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1. VATURNER POWERTRAIN SYSTEMS COMPACT PLUS SERVICE MANUAL WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE BOLTON LANCS BL4 OLS TEL 44 0 1204 854650 FAX 44 0 1204 854663 service winget co uk parts winget co uk www winget co uk INTRODUCTION The contents of this manual although correct at the time of publication may be subject to alteration by the manufacturers without notice and Winget Limited can accept no responsibility for any errors or omissions contained within the following pages Nor can Winget Limited accept any liability whatsoever arising from the use of this manual howsoever caused Winget Limited acknowledge that that the design and production of the following manual is the copyright of D Double U Design and Turner Powertrain Systems Ltd For authorised use only D Double U Design Star Works Frederick Street Wolverhampton WV2 4DU Tel 01902 450022 Fax 01902 450020 E mail info ddoubleu com Web www ddoubleu com Technical Service Department Turner Powertrain Systems Ltd Racecourse Road Wolverhampton West Midlands WV6 OQT England Tel 01902 833000 Fax 01902 831850 TURNER POWERTRAIN SYSTEMS Compact Plus Transmission Service and Repair Manual CONTENTS Introduction Tordue Converter Installation Guide Gear Ratios Lubrication Explanation of Hydraulic circuits Service Tools Technical Data Exploded Illustrations Stri2. 5 Remove the 4 wheel drive gear remove the sealing ring 6 3 Using the appropriate bearing puller remove 6 6 Remove the two needle bearings and the rear bearing Tool No KM3516 Spacer HYDRAULIC DOG CLUTCH 4 WHEEL DRIVE DISASSEMBLY 6 7 Invert the shaft and using the appropriate 6 10 Remove the piston drum assembly bearing puller remove the front bearing Tool No KM3516 6 8 Using the appropriate tool compress the 6 11 Remove the piston seal and O ring from the spring and release the circlip shaft and discard Tool No KM3523 6 9 Remove the circlip retainer and spring 6 12 Remove and discard the piston seal and O ring from the piston drum RE ASSEMBLY 6 13 Fita new O ring and sealing ring to the 6 16 Replace the piston spring and retainer shaft 6 14 Fit a new O ring and sealing ring into the 6 17 Using the appropriate tool compress the piston Bend the sealing ring into a heart spring and retainer and refit the circlip shape as shown to assist assembly Tool No KM3523 6 15 Lubricate the seals with a light grease and 6 18 Using an appropriately sized tube refit the refit the piston to the shaft front bearing RE ASSEMBLY 6 19 Invert the shaft and refit the two needle 6 22 Using an appropriately sized tube replace bearings and spacer as shown the rear bearing 6 20 Replace the 4 wheel drive gear 6 23 Fit a new sealing ring To avoid damage the sealing ring should be left off until a
3. Check that the outer bolt circle of the drive plate is concentric to the converter pilot dia within 015 T I R Then torque the bolts to the manufacturers specification 3 Apply an anti seize compound to the pilot dia of the converter 4 Ensure that the converter drive tangs are correctly aligned with the transmission pump tangs then assemble the torque converter and drive plate assembly onto the transmission Take care not to damage the pump oil seal or support bush Rotate the converter assembly to check that it is correctly engaged in the pump 5 Assemble the transmission and converter assy onto the engine and tighten the bell housing bolts Loosely fit the drive plate to flywheel bolts and rotate the converter several times to seat it then torque the bolts to the manufacturers specification Note If this procedure cannot be followed due to the absence of an access hole in the flywheel housing then the converter and drive plate assembly will have to be fitted to the engine first This method however is not recommended as the possibility of damaging the transmission pump or oil seal is greatly increased If this method must be used then the following check should be made With the converter fitted to engine attach a dial indicator to the flywheel housing and check that the run out of the converter drive hub does not exceed 008 1 1 8 COMPACT TRANSMISSION GEAR RATIOS 1 TESE 1 COM 4 2029 5 635 3 50
4. hydraulic fault Gear shift stub lever worn or damaged Incorrect grade of oil in transmission Low oil level Jumping out of Gear Detent springs worn or broken Synchroniser or gear dog teeth worn or damaged Synchroniser assemblies worn or damaged Shift forks worn loose or twisted Restriction or wear in gear linkage or stub lever assy not allowing gears to be fully selected Excess end float on output shaft assembly or gears
5. sleeve 120 Bearing spacer 121 124 Shim 125 Cold start spring housing 126 Co axial drive shaft 127 Capscrew 128 Pressure regulator valve 129 4wd solenoid valve 130 Directional control valve 131 Oil filter 132 Oil filter adapter 134 Dowel 135 Oil seal 136 Sealing cap 137 Suction strainer 138 Ring suction strainer 139 Support washer 140 Strainer cover plate 141 Setscrew 142 Breather 143 0 Ring 146 O Ring 149 Expansion plug 150 Brake calliper nut 151 Pump mounting stud 152 Oil filter housing 153 Filter housing gasket 154 Bolt 155 0 Ring 156 Cold start spring 157 Ball 158 Setscrew 160 Setscrew 161 Copper washer 162 Banjo bolt 163 Remote test port assembly 164 Remote test port pipe 165 Remote test port pipe Pump mounting stud nut 4wd gear bearing Spacer 4wd gear bearings COMPACT PLUS WITH CO AXIAL PUMP DRIVE AND HYDRAULIC DOG CLUTCH 4WD KEY TO HYDRAULIC MULTI PLATE CLUTCH 4WD COMPONENTS O Ring Piston return spring Piston seal outer Piston Clutch plate friction Clutch plate Shaft and drum assembly 4wd Gear assembly Thrust washer Sealing ring Spacer Shim Bearing Spring retainer End yoke assembly End yoke spacer End yoke washer Screw O Ring Clutch pack retaining ring Circlip Clutch pack retaining ring Oil seal Thrust washer Thrust bearing Be
