GRADER ANER ROLLER 2 CRANE 0 ) ’ Shop Manual ¢-9 TRANSMISSION (FOUR SPEED MODEL 28420) Applicable Models Serial Numbers T-6008 02194 thru 02535 T-500C & M 07995 & Up T-600C 02536 & Up CAUTION COMPONENTS MUST BE PROPERLY SUPPORTED DURING DISASSEMBLY AND ASSEMBLY. JACKING, HOISTING, AND GENERAL WORKSHOP EQUIP- MENT REQUIRED FOR THIS OPERATION MUST BE IN GOOD WORKING ORDER. EXTREME CAUTION TO BE OBSERVED AT ALL TIMES TO PREVENT INJURY. SAFE WORKSHOP PRACTICES ARE A MUST. CONTENTS Page Torque Sheet... . . eee Back of Cover Special Tools»... ee eee ee 1 Troubleshooting... 2... eee ee ee 2 Pressure Checks»... 2.2... eee ee 4 siransiissionfRenovall ee) ee 5 Disnscemblypereemee 6 ee ee 7 Cleaning and Inspection 2... 2... 0. 23 Reassembly 2... 25 Transmission Installation... . . ee Servicing Transmission... 2... eee 45 Plumbing Flow Diagrams... . Le 46 c2 | Gaston | Galion Manufacturing Division 0 Dresser Industries, Inc., Galion, Ohio 44833, USA . 79| GENERAL TORQUE VALUES THE FOLLOWING GENERAL TORQUES ARE TO BE USED IN ALL CASES WHERE SPECIFIC TORQUES ARE NOT GIVEN. NOTE! TORGUE VALUES LISTED THROUGHOUT THIS MANUAL ARE FOR LUBRICATED (WET) THREADS: VALUES SHOULD BE INCREASED 1/3 FOR NON-LUBRICATED (DRY) THREADS. THREAD SIZE HEAT TREATED MATERIAL GRADE S & GRADE 8 (3 RADIAL DASHES ON BOLT OR GRADE 5 CAP SCREW HEAD) RADE 8 (6 RADIAL DASHES ON BOLT OR ‘CAP SCREW HEAD) Foot PouNDs | NEWTON METERS | FOOT POUNDS | NEWTON METERS (FT. LBS.) i) (FT. LBS.) (Nw) 174 = 20 6 eet 9 12.2 174 ~ 28 7 9.5 a 14.9 5/16 - 18 13 17.6 18 24.4 5/16 = 24 15 20.3 21 28.5 3/8 - 16 24 32.5, 34 46.1 3/8 - 24 27 36.6 38 51.5 1/6 ~ 14 38 51.5 54 73.2 7/16 ~ 20 42 56.9 60 81.3 172 - 13 58 78.6 82 1142 172 ~ 20 65 88.1 90 122.0 9/16 - 12 84 113.9 120 162.7 9/16 - 18 93 126.1 132 178.9 5/8 - 11 118 155.9 165, 223.7 5/8 - 18 130 176.3 185 250.8 3/4 - 10 205 277.9 290 393.2 3/4 - 16 230 311.8 320 433.9 e- 9 305, 413.5 455 616.9 1/8 - 16 335 454.2 515 698.2 1-8 455 616.9 695 942.3 1-14 510 691.5 795 1 064.3 11-7 610 827.0 990 1 342.3 1178 - 12 68s 928.7 1 110 1 505.0 11-7 860 1 166.0 1 400 1 898.1 11/4 ~ 12 955 1 294.8 1 550 2 101.5 13/8- 6 1 130 1832.1 1 830 2 48161 13/8 - 12 1 290 1 749.0 2 085 2 826.9 12-6 1 500 2 033.7 2 430 3 294.6 12-12 1 690 2 291.3 2 730 3 701.4 1374-5 2 370 3 213.3 3 810 5 165.7 2-42 3 550 4 813.2 5 760 7 809.5Fie__C. $ SECTION. SHOP MANUAL SPECIAL TOOLSeA SHOP MANUAL section TROUBLESHOOTING Prior to removal and disassembly of torque converter and transmission assembly the following troubleshooting should be performed. The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit. It is necessary to consider the torque converter charging pump, transmission, oil cooler, and connecting lines as a complete system when running down the source of trouble since the proper operation of any unit therein depends greatly on the condi- tion and operations of the others. By studying the principles of oper- ation together with data in this section, it willbe possible to correct any malfunction which may occur in the system. Troubleshooting procedure basically consists of two classifications: mechanical and hydraulic. MECHANICAL CHECKS Prior to checking any part of the system from a hydraulic standpoint, ‘the following mechanical checks should be made: 1, A check should be made to be sure all control lever linkage is properly connected and adjusted at all connecting points. 2. Check shift levers and rods for binding or restrictions in travel that would prevent full engagement. Shift levers by hand at con- trol valve, if full engagement cannot be obtained, difficulty may be in control cover and valve assembly. HYDRAULIC CHECKS Before checking on the torque converter, transmission, and allied hydraulic system for pressures and rate of oil flow, it is essential that the following preliminary checks be made. 1. Check oi] level in transmission. This should be done with oi] temperatures of 180 to 200 degrees - 00 NOT ATTEMPT THESE CHECKS WITH COLD OIL. To bring the oi] temperature to this specification it is necessary to either work the machine or "stall" out the con- verter. Where the former means is impractical, the latter means should be employed as follows: Engage shift levers in forward and high speed and apply brakes. Ac- celerate engine half to three-quarter throttle. CAUTION: DO NOT KEEP UNIT IN STALL FOR MORE THAN 30 SECONDS ‘AAT ANY ONE TIME. IF OIL TEMPERATURE IS NOT FROM 180° TO 200°, RUN ENGINE NORMALLY FOR FIVE MINUTES BEFORE RETURNING TO THE STALL CONDITION.SAW SHOP MANUAL eect LOW CLUTCH PRESSURE Cause 1. Low of1 Tevet. 2. Clutch pressure regulating valve spool stuck open. Faulty charging pump. Broken or worn clutch shaft or piston sealing rings. 5. Clutch piston bleed valve stuck open. LOW CONVERTER CHARGING PUMP OUTPUT Cause 1. Low 071 Tevet. 2. Suction screen plugged. 3. Defective of1 pump. OVERHEATING Cause 1. Worn of1 sealing rings. 2. Worn of pump. 3. Low ofl level. NOISY CONVERTER Causes 1. Worn coupling gears. 2. Worn oi pump. 3. Worn or damaged bearings. LACK OF POWER Cause 1. Low engine RPM at converter stall. 2. See "Overheating" and make same checks. 