Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
B | 138-7575 | Link Bracket | 2 |
C | 1P-7407 | Eyebolt | 1 |
D | FT-0833 | Clamp | 2 |
E | 1P-1863 | Retaining Ring Pliers | 1 |
G | 1P-0520 | Driver Gp | 1 |
H | 1P-0510 | Driver Gp | 1 |
J | 1P-1861 | Retaining Ring Pliers | 2 |
K | 3/8 - 16 in Bolt | 2 |
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
Note: Use the correct method to make the new rings ready for installation. Place your hands on each end of the ring and expand the ends by each other. Keep the ring in a circular shape to ensure an even bend fully around the ring. The notches in the ends of the rings must contact each other. The ring will damage the edge of the bore if the ring is not installed correctly. The notches must be fully engaged.
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Illustration 1 | g00397059 |
Correct method for compressing the rings |
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Illustration 2 | g00397061 |
The ends of the ring must contact the inner notches (bottom half of the above illustration). |
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Illustration 3 | g00397157 |
Do not use this method to make new rings ready for installation. |
- Use Tooling (G) to install bearing (144) in the clutch housing. Install the bearing with the notch in the UPWARD position. Use Tooling (J) to install retaining ring (143) in the groove of the clutch housing.
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Illustration 5 g01887224 - Install seals (141) and (142) on the clutch piston so that the oil grooves are facing toward the inside of the clutch housing. Apply clean transmission oil on the seal rings.
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Illustration 6 g03811404 - Install piston (140).
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Illustration 7 g01909917 - Use Tooling (H) to install bearing (138) in the end of the shaft assembly.
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Illustration 8 g01909936 - Raise the temperature of seal carrier (137) to a maximum temperature of
149 °C (300 °F) . Install seal carrier (137) on the shaft assembly.Show/hide tableIllustration 9 g01889333 - Install bearing (136). Use Tooling (J) to install retaining ring (135) onto the shaft assembly.
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Illustration 10 g01887219 - Install shaft assembly (134) in shaft assembly (133).
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Illustration 11 g01887218 - Install spiral lockring (132) that holds the shaft in position.
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Illustration 12 g01887217 - Put the shaft assembly in position on suitable blocks, as shown. Install gear (129) on the shaft assembly.
- Install seals (130) and (131) on the seal carrier. Put a small amount of SAE 30 oil on the seals.
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Illustration 13 g01887216 - Install bearings (121) and (125) in gears (122) and (126).
- Position thrust discs (120), (123), (124), and (127) on each side of the gears.
- Position gears (122) and (126) in the carrier and install shaft (128).
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Illustration 14 g01887215 - Use a hammer and a punch to install spring pin (119) that holds the shaft in the carrier assembly. Make sure that spring pin (119) is flush with the counterbore in the carrier.
- Repeat Steps 11 through 14 for the installation of the remaining gears.
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Illustration 15 g01887213 - Use Tooling (G) to install bearing (117). Install bearing (117) with the notch in the UPWARD position. Install spiral lockring (116) in the carrier.
- Install seal rings (118). Apply clean transmission oil on seal rings (118).
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Illustration 16 g01887212 - Install retainer ring (115) in the carrier. Compress retainer ring (115) to install gear (114).
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Illustration 17 g06109942 - Use two people to install carrier assembly (113) on the shaft assembly. Make sure that the notch in the carrier bearing is in alignment with the dowel in the shaft assembly. Install seal ring (145).
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Illustration 18 g01887209 - Install gear (111) and spacer (112) on the shaft assembly.
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Illustration 19 g01888539 - Install bearing (108) in gear (107).
- Place thrust discs (106) and (109) on each side of gear (107).
- Position gear (107) in the carrier. Install shaft (110).
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Illustration 20 g01887207 - Use a hammer and a punch to install the spring pin (105) that holds shaft (110) in the carrier assembly. Make sure that spring pin (105) is flush with the counterbore in the carrier.
- Repeat Steps 21 through 24 for the installation of the remaining gears.
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Illustration 21 g01887203 - Use Tooling (G) to install bearing (102) in the carrier. Install bearing with the notch in the DOWNWARD position. Install seals (103) and (104) and spiral lockring (101).