6. tighten to a torque of 17 to 22 Ib ft 12 29 Refit the cold start ball spring and 12 32 Refit the temperature sender and tighten housing Then tighten to a torque of to a torque of 15 to 20 Ib ft 34 to 44 5 TRANSMISSION RE ASSEMBLY CONTD 12 33 Ensure the 4 O rings are in place then re fit 12 36 Refit the 4th gear lock out screw when the control valve assembly tighten the 4 cap this feature is not reguired a shorter screws to a torque of 5 0 to 6 3 Ib ft Re fit blanking screw is fitted On some the 4 plastic caps to the capscrew holes applications an additional sealing plug Note The valve can only be fitted one way may be fitted round as it is located by a small dowel pin 12 34 Refit the strainer spacer O ring and 12 37 Apply a bead of RTV joint compound cover plate Then tighten the two screws to Loctite 5900 to the gear case as shown a torque of 13 to 23 Ib ft 12 35 Refit the drain plug and O ring assembly 12 38 Refit the gear lever assembly and tighten Tighten to a torque of 25 to 40 Ib ft the three bolts to a torque of 12 to 18 Ib ft TRANSMISSION RE ASSEMBLY CONTD 12 39 Refit the filter housing and gasket Tighten 12 42 Refit the 4 wheel drive solenoid coil and the two bolts to a torque of 33 to 47 Ib ft nut Tighten to a torque of 4 Ib ft maximum Not fitted on 2 wheel drive model Note Do not use sealant on this gasket as it is graphite coated 12 40 Lubricate the seal with a
7. 1 1 533 0 762 2 Note Due to legal requirements certain applications have 4th gear blanked off in order to limit the maximum speed of the vehicle Shift Pattern at Gear Stub Lever Front of Transmission 1 3 TRANSMISSION LUBRICATION To ensure proper lubrication and operating temperatures it is most important that appropriate lubricants are used and that the correct oil level is maintained Oil Level Checking The oil level should be checked daily and corrected if necessary The oil level must be checked with the engine idling and with the transmission oil cold In this condition the oil level should fall between the Max and Min marks on the dipstick At normal operating temperature 80 Deg C the oil level will rise to 20 30 mm above the Max mark on the dipstick Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the churning action of the gears Early breakdown of the oil will result in heavy sludge deposits that block oil ports and build up on splines and bearings Overfilling may also cause oil leaks Oil Changes An initial oil change and flush is recommended after the transmission is placed in actual ser vice This change should be made at any time following 50 hours in service but should not exceed 100 hours An oil change and flush should be scheduled for every subsequent 750 hours of operation When changing the oil it is essential to renew the o
8. 2 wheel drive model 1 9 Remove 17 screws and using a suitable 1 12 Remove the reverse idler shaft assembly hoist take off the rear transmission case Lever slots are provided to assist removal Note The bearing cones and shims may fall from the rear case during removal TRANSMISSION DISASSEMBLY 1 13 Remove the outer detent plug spring 1 16 Remove the 3rd 4th shift fork screw and ball Safety Note before attempting to remove the 3 4th shift rail replace the detent plug as the ball and spring may shoot out and cause injury 1 14 Ensure both synchronisers are in the 1 17 Turn the 3rd 4th shift rod through 90 neutral position then remove the 1st 2nd degrees and withdraw from the housing shift fork screw 1 15 Withdraw the 1st 2nd shift rod from the 1 18 Remove the detent plug inner detent ball housing Then using a magnetic probe and spring remove the interlock ball from the detent bore TRANSMISSION DISASSEMBLY 1 19 Remove the counter shaft assembly 1 22 Remove the 41 gear lock out screw If fitted 1 20 Remove the 1st 2nd and 3rd 4th 1 23 Remove 2 screws and withdraw the strainer shift forks cover O ring spacer and strainer 1 21 Remove the output shaft assembly 1 24 Using a strap wrench remove and discard the oil filter TRANSMISSION DISASSEMBLY 1 25 Remove 2 bolts and take of the oil filter 1 26 Remove and discard the expansion plug housing and gasket from the s
9. N HYDRAULIC CIRCUITS The Clutch Circuit Oil from the transmission sump is drawn up through the suction strainer by the pump It is forced under pressure from the pump through the full flow oil filter into the clutch circuit To protect the filter during cold start up a relief valve dumps oil back to the sump should it exceed 26 bar pressure From the filter the oil flows through the main pressure regulator valve This maintains the clutch system pressure at 14 bar From this valve oil also enters the Torque converter circuit The solenoid actuated direction control valve when operated sends oil from the clutch circuit to the forward or reverse clutch piston which then applies the appropriate clutch When in neu tral the valve closes and oil from the clutch pistons is returned to the sump On hydraulic 4 wheel drive models an additional solenoid valve when actuated sends oil from the clutch circuit to the 4wd clutch piston which then applies the clutch When de selected the valve closes and oil from the clutch piston is returned to the sump On Sprung On hydraulic 4wd models the dog clutch is engaged by a spring To disengage the clutch the 4wd solenoid valve is actuated and the piston compresses the spring and dis connects the clutch The Torque Converter Circuit Oil enters the converter circuit from the main pressure regulator valve It flows through passages in the oil pump housing and into the torque converter Pr
