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Velvet Drive Marine Transmisson Service Manual 71 C

1. STEP 4 Install pinion cage and output shaft 7 in reduction housing 26 Support pinion cage and output shaft 7 Install original spacer 19 and bearing cone 22 in re duction housing 26 CAUTION If original spacer is not used the replacement spacer should be the same length Using an incor rect size spacer can result in prema ture failure of reduction unit STEP 5 Place reduction housing 26 in press with pinion cage and output shaft 7 supported Press bearing cone 22 on pinion cage and out put shaft 7 Remove reduction housing 26 from press STEP 6 Install oil seal 20 in reduction housing 26 Outer surface of oil seal 20 should be flush with face of reduction housing 26 60 PINION CAGE AND OUTPUT BEARING CONE SOLID SPACER Spacer and Bearing Cone Assembly PRESS BEARING CONE REDUCTION HOUSING PINION CAGE AND OUTPUT REDUCTION HOUSING Oil Seal Assembly GE Sn e eg STEP 7 Slide coupling 6 on pinion cage and output shaft 7 Thread nut 5 on pinion cage and output shaft 7 Tighten nut 5 to torque shown in Table 4 Attach a torque wrench to nut 5 Turn torque wrench to check rolling torque of bearings 17 and 22 Rolling torque should be 5 to 30 in Ibs If rolling torque is over 30 in lbs replace spacer 13 with a longer one If rolling torque is under 5 in lbs replace spacer 13 with a shor
2. 78 SE eA ASSASSINS TT Q d EN L tete mieten ett mie voe inet tte Form No 1288 2 94 BorgWarner Marine amp Industrial Transmissions Distributed By Borg Warner Automotive Diversified Transmission Marine amp industrial Transmissions Products Corporation Borg Warner Automotive GmbH Marine amp industrial Transmissions KA SCopyrignht Borg Warner Marine and Industria Transmissions 1990 5401 Kilgore Avenue Kenfig industrial Estate Margam Nr Port Talbot Muncie Indiana 47304 West Glamorgan SA13 2PG United Kingdom RR Telephone 317 286 6100 Telex 27 491 Fax 317 286 6891 Telephone 656 741001 Telex 85149861 a Fax 656 747811 Printed in USA
3. Oil has been overheated Lost anti foam additive 5 Oil out of breather Replace oil Correct oil level High or low oil level Change oil Water in oil MALFUNCTION IN BOTH FORWARD AND REVERSE 1 Low oil pressure Regulator valve jammed Clean and polish Replace defective sealing rings internal leakage Low oil level Add oil Pump defective Replace pump Regulator valve jammed Clean and polish 2 No oil pressure internal leakage Replace defective parts Pump defective Replace pump No oil Add oil Pump incorrectly indexed Rotate pump to correct position 3 High oil temperature Regulator vaive jammed Clean and polish Cooler line defective Replace cooler line Oil cooler too small install larger cooler Restrictions in cooler lines or Back flush to remove restrictions cooler ENEE eet Table 3 Troubleshooting Continued PROBLEM CAUSE CORRECTION e MALFUNCTION IN BOTH FORVVARD AND REVERSE Cont 3 High oil temperature 4 No power noise 5 No line pressure 6 Noisy in Forward and Reverse MALFUNCTION IN FORWARD OR REVERSE 1 Clutch drags or does not release 2 Clutch does not apply 3 Harsh engagement 4 Soft engagement 5 Won t move or sluggish Defective cooler Defective temperature sensor Broken
4. STEP 37 Lubricate control valve O D Slide con trol valve assembly 33 into side of case 98 STEP 38 Install switch cam 31 on end of valve assembly 33 Be sure tab on switch cam 31 sets in notch of valve assembly 33 STEP 39 Install valve cover 28 as follows Position gasket 31 on case 98 Place valve cover 28 over gasket 32 and align bolt holes Thread three bolts 29 and lockwashers 30 into case 98 Tighten bolts in a criss cross pattern to final torque specified in Table 4 If removed lubricate O ring 27 with vasoline and install in groove of neutral switch 26 Thread neutral switch assembly 25 into valve cover 28 and tighten to torque specified in Table 4 26 CONTROL VALVE ASSEMBLY NOTCH ALIGNED WITH THIS BOLT HOLE SWITCH CAM e SWITCH Valve Cover Installation ET I I B m STEP 40 Install shift lever 19 as follows Lubricate poppet spring 24 and hole in case 98 with grease shell alvania 2 or equivalent Place poppet spring 24 and steel ball 23 in case 98 Slide shift lever 19 over end of control valve as sembly 33 and against steel ball 23 Rotate shift lever 19 to engage steel ball 23 in hole of shift lever 19 Hold shift lever 19 against steel bail 23 instail washers 21 and 22 and thread nut 20 on con trol valve assembly 33 Tighten nut 20 to torque specified in Table 4 STEP 41 Insta
5. 10 18 659 012 72 1A2C 10 17 659 068 NOT USED 10 18 565 002 72 A1K 10 18 659 014 10 18 565 002 10 18 565 002 72 A1K 10 18 659 014 10 18 659 002 NOT USED 10 17 193 001 10 18 659 002 NOT USED 72 A1K 10 18 659 008 72 1A2A NOT USED 10 17 193 001 72 A1K 10 18 659 008 72 A1J 10 18 659 006 72 1A2A NOT USED 72 1A2 10 18 659 012 72 1A2C Model Chart 71C and 72C Transmissions D ERA NOT USED NOT USED 10 17 193 001 10 17 193 001 NOT USED 10 17 659 021 10 17 065 003 NOT USED IGNITION SWITCH 2 6 i ar IGNITION TO TRANSISTOR SWITCH CIRCUIT TEST SWITCH 126928 Figure 9 Optionai Drive Gear Alarm Kits PART DESCRIPTION NUMBER NO NUMBER OPTIONAL DRIVE GEAR ALARM KITS A4867HN DRIVE GEAR ALARM KIT 71C 309 PILOT LIGHT 71C 308 PLATE 71C A312 TRANSISTOR CIRCUIT TEST SWITCH 4900E Ya MALE TERMINAL 4927 INSTALLATION WIRE 4924 SPADE TERMINAL 71C A102 TEMPERATURE SWITCH 4925 EYELET TERMINAL TEMPERATURE SWITCH FEMALE TERMINAL FEMALE CONNECTOR WIRING DIAGRAM INSTRUCTION SHEET PILOT LIGHT KIT 10 00 140 004 10 00 140 005 10 00 140 006 71C 310 A4867HS 710 908 PILOT LIGHT 710 308 PLATE 4924 SPADE TERMINAL WIRING DIAGRAM INSTRUCTION SHEET 71C 310 E o 9 9 9 o Q o 05 9
6. Figure 5 Hydraulic Circuit Schematic Model 72C Direct Drive Shown HR otto INSPECTION A GENERAL The transmission cooler cooler lines and con trol linkage should be inspected at regular inter vals Regular inspections will ensure proper operation and help detect minor problems that can be corrected before they cause a transmis sion failure B SCHEDULED INSPECTIONS See Table 2 The following recommended inspection intervals are based on normal operating conditions Inter vals should be adjusted for extremes of tempera ture or other adverse operating conditions Table 2 Scheduled Inspections INSPECTION INTERVAL INSPECTION TASK WEEKLY PERIODIC SAFETY GENERAL f i WARNING FAILURE TO PER he FORM THESE INSPECTIONS AT REQUIRED INTERVALS CAN RE SULT IN INJURY TO PERSONNEL Inspect contro linkage and shift lever for oper ation There should be no sticking binding or looseness OIL COOLER AND LINES CAUTION Failure to perform these inspections at required in tervals can resuit in transmission failure inspect cooler for signs of leakage damage or loose mounting bolts inspect all connection points for signs of leak age 1 month or 100 Annual or 1000 hours whichever hours whichever comes first comes first X X X X X X Table 2 Scheduled Inspections Continued INSPECTION INTERVAL INSPECTION TASK TRANSMISSION Inspect for darnage or
7. 71 244A 71C A60 10 00 183 021 10 00 044 014 3 61 4873 4911 NO NUMB R 4840D 71 144B 0000444858 71 35 4805A 4804G 71 71 72 176 72 A66B 71 97 71 87A R6 177 4622E 71 15B 10 16 193 001 4822 R6A 71 4766B 4734 4559A B107A B108A 71 70 72 70 10 16 124 001 71 45 5M 122 5L 36 5C 33 3 37 4755 5C 175A 3 176 3 176 5C A68A 5C A66A 5L 67 10 00 139 048 10 00 139 049 4768 4768A 4768B 10 00 139 018 e 9 9 49 eege E ee 0 ee 6 9 BB 6 9 9 e 9 9 5 9 E BS 0 9 9 9 e 9 9 9 46 0 e 9 CONTROL VALVE PUMP ASSEMBLY HEX HEAD BOLT 5 e 18 x 1 39 OIL SEAL PUMP GASKET WOODRUFF KEY CAPSCREW 3 e 16 x 1 1 4 e FORWARD AND REVERSE ADAPTER NSS NEEDLE BEARING GASKET PIPE PLUG 1 4 REVERSE CLUTCH PISTON CLUTCH SEALING RING O RING REVERSE CLUTCH PRESSURE PLATE STEEL CLUTCH PLATE FRICTION CLUTCH PLATE PRESSURE PLATE SPRING DOWEL PIN 312 DIA x 438 LONG DOWEL PIN 312 DIA x 621 LONG DOWEL PIN 312 DIA x 875 LONG THRUSTWASHER THRUSTWASHER SNAP RING SNAP RING 10 17 ONLY SNAP RING 10 18 ONLY SNAP RING 10 17 ONLY SNAP RING 10 18 ONLY BEARING 10 17 ONLY BEARING 10 18 ONLY FORWARD CLUTCH CYLINDER 10 17 ONLY FORWARD CLUTCH CYLINDER 10 18 ONLY FORWARD CLUTCH PISTON FORWARD CLUTCH PISTON O RING PISTON SEALING RING CLUTCH SPRING BEARING RING CLUTCH BELLEVILLE SPRING SNAP RING CLUTCH PRESSURE PLATE STEEL CLUTCH PLATE 10 17 ONLY
8. 10 17 065 001 NOT USED 10 17 565 002 71 1 10 17 659 018 71 1A2C 10 17 659 008 10 17 065 001 NOT USED 17 565 002 71 A1K 10 17 659 018 71 1A2C 10 17 659 008 NOT USED 565 002 71 A1K 10 17 659 020 10 17 565 002 71 A1K 10 17 659 020 71 1A2A NOT USED 71 1A2A NOT USED NOT USED 10 17 193 001 10 17 193 001 7 565 002 71 A1K 10 17 659 018 71 1A2C 10 17 659 021 10 17 065 003 72 A1J 10 18 659 006 72 1A2 NOT USED NOT USED 72 A1J 10 18 659 006 72 1A2 NOT USED NOT USED NOT USED 72 A1K 10 18 659 014 10 18 659 002 L4 A150 _ 10 17 065 001 10 17 193 001 10 18 565 10 18 565 002 72 A1K 10 18 659 014 10 18 659 002 LA A150 T2 MK 10 18 659 012 72 1A2C L9 A150 8 565 002 72 A1K 10 18 659 012 10 18 565 002 72 A1K 10 18 659 010 10 18 585 002 10 18 565 002 72 A1K 10 18 659 010 721426 L9 A150 NOT USED NOT USED 72 1A2B 10 17 659 006 10 17 193 001 72 1A2B 10 17 659 010 10 17 065 002 10 17 193 001 72 A1K 10 18 659 012 72 1A2C 10 18 565 002 72 A1K 10 18 659 012 10 17 659 007 10 17 065 001 72 1A2C 10 17 659 007 10 18 565 002 10 18 565 002 72 A1K 10 18 859 012 72 1A2C 10 17 659 008 NOT USED
9. 2 STEP 2 If removed install bushing 9 in output shaft 8 Install output shaft 8 in ring gear 9 Install snap ring 7 in groove of ring gear 10 STEP 3 If removed press bearing cups 13 and 18 into reduction housing 20 69 Output Shaft Assembly BEARING CUP REDUCTION HOUSING Bearing Cup Assembly STEP 4 Install output shaft 8 and ring gear 10 in reduction housing 20 Turn reduction housing 20 over and install origi nal spacer 14 and bearing cone 17 in reduc tion housing 20 CAUTION If original spacer is not used the replacement spacer should be the same length Using an incor rect size spacer can result in prema ture failure of reduction unit STEP 5 Place reduction housing 20 in press with ring gear 10 supported Press bearing cone 17 on output shaft 8 Remove reduction housing 20 from press STEP 6 Install oil seal 15 in reduction housing 20 Outer surface of oil seal 15 should be flush with reduction housing 20 face 70 BEARING CONE SPACER REDUCTION HOUSING 12790A Spacer and Bearing Cone Assembly BEARING PRESS REDUCTION HOUSING REDUCTION HOUSING 12792A Cil Seal Assembly STEP 7 Slide coupling 6 on output shaft 8 Thread nut 5 on output shaft 8 Tighten nut 5 to torque shown in Table 4 Attach a torque w
