Assembly Procedure
Required Tools     | |||
Tool     | Part Number     | Part Description     | Qty     |
A     | 138-7573     | Link Bracket     | 1     |
C     | 1P-2420     | Transmission Repair Stand     | 1     |
D     | 2P-8312     | Retaining Ring Pliers     | 1     |
E     | 8S-2328     | Dial Indicator Gp     | 1     |
F     | 9U-7480     | Compressing Tube     | 1     |
G     | 1P-1863     | Retaining Ring Pliers     | 1     |
H     | 9U-7479     | Compressing Tube     | 1     |
J     | 1U-6341     | Threaded Rod     | 1     |
K     | 5P-7970     | Nut     | 1     |
M     | 1P-0520     | Driver Gp     | 1     |
- Install bearing (158) , bearing cup (159) , and seal (160) in cover (155) .
Illustration 1 | g00960522 |
- Install bearings (156) and (157) in cover (155) .
Illustration 2 | g00960379 |
- Install the torque converter to cover (155) .
- Install magnetic screen (154) and suction screen (153) .
Illustration 3 | g00984256 |
- Install cover (152) and install bolts (151) .
Illustration 4 | g00984255 |
- Lower the temperature of cup (150) . Install cup (150) , seal (149) , and shims (148) in bearing cage (146) .
Illustration 5 | g00984254 |
- Install bearing cage (146) and bolts (147) in transmission case (132) .
Illustration 6 | g00984253 |
- Raise the temperature of bearing cone (145) and install bearing cone (145) and gear (144) on shaft (133) .
Illustration 7 | g00984252 |
- Install shaft assembly (133) .
Illustration 8 | g00984251 |
- Lower the temperature of cup (141) and install cup (141) with Tooling (M) .
Illustration 9 | g00986212 |
Illustration 10 | g00986213 |
Illustration 11 | g00984249 |
- Use Tooling (M) in order to install seal (142) .
- Install shims (140) , bearing cup (141) , seal (142) , and seal (143) in bearing cage (139) .
- Install the bearing cage and install bolts (138) .
Illustration 12 | g00984247 |
- Raise the temperature of bearing cone (131) . Install bearing cone (131) on shaft (133) .
Illustration 13 | g00986214 |
- Lower the temperature of bearings (128) , (129) , and (130) . Install the bearings in transmission case (132) .
Illustration 14 | g00984240 |
- Install thrust disc (127) in transmission case (132) .
Illustration 15 | g00984239 |
- Install seals (124) and (126) on piston (124) .
Illustration 16 | g00984236 |
- Balance seal assembly (124) , wave spring (123) , and piston (122) upon installation. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.
Illustration 17 | g00984232 |
- Install piston (124) .
Illustration 18 | g00979099 |
- Install wave spring (123) .
Illustration 19 | g00979091 |
- Install balance piston (122) .
Illustration 20 | g00979089 |
- Position the shaft assembly so snap ring (121) lines up with the opening on Tooling (H) .
Illustration 21 | g00979073 |
Illustration 22 | g00979077 |
- Install Tooling (H) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) in order to install snap ring (121) . Remove Tooling (H) .
- Use Tooling (G) to install snap ring (120) .
Illustration 23 | g00979070 |
- End plate (117) , clutch plates (118) , and friction discs (119) upon installation.
Illustration 24 | g00979064 |
- Install one friction discs (119) , clutch plates (118) , and end plate (117) .
Illustration 25 | g00979063 |
- Install retaining ring (116) .
Illustration 26 | g00979060 |
- Install ring retainer (115) and thrust disc (114) .
Illustration 27 | g00979059 |
- Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:
- Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.
- Make sure that End Plate (W) is free.
- Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .
- Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.
Show/hide tablePersonal injury can result from applying air pressure without the lock ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come out with great force.
Make sure lock ring is securely in place before applying air pressure to clutch pack.
- End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.
Illustration 28 | g00744470 |
Illustration 29 | g00744313 |
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance. |
- Connect hub assembly (112) to gear (110) .
Illustration 30 | g00979056 |
- Use Tooling (G) to install retaining ring (111) .
- Install sleeve bearing (113) .