10. Output shaft 3rd Gear Output shaft 2nd Gear Output shaft 1st Gear Output shaft 4wd Gear Output shaft Bearing 1st Gear Output shaft Bearing spacer Bearing sleeve Circlip Sealing ring 4wd shaft Bearing spacer Shim Thrust washer Bearing spacer Shim Bearing Output shaft Bearing Bearing spacer Shim Bearing Bearing Bearing Thrust washer Countershaft Reverse idler gear Input shaft assembly Co axial Forward primary gear Reverse primary gear Clutch pack retaining ring Clutch pack retaining plate Clutch plate steel Clutch plate friction Circlip Spring retainer Piston return spring Clutch piston Piston sealing ring O Ring Piston sealing ring O Ring Brake calliper bolt End yoke Spacer ring Needle bearing spacer Bolt Needle bearing Bearing Output flange washer Screw O Ring Brake flange assembly Pump assembly Sealing ring Sealing ring Detent ball Detent spring 1st 2nd Shift fork 3rd 4th Shift fork 1st 2nd shift rod ard Ath Shift rod Shift fork screw Gear stub lever Bolt Gear lever seating Pin KEY TO TRANSMISSION COMPONENTS CONTD 106 Rubber boot 168 107 Washer 170 109 Hydraulic pipe nut 171 110 Plastic clip 111 Plastic clip 112 Plug 113 Converter relief valve 114 Setscrew 115 Banjo bolt washer 116 4WD Clutch supply pipe 118 Drain plug assembly 119 Hydraulic pipe
11. Tool No KM3516 RE ASSEMBLY 8 16 Using an appropriately sized tube re fit the 8 19 Lubricate the seals with a light grease and front bearing re fit the piston into the clutch drum Then replace the spring retainer and circlip as shown 8 17 Re new the piston sealing rings to assist 8 20 Using the appropriate tool compress the assembly the seals may be warmed in piston return spring and locate the circlip lukewarm water prior to assembly into its groove Tool No KM3521 Note the outer seal must be fitted with the open edge facing away from the clutch pack A ET Anc Ci od sad d yd EN a 8 18 Using the appropriate tool compress the 8 21 Replace an externally splined plain disc piston sealing rings The seals should be then an internally splined friction disc left in the tool for a minimum of 30 minutes alternately until 8 plain discs and 8 friction prior to assembly into the clutch drum discs have been fitted Tool No KM3510 RE ASSEMBLY 8 22 Replace the retaining plate and fit a new 8 25 Refit the needle bearings and spacer retaining clip 8 23 Refit the thrust washer and needle bearing 8 26 Refit the needle bearing and thrust washer 8 24 Refit the 4 wheel drive gear 8 27 Using an appropriately sized tube re fit the rear bearing RE ASSEMBLY 8 28 Refit a new sealing ring and lubricate with a light grease To avoid damage the sealing ring should be
12. ULIC SYSTEM CONTD FAULT POSSIBLE CAUSES No drive from 4wd 4wd solenoid valve or coil not operating Mechanical failure in transmission Low 4wd clutch pack pressure 4wd clutch pack worn Transmission overheating Oil level too high or low Restriction in cooler flow Low oil pressure Clutch packs slipping due to low pressure or wear Mechanical failure in transmission Excessive stall operation Difficult gear selection Fwd or Rev clutch pack pressurised when not selected Direction valve faulty Input shaft sealing rings leaking Mechanical failure in transmission Fwd or Rev clutch pack not releasing due to mechanical failure Vehicle moves with direction See Difficult gear selection valve in neutral position High stall speed Low oil level Air in oil Clutch plates slipping due to low pressure or wear Torque converter faulty Converter relief valve faulty Incorrect torque converter fitted Low stall speed Poor engine performance Torque converter defective Incorrect torque converter fitted Low Pump Pressure Worn or broken pump Leaking pump sealing ring Blocked oil strainer or filter Blockage in oil ports between transmission sump and oil pump Pressure regulator valve stuck open Cold start valve stuck open High pump pressure Pressure regulator valve faulty Has normal operating oil temperature been reached Low forward or reverse clutch Faulty direction control valve pack pressure Pisto
13. ad to the end of the 4 liguid gasket Loctite 5203 taking care not wheel drive shaft Position a D T l as to damage the input shaft or 4WD shaft shown and using a pry bar lift the shaft sealing rings Tighten the 17 bolts to a then measure and note the end float torque of 33 to 47 Ib ft Tool No KM3524 Not fitted on 2 wheel drive model Remove the rear case and add or remove shims as necessary to give 001 to 003 inches end float on all shafts Repeat steps 12 17 to 12 22 until all shaft end floats are correct 12 25 Replace the shaft end plug and O ring assemblies Note the special breather plug is fitted in the reverse idler position Tighten to a torque of 30 to 40 Ib ft 12 23 Replace the 4 O rings in the front case 12 26 Fit a new expansion plug to the shimming There are only 3 fitted on the 2 wheel access hole using an approved sealant drive model Loctite 649 Note The input shaft and 4wd shaft sealing rings should now be fitted TRANSMISSION RE ASSEMBLY CONTD 12 27 Replace the output yoke O ring washer 12 30 Lubricate the seals with transmission fluid and bolt Then tighten to a torgue of 50 to then re fit the pressure regulator valve and 65 Ib ft tighten to a torque of 34 to 44 5 12 28 Replace the spacer 4WD yoke O ring 12 31 Lubricate the seals with transmission fluid washer and bolt Then tighten to a torque of then re fit the converter regulator valve and 50 to 65 Ib ft
