TR 25 regarding output shafts NOTE Use a spacing tool to secure the previously installed Bearing inside the Aluminum Cage while the Output Shaft is pressed into place Photo TR 77 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 28 Argo Service Manual Transmission 7 Orient the Sun Gear as in Photo TR 78 with the higher shoulder side facing up Install it to the splined end of the Output Shaft Photo TR 79 amp 80 8 Secure the Sun Gear with a Snap Ring Photo TR 81 9 Be sure
13. 2421 I Argo Service Manual Transmission TPs Nod ts Me Retaining Ring Installed LA W r f y Dos Y 5 n T ae lt A lt x Y P ec j o E ve gt best fa gt Z 9 12 Install the 104 40 Dowel Pin to secure the Reverse Shift Shaft Photo TR 101 M 13 Assemble the 34 115 Reverse Shift Block to the Reverse Shift Shaft by aligning the keyway with the previously installed Dowel Pin Photo TR 102 14 Tap the Shift Block on until the machined hole in both the Reverse Shift Shaft and the Shift Block are aligned then install the 104 39 Spring Pin Photo TR 103 104 amp 105 NOTE Install the Roll Pin flush to the machine corner of the shift block as shown in Photo TR 105 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 25A Transmission Argo Service Manual Dowel Pin ETO Pin Flush Install Roll Pin Flus TR 105 Worse this edae PESAN 9 15 Install a 106 03 Retaining Ring to top groove of the Housing Photo TR 106 16 Press and install the 101 03 bearing into the Housing Photo TR 107 amp 108 a 4 n A f d A aN Press Into Housin J e _ ft NOTE If the differential consists of the high ratio 3 3 Gear Plate it will be advantages to install the 101 01 Bearing into the cover as well at this point to avoid any interference later when installing the as
14. 3 Retaining ring to the machined groove just above the previously in stalled Oil Seal Photo TR 135 ri TR 135 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 31A Transmission Argo Service Manual 38 Install a 101 05 Bearing to the Output Shaft Photo TR 136 137 an r a das a Mini ji a AD o i a is A P E fas 39 Repeat Steps 36 through 38 for the other Output Shaft 40 Using the Output Shaft puller pull each of the Output Shafts Install a 114 04 Shim under the 107 02 Retaining Ring at the Output Shaft on the Left Side Housing Install a 114 05 Shim under the 107 02 Retaining Ring at the Output Shaft on the Right Hand Side Housing Photo TR 138 139 amp 140 IMPORTANT Ensure that all retaining rings are seated properly de Ontario Drive amp Gear Limited TR 32A www odg com PH 519 662 2840 FAX 519 662 2421 I _ Argo Service Manual Transmission 41 Locate the shift lever opening and place the transmission shift blocks in the neutral postion See Photo TR 141 42 Place the 113 11 O ring into the 34 118 Shifter Plate Photo TR 142 43 Assemble the 34 117 Shift Lever to the Shifter Plate Apply a small amount of axle grease to the ball area of the shifter lever Photo TR 143 ME TR 142 A biei oe E 44 Apply Blue LOCTITE to each of the 112 04 Fasteners and secure the Shift Lever assembly to transmission Pho
15. 9 662 2840 FAX 519 662 2421 SOWeolkleaa Argo Service Manual Transmission 39 Insert the Dowel Pin into the boss of the transmission housing and using a soft face mallet tap it flush to the sealing edge of the housing Photo TR 145 40 Install the Retaining Ring to the bottom of the Dowel Pin Photo TR 146 41 Attach the Shifter Lever assembly temporarily to the Holder Photo TR 147 42 Place the Housing into a fixture for final assembly Photo TR 148 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 41 Transmission Argo Service Manual 43 Use compressed air to blow any foreign debris from the Housing before attempt ing to install the sub assembled com ponents Photo TR 149 Install the Differential Assembly 44 Place the Differential into the Housing slipping the Output Shaft into the Output Shaft Bearing Press at the arbor until the shoulder of the Aluminum Cage is seated to the Bearing Photo TR 150 151 amp 152 Install the Shifter Assembly 45 Take the pre assembled Shifter Assembly and place the Double Gear into the high gear gate on the spline Lowest Position Photo TR 153 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 42 o Argo Service Manual Transmission TR 152 46 Install the Shifter Assembly into the Housing lining up the one end of the Spline Shaft wi
16. Argo Service Manual Transmission Transmission Table of Contents General US CTC COINS os aicecescecscaccaceciseescesecnssousceasecesssascasecssesacssaenieascsenes TR 2 Transmission Oil Maintenance Schedulle ccccccccsssssssssssccccseees TR 3 Recommended O eiee TR 3 Oil Level Inspection ssssecccscscccssscoscccssceccocsscesocssscccososseccsscsscecessssecee TR 4 Changing the Transmission Oil sssceccesssececccssccceccsscccecccsseceecssseeeooso TR 5 Refilling the Transmission with Oll cccccccssssssscccssssssccccees conos TR 7 General Inspection of the Transmissi0n ssscsccccssssssscccssscooees TR 7 Removing the Transmissin sscccccccssssssccccssssssccccccsssssscccees sessonos TR 8 Disassembling the Transmission cccccsssssssccsssssscccccssssssscccsssssees TR 10 Disassembling the Transmission 34 100 Supplement Pages TR 2A Separating the Side Cover Earlier Models ssscscccccssssssssessees TR 11 Separating the Side Cover Later Models sssssscccccsssssssssseeees TR 12 Disassembling the Shifter ASSeEMDLY scccccccsssssssccccsssssscccccseees TR 18 Disassembling the Differential ssssssccccsssssssssscccccccees ses TR 19 Transmission Component nspection cccccccccccsssssssssssssses covssees TR 23 Transmission Component Changes Cha t sscccsccccssssssses coco TR 25 Transmission Assembly socsevrecsceur
17. Drive Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 14 Argo Service Manual Transmission 23 Flip the Housing over to remove the outer Retaining Ring Photo TR 32 24 Using the drift punch and hammer remove the inner Bearing in the same manner as in step 20 Photo TR 33 IMPORTANT When removing this Bearing take note of the number of Shims that were installed behind it This may vary from 1 to 2 shims In any case be sure to install the same amount as was used previously Photo TR 34 25 Flip the transmission and remove the inner Retaining Ring Photo TR 35 E Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 15 Transmission Argo Service Manual 26 Remove the inner Seal with a hammer and drift punch Photo TR 36 27 If the transmission you are disassembling still has the differential assembly in the Side Cover as described in step 8 1t will have to be removed from the Cover using an arbor press First you must remove the Retaining Ring and Shim washer from the Output Shaft Photo TR 37 amp 38 28 Supporting the Cover on each side with 2 short 2x4 s place it in an arbor press and apply pressure to the Output Shaft Press the differential from the Cover Photo TR 39 29 Place the Cover into the assembly fixture and remove all Bearings Seals amp Retain ing Rings in a similar manner as performed on the housing There are 2 plug plates in the Cover side compa