Note: After the bearing is installed, the diameter must be 79.113 ± .05 mm (3.1147 ± 0.0020 inch).
- Install gear and hub assembly (110) .
Illustration 31 | g00979054 |
- Install thrust disc (109) .
Illustration 32 | g00979049 |
- Install gear (108) .
Illustration 33 | g00979043 |
- Use Tooling (D) to install retaining ring (107) .
Illustration 34 | g00979038 |
- Install thrust disc (106) .
Illustration 35 | g00977455 |
- Install seal rings (105) .
Illustration 36 | g00977453 |
- Attach a suitable lifting device and rotate shaft (78) to the opposite side. The weight of shaft (78) is approximately 45 kg (100 lb).
Illustration 37 | g00977449 |
- Balance seal assembly (102) , wave spring (103) , and piston (104) upon installation. Check the lips on the seals for damage or wear. Replace the seals, if necessary.
Illustration 38 | g00977446 |
- Install piston (104) on the shaft.
Illustration 39 | g00977444 |
- Install wave spring (103) .
Illustration 40 | g00977441 |
- Install balance seal assembly (102) .
Illustration 41 | g00977438 |
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown).
Illustration 42 | g00977426 |
- Use Tooling (D) to install retaining ring (101) . Release the pressure on the wave spring and remove Tooling (F) .
- Install one disc assembly (99) , clutch plates (100) , and end plate (98) .
Illustration 43 | g00977424 |
Illustration 44 | g00977433 |
- Install retaining ring (97) .
Illustration 45 | g00977422 |
- Use Tooling (D) to install retaining ring (96) .
Illustration 46 | g00977380 |
- Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:
- Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.
- Make sure that End Plate (W) is free.
- Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .
- Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (Z) in the shaft for the clutch that is being checked.
Show/hide tablePersonal injury can result from applying air pressure without the lock ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come out with great force.
Make sure lock ring is securely in place before applying air pressure to clutch pack.
- End Plate (W) should moveupward and End Plate (W) should contact retaining ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.
Illustration 47 | g00744470 |
Illustration 48 | g00744313 |
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance. |
- Install retainer (95) and thrust disc (94) .
Illustration 49 | g00976232 |
- Connect hub assembly (92) to gear (90) .
Illustration 50 | g00976230 |
- Install bearing (93) in hub assembly (92) .
Note: After bearing (93) is installed the inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).
- Use Tooling (D) to install retaining ring (91) .
- Install gear (90) .
Illustration 51 | g00976229 |
- Install thrust disc (89) . Use Tooling (D) to install retaining ring (88) .
Illustration 52 | g00976228 |
- Position shaft assembly (87) on Tooling (C) .
Illustration 53 | g00976227 |
- Use Tooling (A) and a suitable lifting device to install shaft assembly (87) . The weight of shaft assembly is approximately 82 kg (180 lb).
Illustration 54 | g00976215 |
- Install sensors (85) and (86) .
Illustration 55 | g00976189 |
- Lower the temperature of bearing cone (83) and gear (84) . Turn shaft (78) in order to install bearing cone (83) , and gear (84) .
Illustration 56 | g00986223 |
- Lower the temperature of carrier (80) , bearing cone (81) , and gear (82) . Install the bearings on shaft (78) .
Illustration 57 | g00986224 |
Illustration 58 | g00975867 |
- Install seal ring (79) .
- Install input shaft group (78) .
Illustration 59 | g00975828 |
- Install seal rings (76) , and (77) on piston (75) . Replace the seals if it is necessary.
Illustration 60 | g00988354 |
- Install piston seal (75) .
Illustration 61 | g00975818 |
- Install wave spring (74) .
Illustration 62 | g00975812 |
- Install balance seal assembly (73) .
Illustration 63 | g00975811 |
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (G) to install retaining ring (72) . Remove Tooling (F) .
Illustration 64 | g00975810 |
- Position the shaft assembly so the opening in retaining ring (72) will be in line with the opening in Tooling (F) .
Illustration 65 | g00975588 |
- End plate (69) , clutch plates (70) , and friction discs (71) upon installation.
Illustration 66 | g00975587 |
- Install one friction discs (71) , clutch plates (70) , and end plate (69) .