14. aring spacer Needle bearing KEY TO TRANSMISSION COMPONENTS 2WD O 0o Oy Ol MERE 54 55 58 Front gear case assembly Rear gear case assembly Plug and O ring Cold start spring housing Bolt Sealing Cap Bolt Reverse shift hub sleeve Synchroniser assembly Sealing ring Copper washer Thrust bearing Thrust washer Ball Cold start spring O Ring Plug Oil filter housing Flywheel housing Washer Filter housing gasket Bolt Cover plate Setscrew 4th Gear output shaft 3rd Gear output shaft 2nd Gear output shaft 1st Gear output shaft Spacer Bearing 1st gear bearing spacer 1st Gear bearing sleeve Circlip Expansion plug Directional valve O Ring 4th Gear thrust washer Bearing spacer Shim Bearing Output shaft Bearing Bearing spacer Shim 101 Support washer Bearing Bearing Thrust washer Countershaft Reverse idler gear Input shaft assembly Forward primary gear Reverse primary gear Clutch pack retaining clip Clutch pack retaining plate Clutch plate Clutch plate friction Circlip Spring retainer Piston return spring Piston Piston sealing ring outer O Ring Piston sealing ring inner O Ring Breather plug Capscrew Breather Needle bearing spacer Bolt Needle bearing Temperature sender Output Yoke washer O Ring Screw O Ring End yoke assembly Pump assembly Pump sealing ring O Ring D
15. bar TEST PORTS CONTD 13 6 Lubrication pressure test point Pressure should be 0 5 to 2 5 bar at Maximum engine speed Approx 2500 RPM PARKING BRAKE Some transmissions are fitted with a mechanical calliper parking brake The calliper assembly is mounted directly onto the rear face of the transmission housing 14 1 Transmission fitted with a parking brake Refer to next page for installation and adjustment PARKING BRAKE INSTALLATION AND ADJUSTMENT Adjust the two mounting bolts and lock nuts to leave a 0 25 1 50mm gap between the lock nut and sleeve Then torque lock nuts against mounting surface to 110 lb ft Lock N Mounting Face oe at M m rx ue m E Outer Lock Nut Adjust this nut until pads are in contact with the brake disc Then back off 4 to 5 flats Finally torque outer lock nut to 45 55 lb ft REPLACING THE FRICTION PADS 14 2 Remove the retaining spring clip 14 3 Withdraw the friction pads Fit the new pads with the friction faces inboard and refit the retaining spring clip COMPACT PLUS TEST PROCEDURE If a malfunction of the transmission is indicated a systematic pressure checking procedure should be followed These checks should be carried out while the transmission is still in the vehicle so that true operating conditions are created Pressure checks are essential since a failu
16. clip into its groove ring into a heart shape as shown Tool No KM3520 2 19 Replace an externally splined plain disc 2 16 Using transmission fluid to lubricate the seals push the piston into the drum and then an internally splined friction disc alternately until six of each have been replaced 2 17 Replace the spring retainer and circlip as 2 20 Replace the clutch pack retaining plate and shown re fit the retaining clip RE ASSEMBLY OF THE INPUT SHAFT 2 21 Replace the thrust washer bearing spacer 2 24 Invert the shaft and repeat steps 2 15 and bearing to 2 23 Then fit a new sealing ring as shown 2 22 Line up the clutch plate splines and replace 2 25 Finally fit 3 new sealing rings to the rear of the primary gear Then replace the the shaft as shown needle bearing and thrust washer as shown To avoid damage the sealing rings should Note The needle bearing should be fitted with the be left off until all shimming operations closed side of its cage agianst the gear have been completed 2 23 Using an appropriately sized tube replace the bearing as shown RE ASSEMBLY OF THE INPUT SHAFT Note On some transmissions the input shaft has a Co axial pump drive shaft which runs through the centre of the input shaft assembly The strip and rebuild procedure for this type of assembly is almost identical The following differences should however be noted 2 28 There is a pump drive shaft bush fitt
17. cription Bearing Extractor use with brg removal collets Input amp Rev Idler shaft brg removal collet Brg Ref 48548 Pt No 9713 Piston seal sizing ring Hydraulic 4WD only 4wd shaft front rear and Co axial input shaft front brg removal collet Brg Ref 32008 Pt No 68609 Output shaft front brg removal collet Brg Ref 32207 Pt No 68116 C shaft and Output shaft rear brg removal collet Brg Ref 33208 Pt No 68608 Co Axial Input shaft rear brg removal collet Brg Ref 32010 Pt No 68772 Input shaft spring compresser 4wd shaft spring compresser Hydraulic multi plate 4WD only C shaft front bearing removal collet Brg Ref 32208 Pt No 65381 Co Axial input shaft and Hydraulic dog clutch 4wd shaft spring compresser Shimming Adapter These service tools are available from V L Churchill Ltd P O Box 3 London Road Daventry Northants England NN11 4NF Tel 01327 704461 Fax 01327 871625 RECOMMENDED TUBE SIZES FOR REPLACING BEARINGS Tube Bore Tube O D C shaft 4wd Output shaft rear amp Co axial input shaft 41mm 47mm front bearing Reverse idler Output shaft front amp input 36mm 41mm shaft bearing Output shaft 1st gear brg sleeve and Co axial input shaft 50 5mm 58mm rear bearing The dummy plug for re fitting inner detent spring amp ball can be made using a piece of bar 18mm dia x 25mm long RECOMMENDED TUBE SIZES FOR REPLACING BEARINGS Tube Bore Tube O D C s
18. e should be fitted into the case first then fit the remaining shims followed by the bearing cup A light grease may be used to help hold the cups in the case TRANSMISSION RE ASSEMBLY CONTD 12 17 Re fit the rear case without sealant at 12 19 Attach a suitable shimming tool with a this stage and secure with at least 6 equally 12mm thread to the end of the reverse spaced bolts When fitting the rear case be idler shaft Position a D T l as shown and careful to avoid damaging the input shaft using a pry bar lift the shaft then measure sealing rings and note the end float Tool No KM3524 12 18 Position a D T l on the end of the input 12 20 Attach a suitable shimming tool with a shaft as shown and using a suitable pry bar 12mm thread to the end of the countershaft through the side access hole measure and Position a D T l as shown and using a pry note the shaft end float bar lift the shaft then measure and note the end float Tool No KM3524 Note All shaft assemblies should be rotated several times to seat the bearings prior to measuring the end float 12 21 Attach a suitable shimming tool with a 12mm thread to the end of the output shaft Position a D T l as shown and using a pry bar lift the shaft then measure and note the end float Tool No KM3524 TRANSMISSION RE ASSEMBLY CONTD 12 22 Attach a suitable shimming tool 12 24 Refit the rear case using an approved with a 12mm thre