18. R 86 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 21A Transmission Argo Service Manual Assembling Transmission Components to Housing 1 Apply some LOCTITE pipe sealant to the threads of the 103 02 drain plug and in stall into the housing Photo TR 87 amp 88 Drain Plug 2 Start the 34 114 Reverse Shift Shaft into the housing boss as illustrated in Photo TR 89 3 Place a 108 78 Thrust washer above the 34 108 Reverse Idler and a 108 81 Retain ing Thrust Washer machined side down below the Reverse Idler Push the 34 114 Reverse Shift Shaft completely through the Reverse Gear and washers and into the opposite side of the housing Install the Reverse gear with the chamfered teeth fac ing up Photo TR 90 amp 91 HS 5 ey 408 78 Thrust Wasiie Ti ea Chamfered Teeth M TR 90 Y etaining Thrust Washer 5 Install the 34 32 Spring into the machined hole of the 34 102 Right Hand Housing at the Reverse Shift Shaft location Photo TR 92 6 Install the 109 05 Steel Ball to the top of the Spring Photo TR 93 7 Push down on the Steel Ball using the access hole from the top of the Transmission Housing While the ball is compressed press the shaft over top of the ball Photo TR 94 Ontario Drive amp Gear Limited TR 22A www odg com PH 519 662 2840 FAX 519 662 2421 I onldcon Argo Service Manual Transmission IMPORTANT Transmissions Manufactu
19. RB 17525 Oct 24 00 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 25 o GaAWenelesmn Transmission Argo Service Manual Transmission Component Description of Change Transmission Cover Aug 11 2000 The side cover is cast solid in the area of the input shaft and shifter assembly at the 101 01 Hom Seca Natabete bearings This eliminates the need for the 31 07 plug plates amp 106 01 retaining rings normally used here SN11905 TB Oct 4 00 Fully Exchangeable 511906 TB Oct 4 00 3F11917 OB Oct 10 00 B17471 YB Oct 12 00 RB17525 TB Oct 24 00 Reverse Idler 34 16A July 3 2001 Reverse Idler has two 105 03 bushings instead of a single 105 05 bushing along with two radial holes drilled in for better lubrication Fully From vehicles manufac Exchangeable tured from July 3 2001 Shim Washer between Apr 16 2002 To address the issue of the retaining ring Housing and Shifter Assy in some cases popping off of the shift yoke due to interference on the casting Any transmission being serviced and rebuilt between Serial Numbers CB17404 CB19432 RB17525 RB19502 BF11917 BF13347 SN11905 SN13349 or S11906 S13350 would benefit from having this new 108 74 shim washer installed at the time of a rebuild Even though this may not have been an issue it will be a good precautionary measure for the future Ontario Drive amp Gear Limited www odg com e pe TR 26 o PH 5
20. Retaining Ring to each of the components during the assembly of the Avenger transmission is extremely important Small variances in retaining ring sizes can make it difficult at first glance to distinguish these differences This could result with the improper placement of a retaining ring to a component The 107 02 Retaining Ring is installed to one side of the High Gear Pinion on the Input Shaft assembly while the 107 10 Retaining Ring is installed on the other side The one Retaining ring is slightly larger Ensure that each is installed to the correct retaining ring seat according to the instructions outlined on the following pages Caution should also be observed with the 107 04 and 107 12 Retaining Rings The 107 04 smaller is used to secure each sun gear to the end of the Output Shafts within the differential The 107 12 larger is seated just above the Reverse Gear Pinion on the Input Shaft Assembly WHEN COMPARING THESE TWO THEY ARE VERY SIMILAR IN SIZE IF IN DOUBT A MEASUREMENT SHOULD BE TAKEN Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 9A Works Learn Transmission Argo Service Manual Reassembling the Transmission l Lay out all components of the AVENGER Transmission on a clean work surface See Photo below and following page Avenger Housing Assembly Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 10A AIN Argo S
21. Shaft opening Use a soft faced mallet to seat the Input Shaft to the Bearing on the Cover Side Photo TR 197 198 amp 199 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 51 Transmission Argo Service Manual 70 Rotate the Input Shaft to check that 1t turns freely Photo TR 200 71 Place the Input Bearing over the Input Shaft and seat 1t with a soft faced mallet and installation tool Photo TR 201 202 amp 203 TR 204 A transmission may utilize either 1 or 2 shims here When reassembling always install the original quantity 73 Install and seat the Retaining Ring Photo TR 205 amp 206 mn By TR 205 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 52 Argo Service Manual Transmission 74 Install the Oil Seal to the Input Shaft using a soft faced mallet and seal instal lation tool Photo TR 207 208 amp 209 75 Apply 680 Green LOCTTTE to the plug plate sealing edge and tap it into the Housing using a steel hammer Photo TR 210 211 amp 212 NOTE See Transmission Component Changes chart on page TR 26 regarding plug plates and side covers Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 53 Transmission Argo Service Manual 76 Place the transmission on the bench and perform a final shift through all gears 77 Fil with 805 Litres of 80 90 Gear Oil Photo TR 213 78 Install the Dipstick
22. Wri Leann Transmission Argo Service Manual 16 Seat the Gear Plate to the Aluminum Cage using a soft faced mallet Photo TR 97 17 Apply Red 271 LOCTITE to each of the 3 fasteners Photo TR 98 and tighten down Torque to specifications Photo TR 99 amp 100 E TR 100 Le Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 IR 32 Argo Service Manual Transmission 18 Locate the Spline Shaft and assemble the appropriate Drive Gear to the splined end of it Orient the gear with the machined side down Photo TR 101 102 amp 103 NOTE Drive Gears are as follows M Drive Gear H Drive Gear G Drive Gear 19 Place a Double Gear into the assembly stand or an aluminum jawed vise on the work bench Place it into the stand with the machined hole side up Photo TR 104 amp 105 20 Install a Spring to the inner hole of the Double Gear Photo TR 106 amp 107 b RA n E Sla 4 a A 7 Pi T i r Y Es a LL a ta Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 33 Transmission Argo Service Manual 21 Place a Ball Bearing to the top of the spring Photo TR 108 amp 109 22 Compress the Ball Bearing into the hole of the Double Gear with a flat screwdriver at the same time inserting the Spline Shaft from the opposite side with the shift gate notches facing down These notches will mate with the Ball Bearing
