Publication No.

W561-0012E

02
Torque converter
Transmission
8FLWN-1350-8
Model TDN-62-807
ｃ2006
◯
PRINTED IN JAPAN
0612 E
 Foreword

Foreword WARNING
This repair manual gives the disassembly and Exposed parts of the torque converter and
reassembly procedures for torque converters and transmission can cause burns. Never touch until
transmissions used in rough terrain cranes. they are cooled down enough.
The models covered are listed below.
Rotating parts of the torque converter and
Before starting to repair these units, check the model
transmission can cause severe injury. Keep away
code given on the model plate on the unit.
from rotating parts during operation.
Use this manual in conjunction with the relevant parts
catalog, service manual and other reference materials Handling of manual locking device Use the
and make proper preparations. manual locking device only when neither the
MDT (multiplex data transmitter ) system nor the
emergency transmission switch is effective.
Do not touch the manual locking device when the
1. Applicable Crane Model engine is running. The manual locking device is
The table below shows the relationship between the intended to manually switch the solenoid valves
crane models and the models of torque converter and mounted on the transmission. When once
transmission used. operate the manual locking device, always return
it to original position. If the solenoid valve is left
manually locked, the vehicle will move as soon
Model as the engine starts, leading to an injury.
Crane Torque converter Transmission Eyes on the body cases of the torque converter
TR-450XL-4 and transmission are provided to hang
themselves only. Before lifting the torque
TR-500XL-4 8FLWN-1350-8A TDN-62-807G
converter or transmission, always remove the
(-540421)
accessories including the pump, propeller shafts,
flexible joints and motors from the main unit,
TR-500XL-4 otherwise the eyes can be damaged due to
(540409, 8FLWN-1350-8B TDN-62-807H excessive loads, leading to an injury.
540422-)

[NOTICE]
There is a case that the appearance and so on
differ from the parts for this crane. Although there is
not so much difference in functions and
disassembly procedures, make sure of the serial
number of this crane and the part sales unit
described in the parts catalog before starting
disassembling operations.

Please note that, for product Improvement, some

changes may have been incorporated in the machine
that are not covered in this manual.

1 W561-0012E
 Foreword
2. Contents
Foreword........................................................... 1
1. Applicable Crane Model.................................... 1
2. Contents............................................................ 2
Structure ........................................................... 4
1. Torque converter .......................................... 4
1.1 Torque converter unit sectional view .......... 4
1.2 Torque converter external view .................. 5
1.3 Torque converter ........................................ 6
2. Transmission ..................................................... 8
2.1 Transmission sectional view....................... 8
2.2 Transmission external view ...................... 10
2.3 Housing group .......................................... 11
2.4 F2/R clutch shaft group ............................ 13
2.5 F1/F3 clutch shaft group........................... 14
2.6 High/Low clutch shaft group ..................... 15
2.7 Output shaft group.................................... 16
2.8 Steering pump / speedometer group........ 17
2.9 Clutch pressure main relief valve group... 18
2.10 High/Low clutch pressure regulator
valve froup.......................................... 19
2.11 Range clutch pressure regulator
valve group......................................... 20
2.12 Range selector valve group...................... 21
2.13 Valve assy ................................................ 22
Function .......................................................... 25
1. Torque converter ............................................. 25
1.1 Converter unit ........................................... 25
1.2 Principle of power transmission through
torque converter ................................. 25
1.3 Pump drive system................................... 28
1.4 Oil circulating circuit ................................. 28
1.5 Lockup clutch pressure regulator valve.... 29
2. Transmission ................................................... 31
2.1 Outline ...................................................... 31
2.2 Valve assy ................................................ 32
2.3 Theory of valve operation......................... 33
2.4 When in Neutral........................................ 33
2.5 When gear is shifted................................. 34
2.6 Clutches.................................................... 35
2.7 Hydraulic circuit ........................................ 36
2 W561-0012E
Troubleshooting.............................................. 37
1. Output remains low..........................................37
2. Non - power transmission................................38
3. Abnormal rise of oil temperature .....................39
4. Too - high clutch pressure
and torque converter pressure............39
5. Too - low clutch pressure
and torque converter pressure............40
6. Noise ............................................................40
7. Speed range can not be switched over ...........41
8. Lockup can not be performed, or can not be
canceled..............................................41
Disassembly ................................................... 42
1. Torque converter..............................................42
1.1 Disassembly of torque converter ..............42
1.2 Disassembly of converter main section ....45
1.3 Disassembly of charging pump
drive sections......................................47
1.4 Disassembly of steering pump
drive sections......................................48
1.5 Disassembly of PTO clutch section ..........48
2. Transmission ...................................................50
2.1 Transmission.............................................50
2.2 Shifter case assy
(2-wheel/4-wheel selector)..................55
2.3 Disassembly of steering
pump/speedometer group...................56
2.4 Disassembly of clutch pack group ............57
2.5 Disassembly of output shaft group ...........59
Checks ........................................................... 60
1. Torque converter..............................................60
1.1 Check items ..............................................60
2. Transmission ...................................................60
2.1 Check items ..............................................60
 Foreword

Reassembly .................................................... 62
1. Torque converter ............................................. 62
1.1 Replace the oil seals, O-rings, packings
and copper packings with new parts. . 62
1.2 Reinstalling the oil seal rings.................... 62
1.3 Reassembling converter
internal components ........................... 62
1.4 Reassembling the PTO clutch.................. 63
1.5 Application of liquid packing ..................... 63
1.6 Shim adjustment points
and bolt tightening torques................. 64
1.7 Checks...................................................... 64
2. Transmission ................................................... 65
2.1 Replace the oil seals, O-rings, packings
and copper packings with new parts. . 65
2.2 Reassembling the clutch .......................... 65
2.3 Reinstalling the oil seal rings.................... 66
2.4 Greasing ................................................... 66
2.5 Application of liquid packing ..................... 67
2.6 Shim adjustment points
and tightening torques........................ 68

Oil ................................................................. 69
1. Recommended oil ........................................... 69
2. Oil change procedure...................................... 69
2.1 Removing oil............................................. 69
2.2 Refilling..................................................... 69

Test ................................................................. 70
1. Checking operating conditions........................ 70
2. Hydraulic pressure measurement ................... 70
3. Stall test........................................................... 70

Maintenance standard .................................... 71

1. Overhaul interval ............................................. 71
2. Replacing intervals of parts............................. 71
3. Part replacing standard ................................... 71
3.1 Torque converter ...................................... 72
3.2 Transmission ............................................ 75

3 W561-0012E
 Structure

Structure This torque converter is a 3-element, 1-stage,

1.Torque converter 2-phase unit, composed of an impeller vane wheel,
a turbine vane wheel, and a stator vane wheel.
1.1 Torque converter sectional view
The unit also incorporates a lock-up clutch.

Lockup clutch
Free wheel inner race
PTO clutch
Input plate Z42

Input guide
Lock-up clutch oil
Z35 pressure regulator valve

Turbine shaft Ass'y

Z41
Z46

Output flange

Output shaft

Front cover Stator wheel

Cover wheel Impeller wheel Free wheel cam, Free wheel roller
Stator wheel
Turbine wheel Ass'y

Z54 Charging pump

Z49

Power-take-off for
steering pump

IW561-0010J06E

4 W561-0012E
 Structure

1.2 Torque converter external view

5 W561-0012E
 Structure

1.3 Torque converter

6 W561-0012E
 Structure

1.Hexagon socket head bolt 47.Dowel pin 98.Output flange 145.Bolt

2.Washer 48.Inner race 99.O-ring 146.Dowel pin
3.Input plate 49.Dowel pin 100.Washer 147.plug
4.Spacer 50.Drive gear 101.Spring washer 148.Bolt
5.Input guide 51.Hexagon socket head bolt 102.Bolt 149.Tapered roller bearing
6.O-ring 52.Oil seal ring 103.Ball bearing 150.Hexagon socket head bolt
7.Ball bearing 53.Stator holder 104.P gear
8.Front housing 54.Hexagon socket head bolt 105.Spline hub
9.O-ring 55.Seal race 106.Ball bearing
10.Bolt 56.Hexagon socket head bolt 108.O-ring
11.Cover 57.Oil seal ring 109.Plate
12.Cover 58.Tapered roller bearing 110.Hexagon socket head bolt
13.Bolt 59.Tubine shaft assy 111.O-ring
14.Front cover 60.Tapered roller bearing 112.Ball bearing
15.Bolt 61.Oil seal ring 113.P gear
16.Spring washer 62.Tapered roller bearing 114.Spline hub
17.Oil seal 63.Thrust washer 115.Ball bearing
18.Oil seal ring 64.Ball bearing 116.Retainer ring
19.Oil seal ring 65.Snap ring 117.Packing
20.Clutch piston 66.Gear 118.Pump assy
21.Fiber plate 70.Snap ring 119.Stud
22.Back plate 71.Washer 120.Nut
23.Cover wheel 72.Spring 121.Shim
24.plug 73.Snap ring 122.Packing
25.Oil seal ring 74.Back plate 123.Supply cover assy
26.Snap ring 75.Fiber plate 124.Bolt
27.Washer 76.Steel plate 125.Steel ball
28.O-ring 77.Fiber plate 126.Plug
29.O-ring retainer 78.Piston assy 127.plug
30.Snap ring 79.Oil seal ring 128.Solenoid valve
31.Turbine wheel assy 80.Oil seal ring 129.Piston
32.Snap ring 81.Clutch shaft assy 130.Spring
33.Side washer 82.Taperd roller bearing 131.Spring
34.Snap ring 83.Oil seal ring 132.Spring
35.Stator wheel 86.Shim 133.Stopper
36.Free wheel cam 87.Packin 134.Packing
37.Leaf spring 88.Plate 135.Cover
38.Roller 89.Bolt 136.Bolt
39.Side washer 90.O-ring 137.Converter housing
40.Impeller hub 91.Tapered roller bearing 138.Plug
41.Impeller wheel 92.Gear B 139.O-ring
42.Bolt 93.Shim 140.O-ring
43.Spring washer 94.Packin 141.Band
44.Washer 95.Seal carrier 142.Hexagon socket head bolt
45.Washer 96.Bolt 143.Rear cover assy
46.Angular contact bearing 97.Oil seal 144.Bolt