19. ed in the end of the shaft which may be replaced if worn The special tools required are also different The input shaft spring compresser is No KM3523 and the front and rear brg removal collets are Nos KM3516 and KM3519 2 26 There are 4 rear sealing rings on the Co axial input shaft assembly 2 27 There is an additional circlip fitted underneath the rear input shaft bearing DISASSEMBLY AND RE ASSEMBLY OF THE COUNTERSHAFT 3 1 The countershaft assembly 3 2 Using the appropriate bearing pullers remove the countershaft front and rear bearings Tool Nos KM3522 and KM3518 3 3 Using an appropriately sized tube replace the countershaft front and rear bearings DISASSEMBLY AND RE ASSEMBLY OF THE REVERSE IDLER SHAFT 4 1 The reverse idler assembly 4 2 Using the appropriate bearing puller remove the front and rear bearings Tool No KM3509 4 3 Using an appropriately sized tube replace the front and rear bearings OUTPUT SHAFT DISASSEMBLY 5 1 Position the shaft assembly in a soft jawed 5 4 Remove the 3rd 4th synchro assembly vice as shown 5 2 Using the appropriate bearing puller remove 5 5 Remove the circlip and synchro hub the front bearing Tool No KM3517 5 3 Remove the thrust washer and 4th gear 5 6 Remove the 3rd gear OUTPUT SHAFT DISASSEMBLY 5 7 Invert the shaft and using the appropriate 5 10 Remove the needle bearings and spacer bearing puller remo
20. er detent spring and ball have not become displaced and remove the loose dummy plug from the case sump 12 6 Dummy plug in place 12 7 Replace the countershaft and reverse idler 12 9 Push the interlock ball into the detent shaft assemblies bore 12 8 Slide the 1st 2nd fork onto the 3rd 4th rail 12 10 Refit the 1st 2nd shift rail and tighten the then refit the 3rd 4th shift fork and tighten shift fork screw to a torque of 13 to 18 Ib ft the screw to a torque of 13 to 18 Ib ft Hold Check that the interlock ball is correctly the forks and rail in place on the output positioned in between the two rails shaft then re fit the complete assembly into the case The shift rail should displace the dummy plug as it enters the bore TRANSMISSION RE ASSEMBLY CONTD 12 11 Replace the outer detent ball and spring 12 14 Rear case with all shaft assemblies fitted Tighten the plug to a torque of 30 to 40 Ib ft 12 12 Replace the 4 wheel drive shaft assembly 12 15 Position the rear case as shown and using Not fitted on 2 wheel drive models a suitably sized tube fit a new output shaft Lubricate the rear seal with a light grease oil seal to a depth of 6mm below the housing face Fill the seal lip with a light grease 12 13 Lubricate the input shaft front and rear 12 16 Invert the case and replace the shim packs seals with a light grease and re fit the and bearing cups The 2mm thick spacer shim shaft assembly into the cas
21. essure is controlled by the converter relief valve which prevents the pressure within the torque converter from exceeding the design limits 7 or 10 bar depending on the type of converter used Any excess is returned to the sump The Cooling and Lubrication Circuit Hot oil flows from the torque converter via the inside of the pump stator tube through the cen tre of the oil pump and out of the transmission via connecting hoses It is then passed through an external oil cooler before being returned to the transmission where it is used to cool the clutches and lubricate the input shaft bearings before being returned to the sump HYDRAULIC CIRCUIT DIAGRAM 0 3 IIO dANS NOT LAITMANI NOISSIWSNUML 3 iNIOd 483 UINIUNIS 28 NOTLONS 272722 C i 272722 MINGS 38 5538 dW3l agni FR FETTE le rroreeaeere d 3483 SES q102 3 886 4 7 aanss3axd EE HI SH anes 934 3 03 a 24 3 KILNS LNIOd 3 LNIOd 4534 9801 38 4934 HUMO 8 983 84 3583 38 JATHA P num EI no1193x1a E 3 e e GIONS 10S dar SPECIAL SERVICE TOOLS Tool Number KM 3003 KM 3509 KM 3510 KM 3516 KM 3517 KM 3518 KM 3519 KM 3520 KM 3521 KM 3522 KM 3523 KM 3524 Des
22. etent ball Detent spring 1st 2nd Shift fork 3rd 4th Shift fork 1st 2nd shift rod 8rd 4th shift rod Shift fork screw 102 Gear shift lever KEY TO TRANSMISSION COMPONENTS CONTD 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 120 121 Bolt Gear lever seating Pin Rubber boot O Ring Suction strainer Pressure regulator valve Plastic clip Plastic clip Plug Converter relief valve Setscrew Oil seal Oil filter Oil filter adapter Drain Plug Dowel Strainer cover plate COMPACT PLUS 2WD TRANSMISSION DISASSEMBLY 1 1 Invert the transmission on a suitable bench 1 4 Remove the Pressure Regulator Valve For convenience the bench top should have a hole in it to accommodate the input shaft and pump Remove 3 screws and withdraw the gear shift lever assembly 1 2 Remove the plastic plugs and 4 cap screws and withdraw the direction control valve 1 5 Remove the cold start housing spring and ball 1 3 Remove the Converter Relief Valve 1 6 Remove the temperature sender TRANSMISSION DISASSEMBLY 1 7 Remove the bolt washer and O ring and 1 10 Remove the 4 wheel drive shaft assembly withdraw the output yoke Not fitted on 2 wheel drive model 1 8 Remove the bolt washer and O ring and 1 11 Tilt the countershaft and withdraw the input withdraw the 4 wheel drive yoke and spacer shaft assembly Not fitted on