3 Remedy Fill to proper level. Clean valve spool and housing. Replace pump. Replace sealing rings. Clean bleed valves thoroughly. Remedy Fill to proper level. Clean suction screen. Replace pump. Remedy Remove, disassemble, and rebuild converter assembly. Replace. Fill to proper level. Remedy Replace. Replace. A complete disassembly will be necessary to determine what bearing is faulty. Remedy Tune engine check governor. Make corrections as explained ‘in "Overheating".Sain, SHOP MANUAL secre ST PRESSURE CHECKS TRANSMISSION OIL LEVEL CHECK "AY a. Oil at operating temperature. b. Moldboard in ground, parking brake set. c. Engine idling. d. Transmission in neutral. e. Remove transmission dipstick, located under operators seat and check for correct level. If level is high remove top plug "A" and allow oi1 to drain out until ofl is Tevel with the bottom of plug hole. Recheck oi1 level with dipstick. nye a. Install 100 psi gauge at Point b. Engine at HIGH idle. trans. in neutral. c. Converter temperature 180° - pressure 35 = 10. TO" COOLER CHECK CONVERTER OUT PRESSURE AT POINT B. CHECK CLUTCH PRESSURES AT POINT "C" ee NOTE: If clutch pressure does not read 260 t 20 psi on instrument panel, install a reliable 300-350 psi gauge at Point C. Record pressures at engine HIGH idle and LOW idle. Noldboard in ground and parking brake set. Check all clutches. 1. Forward & Reverse clutch in neutral, Low, Second, Third, & Fourth. 2. Forward clutch engaged and Low speed. 3. Reverse clutch engaged and Low speed. Record all Pressure Pressures may range form 240 to 280, however, they should not vary over five pet between clutches. FROM COOLERFie_C__ SHOP MANUAL section_9 TRANSMISSION REMOVAL The front of the transmission when installed in grader, will be facing the rear. All references for removal, such as front, rear, left and right will pertain to the actual sides of transmission only and does not indicate sides of grader. io 2. 3. 10. nu. 12. ‘132 Remove drain plug from bottom of grader fuel tank and drain into a suitable container. * Remove two fuel lines,(supply and return)from fuel tank and cap or plug both lines and fittings. Remove six capscrews, lockwashers, flat washers and with a suit- able lifting device remove fuel tank and support brackets from grader. Remove eight nuts, lockwashers, and separate drive line from transmission. Use cribbing and block up under rear of the engine assembly. NOTE: iwhen blocking engine make certain it is properly supported and at correct height. When engine and tranemission are conbined, the transmission serves as rear eupport mount. Using a suitable lifting device with a minimum lifting capacity of 2,000 LBS. attach a sling around transmission (approx. two inches behind the torque converter housing) and tighten hoist enough to support transmission weight. Remove clutch oi] pressure gauge line from filter head located on top of transmission. Remove four nuts, Tockwashers and slide system hydraulic pump away from transmission. Disconnect two transmission control cables from control valve, located on left side of transmission. NOTE: Tag control cables and electrical leads for correct installation. Remove two capscrews, lockwashers and control mounting plate from transmission rear cover. Remove brake disconnect line from end of control valve. Remove two screws and electrical leads from neutral start switch located on top of control valve. Remove nuts and electrical leads from back-up sending unit, located on the side of control valve.i i f SHOP MANUAL scorn Remove converter return line from cooler located on front left hand side of transmission. Plug ofl Tine. Disconnect electrical leads from oil temperature sending unit, located on the converter out line. Remove converter out line from transmission, located on right hand side of transmission. Disconnect and remove dipstick tube from transmission. Remove twelve nuts, lockwashers and capscrews which secures the transmission converter housing to the engine assembly. Remove four nuts, lockwashers, flat washers and carefully lift transmission off the lord mounts and mounting brackets. Move transmission toward grader cab approximately six inches to un- couple from engine and lower transmission. NOTE: A cuttable dolly placed under transmission when Lowering vill help to renove fron under grader. asiti, SHOP MANUAL a DISASSEMBLY A._ INTRODUCTION, The following is one method of disassembly and re- assembly procedures recommended when complete dis- assembly for overhaul of the transmission is neces- sary. 1 Remove all drain and level plugs (1 thru 4). Allow oi] to drain into a suitable container. Using a suitable lifting device, position transmission in a clean work area, with sufficient work area 360° around the transmission. Clean trans- mission thoroughly prior to disassem- bly. Use extreme care during the clean ing operation to prevent dirt or other contamination from entering the trans- mission. ACCESSORIES DISASSEMBLY 2 Unscrew filter housing (1) from filter head (2). Remove filter from hous- ing and discard. Remove four capscrews (3), Tockwashers (4), filter head (2) and gasket (5) from charging pump (6). Remove four nuts (7) and lockwashers (8). Slide charging pump (6) gasket (9), pressure regulating valve assembly (10) ond gasket (11) off studs (12) and away from converter housing (13).Shor SHOP MANUAL 3 Remove spring (10) from filter housing (11). Remove four springs (2), pipe plug (13), adaptor plug 8) and "0" ring (8) from filter head (12). Remove retaining ring (7), disc seat (6), fil- ter disc (5) and disc spring (4) from head (12 4 Remove two pump shaft seals (1) and pump drive shaft of1 seal (2) from pump (3). Remove pipe plug (5) and roll pin (4) from regulator valve (19). Remove roll pin (6), valve stop (7), "0" ring (8), spring (9), plunger (10), valve spacer (11) and valve seat (12) from valve assembly (19). Remove roll pin (13), valve stop (14), "O" ring (15), valve piston (16), inner spring (17) and outer spring (18) from valve assembly (19). 