7 W561-0012E
 Structure

2. Transmission

2.1 Transmission sectional view

Input shaft

F2 R
Z31 Z41 Z31

A B C

Z50
D F1
Z41 Z31
E F

Z63

Z61 K
F3
J
Z41 Z31 H
G

Z80

Low High

Output shaft Rear Output shaft Front

Z61

M
Z47
Z23
Z5

2-WD / 4-WD Z88

switching mechanism

IW561-0010J13E

8 W561-0012E
 Structure

Speedometer gear
IW561-0010J15E

Strainer
IW561-0010J17E Emergency steering drive
IW561-0010J16E

9 W561-0012E
 Structure

2.2 Transmission external view

10 W561-0012E
 Structure

2.3 Housing group

11 W561-0012E
 Structure

1.Housing assy 23.Bolt 45.Switch 67.Bolt

2.Housing cover 24.Cover 46.packing 68.Bolt
3.breather 25.Packing 47.Supply cover 69.O-ring
4.Elbow 26.Spring 48.Dowel pin 70.Adapter
5.Drain plug 27.Spring 49.Bolt 71.O-ring
6.Copper packing 28.Shifter fork 50.Bolt 72.Pipe
7.Oil level gauge 29.Shifter shaft 51.Steel ball 73.Hexagon socket head bolt
8.O-ring 30.O-ring 52.Spring 74.Strainer
9.Pickup sensor 31.Piston 53.Copper packing 75.O-ring
10.Dowel pin 32.O-ring 54.Hexagon socket plug 76.Cover
11.Bolt 33.Nut 55.O-ring 77.Packing
12.Hexagon socket head bolt 34.Sleeve 56.O-ring 78.Bolt
13.Bolt 35.O-ring 57.Filter element 79.Slector valve assy
14.Packing 36.Cover 58.Rubber washer 80.Solenoid valve assy
15.Seal carrier 37.Bolt 59.Washer 81.Clutch pressure regulator
16.Oil seal 38.Oil seal 60.Spring valve assy
17.Oil seal 39.Oil seal 61.Filter case 82.High/Low selector valve assy
18.Bolt 40.Bolt 62.Seal washer 83.Solenoid valve assy
19.Oil seal 41.Hexagon socket head bolt 63.Bolt 84.Main relief valve assy
20.Shroud 42.Shifter case 64.Band
21.Bolt 43.Packing 65.Spacer
22.Dowel pin 44.Copper packing 66.Packing

12 W561-0012E
 Structure

2.4 F2/R clutch shaft group

91.Bolt 99.Snap ring 107.Spring 115.Gear C

92.Spring washer 100.Gear A 108.Clutch piston 116.Washer
93.Washer 101.Snap ring 109.Oil seal ring 117.Tapered roller bearing
94.O-ring 102.Back plate 110.Oil seal ring 118.Shim
95.Input flange 103.Fiber plate 111.Clutch shaft assy 119.Oil seal ring
96.Tapered roller bearing 104.Fiber plate 112.Seal carrier
97.Washer 105.Steel plate 113.Oil seal ring
98.Ball bearing 106.Snap ring 114.Clutch piston

13 W561-0012E
 Structure

2.5 F1/F3 clutch shaft group

131.Tapered roller bearing 138.Snap ring 145.Clutch piston 152.Gear F

132.Washer 139.Back plate 146.Oil seal ring 153.Ball bearing
133.Thrust washer 140.Fiber plate 147.Oil seal ring 154.Snap ring
134.Thrust needle 141.Fiber plate 148.Clutch shaft assy 155.Spacer
135.Thrust washer 142.Steel plate 149.Seal carrier 156.Shim
136.Needle bearing 143.Snap ring 150.Oil seal ring 157.Oil seal ring
137.Gear D 144.Spring 151.Clutch pin

14 W561-0012E
 Structure

2.6 High/Low clutch shaft group

161.Bolt 167.Snap ring 173.Steel plate 179.Clutch shaft assy

162.Spring washer 168.Gear H 174.Snap ring 180.Gear K
163.Washer 169.Snap ring 175.Spring 181.Washer
164.Tapered roller bearing 170.Back plate 176.Clutch piston 182.Tapered roller bearing
165.Gear G 171.Fiber plate 177.Oil seal ring 183.Shim
166.Ball bearing 172.Fiber plate 178.Oil seal ring 184.Oil seal ring

15 W561-0012E
 Structure

2.7 Output shaft group

191.drive shaft 197.Needle bearing 203.Snap ring 209.Output flange

192.Ball bearing 198.Snap ring 204.Gear L 210.O-ring
193.Snap ring 199.Snap ring 205.Output Shaft 211.Washer
194.Washer 200.Roller bearing 206.Ball bearing 212.Spring washer
195.Retainer ring 201.Snap ring 207.Seal race 213.Bolt
196.Slide sleeve 202.Spacer 208.Oil seal ring

16 W561-0012E
 Structure

2.8 Steering pump / speedometer group

221.O-ring 226.Bushing 231.Bolt 236.Gear assy

222.Bushing 227.Plug 232.Ball bearing 237.Shroud
223.Oil seal 228.Copper packing 233.Washer 238.Bolt
224.Bushing 229.Speedometer casing 234.Snap ring
225.Gear 230.Packing 235.Ball bearing

17 W561-0012E
 Structure

2.9 Clutch pressure Main relief valve group

245.Valve body 249.Spring 253.Spring 257.Bolt

246.Piston 250.Outer piston 254.Packing 258.Bolt
247.Spring 251.Spring 255.Cover 259.Hexagon socket head bolt
248.Inner piston 252.Spring 256.Bolt 260.Packing

18 W561-0012E
 Structure

2.10 High/Low clutch pressure regulator valve group

265.Valve body 273.Valve body 281.Spring 289.Piston

266.packing 274.Packing 282.Spring 290.Stopper
267.Bolt 275.Bolt 283.Spool 291.Spring
268.Bolt 276.Bolt 284.Spring 292.Spring
269.Bolt 277.Nut 285.Spool 293.Spring
270.Bolt 278.Bracket 286.Spring 294.Packing
271.Bolt 279.Bolt 287.Spring 295.Cover
272.Solenoid valve 280.Piston 288.Spool 296.Bolt

19 W561-0012E
 Structure

2.11 Range clutch pressure regulator valve group

301.Valve body 306.Cover 311.Spool 316.Piston

302.Packing 307.Packing 312.Stopper 317.Cover
303.Bolt 308.Hexagon socket head bolt 313.Spring 318.packing
304.Bolt 309.Spring 314.Spring 319.Bolt
305.Bolt 310.Spring 315.Spring

20 W561-0012E
 Structure

2.12 Range selector valve group

325.Valve body 330.Cover 336.Hexagon socket head bolt 341.Bolt

326.Packing 331.Hexagon socket head bolt 337.Hexagon socket head bolt 342.Bracket
327.Spool 332.Hexagon socket head bolt 338.Valve body 343.Bolt
328.Spring 334.Spacer 339.Packing 344.Bolt
329.Packing 335.Packing 340.Solenoid valve 345.Nut

21 W561-0012E
 Structure

2.13 Valve assy

1. Clutch pressure main relief valve group

Bleeding valve

Clutch pressure main relief valve

From torque converter charging pump

To torque converter Cold oil relief valve

IW561-0010J18E

2. High/Low clutch pressure regulator valve assy

Lubrication pressure relief valve

Low selector valve

Hi selector valve

Orifice D
Flow valve
Orifice C

Accumulator valve

IW561-0010J19E

22 W561-0012E
 Structure

3. Range clutch pressure regulator valve assy

Flow valve

Orifice B
Orifice A

Accumulator valve

IW561-0010J20E

4. Range selector valve assy

R selector valve F1 selector valve

F2 selector valve
F3 selector valve
IW561-0010J21E

23 W561-0012E
 Structure

5. Solenoid valve assy

R solenoid valve F1 solenoid valve

F2 solenoid valve F3 solenoid valve

IW561-0010J22E

6. Solenoid valve assy

Low solenoid valve Hi solenoid valve

IW561-0010J23E

24 W561-0012E
 Function

Function 1.2 Principle of power transmission through

torque converter

1. Torque converter 1. Fluid clutches, transmitting rotational power by

means of fluid, are classified into two major
1.1 Converter unit categories.