23. haft 4wd Output shaft rear amp Co axial input shaft 41mm 47mm front bearing Reverse idler Output shaft front amp input 36mm 41mm shaft bearing Output shaft 1st gear brg sleeve and Co axial input shaft 50 5mm 58mm rear bearing The dummy plug for re fitting inner detent spring amp ball can be made using a piece of bar 18mm dia x 25mm long TECHNICAL DATA Shaft End Floats All shaft end floats should be 0 025 to 0 075 mm 0 001 to 0 003 ins Gear End Floats Input shaft forward and reverse primary gears 0 061 to 0 41 mm 0 0024 to 0 016 ins Output Shaft Gears 4th Gear 0 20 to 0 56 mm 0 008 to 0 022 ins 3rd Gear 0 38 to 0 84 mm 0 015 to 0 033 ins 2nd Gear 0 36 to 0 56 mm 0 014 to 0 022 ins 1st Gear 0 33 to 0 51 mm 0 013 to 0 020 ins 4 Wheel Drive Output gear 0 051 mm to 0 28 mm 0 002 to 0 011 ins Bolt Torques Strainer bolts 18 to 31 Nm 13 to 23 Ib ft Pump retaining bolts 18 to 31 Nm 13 to 23 Ib ft Output Yoke bolts 68 to 88 Nm 50 to 65 Ib ft Pressure test plugs 41 to 54 Nm 30 to 40 Ib ft Main transmission case bolts 45 to 64 Nm 33 to 47 Ib ft Shift detent plug 41 to 54 Nm 30 to 40 Ib ft Shift fork screws 18 to 25 Nm 13 to 18 Ib ft Shift lever assembly screws 16 to 24 Nm 12 to 18 Ib ft Drain plugs 34 to 54 Nm 25 to 40 Ib ft TECHNICAL DATA CONTD Converter relief valve Pressure regulator valve Cold start valve AWD solen
24. himming access hole 1 26 Remove the 4 wheel drive solenoid coil 1 29 Invert the case Remove 4 screws and cop and retaining nut per washers then withdraw the pump Only fitted on 4 wheel drive model assembly and sealing ring 1 27 Remove the 4 wheel drive solenoid spool Only fitted on 4 wheel drive model INPUT SHAFT DISASSEMBLY 2 1 Position the shaft in a soft jawed vice as 2 4 Remove the thrust washer and needle shown bearing 2 2 Remove and discard the 3 sealing rings 2 5 Remove the reverse primary gear 2 3 Using the appropriate bearing puller remove 2 6 Remove the bearing spacer bearing and the rear bearing Tool No KM3509 thrust washer INPUT SHAFT DISASSEMBLY 2 7 Remove the clutch pack retaining ring 2 10 Using the appropriate tool compress the piston spring and release the circlip Tool No KM3520 2 8 Remove the clutch pack retaining plate 2 11 Remove the circlip retainer and spring 2 9 Remove the clutch pack 2 12 Using pliers as shown pull the piston out of the drum INPUT SHAFT DISASSEMBLY 2 13 Invert the shaft and remove the sealing ring Repeat steps 2 3 to 2 12 to dismantle the forward clutch pack S 2 14 Remove and discard the piston sealing rings and O rings RE ASSEMBLY OF THE INPUT SHAFT 2 15 Re new the piston sealing rings and O rings 2 18 Using the appropriate tool compress the To assist assembly bend the inner sealing Spring and locate the cir
25. il filter and clean out the suction strainer The object in draining the oil is to eliminate possible bearing surface abrasion and attendant wear Minute particles of metal the result of normal wear in service are deposited in and circu lated with the oil Oil changes are best carried out when the transmission is thoroughly warm Caution Towing To prevent oil starvation and possible seizure of the transmission whilst towing the vehicle it is imperative that the propeller shafts are disconnected Failure to observe this precaution may result in extensive damage to the transmission RECOMMENDED LUBRICANTS 10W or 10W 30 Grade mineral oils or automatic transmission fluids which meet at least one of the following specifications are allowable for use in ambient temperatures of between 20 and 40 Deg C 1 GLA Allison C3 MIL L 2105B or Caterpillar TO2 The following lubricants meet these requirements Note this list has been compiled for guidance only Turner Powertrain or the appropriate oil company should be consulted on any specific application Oil Company A T F Mineral Oils Mobil Delvac 1310 or Mobilube HD 80 Shell Donax TM or TA Donax TC 10W B P Autran MBX Vanellus C3 10W Esso Torque Fluid 56 Unifarm Castrol Castrol RX 10 or Multiplant Texaco Texamatic C3 9230 or 9226 Total Total Fluid ATX EIf Elfmatic G3 or Elfmatic H Fina Finamatic HD Kappa TD 10W EXPLANATION OF COMPACT PLUS TRANSMISSIO
26. left off until all shimming operations have been completed DISASSEMBLY AND RE ASSEMBLY OF THE OIL PUMP Note Transmissions fitted with a Co axial pump Note drive shaft use a slightly different pump Individual components of the oil pump are non serviceable The pump may however assembly be stripped for cleaning and examination purposes 9 1 View showing a dismantled pump assembly 9 3 The two types of pump assembly used The Co axial type is on the left 9 2 The pump oil seal may be replaced using an appropriately sized tube DIRECTION CONTROL VALVE Note Dis assembly of the control valve is not generally recommended as with the exception of the solenoids individual parts are non serviceable It may however be dismantled for cleaning and examination The valve fitted may be either the modulated type or the non modulated type 10 3 There are 4 O rings fitted to the underside of the valve which may be renewed if necessary The Modulated Valve The Non modulated Valve 10 1 The retaining nut coil and washer removed 10 4 The retaining nut coil and washers removed 10 2 The modulation components removed 10 5 There are 4 O rings fitted to the underside of the valve which may be renewed if necessary GEAR LEVER HOUSING DISASSEMBLY AND RE ASSEMBLY 11 1 Remove the plastic ties from the rubber 11 2 Apply a bead of RTV joint compound gaiter and pull the assembly apart as Loctite 5900 t