5 Remove two capscrews (1), lockwashers (2), accessory drive cover plate (3) and gasket (4) from converter housing. Remove four capscrews (5) accessory drive cover plate (6) and gasket (7) from converter housing (8). Fire_C SECTION,Sian, SHOP MANUAL ae 6 Remove auxiliary drive sleeves (1 and 2) from auxiliary drive gears (3 and 4). CONTROL VALVE DISASSEMBLY 7 Remove nine capscrews (1), lockwashers (2), control valve (3), gasket (4), valve adaptor plate (5) and gasket (6) from valve adaptor housing (7). NOTE: Use extreme care not. to lose detent springs or bale from valve or valve adaptor housing. 8 Remove five socket head screws (1), four capscrews (2), lockwashers (3), valve adaptor housing (4) and gasket (5) from converter housing (6). Remove detent ball springs (7).iin, SHOP MANUAL sccrion 074 Figure 9 9 Remove neutral switch (1) and neutral switch detent ball (2) from valve housing (3). Remove plug (4) and plug "O" ring (5) from valve housing. Remove plug (6) washer (7), spool (8) and spring (9) from valve housing (3). Remove oil seals (10 & 11), retaining rings (12 & 13), washers (14 & 15) and slide forward/reverse valve spool (16) and speed selector spool (17) out of their respective positions in valve housing (3). Slide spacer (18) from speed selector spool. (17) and remove pipe plug from spool only if replacement is necessary. Remove springs (19) and detent balls (20) from housing (3). NOTE: Plug item (6) ie replaced by bushing for traneniesion brake disconnect line when adapted to grader. ahsaan, SHOP MANUAL echo 10 Remove twenty-four capscrews (1), lock- washers (2) and impeller cover (3) from impeller. Remove impeller bearing from cover only if replacement is necessary. Remove "0" ring from impeller cover (3). u Remove turbine retaining ring (1) and slide turbine (2) from turbine shaft (3) and torque converter assembly. Cut and remove lockwire (4). Remove eight cap- screws (5), washers (6) and separate turbine (2) and turbine hub (7. 12 Remove turbine locating ring (1), re- action member retaining ring (2) and Slide reaction menber (3) and spacer off stator support (4). Figure 12 -n-SAN, SHOP MANUAL scorn 13 Using a screwdriver or other suitable tool, remove oi] baffle retaining ring (1). Using a suitable tool at slots "A" in converter housing (2), remove oi1 baffle (3) and impeller (4) as an assem bly. 14 Using lockring pliers, remove retaining ring (1), impeller hub gear (2) and oi baffle (3) from impeller (4). Remove oi] seal (5) from oi] baffle if replace- ment is necessary. 15 Cut and remove safety wire (1). Remove capscrews (2) lockwashers (3) and impel- ler hub (4) from impeller (5). Press bearing (6) out of impeller only if re- Placement is necessary. Figure 15 -12-itn, SHOP MANUAL section 16 Remove oi] sealing ring (7) from stator support (3). Remove six capscrews (1), lockwashers (2), and stator support (3) from converter housing (5). NOTE: Stator support must be rotated to allow the casting to pase the pup gear (6). 7 Remove two capscrews (1), Tockwashers (2) and position center pump gear (3) toward the rear of the converter housing (4). Remove two capscrens (5), lock- washers (6) and pump drive gear (7) from the right hand side of converter. Re- move two capscrews (8), lockwashers (9) and pump drive gear (10) from the left side of converter. Remove center pump drive gear from converter housing (4). 18 Support converter housing (1) with suit- able chain fall and hoist. Remove eight- een capscrews (2) and lockwashers (3) that secures torque converter housing (1) oa gasket (4) to transmission housing (5). -13Fie_C SECTION. 19 Using snap ring pliers, spread ears on forward clutch front bearing retaining ring (1). While holding retaining ring open, tap converter housing (2) away from transmission housing. 20 Remove retaining ring (1) and slide tur- bine shaft gear (2) from turbine shaft (3). Using soft hammer, tap turbine shaft out of bearing and converter hous- ‘ing (4). Remove bearing from housing only if replacement is necessary. Remove capscrews (5), lockwashers (6), sleeve Tock (7) and housing sleeves (8 and 9) only if replacement is necessary. Remove retaining ring (10) as necessary. Remove retaining ring (11) governor drive gear (12) and woodruff key from tachometer drive shaft (13). ai Remove bearing retaining ring (6) and slide the shaft assembly out of converter housing. Press bearings (3 and 5) from shaft (4). Remove oil seal (2) and tube nut (1) from converter housing if replace- ment is necessary. 14. Figure 21sain SHOP MANUAL secrin 8 E. FORWARD AND SECOND CLUTCH DISASSEMBLY 22 Slide forward and second clutch assenbly (1) off second gear and out of t mission housing (2).SHOP MANUAL ore 23 Remove three shaft piston rings (1) and retaining ring (2). Using a suitable puller, remove bearing (3) from clutch shaft. Remove retaining ring (4), and pull clutch driven gear (7) from clutch and drum assembly (14). Press bearings (5 and 10) out of driven gear (7). Remove snap rings (6 and 9) and of1 baffle ring (8) fron driven gear: Using special tool illustrated on page 1, depress piston spring (13). Remove snap ring (11), spring retainer (izh and spring (13) from clutch and drum assem- bly (14). Remove snap ring (17) spring retainer (16) and spring (15) from the opposite end of drum assembly in the same manner. 24 Remove end plate retaining ring (1), end plate (2), six clutch inner discs (3) and six outer disc (4) from clutch drum (8). Remove piston (5) from clutch drum. Remove inner sealing ring (7) and outer sealing ring (6) from piston (5). Disassemble remaining end of clutch drum in the same manner. 8089 Figure 24 -16-Fire_C SALON, SHOP MANUAL section_9_ 25 Remove second gear retaining ring (1), second gear (2) and bearing end plate from low clutch shaft (3). Remove low clutch shaft pilot needle bearing from low clutch shaft (3). F. REAR COVER DISASSEMBLY 26 Remove five capscrews (1), lockwashers (2), low clutch rear bearing cap (3) and gasket (4) from transmission rear cover (5). Remove four capscrews (6), lockwashers (7), idler shaft bearing cap (8) and gasket (9) from transmission rear cover. 