10. Transmission knocks at idie or low RPM then stops at 1 000 RPM or higher If the damper plate springs are too soft the sides of the windows will wear If the springs are too hard the splines will wear Consult engine OEM for correct damper plate recommended Clutches Check and or replace clutches if the following problem occurs Excessive engine RPM over the rated RPM This can indicate a slipping clutch The slipping clutch will usually squeal WARNING DO NOT OPERATE TRANSMISSION IF THE FOLLOWING CONDITION IS SUSPECTED FAIL URE TO COMPLY CAN RESULT IN PERSONAL INJURY BECAUSE TRANSMISSION CAN NOT BE DIS ENGAGED The slipping clutch will normally overheat This can result in warped plates In severe overheat ing plates can weld together This will cause a tie up condition in transmission when the other clutch is applied REG A Table 3 Troubleshooting PROBLEM CAUSE CORRECTION LEAKS 1 At pump or output shaft seal Faulty seal Replace Misalignment Correct Rough shaft Replace 2 Between seal and bore Replace seal Rough housing bore Loose bolts Torque bolts properly 3 At gasket s Defective gaskets Replace gaskets Face s not flat Replace defective parts Repiace cooler or cooler lines that are defective 4 Loss of oil with no trace of Oil leaking from cooler or cooler missing oil lines
11. ae Velvet Drive Marine Transmisson Service Manual 71C 72C Direct Drive and Reduction Ratios 1 5 1 1 88 1 1 91 1 2 1 1 2 57 1 2 91 1 BorgWarner Marine amp Industrial Transmissions MARINE TRANSMISSIONS Pa Ba e iss EM Y CO Rev 1 August 31 1988 Price 15 00 71C 72C Direct Drive and Reduction Ratios 1 5 1 1 88 1 1 91 1 2 1 1 2 57 1 2 91 1 Borg Warner Transmission Post Office Muncie Telephone Automotive Systems Box 2688 Indiana 317 286 6100 inc 47307 Telex LEET This manual reflects the transmission models as of April 1986 Later models may have differences The following direct drive and reduction models are covered in this manual Transmission Previous Trans Transmission Ratio i Assembly Number Assembly Number Forward Reverse I 10 17 000 001 AS1 71C 1 1 10 17 000 002 AS1 71CR 1 1 1 1 10 17 000 003 AS1 71CB 1 1 10 17 000 005 10 17 000 006 10 17 000 007 10 17 000 008 AS2 71C AS2 71CR AS7 71C AS7 71CR 1 52 1 1 52 1 1 91 1 1 91 1 1 52 1 1 52 1 1 91 1 1 91 1 10 17 000 009 10 17 000 010 AS3 71C AS3 71CR 2 10 1 2 10 1 2 10 1 2 10 1 5 10 17 000 011 AS14 71C 10 17 000 012 AS14 71CR Re sas s 10 17 000 013 AS15 71C 10 17 000 014 AS15 71CR 2 91 1 2 91 1 10 17 000 015 e EG 1 i l L 10 18 000 008 AS13 72CR 2 10 1 2 31 1 10 18 000 0
12. Lightly tap woodruff key 44 into place in drive gear 82 with a soft faced mallet STEP 32 Press oil seal 42 into pump body CAUTION Oil seal must be installed AN dry Lubricants can damage rubber coating STEP 33 Install driven gear in pump body NOTE Pump gear should be installed the same side down as removed FORWARD AND REVERSE CAPSCREWS ADAPTER SHA 12658A DRIVEN 12659A Pump Driven Gear Assembly 24 EE STEP 34 Lubricate pump gasket 43 with vaso line and install in groove of adapter 47 Install pump drive gear onto input shaft 82 Check that pump drive gear locates freely on woodruff key 44 and shaft 82 STEP 35 Install pump assembly 40 on top of P adapter 47 and align boit holes pulp 7 ASSEMBLY CAUTION Position pump housing di with cast arrow at top pointing in the same direction as engine rotation Thread four bolts 41 into adapter 47 Tighten Z BOLTS in a criss cross pattern to final torque specified in gt Table 4 el IASA D Pump Assembly Installation STEP 36 Assemble control valve assembly 33 O RING Refer to Figure 6 CONTROL VALVE Lubricate O ring 38 with vasoline and instali on end of valve assembly 33 VALVE SPRING SPRING NOTE Gap in snap ring must be aligned with RETAINER notch in control valve SNAP A REGULATOR RING m VALVE 12693A Valve Assembly 25 e SERENAN EEEE EE
13. STEEL CLUTCH PLATE 10 18 ONLY FRICTION CLUTCH PLATE 10 17 ONLY FRICTION CLUTCH PLATE 10 18 ONLY CLUTCH PRESSURE PLATE SNAP RING 033 037 THICK 10 17 ONLY SNAP RING 050 054 THICK 10 17 ONLY SNAP RING 050 054 THICK 10 18 ONLY SNAP RING 074 078 THICK 10 18 ONLY C Yellow Pink Green Orange White Purple SNAP RING 096 100 THICK 10 18 ONLY SNAP RING 062 066 THICK 10 18 ONLY e pi a ZG s sms BUY NEXT HIGHER ASSEMBLY 31 1 cA s mh N sch a ll UD CD A A sch zb ch D G GO M o URT Metri Arr sert 71 6 RING GEAR 10 17 ONLY 1 72 6 RING GEAR 10 18 ONLY 1 77 71 17 THRUSTWASHER 1 78 4806J e SEALING RING 2 79 4495 SNAP RING 1 80 71 40 FORWARD CLUTCH HUB 10 17 ONLY 1 80A 10 16 179 001 FORWARD CLUTCH HUB 10 18 ONLY 1 81 000021821 1 WOODRUFF KEY 10 17 ONLY 1 81A 0000124553 WOODRUFF KEY 10 18 ONLY 1 82 71C 3A16 e DRIVE GEAR ASSEMBLY 10 17 ONLY 1 82A 72C 2A16 DRIVE GEAR ASSEMBLY 10 18 ONLY 1 83 48068 e SEALING RING 4 84 A4867 DD KIT e BUSHING 2 85 10 17 659 e PINION CARRIER ASSEMBLY 10 17 ONLY 1 85A 10 18 659 e PINION CARRIER ASSEMBLY 10 18 ONLY 1 86 71 159 THRUSTWASHER USE W BUSHING STYLE CASE 1 86A 10 17 193 001 THRUSTWASHER USE W SEALING RING S
14. e e e 5 9 9 9 HEX HEAD BOLT 7 16 14 x 1 3 4 LOCKWASHER 7 16 HEX HEAD BOLT S s 18 x 1 1 a LOCKWASHER 3 e COUPLING NUT COUPLING SNAP RING MAIN SHAFT 1 91 1 ONLY MAIN SHAFT 1 88 1 ONLY RING GEAR 1 91 1 ONLY RING GEAR 1 88 1 ONLY BEARING ASSEMBLY e BEARING CONE e BEARING CUP SOLID SPACER 820 821 INCH LONG SOLID SPACER 829 830 INCH LONG SOLID SPACER 832 833 INCH LONG SOLID SPACER 835 836 INCH LONG SOLID SPACER 838 839 INCH LONG SOLID SPACER 841 842 INCH LONG SOLID SPACER 844 845 INCH LONG SOLID SPACER 847 848 INCH LONG SOLID SPACER 850 851 INCH LONG SOLID SPACER 853 854 INCH LONG SOLID SPACER 856 857 INCH LONG OIL SEAL BEARING ASSEMBLY BEARING CONE e BEARING CUP REDUCTION HOUSING SNAP RING SUN GEAR 1 91 1 ONLY SUN GEAR 1 88 1 ONLY LOCK BOLT S 16 18 x 3 4 LOCKWASHER 5 1 1 88 1 ONLY LOCK PLATE 1 91 1 ONLY PINION CARRIER ASSEMBLY 1 91 1 ONLY PINION CARRIER ASSEMBLY 1 88 1 ONLY RETAINING RING PINION SHAFT PIN REPLACE BOTH PARTS IF ONE IS DAMAGED SELECT CORRECT SIZE SPACER AT ASSEMBLY ONLY ONE REQUIRED 55 ES QY G e A A seh sch sch lk sch sch sch sch sch 4 e c4 CD PO P2 TT rrt aret INDEX PART DESCRIPTION NO NUMBER L5 39 e PINION SHAFT L3 43 PINIO
15. slings or hoists for the job WARNING KEEP WORK AREA TOOLS AND TRANSMISSION CLEAN WIPE UP ANY SPILLED TRANSMISSION FLUID TO PREVENT ACCIDENTS AS REQUIRED WEAR SAFETY GLASSES SAFETY SHOES AND A HARD HAT TO PREVENT PER SONAL INJURY B DISASSEMBLY NOTE Read OEM Vehicle manual for specific re moval instructions Before starting disassembly review the exploded view shown in Figure 8 The transmis sion can be disassembled following the index numbers shown in Figure 8 Seals Remove O rings sealing rings and oil seais carefully to prevent damage if they must be reused It is best to replace these items Bearings Do not remove bearings unless re placement is required or cleaning can not be done properly Keep matched parts or sets together Do not reverse or mix them C CLEANING WARNING CLEANING SOLVENTS CAN BE TOXIC FLAMMABLE AN IR RITANT TO THE SKIN OR GIVE OFF HARMFUL FUMES AVOID PRO LONGED CONTACT INHALATION OF VAPORS OR SMOKING FAILURE TO COMPLY CAN RESULT IN INJURY OR DEATH TO PERSONS Rinse all metal parts in solvent to remove dirt grease and transmission fluid Take special care to remove solvent from ail parts Air dry clutch plates e If O rings are to be reused air dry them D INSPECTION Case Inspect for cracks Check sealing surfaces for nicks scratches or burrs that can cause leaks Inspect output shaft bore for signs of wear on one side This ca
16. 72C Transmission Assembly A INTRODUCTION See Figure 1 The 71C and 72C transmissions consist of a planetary gear set and multiple disc clutches The input and output shafts are in line Hydraulic Pressure is provided by a crescent type pump The pump is driven at engine speed by the input shaft Oil from the pump is sent to the control valve The positions on the control valve are forward neutral reverse An internal regulator valve controis system pressure Oil dis charged by the regulator valve is sent to the oil cooler B THEORY OF OPERATION General Forward is direct drive A planetary gear set 1 1 to 1 0 ratio for 72C and 1 0 to 1 0 ratio for 71C is used to obtain reverse Tabie 1 Technical Specifications Speeds Horsepower Gasoline maximum Diesel maximum Torque and Input Speed Approximate Dry Weight Direct Drive Reduction 95 Ib 145 Ib DESCRIPTION MODEL 71C MODEL 72C One Forward One Reverse 310 HP 4200 RPM 182 HP 3200 RPM See Ratings Charts Form No 1237 One Forvvard One Reverse 475 HP 4200 RPM 274 HP 3200 RPM See Ratings Charts Form No 1237 109 Ib 153 Ib The transmission oil pump is driven by the input shaft It supplies oil pressure to operate the clutch packs lubricate parts and provide cool ing A damper plate is bolted to the engine flywheel The damper plate is splined to conn
17. E Type of Oil Dexron Type F or any hydraulic fluid which meets the C 3 oil specification is acceptable Do not mix different brands If engine doesn t ex ceed 3 000 R P M a premium grade 30 weight engine oil is acceptable SAE 40 and multi viscosity oils are not recommended if the transmission oil temperature has exceeded 1909 F or the alarm sounds the oil must be changed in the transmission and cooler system Changing Oil Oil in transmission cooler and cooler lines should be changed after every 1 000 hours of op eration or annually Severe service conditions or high operating temperatures may require more frequent changes e Place selector lever in neutral Run engine for five minutes at 1500 RPM Shut down engine AI CAUTION Clean around the area of drain plug before removing Small e particles of dirt can cause damage to internal components and cause valves to stick e Drain oil from transmission cooler and cooler lines into a suitable container Check oil for signs of metal or rubber particles CAUTION A few small metal parti cles are normal However if large metal chips or a large number of par ticles are found this could be an early sign of transmission failure The transmission should be disas sembled and inspected for internal damage NOTE Particles of rubber can indicate cooler line wear Each line should be inspected for cracks or fraying and should be replaced if d