27. light grease and 12 43 If previously removed re fit the 4 wheel Screw on a new oil filter Tighten to a drive clutch supply pipe apply sealant torque of 7 to 10NM or a half to three Loctite 542 to threads and tighten nuts to quarters of a turn after initial seal contact a torque of 5 to 7 5 Ib ft Not fitted on 2 wheel drive model 12 41 Lubricate the seals with a light grease and re fit the 4 wheel drive solenoid spool Tighten to a torque of 15 to 20 Ib ft Not fitted on 2 wheel drive model TEST PORTS Test Notes The transmission oil should be at an approximate temperature of 80 0C during pressure tests All test ports have a 9 16 UNF thread Forward Reverse and 4wd Clutch pack pressures should not be more than 1 bar lower than the oil pump pressure 13 3 Forward clutch pressure test point Pressure should be 12 5 to 15 5 bar at Maximum engine speed Approx 2500 RPM 13 1 Oil pump pressure test port Pressure 13 4 Four wheel drive pressure test point should be 13 5 to 15 5 bar at Maximum Pressure should be 12 5 to 15 5 bar at engine speed Approx 2500 RPM Maximum engine speed Approx 2500 RPM 13 2 Reverse clutch pressure test point 13 5 Converter relief pressure test point Pressure should be 12 5 to 15 5 bar at Pressure should not exceed 7 5 bar at Maximum engine speed maximum engine speed Approx 2500RPM Approx 2500 RPM For Co Axial Transmissions max pressure should be 10 5
28. ll shimming operations have been completed 6 21 Replace the thrust washer PERMANENT 4 WHEEL DRIVE SHAFT DISASSEMBLY 7 1 The permanent 4 wheel drive shaft 7 2 Using the appropriate bearing puller remove the front and rear bearings Tool No KM3516 7 3 Remove the 4 wheel drive gear RE ASSEMBLY 7 4 Replace the 4 wheel drive gear using Loctite 649 or equivalent on the shaft splines Then using a suitably sized tube re fit the front and rear bearings HYDRAULIC MULTI PLATE CLUTCH 4 WHEEL DRIVE SHAFT DISASSEMBLY 8 1 The hydraulic multi plate clutch 4wd shaft 6 4 Remove the thrust washer and needle assembly bearing 8 2 Mount the shaft assembly in a suitable soft 8 5 Remove the 4wd gear jawed vice and remove the rear sealing ring 8 3 Using the appropriate tool remove the rear 8 6 Remove the needle bearings and spacer bearing Tool No KM3516 DISASSEMBLY CONTD 8 7 Remove the needle bearing and thrust 8 10 Remove the clutch pack washer 8 8 Remove the clutch pack retaining clip 8 11 Using the appropriate tool compress the piston return spring and release the circlip Tool No KM3521 8 9 Remove the clutch pack retaining plate 8 12 Remove the clip retainer and spring DISASSEMBLY CONTD 8 13 Remove the piston from the drum 8 14 Remove and discard the piston sealing rings 8 15 Invert the shaft and remove the front bearing using the appropriate tool
29. n seal or O ring leaking Input shaft sealing ring leaking High forward reverse clutch Pressure regulator valve faulty pack pressure Converter pressure low Converter relief valve faulty Leak in converter oil cooler or connecting hoses Very hot oil FAULT DIAGNOSIS HYDRAULIC SYSTEM CONTD FAULT POSSIBLE CAUSES Converter pressure high Converter relief valve faulty Blockage or restriction in oil cooler Very cold oil Low 4wd clutch pack pressure 4wd piston seals leaking 4wd shaft sealing ring leaking Leak from 4wd clutch supply pipe Faulty 4wd solenoid Blockage or restriction in 4wd clutch supply pipe High 4wd clutch pack pressure Pressure regulator valve faulty Low lubrication pressure Blockage or restriction in oil cooler Input shaft front sealing ring leaking Very hot oil FAULT DIAGNOSIS MECHANICAL SYSTEM FAULT POSSIBLE CAUSES Vehicle Driveline Problem Axles Propshafts Engine Engine mounts Mis alignment of transmission engine Bearings worn or damaged Gear teeth damaged or broken Excessive end float of shafts or gears Clutch plate failure forward reverse or 4wd Incorrect grade of oil in transmission Low oil level Gear or thrust washer beginning to seize Difficult gear selection Shift rods worn or bent Shift forks worn loose or twisted Synchroniser assemblies worn or damaged Clutch pack not releasing due to mechanical fault Clutch pack not releasing due to
30. o the sealing face as shown shown Note Before re assembly remove all traces of old sealant from the joint faces 11 3 Lubricate the ball seating with a light grease and push the two halves of the assembly together Secure the rubber gaiter with two new plastic ties TRANSMISSION RE ASSEMBLY General Re assembly Notes All nylon patch bolts may be re used 5 to 6 times provided a prevailing thread torque of 15 to 18 Ib in is recorded All shafts and bearings should be lubricated with transmission fluid prior to assembly To prevent possible contamination of hydraulic parts lint or cotton rags should not be used 12 3 Refit the oil pump assembly and sealing ring Tighten 4 bolts to a torque of 13 23 Ib ft New copper washers must be fitted under the bolt heads Finally check for free rotation of pump rotor 12 1 Position the front case as shown and using 12 4 Invert the case and then re fit the bearing a suitably sized tube fit a new 4 wheel drive cups if previously removed output shaft oil seal to a depth of 6mm below the housing face Fill the seal lip with light grease Not fitted on 2WD model 12 2 If previously removed replace the two 12 5 Using a suitable tool push the inner detent plug and O ring assemblies as shown and spring and ball into the case and secure in tighten to a torque of 30 to 40 Ib ft place with a dummy plug as shown TRANSMISSION RE ASSEMBLY CONTD Note Check that the inn
31. oid valve spool AWD Solenoid coil retaining nut Directional control valve ret screws 4WD hydraulic pipe connections Filter housing bolts Oil filter Temperature sender Recommended Sealants Transmission case joint 4wd Output gear 4wd gear Permanent 4wd assy 4wd clutch supply pipe Gear lever housing Shimming access expansion plug Filter housing gasket 23 to 30 Nm 17 to 22 Ib ft 46 to 60 Nm 34 to 44 Ib ft 46 to 60 Nm 34 to 44 Ib ft 20 to 27 Nm 15 to 22 Ib ft 5 4 Nm Max 4 lb ft Max 6 8 to 8 5 Nm 5 to 6 3 Ib ft 6 8 to 10 2 Nm 5 to 7 5 Ib ft 45 to 64 Nm 33 to 47 Ib ft 7 to 10 Nm 5 to 7 5 Ib ft 20 to 27 Nm 15 to 20 Ib ft Loctite 5203 Loctite 649 spline lock Loctite 649 spline lock Loctite 542 Loctite 5900 RTV jointing compound Loctite 649 This gasket is graphite coated and should be fitted dry Do not use sealant COMPACT PLUS WITH CO AXIAL PTO DRIVE AND SPRUNG ON 4WD Key to Transmission Components 54 55 58 Front gear case assembly Rear gear case assembly Plug assembly Bolt Bolt Bolt Reverse shift hub sleeve Synchroniser assembly Sealing ring Copper washer Thrust bearing 4wd piston sealing ring Support washer Torque converter O Ring 4wd piston Circlip Clutch collar Spring 4wd Spring support Flywheel housing Parking brake assembly 4wd Shaft 4wd Gear Converter drive plate Thrust washer 4th Gear