1. The periphery of the impeller wheel is bolted to 2. The fluid coupling, and the torque converter.
the cover wheel，and the latter is fixed to the Their main components are shown below.
engine flywheel via the front cover and the input
Torque converter Fluid coupling
plate. The bore of the impeller wheel is supported，
via an angular contact bearing，by the freewheel
inner race.
T P T P
2. The engine drive motion is directly transmitted to
the impeller wheel， which transmits the motion to S
the turbine wheel assembly through the working
IW561-0010J01E
fluid，but，while the lockup clutch is ON，the engine
motion is directly transmitted from the cover wheel，
P:Pump (impeller) wheel
via the lockup clutch，to the turbine wheel
T:Turbine wheel
assembly.
S:Stator wheel
3. The turbine wheel asseembly is splined to one
3. Fluid coupling are fluid clutches consisting only of
end of the turbine shaft.
pumps and turbines, and they convey rotational
There is a gear on the other end of the turbine
motion just as a wind wheel installed face to face
shaft.The gear is in mesh with the output gear,
with an electric fan is driven by the fan.
transmitting power to the flange splined to the
output shaft after one-stage speed reduction. 4. When the pump is driven by an engine, the fluid
starts to rotate around the shaft, and is driven
4. The stator wheel is fixed to the converter housing
outwavd by centrifugal force.
via the freewheel cam，freewheel roller，freewheel
inner race and the stator holder. 5. With the pump provided with radial vanes, oil
flows out from the periphery of the vane wheel of
5. The stator wheel serves to raise the turbine torque
the impeller, and flows into the periphery area of
above the input torque by adding the reaction
the turbine wheel which is installed face to face
torque，generated by the working fluid returning
with the imperller.
from the turbine wheel assembly to the impeller
wheel，to the impeller wheel. 6. From the periphery area of the turbine, the oil
flows towards the center area along the turbine
6. The stator wheel idles during high-speed
blades, exerting rotational force to the blades, and
operation to maintain the transmission efficiency
eventually, returns to the pump through the center
at a high level.
area.

25 W561-0012E
 Function

Rotational motion
9. When the pump and the turbine run at a large
speed difference, that is, when starting the turbine
from standstill, and when climbing an uphill.

10. With a torque converter, a stator wheel is placed

Pump Turbine
(impeller) between the turbine outlet and the pump inlet, to
Spiral motion improve the transmission efficiency under heavy
IW561-0010J02E
loads.

11.In the fluid coupling, the oil return flow from the
7. In this way, the oil motion resulting from the
turbine to the pump is in the direction to detard the
rotational motion around the shaft driven by the
pump rotation at the impeller vane inlet, but in a
pump and the centrifugal motion, is a circulating
torque converter, the return oil flow is turned
spiral motion.
around by the stator wheel into the direction of
8. Since oil, the transmission medium, must be pushing the impeller blades forward, redulting in
continuously used within the sealed space in a the improvement of efficiency under heavy loads,
fluid coupling, the transmission efficiency is low and even results in the transmission of larger
and large input torque is required to drive the torque than the input torque to the turbine.
turbine.

Fluid flowing opposite

to pump rotation
Pump Turbine Pump

Fluid coupling

Pump Turbine
Detarding pump rotation

IW561-0010J03E

Stator
Pump Turbine Stator Pump

Torque converter

Fluid flowing to push

Same direction as pump rotation
pump forward Pump Turbine
IW561-0010J04E

26 W561-0012E
 Function

12.The stator is so designed that it can be either left

free to be directed by the flow of oil discharged
from the turbine outlet, or fixed to guide the return
oil into the direction to improve the converter
efficiency.

13.when the load is small, such as in cruising at high

speeds, the speeds of the impeller and the turbine
are not much different.

14.As this condition is approached, the discharge oil

from the turbine outlet changes flow direction
towards the rotating direction, and eventually, it
starts to hit the rear side of the stator blades.

Fixed stator
Running stator

Fixed stator Running stator

IW561-0010J05E

15.When this happens, the stator impedes the oil

flow, and the efficiency of the converter is reduced.
To prevent this, the stators of torque converters
are provided with a one-way clutch allowing the
stators to freely run to follow the oil flow, when the
stator blades are pushed from the rear side.

16.This means that the stator is locked in one

direction to amplify torque, and in the opposite
direction, it moves free to make the converter
operate as a fluid coupling under light load
conditions.

27 W561-0012E
 Function

Power transmission route

Z35 Z35

Z41 Z41
Z46 Z46

Torque converter Look-up

IW561-0010J07E

1.3 Pump drive system

1. The converter housing is provided with three
power take-off : the main pump drive PTO clutch,
the steering pump drive, and the charging pump
drive, and the charging pump drive, and they are
driven by the drive gear bolted to the impeller
wheel.
PTO clutch Charging pump drive
4. The steel ball serves to eliminate the possibility of
faulty clutch actuation by the residual oil in the
clutch shaft and the piston under centrifugal force
during the time of clutch disengagement.
5. As shown, the steel ball opens the relief port in
the center under centrifugal force to allow the oil
to flow to the outside.

Neutral Operating

Drive gear

Drive gear
Output flange Steering pump drive Clutch piston
IW561-0010J08E

2. The sokenoid valve switches the hydraulic oil to
the oil passage in the shaft leading to the clutch
piston, and the oil pushes the piston to engage
the fiber plates and the steel plates to create the
PTO ON state to drive the pumps.
3. The clutch piston is provided with a steel ball in
the oil passage connecting the working side and
outsids.
IW561-0010J09E
1.4 Oil circulating circuit
1. The torque converter oil is drawn by the charging
pump from the transmission oil tank through a
strainer. The oil is then forced into the torque
converter after passing through the clutch
pressure main relief valve and cold oil relief valve.

28 W561-0012E
 Function

2. The oil flowing into the converter passes through 1.5 Lockup clutch pressure regulator valve
the space between the turbine shaft and the free
1. Directed to the lockup solenoid valve is the
wheel innner race, and flows into the converter
pressure whose level has been regulated by the
circuit from between the stator wheel and the
clutch pressure main relif valve on the
turbine wheel.
transmission side.
3. After being used for power transmission, the oil,
2. The solenoid valve operates under control of an
now high in temperature, flows out of the
external controller (multipl data transmitter) which
converter circuit through the space between the
outputs a command signal to the valve when the
stator wheel and the impeller wheel, and via the
pickup sensor output pulse rate increases as
grooves in the free wheel inner race and in the
transmission input shaft speed increase and
stator holder, flows out of the converter housing.
reaches a predetermined speed.
4. Befor the outlet of the converter housing, there is
3. The pressure is now directed to the lockup clutch
a port through which a part of the oil is directed to
pressure regulator valve to be adjusted to a
the PTO clutch to lubricate it.
certain high pressure level and the pressure thus
5. This oil is cooled in the oil cooler, and after being increased is applied to the lockup clutch.
adjusted in pressure by the lubrication oil relief
4. This allows the transmission to be driven directly
valve, circulates to various parts of the
by the engine.
transmission for their lubrication, before returning
to the oil tank.

Accumulator piston Orifice a

Check valve
A

A-A

IW561-0010J10E

29 W561-0012E
 Function

5. When the solenoid valve is energized, the oil

flows through orifice•a and pushes the
accumulator piston.
Since the pressure increases only gradually at a
specific rate, the accumulator piston causes the
clutch to engage gently, thus minimizing shocks.

6. Once the clutch has engaged and the pressure

built up to a certain level, port•1 opens, letting the
hydraulic pressure increase immediately to the
loclup pressure.

7. When the solenoid valve is deenergized, the

pressure in the clutch port is quickly releases
through check valve•2, so that the clutch is
disengaged.

Lockup cluch
solenoid valve 1
a 2

Accumulator valve

Lockup clutch
IW561-0010J11E

30 W561-0012E
 Function

Function B
A C
2. Transmission Input shaft
　
Clutch shaft 1 (F2) (R)

2.1 Outline
D E
1.This transmission consists of four hydraulic wet F
Clutch shaft 2 (F3) (F1) (C)
multi-disc type clutches (for gear combination
selection and forward-reverse drive switching), J
K
G
reduction gears, shafts and a hydraulic system. H
Clutch shaft 3 (Low) (High)

2. Multi-disk clutches F2 (2nd forward) and R

(reverse) are monted on clutch shaft 1, and F1
L
(1st forward) and F3 (3rd forward) on clutch shaft M

2. Output shaft

3. Engagement of each clutch transfers the power as 4-WD 2-WD

shown in the tables below. The output shaft is Rear Front
equipped with a 2-wheel/4-wheel drive selector a
IW561-0010J12E
high/Low speed selector.

High speed 2-wheel drive

Gear combination
1st Forward B, E, D, G ,H ,L
2st Forward B, E, F, J, K, M
3st Forward A, D, G, K, M
4st Forward B, E, D, G, K, M
Reverse C, J, K, M

Low speed 2-wheel and 4-wheel drive

Gear combination
1st Forward B, E, F, J, H, L
2st Forward B, E, D, G, H, L
3st Forward B, E, F, J, K, M
4st Forward A, D, G, K, M
Reverse C, J, H, L

31 W561-0012E
 Function

2.2 Valve assy

The valve assy consists of clutch pressure main

relief valve assy, High/Low clutch presseure
regulator valve assy, range clutch presseure
regulator valve assy, range switching valve assy,
and solenoid valve assy.
Each of these component valves is constructed
and has functions as follows.