18. Purple SNAP RING SNAP RING REDUCTION UNITS ONLY SNAP RING REDUCTION UNITS ONLY SNAP RING REDUCTION UNITS ONLY SNAP RING REDUCTION UNITS ONLY 34 c c N o NM sch sch sch sch THRUSTWASHER If used between FORWARD PINION FORWARD PINION CASE ASSEMBLY CASE ASSEMBLY CARRIER ASSEMBLY CARRIER ASSEMBLY REDUCTION SE TRANSMISSION MODEL NUMBER 10 17 000 001 NEW STYLE W O BUSHINGS 10 17 065 004 OLD STYLE W BUSHINGS 71B 1A NEW STYLE W SEALING RINGS 10 17 659 012 OLD STYLE W O SEALING RINGS 71 1A2 PINION CARRIER ASSEMBLY NOT USED REDUCTION HOUSING NOT USED forward pinion carrier 0 17 065 004 71B 1A 71C 1 10 17 659 012 71 1A2 NOT USED NOT USED 10 17 659 012 71 1A2 NOT USED NOT USED NOT USED 71 A1K 10 17 659 020 71 1A2A L4 A150 10 17 193 001 10 17 565 002 10 17 565 002 10 17 565 002 _ 71 A1K 10 17 659 020 71 1A2A 10 17 193 001 71 A1K 71 1 71 1A2C 10 17 659 018 71 1A2C NOT USED 71 A1K 10 17 659 016 71 1A2B 10 17 659 006 10 17 193 001 LIL1A2B 10 17 659 010 10 17 193 001 71 A1K 10 17 659 018 71 1A2C 10 17 659 007 10 17 065 001 NOT USED 10 17 565 002 71 A1K 10 17 659 018 71 1A2C 10 17 659 007
19. be tightened to torque shown in Table 4 to prevent premature reduction unit failure Anew coupling nut must be used at assembly Do not disassembie the pinion cage and out put shaft assembly unless damaged The neces sary tools must be available for proper assembly Use exploded view Figure 14 for disassembly and assembly The bearing cup and cone are a matched set If one is damaged both must be replaced A solid spacer is used to control rolling torque end play Rolling torque must be checked after assembly of the reduction unit before assemblv to the transmission NOTE Early reduction units used a collapsible spacer If this spacer must be replaced use the solid spacer NOTE Early reduction units used a bearing re tainer on the output shaft end of the reduction housing To order correct parts refer to exploded view Figure 15 STEP 1 If removed press bearing cone 17 on pinion cage and output shaft 7 STEP 2 If removed press bearing cups 18 and 23 into reduction housing 26 STEP 3 Place oil baffle 25 in reduction hous ing 26 Thread two bolts 24 into reduction housing 26 Tighten bolts 24 to torque shown in Table 4 59 PINION CAGE AND OUTPUT 12804A Bearing Cone Assembly BEARING CUP REDUCTION HOUSING REDUCTION BAFFLE 1 12807A Oil Baffle installation
20. each selector location See Figure 7A e Read OEM manual for complete installation in structions Installation literature is available from Borg Warner Automotive Transmission Systems Request Form No 1131 e Connect oil line to oil to the cooler outlet See Figure 7B 28 SHIFT LEVER DETENT BALL O CENTERED IN Figure 7A Shift Cable Adjustment BREATHER MAINLINE PRESSURE TAP REVERSE CLUTCH PRESSURE TAP e 3 A REMOVE PLASTIC SHIPPING PLUG p S Y 5 5 2 N COOLER OUTLET 127T85A Figure 7B Oil to Cooler Outlet Figure 8 71C and 72C Transmission Assembly Current Production 29 127186 M 10 17 000 10 18 000 4775L 4547BA 4547AY 72 7 0000179859 10 00 183 043 0000103322 710 110 B111AG B308AGS B309AGS 71 147 72 147 10 17 559 001 10 13 559 001 10 04 034 002 71 79B 9418892 0000108579 0000103340 0000453632 71 42 10 00 640 004 NO NUMBER 10 00 141 046 10 16 039 001 0000179796 0000103318 10 16 039 001 71 14 71 A244A 4821 71 246 71 242 71 243 4804H PART DESCRIPTION NUMBER TRANSMISSION ASSEMBLY MODEL 71C TRANSMISSION ASSEMBLY MODEL 72C 9 e a e 9 e e e e 9 9 8 9 8 9 e e e 9 9 9 OUTPUT SHAFT NUT COUPLING 10 17 ONLY COUPLING 10 18 ONLY BEARING RETAINER 10 17 O
21. parts in Figure 12 All other parts are the same DESCRIPTION REDUCTION UNIT 1 91 1 ONLY e e e 9 4 e e e 9 9 e COUPLING NUT COUPLING 72C ONLY COUPLING 71C ONLY HEX HEAD BOLT 7he 14 x 1 14 LOCKWASHER hei BEARING RETAINER BEARING RETAINER GASKET OIL SEAL BEARING MAIN SHAFT REDUCTION HOUSING 57 12803A A ck sch D ED ch nuestra bp Ptr e UT NN E e HH ANE tt 2 57 1 AND 2 91 1 REDUCTION UNITS A DESCRIPTION The 2 57 1 and 2 91 1 reduction units are mounted on the back of a 71C or 72C transmis sion The reduction unit output shaft rotates the same direction as the input shaft on the transmis sion The output shaft rotates about one turn for every two and one half to three turns of the input shaft Lubricating oil is supplied to the reduction unit through ports on the back of the transmis sion NOTE For inspection maintenance and troubleshooting refer to the Table of Contents at the front of this manual B OVERHAUL The general overhaul information described on page 12 applies to these reduction units Before starting disassembly review the exploded view shown in Figure 14 The reduction unit can be disassembled following the index numbers in Figure 14 The following procedures are correct for most reduction units Minor differences may be found 58 CAUTION Threaded plugs screws bolts and coupling nut must
22. shown in Table 4 63 Reduction Housing Installation EE eM DON AN We MAK Q i eg x NS PA RAS i BN Figure 14 2 57 1 and 2 91 1 Reduction Units Current Production 64 19J 20 21 NO NUMBER NO NUMBER 0000179864 0000103322 0000179840 0000103321 10 00 71 49 034 10 00 031 001 10 17 659 007 10 17 659 008 L6 135 L4 135 R10B 40 4717B L5 39 L6 43 L3 43 4741 L3 41 L6 5 L4 5 10 17 159 003 10 17 159 004 NO NUMBER 10 00 133 010 10 00 133 009 10 17 053 002 10 17 053 003 10 17 053 004 10 17 053 005 10 17 053 006 10 17 053 007 10 17 053 008 10 17 053 009 10 17 053 010 10 17 053 011 10 17 053 012 10 00 044 017 NO NUMBER REDUCTION UNIT ASSEMBLY 2 57 1 REDUCTION UNIT ASSEMBLY 2 91 1 9 4 9 9 9 9 9 99 e e HEX HEAD BOLT 7he 14 x 1 9 4 LOCKWASHER 7 16 HEX HEAD BOLT 3 e 18 x 1 e LOCKWASHER 5 8 COUPLING NUT COUPLING PINION CAGE AND OUTPUT SHAFT ASSEMBLY 2 57 1 ONLY PINION CAGE AND OUTPUT SHAFT ASSEMBLY 2 91 1 ONLY OIL COLLECTOR RING 2 57 1 ONLY OIL COLLECTOR RING 2 91 1 ONLY PINION SHAFT PIN 2 57 1 ONLY PINION SHAFT PIN 2 91 1 ONLY PINION SHAFT THRUSTWASHER 2 57 1 ONLY THRUSTWASHER 2 91 1 ONLY ROLLER BEARING PINION BEARING SPACER PINION GEAR 2 57 1 ONLY PINION GEAR 2 91 1 ONLY PINION CAGE AND OUTPUT SHAFT 2 57 1 ONLY PINION CAGE AND OUTPUT SH
23. signs of leakage around housing and or bolts CAUTION if oil is discolored or A has been overheated above 190 F it must be replaced Remove dipstick Check oil for signs of water or other contaminants Check smell oil for signs of burnt oil overheating If found replace fluid See Maintenance Inspect breather Check for movement of cap H no movement replace breather Check mounting bolts for tightness If loose tighten to torque specified in OEM manual WEEKLY PERIODIC 1 month or 100 hours whichever comes first SAFETY Annual or 1000 hours whichever comes first MAINTENANCE A GENERAL Maintenance to the transmission will normally consist of the following items e Checking oil level or changing oil Regular scheduled oil changes are an important part of transmission maintenance WARNING SHIFT LINKAGE MUST A BE ADJUSTED FOR PROPER OPER ATION OF TRANSMISSION NOTE For details on each of these adjustments refer to the OEM manual e Checking pressure in each circuit if a problem is detected CAUTION Transmission mounting AN boits should be checked and tight ened to torque specified in OEM manual Do not overtighten Damage to the transmission can result B LUBRICATION Due to the various installation angles and oil cooler set ups it may be necessary to adjust your oil level WARNING DO NOT REMOVE DIP STICK WITH ENGINE RUNNING HOT OIL CAN CAUSE BURNS the
24. 09 10 18 000 010 10 18 000 011 10 18 000 012 AS14 72C AS14 72CR AS15 72C AS15 72CR 2 57 1 2 57 1 2 91 1 2 91 1 2 83 1 2 83 1 3 20 1 3 20 1 bx 10 18 000 013 10 18 000 014 AS20 72CR 10 18 000 015 None 10 18 000 106 None 10 18 000 017 None AS20 72C 1 10 1 1 10 1 1 10 1 1 1011 1 10 1 1 1 pr E ES sis The following international symbols are used in this service manual WARNING THIS SYMBOL WARNS OF POSSIBLE PERSONAL INJURY CAUTION This symbol warns of possible damage to transmission OEM Original Equipment Manufacturer Boat Engine Manufacturer TABLE OF CONTENTS Section Page DESCRIPTION us deg ass OAR beds Bone eds ee ibq a pu ek OES ee 1 As Introduction da coke ws E ERES ve OR ep E ERR 1 B Theory ol Operation r ous oyu redu E adve dra iate dev CH SH ct e o dn 1 INSPECTION s ed eae e argus EA aoi o Ee 4 A GONG Al eres ce ys r p E Sq s OL QUE Mau Fea es 4 B Scheduled inspection Z tee 4 MAINTENANCE z na i dh pa jt en ON a eer e x ed s ua SN ILE eh 6 A GENTA EE 6 B L bricatl n n a ege IR t 6 TROUBLESHOOTING cran E xa x ACE ESTEE A DeL DORT OPERE We ee 8 A Generales ck eae efus x peus RU s sve Aga 8 B Guidelini s RR USERS EX PESO apu Da Reda ulus Ve 8 e et ET EEN 12 A General ERIE E Oke uL LP Raed NA 12 B Dis assemDiy a e pea
25. 14 Place reduction housing 20 on trans mission Turn coupling 6 to engage ring gear 10 with pinion gears 29 and 35 Thread two bolts 1 with lockwashers 2 into transmission Thread six bolts 3 with lockwashers 4 into re duction housing 20 Tighten bolts 1 and 3 in a criss cross pattern to torque shown in Table 4 73 ka REDUCTION HOUSING REDUCTION HOUSING Reduction Housing Installation PS E 5 m o gt ke D det c o x dew o o Ls E 2 o 2 o o a Leg e y x 2 o U 74 PART DESCRIPTION QTY NUMBER FIG 16 NO NUMBER REDUCTION UNIT ASSEMBLY 2 10 1 1 0000179864 HEX HEAD BOLT 746 14 x 1 314 2 2 0000103322 e LOCKWASHER 7 16 2 3 0000179840 e HEX HEAD BOLT 26 18 x 1 e 6 4 0000103321 e LOCKWASHER is 6 5 10 00 149 034 COUPLING NUT 1 6 10 00 031 001 e COUPLING 1 7 4756D e SNAP RING 1 8 10 17 671 001 e OUTPUT SHAFT AND BUSHING ASSEMBLY 1 9 A4867DD e BUSHING KIT 1 10 L3 6 RING GEAR 1 11 NO NUMBER BEARING ASSEMBLY 1 12 10 00 133 010 e BEARING CONE 1 13 10 00 133 009 e BEARING CUP 1 14 10 17 053 002 SOLID SPACER 820 821 INCH LONG 1 14A 10 17 053 003 SOLID SPACER 829 830 INCH LONG 1 148 10 17 053 004 e SOLID SPACER 832 833 INCH LONG 1 14C 10 17 053 005 SOLID SPACER 835 836 INCH LONG 1 14D 10 17 053 006 e SOLID SPACER 838 839