27 Remove low clutch rear bearing locating ring (1) from rear bearing (2). Remove jdler shaft rear bearing locating ring (3) from rear bearing (4). Remove thirteen capscrews (5), two nuts (6) and fifteen lockwashers (7) that secures the rear cover (8) and gasket (9) to transmission housing (10). Remove rear cover by inserting pry bars at "A" location. While applying pressure at slots "A", tap low clutch and idler shafts (11 and 12) to allow cover re~ moval without binding. Remove plug (13) only if replacement is necessary. Figure 27 eleAti SHOP MANUAL secre = G. FOURTH CLUTCH DISASSEMBLY 28 Remove lock balls (6 & 7) from the rear bearings of the low clutch and idler shaft. Remove piston ring (2), capscrews (1) and thrust plate (3) from low clutch shaft (10). Using a suitable puller re- move tapered bearing (8) from low clutch shaft. NOTE: Low clutch shaft rear bearinge must be removed to allow the removal of the fourth clutch avsenbly, Remove fourth clutch assembly (5) from transmission assembly (9). 29 Remove nut (27), using a suitable puller, remove bearing (25). Slide gear (24) from shaft (22) and remove woodruff key (23). Remove three piston rings (1), snap ring (2) and pull bearing (3) from idler shaft (22). Remove locating ring (4) and pull fourth gear assembly (7) with bearing (5) from hub assembly (21). Re- move spacer (6) and pull bearing (8) from shaft (22). Remove oi] baffle ring (12) from fourth gear (7) only if replacement is necessary. Using special tool illus- trated on page 1, depress piston spring (11). Remove snap ring (9), release spring tension slowly and remove spring retainer (10) and spring (11) from shaft and hub assembly. Remove snap ring (13), backing plate (14), six inner rings (15), and inner seal (19) from piston (17). Remove locating ring (20) from shaft (22). -18-sili SHOP MANUAL a H._LOW CLUTCH DISASSEMBLY 30 8095, Figure 30 Remove low clutch assembly from transmission case. NOTE: Fourth clutch assembly must be removed from transmission prior to removing low clutch assembly, refer to Item 28 above. Using a suitable puller, remove inner bearing race (1) from low clutch shaft (16). Remove retaining ring (2) and pull low speed gear (6) from shaft and drum assembly (16). Remove bearing cone (3s bearing cups (4 & 8), locating rings (5 & 7) and oi] baffle ring (10) from low speed gear (6). Pull bearing cone (9) from shaft and drum assembly (16). Remove retainer ring (11) from low clutch shaft (16). Using special tool illustrated on page 1, depress piston spring (14). Re- move snap ring (12), spring retainer (13), spring (14) and spring retainer (15) from shaft and drum assembly (16). Refer to item 24 above for disassembly of clutch discs. NOTE: Friction discs in low clutch has a higher co-efficient rating than friction dises in other clutches, therefore the disce met not be mized. The inner dise can be identified by an "x" stamped on one side of the inner teeth. There are eighteen clutch dises in the low clutch assembly, nine inner and nine outer, ~19-SAN SHOP MANUAL ee I._THIRD & REVERSE CLUTCH DISASSEMBLY 31 Remove retaining ring (1) and fourth clutch drive gear (2) from third and reverse clutch shaft (3). Figure 32 32 Slide third and reverse clutch assembly from the front of transmission case. Remove three piston rings (1), retainer ring (2) and pull bearing (3) from clutch shaft assembly (14). Remove retaining ring (4) and pull clutch driven gear (7) from shaft and drum assembly (14). Pull bearing (5), remove locating ring (6 & 9), and oi] baffle ring (8) from driven gear (7). Pull bearing (10) from clutch & shaft assembly (14). Using special tool illustrated on page 1, depress spring. Remove snap ring (11), spring retainer (12) and spring (13) from clutch and shaft assembly (14). ~20-Fie_C SHOP MANUA section_9 32 Pull third gear assembly (21) from shaft and drum assembly (14). Pull bearing (24), locating rings (19 & 23), spacer (22) and oi] baffle ring (20) from third gear (21). Pull bearing (18) from shaft and drum assembly (14). Remove retainer ring (17), spring retainer (16) and spring (15) from the shaft and clutch assembly (14) as instructed above. Remove clutch assemblies from hub in the sume nanner as instructed in item 24. Remove bearing (25) from transmission jousing.. J. OUTPUT SHAFT DISASSEMBLY 33 Figure 33 Remove four capscrews (1), Tockwashers (2) and bearing cap (3) from transmission housing (4), remove "O" ring seals (5 & 6). Using suitable puller remove bearing cup (7) from bearing cap (3) only if replacement is necessary. Remove nut (8) washer (9), "0" ring (10) and output flange (11) from output shaft (21). Remove four: capscrews (13), lockwashers (14) front bearing cap (15) and shims (16) from transmission case (4). Remove oi] seal (12), "0" ring (17) and bearing cup (18) from bearing cap (15) only if replacement is necessary. Using a soft headed hammer and drift, tap output shaft (21) from rear to front. This will remove bearing cone (22), gear (23) and spacer (20) from the shaft. Press bearing cone (19) off shaft (21) eos- Fite_C Aan SHOP MANUAL section_9 TRANSMISSION CASE DISASSEMBLY 34 Remove two locating rings (1) and slide oi] distributor (2) from transmission housing (3). Press bearing (4) out of housing. Remove oi1 lines and "0" ring seals (5) fron torque converter and transmission housings only if replace ment is necessary. -22-Sao SHOP MANUAL echo CLEANING & INSPECTION 1. Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down slowly unti7 all old lubricant and foreign material is dissolved and parts are thoroughly clean. CAUTION: CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS AND INHALATION OF VAPORS WHEN USING SOLVENT TYPE CLEANERS. 2. Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Re- peat above operation until bearings are thoroughly clean. Dry bearings using moisture free compressed air. Be care- ful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process. 3. Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with a steam cleaner. CAUTION: CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPORS AND SKIN RASHES WHEN USING ALKALI CLEANERS! Al] parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oi1 or lapping compound. 4. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not replace a bearing cone or cup individually without replac- ‘ing the mating cup or cone at the same time. After in- spection, dip bearings in Type "A" automatic transmission fluid and wrap in clean lintless cloth or paper to protect them until installed. 5. Replacement of spring loaded oi] seals, "0" rings, metal sealing rings, gaskets and snap rings are more economical when unit is disassembled than premature failure, refer to Parts Book No. 2227 for replacement items. Be extremely careful when installing sealing members, to avoid cutting or scratching. Curling under of any seal lip will seriously ‘impair its efficiency. Apply a thin coat of Permatex No. 2 on the outer diameter of the oi1 seals to assure an ofl tight fit into the retainer. 23+SHOP MANUAL seorion 8 When assembling new metal type sealing rings, lubricate with of] soluble grease to stabilize ring in their grooves for ease of assembly of mating members. Lubricate all “O" rings and seals with recommended type automatic trans- mission fluid before assembly. If available, use magna-flux process for checking for cracks that are not visible to the naked eye. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all gears showing cracks or spots where case hardening has worn through. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they have not been sprung, bent, or splines twisted, and that shafts are true. Inspect housings, covers and bearing caps to be certain they are thoroughly cleaned and that mating surfaces, bear- ing bores, etc., are free from nicks or burrs. Check all parts carefully for evidence of cracks or condition which would cause subsequent oi1 leaks or failures. 24l c SAN. SHOP MAN secrion_9 ( REASSEMBLY A. TRANSMISSION CASE _REASSEMBLY 35 Position oi] distributor (2) in trans- mission housing (3) and instal] two locating rings (1). Press bearing (4) into housing (3). Install all oil lines and "0" ring seals (5) in the torque converter and transmission hous- ‘ing if they were removed during dis- assembly procedures. NOTE: folerances, torque data and specifications are extrenely ‘important and must be adhered to. This will enoure satisfactory operation after vebuild, Att bearings to be well lubricated during assenbly vith Type A Hydraulic Fluid. B. OUTPUT. SHAFT REASSEMBLY Figure 36 25+) SHOP MANUAL secre 36 Press bearing cone (19) on output shaft (21). Press bearing cup (18) in bearing cap (15). Slide spacer (20) on shaft, position gear (23) in transmission and slide end of shaft (21) through gear. Press of] seal (12) in cap (15) and install "0" ring {17} on cap. Position sane anount of shims (16) and bear- ‘ing cap (15) on transmission housing (4) and install Tockwashers (14) ‘and capscrews (13). Install "0" rings (5 & 6) on bearing cap (3) and press bearing cup (7) in cap if removal was nec- essary during disassembly. Press bearing cone (22) on output shaft (21). Position bearing cap (3) on transmission housing (4) and install lockwashers (2) and capscrews (1). NOTE: Make certain "0" wing (5) remains in proper location during installation of rear bearing eap (3). Tighten capscrews (13) from 91 to 100 ft. Tb. torque. Tap out- put shaft to seat tapered bearings. Loosen capscreus in front bearing cap, and with the use of an inch 1b. torque wrench determine rolling torque of output shaft and record the reading. Retighten capscrews (13) from 91 to 100 ft. Ib. torque. Check rolling torque with capscrews tight. Torque must read from 6 to 8 inch Ibs. move than when capscrews were loose. Add or omit shims (16) on bearing cap (15) to achieve proper preload. Position output flange (11), "0" ring (10) and washer (9) on output shaft (21) and install nut (a). NOTE: Tighten nut (8) from 200 to 250 ft. Lbs. torque. C. THIRD AND REVERSE CLUTCH REASSEMBLY 8089 Figure 37 -26-sation, SHOP MANUAL eaaetes 37 Position outer sealing ring (6) and inner sealing ring (7) on piston (5) and position the piston assembly in clutch drum (8). Place an outer disc (4) in clutch drum (8), followed by an inner disc (3). Alternate remaining discs into drum. Position end plate (2) in drum (8) and install end plate retaining ring (1). Reassemble remaining clutch end in the same manner. 