Name Constitution Function

This valve adjust the pressure to the clutch main
Clutch pressure main relief valve
pressure level.
Clutch pressure When the torque converter starts , this valve discharges
Air bleeder valve
main relief the air into the pump discharge port.
valve assy This valve prevents the torque converter insid pressure
Cold oil relief valve from rising to an abnormally high level due to high oil
viscosity when it is cold.
Accumulator valve This valve maintains the High/Low clutch pressure.
After the clutch pressure has been increased, this valve
Flow valve allows the clutch pressure to be raised to a
predetermined level.
High/Low This valve operates by using the pressure resulting from
clutch pressure High selector valve switching action of the High solenoid valve as a pilot
regulator valve pressure to direct the oil to the High clutch
assy This valve operates by using the pressure resulting from
Low selector valve switching action of the Low solenoid valve as a pilot
pressure to direct the oil to the Low clutch
This valve prevents an excessive increase of lubricating
Lubrication pressure relief valve
oil pressure.
Range clutch Accumulator valve This valve maintains the range clutch pressure.
pressure After the clutch pressure has been increased, this valve
regulator valve Flow valve allows the clutch pressure to be raised to a
assy predetermined level.
This valve operates by using the pressure resulting from
F1 seliction valve switching action of the F1 solenoid valve as a pilot
pressure to direct the oil to the F1 clutch
This valve operates by using the pressure resulting from
F2 seliction valve switching action of the F2 solenoid valve as a pilot
Range pressure to direct the oil to the F2 clutch
selection valve
assy This valve operates by using the pressure resulting from
F3 seliction valve switching action of the F3 solenoid valve as a pilot
pressure to direct the oil to the F3 clutch
This valve operates by using the pressure resulting from
R seliction valve switching action of the R solenoid valve as a pilot
pressure to direct the oil to the R clutch
Each solenoid valve operates in response to a command
Solenoid valve
Solenoid valve from the controller and leads pressure to the
assy
corresponding selector valves.

32 W561-0012E
 Function

2.3 Theory of valve operation

The following table shows the status of each

solenoid valve for each gear position.

Mode High Low

Gear position 1st 2nd 3rd 4th Rev 1st 2nd 3rd 4th Rev
F1 Solenoid valve OFF ON OFF OFF OFF ON OFF OFF ON OFF
F2 Solenoid valve OFF OFF ON OFF OFF OFF ON OFF OFF OFF
F3 Solenoid valve ON OFF OFF ON OFF OFF OFF ON OFF OFF
R Solenoid valve OFF OFF OFF OFF ON OFF OFF OFF OFF ON
High Solenoid valve OFF ON ON ON ON OFF OFF OFF ON OFF
Low Solenoid valve ON OFF OFF OFF OFF ON ON ON OFF ON

[NOTICE] 2.4 When in Neutral

◆In the above table, “ON” indicates that the
associated valve is energized (activated) and “OFF”
indicates that the valve is deenergized
(deactivated).
In the neutral position, all the solenoid valves are
in the “OFF” state, which means that there are no
pressure in the pilot circuit•1 through 6 and that
the range clutch port•7 and High-Low clutch port 8
are blocked by the R selector and Low selector
valve. The pressure at the clutch port 7,8 is,
therefore, retained in the accumulator, being
ready for next clutch selection.

Orifice A
Orifice B
Accumulator valve Pressure gauge
Flow valve φ1

F3 SOL
2 1

F2 F3
F2 SOL

F2 F3
Selector valve
F1 SOL 3

4
R F1

R SOL
R Orifice C F1

Orifice D
Accumulator valve
Flow valve
From clutch pressure 8
main relief valve Low SOL

High Low 5

High SOL 6

High Low IW561-0010J24E

33 W561-0012E
 Function

2.5 When gear is shifted

[NOTICE]
◆The explanation of gearshift is represented by a one
for the shift from N (neutral) to D (drive).
1. By a command from the external controller the F3
solenoid valve and Low solenoid valve is
energized.
2. Passing through the opened valve, the hydraulic
oil flows to the pilot circuit•1 and the pressure
established in this circuit causes the F3 selector
valve to open the range clutch port•7 to the F3
clutch port.
5. When the clutch has engaged and the
predetermined pressure level has been reached,
the flow valve switches the oil passage, allowing
the pressure to increase instantly to the level
necessary for maintaining the clutch engaged.
6. The pressurized oil passed through the Low
solenoid valve is led to the Low selector valve via
pilot circuit•5, then the Low selector valve
connects High-Low clutch port•8 and Low clutch
port.
7. The pressurized oil in the accumulator is released
into the clutch port and fills the clutch port up.

3. At the same time, the pressure retained in the
accumulator valve is released into the clutch port
to establish the pressure in the port.
4. Once the predetermined pressure has been
established in the port, the oil flowing through the
orifices A and B gradually pushes the accumulator
piston with a pressure that increases in an
optimum gradient to engage the clutch. This
gradual increase of pressure reduces shock that
occur when the clutch engages.
8. The oil filled the clutch port pushes gradually
accumulator piston, engages the clutch under the
given rising characteristic, then relief the engaging
schock.
9. When the clutch engagement finishes and the
pressure reaches to the required level, the flow
valve switched increases instantaneously the oil
pressure by the required clutch pressure.

Orifice A
Orifice B
Accumulator valve Pressure gauge
Flow valve φ1

F3 SOL
2
1

F2 F3
F2 SOL

F2 F3
Selection valve
F1 SOL
3

4
R F1

R SOL
R Orifice C F1

Orifice D
Accumulator valve
Flow valve
From clutch pressure 8
main relief valve Low SOL
5
High Low

6
High SOL

High Low
IW561-0010J25E

34 W561-0012E
 Function

2.6 clutches
3. The oil in the chamber pushes the clutch piston to
1. Each of these clutches comprises a clutch piston, press the steel plates and the fiber plates together,
steel plates, and fiber plates, as shown. overcoming the pressure of the return spring.

2. Clutch pressure supplied through the solenoid 4. In this way the torque of the clutch shaft assy is
valve flows, via the housing cover, supply cover, transmitted to the reduction gear.
and passage in the clutch shaft assy, into the oil
chamber of the clutch carrier.

Clutch piston Steel plate

Fiber plate

Clutch shaft assembly

(Input shaft)

To R clutch
Z41
To F2 clutch
Z31 B Z31

クラッチシャフト
Ass'y F2 R
Lubrication

A C Supply cover
Z50
To F1 clutch
Z41 F
To F3 clutch
Z31
Clutch shaft assembly D E
F3 F1
Lubrication

Z63
Clutch shaft assembly Z61
H
J K To High clutch
Z41 Z31
To Low clutch
G
Low High
Lubrication

Z80

Z47

IW561-0010J26E

35 W561-0012E
 Orifice A

Orifice B
To accumulator valve Pressure
Lockup clutch for range gauge
SOL G 3/8 G 3/8 Flow valve Φ1
Orifice a Breather ACC
2.7 Hydraulic circuit

F3 SOL
Lockup clutch
accumulator valve

Lockup clutch G 3/8 G 3/8 F2 selector F3 selector valve

valve
F2 SOL

PTO clutch Thermo. sensor 2nd 3rd

SOL

Lubricating oil F1 SOL

PTO clutch relief valve
G1 G1 Orifce C

Oil cooler
R selector F1 selector valve

36
valve
Cold oil
T/C relief valve
R SOL
Function

Rev Orifice C 1st

G1 G1

Hifg/Lo accumulator Orifice D

valve Flow valve
G1 G1

W561-0012E
ACC
Clutch pressure
Charging Filter main relief valve
pump
Low SOL
High selector valve Low selector valve

G 1-1/4 G 1-1/4

G 1-1/4 G 1-1/4
High SOL

Torque converter Transmission High Low

IW561-0010J29E
 Troubleshooting

Troubleshooting
1. Output remains low.
Fault area and cause Correction
Measure engine speed during neutral and
Engine

during stall, and adjust or repair engine if

Engine speed is abnormal.
speed is faulty. (See the sub-section for stall
test.)
Insufficient oil Add oil
Torque converter Wrong oil Replace with specified oil.
oil Air in oil Tighten fittings and joints in hydraulic circuit.
Blocked oil filter Clean or replace filter.
Torque converter

Measure stall speed, and if very low, replace

Damage in stator freewheel the freewheel inner race, freewheel cam and
rollers. (See the sub-section for stall test)

Measure oil temperture rise under no load,

Torque converter
Stator wheel seizure and if abnormally high, replace the freewheel
inner race, freewheel cam and rollers.

Check torque converter oil for aluminum

Damage or contact of vane wheel
powder, and if found, replace vane wheel.

Charging pump Faulty pump Replace

Insufficient oil Add oil
Use of unspecified oil Replace with specified oil.
Torque converter
oil Drop of torque converter pressure
Check toque converter pressure, and adjust.
causing bubbles
Water mixed in oil Check oil cooler and replace entire oil.
Clutch pressure drop due to spring
Transmission

Replace
setting or break
Valve assy
Valve seized open Replace or repair
Clogged orifices Clean and wash
Damaged seal rings on shaft end
Replace
and clutch pressure
Clutch plate slipping due to low
Clutch area Measure pressure
clutch pressure
Worn or damaged clutch plates Replace
Clutch piston malfunction Replace or repair

Brake remains on Check electric and air circuits in brake system.