23. alling the Brake Disc IMPORTANT A small number of vehicles used a shim washer in behind the brake disc This shim washer will need to be installed to the output shaft before the brake disc is slipped on This is required to align the brake disc to the hydraulic caliper properly Take note of the transmission serial number to correctly identify these vehicles They are as follows All 6 wheel hydraulic brake vehicles with serial numbers between BF11321 amp BF11390 All 8 wheel vehicles with serial numbers between RB16700 amp CB16778 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 55 Transmission Argo Service Manual 7 Perform the servicing procedure Installing the Idler Chain 8 Perform the servicing procedure Installing the Driven Clutch 9 Perform the servicing procedure Installing the Drive Belt 10 Perform the servicing procedure Installing the Firewall Ontario Drive amp Gear Limited www odg com q 2 TR 56 y PH 519 662 2840 FAX 519 662 2421 6x6GWond com Argo Service Manual Transmission Supplement Pages Ontario Drive amp Gear ltd www odg com centaur 519 662 2840 FAX 519 662 2421 a 6x6Wonid comi Argo Service Manual Transmission Transmission Re amp Re 34 100 Series Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 1A Transmission Argo Service Manual Argo Transmission Disa
24. and check oil level Installing the Transmission 1 Locate the dash support and move it 90 degrees so that it will not interfere when installing the transmission back into the vehicle Photo TR 214 2 Place the transmisson back into the power pack frame of the vehicle and install both mounting bolts Apply blue 242 LOCTITE to the threads of the bolts and secure with a lockwasher and nut Torque to specifications Photo TR 215 3 Next install the driven clutch guard Apply blue 242 LOCTITE to the 2 mounting bolts and secure tightly Torque to specifications Photo TR 216 4 Reposition the dash support back down to the top of the transmission and tighten Photo TR 217 Ontario Drive amp Gear Limited TR 54 www odg com PH 519 662 2840 FAX 519 662 2421 O Wonalcom Argo Service Manual Transmission T 5 Ifthe vehicle utilizes the hydraulic brake TR 278 system reattach the entire assembly to a the transmission using the 3 mounting n bolts and lockwashers Torque to speci fications Photo TR 218 NOTE All brake lines and calipers should still be attached to the assembly If not once the hydraulic brake calipers have been remounted to the transmission and the brake lines reconnected the brake fluid system will need to be filled with fresh new fluid and the brake system will have to bled Refer to Bleeding the Hydraulic Brake System in this service guide if necessary 6 Perform the servicing procedure Inst
25. ansmission oil NOTE Be sure to follow any federal or state laws regarding the proper procedure for disposing of oils Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 IR 6 o Argo Service Manual Transmission Refilling the Transmission with Oil 1 Apply a pipe sealant compound or tape to the drain plug and reinstall Do not over tighten 2 Place a clean funnel into the oil fill dipstick hole 3 Fill the gear box with approximately 0 85 litres 1 5 Imperial Pints 1 8 U S Pints of clean fresh 80W 90 Gear Lube Hypoy C or an EP rated 80W 90 gear oil for Ex treme Gear Pressure applications Inspect the level with the dipstick occasionally 4 Perform the servicing procedure Transmission Oil Level Inspection 5 Replace the dipstick If the dipstick is the thread in type apply a little anti seize compound to the threads before installing it back into the transmission General Inspection Of The Transmission Maintenance Schedule Inspect every 50 hours Inspect more often if the vehicle is used under heavy duty applications 1 Lift the engine access cover Problems can occur 1f ARGO component parts are used for heavy duty applications Inspect the transmission for the problems listed below and perform the recom mended servicing procedures 1 Inspect the transmission casting on both housing and cover for e cracks or breakage e transmission leakage through the casing If eithe
26. ar Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 36 Argo Service Manual Transmission a dal TR 121 28 Install a Retaining Ring to the inner groove of the Housing s Output Shaft side Photo TR 123 amp 124 29 Install a Retaining Ring into the Housing at the shifter assemblies bearing side Photo TR 125 amp 126 30 Apply 592 LOCTITE Teflon pipe sealant to the Magnetic Oil Drain Plug and install it into the housing Tighten only snug into Housing Photo TR 127 amp 128 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 37 Transmission Argo Service Manual d i TR 128 N A 31 Tap a burnishing tool through the shifter assembly s Oilite Bushing if the old bushing has been replaced with a new one Photo TR 129 32 Place a Shim Washer on top of the previously installed Retaining Ring in the Hous ing s Output Shaft side Photo TR 130 amp 131 This may vary between 1 or 2 shims Use the quantity previously used 33 Install the Bearing to the top of the shim and seat with the arbor press Photo TR 132 amp 133 34 Install 1 Bearing shielded side down into the Housing s Shifter Assembly side Photo TR 134 amp 135 following Page Ontario Drive amp Gear Limited TR 38 www odg com PH 519 662 2840 FAX 519 662 2421 OM O narco m Argo Service Manual Transmission 35 Install the 34 63 Shifter Yoke to the 34 65 Shifter
27. ard or easy the trans mission shifts when tested Photo TR Set Screw 23 Assemble the 34 116 Shift Fork to the a I Dog Clutch on the Input Shaft Assem Me TR 119 bly Photo TR 120 24 Raise the Reverse Shift Block up into reverse Align the the machined hole of the Hi Lo Shift Block Fork with that of the Hi Lo Shift Shaft and install the complete Input Shaft assembly into the housing Photo TR 121 amp 122 Ontario Drive amp Gear Limited TR 28A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission y A Slip Shift Fork or ov to Shift Shaft Y ay a 3 ge ar i sali TR 121 hift Blocks Alignec eutral Position Vr o TR 123 25 Place the transmission into the neutral position Photo TR 123 26 Secure the Hi Lo Shift Fork to the Shift Shaft using a 104 39 Spring Pin Photo TR 124 27 Install a 106 03 Retaining Ring to the top groove of the 34 101 Left Transmission Housing at the output shaft opening and a 106 05 Retaining ring at the input shaft opening Photo TR 125 28 Place a 114 01 shim to the top of the 106 03 Retaining Ring Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 29A Beg at i ir Y F l e a E pr mera r F ht dF 7 1 ri f LI I fa Y o Li Y i tt E La Ch ni ee 1 d LI L Transmission Argo Service Manual 28 Press a 101 03 amp 101 16 Bearing into the Left Tra
28. eossscecessececeussessensetesaesscesvenssesneossessecns TR 27 Transmission Assembly 34 100 Supplement Pages ssee0 TRIOA Assembling the Differential scssccccsssssssccsssssssssccccsssssscccsscsess TR 27 Assembling the Differential 34 100 Supplement Pages TR 17A Assembling the Shifter ASSEMmDLY sssccsssssssscccccssscsssssssssssssscees TR 33 Assembling the Housing amp Covetn cccccccsssssscccccsssssccccccssssscccceees TR 36 Nc A ii TR 42 Install the Shifter ASSEMDLY ccccsssssssscccssssssssssssccccccssssssssscosees TR 42 l stall the AAA TR 43 Installing the TransmissiOn sssccccccsssssssccccssssssccccccssssscccscsssssees TR 54 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 1 o GA Wenkelesmn Transmission Argo Service Manual General Instructions A WARNING Detailed information on standard workshop and safety procedures and general servicing operations is not included in this manual which has been prepared to assist qualified service personnel ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed including those instructions outlined in this manual Before performing a servicing operation an individual must have determined to his her satisfaction that a personal injury or vehicle damage will not result from the servic