38 Figure 38 Position spring (15) spring retainer (16) and snap ring (17) in clutch assembly (14). Using special tool illustrated on page 1, and a suitable press, compress spring (15) and install snap ring (17). Position spacer (22) in third gear (21), in- stall locating rings (19 & 23). Press bearings (18 & 24) into third gear (21). Position third gear assembly on the shaft and drum assembly (14). Rotate third gear while applying a slight pressure against the clutch discs, until the splines on third gear aligns with clutch discs. NOTE: Make certain third gear is fully engaged with clutch discs. -27-Bees SHOP MANUAL section 38 Position spring (13), retainer (12) and snap ring (11) on drum shaft. Using special tool, illustrated on page 1, depress spring (13 and install snap ring. Install clutch discs in drum as outlined in Fig. 37. Install snap rings (6 & 9) and baffle ring (8) in driven gear (7). Press bear- ‘ing (10) on drum shaft. Slide driven gear (7) in drum assembly, rotate while applying ‘a slight pressure against clutch discs, until driven gear (7 aligns with the clutch discs. Press bearing (5) on drum shaft and in driven gear. Instal] locating ring (4) and press bearing (3) on drum shaft. Instal] retaining (25) 39 Position third and reverse clutch assembly in transmission housing and install fourth clutch drive gear (2) and retaining ring (1) on shaft (3). -28- ring (2) and three piston rings (1) on shaft. Install bearing in transmission housing. FILE. £) E Saw. SHOP MANUAL aerial ( D. LOW CLUTCH REASSEMBLY Figure 40 40 Reassemble low clutch discs into shaft and drum assembly (16) in the same manner as outlined under item 37. Position spring re- tainer (15), spring (14) spring retainer (13) and snap ring (12) on shaft.and drum assembly (16). Using special tool. {VTustrated on page 1, depress piston spring and install snap ring (12). Re- move special tool. Install retainer ring (11) and press bearing cone (9) on drum shaft. Install retaining rings (5 & 7) in low speed gear (6). Position gear assembly (6) on shaft and drum assem- bly (16), rotate gear (6) while applying a slight pressure against clutch discs, until driven gear (6) aligns with the clutch discs. Press bearing cups (4 & 8) into gear(6) Press bearing cone (3) on low clutch shaft (16). Install retaining ring (2) and press inner bearing race (1) on shaft. NOTE: hen rebuilding Low clutch assembly, the retaining ring (2) is selected at assembly for proper thickness. variable thickness rings are used in snap ring grooves to assure proper taper bearing tightness. Fourth elutch and idler gear mist be installed prior to installation of low elutch rear bearing assembly. Position low clutch assembly into transmission housing. -29-satin SHOP MANUA Fite_ section__9 E. FOURTH CLUTCH: REASSEMBLY Figure 41 4 Install locating ring (20) on shaft (22). Position outer seat (18) and inner seal (19) on piston (17) and install piston on shaft (22). Slide shaft and piston in hub (21). Place an outer disc (16) in clutch drum (21), followed by an inner disc (15 + Alternate remaining discs into drum. Position end plate 14) in drum and install end plate retaining ring (13). Place spring (11), spring retainer (10) and snap ring fa) on’ clutch shaft. Using special tool illustrated on page 1, depress spring and install snap ring (9) on the shaft. Press bearing (8) on shaft, position fourth gear (7) and spacer (6) on clutch shaft. Press bearing (5) on shaft and install locating ring (4). Press bearing (3) on shaft and install snap ring (2). Install three piston rings (1) on clutch shaft. Install woodruff key (23) and gear (24) on shaft (22). Press bearing (25) on shaft and instal] nut (27). NOTE: Tighten nut (27) from 250 to 300 Ft. Lbs. Torque. -30-SHOP MANUAL secre 8 42 Install fourth clutch assembly (5) in transmission assembly (9). Press bearing (8) on shaft (10). Position thrust plate ai on shaft and install three capscrews NOTE: ‘Tighten capserewe (1) from 26 to 29 ft. Ibs. torque. Install piston ring (2) on low clutch shaft (10). Place lock balls (6 & 7) in bearing races (8 & 4). CAUTION: BE EXTREMELY CAREFUL NOT TO DROP LOCK BALL INSIDE THE ‘TRANSMISSION. Figure 42 REAR COVER REASSEMBLY. 43 Install plug (13) if it was removed during disassembly. Position gasket (9) and rear cover (8) on transmission (10) and ‘install fifteen lockwashers (7), thirteen capscrews (5) and two nuts (6). NOTE: Tighten capserevs (5) and nuts (6) from 37 to 41 ft. lbs. torque. CAUTION: MAKE CERTAIN THAT LOCK BALLS LOCATED ON THE LOW AND FOURTH CLUTCH REAR BEARINGS ARE PROPERLY LINED UP WITH SLOTS IN TRANS MISSION REAR COVER. Install locating ring (1) on low clutch shaft rear bearing (2). Install locating Figure 43 ring (3) on fourth clutch rear bearing (4). e3leoe SHOP MANUAL 44 Position gasket (9) and idler shaft bearing cap (8) on rear cover (5) and install four lockwashers (7) and cap- screws (6). NOTE: Tighten capecrews (6) from 82 0 90 ft. Lbs. torque. CAUTION: MAKE CERTAIN “O" RING LOCATED BETWEEN THE BEARING CAP AND TRANSMISSION IS IN PROPER LOCATION DURING INSTALLATION. Position gasket (4) and low clutch rear bearing cap (3) on rear cover (5) and install five lockwashers (2) and cap- screws (1). NOTE: Tighten capscrevs (1) from 23 to 25 ft. Ube. torque. CAUTION: KE CERTAIN GASKET (3) AND RING LOCATED BETWEEN BEAR~ ING CAP AND TRANSMISSION IS IN PROPER LOCATION DURING INSTAL~ LATION. FORWARD & SECOND CLUTCH REASSEMBLY, 45 Position bearing end plate and second gear (2) on low clutch shaft (3) and install second gear retaining ring (1). Position needle bearing in the end of the low clutch shaft (3). are Figure 44 Figure 45 FILE. SECTION. c(® L SHOP MANUAL seca FORWARD & SECOND CLUTCH REASSEMBLY 8088 Figure 46 46 Reassemble clutch discs in forward and second clutch assembly in the same manner as instructed in item 37. Place spring (13) spring retainer (12) and snap ring (11) on clutch shaft and drum (14). Using special tool illustrated on page 1, depress spring, retainer and install the snap ring (11). Install the renaining spring (15), retainer (16) and snap ring (17) in the sane manner. Press bearing (10) on clutch shaft. Install snap rings (6 & 9) and of1 baffle ring (8) in clutch driven gear (7). Position clutch driven gear (7) in forward clutch drum assembly ( (14). Rotate driven gear while applying a slight pressure ( against clutch discs, until the splines align with clutch discs. Press bearing (5) on clutch shaft and into gear (7), install retaining ring (4). Press bearing (3) on shaft and install retaining ring (2). Install three piston rings (1) on clutch shaft. 