Shassis
parts

Breake
Incomplete unbraking Check and adjust

37 W561-0012E
 Troubleshooting

2. Non- power transmission

Fault area and cause Correction

Damaged input plate Replace

Torque converter

Insufficient oil Add oil

Worn shaft and spline Replace

Damaged gear Replace

Faulty charging pump Replace

Troque converter oil Insufficient oil Add oil

Worn or damaged clutch plates Replace
Clutch plate seizure Replace

Clutch Wear in clutch shaft splines Replace

Clutch pressure drop due to faulty oil
seal rings at clutch shaft ends and on Replace
Transmission

clutch piston.
Worn shaft spline Replace
Output shaft
Domaged gear Replace
Broken solenoid wire Replace
Solenoid valve
Malfunction of spool Repair or replace
Clutch pressure drop due to setting or
Replace
broken springs.
Valve assy
Valve seized open Repair or replace
Blocked orifice Wash and clean
Electric circuit for solenoid

Faulty switch and relay Repair according to circuit diagram.

control

Disconnected or broken wires Repair according to circuit diagram.

Chassis
parts

Propeller shafts and

Damged Replace
universal joints

38 W561-0012E
 Troubleshooting

3. Abnormal rise of oil temperature

Fault area and cause Correction
Check stall speed, and replace stator assy if
Faulty stator wheel below specified speed. (See the sub-section for
stall test)
Troque converter
If torque converter oil contains aluminum
Fauling vane wheel
Torque converter

powder, etc., replace vane wheel.

Worn or seized bearings
Improper oil volume
Improper oil quality
Troque converter oil
Air in oil
Water in oil
Excessive piping Bent or folded hoses
resistance Blocked oil cooler
Correct or replace.
Check oil level.
Replace with specified oil.
Tighten pipe fittings.
Check cooler, and replace entire oil.
Correct or replace.
Wash or replace.

Seized clutch plates Replace

Transmission

Clutch drags Clutch piston malfunction Repair or replace

Low clutch pressure Check

Worn or seized
--------------------------- Replace
bearings
Instruments

Faulty instruments ------------------------- Replace

4. Too- high clutch pressure and torque converter pressure

Fault area and cause Correction

Bent or damaged discharge pipes, or blocked oil cooler Repair or replace

Torque converter

Heat oil when ambient temperature is below

Too high oil viscosity (cold season)
zero.

Use of unspecified oil Replace with specified oil.

Transmission

Valve malfunction due to damage,

Valve assy Repair or replace
dust, etc.

39 W561-0012E
 Troubleshooting

5. Too- low clutch pressure and torque converter pressure

Fault area and cause Correction

Insufficient oil Add oil

Torque converter

Use of unspecified oil Replace with specified oil

Worn or damaged charging pump Replace

Worn oil seal rings or O-rings Replace

Blocked oil filter Clean or replace

Set or broken springs Replace

Transmission

Valve assy Valve seized open Correct or replace

Blocked orifices Wash and clean

Faulty seal rings at shaft ends and on clutch

Clutch Replace
piston

6. Noise
Fault area and cause Correction
Broken input plate Replace

Damaged or worn bearings Replace

Torque converter

Damaged gears Replace

Fouling vane wheel Replace

Loose or broken bolts, rivets Repair or replace

Worn splines Replace

Faulty pumps Replace

Clutch seizure, dragging Replace

Transmission

Bearing seizure or wear Replace

Damaged gears Replace

Worn splines Replace

Loose or broken bolts Repair or replace

Chassis parts

Damaged universal joints Replace

Other parts Check brake and differential areas.

40 W561-0012E
 Troubleshooting

7. Speed range can not be switched over

Fault area and cause Correction

Clutch plate seizure Replace

Transmission

Solenoid valve malfunction Repair or replace

Damaged gears Replace

Electric circuit for solenoid

Faulty switches, relays Repair by referring to circuit diagram.

switching

Disconnected or broken wires Repair by referring to circuit diagram.

8. Lockup cannot be effected, or cannot be canceled.

Fault area and cause Correction

Worn or damaged clutch plates Replace

Torque converter

Faulty oil seal rings on turbine shaft Replace

Faulty O-rings on input shaft Replace

Faulty seal rings on clutch piston Replace

Lockup pressure
Lockup reducing valve piston malfunction Repair or replace
reducing valve
Transmission

Lockup solenoid malfunction Repair or replace

Solenoid valve
Excessive leak from lockup solenoid
Replace
valve

Faulty multipe data transmitter unit Replace

Electric circuit

Faulty pickup sensor Replace

Blown fuse Replace
Disconnected or broken wire Repair by referring to circuit diagram.

41 W561-0012E
 Disassembly

Disassembly Hex. socket Spacer

head bolt

1. Torque converter
[NOTICE]
◆The following parts should not be disassembled.
1) Charging pump Washer
2) Clutch shaft assy
(clutch shaft and clutch carrier are shrunken fit) Input shaft Input guide
3) Turbine wheel assy (riveted) IW561-0010J32E

4) PTO clutch piston ( steel ball, plug)

5) Drive-in plug
3. Lay the converter, the input side up. Unscerw
◆Place removed parts in order, and tag them with
bolts, and by utilizing the therded extraction holes,
mounting position.
remove front housing. Remove O-ring and oil seal
from front housing.
1.1 Disassembly of torque converter
Bolt O-ring
1. Remove plug on the right side (as viewed from the
output shaft) of the converter housing, remove
plug on cover wheel through the opened plug hold
on the converter housing, and drain the converter
circuit. Front housing

Converter housing

Plug

Oil seal

IW561-0010J33E

4. Remove snap ring, and remove washer.

IW561-0010J31E

2. Unscrew hexagon socket head bolts, and remove

washer, input plate, spacer and input guide.

Snap ring

Washer
IW561-0010J34E

42 W561-0012E
 Disassembly

5. Place the converter on wood blocks, with the 7. Unscrew bolts and hexagon socket head bolt, and
input side down, resting the rim of the housing remove the lockup clutch pressure regulator valve.
on the blocks. Remove shims.

Unscrew bolt, spring washer and washer ,and Bolt

remove output flange.
Hexagon socket head bolt
Bolt
Output flange
Spring washer Lockup clutch
Washer pressure regulator valve

Shim

IW561-0010J37E

8. Unscrew bolts and plate. Remove shims.

Bolt
Front
cover
Plate
Wood block

IW561-0010J35E
Shim

6. Unscrew bolts, and remove seal carrier by prying

the recesses in the seal carrier. Remove shim.

Bolt

Seal carrier IW561-0010J38E

Shim

IW561-0010J36E

43 W561-0012E
 Disassembly

9. Remove hexagon socket head bolt, and plate. 11.Remove gear B (output shaft), and remove
Remove shim and o-ring. turbine shaft

Hexagon socket head bolt

Turbine shaft assy Gear B
Plate

O-ring

IW561-0010J41E

12.Unscrew nuts, and remove pump assy.

IW561-0010J39E

Pump assy
10.Unscerw bolts, and remove rear cover by utilzing Nut
the theraded extraction holes.
Remove PTO clutch section as a whole.

Bolt Rear cover

PTO clutch section

IW561-0010J42E

IW561-0010J40E

44 W561-0012E
 Disassembly

Tapered roller bearing

13.Unscrew hexagon socket head bolts. With a
wood board inserted under the converter and with
housing slightly lifted, lightly tap the end surface of Gear B
seal race, until the internal converter section
comes off, down on the board.

Hex. socket head bolt

Converter housing Tapered roller beating
(large size)
IW561-0010J45E

Seal race

1.2 Disassembly of converter main section

1. Unscrew hexagon socket head bolts, and remove

seal race.

Hexagon socket head bolt

Wood block Seal race

IW561-0010J43E

14.Remove oil seal rings, and tapered roller bearings

from turbine shaft assy.
IW561-0010J46E

Oil seal ring

Tapered roller bearing
2. Unscrew bolts; utilizing the threaded extraction
holes, separate impeller wheel from cover wheel;
Turbine shaft assy remove turbine wheel assy.

Impeller wheel
Bolt

Tapered rolleer bearing

Oil seal ring

IW561-0010J44E

Turbine wheel assy

15.Remove tapered roller bearing (large size), from
gear B (output shaft).

Cover wheel

IW561-0010J47E

45 W561-0012E
 Disassembly

3. Unscerw bolts; utilizing the threaded extracrion 6. Remove snap ring, and remove side washer and
holes, remove front cover. Remove clutch piston pin. Remove stator wheel and free wheel cam.
from the front cover. Rollers and leaf springs will come off then.

Bolt Snap ring

Front cover Side washer
Stator wheel Pin

Clutch piston Free wheel cam Rollr, Leaf spring

IW561-0010J48E

4. Remove oil seal rings from front cover and clutch Impeller wheel
piston. IW561-0010J51E

Front cover
7. After removing side washer and pin, remove
snapring. With wood blocks inserted under
impeller wheel, remove free wheel inner race by
tapping its input-side end.
Oil seal ring Oil seal ring
Side washer
Pin
Washer
Snap ring
Clutch piston
IW561-0010J49E

5. Remove fiber plate and back plate from cover

wheel.

Fiber plate Impeller wheel Free wheel

Inner race

Back plate
Wood block

IW561-0010J52E
Cover wheel

IW561-0010J50E

46 W561-0012E
 Disassembly

8. Unscrew hexagon socket head bolts, and remove

drive gear. Rmove angular contact bearing and
Disassembling stick
impeller hub tapping the angular cortact bearing.