29. ervice Manual Transmission Avenger Internal Components Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 11A aon tore Leann Transmission Argo Service Manual Assembling the Idler Gear Bore Assembly 1 Install the 34 109 High Gear to the short side of the 34 112 Splined Shaft Photo TR 41 IMPORTANT Install the High Gear with the machined shoulder up See Photo TR 41 2 Press the 101 01 Bearing to the High Gear end of the Splined Shaft with the shielded side facing out Photo TR 42 Pd High Gear 3 Install the 34 110 Low Gear to the opposite side of the Splined Shaft long side Photo TR 43 IMPORTANT Install the Low Gear with the machined shoulder up Ontario Drive amp Gear Limited TR 12A www odg com PH 519 662 2840 FAX 519 662 2421 Argo Service Manual Transmission 4 Slip on the 34 111 Reverse Gear up against the previously installed Low gear Photo TR 45 N Teeth Chamferec i j i Y a MY j F d LI a Fi at N IMPORTANT The 34 111 Reverse gear must be assembled to the Splined Shaft with the chamfered teeth side facing up Photo TR 45 5 Install the 34 123 Drive gear to the top of the previously installed Reverse Gear Photo TR 46 1 01 Bi 4 Sealed s 6 Press on the 101 01 bearing to the end of the shaft shielded side up Photo TR 47 See assembled component on the following page IMPORTANT
30. from the input shaft side Photo TR 7 8 Shift to top position High Gear and remove roll pin from the shift block on the high low shift shaft Photos TR 8 amp 9 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 3A Transmission Argo Service Manual 9 Place shift shaft back into neutral Photo TR I0 10 Place reverse shift shaft into reverse Photo TR 11 11 Pull the input shaft from the transmission housing Photo TR 12 12 Remove the spline shaft drive gear assembly Photo TR 13 13 Remove the set screw securing the ball and HS spring within the housing at the hi lo shift shaft assembly Photo TR 14 14 Remove the spring and steel ball Photo TR 15 amp 16 15 Place the reverse shift shaft block back down against the housing out of reverse Photo TR 17 16 Remove the hi lo shift shaft from the hous ing Photo TR 18 Ontario Drive amp Gear Limited TR AA www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission a Li A i n n A a by if i j DI A y i i i t Ll r a j 1 T r j pi J a Y Ji i A F P i J i 19 i s n E 4 la S i i 5 T Spring a Mi poly 4 kl m Hi Lo Shift Shaft T L 17 Using an arbor press remove the smaller ball bearing from the end of the input shaft Photo TR 19 18 Remove the retaining ring at the reverse gear Photo TR 2
31. g at the igniter box which is mounted to the steering assembly Photo TR 04 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 8 Argo Service Manual Transmission 8 Untfasten the twist grip assembly from the steering handle and remove it Photo TR 05 9 Remove the entire hydraulic brake system from the vehicle The calipers master cylinders and brake lines can all remain attached without the loss of any brake fluid Photo TR 06 0 T fi z i ua BoA 9 ala nd i E s h i I F e B E AY Ty 4 ia A ME cl we ha Taa W ST F n de q E a oy oat 4 A dd Ta j i A y de Ca i A k i II f 6 4 i fo a A E e ont a ss 3 sell A ia we a El T i o ne k e E AA 10 Perform the servicing procedure Re moving the Drive Chains in Section WA of this service manual 11 Perform the servicing procedure Re moving the Brake Disc in Section BR of this service manual 12 Locate unfasten and remove the 2 bolts lock washers and nuts that secure the transmission to the power pack frame Photo TR 07 13 Remove the transmission guard from the transmission It 1s secured with 2 bolts and 2 flatwashers Photo TR 08 14 Loosen off the carriage bolt of the dash support and turn it 90 degrees Tilt the transmission back towards the drivers compartment and lift it from the vehicle 15 Place the transmission on a clean workbench for disas
32. he center and slip it on to the threaded adjustment rod of the puller Secure 1t with a nut Photo TR 44 34 Flip the Cover on the assembly jig so that the 101 01 Bearings are facing down Photo TR 45 35 Use a mallet to strike the flat stock and knock the 101 01 Bearing from the casting Photo TR 46 Disassembling the Shifter Assembly 36 The Shifter Assembly consists of the Splined Shaft Drive Gear and Double Gear Photo TR 47 The Double Gear slides along the Splined Shaft and locks into 4 different shift gate positions Re verse Neutral Low amp High Gear Each position is locked by a Ball amp Spring within the Double Gear and gates machined within the Splined Shaft Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 18 Argo Service Manual Transmission 37 Place the Shifter Assembly into the arbor and press the Splined Shaft from the 101 01 Bearing and the Double Gear Photo TR 48 NOTE Be aware of the Ball amp Spring within the Double Gear when pressing the spline shaft from the assembly 38 Turn the Splined Shaft to the other end to remove the 101 01 Bearing and Drive Gear Photo TR 49 Disassembling the Differential 40 Secure the Differential by the Output shaft on the cage side within a vise A vise equipped with aluminum jaws must be used to avoid any damage to the out put shaft Photo TR 51 NOTE When removing the 3 fasteners that secure the differentia
33. he recommended oil could cause serious damage to the transmission components The approximate refill capacity of the ARGO transmission is 0 85 Liters 1 5 imperial pints 1 8 U S pints However be sure that it is filled to the full mark on the dipstick DO NOT OVERFILL Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 3 o GA Wenkelesmn Transmission Argo Service Manual Oil Level Inspection Inspect the transmission oil on a daily basis A CAUTION Do not run the ARGO if the oil level in the transmission shows above or below the mark on the dipstick Damage to transmission components could occur 1 Place the vehicle on a level surface This will allow the correct measurement of gear lube in the transmission 2 Remove the engine access cover and locate the transmission dipstick Photo to right 3 Clean the transmission around the dip stick location to prevent any dirt from entering the gearbox and causing pre mature wear to the internal components 4 Remove the dipstick and wipe it clean of oil Return the dipstick to the transmission and remove it once again NOTE Depending on the age of the vehicle the dipstick may require a 3 8 opened end wrench to unthread the dipstick from the transmission housing This could be the case for models built prior to mid 1994 To check the oil level correctly with this style dipstick unthread it and wipe it clean Re thread it back into