33--_ Salon SHOP MANUAL section 7 Position second and forward clutch assembly (1) in transmission housing (2) and onto the second gear. While applying a slight pressure, rotate clutch until clutch discs, engage with the second gear. H. TORQUE CONVERTER & HOUSING REASSEMBLY 48 Install of1 seal (2) and tube nut (1) in converter housing if removed during disassembly procedures. Press bearings (3 & 5) on shaft (4). Position shaft assembly in converter housing and install bearing retaining ring (6). 49 Install woodruff key in tachometer drive shaft (13), slide governor drive gear (12) on shaft and install retaining ring (11). Install retaining ring (10) if replace- ment was necessary. Position housing sleeves (8 & 9) in converter housing (4). Install sleeve locks (7), lockwashers (6) and capscrews (5). install turbine shaft bearing in converter housing if removed during disassembly. Slide shaft (3) through bearing from the front of converter housing. Position gear (2) on shaft and install retaining ring (1). -34--_ c SALON, SHOP MANUAL secrion—@— 50 Using a suitable lifting device position converter gasket and housing (2) in proper location. Hold retaining ring (1) open with snap ring pliers and tap converter housing to allow retaining ring to seat in the second and forward clutch bearing (3). 51 With converter housing supported with a suitable chain fall, install eighteen lockwashers (3) and capscrews (2) that secures converter housing (1) and gas- ket (4) to the transmission housing (5). NOTE: Tighten capserews (2) from 37 to 41 ft. tbs. torque. 52 Position center auxiliary drive gear (3) ‘in top of converter and move to the rear, in order to allow auxiliary drive gear (10) to pass and be located on the left side of converter housing (4). Install two lockwashers (9) and capscrews (8). Locate right side auxiliary drive gear (7) in converter housing (4) and install j Tockwashers (6) and capscrews (5). Re- position center auxiliary drive gear (3) in correct alignment and in mesh with gears (7 & 10) and install lockwashers NOTE: Tighten capserews (1,5 & 8) from 23 to 26 ft. Ibs. torque. -35-siti, SHOP MANUAL scorn 53 Position stator support (3) on turbine shaft (4), rotate support until it passes center drive gear (6). Install six Tockwashers (2) and capscrews (1). NOTE: Tighten capserens (1) from 37 to 41 ft. Ibs. torque. Install of] sealing ring (7) on stator support (3). 54 Press bearing (6) in impeller (5) if it was removed during disassembly. Position impeller hub (4) on impeller (5) and install lockwashers (3) and capscrews (2). NOTE: Tighten capscrews (2) from 30 to 85 ft. tba. torque. Install. safety wire (1) in capscrews (2) as illustrated. Figure 54 aesation, SHOP MANUAL soto 56 Install of1 seal (5) on oi] baffle (3) if removed during disassembly. Position oft baffle (3) and, inpetier hub gear (2) on impeller (4) and install retaining ring (1). Figure 55 56 Position of1 baffle (3) and impeller (4) as an assembly in converter housing (2) and install of! baffle retaining ring (1). 37s)Fice_C SHOP MANUAL section_9 _ 57 Slide reaction member spacer and re- action member (3) on stator support (4) and install retaining ring (2) on stator support. Install turbine locating ring (1) on turbine shaft. 58 Position turbine (2) on turbine hub (7) and install washers (6) and capscrews (5) if they were removed during disassem- bly. NOTE: Tighten capserews (5) from 30 to 35 ft. lbs. torque. Install safety wire (4) in capscrews (5). Slide turbine and hub in position on turbine shaft (3) and install retain- ‘ing ring (1). 59 Install "0" ring and bearing on impeller cover if removed during disassembly. Position impeller cover (3) on converter and install twenty-four lockwashers (2) and capscrews (1). -38- Figure 59Fite_C OM SHOP MANUA section_9 CONTROL VALVE REASSEMBLY 8074 Figure 60 60 Install detent balls (20) and springs (19) in housing (3). Install pipe plugs in spools (16 & 17) if removed during disassembly. Position valve spools (16 & 17) in valve hous- ing (3) and install spacers (18), washers (14 & 15), retain- ing rings (12 & 13) and oil seals (10 & 11). Slide spring (5) and‘spoot (8). in valve body (3).. Place washer (7) on plug (6) and install plug in valve housing (3). Install "0" ring (5) and plug (4) in valve housing (3). Position neutral switch detent ball (2) in valve housing (3) and install neutral switch (1). NOTE: Item (6) te replaced by bushing in order to adapt transmission brake disconnect. -39-a SHOP MANUAL © 61 Position gasket (5) and valve adaptor housing (4) on converter housing (6) and install four. Tockwashers. (3), cap a (2) and five socket head screws 1). 62 Position gasket (6), valve adapter plate (5), gasket (4) and control valve (3) on the valve adapter housing (7) and install nine lockwashers (2) and cap- screws (1). J, ACCESSORIES REASSEMBLY 63 Position auxiliary drive sleeves (1 & 2) in auxiliary drive gears (3 & 4). -40- Figure 63 Fite__C secTion__9Satin, SHOP MANUAL section 64 Position gasket (4) and accessory drive cover plate (3) on converter (8) and install lockwasher (2) and capscrew (1). Position gasket (7) cover plate (6) on converter housing (8) and install cap- screw (5). 