P gear Converter housing

Hexagon socket head bolt
Drive gear

Angular bearing

Boll bearing
Spline hub
IW561-0010J55E

Impeller hub
Impeller wheel 2. Remove P gear and ball bearing out of converter
IW561-0010J53E
housing.

Boll bearing Converter housing

9. After removing oil seal ring, unscrew hexagon
socket head bols, and separate free wheel inner P gear
race from stator holder.

Hexagon socket head bolt

Stator holder IW561-0010J56E

Oil seal ring

Free wheel inner race

IW561-0010J54E

1.3 Disassembly of charging pump drive

sections

1. Insert a disassembling stick into the

disassembling hole (Φ11) inside the converter
housing.
Remove spline hub and ball bearing, rotating P
gear and tapping the end of the spline hub with
the disassembling stick.

47 W561-0012E
 Disassembly

1.4 Disassembly of steering pump drive sections 1.5 Disassembly of PTO clutch section

1. Insert a disassembling stick into the 1. Remove oil seal ring, and tapered roller bearing.
disassembling hole (Φ11) inside the converter
housing. Oil seal ring
Remove retaining ring, and spline hub and ball Tapered roller bearing
bearing, rotating P gear and tapping the end of the
spline hub with the disassembling stick.

Disassembling stick
Converter housing
P gear

IW561-0010J59E

Spline hub
Boll bearing 2. Remove tapered roller bearing, P gear, thrust
Retaining ring washer, ball bearing and snapring from shaft.
IW561-0010J57E
Tapered roller bearing

2. Remove P gear and ball bearing out of the P gear Thrust washer
converter housing. Ball bearing

Ball bearing Converter housing

Snap ring
P gear
Ball bearing

IW561-0010J58E
IW561-0010J60E

48 W561-0012E
 Disassembly

3. Remove snap ring, and remove back plates, fiber 5. Withdraw piston assy. Remove oil seal rings from
plates and steel plates. the piston assy and the clutch assy.

Snap ring Piston assy

Back plate
Oil seal ring
Steel plate Fiber plate
Oil seal ring
Steel plate
Fiber plate
Clutch shaft assy
Steel plate
Fiber plate

IW561-0010J63E

IW561-0010J61E

4. Remove snap ring, and remove washer and

spring.

CAUTION
When removing the snap ring, take care to
prevent the ring from being thrown out by the
spring force.

Snap ring

Spring

IW561-0010J62E

49 W561-0012E
 Disassembly

2. Transmission
2. Unscrew bolt, and remove input flange.
[NOTICE]
◆The following parts shall not be disassembled.
1) Drive plug, piping and steel bolls in housing. Input flange
2) Clutch shaft and clutch carrier (shrink fit).
3) Output shaft, gear M, and gear P (shrink fit)
Bolt
4) Needle roller bearing in the bore of output shaft.
5) Drive plugs and steel balls in valves.
◆Place removed parts in order, and tag them with
mounting position.

2.1 Transmission

1. Remove the valves, the strainer and other

external attachments.

IW561-0010J81E

3. Remove the bolts and hexagon socket head bolts.

Remove the shifter case (2WD-4WD selector
assy) by screwing a bolt into the threaded hole
provided for disassembly.

Hexagon socket head bolt

Bolt Snap ring

Shifter cace

IW560-0010J82E

50 W561-0012E
 Disassembly

4. Place the transmission on wooden blocks with the 6. Unscrew bolts and hexagon socket head bolt, and
front output end upward. remove clutch pressure main relief assy.

5. Unscrew bolt, and remove output flange.

Bolt

7. Unscrew bolts, and remove bracket and solenoid

valve assy.

Output flange

IW561-0010J84E

51 W561-0012E
 Disassembly

8. Unscrew bolts, and remove bracket and solenoid 10.Unscrew hexagon socket head bolt, and remove
valve assy. range selector valve assy.

Hexagon socket head bolt

Valve body

9. Unscrew hexagon socket head bolt, and remove IW561-0010J89E

spacer.

11.Unscrew bolt, and remove High/Low clutch

pressure regulator valve assy.

52 W561-0012E
 Disassembly

12.Unscrew bolt, and remove spacer. 14.Remove the bolts, and screw a bolt into the
threaded hole in the seal carrier to remove the
Bolt carrier.

Bolt
Spacer
Seal carrier
Bolt

IW561-0010J91E

13.Remove the bolts and hexagon socket head bolts.

Remove the cover and range clutch pressure
regulator valve assy.
IW561-0010J93E

[NOTICE]
◆If the shaft group components and supply cover are
not replaced, put marks on all shims so that they
can be replaced correctly at the time of reassembly.

15.Remove the bolts, and screw a bolt into the

threaded hole in the supply cover to remove the
carrier.

Bolt Supply cover

IW561-0010J94E

[NOTICE]
◆Tapping the output shaft end surface, remove the
housing cover. Do not remove the emergency
steering pump from the housing.

53 W561-0012E
 Disassembly

Output shaft group

16.Remove the bolts and the hexagon socket head
bolts. Remobe the housing cover screwing bolts High/Low Clutch pack group
into the threaded hole for disassembly.

Hexagon socket head bolt

Bolt Housing cover
Bolt
Shroud

Emargency steering pump group

IW561-0010J95E
IW561-0010J97E

17.Remove pipe ,adapter and O-ring.

19.Using the lifting jig, remove the F2-R and F1-F3
O-ring clutch pack groups simultaneously out of the
Adapter housing.
O-ring
F1,F3 Clutch pack group

pipe F2,R Clutch pack group lifting jib

O-ring
Adapter
O-ring

IW561-0010J96E

18.Remove the shroud mounting bolts. Using the

lifting jib, remove the High/Low clutch pack group,
output shaft group, and shroud together out of the
housing.

IW561-0010J98E

54 W561-0012E
 Disassembly

20.Remove snap ring, and remove roller bearing.

Spring
Snap ring
Slide sleeve
Roller bearing

Shifter case
Shifter fork
Retainer ring
IW561-0010J99E

Washer
2.2 Shifter case assy (2-wheel/4-wheel selector)

Shifter case

Slide sleeve
Drive gear

Shifter fork

IW561-0010J101E

Shaft 2. Remove snap ring; then remove ball bearing.

Cover Piston Snap ring

IW561-0010J100E

1. Remove springs, silde sleeve and shifter fork. Ball bearing

Remove retainer ring; then remove drive shaft
from shifter case by tapping the shaft end.

Shaft case
IW561-0010J102E

55 W561-0012E
 Disassembly

2.3 Disassembly of steering

3. Unscrew bolt, and remove cover; then remove pump/speedometer group
O-ring.

Bolt
Gear

Cover Case

O-ring

Gear assy

Shroud

IW561-0010J105E
IW561-0010J103E

4. Unscrew nuts, and remove piston, O-ring, and 1. Remobe bolt, then remove shroud, and remove
shifter shaft. snap ring and washer.

Nut Bolt
Shroud
Piston
O-ring
O-ring

Washer
Shifter shaft Snap ring
IW561-0010J106E
IW561-0010J104E

56 W561-0012E
 Disassembly

2.4 Disassembly of clutch pack group

2.Remove gear assy by tapping its end; remove bolt,
then remove casing. [NOTICE]
◆In this sub-section, the F1, F3 clutch pack group is
used as an example in describing disassembling
Case
processes.

Bolt 157

131

135
143
152
138
142
139
141 140
Gear assy 143
144
150
149 151
144 146
IW561-0010J107E

3. Remove plug and copper packing, and remove 136

bushing, oil seal, and O-ring. 137

133,134,135
131 132
IW561-0010J109

1. Remove oil seal ring. Applying a bearing puller to

gear F(C), remove tapered roller bearing and
spacer.

Oil seal ring

Tapered roller bearing

Spacer

Gear C

IW561-0010J110E

57 W561-0012E
 Disassembly

5. Aplyin a bearing puller to gear D , remove tapered

2. Remove snap ring, and remove back plate, fiber
roller bearing, washer, thrust washers, thrust
plates, and steel plates.
needles, and needle bearinng.
Snap ring
Teperd roller bearing
Back plate
Washer
Fiber plate Thrust washer
Thrust needle
Thrust washer
Steel plate Fiber plate
Needle bearing

Gear D
Fiber plate

Thrust washer
Thrust needle
IW561-0010J111E
Thrust washer

3.Remove snap ring, and remove spring.

CAUTION
Remove snap ring, taking care to prevent the
ring from being thrown out by spring.
IW561-0010J113E

6. Remove snap ring, and remove back plate, fiber

4. Remove clutch piston, and snap ring, and seal plates, and steel plates.
carrier.
Then remove oil seal ring. Snap ring
Back plate
Snap ring
Fiber plate
Spring

Clutch piston Fiber plate

Steel plate
Oil seal ring
Snap ring
Seal carrier Fiber plate
Oil seal ring

IW561-0010J114E
IW561-0010J112E

58 W561-0012E
 Disassembly

1. Remove snap ring, and remove inner race of roller

7. Remove snap ring, and remove spring.
bearing.

CAUTION Snap ring

Remove snap ring, taking care to prevent the
ring from being thrown out by spring.