26. 4 STEP 21 Apply vasoline to bronze thrustwasher 77 install over end of shaft and against face of gear 20 BRONZE THRUST WASHER Thrustwasher Assembly 12636A Nae i D PSE sta STEP 22 Install clutch and drive gear assembly 82 in case 98 Rotate clutch and drive gear assembly 82 back and forth to engage ring gear teeth with pinion gear teeth STEP 23 If original case and clutch cylinder are used install thrustwasher 59 on face of clutch cylinder On mode 10 18 transmissions select new thrustwasher 59 as follows Position case vertically as shown Measure from face of case 98 without gasket 49 to face of clutch cylinder When dimension is 0 433 inch 11 0 mm or less use 71 15B thrustwasher When dimension is greater than 0 433 inch 11 0 mm use 10 16 193 001 thrustwasher STEP 24 Install one bronze reverse clutch fric tion plate 56 in case 98 21 FACE OF CLUTCH CYLINDER Thrustwasher installation REVERSE CLUTCH FRICTION 12654A Friction Plate Installation 7 BEQMBNRBUBERTRSNU terret ttt PN MIA STEP 25 install three dowel pins 58 and eleven pressure plate springs 57 in case 98 STEP 26 Install one steel separator plate 55 in case 98 with large part of tab to left of dowel pin 58 Alternately stack remaining reverse clutch fric tion plates 56 and steel separator plates 55 in case 98 STEP 27 In
27. 4741A e ROLLER BEARING 192 L3 5 e LH PINION GEAR 4 10 17 659 005 PLANETARY CAGE ASSEMBLY 1 10 17 659 009 e PLANETARY CAGE ASSEMBLY 1 L4 146 REAR ADAPTER GASKET 1 10 00 183 073 e LOCK BOLT 7he 14 x 7e 6 115550 LOCKWASHER 7 16 6 4766A e SNAP RING 1 10 17 165 002 SUN GEAR 1 L5 8A e REDUCTION UNIT ADAPTER 1 L4 145 FRONT ADAPTER GASKET 1 REPLACE BOTH PARTS IF ONE IS DAMAGED SELECT CORRECT SIZE SPACER AT ASSEMBLY ONLY ONE REQUIRED USED WITH TRANSMISSIONS 10 17 000 009 AND 10 18 000 007 HAS DRILL SPOTS ON PLANETARY CAGE FOR IDENTIFICATION USED WITH TRANSMISSIONS 10 17 000 010 AND 10 18 000 008 76 M sey Figure 17 2 10 1 Reduction Units Early Production INDEX PART DESCRIPTION NO NUMBER REDUCTION UNIT 2 10 1 Uu ege eege 9 6 5 e OO OD JO Q Q FO N mub ok COUPLING NUT COUPLING 72C ONLY COUPLING 71C ONLY HEX HEAD BOLT 7he 14 x 1 1 4 LOCKWASHER 7he BEARING RETAINER BEARING RETAINER GASKET OIL SEAL BEARING OUTPUT SHAFT AND BUSHING ASSEMBLY SUN GEAR REDUCTION HOUSING A e 0 NOTE These early production parts are not interchangeable with current production parts in Figure 16 All other parts are the same 77 EENEG tt I EQ POP md idene ar SERVICE NOTES
28. 5 0 055 Clearance for paper pack 71C 0 018 0 053 Clearance for paper pack 72C 0 021 0 046 PART SNAP RING THICKNESS 4768 050 054 1 3 1 4 4768A 074 078 1 9 2 0 4768B 096 100 2 4 2 5 10 00 139 018 062 066 1 6 1 7 10 00 139 048 033 037 84 94 10 00 139 049 050 054 1 27 1 37 aman tins STEP 17 install 5 groove of ring gear STEP 18 If removed install woodruff key 81 in drive gear assembly 82 Slide forward clutch hub 80 on drive gear assembly 82 and align with woodruff key 81 Press forward clutch hub 80 on drive gear assembly 82 and against shoulder Install snap ring 79 in groove of drive gear as sembly 82 Lubricate sealing rings 78 with vasoline and in stall in grooves of drive gear assembly 82 Compress each sealing ring 78 until it locks in place 19 SNAP RING GROOVE 11840A Snap Ring Selection SNAP RING GROOVE 11841A Snap Ring Assembly FORWARD CLUTCH HUB SEALING RINGS DRIVE GEAR ASSEMBLY Sealing Ring Installation eA TIPE pe PSR Aan STEP 19 Install drive gear assembly 82 in clutch assembly Slide bearing 63 down drive gear assembly 82 Place complete assembly in press Press bearing 63 into drive gear assembly 82 until seated against shoulder STEP 20 Install snap rings 61 and 62 in grooves of drive gear assembly 82 and forward clutch cylinder 6
29. 6 REAR ADAPTER GASKET 1 L7 8A REDUCTION UNIT ADAPTER 1 4816 SNAP RING 1 B308AGS BEARING 1 L4 145 FRONT ADAPTER GASKET 1 REPLACE BOTH PARTS IF ONE IS DAMAGED SELECT CORRECT SIZE SPACER AT ASSEMBLY ONLY ONE REQUIRED E P 66 12813A Figure 15 2 57 1 AND 2 91 1 Reduction Units Early Production PART DESCRIPTION NUMBER FIG 15 NO NUMBER REDUCTION UNIT 2 57 1 ONLY E 15A NO NUMBER REDUCTION UNIT 91 1 ONLY E 1 10 00 149 034 e COUPLING NUT 1 2 4912 e COUPLING 1 3 0000179860 HEX HEAD BOLT 7he 14 x 1 1 4 6 4 0000103322 LOCKWASHER 7 16 6 5 L4 7 BEARING RETAINER 1 6 L4 147 BEARING RETAINER GASKET 1 7 71C 110 e OIL SEAL 1 8 4920 BEARING 1 9 L6 A2D PINION CAGE AND OUTPUT SHAFT 1 ASSEMBLY 2 57 1 ONLY 9A L7 A2D PINION CAGE AND OUTPUT SHAFT 1 ASSEMBLY 2 91 1 ONLY 10 L7 1A REDUCTION HOUSING 1 NOTE These early production parts are not interchangeable with current production parts in Figure 14 Ail other parts are the same 67 MM x vem emmer LP Y vr P 2 10 1 REDUCTION UNIT A DESCRIPTION The 2 10 1 reduction unit is mounted on the back of a71C or 72C transmission The reduction unit output shaft rotates the same direction as the in put shaft on the transmission The output shaft rotates about one turn for every two turns of the input shaft Lubricating oil is supplied to the re duction unit through ports on the back of the transmission NOTE For in
30. 6 06 9 49 9 CAN BE PURCHASED TO ADD ANOTHER PILOT LIGHT TO THE DRIVE GEAR ALARM KIT CAN NOT BE USED SEPARATELY M soe a n SPECIFICATIONS CAUTION Threaded plugs screws bolts and coupling nuts must be AN tightened to torque shown in this table to prevent premature failure of transmission or reduction unit Tabie 4 Bolt and Fastener Torques Non Lubricated PART NUMBER DESCRIPTION FTLB Nm 9418892 0000179796 4775L 0000179859 10 00 183 043 10 00 183 073 0000179864 10 04 034 002 10 00 183 021 4911 4885B 0000444866 0000444687 10 00 640 004 4853E 0000179840 4853B 4776BB 10 00 149 034 5he 24 Shift Lever Nut 4 20 x Ya Hex Head Bolt Coupling Nut 76 14 x 1 14 Hex Head Bolt 7The 14 x 1 1 4 Hex Head Bolt Self Locking 7hie 14 x 78 Lock Bolt 76 14 x 1 3 4 Hex Head Bolt Dipstick Tube She 18 x 1 Hex Head Bolt 3 s 16 x 1 1 4 Capscrew 3 4 14 Dryseal Bushing 3 s 18 Pipe Plug 1 e 27 Pipe Plug 56 18 Switch Assembly 7he 14 x 1 3 4 Lock Bolt 3 6 18 x 1 s Hex Head Bolt 5 16 18 x 3 4 Lock Bolt 7he 14 x a Lock Bolt Coupling Nut Table 5 Spring Dimensions PART WHERE NUMBER Eed 6 jo APPROX FREE LENGTH 37 8 11 8 11 160 260 42 50 42 50 42 50 42 50 10 40 17 22 27 37 25 35 17 27 7 12 20 30 42 50 27 37 17 22 42 50 220 260 APPROX 0 D mm m mm DIAMETER OF WIRE in mm 11 15 11 15 217 353 57 6
31. 7 053 007 10 17 053 008 10 17 053 009 10 17 053 010 10 17 053 011 10 17 053 012 10 00 044 017 NO NUMBER 10 00 133 002 10 00 133 001 10 17 065 001 L4 146 10 00 183 073 0000103322 L4 8B 4766 B111AG 4756D 4 16 L3 6 L4 145 DESCRIPTION REDUCTION UNIT ASSEMBLY 1 523 1 HEX HEAD BOLT 7he 14 x 1 3 4 9 e e e ee 5 e 9 9 e 0 0 e e e e 9 5 94 46 e 9 amp e e e 6 9 9 9 9 ge 0 9 ge 99 go LOCKWASHER 7 16 HEX HEAD BOLT 05 18 x 1 1 8 LOCKWASHER 3 6 COUPLING NUT COUPLING SNAP RING PINION CARRIER ASSEMBLY OIL COLLECTOR RING PINION SHAFT PIN PINION SHAFT PINION THRUSTWASHER PINION BEARING SPACER ROLLER BEARING PINION GEAR PINION CAGE LOCK BOLT 7he 14 x 7 8 SUN GEAR HUB SNAP RING SUN GEAR MAIN SHAFT BEARING ASSEMBLY BEARING CONE BEARING CUP SOLID SPACER 820 821 INCH LONG SOLID SPACER 829 830 INCH LONG SOLID SPACER 832 833 INCH LONG SOLID SPACER 835 836 INCH LONG SOLID SPACER 838 839 INCH LONG SOLID SPACER 841 842 INCH LONG SOLID SPACER 844 845 INCH LONG SOLID SPACER 847 848 INCH LONG SOLID SPACER 850 851 INCH LONG SOLID SPACER 853 854 INCH LONG SOLID SPACER 856 857 INCH LONG OIL SEAL BEARING ASSEMBLY BEARING CONE BEARING CUP REDUCTION HOUSING REAR ADAPTER GASKET LOCK BOLT he 14 x 7 6 LOCKWASHER 7 16 REDUCTION UNIT ADAPTER SNAP RING BEARING SNAP RING INPUT GEAR RING GEAR FRONT ADAPTER
32. 8 57 68 57 68 57 68 14 55 23 30 37 50 34 48 23 37 9 16 28 42 57 68 37 50 23 30 57 68 298 352 3 1 1 i PRESSURE TAP Neutral Line Reverse Clutch Reverse Main Forward Main Reverse Cooler Flow Forward Cooler Flow SPECIFICATIONS Continued Table 6 Test Pressures NOT USED NOT USED 125 NOT USED 120 125 NOT USED 160 NOT USED NOT USED NOT USED 827 862 NOT USED 827 862 NOT USED 13 25 NOT USED NOT USED NOT USED 1103 NOT USED 965 1103 NOT USED 6 8 24 6 NOT USED f i NOTE Pressures shown are typical at an oil temperature of 140 degrees F Variations can occur due io plumbing fittings and cooler differences NOTE Forward clutch feed does not have an external tap for checking pressure When selector is in F position line pressure indicates clutch pressure Pressure drop from N to F indicates leak age in forward clutch circuit i 38 1 523 1 REDUCTION UNITS A DESCRIPTION The 1 523 1 reduction unit is mounted on the back of a 716 or 72C transmission The reduc tion unit output shaft rotates the same direction of the input shait on the transmission The output shaft rotates about one turn for every one and one half turns of the input shaft Lubricating oil is supplied to the reduction unit through ports on the back of the transmission NOTE For
33. AFT 2 91 1 ONLY BEARING ASSEMBLY BEARING CONE BEARING CUP SOLID SPACER 820 821 INCH LONG SOLID SPACER 829 830 INCH LONG SOLID SPACER 832 833 INCH LONG SOLID SPACER 835 836 INCH LONG 3 SOLID SPACER 838 839 INCH LONG SOLID SPACER 841 842 INCH LONG y 9 9 4 e 9 99 SOLID SPACER 844 845 INCH LONG SOLID SPACER 847 848 INCH LONG SOLID SPACER 850 851 INCH LONG SOLID SPACER 853 854 INCH LONG SOLID SPACER 856 857 INCH LONG OIL SEAL BEARING ASSEMBLY REPLACE BOTH PARTS IF ONE IS DAMAGED SELECT CORRECT SIZE SPACER AT ASSEMBLY ONLY ONE REQUIRED 65 INDEX PART DESCRIPTION NO NUMBER sch sch ch sech sech seh s PART DESCRIPTION QTY NUMBER 10 00 133 002 BEARING CONE 1 10 00 133 001 BEARING CUP 1 4776BB e LOCK BOLT 7he 14 x 7s 2 10 17 036 001 OIL BAFFLE 1 10 17 065 001 REDUCTION HOUSING 1 4734 e SNAP RING 1 L6 104 SUN GEAR 2 57 1 ONLY 1 L7 104 SUN GEAR 2 91 1 ONLY 1 4853E e LOCK BOLT 7 e 14 x 1 1 6 0000115550 e LOCKWASHER 716 6 4756E SNAP RING 2 57 1 ONLY 1 4756D SNAP RING 2 91 1 ONLY d L6 31 STATIONARY GEAR PLATE 2 57 1 ONLY 1 L7 31 e STATIONARY GEAR PLATE 2 91 1 ONLY 1 L6 6 RING GEAR 2 57 1 ONLY 1 L3 6 e RING GEAR 2 91 1 ONLY 1 L4 14
34. Cable Adjustment 28 7B Olto Cooler Qute osue ead rre eee 28 8 71C and 72C Transmission Assembly Current Production 29 9 Optional Drive Gear Alarm KIS nte vde Dhe e Ea eer bes ee OR aod ced 35 10 1 523 1 Reduction Units Current Production aaa 45 11 1 523 1 Reduction Units Early Production 47 12 1 88 1 and 1 91 1 Reduction Units Current Production 54 13 1 88 1 and 1 91 1 Reduction Units Early Production 57 14 2 57 1 and 2 91 1 Reduction Units Current Production 64 15 2 57 1 and 2 91 1 Reduction Units Early Production 67 16 2 10 1 Reduction Units Current Production 74 17 2 10 1 Reduction Units Early Production e 77 LIST OF TABLES Title Page 1 Technical Specifications 1 2 Scheduled Inspections 4 8 Iro bleshootirig L u ce fy uw eee umay 24840 cen Eh Ha EE AR SEH 9 4 Bolt and Fastener Torques Non Lubricated 37 RR e EE 37 6 Testi PresSUleS an pos ban URL AREA e RR a ed e ate 38 iii EE DESCRIPTION SHIFT LEVER COOLER OUTLET SEE FIG 7B PAGE 28 BREATHER DIPSTICK ID TAG MODEL NO SERIAL NO NEUTRAL SWITCH COOLER RETURN NOTE SHOWN WITHOUT REDUCTION UNIT 12646A Figure 1 71C and