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Illustration 22 g01910043 - Install carrier assembly (100) on the shaft assembly (99). Align the notch in the bearing with the dowel in the shaft.
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Illustration 23 g01887200 - Use Tooling (E) to install retaining ring (98).
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Illustration 24 g03811387 - Position the retaining ring on to output shaft assembly (97). Install gear (139).
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Illustration 25 g01887199 - Attach Tooling (C) and a suitable lifting device to output shaft assembly (97). The weight of output shaft assembly (97) and the carrier is approximately
90 kg (200 lb) . - Put the clutch housing in position on suitable blocks, as shown. Install shaft assembly and carriers in the clutch housing. Make sure that the notch in the bearing is in alignment with the dowel in the carrier assembly.
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Illustration 26 g01887198 - Start with a friction disc and install friction discs (95) and clutch plates (96) in the housing.
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Illustration 27 g01887197 - Install plate assembly (94) on the housing. Install gear assembly (93).
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Illustration 28 g01887195 - Start with a friction disc and install friction discs (91) and clutch plates (92).
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Illustration 29 g01887093 - Apply clean transmission oil on seals (89) and (90) and install seal (89) and (90) on the clutch piston.
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Illustration 30 g01887014 - Install piston (88) in the No. 2 clutch housing.
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Illustration 31 g01886953 - Install springs (85).
- Use Tooling (D) to hold the piston in clutch housing (84). Attach Tooling (B) and a suitable lifting device to clutch housing (84). Install clutch housing (84). Install bolts (86) that hold the No. 1 housing and No. 2 clutch housing (84) together. Install dowels (87).
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Illustration 32 g01886934 - Install gear (83) on the shaft assembly.
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Illustration 33 g01888354 - Install bearing (80) in gear (79).
- Position thrust discs (78) and (81) on each side of gear (79).
- Position gear (79) in the carrier. Install shaft (82).
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Illustration 34 g01888333 - Use a hammer and a punch to install spring pin (77) that holds shaft (82) in the carrier assembly. Make sure that spring pin (77) is flush with the counterbore in the carrier assembly.
- Repeat Steps 40 through 43 for the installation of the remaining gears.
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Illustration 35 g01886900 - Use Tooling (G) to install the bearing (76) in the carrier. Install bearing with the notch in the UPWARD position. Install spiral lockring (75).
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Illustration 36 g01886898 - Compress the retaining ring and install gear (74).
- Install the carrier on hub (73). Make sure that the notch in the bearing is in alignment with the dowel on hub (73). Use Tooling (E) to install retaining ring (72) on hub (73).
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Illustration 37 g01886897 - Install Tooling (B) and a suitable lifting device on carrier (71). The weight of carrier (71) is approximately
26 kg (58 lb) . Install carrier (71). Use Tooling (E) to install retaining ring (70) on the shaft assembly.Show/hide tableIllustration 38 g01886896 - Start with a friction disc and install friction discs (68) and clutch plates (69).
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Illustration 39 g01888273 Show/hide tableIllustration 40 g01886861 - Install seals (66) and (67) on piston (65). Apply clean transmission oil to the seals. Install piston (65) in the housing.
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Illustration 41 g01886860 - Position springs (64).
- Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to clutch housing (63). The weight of clutch housing (63) is approximately
38 kg (85 lb) . Install clutch housing (63).Show/hide tableIllustration 42 g01910593 - Install ring gear (50) and gear (51).
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Illustration 43 g01910598 - Place housing assembly (55) in position on gear (51).
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Illustration 44 g01910614 - Start with a friction disc and install five friction discs (53) and four clutch plates (54) in housing (55).
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Illustration 45 g01910619 - If the ring carrier was removed from the housing assembly, heat a new ring carrier to a maximum temperature of
149 °C (300 °F) . Install ring carrier (47). Install pin (49).Show/hide tableIllustration 46 g01910634 - Install seal rings (48). Apply clean transmission oil to seal rings (48).
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Illustration 47 g01910637 - Install seals (61) and (62) on piston (60). Apply clean transmission oil to seals (61) and (62).
- Install piston (60) in reaction plate (56).
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Illustration 48 g01910640 - Install springs (59):
- Install the first spring (59) with the outside diameter in contact with the housing assembly.