Roller bearing
8. Remove clutch pin, and remove oil seal ring.

Snap ring

Spring

Clutch piston
Oil seal ring
Snap ring IW561-0010J117E

Seal carrier
Oil seal ring 2. Remove spacer, and snap ring, and remove
gear L.

Spacer
IW561-0010J115E
Snap ring

2.5 Disassembly of output shaft group

Gear L

Shaft

IW561-0010J118E

Gear L

IW561-0010J116E

59 W561-0012E
 Checks
Checks
[NOTICE]
◆Wash the disassembled parts in kerosene, and
check the following parts, and replace if they are
deformed, damaged, or worn beyond the limits of
the maintenance standards table given later.
1. Torque converter
1.1 Check items
1. Input plate•3 and tightening hole for deformation.
2. Oil seal ring sliding surfaces of front cover•14,
clutch piston•20, pump drive gear•50, seal
race•55, supply cover•123, piston assy•78 and
cluch shaft assy•81 for wear and damage.
3. Oil seal ring grooves of front cover•14, clutch
piston•20, turbine wheel assy•31, stator holder•53,
turbine shaft assy•59, piston assy•78 and clutch
shaft assy•81 for wear and damage.
4. Stator wheel•35, free wheel inner race•48, free
wheel cam•36, roller•38, leaf spring•37 and side
washer•33•39 for wear, damage, change of color,
play and others.
5. Cogs of drive gear and driven gear for wear and
damage.
6. Splines of each gear and shaft for wear and
damage.
7. Oil seal slide surface of input guide•5, output
flange•98 for wear and damage.
8. Clutch section
• Fiber plate•21•75•77 and steel plate•76 for wear,
deformation and seiqure.
•Rolling element surface of needle bearing of
clutch shaft assy•81 for wear and damage.
9. Other parts for remarkable wear and damage.
60
2. Transmission
2.1 Check items
1. All the gears for wear and damage on tooth
surface.
2. All the bearings for wear, damage, deformation,
play, and abnormal noise while rolling.
3. Clutches (R, F1, F2, F3,High, Low)
• Fiber plates and steel plates for wear, deformation
and seizure
• Seal ring sliding surfaces and grooves of outer
and inner surface of piston assy for wear and
damage.
• Oil seal ring sliding surfaces of supply cover and
oil seal ring grooves in clutch shaft end for wear
and damage.
• Splines of gears and clutch carriers for wear and
damage.
• Needle bearing rolling surfaces of clutch shafts for
wear (Check also the needles for crack and wear,
check holder for play).
4. Output shaft
• Tooth surfaces of gear L, gear M and pump drive
gear for wear and damage.
• Splines of drive shaft, slide sleeve, gear L and
output shaft for wear and damade
• Needle bearing rolling surfaces of output shaft for
wear.
• Sliding surfaces of shifter fork and slide sleeve for
wear and damage.
5. Speedometer
• Drive gear and driven gear for tooth surface wear
and damage.
• Bushes for wear and damage.
W561-0012E
 Checks

6. Valves

• Valve piston for wear in sliding surface

• Spring for deformation, setting, and damage

• Orifice for clogging

7. Filter and strainar for damage and clogging.

8. Drain plug magnet for contamination.

61 W561-0012E
 Reassembly

Reassembly
[NOTICE]
◆Reassemble by reversing the disassembly
processes, observing the following.

1. Torque converter

1.1 Replace the oil seals, O-rings, packings

and copper packings with new parts.

1.2 Reinstalling the oil seal rings

When inserting shafts with seal rings into the bore,

keep turning the shaft to prevent damaging the
seal rings.

1.3 Reassembling converter

internal components

Install angular contact bearing•46 with the side of

the ball setting recess towards drive gear•50
The ball setting recess in the inner race should be
at the shown position.

30°

Ball setting recess

Bearing lnner Race lnstallation position

(seen from output side)
IW561-0010J64E

Install the free wheel leaf springs with the cut

ends towards the cam surface as shown below.

Stator wheel

Lock Free wheel cam Free

Leaf sprin

Freewheel operates Roller

so that the stator wheel
is locked when it is
pushed CCW as viewed Free wheel
from the input side. inner race

IW561-0010J65E

62 W561-0012E
 Reassembly

1.4 Reassembling the PTO clutch

Insert the fiber plates (outside teeth) and the steel
plates (inside teeth) into the PTO clutch alternately,
starting with the former, and then, with the teeth of
the steel plates aligned, insert the gear.
The fiber plates on both ends should be ones
linded with fiber tissue (friction material) on only
one side, and then; lined surfaces should face
toward steel plates.

1.5 Application of liquid packing

Install the back plate (outside teeth) on the cover
wheel side, and the fiber plate (inside teeth) on 1, 2 : Oil seal force-fit areas (Three-Bond 1104)
the clutch piston side. 3 : Maching surface of front cover and cover
wheel
(Three-Bond 1212)
4 : Maching surface of front cover and input guide
(Three-Bond 1212)
5 : Maching surface of converter housing and rear
cover (Three-Bond 1212)
5

2
4

IW561-0010J68E

63 W561-0012E
 Reassembly

1.6 Shim adjustment points and bolt tightening torques

Application of liquid
packing 39.3~44.9N•m
39.3~44.9N•m 51.1~58.3N•m (Three-Bond No.1212) (29~33ft•lbf)
(29~33ft•lbf) (37.7~43.0ft•lbf) (M10×1.5)
(M10×1.5) (M10×1.5)

123.6~141.2N•m Shim
(90.3~104ft•lbf) Z42 adjustment
(M12×1.75)

Shim
adjustment
Z35

51.1~58.3N•m
(37.7~43.0ft•lbf)
(M10×1.5)
Z41
39.3~44.9N•m
Z46
(29~33ft•lbf)
(M10×1.5)

179.5~205N•m
(132~151ft•lbf)
(M16×1.5)

Shim adjustment

25.9~29.4N•m
(19.1~21.7ft•lbf)
Application of liquid packing (M8×1.25)
(Three-Bond No.1212)

51.1~58.3N•m 22.5~24.5N•m
(37.7~43.0ft•lbf) (16.6~18.1ft•lbf)
(M10×1.5) (M10×1.5)

P
Z49 Z54

IW561-0010J69E

1.7 Checks

After reassembling, make sure the input and output shaft turn easily by hand.

64 W561-0012E
 Reassembly

2. Transmission

2.1 Replace the oil seals, O-rings, packings and

copper packings with new parts.

2.2 Reassembling the clutch

Insert the fiber plates (outside teeth) and the steel

plates (inside teeth) into the clutch shaft
alternately, starting with the former.
With the teeth of the steel plates aligned, insert
the spline of the gear into them.

65 W561-0012E
 Reassembly

2.3 Reinstalling the oil seal rings

When inserting shafts with seal rings into bores,

keep turning the shaft or the bore to prevent the
seal rings the damaging.

2.4 Greasing

・ Apply a thin coat of grease to the lip of the input

shaft oil seal.

・ For the double oil seals at the front and rear of the
output shaft, fill the gap of each oil seal pair with
approximately 0.06 pounds (25 grams) of grease.

Oil seal

IW561-0010J121E

・ 2WD-4WD selector section

Fill the piston groove with grease. Also apply
grease to the sliding surface of the piston.

Fill grease between oil seal lips with approximately

0.06 pourds (25 grama) of grease.

Rear output Front output

Fill the piston groove with grease.

Also apply grease to the sliding surface of the piston. IW561-00100J122E

66 W561-0012E
 Reassembly

2.5 Application of liquid packing

When installing the input shaft oil seal and the

output shaft oil seals (front and rear), apply
Three-Bond 1104 to the areas to which the oil
seals are force-fit.

Apply Three-Bond 1104

IW561-0010J124E

Apply Three-Bond 1212 to the joint surfaces of

housing and housing cover.

Apply Three-Bond 1212

Housing cover

Housing

IW561-0010J124E

67 W561-0012E
 Reassembly

2.6 Shim adjustment points and bolt torques

Application of liquid packing

(Three-Bond No.1212)
39.3-44.9N•m
(29-35ft•lbf)
(M10× 1.5 8.8)

Z41
Z31 Z31

179.5-205N•m
(132-151ft•lbf)
(M16×1.5 5.6)
Shim adjustment
0-0.1mm (0-0.004inch)
Z50
Z41
Z31

22.1-25.1N•m
Shim adjustment
(16.3-18.5ft•lbf) Z63 0-0.1mm (0-0.004inch)
Z61
(M10×1.5 5.6)
Z41 Z31
116.7-134.4N•m
(86-99ft•lbf)
(M14×1.5 8.8)

22.1-25.1N•m Shim adjustment

(16.3-18.5ft•.lb)
Z80 0-0.1mm (0-0.004inch)
(M10× 1.5 5.6)
22.1-25.1N•m
(16.3-18.5ft•lbf)
(M10× 1.5 5.6)
Z47
Z61

179.5-205N•m
(132-151ft•lbf)
(M16× 1.5 5.6)

Z23
Z5

29.4-83.4N•m
(21.7-61.5ft•lbf)
(M14×1.5)
Z88 22.1-25.1N•m
(16.3-18.5ft•lbf)
(M10× 1.5 5.6)

IW561-0010J119E

68 W561-0012E
 Oil

Oil
1. Add oil through the torque coverter oil filler to the
1. Recommended oil level H in the transmission oil level gauge, with
the engine standing still.
[NOTICE]
◆The following properties are required of torque 2. Then, run the engine at idle speeds, with the PTO
converter oil. switch OFF and the gear shift lever in neutral.
・Proper viscosity at high temperatures
・Good fluidity at low temperatures 3. As the oil enters the converter, cooler, piping, etc.,
・High stability against oxidation the oil level lowers.
・Non-foaming property and lubrication property
4. Add oil while running the engine for about 5
◆Be sure to use oil listed below, and be sure to add
minutes until the oil level stabilizes between H and
the same oil as the oil in the system.
L in the oil level gauge.
Recommended commercial oils
[NOTICE]
Manufacture Brand Name ◆Check the oil level while the oil temperature is
Esso Esso ATF between 50 - 60°C (122 - 140°F)
Mobil Mobil ATF Total oil quantity : approx. 9gallons (34liters)

2. Oil change procedure

2.1 Removing oil

1. Unplug the drain plug in the lower part of the

transmission.