34. ing procedure or tools selected A CAUTION All transmission work should be performed by a qualified mechanic Severe damage and or reduced performance can result from an improperly serviced transmission A CAUTION Do not attempt to move the gearshift from the neutral starting position until the engine idles down completely The Argo is equipped with an automatic clutch that is activated by engine speed If the engine idle speed is too high the transmission will grind during gear engagement Ontario Drive amp Gear Limited www odg com ps e TR 2 PH 519 662 2840 FAX 519 662 2421 6x6GWond com Argo Service Manual Transmission Transmission Oil Maintenance Schedule The transmission oil should be changed after the initial 25 hours of vehicle operation After this it should be changed every 150 operating hours 44 CAUTION Proper transmission lubrication will reduce wear and extend gearbox life Please use the type and quantity of transmission oil specified below A CAUTION Inspecting the condition and level of oil in the transmission must be done on a regular basis Do not operate the ARGO if the transmission oil level on the dipstick is above or below the grooved indicator Damage to the transmission or a reduction in vehicle performance could occur Recommended Oil Type Oil Type 80W90 Gear Oil HYPOY C or an EP Rated 80W90 Gear Oil for Extreme Pressure Gear applications Using any other than t
35. ission Assembly Transmission Component Changes Since 1992 This chart indicates changes to some of the transmission components since 1992 Most if not all are fully exchangeable 1f your original part is no longer available When or dering replacement parts begin by referring to the correct parts manual for your year and model of ARGO If the component is no longer listed in your Spare Parts Price List Distributors amp Dealers Only check the Superceded Section for the correct part s that replace s the original Shaft Splined amp Apr 29 1992 Keys are eliminated on the spline shaft ear Helical Helical gears and splined shafts are coupled by an Affects earlier Vanguards extended 6PL spline Fully Exchangeable 34 81 Output Shaft Jul 07 1999 The output shaft and brake discs are 610 24H Brake Disc now splined eliminating the need for the 110 14 810 01 Brake Disc keys Older stock 1s still available From Serial Numbers Fully Exchangeable but both shaft and disc need to CB16459 TB Oct 27 99 be replaced together Refer to the appropriate illus RB16446TB Oct 26 99 trated parts manual for the new part numbers BF11143 TB Oct 21 99 S11188 TB Nov 17 99 SN11196 TB Nov 17 99 Shift Gate New Jun 12 2000 Reason for Change To limit the possi bility of the transmission coming out of gear in certain situations From Serial Numbers SN 11905 TB Oct 4 00 511906 TB Oct 4 00 3F11917 TB Oct 10 00 B17471 YB Oct 12 00
36. l s Gear Plate and Aluminum cage together earlier transmissions may also have a lockwasher installed If this is the case when reassembling the differential eliminate the lockwashers and use Red 271 LOCTITE on both the threads of the fastener as well as on the internal threads of the aluminum cage Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 19 Transmission Argo Service Manual 41 Hold the Output Shaft from turning while removing the 3 Fasteners that hold the Gear Plate and Aluminum Cage together Photo TR 52 42 With the Fasteners removed gently tap the Gear Plate from the Aluminum Cage using a soft faced mallet Photo TR 53 w Tm ii hy ihe DA is Sl A CAUTION When lifting the Gear Plate from the Cage be aware of any Pinions that may come with the Gear Plate Avoid any of these falling to the floor Any damage to these pinions can result in reduction of gear life or noise issues 43 Remove each of the 6 Pinions Photo TR 54 44 Remove the Retaining Ring that secures the Sun Gear to the Output Shaft on the Aluminum Cage side Photo TR 55 45 Slip the Sun Gear from the Output Shaft Photo TR 56 46 Remove the Retaining Ring that secures the second Sun Gear to the Output Shaft on the Gear Plate side Photo TR 57 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 20 SANELEE ordo KAROTO Kaaf Argo Service Manual Transmissi
37. n Argo Service Manual 28 Remove the 3 steel balls located in the housing between the hi lo shift shaft and the reverse shift shaft Photo TR 34 29 To remove the reverse shift shaft and reverse idler gear from the housing first re move the retaining ring located above the reverse idler Photo TR 35 30 Raise the reverse idler up and remove the retaining ring found below Photo TR 36 Pull Reverse Shift Shaft Up Until Reversong a Idler is Freed lt gt y Did i i x i rn 1S See 1 ipe 5 m n 4 ae F SOA gt i 7a E pmo e Coal i sf n i i APT A TR 37 Remove Reverse Idler Gear 31 Pull the reverse shift shaft up and free from the housing Photo TR 37 32 Remove the Steel Dowel Pin from the reverse shift shaft IMPORTANT There is 1 Thrust Washer to the top side of the reverse idler gear and a Retaining Thrust Washer to the underside of the reverse idler gear 33 Remove the reverse shift shaft from the housing Photo TR 38 34 Remove the last ball and spring from the housing Photo TR 39 Ontario Drive amp Gear Limited TR 8A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission 35 Remove all remaining Retaining Rings Bearings and Seals from both the left and righthand side housings 36 Wash and soak all components in a degreasing bath before inspection Reassembling the Transmission IMPORTANT Installing the correct
38. ner of the two washers fit on the Cover Side and rare cases when the Output Shafts receive no Shim Washers at all Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 49 Transmission Argo Service Manual d im Washer e F TR 190 Rotate the transmission to access the Input Shaft side of the transmission Photo TR 192 66 Seat the Reverse Idler Pin s Retaining Ring to the pin boss located in the transmis sion Housing Through the Input Shaft opening use a hammer and pin installer to tap the Reverse Idler Pin through the boss and out the Transmission Cover side Seat the Retaining Ring to the boss Photo TR 193 amp 194 AUTION A CAUTIO Do not over drive the Idler Pin Retaining Ring against the boss Damage and deformation to the retaining ring could result in the possibility of it coming off during application 7 65 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 50 Argo Service Manual Transmission 67 Rotate the Transmission and secure the opposite end of the Reverse Idler Pin with a 2 Retaining Ring Photo TR 195 68 Once the Retaining Ring has been secured to the Cover Side use a hammer and tap the pin back in the opposite direction to seat the Retaining Ring to the Cover Photo TR 196 i IS T Li i TR 197 69 Wipe off the Input Shaft with a lint free rag to remove any oil and debris and insert 1t into the Input