35. GASKET REPLACE BOTH PARTS IF ONE IS DAMAGED SELECT CORRECT SIZE SPACER AT ASSEMBLY ONLY ONE REQUIRED 46 ze xx KR A m oA 0 2 A oA o A zeck ck e o eA A sch o o P sch 39 OO CD GO CO o sch CO PO N LEES Figure 11 1 523 1 Reduction Units Early Production INDEX PART NO NUMBER NO NUMBER 4775L 4547AY 4547BA 0000179860 0000103322 L4 7 L4 147 71C 110 4920A L9 2 L4 4 4808 L4 151 103891 L4 1A 0 0 DA Q N O o NOTE These early production parts are not interchangeable with current production parts in Figure 10 All other parts are the same DESCRIPTION REDUCTION UNIT 9 9 99 9 e 49 e 0 e 9 e COUPLING NUT COUPLING 72C ONLY COUPLING 71C ONLY HEX HEAD BOLT 7he 14 x 1 14 LOCKWASHER BEARING RETAINER BEARING RETAINER GASKET OIL SEAL BEARING MAIN SHAFT SUN GEAR SPRING PIN PINION CAGE DRIVE PIN EXPANSION PLUG REDUCTION HOUSING 47 128i7A M sch sch eL G QD sch RRRRRRRRRRRRRRRRRRRRRRRRERE R E 1 88 1 AND 1 91 1 REDUCTION UNITS A DESCRIPTION The 1 88 1 and 1 91 1 reduction units are mounted on the back of a 71C or 72C transmis sion The reduction unit output shaft rotates the opp
36. HOUSING 12790A Spacer and Bearing Cone Assembly PRESS BEARING CONE REDUCTION HOUSING REDUCTION HOUSING Oil Seal Assembly STEP 7 Slide coupling 6 on main shaft 8 Thread nut 5 on main shaft 8 Tighten nut 5 to torque shown in Table 4 Attach a torque wrench to nut 5 Turn torque wrench to check rolling torque of bearings 11 and 16 Rolling torque should be 5 to 30 in Ibs If rolling torque is over 30 in lbs replace spacer 13 with a longer one If rolling torque is under 5 in ibs replace spacer 13 with a shorter one NOTE Selection of the proper spacer 13 wiil result in 0 to 0 005 inch end play STEP 8 if removed instali bearing 41 and snap ring 40 in transmission Lubricate front adapter gasket 42 with vasoline and install on transmission STEP 9 install reduction unit adapter 39 on transmission Thread six boits 37 with lockwashers 38 into transmission Tighten bolts 37 in a criss cross pattern to torque shown in Tabie 4 51 COUPLING COUPLING NUT REDUCTION HOUSING Reduction Unit Adapter Installation PP EEEEEen E i x STEP 10 For the 1 91 1 reduction unit do the following CAUTION The o ring can only be in AN stalled on a reduction unit adapter with the hub turned down For com plete details refer to Borg Warner Automotive Service Bulletin MB62 Lubricate o ring 35 with vas
37. INCH LONG 1 14E 10 17 053 007 SOLID SPACER 841 842 INCH LONG 1 14F 10 17 053 008 SOLID SPACER 844 845 INCH LONG 1 14G 10 17 053 009 e SOLID SPACER 847 848 INCH LONG 1 14H 10 17 053 010 SOLID SPACER 850 851 INCH LONG i 141 10 17 053 011 SOLID SPACER 853 854 INCH LONG 1 14J 10 17 053 012 SOLID SPACER 856 857 INCH LONG 1 15 10 00 044 017 OIL SEAL 1 16 NO NUMBER BEARING ASSEMBLY 1 17 10 00 133 002 e BEARING CONE 1 18 10 00 133 001 BEARING CUP 1 19 10 00 191 002 PLASTIC PLUG 1 20 10 17 065 002 e REDUCTION HOUSING 1 21 L3 24 THRUSTWASHER 2 22 10 17 659 006 e PINION CAGE ASSEMBLY 1 22A 10 17 659 010 e PINION CAGE ASSEMBLY 1 23 L4 135 OIL COLLECTOR RING 1 24 4717L PINION SHAFT PIN 4 25 L5 39A e PINION SHAFT 4 26 72 43 e e PINION THRUST PLATE 4 27 4741A e ROLLER BEARING 192 28 L3 41 e PINION BEARING SPACER 4 REPLACE BOTH PARTS IF ONE iS DAMAGED SELECT CORRECT SIZE SPACER AT ASSEMBLY ONLY ONE REQUIRED USED WITH TRANSMISSIONS 10 17 000 009 AND 10 18 000 007 HAS DRILL SPOTS ON PLANETARY CAGE FOR IDENTIFICATION USED WITH TRANSMISSIONS 10 17 000 010 AND 10 18 000 008 75 EENS n INDEX PART DESCRIPTION NO NUMBER L3 105 e RH PINION GEAR 4 R4 40 PINION SHAFT PIN 4 L5 39 PINION SHAFT 4 72 43 e PINION THRUST PLATE 4 L3 41 e PINION BEARING SPACER 12
38. LLEVILLE SPRING DISHED FORWARD CLUTCH CYLINDER 11836A Clutch Spring Assembly e SE S ESSE STEP 13 Install ring gear 76 over forward clutch cylinder 64 with piston 65 and spring 69 facing up Press ring gear 76 down over for ward clutch cylinder 64 CAUTION Check to see that clutch spring bearing ring 68 is still seated in the groove of clutch piston 65 STEP 14 Remove clutch assembly from press Install snap ring 60 in groove of ring gear 76 CAUTION Several different snap rings are used to assemble the clutch group They have different thicknesses Be sure the correct snap ring is used STEP 15 Place ring gear 76 in press with ex ternal splines facing down Assembly tool should support the ring gear 76 only The forward clutch cylinder 64 should not be touching the assembly tool Press forward clutch cylinder 74 against snap ring 60 Remove clutch assembly from press 18 EXTERNAL TEETH FORWARD CLUTCH CYLINDER 12652A 11838A RIM OF CLUTCH CYLINDER Compressing Clutch Pack HG ewes STEP 16 Push down by hand on clutch plates Measure snap ring gap Select proper thickness snap ring 75 or combination of snap rings 75 to set clutch pack clearance Refer to chart be low More than one snap ring may be required Clearance for bronze pack 71C 0 018 0 053 Clearance for bronze pack 72C 0 03
39. LUTCH PLATE STEEL CLUTCH PLATE PLATE 11830A Forward Clutch Pack Arrangement STEP 7 Install clutch plates 72 and 73 and pressure plate 71 in ring gear 76 STEP 8 STEP 9 Install snap ring 70 in ring gear 76 CAUTION Several different snap rings are used to assemble the clutch group They have different thicknesses Be sure the correct snap ring is used Lubricate O ring 66 lightly with vaso line and install in groove of forward clutch cylin der 64 16 PRESSURE CLUTCH aue PEATE PLATES f ee 11831A PRESSURE 11832A FORWARD CLUTCH CYLINDER O Ring Installation ka u lt lt lt racr Amen STEP 10 Lubricate clutch spring bearing ring 68 and piston sealing ring 67 with vasoline Install clutch spring bearing ring 68 in groove on piston 65 face Install piston sealing ring 67 in outer groove of piston 65 NOTE Check that piston sealing ring 67 is not twisted cut or deformed Replace if damaged STEP 11 install piston 65 in forward clutch cyl inder 64 STEP 12 Place clutch belleville dish spring 69 inside rim of forward clutch cylinder 64 Spring is dished The inside of the spring should be lower than the outside 17 CLUTCH SPRING BEARING RING PISTON PISTON SEALING RING Clutch Rings installation FORWARD CLUTCH CYLINDER PISTON 11835A Piston Installation CLUTCH BE
40. N THRUSTWASHER 4741A e ROLLER BEARING 1 91 1 ONLY 2 e 29A 10 00 131 011 e ROLLER BEARING 1 88 1 ONLY 288 30 L3 41 PINION BEARING SPACER 1 91 1 ONLY 6 30A 10 00 053 024 e PINION BEARING SPACER 1 88 1 ONLY 18 31 L4 5 e PINION GEAR 1 91 1 ONLY 6 31A 10 17 163 002 e PINION GEAR 1 88 1 ONLY 6 32 L9 150 e e PLANETARY CAGE 1 91 1 ONLY 1 32A 10 17 159 011 PLANETARY CAGE 1 88 1 ONLY 1 33 10 17 045 001 PINION CARRIER GASKET 1 91 1 ONLY 1 34 L9 99 LUBE OIL STRAINER 1 91 1 ONLY 1 35 10 00 141 149 O RING 1 91 1 ONLY 1 36 L4 146 5 REAR ADAPTER GASKET 1 37 10 00 183 073 e LOCK BOLT 76 14 x 7la 6 38 0000103322 e LOCKWASHER he 6 39 L9 8A e REDUCTION UNIT ADAPTER 1 39A 10 17 172 001 REDUCTION UNIT ADAPTER 1 40 4816 e SNAP RING 1 41 B308AGS e BEARING 1 42 L4 145 e FRONT ADAPTER GASKET 1 REPLACE BOTH PARTS IF ONE IS DAMAGED SELECT CORRECT SIZE SPACER AT ASSEMBLY ONLY ONE REQUIRED FOR USE WITH 1 91 1 NOISE REDUCTION PARTS THESE INCLUDE LOCK PLATES 23 PINION CARRIER GASKET 33 AND O RING 35 FOR USE WITH 1 88 1 OR 1 91 1 WITHOUT NOISE REDUCTION PARTS e 56 Figure 13 1 91 1 Reduction Units Early Production PART NUMBER NO NUMBER 4775L 4547AY 4547BA 0000179860 0000103322 L4 7 L4 147 71C 110 4920A L5 A2 L5 1A 1 2 2 3 4 5 6 7 8 9 0 NOTE These early production parts are not interchangeable with current production
41. NLY BEARING RETAINER 10 18 ONLY HEX HEAD BOLT 6 14 x 1 14 10 17 ONLY HEX HEAD BOLT 7he 14 x 1 1 10 18 ONLY LOCKWASHER 7 16 10 17 ONLY OIL SEAL BEARING 1 Pkg BEARING 10 17 BEARING 10 18 BEARING RETAINER GASKET 10 17 ONLY BEARING RETAINER GASKET 10 18 ONLY ADAPTER ADAPTER ADAPTER LOCK BOLT 7he 14 x 7 6 LOCKWASHER 7 16 10 18 ONLY LOCKWASHER 7 16 10 17 ONLY HEX HEAD BOLT he 14 x 1 3 4 LOCKWASHER 7 16 ADAPTER GASKET BEARING RETAINING RING DIPSTICK ALL DIRECT DRIVES EXCEPT 015 AND 016 DIPSTICK FOR 015 AND 016 DIPSTICK TUBE SHIFT LEVER HEX NUT 5 16 24 LOCKWASHER 5 16 FLATWASHER 5 16 STEEL BALL 5 19 POPPET SPRING NEUTRAL SWITCH ASSEMBLY NEUTRAL SWITCH NSS O RING VALVE COVER HEX HEAD BOLT 1 20 x 1 2 LOCKWASHER 1 4 SWITCH CAM VALVE COVER GASKET CONTROL VALVE ASSEMBLY SNAP RING e SPRING RETAINER VALVE SPRING REGULATOR VALVE O RING REFER TO ASSEMBLY NUMBER ON ID TAG See Figure 1 REFER TO REDUCTION SECTION IN BACK OF MANUAL NSS NOT SERVICED SEPARATELY BUY NEXT HIGHER ASSEMBLY 30 G sch A sech wb sch sch sch M Mi OD CD 6 sch sch sch eh he 6 seh sch ENE ui EE ree AA D INDEX PART DESCRIPTION NO NUMBER p 41 42 43 44 45 46 47 NSS NOT SERVICED SEPARATELY
42. ONLY 10 17 410 002 SERVICE GASKET KIT FOR CONTENTS SEE NEXT KIT LIST ee 9 E 9 4 e e 49 4 e b Mi sch sch sch sch sch sch sch PART DESCRIPTION NUMBER 10 17 410 002 SERVICE GASKET KIT 71 147 BEARING RETAINER GASKET 10 17 ONLY 72 147 BEARING RETAINER GASKET 10 18 ONLY L4 146 ADAPTER GASKET 71 14 VALVE COVER GASKET 71 144B GASKET L4 145 GASKET REDUCTION UNITS ONLY L4 147 GASKET REDUCTION UNITS ONLY 10 04 420 052 NEUTRAL SWITCH KIT 10 04 539 001 SWITCH AND BODY ASSEMBLY 10 00 640 004 e NEUTRAL SWITCH ASSEMBLY 10 16 039 001 VALVE COVER 0000179796 HEX HEAD BOLT 4 20 x 0000103319 LOCKWASHER 1 4 10 16 099 001 SWITCH CAM 71 14 VALVE COVER GASKET 1340 INSTRUCTION SHEET C s e 9 9 E 4 8 33 10 95 41 0 002 4766 4821 4822 R6A 7 1 2 4766B 4734 4755 10 00 139 048 10 00 139 049 4768 4768A 4768B 10 00 139 018 4495 4756D 4756E 4816 4766A DESCRIPTION SNAP RING SERVICE KIT RETAINING RING SNAP RING SNAP RING SNAP RING 10 17 ONLY SNAP RING 10 18 ONLY SNAP RING 10 17 ONLY SNAP RING 10 18 ONLY SNAP RING SNAP RING 033 037 THICK 10 17 ONLY Yellow SNAP RING 050 054 THICK 10 17 ONLY Pink SNAP RING 050 054 THICK 10 18 ONLY Green SNAP RING 074 078 THICK 10 18 ONLY Orange SNAP RING 096 100 THICK 10 18 ONLY White SNAP RING 062 066 THICK 10 18 ONLY