32. p and Rebuild Procedure DEP MR HAD ME Transmission Disassembly Input shaft Countershaft Reverse Idler shaft Output shaft Hydraulic Dog Clutch 4wd Permanent 4wd Hydraulic Multi Plate Clutch 4wd Oil Pump Directional control valve Gear lever housing Transmission Re assembly Test Ports and Pressures Parking Brake Test Procedure Fault Diagnosis INTRODUCTION The Compact Plus is a synchroshift reversing shuttle with an integral 4 speed fully synchronised transmission Designed for a variety of mobile off highway applications the Compact Plus allows in motion shifting between forward and reverse without braking It is suitable for use with engines in the 60 110 HP range Features Available with or without a co axial engine driven PTO drive to accommodate SAE B or C pumps Optional soft shift modulation to improve operator comfort during reversals Automotive shift pattern with reduced lever movements to allow greater freedom in cab design Ratio options and converter matches to maximise performance in all applications Electro hydraulic directional and 4WD controls to eliminate cable and rod connections Optional parking brake 4th gear lock out and harness connectors Optional 2 or 4 wheel drive configuration with hydraulic multi plate clutch hydraulic dog clutch or permanent mechanical engagement Za TURNER POWERTRAIN SYSTEMS Turner Powertrain Systems Ltd Racecour
33. re in the hydraulic system may not be easily traceable when the transmission is stripped down on a bench All pressure checks should be carried out with the transmission gear lever in the neutral position the oil temperature at 80 to 85 deg C and the engine speed maintained at 2000 to 2500 RPM As a safety precaution the vehicles parking brake should be applied All pressure test ports have a 9 16 ins UNF thread A pressure gauge is required that will measure up to 20 bar 290 Ib in For test port locations refer to illustrations 13 1 to 13 6 FAULT DIAGNOSIS HYDRAULIC SYSTEM FAULT POSSIBLE CAUSES Transmission fails to drive in Low or no pump pressure either direction Low or no oil in transmission Mechanical failure in transmission Worn or broken input shaft sealing rings Pressure regulator valve faulty Direction control valve not operating Blockage in oil ports restricting flow Transmission drives in one Low oil pressure on one clutch pack due to leaks direction only Clutch piston seals worn or damaged Clutch pack excessively worn Direction valve or coil faulty Mechanical failure in transmission Blockage in oil ports restricting flow Worn or damaged input shaft sealing ring Delay in taking up drive Low converter pressure Low oil level Low clutch pressure Faulty modulation in direction control valve Blockage in direction valve Blockage in oil ports restricting flow FAULT DIAGNOSIS HYDRA
34. se Road Wolverhampton West Midlands WV6 OQT England Tel 01902 833000 Fax 01902 831850 COMPACT PLUS WITH CO AXIAL PUMP DRIVE AND HYDRAULIC DOG CLUTCH 4WD f I 2222 GET ae I s 1 GES pa 7 AM eee SSS EVA SEE ISS 2 EL EA bP a a T P EP T Zi EE c 291 is A AN 2222 SE S 2 zm Ez i ETE at sd Som N UI des ANZ EER PE Nees wz Voge T b if A a E zi PATI nes Len EE 5 NS aet A PU ESSI En H Ht N SA Ory eS PT BE ZZ ARES COMPACT PLUS WITH HYDRAULIC MULTI PLATE 4WD N Vx Sa RE 7 ERES 5 lt Q f N fe ak 5 N 7 yj TNN Re R IAL A S 2 A m EED Vd 34 2 AZ EE ap TOROUE CONVERTER INSTALLATION GUIDE In order to ensure correct installation of the torgue converter the following procedure is recommended 1 Attach a dial indicator to the engine flywheel and check that the runout of the flywheel housing bore dia and the housing mounting face are within 008 T I R With the dial indicator attached to the flywheel housing check that the run out of the flywheel pilot bore does not exceed 005 T I R 2 Loosely assemble the drive plate to the converter
35. ve the rear bearing Tool No KM3518 5 8 Remove the 4 wheel drive gear 5 11 Remove the 1st 2nd synchroniser On 2 wheel drive models a spacer is fitted assembly in place of a gear 5 9 Remove the 1st gear 5 12 Using a suitable bearing puller or press Remove the bearing sleeve synchro hub and 2nd gear OUTPUT SHAFT DISASSEMBLY 5 13 Remove the bearing sleeve synchro hub and 2nd gear OUTPUT SHAFT RE ASSEMBLY 5 14 Replace the 2nd gear and synchro hub 5 17 Replace the 1st gear needle bearings and spacer as shown 5 15 Using an appropriately sized tube refit the 5 18 Replace the 1st gear 15 gear bearing sleeve 5 16 Replace the 1st 2nd synchroniser 5 19 Replace the 4 wheel drive gear using Loctite assembly 649 spline lock or equivalent Note the gear should be fitted with the fluted boss against the 1st gear On 2 wheel drive models a spacer is fitted in place of the gear OUTPUT SHAFT RE ASSEMBLY 5 20 Using an appropriately sized tube refit the 5 23 Refit the 4th gear and thrust washer as rear bearing shown 5 21 Invert the shaft and refit the 3rd gear 5 24 Using an appropriately sized tube replace synchro hub and circlip the front bearing 5 22 Refit the 3rd 4th synchroniser assembly HYDRAULIC DOG CLUTCH 4 WHEEL DRIVE DISASSEMBLY 6 1 The hydraulic dog clutch 4 wheel drive 6 4 Remove the thrust washer assembly 6 2 Position the shaft in a soft jawed vice and 6
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