39. nsmission Housing Photo TR 126 29 Apply Black 598 LOCTITE RTV Silicon Gasket Maker around the perimeter of the Transmission Housing 30 Press the Left Hand Housing to the Right Hand Housing at the arbor press Tap with a soft face mallet while pressing at the output shaft area This will ensure that the housing is pressed on squarely and evenly to the lower half Photo TR 127 y a i 2 TR 126 31 Secure the halves of the transmission together using 10 112 143 1 112 144 fas teners amp 11 108 05 lockwashers installed from the left side of the Housing Three 3 112 143 1 112 144 fasteners and 4 108 05 lockwashers are installed from the right side of the Housing Photo TR 128 Torque to 20FT LBS NOTE Two of these fasteners are shorter and are assembled into the transmission casting at blind holes One is assembled at the drain plug area from the left side of the housing Photo TR 129 and the other at the Shifter Lever area from the right side of the housing Photo TR 130 TR 128 Ontario Drive amp Gear Limited TR 30A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission 1TR 131 a 3 ES Apply a Little Motor Oil to RR SR o Ease Installation 35 Install the 102 05 Oil Seal to the Input Shaft Photo TR 131 amp 132 36 Install the 102 03 Oil Seal to the Output Shaft Seat below the Retaining Ring groove Photo TR 133 amp 134 37 Seat a 106 0
40. o the maintenance schedule in section GI for time change intervals 1 Drive the vehicle until the transmission is warmed up thoroughly 2 Park the vehicle on a level surface Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 5 Transmission Argo Service Manual 3 Perform the servicing procedure Removing the Firewall in Section VB of this service manual 4 Perform the servicing procedure Removing the Front Floor Pan in Section VB of this service manual 5 Remove the hood 6 Clean the transmission around the dipstick location This will keep dirt from enter ing the gearbox 7 Remove the dipstick Vehicles manufactured prior to mid 1994 will require the dipstick to be threaded from the gearbox using a 3 8 opened end wrench Dipsticks on newer models utilize an O ring and need only be pulled straight up and out from the transmission however the gearshift lever may need to be shifted into low or high gear to allow the dipstick to be removed 8 Forma piece of sheet metal to place beneath the drain plug to route the oil from the transmission to a plastic bag on the front floor Photo TR 02 9 Remove the drain plug and clean off any metal filings from the magnet NOTE To remove the drain plug easily and effectively a 7 16 Point Socket must be used An opened end style wrench or vise grip wrench is not recommended as they will damage the plug 10 Dispose of the used tr
41. on 47 Slip the Sun Gear from the Output Shaft Photo TR 58 48 Press the Output Shafts from both Cage and Gear Plate Photo TR 59 amp 60 49 Remove each of the 101 15 Bearings from both Cage and Gear Plate Slip the bearing remover tool into each of the aforementioned components and tap with your hand or soft faced mal let Photo TR 61 amp 62 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 21 Transmission Argo Service Manual 50 Remove all 12 Oilite Bushings from both Cage and Gear Plate using a bushing removal tool This procedure will also push out the Output Shaft Bearing that has more than likely remained assembled to both of these components Photo TR 63 64 amp 65 51 Remove the Bearing from the Input Shaft Place the Input Shaft into an aluminum jawed vise lightly clamping 1t to the High Gear The vise need only make contact with the gear Being the Bearing is slightly larger in diameter than the High Gear the vise jaws will hold the bearing up while gently tapping the Input Shaft down with a soft faced mallet Photo TR 66 Ontario Drive amp Gear Limited www odg com 662 660 TR 22 PH 519 662 2840 FAX 519 662 2421 aaa MerkiLeam Argo Service Manual Transmission 52 Wash all parts in a clean varsol bath and dry all parts with compressed air or a lint free rag Lay out all parts for inspection Photo TR 67 A WARNING Always exercise ex
42. r of these conditions are noted replace either or both immediately 2 Inspect the outside of the transmission for e fluid leakage around seals e fluid leakage around bolt holes e loose bolts If any of these conditions are noted replace the gasket or seals immediately and tighten all cover bolts to torque specifications Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 7 Transmission Argo Service Manual Removing the Transmission 1 Disconnect all wiring to the battery before proceeding with the following component removal 2 Perform the servicing procedure Removing the Firewall Quick Release for Response Bigfoot and Conquest in Section VB of this manual Or Removing the Firewall for Vanguard models prior to May 19 1999 Or Removing the Firewall Quick Release for Vanguard models manufactured after May 19 1999 3 Perform the servicing procedure Removing the Front Floor Pan in the Vehicle Body Section of this service manual 4 Perform the servicing procedure Removing the Driven Clutch in the Clutch Section of this manual 5 Perform the servicing procedure Removing the Brake Pads Hydraulic steps 1 5 or Removing the Mechanical Brake Calipers in the Brake System Section of this manual 6 Locate the 3 mounting bolts that secure the hydraulic brake caliper system to the transmission and remove them Photo TR 03 7 On Conquest models disconnect the wirin
43. red From Serial Number A3784 require a 113 16 O Ring installed to the machined groove located near the end of the reverse shift shaft and require these extra steps to install it 1 Continue to push the reverse shift shaft through the housing until the machined groove for the O ring location is visible to the outside of the housing Photo TR94A i Install the 113 16 O ring to the groove and apply some oil lubrication Photo TR94B TR 94A Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 23A Pur RSI dali LI LI Pe af a Zi Up n i be ns pala lordoah aca all oca GINI ARAN ATA AL a Transmission Argo Service Manual it Push the reverse shift shaft back through the housing ensuring that you don t damage the O ring as re enters the housing 8 Pull the Reverse Shift Shaft up until the lower retaining ring groove location is visible shaftis Photo TR 95 9 Install the 107 11 Retaining Ring onto the Reverse Shift Shaft Photo TR 96 amp 97 10 Lower the Reverse Idler Gear and install the second 107 11 Retaining Ring to the machined groove at the top of the Reverse Idler Gear Photo TR 98 amp 99 11 Insert a tool eg an allen wrench into the machined hole of the Reverse Shift Shaft and turn the shaft until the keyways of both shaft and transmission boss are aligned Photo TR 100 Ontario Drive amp Gear Limited TR 24A www odg com PH 519 662 2840 FAX 519 662