Illustration 67 | g00975585 |
- Install retaining ring (68) . Use Tooling (D) to install retaining ring (67) .
Illustration 68 | g00975584 |
- Install retainer (66) and thrust disc (65) .
Illustration 69 | g00975579 |
- Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:
- Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.
- Make sure that End Plate (W) is free.
- Position the tip of Tooling (E) onEnd Plate (W) . Zero Tooling (E) .
- Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.
Show/hide tablePersonal injury can result from applying air pressure without the lock ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come out with great force.
Make sure lock ring is securely in place before applying air pressure to clutch pack.
- End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.
Illustration 70 | g00744470 |
Illustration 71 | g00744313 |
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance. |
- Install two sleeve bearings (64) , if necessary.
Note: Bearing (64) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).
Illustration 72 | g00975578 |
- Install gear assembly (63) and thrust disc (62) .
Illustration 73 | g00975576 |
- Position the shaft assembly with the opposite end upward, as shown. Install three seal rings (60) . Use Tooling (D) to install retaining ring (61) .
Illustration 74 | g00975570 |
- Install seal rings (59A) , and (59B) on piston (59) . Replace the seals if it is necessary.
Illustration 75 | g00988355 |
- Install piston assembly (59) .
Illustration 76 | g00975564 |
- Install wave spring (58) .
Illustration 77 | g00975562 |
- Install balance seal assembly (57) .
Illustration 78 | g00975558 |
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. Use Tooling (D) to install the retaining ring (56) . Remove Tooling (F) .
Illustration 79 | g00975555 |
- Position the shaft so the opening in retaining ring (56) will line up with the opening in Tooling (F) .
Illustration 80 | g00975553 |
- Install one friction discs (55) , clutch plates (54) , and end plate (53) .
Illustration 81 | g00975467 |
- Install retaining ring (52) .
Illustration 82 | g00975463 |
- Use Tooling (D) to install retaining ring (51) .
Illustration 83 | g00975458 |
- Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:
- Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.
- Make sure that End Plate (W) is free.
- Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .
- Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.
Show/hide tablePersonal injury can result from applying air pressure without the lock ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come out with great force.
Make sure lock ring is securely in place before applying air pressure to clutch pack.
- End Plate (W) should moveupward and end plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.
Illustration 84 | g00744470 |
Illustration 85 | g00744313 |
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance. |
- Install retainer (50) and thrust disc (49) .
Illustration 86 | g00975456 |
- Install sleeve bearing (48) , if necessary. Connect gear (45) to hub assembly (47) . Use Tooling (G) to install retaining ring (46) .
Note: Bearing (48) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).
Illustration 87 | g00975454 |
- Install gear and hub assembly (45) .
Illustration 88 | g00975452 |
- Install thrust disc (44) . Use Tooling (D) to install retaining ring (43) .
Illustration 89 | g00975449 |
- Position shaft (42) on Tooling (C) , as shown.
Illustration 90 | g00975447 |
- Use Tooling (A) and a suitable lifting device in order to install shaft assembly (42) . The weight of shaft assembly is approximately 41 kg (90 lb).
Illustration 91 | g00974967 |
- Install seal rings (41A) , and (41B) on piston (41) . Replace the seals, if necessary.
Illustration 92 | g00988356 |
- Install piston seal (41) .
Illustration 93 | g00974965 |
- Install wave spring (40) .
Illustration 94 | g00974964 |
- Install balance seal assembly (39) .
Illustration 95 | g00974963 |
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to install retaining ring (38) and remove Tooling (F) .
Illustration 96 | g00974961 |
Illustration 97 | g00974962 |
- Position the shaft assembly with the opening in retaining ring (38) in line with the opening in Tooling (F) .
- Exploded view of end plate (35) , clutch plates (36) , and friction discs (37) upon installation.
Illustration 98 | g00974960 |
- Install one friction discs (37) , clutch plates (36) , and end plate (35) .
Illustration 99 | g00974959 |
- Install retaining ring (34) .
Illustration 100 | g00974958 |
- Use Tooling (D) to install retaining ring (33) .
Illustration 101 | g00974957 |
- Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:
- Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.