43. TYLE CASE 1 87 71 140 OIL BAFFLE 1 87A 718 140 OIL BAFFLE 1 88 10 00 191 002 e PLUG 3 s 18 2 89 4885B e DRYSEAL BUSHING 514 14 1 90 51 222 SPRING 1 91 35 143 FLAT WASHER 1 92 72C 98 OIL INLET SHIELD 1 93 71C 84 OIL RETURN TUBE 1 94 71C A98 OIL STRAINER ASSEMBLY 1 A4740G e BREATHER 1 0000444866 PIPE PLUG 3 18 1 0000444687 e PIPE PLUG 1 27 1 10 17 565 CASE 10 17 ONLY 1 1 10 18 565 CASE 10 18 ONLY CHECK MODEL CHART TO DETERMINE CORRECT PART NUMBER NOTE The following kits are available for the Model 71C and 72C transmissions Index numbers shown match the index numbers on the exploded view Figure 8 PART DESCRIPTION NUMBER A4867AB FORWARD CLUTCH PACK KIT 10 18 ONLY 5C 175A CLUTCH PRESSURE PLATE 3 176 STEEL CLUTCH PLATE 5C A66A FRICTION CLUTCH PLATE 5L 67 CLUTCH PRESSURE PLATE 32 ER PART DESCRIPTION 4 NUMBER A4867AE FORWARD CLUTCH PACK KIT 10 17 ONLY 5C 175A CLUTCH PRESSURE PLATE 3 176 e STEEL CLUTCH PLATE 5C A68A FRICTION CLUTCH PLATE 5L 67 CLUTCH PRESSURE PLATE DESCRIPTION NUMBER A4867HA OIL SEAL AND SEALING RING KIT 71C 110 OIL SEAL 4804H O RING 10 00 044 014 OIL SEAL 3 61 PUMP GASKET 4805A CLUTCH SEALING RING 4804G O RING 5M 122 O RING 5L 36 CLUTCH SEALING RING 4806J SEALING RING 48068 SEALING RING 10 00 044 017 OIL SEAL REDUCTION UNITS
44. allation 43 AA STEP 13 install reduction unit adapter 34 on transmission Thread six bolts 32 with lockwashers 33 into transmission Tighten bolts 32 in a criss cross pattern to torque shown in Table 4 NOTE To install bolts 32 turn ring gear 39 This will align two holes in input gear 38 with re duction unit adapter 34 STEP 14 Lubricate rear adapter gasket 31 with vasoline and install on reduction unit adapter 34 STEP 15 Place reduction housing 30 on trans mission Turn coupling 6 to engage pinion gears 15 with ring gear 39 Thread two bolts 1 with lockwashers 2 into transmission Thread six bolts 3 with lockwashers 4 into re duction housing 30 Tighten bolts 1 and 3 in a criss cross pattern to torque shown in Table 4 44 LOCKWASHER ADAPTER 12830A REDUCTION UNIT ADAPTER LOCKWASHER Reduction Housing Installation HS Figure 10 1 523 1 Reduction Units Current Production 45 ESL PEST e asss PYES KSERA NO NUMBER 0000179864 0000103322 0000179840 0000103321 10 00 149 034 10 00 031 001 4734 L4 A150 L4 135 4717L L5 39 L3 43 L3 41 47414 L4 5 L4 150 4776BB 10 17 179 001 10 00 139 013 10 17 165 001 10 17 171 001 NO NUMBER 10 00 133 010 10 00 133 009 10 17 053 002 10 17 053 003 10 17 053 004 10 17 053 005 10 17 053 006 10 1
45. am aged Fill transmission with new oil NOTE The amount of oil required will vary based on length of cooler lines Use an amount equal to about three fourths the quantity removed install dipstick Run engine for two minutes to fill cooler and cooler lines with oil Set oil level ac cording to procedure at start of section B Lubri cation EE TROUBLESHOOTING A GENERAL Before troubleshooting the transmission do the following e Check ail level and condition of oil See Main tenance section for details e Check transmission oil cooler and oil cooler lines for physical damage or leakage Correct any problem Check that engine damper plate or drive train alignment are not causing the problem Refer to OEM manual or Velvet Drive Installation Manual Form No 1131 for drive train alignment requirements Perform all pressure checks at normal operating temperature Refer to Specification section for details Pressure gauges used should have a range of 0 200 or 0 300 psi They must be accu rate B GUIDELINES When troubleshooting shift into each selector position to determine when noise or problem oc curs Determine which parts are moving This will help pinpoint the cause Use the following infor mation as a guide to common problems Damper Plate Some transmission problems are damper plate related Check and or replace damper plate when the following problem occurs
46. bie the transmission using the following procedures If a reduction unit is mounted to the transmission refer to the correct section at the back of this manual for assembly procedures CAUTION Transmissions manufac AN tured prior to September 1978 used bushings instead of sealing rings If bushings were in case they must be installed before assembly of trans mission See Figure 6 for details HOLES IN BUSHING MUST REGISTER WITH HOLES IN CASE AS SHOWN EACH BUSHING TO BE ASSEMBLED IN CASE BORE TO DIMENSIONS SHOWN 1 3 32 71 28C KIT A4867VV NOTE THE 71 28C BUSHING IS THE PRE SIZED BUSHING FOR FIELD SERVICE OF THE ORIGINAL 71 28B BUSHING INSTALLED AT FACTORY 127T65A Figure 6 Bushing Installation TT NEIN STEP 1 If removed install the following parts in case 98 Tighten threaded parts to torque shown in Table 4 Press bearing 7 into back of case 98 Apply loctite 92 or equivalent to threads of pipe plugs 96 and 97 and thread into top of case 98 Apply loctite 592 or equivalent to threads of dipstick tube 18 and thread into side of case 98 NOTE Piug 88 is a plastic shipping plug and should be installed hand tight STEP 2 install shield 92 in case 98 with siot facing bottom of case 98 Install washer 91 and spring 90 inside shield 92 Apply loctite 92 or equivalent to threads of bushing 89 Thread bushing 89 into side of case 98 and tigh
47. dipstick before removing Small particles of dirt can cause damage to internal components and cause valves to stick CAUTION Clean around the area of Check Oil Level The transmission should he at operating temper ture 190 max to get an accurate oil level read ing Oil will expand when it is heated Oil will drain back from the cooler Expansion and drain back can significantly affect oil level Warm Oil Level Check When the transmission is at operating tempera ture place selector lever in neutral Shut off en gine Carefully remove transmission dipstick immediately insert clean dipstick and read oil level NOTE Oil level must be checked immediately af ter engine shut down to prevent an incorrect reading Oil drains back into transmission from the cooler and cooler lines Add or remove oil if necessary Repeat the above checking procedure as required until oil is at the dipstick mark Cold Oil Level Check For ease of checking the oil prior to engine start up a cold oil level mark can be made To find the cold oil level mark the oil level must first be set according to the warm oil level checking proce dure Then let the boat sit overnight Insert clean dipstick and read oil level Put a mark on the dipstick at the cold oil level reading You can use the new mark to check the oil level when cold If oil level adjustment is needed add oi to the new mark M
48. duction unit adapter 39 STEP 15 Place reduction housing 18 on trans mission Turn coupling 6 to engage ring gear 9 with pinion gears 31 Thread two bolts 1 with lockwashers 2 into transmission Thread six bolts 3 with lockwashers 4 into re duction housing 18 Tighten bolts 1 and 3 in a criss cross pattern to torque shown in Table 4 53 o LOCKPLATE taps H Z 12799A REDUCTION UNIT ADAPTER REDUCTION HOUSING Reduction Housing Installation Premte s RR 098 128 A Ss e ee fl ft AM p ERS N gt H 2 D x ft te Figure 12 1 88 1 and 1 91 1 Reduction Units Current Production FIG 12 PART NUMBER NO NUMBER NO NUMBER 0000179864 0000103322 0000179840 0000103321 10 00 149 034 10 00 031 001 4756D 10 17 171 002 10 17 171 004 L3 6 10 17 162 001 NO NUMBER 10 00 133 010 10 00 133 009 10 17 053 002 10 17 053 003 10 17 053 004 10 17 053 005 10 17 053 006 10 17 053 007 10 17 053 008 10 17 053 009 10 17 053 010 10 17 053 011 10 17 053 012 10 00 044 017 NO NUMBER 10 00 133 002 10 00 133 001 10 17 065 003 4734 L7 104 10 17 165 004 4853B 0000114605 10 00 01 4 002 L9 A150 10 17 659 021 4827 4717L DESCRIPTION QTY REDUCTION UNIT ASSEMBLY 1 91 1 REDUCTION UNIT ASSEMBLY 1 88 1 9 5 9 e 9 5 9 e 9 2 9 9 9 e 9
49. e sticking Broken pitted or cracked gear teeth Broken pitted or cracked gear teeth Broken sealing rings or bushings Warped forward clutch plates or mechanical failure of clutch Exhaust blocked in control valve Warped reverse clutch plates or mechanical failure of clutch Exhaust blocked in control valve Low oil pressure Pump gears worn Cil level low Oil level low Cooler too small or restricted lines Pump pressure low worn or damaged pump Clutches slipping Internal leakage bypassing cooler Temperature sensor defective Incorrect type of oil Regulator valve sticking 11 Check oit level and fill if low Operate engine in neutral at 1200 RPM to remove air Clean and polish Replace defective parts Replace defective parts Replace defective parts Replace defective parts Clean control valve Replace defective parts Clean control valve Repiace pump assembly Add oil Add oil All external oil lines should have minimum inside diameter of 13 32 Cooler must permit free flow of oil Check pressures If low inspect pump If worn or damaged replace Check sealing rings Replace if damaged Locate and fix leak Replace sensor Drain flush and replace with correct type of oil Clean and polish See ene t tS EN OVERHAUL A GENERAL Before removal and disassembly review the fol lowing procedures Use the proper hand tools
50. ect to the in put shaft The damper plate reduces torsional vi brations to the transmission from the engine See Figure 2 ENGINE FLYWHEEL DAMPER ASSEMBLY FLYWHEEL HOUSING Figure 2 Typical installation Forward The forward clutch is applied hydrauli cally when the shift lever is placed in the forward position This connects the input shaft to the out put shaft The unit then transmits power at a 1 to 1 speed ratio in the same direction of rotation as the engine See Figure 3 FORWARD CLUTCH 12668A Figure 3 Forward Power Fiow Reverse The reverse clutch is applied hydrauli cally when the shift lever is placed in the reverse position See Figure 4 The applied clutch holds the rina gear The input shaft and sun gear driven by the engine drive pinions which drive the carrier output shaft The output shaft turns opposite to engine rotation at a 1 1 to 1 speed re duction ratio for model 72C and 1 to 1 speed ra tio for model 71C REVERSE CLUTCH OE d LM LX wb di ken SS Ki 4 SANS X Siy Lhe lt lt ya SS e E Figure 4 Reverse Power Flow MO Ji Hydraulic Circuit Oil from the sump enters the pump suction passage and is directed to the pump See Figure 5 The pump supplies oil un der pressure through passages to the control and regulator valves Oil pressure on the end of the regulator valve moves the valve compressi