44. red to the single one used in the Housing NOTE There are no Shims used behind the inner Bearing of the Cover Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 16 Argo Service Manual Transmission IMPORTANT Transmissions manufactured from Oct of 2000 have had a design change to the Side Cover This new Side Cover begins on vehicles manufactured from serial numbers SN11905 TB Oct 4 00 S11906 TB Oct 4 00 BF11917 OB Oct 10 00 CB17471 YB Oct 12 00 RB17525 TB Oct 24 00 This Side Cover no longer requires the 31 07 plug or the 106 01 Retaining Ring The Side Cover has been cast and machined in this area to eliminate the need for both of these parts The cover will replace all earlier side covers Photo TR 40 The procedure for removing the 101 01 Bearings will require the use of an internal style of puller as described below 30 31 32 Place the Side Cover into the assembly fixture with the Bearings facing up Photo TR 41 Adjust the internal bearing puller to the closed position Photo TR 42 Insert the bearing puller into the inner race of the 101 01 bearing and tighten the adjustment nut until the puller has spread enough to secure the bearing from the inside Photo TR 43 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 17 Wondlcom Transmission Argo Service Manual 33 Take a piece of flat stock with a hole drilled to t
45. sembled Idler Gear Bore Assembly See IMPORTANT on page TR 13 17 Press the assembled differential into the Housing Photo TR 109 amp 110 18 Install the Idler Gear Bore Assembly at the arbor press Photo TR 111 amp 112 Ontario Drive amp Gear Limited TR 26A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission 19 Next push the Reverse Shift Shaft and Block down against the Housing boss out of reverse Install 3 109 05 Steel Balls into the Hi Low Shift Shaft cavity of the Housing and push each one into the machined hole at the Reverse Shift Shaft These 3 Steel balls will be lo cated between the Reverse Shift Shaft and Hi Low Shift Shaft Photo TR 113 amp 114 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 27A 43 041 Transmission Argo Service Manual 20 Install the 34 113 Hi Low Shift Shaft into the Housing with the 3 machined gates facing to the outside of the housing and the machined gate facing the Reverse Shift Shaft Photo TR 115 n A o i x Sa n y oN i gt Y d i la j d r a a LI P s v ld dl 9 i O a Ca ie vy a y e E hg d li ISS r al E La i s i gt E 7 Pa ere a le RA nn tg 1 SER TR 117 22 Apply Blue LOCTITE to the threads of the 112 145 Set Screw and tighten into the Housing approximately 2 1 2 turns This may need to be adjusted later de pending on how h
46. sembly Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 9 Transmission Argo Service Manual Disassembling the Transmission 1 Remove the Drain Plug amp drain the oil from the transmission Photo TR 09 2 Remove the Dipstick 3 Remove the Retaining Ring that secures the Reverse Idler Dowel Pin on the outside of the Cover Photo TR 10 4 Tap the Dowel pin back into the transmission far enough to free it from the Side Cover You will need a drift punch to tap it below the surface of the cover TR I 5 Remove all side cover fasteners Photo TR 12 6 Position the transmission to remove the Retaining Ring on the Output Shaft of the Housing side Photo TR 13 7 Remove the Shim from the Output Shaft Photo TR 14 Ontario Drive amp Gear Limited TR 10 www odg com PH 519 662 2840 FAX 519 662 2421 Ae SV 519 519 XOVV Onc cor Argo Service Manual Transmission A CAUTION All retaining rings spacers amp seals need to be replaced during a transmission rebuild It is usually recommended to replace all bearings as well Bearings should only be reused if the technician has determined to his her own satisfaction that they are Okay to reuse Separating the Side Cover on Transmissions Manufactured Prior to Serial Numbers a 25631GU Da 25668HU E 25700MU 8 With a dead blow mallet alternate between striking the Input Shaft and Output Shaft until the Cover begins
47. ssembly 1 Drain oil and unthread the 4 fasteners securing the shifter lever assembly to top end of the transmission and remove the lever Photo TR I amp 2 2 Remove all fasteners securing the housing halves together There are 11 located on the input shaft side and 4 located on the opposite side Ensure that all fasteners have been removed before proceeding to seperate the transmission housings 3 Remove the oil seal from the input shaft Photo TR 3 4 Remove the retaining ring from the input shaft Photo TR 4 5 Remove the retaining rings from both output shafts There may or may not be shims below the retaining rings Photo TR 5 Separating the Transmission 6 There are 3 threaded tab locations provided on the Avenger transmission housing input shaft side These locations are used to assist in separating the two halves of the transmission during disassembly As 3 bolts are threaded into the housing they come into contact with the opposite housing pushing and separating the 2 halves Ontario Drive amp Gear Limited TR 2A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission Thread each of these bolts a little at a time and in an uniform alternating pattern DO NOT overtighten to avoid the risk of breaking the housing tab Stop occasionally to tap the output shaft with a soft faced hammer Repeat this until the cover has separated Photo TR 6 7 Pull the housing halve up and off
48. th the bearing in the Housing At the same time be sure to slip the Shift Yoke over the larger di ameter gear of the Double Gear Photo TR 154 47 Tap the assembly with a soft faced ham mer until the shoulder of the Spline Shaft seats to the Bearing Photo TR 155 amp 156 Install the Reverse Idler 48 Press 2 Oilite Bushings into the Re verse Idler Press one in from each end Photo TR 157 amp 158 Models manufactured prior to July 3 2001 have a single oilite bushing and no radial holes drilled in the reverse gear Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 43 Transmission Argo Service Manual ACTA TR 158 49 If the old bushing s was were replaced with new press a burnishing tool through the Oilite Bushing of the Reverse Idler Photo TR 159 amp 160 50 Slip the Reverse Idler on to the Dowel Pin making sure that the chamfer side is facing down Photo TR 161 162 amp 163 0 3 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 IR 44 a Argo Service Manual Transmission 51 While one hand holds the top of the Shifter Assembly Use the other to shift the Lever through all gates Check that all shift smoothly Photo TR 164 52 Spin the entire assembly at the Output Shaft to check for any tight spots or unusual noises Photo TR 165 53 Apply Black 598 LOCTITE RTV Silicon Gasket Maker to the bottom half of
49. the shielded side up Photo TR 57 x e Y Retaining Ring le gt ILE TR 56 Ontario Drive amp Gear Limited TR 16A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission Assembling the Differential 1 Install all 105 03 Oilite Bushings into both 34 122 cage and 34 124 Gear Plate Photo TR 58 amp 59 2 Blow all foreign debris from the Cage and Gear Plate 5 Install the 101 15 Bearing into both Cage and Gear plate Photo TR 60 amp 61 6 Wipe the 34 98 Output Shaft free of debris with a lint free rag Install this Output Shaft into the Aluminum Cage Photo TR 62 63 See Note following page Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 17A Transmission Argo Service Manual NOTE Use a specialized spacing tool to secure the previously installed 101 15 Bearing inside the Aluminum Cage while the Output Shaft is press into place Photo TR 64 7 Orient the 34 14 Sun Gear as in Photo TR 65 with the higher shoulder side fac ing up Install 1t to the splined end of the Output Shaft Photo TR 66 amp 67 8 Secure the Sun Gear with a 107 04 Snap Ring Photo TR 68 9 Be sure the Retaining Ring is properly seated to the machined groove of the Output Shaft Photo TR 69 Press the Output Shaft from the inside of the cage to seat the Retaining Ring snuggly against the Sun Gear Photo TR 70 Ontario Drive