- Install the next two springs (59) with the outside diameter of the springs in contact with each other, as shown.
- Install plate (57) on the springs. Make sure that the holes in the plate, and the springs are in alignment with the holes in the housing assembly.
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Illustration 49 g01910655 Show/hide tablePersonal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to release the spring force.
- Install Tooling (K) in the housing assembly, as shown. Compress the springs until spiral lockring (58) can be installed on the housing assembly. Release the pressure on the springs and remove Tooling (K).
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Illustration 50 g01910673 - Install reaction plate (56) on the clutch housing (55). Install bolts (52) that secure the clutch housing (55). Install retainer ring (45) on the shaft assembly.
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Illustration 51 g01910733 - Start with a friction disc and install friction discs (43) and clutch plate (42) over dowels (44).
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Illustration 52 g01886846 - Install seals (40) and (41) on the clutch piston. Apply clean transmission oil on the seal rings.
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Illustration 53 g01886845 - Install clutch piston (39) in the clutch housing.
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Illustration 54 g01886843 - Install springs (38) in the clutch housing.
- Use Tooling (D) to hold the piston in the clutch housing (37). Attach Tooling (B) and a suitable lifting device to clutch housing (31). The weight of clutch housing (37) is approximately
25 kg (55 lb) . Install clutch housing (31).Show/hide tableIllustration 55 g01886841 - Install bolts (36) that secure the clutch housing.
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Illustration 56 g01886839 - Use Tooling (G) to install bearing (35) in the manifold assembly. Install bearing with the notch in the DOWNWARD position.
- Install retaining ring (34) in the manifold.
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Illustration 57 g01886838 - Install O-ring seal (33) on the manifold assembly (32). Apply clean transmission oil to O-ring seal (33).
- Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of manifold assembly (32) is approximately
72 kg (160 lb) .Show/hide tableIllustration 58 g01886836 - Install bolts (31) that hold the manifold assembly to the clutch housing.
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Illustration 59 g01886835 - Install the O-ring seal (30) on the manifold assembly. Apply clean transmission oil to O-ring seal (30).
- Install gear (28) and retaining ring (29).
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Illustration 60 g01886833 Show/hide tableIllustration 61 g01886826 - Install bearings (24) and (26) in gear (25).
- Position thrust discs (23) and (27) on each side of the gear (25).
- Put gears (25) in position in the carrier. Install planetary shafts (21). Make sure that the holes in planetary shafts (21) are in alignment with the holes in the carrier. Install spring pin (22). Make sure that spring pins (22) are flush with the counterbore in the carrier.
- Repeat Steps 77 through 79 for the installation of the remaining gears.
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Illustration 62 g01886819 - Put slinger (20) in position in the carrier. Install locks (18) and bolts (19) that hold the slinger (20) in position. Bend the tabs on locks (18).
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Illustration 63 g01886818 - Put carrier assembly (17) in position on the shaft assembly. Install the spacer on the carrier. Use Tooling (E) to install retaining ring (16) on the shaft assembly.
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Illustration 64 g01886816 - Install gear (15) on the manifold assembly.
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Illustration 65 g01886815 - Install dowels (14) in the manifold assembly.
- Start with a friction disc and install friction discs (12) and clutch plates (13).
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Illustration 66 g01886814 - Install seals (10) on the piston. Apply clean transmission oil to seals (10).
- Install piston (11) in clutch housing (9).
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Illustration 67 g01886813 Show/hide tableIllustration 68 g01886812 - Install springs (8). Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to the housing. The weight of clutch housing (9) is approximately
32 kg (70 lb) . - Install clutch housing (9). Install bolts (7) that secure the planetary group.
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Illustration 69 g01915294 - Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of planetary group (5) is approximately
565 kg (1250 lb) . Install planetary group (5) into transmission case (6).Show/hide tableIllustration 70 g01915279 - Install tubes (4) and the O-ring seals.
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Illustration 71 g01915255 - Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The weight of modulating valve assembly (2) is approximately
43 kg (95 lb) . - Install bolts (3).
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Illustration 72 g01915234 - Connect tube assembly (1).
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Illustration 73 g01915213 - Remove the transmission assembly from Tooling (A).
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Illustration 4 | g01887226 |
End By:
- Connect the transmission and the output transfer gears. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Connect".