51. ed after assembly of the reduction unit before assembly to the transmission NOTE Early 1 91 1 reduction units used a col lapsible spacer If this spacer must be replaced use the solid spacer NOTE Early 1 91 1 reduction units used a bear ing retainer on the output shaft end of reduction housing To order correct parts refer to exploded view Figure 13 STEP 1 if removed press bearing cone 11 on to main shaft 8 STEP 2 Install main shaft 8 in ring gear 9 In stall snap ring 7 in groove of ring gear 9 12788A Main Shaft Assembly E E STEP 3 If removed press bearing cups 12 and BEARING CUP 17 into reduction housing 18 mp HOUSING Bearing Cup Assembly 49 STEP 4 Install main shaft 8 and ring gear 9 in reduction housing 18 Support ring gear 9 Instail original spacer 13 and bearing cone 16 in reduction housing 18 CAUTION If original spacer is not AN used the replacement spacer should be the same length Using an incor rect size spacer can result in prema ture failure of reduction unit STEP 5 Place reduction housing 18 in press with ring gear 9 supported Press bearing cone 16 on main shaft 8 Remove reduction housing 18 from press STEP 6 Install oi seal 14 in reduction housing 18 Outer surface of oil seal 14 should be flush with reduction housing 18 face 50 d BEARING 5 SOLID SPACER REDUCTION
52. gear teeth gears not meshed Heavy weight oil 90 weight Pump Incorrectly indexed Oil inlet shield or screen blocked Misalignment of damper plate with engine or misalignment of output shaft components Damaged gears Warped clutch plate Mechanical failure Tight pack clearance Low pressure Defective parts High pressure valve sticking Engine idie too fast Linkage binding or misadjusted Low pressure Forward clutch seized Worn or broken sealing rings 10 Replace cooler Replace sensor Replace defective parts Remove and use proper weight oil Rotate pump to correct position Inspect and clean Align drive train components Replace damaged gears Replace defective parts Replace defective parts Increase clearance to specification See low oil pressure Replace defective parts Clean and polish regulator valve Adjust engine idle Repair as required and adjust to OEM spec See low oil pressure Replace defective parts Replace defective parts PR Table 3 Troubleshooting Continued PROBLEM CAUSE CORRECTION MISCELLANEOUS PROBLEMS 1 Hydraulic noise or buzz 2 Gear noise in forward 3 Gear noise in reverse MALFUNCTION IN NEUTRAL 1 Drives in forward direction 2 Drives in reverse direction 3 Noisy in neutral only 4 Transmission overheating Low oil level or air in hydraulic circuit EN Regulator valv
53. inspection maintenance and troubleshooting refer to the Table of Contents at the front of this manual B OVERHAUL The general overhaul information described on page 12 applies to these reduction units Before starting disassembly review the exploded view shown in Figure 10 The reduction unit can be disassembled following the index numbers shown in Figure 10 The following procedures are correct for most reduction units Minor differ ences may be found 39 CAUTION Threaded plugs screws bolts and coupling nut must be tightened to torque shown in Table 4 to prevent premature reduction unit failure A new coupling nut must be used at assembly Do not disassemble the pinion carrier assem bly unless damaged The necessary tools must be available for proper assembly Use the ex ploded view Figure 10 for disassembly and as sembly The bearing cup and cone are a matched set If one is damaged both must be replaced A solid spacer is used to control rolling torque end play Rolling torque must be checked after assembly of the reduction unit before assembly to the transmission NOTE Early reduction units used a collapsible spacer If this spacer must be replaced use the solid spacer NOTE Early reduction units used a bearing re tainer on the output shaft end of reduction hous ing To order correct parts refer to exploded view Figure 11 STEP 1 If removed press bearing cone 23 on
54. ll result in 0 to 0 005 inch end play 41 PRESS BEARING CONE REDUCTION HOUSING REDUCTION HOUSING 127924 COUPLING NUT REDUCTION HOUSING Coupling Assembly 12793A ps s r STEP 7 Slide sun gear 20 into sun gear hub SUN GEAR HUB 21 Turn sun gear hub 21 over Install snap ring 19 in groove of sun gear 20 S SUN GEAR 127864 Sun Gear Assembly STEP 8 Install sun gear 20 and sun gear hub 21 in reduction housing 30 Thread four bolts 17 into reduction housing Tighten boits 17 to torque shown in Table 4 STEP 9 Install pinion carrier 8 in reduction PINION housing 30 Install snap ring 7 in groove of CARRIER main shaft 21 REDUCTION HOUSING Pinion Carrier instaliation IS ILRI BVI ATL II NY i i d i E i i 42 STEP 10 Install input gear 38 in ring gear 39 Install snap ring 37 in groove of ring gear 39 Input Gear Assembly STEP 11 install bearing 36 in reduction unit adapter 34 Snap ring groove in bearing 36 must be next to reduction unit adapter 34 Press bearing 36 on input gear 38 Install snap ring 35 in groove of input gear 38 REDUCTION UNIT ADAPTER 12828A STEP 12 Lubricate front adapter gasket 40 with vasoline and instali on transmission 12829A Front Adapter Gasket Inst
55. ll bearing retainer 3 as follows If removed press oil seal 6 into bearing retainer 3 CAUTION Oil Seal must be installed dry Lubricants can damage rubber coating Install gasket 8 and bearing retainer 3 on back of case 98 Thread bolts 4 and lockwashers 5 into case 98 Tighten boits 4 in a criss cross pattern to torque shown in Table 4 STEP 42 Slide coupling 2 on output shaft Thread nut 1 on output shaft Tighten nut 1 to torque shown in Table 4 27 DIPSTICK TUBE SPOPPET SPRING STEEL BALL CONTROL VALVE LOCKWASHER FLATWASHER Shift Lever Assembly BEARING LOCKWASHER CASE 12644A Coupling Installation STEP 43 Instali dipstick 17 in side of case 98 Turn handle until snug Do not overtighten NOTE For assembly of reduction units refer to 16 sections in the back of this manual DIPSTICK 12663A Dipstick Installation INSTALLATION CAUTION After a transmission fail AN ure the cooler and cooler lines must be flushed to remove contaminated hydraulic fluid and metal rubber par ticles Failure to comply can result in premature wear or failure of over hauled transmission Align input shaft spline with damper plate e Assemble transmission to engine and then in Stall bolts Do not use boits to draw transmission gainst engine Adjust the shift cable so the holes in the shift lever are centered over the detent ball at
56. main shaft 21 STEP 2 If removed press bearing cups 24 and 29 into reduction housing 30 STEP 3 Install main shaft 21 in reduction housing 30 used the replacement spacer should be the same length Using an incor rect size spacer can result in prema ture failure of reduction unit CAUTION If original spacer is not WK Support main shaft 21 Install original spacer 25 and bearing cone 28 in reduction housing 30 40 12824A Bearing Cone Assembly BEARING CUP REDUCTION HOUSING BEARING CONE SPACER HOUSING 12790A Spacer and Bearing Cone Assembly STEP 4 Place reduction housing 30 in press with main shaft 21 supported Press bearing cone 28 on main shaft 21 Remove reduction housing 30 from press STEP 5 Install oil seal 26 in reduction housing 30 Outer surface of oil seal 26 should be flush with face of reduction housing 30 STEP 6 Slide coupling 6 on main shaft 21 Thread nut 5 on main shaft 21 Tighten nut 5 to torque shown in Table 4 Attach a torque wrench to nut 5 Turn torque wrench to check rolling torque of bearings 11 and 16 Rolling torque should be 5 to 30 in Ibs If rolling torque is over 30 in lbs replace spacer 25 with a longer one If rolling torque is under 5 in Ibs replace spacer 25 with a shorter one NOTE Selection of the proper spacer 25 wi
57. n indicate misalignment of prop shaft Gears Inspect for unusual wear patterns chipped cracked or broken teeth Bearings Inspect for chips cracks galling or missing bearings Check for signs of overheat ing Threaded Parts Inspect for stripped damaged threads or burrs Springs Inspect for distortion cracks or other damage Check springs against dimensions in Specification section E REPAIR Remove scratches burrs or minor surface de fects with very fine emery cloth e Threaded holes can be retapped using the same size tap Do not make the hole oversize Repair or replace all damaged parts F ASSEMBLY CAUTION Threaded plugs screws A A bolts and coupling nuts must be 4 tigtened to the torques shown in Ta ble 4 to prevent premature failure of transmission Anew coupling nut must be used at assembly Prior to assembly dip or coat internal parts with transmission fluid Let excess fluid drain off Use a light coat of vasoline to position or hold a gasket O ring or small part for assembly Apply to sealing rings before assembly inspect assemblies pressed together for proper fit and position Check that each snap ring is fully engaged in groove Threaded plugs screws and bolts should be tightened to the torques shown in Table 4 NOTE The following procedures are correct for m st transmissions Minor differences may be found on some models Assem
58. ng the spring This movement allows oil to flow to the cooler pa PUMP PRESSURE TO SELECTOR VALVE Selector Valve The selector valve shifts the transmission from neutral to forward or reverse When selector valve is placed in the forward po sition oil is directed to the forward clutch When the selector valve is placed in reverse position oil is fed to the reverse clutch When one clutch is engaged the other is exhausted by a slot in the selector valve SELECTOR VALVE OR REVERSE SER au LUBE FEED TO OIL COLLECTOR RING Se N ANDR ONLY FORWARD NEUTRAL SUMP 7 Sume cS REGULATOR VALVE EXHAUSTS TO SUMP WHEN PUMP PRESSURE EXCEEDS APPROXIMATELY 200 P S 1 REVERSE CLUTCH PRESSURE TAP A 1 4 PIPE PLUG LO CATED IN ADAPTER AT TOP CENTER OR 1 8 PIPE PLUG CENTERED AT REAR OVER VALVE IMPORTANT ALL EXTERNAL OIL LINES AND FITTINGS SHOULD HAVE MINIMUM INSIDE DIAMETER OF 13 32 INCH COOLER MUST PERMIT FREE FLOW OF FLUID FROM REGULATOR VALVE LUBE TO BUSHINGS FORWARD CLUTCH FEED DOES NOT HAVE AN EXTERNAL TAP FOR CHECKING PRESSURE WHEN SELECTOR IS IN F POSITION LINE PRESSURE INDICATES CLUTCH PRESSURE PRESSURE DROP FROM N TO F INDICATES LEAKAGE IN FORWARD CLUTCH CIRCUIT INSTALL COOLER IN A POSITION WHICH WILL INSURE IT IS FILLED WITH OIL AT ALL TIMES AND WILL NOT DRAIN BACK TO SUMP COOLER RETURN TO SUMP COOLER