- Make sure that End Plate (W) is free.
- Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .
- Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.
Show/hide tablePersonal injury can result from applying air pressure without the lock ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come out with great force.
Make sure lock ring is securely in place before applying air pressure to clutch pack.
- End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.
Illustration 102 | g00744470 |
Illustration 103 | g00744313 |
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance. |
- Install retainer (32) and thrust disc (31) .
Illustration 104 | g00974956 |
- Connect gear (27) to hub assembly (29) . Use Tooling (G) to install retaining ring (28) . If necessary, install sleeve bearing (30) .
Note: Bearing (30) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).
Illustration 105 | g00974955 |
- Install hub assembly (27) , thrust disc (26) , and the gear.
Illustration 106 | g00974954 |
- Install spacer assembly (25) .
Illustration 107 | g00974953 |
- Install gear (24) and washer (23) .
Illustration 108 | g00974951 |
- Install thrust disc (22) .
Illustration 109 | g00974950 |
- Reposition the shaft assembly, as shown. Install three seal rings (20) . Use Tooling (D) to install retaining ring (21) .
Illustration 110 | g00974949 |
- Balance seal assembly (17) , wave spring (18) , and piston (19) upon installation. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.
Illustration 111 | g00974948 |
- Install piston assembly (19) .
Illustration 112 | g00974947 |
- Install wave spring (18) .
Illustration 113 | g00961678 |
- Install balance seal assembly (17) .
Illustration 114 | g00961656 |
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to install retaining ring (16) . Remove Tooling (F) .
Illustration 115 | g00961647 |
- Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) .
Illustration 116 | g00961639 |
- End plate (13) , clutch plates (14) , and friction plates (15) .
Illustration 117 | g00961630 |
- Install one friction discs (15) , clutch plates (14) , and end plate (13) .
Illustration 118 | g00961507 |
- Install retaining ring (12) .
Illustration 119 | g00961492 |
- Install retaining ring (11) .
Illustration 120 | g00961468 |
- Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:
- Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.
- Make sure that End Plate (W) is free.
- Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .
- Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.
Show/hide tablePersonal injury can result from applying air pressure without the lock ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come out with great force.
Make sure lock ring is securely in place before applying air pressure to clutch pack.
- End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.
Illustration 121 | g00744470 |
Illustration 122 | g00744313 |
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance. |
- Install retainer (10) and thrust disc (9) .
Illustration 123 | g00961455 |
- Use Tooling (G) to install retaining ring (6) .
Illustration 124 | g00961444 |
- Connect hub (7) and gear (5) . If necessary, install sleeve bearing (8) .
Note: Bearing (8) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).
- Install gear and hub assembly (5) .
Illustration 125 | g00961435 |
- Use Tooling (D) to install retaining ring (3) and install thrust disc (4) .
Illustration 126 | g00961189 |
- Position shaft (1) on Tooling (C) , as shown.
Illustration 127 | g00961151 |
- Install Tooling (A) to shaft (1) . Attach a suitable lifting device to Tooling (A) .
Note: Hold input shaft (2) away from shaft (1) for clearance.
Illustration 128 | g00984312 |
- Use a suitable lifting to lower shaft (1) straight up out of transmission case. The weight of shaft (1) is approximately 50 kg (110 lb).
Note: Connect the transmission and the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Connect".
- Use shims to obtain a thickness of 0.05 mm (0.002 inch) to 0.15 mm (0.006 inch). Use Tooling (E) to check the end play on the output shaft and the input shaft.
Illustration 129 | g00748030 |
- Use Tooling (E) to check the end play. Make sure that the shafts are free. The maximum end play is 0.05 mm (0.002 inch) to 0.15 mm (0.006 inch).
Illustration 130 | g00988280 |
- Use shims to obtain a thickness of 0.05 mm (0.002 inch) to 0.15 mm (0.006 inch). Use Tooling (E) to check the end play on the input shaft.
Illustration 131 | g00748037 |
- Install parking brake group (137) . Install bolts (136) .
Illustration 132 | g00984245 |
- Install the yoke and brake drum (135) . Install bolts (134) . Rotate the transmission case.
Illustration 133 | g00984244 |