50. to TR 144 amp 145 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 33A Transmission Argo Service Manual 46 Install the CE 035 Dipstick Photo TR 146 47 Fill the transmission with 1 1 L 38 7 oz of 80 W 90 Gear Lube HYPOY C Ontario Drive amp Gear Limited TR 34A www odg com PH 519 662 2840 FAX 519 662 2421 I Argo Service Manual Transmission 1 Transmissions built from A5883 Locate the 34 130 Input Shaft and install the first half of the 107 14 Retaining Ring to the machined groove at the High Gear Pinion location Photo I amp 2 2 Interlock the second half of the 107 14 Retaining Ring into the previously installed one Photo 3 At the opposite side squeeze the retaining ring assembly together to lock and seat securely into the machined groove Photo 4 amp 5 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 35A Transmission Argo Service Manual 4 Locate the 108 85 Retaining Thrust Washer and slip it over the input shaft cupped side towards retaining ring and up against the retaining ring assembly Photo 6 amp 7 5 Install the High Gear Pinion on to the Input Shaft dog teeth facing towards the Thrust Washer Rest it against the Thrust Washer Photo 8 Ontario Drive amp Gear Limited TR 36A www odg com PH 519 662 2840 FAX 519 662 2421 I ne Argo Service Man
51. to separate from the Housing Continue until the Cover is completely free of the Housing In most cases the differential will remain with the Cover Photo TR 15 amp 16 Ontario Drive amp Gear Limited PH 519 662 2840 FAX 519 662 2421 TR 11 Transmission Argo Service Manual Separating the Side Cover on Transmissions Manufactured From Serial Numbers 25631GU 25668HU 25700MU These Side Covers utilize a threaded boss in 2 locations Photo TR 17 O HH E 10 Remove the Retaining Ring and Shim on the Output Shaft side of the Cover Photo TR 18 and ensure that the reverse idler dowel pin has been freed of the cover as in step 3 amp 4 11 Thread 2 5 16 x18 bolts into the threaded boss at both locations on the Side Cover As the bolts come in to contact with the Housing below the Cover is pulled from the Output Shaft Thread the bolts a little at time alternating between the two This will ensure that it does not bind during separation Photo TR 19 NOTE Make sure that the bolts threaded into the Cover are long enough to guarantee that the Cover will completely separate itself from the Housing and may be easily lifted off by hand In most cases with this type of separation the differential will remain within the Housing Photo TR 20 Remove the differential from the Housing as described in step Ontario Drive amp Gear Limited TR 12 www odg com PH 519 662 2840 FAX 519 662 2421 BN Lean Argo Service
52. treme caution when using compressed air Compressed air can be potentially dangerous causing serious injury or even death if misused Transmission Component Inspection Mechanical transmissions do not need a great deal of maintenance beyond periodic and regular oil changes However once a problem has been detected and the transmission has been disassembled it is important to examine all transmission components for wear cracks or breakage Repairing or replacing all faulty components will prevent further premature breakdowns and the need to disassemble the transmission again in the near future Inspect all transmission components and look for Broken or badly worn teeth Worn out or seized up bearings Badly worn spline shafts Cracks in the transmission housing or cover Gear Wear Lack of lubrication wrong type of lubrication or transmission overheating may cause excessive wear or damage to transmission gears When inspecting gears follow these guidelines Normal Wear As gears operate the meshing operation and oil wash will polish the gear teeth removing any sharp edges imperfections or shards The polished surface should cover the entire length and depth of the teeth Well lubricated gears will show this condition after many Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 23 Transmission Argo Service Manual hours of operation The initial 25 hrs of operation on a new transmission
53. ual Transmission 6 Slip a 108 79 Thrust Washer to the other side of the High Gear Pinion and secure with a 107 02 Retaining Ring Photos 9 10 amp 11 Thrust Washer Installed Retaininc Ae g Retaining Ring Seated to Groove 6 Slip the Dog Clutch to the Input Shaft Photo 12 IMPORTANT The Dog Clutch needs to be oriented correctly when assembled to the Input Shaft The dogs on one side of the clutch have a small machined shoulder These dogs will engage with the Low Gear Pinion so they face away from the previously installed High Gear Pinion Photo 12 7 Install the Low Gear Pinion with the dogs facing towards the previously installed Dog Clutch Photo 13 8 Slip the Reverse Gear Pinion on to the Input Shaft and up against the Low Gear Pinion Orient the Reverse Gear Pinion with the chamfered teeth facing up Photo 14 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 37A Transmission Argo Service Manual Chamfered Te Reverse Gear Pinion ASE i Completed Input Shaft Assembly Ontario Drive amp Gear Limited TR 38A www odg com PH 519 662 2840 FAX 519 662 2421 I
54. within the Double Gear when the shifter assembly is completed Photo TR 110 111 amp 112 following page Ontario Drive amp Gear Limited TR 34 www odg com PH 519 662 2840 FAX 519 662 2421 aq Won Lean Argo Service Manual Transmission Shift Gates ane 23 Use a soft face mallet to tap the Spline Shaft completely through the Double Gear Photo TR 113 amp 114 24 Remove the assembly to the bench Grabbing the Double Gear in your hands shift the Double Gear up and down the length of the Spline to check that all shift gates are smooth and lock securely Photo TR 115 I TR 115 Ontario Drive amp Gear Limited www odg com PH 519 662 2840 FAX 519 662 2421 TR 35 Transmission Argo Service Manual Assembling the Housing and Cover 25 Install a Retaining Ring into the inner groove on the Output Shaft side of the Trans mission Cover Photo TR 116 amp 117 26 Install the Bearing into the Side Cover with the arbor press Seat it to the previously installed Retaining Ring Photo TR 118 amp 119 27 Apply yellow LOCTITE 641 to the outer edge of 2 Bearings and press them into the Side Cover Be sure the shielded side is facing down Photo TR 120 121 amp 122 IMPORTANT Vehicles Manufactured prior to S N CB17471 RB17525 BF11917 SN11905 amp S11906 require 2 retainings rings to be installed to the cover first before the bearings are pressed into place Ontario Drive amp Ge
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