59. oline and install on center hub of reduction unit adapter 39 NOTE Be sure o ring 35 is not twisted cut or distorted Replace if damaged install lube oil strainer 34 on reduction unit adapter 39 STEP 11 Place pinion carrier gasket 33 on lube oi strainer 34 STEP 12 Install pinion carrier 24 on pinion car rier gasket 33 and align bolt holes For 1 91 1 reduction units install three lockplates 23 and thread six bolts 21 into reduction unit adapter 39 until finger tight For 1 88 1 reduction units thread six bolts 21 with lockwashers 22 into reduction unit adapter 39 until finger tight Slide sun gear 25 partially into pinion carrier 24 Turn sun gear 25 by hand to be sure pinion carrier 24 is centered and pinion gears 31 turn freely 52 Lube Oil Strainer Installation PINION CARRIER ASSEMBLY Pinion Carrier Installation 12798A M N X STEP 13 Tighten six bolts 21 in a criss cross pattern to torque shown in Table 4 CAUTION For 1 91 1 reduction IN units bolts are torqued to 5 ft Ibs Tabs on lockplates must be bent tightly against flats of bolts Push sun gear 20 into pinion carrier 24 Install snap ring 19 in groove of transmission output shaft STEP 14 Lubricate rear adapter gasket 36 with vasoline and install on re
60. osite direction of the input shaft on the trans mission The output shaft rotates about one turn for every two turns of the input shaft Lubricating oil is supplied to the reduction unit through ports on the back of the transmission NOTE For inspection maintenance and troubleshooting refer to the Table of Contents at the front of this manual B OVERHAUL The general overhaul information described on page 12 applies to these reduction units Before starting disassembly review the expiodea view shown in Figure 12 The reduction unit can be disassembled following the index numbers in Figure 12 The following procedures are correct for most reduction units Minor differences may be found NOTE Current Production 1 91 1 reduction units use a reduction unit adapter 39 lock plates 23 pinion carrier gasket 33 and o ring 35 for noise reduction K 48 CAUTION Threaded plugs screws AN boits and coupling nut must be tightened to torque shown in Table 4 gt to prevent premature reduction unit failure A new coupling nut must be used at assembly Do not disassemble the pinion carrier assem bly unless damaged The necessary tools must be available for proper assembly Use exploded view Figure 12 for disassembly and assembly The bearing cup and cone are a matched set If one is damaged both must be replaced A solid spacer is used to control rolling torque end play Rolling torque must be check
61. rench to nut 5 Turn torque wrench to check rolling torque of bearings 12 and 17 Rolling torque should be 5 to 30 in ibs it rolling torque is over 30 in Ibs replace spacer 14 with a longer one If rolling torque is under 5 in Ibs replace spacer 14 with a shorter one NOTE Selection of the proper spacer 14 will result in 0 to 0 005 inch end play STEP 8 Lubricate front adapter gasket 43 with vasoline and install on transmission STEP 9 Slide sun gear 41 into reduction unit adapter 42 Turn reduction unit adapter 42 over Install snap ring 40 in groove of sun gear 41 71 COUPLING REDUCTION HOUSING Coupling Assembly REDUCTION UNIT ADAPTER Sun Gear Assembly COUPLING I STEP 10 Install reduction unit adapter 42 on transmission Thread six bolts 38 with lockwashers 39 into transmission Tighten bolts 38 in a criss cross pattern to torque shown in Table 4 STEP 11 Lubricate one thrustwasher 21 with vasoline and install on sun gear 41 STEP 12 Slide pinion cage assembly 22 on transmission output shaft Lubricate thrustwasher 21 with vasoline and in stall on pinion cage assembly 22 72 REDUCTION UNIT ADAPTER ir a e PINION CAGE ASSEMBLY Pinion Cage Installation 12822A RR RR STEP 13 Lubricate rear adapter gasket 37 with vasoline and install on reduction unit i J adapter 42 STEP
62. se ob a ee SOAR E Os SR Tees 12 C eee Ee A 12 D Inspection xcov race Gy bed Nae SEs a we ee ws Re d Rc ora 12 E Repa s z 1 obire d P eye eat a d 12 F SI DI na oes ine due ce Md eet se a Ao bobo e eee ta Sy 13 INSTALLATION an es Sk a eet E E aoa a 28 SPECIFICATIONS as oS ines ots Oe ee ew ht Se EA NC e et 37 1 523 1 REDUCTION UNITS a La dee e Yers ve RE heed PEE WS 39 A Descriptl h css Cea sa esee itu e ee dere s a ees CR 39 B DuBrhdul s Suis oS sat Ne DRM EE 39 1 88 1 AND 1 91 1 REDUCTION UNITS n 48 A Deschpllon zoe oe Ms MRR a SN eg Sa 48 EE 48 2 57 1 AND 2 91 1 REDUCTION UNITS iced bud ERE E CRM a Cet 58 A DOSSUHBUDI seni te AE d adea e ARTE RC URDU n E Bank d Sao WE SUED RS 58 Bo Overha l s ftp sce Sas n a at EE 58 240 1T HEDUCTHION UNITS coo ku wa etna ae wed ded ER ERA 68 A ah ILU b e wes ened Aeneid d e d a ded 68 B Ove malas cut uh x toe ER oV CE a Fecha A DRE 68 LIST OF FIGURES Title Page o 1 71C and 72C Transmission Assembly 1 2 typical installatloli coe ceva exce EQUO EA Re nt edo ACA Nok 2 3 Forward Power S qm Debe ate ced wis 2 4 Reverse Power Elow hr 2 5 Hydraulic Circuit Schematic ue x deu bres ete et heer eens 3 6 Bushing installation su ua ia uku ee 13 7A Shift
63. spection maintenance and troubleshooting refer to the Table of Contents at the front of this manual B OVERHAUL The general overhaul information described on page 12 applies to these reduction units Before starting disassembly review the exploded view shown in Figure 16 The reduction unit can be disassembled following the index numbers in Figure 16 The following procedures are correct for most reduction units Minor differences may be found 68 CAUTION Threaded plugs screws bolts and coupling nut must be tightened to torque shown in Table 4 to prevent premature reduction unit failure new coupling nut must be used at assembly Do not disassemble the pinion carrier assem bly unless damaged The necessary tools must be available for proper assembly Use the ex ploded view Figure 16 for disassembly and as sembly The bearing cup and cone are a matched set If one is damaged both must be replaced A solid spacer is used to control rolling torque end play Rolling torque must be checked after assembly of the reduction unit before assembly to the transmission NOTE Early reduction units used a collapsible spacer If this spacer must be replaced use the solid spacer NOTE Early reduction units used a bearing re tainer on the output shaft end of reduction hous ing To order correct parts refer to exploded view Figure 17 STEP 1 If removed press bearing cone 12 on output shaft 8
64. stall reverse clutch pressure plate 54 in case 98 with three half moons aligned with dowel pins 58 Be sure all springs are seated in their holes 22 PRESSURE NO SPRING HERE SIDE OF N TAB HERE REVERSE CLUTCH Pressure Plate Installation STEP 28 Lubricate sealing ring 52 with vaso line and install in groove of reverse clutch piston 51 Se NOTE Be sure sealing ring 52 is not twisted cut or distorted Replace if damaged STEP 29 If removed press needle bearing 48 into adapter 45 Needle bearing must be in stalled flush even with back face of adapter 45 Lubricate O ring 53 with vasoline and install in groove of adapter 45 NOTE Be sure O ring 52 is not twisted cut or distorted Replace if damaged if removed install dryseal plug 50 in adapter 45 STEP 30 Install reverse clutch piston 51 in adapter 45 Lightly coat gasket 49 with vasoline and place on adapter 45 23 REVERSE CLUTCH PISTON 11852A FORWARD AND REVERSE ADAPTER SEALING NEEDLE BEARING 12638A Sealing Ring Installation FORWARD AND REVERSE ADAPTER REVERSE CLUTCH PISTON GASKET 12639A Reverse Clutch Piston Assembly ret ier ei NENSI EAEAN Pe STEP 31 install adapter 45 on case 98 and align bolt holes Thread four capscrews 46 into case 98 Tighten in a criss cross pattern to final torque specified in Table 4
65. ten to torque shown in Table 4 NOTE Plug 88 is a plastic shipping plug and should be installed hand tight STEP 3 Install baffle 87 in case 98 Place thrustwasher 86 on face of bearing bore Notch in thrustwasher 86 must align with notch in case 98 CAUTION Thrustwasher is used AN only on some models See Model e Chart 71C and 72C Transmissions 14 PIPE PLUGS BREATHER SNAP RING GROOVE IN BEARING MUST FACE AWAY FROM CASE 12648A Case Assembly WASHER DRYSEAL BUSHING SHIELD SPRING 12649A 12650A Thrustwasher and Baffle Installation Spo cres un iN e evt vt tye STEP 4 Lubricate sealing rings 83 and bush ings 84 with vasoline If removed press bushings 84 into pinion Car rier 85 install sealing rings 83 in grooves of pinion car rier 85 Compress each sealing ring 83 until it locks in place CAUTION Do not block pressure holes in pinion carrier 85 with bushings 84 i Install pinion carrier 85 in case 98 STEP 5 Install pressure piate 74 in ring gear 76 STEP 6 Starting with a friction clutch plate 73 alternately stack friction clutch plates 73 and steel clutch plates 72 Place pressure plate 71 on top of clutch plates 72 and 73 15 SEALING BUSHING PRESSURE HOLES 126664 Pinion Carrier Assembly EXTERNAL SPLINES Pressure Plate Assembly FRICTION C
66. ter one NOTE Selection of the proper spacer 19 will result in Q to 0 005 inch end play STEP 8 If removed install bearing 37 and snap ring 36 in transmission Lubricate front adapter gasket 38 with vasoline and install on transmission STEP 9 Install stationary gear plate 32 in ring gear 33 Install snap ring 31 in groove of ring gear 33 61 COUPLING COUPLING NUT REDUCTION HOUSING 12793A Coupling Assembly EES BEARING 12794A STATIONARY GEAR PLATE Stationary Gear Plate Assembly STEP 10 install reduction unit adapter 35 and REDUCTION UNIT ADAPTER ring gear 33 on transmission Thread six bolts 29 with lockwashers 30 into transmission Tighten bolts 29 in a criss cross pattern to torque shown in Table 4 STEP 11 Slide sun gear 28 on transmission output shaft E Nba re PSU Install snap ring 27 in groove of output shaft Sun Gear Installation STEP 12 Lubricate rear adapter gasket 34 GASKET with vasoline and install on reduction unit i adapter 35 12811A Rear Adapter Gasket Installation 62 STEP 13 Place reduction housing 26 on trans mission Turn coupling 6 to engage pinion gears 14 with ring gear 33 Thread two bolts 1 with lockwashers 2 into transmission Thread six bolts 3 with lockwashers 4 into re duction housing 18 Tighten bolts 1 and 3 in a criss cross pattern to torque

Velvet Drive Marine Transmisson Service Manual 71 C

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