65 NOTE: Pump (3) CAN NOT be overhauled. Repair is accomplished by re- placement only. Position outer spring (18), inner spring (17), valve piston (16), "0" ring (15), and valve stop (14) in valve assembly (19) and install roll pin (13). Position valve seat (12), spacer (11), plunger (10), spring (9), "0" ring (8) and valve stop (7) in valve assembly (19) and instal] roll pin (6). Install pipe plug (5) and roll pin (4) in regulator valve (19). Install two pump shaft ae seals (1) and pune drive shaft oi1 seal ASD \ am (2) on pump (3 66 Postion spring (4), filter disc (5), and disc seat (6) in adaptor (12) and instal] retaining ring (7). Install four springs Qe ”\ (2), pipe plug (13), adapter plug (3) / and’"O" ring (8), in’filter. head (12). ‘ Position spring (10) and element (9) oS ‘in housing (an) and install housing on head (12). NOTE: Tighten housing (11) from 20 to 26 ft. Tbs. torque. 44Fie_C SALON SHOP MANUAL section_9 67 Slide gasket (11) and regulating valve assembly (10) on mounting studs (12). NOTE: Make certain the "0" ring seal located between converter housing (13) and regulating valve has remained in ite proper location during installation. Slide gasket (9) and charging pump (6) on mounting studs (12) and install Tock- washers (8) and nuts (7). Position gas- ket (5) and filter head (2) on charg- ‘ing pump (6) and install lockwashers (4) and capscrews (3). NOTE: Make certain the four thrust plate springs are in proper location during installation of filter . head « Figure 67 68 Install drain and level plugs (1 through 4). Fil] transmission with ATF or Dexron. Capacity 8 U.S. gallons (30,28 liters). 42+Saw SHOP MANUAL Eaaeies TRANSMISSION INSTALLATION NOTE: If available use a low wheeled dolly to position transmission in proper Location under the grader. 1. Using a suitable lifting device and sling with a minimum lifting capacity of 2,000 LBS., attach sling around transmission approxi- mately two inches behind torque converter housing. NOTE: Inepect fiber ring gear uhich ie mounted on engine flywheel for excessive wear or any other vieual damage. Lift transmission and aline impeller gear with fiber ring gear on Fiywheel. Lower transmission to proper location on the lord mounts. Install four bolts, flat washers, lockwashers and nuts. 3. Install twelve capscrews, Tockwashers, and nuts which secure transmission mounting flange to engine assembly. 4. Install oi] dipstick tube on rear of transmission. 5. Install converter out line on right hand side on transmission and install electrical leads on temperature sending unit located on converter out Tine. 6. Install converter in line on left front side of transmission. 7. Position electrical leads on back-up alarm sending unit, located on the side of control valve and install nuts (not illustrated with transmission). 8. Position two electrical leads on neutral start switch, located on top of control valve and install screws (not illustrated with transmission). |. Install brake disconnect line on end of control valve, (not i1lus- trated with transmission). 43.SHOP MANUAL scone 10. ne 12. 13. 4. 15. 16. Ww. 18. 19. Place control cable mounting plate on left, rear side of transmission cover. 7 Install two control cables to the control valve. Position system hydraulic pump on transmission and install four Jockwashers and nuts. Install clutch oi] pressure gauge line on filter head located on top of transmission housing. Position drive line on transmission and install eight lockwashers and nuts. Remove sling from transmission and remove blocking from under the engine assembly. Using a suitable lifting device and sling, position fuel tank and mounting on frame assembly and install six capscrews, lockwashers, and nuts. Install two fuel Tines on fuel tank and install drain plug. Fill fuel tank and prime fuel system as necessary. Fill transmission to proper level, operate engine and recheck transmission level. ~44- =oN, SHOP MANUAL seorino SERVICING TRANSMISSION The transmission, torque converter, and its allied hydraulic system are important links in the drive line between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other; therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the job can be considered completed. After the overhauled or repaired transmission has been installed in the machine, the oi1 cooler, and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgment must be exercised as to the method employed. The following are considered the minimum steps to be taken: 1. Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning. 3. Replace oi] filter elements, cleaning out filter cases thor- oughly. The oi1 cooler must be thoroughly cleaned. The cooler should be “back flushed" with oi] and compressed air until all foreign mat- erial has been renoved. Flushing in direction of normal oi] flow will not adequately clean the cooler. If necessary, cooler as- senbly should be removed from machine for cleaning, using oil, compressed air and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes. 5. Reassembleall components and use only recommended oils (Refer to Operator's Manual). Fill until fluid overflows from upper drain cock at lower end of transmission. Close drain cock and run engine two minutes at 500-600 RPM to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine running at idle (500-600 RPM) and add quantity necessary fo Bring Tevet up to FULL mark on dipstick. Recheck with hot 11 (180 to 200 degrees). 6. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.—_ c Sal SHOP MANUAL seorion_9 28420 SERIES TRANSMISSION PLUMBING DIAGRAM mag-_ c tin SHOP MANUAL secon 8 28420 SERIES TRANSMISSION PLUMBING DIAGRAM eaec 9 FILE. SECTION, SHOP MANUAL coLoR KeY 28420 SERIES TRANSMISSION PLUMBING DIAGRAMsin SHOP MANUAL scorer 3 28420 SERIES TRANSMISSION PLUMBING DIAGRAM -49-sition SHOP MANUAL secon 28420 SERIES TRANSMISSION PLUMBING DIAGRAM ~50-