2. Disconnect the hoses at the connectors, and drain

the oil cooler and the hoses completely.

2.2 Refilling

[NOTICE]
◆Take extreme care not to let dust, water enter, while
pouring in oil.
◆Insufficient or excessive oil can cause faulty
operation.

69 W561-0012E
 Test

Test 3. Stall test

[NOTICE]
◆When driving the tires for measurements and
adjustment with them lifted off the ground with the
outrigger jacks extended, be sure to drive the tires
in the 4-weel drive mode.
1. Checking operating conditions
[NOTICE]
◆The torque converter is generating the maximum
torque, take extreme care to prevent the vehicle
from running forward.
◆During stalling, much heat is generated in the
torque converter. Do not stall the torque converter
for over 30 seconds, and do not stall when the oil
temperature is over 90°C ( 194°F).

1. With the gear shift lever set to N, check the torque
converter condition while changing its speed from
low to high.
・ Must be free from abnormal noise
・ Must be free from abnormal vibration
・ Must be free from oil leakage
2. Hydraulic pressure measurement
1. Run the torque converter to warm the torque
converter oil to approx 60°C (140°F).
1. Firmly apply the parking brake and the foot beake.
2. Set the switches and the levers to :
・PTO switch : OFF
・Gear shift lever : 2nd
・Drive / speed selector switch : 4-wheel, Hi
・Service brake : ON
3. Depress the accelerator pedal fully, and read the
engine revolution when the engine speed
becomes stable.
Standard max. engine speed under stall condition:
Approx. 2240 min-1

2. Start theingine, and measure the clutch oil

pressure and torque converter oil outlet pressure
at idle speed (600min-1) and at (*1) 2600 min-1.
For this measurement, place gear shift lever at the
N position, and use a multi-display and a pressure
check port (RC 1/8) to check the clutch oil outlet
pressure, respectively.

3. Measure the individual clutch pressure, the PTO

clutch pressure, and the lubrication pressure with (*1)
pressure gauge connected to the respective ports,
TR-450XL-4
while the tires lifted off the ground with the 2700 min-1
TR-500XL-4 (-540421)
outrigger jacks extended.
TR-500XL-4
2600 min-1
(540409, 540422-)

Standard pressure
Standard pressure(Mpa) Standard pressure (psi)
Item -1 -1
600 min (*1) 2600 min 600 min-1 (*1) 2600 min-1
Torque converter outlet pressure Approx. 0.04 Approx. 0.39 Approx. 5.8 Approx. 0.39
PTO clutch oil pressure 1.77 or more 2.16 - 2.46 256.6 or more 2.16 - 2.46
Transmission clutch oil pressure 1.72 or more 2.21 - 2.55 249.4 or more 2.21 - 2.55
Lubrication oil pressure (shaft end) 0.01 or more 0.1 - 0.25 1.45 or more 0.1 - 0.25

70 W561-0012E
 Test

Lockup clutch oil pressure 1.72 or more 2.06 or more 249.4 or more 2.06 or more

71 W561-0012E
 Maintenance standard

Maintenance standard
3. Check all the disassembled parts visually and
1. Overhaul interval otherwise, and if they are cracked, damaged,
abnomally worn, corroded, or otherwise defective,
1. Overhaul the torque converter and transmission at
replace or repair them.
every 2 years or every 4000 operating hours,
whichever comes earlier. 4. Replace also those parts which are worn beyond
the wear limits given in PART TREPLACING
2. At each overhaul, replace the oil seals, O-rings
STANDARD. Replace them alone or in
and other rubber parts, the packings and the
assemblies, as the case may be.
copper packings.

2. Replacing intervals of parts

Inteval
1st overhaul 2nd and subsequent overhauls
Part Name
Oil seal
O-ring
Replace all Replace all at each overhaul
Packing
Copper packing
Oil seal ring Replace all at 2nd and 4th overhauls.
Seal ring race surface
Replace if worn beyond limit.
Sintered plate
Replace if worn beyond limit.
Stator freewheel
Replace leaf springs if faulty.
Oil seal sliding surface Check
Clutch piston slinding
surface
Replace if worn beyond limit.
Bush bore
Bearing
Spring

3. Part replacing standard

Dev. Description Application Parts
To be replaced each time Packings,
A disassembled in overhaul, or Packing, O-ring, copper packing, oil seal
check/cleaning rubber parts

Frequently replaced at each

Oil seal ring, snap ring, fiber plate, steel
B overhaul, because of Seal ring, clutch plate
plate
comparatively heavy wear
Not necessarily replaced at
C overhauls, but replaced if found Beating seal ring race Bearing, bush, freewheel parts, seal race
faulty
Normally not replaced, and
D replaced only when become Grar, shaft Gear, clutch shaft, turbine shaft, flange
faulty

72 W561-0012E
 Maintenance standard

3.1 Torque converter

Std. in Limit in
Check item Name No. Measured portion
(mm) (mm)
t=0.090 t=0.079
(2.3) (2.0)
19
H=0.177 H=0.161
(4.5) (4.1)
t=0.094 t=0.083
(2.38) (2.1)
18
H=0.126 H=0.110
(3.2) (2.8)
t=0.094 t=0.083
(2.4) (2.1)
25
H=0.102 H=0.087
(2.6) (2.2)
t=0.094 t=0.083
(2.38) (2.1)
52 t H=0.126 H=0.110
(3.2) (2.8)
t=0.079 t=0.071
(2.0) (1.8)
Wear of oil seal ring Oil seal ring 57 H
H=0.079 H=0.071
(2.0) (1.8)
t=0.122 t=0.110
IW561-0010J126 (3.11) (2.8)
61
H=0.114 H=0.108
(2.9) (2.75)
t=0.079 t=0.071
(2.0) (1.8)
80
H=0.094 H=0.083
(2.4) (2.1)
t=0.094 t=0.083
(2.38) (2.1)
79
H=0.142 H=0.126
(3.6) (3.2)
t=0.094 t=0.083
(2.38) (2.1)
83
H=0.110 H=0.094
(2.8) (2.4)
h=0 h=0.006
(0) (0.15)
Front cover 14
T=0.098 T=0.106
h (2.5) 2.7
Wear of oil seal ring h=0 h=0.006
contact areas and (0) (0.15)
Clutch piston 20
oil seal ring T=0.098 T=0.106
grooves (2.5) (2.7)
T T=0.098 T=0.106
Turbine wheel assy 31
(2.5) (2.7)
IW561-0010J127
h=0 h=0.006
Pdrive gear 50
(0) (0.15)

73 W561-0012E
 Maintenance standard

Wear of oil seal ving T=0.098 T=0.106

Stator holder 53
contact areas and (2.5) (2.7)
oil seal ring T=0.083 T=0.090
grooves (2.1) (2.3)
Turbine shaft assy 59
T=0.126 T=0.134
(3.2) (3.4)
h=0 h=0.006
Seal race 55
(0) (0.15)
h h=0 h=0.006
Supply cover 123
(0) (0.15)
h=0 h=0.006
(0) (0.15)
Clutch piston 78
T=0.098 T=0.106
T (2.5) (2.7)
IW561-0010J127
h=0 h=0.006
(0) (0.15)
T=0.083 T=0.090
Clutch shaft assy 81
(2.1) (2.3)
T=0.098 T=0.106
(2.5) (2.7)
h=0 h=0.006
P mount 88
(0) (0.15)
T=0.153 T=0.148
21
(3.9) (3.75)
Fiber plate t
Fiber plate
thickness T=0.094 T=0.088
77 IW561-0010J128
(2.4) (2.25)

Std. in Limit in
Check item Name No. Measured portion
(mm) (mm)

Fiber plate t T=0.094 T=0.088

Fiber plate 75
thickness (2.4) (2.25)
IW561-0010J128

T=0.197 T=0.191
Back plate 22
Steel plate t (5) (4.85)
thickness T=0.006 T=0.053
Steel plate 76 IW561-0010J129
(1.5) (1.35)

d=5.25 d=5.25
Input guide 5 d
(133.35) (133.15)
IW561-0010J130
Wear in oil seal lip
contact areas

d=2.362 d=2.354
Output flange 98
d (60) (59.8)
IW561-0010J131

74 W561-0012E
 Maintenance standard

Replace if any of the following faults exists.

Curved portions flattened

IW561-0010J132

Both sides not paralle

IW561-0010J133

Check of leaf spring•41

Uniformly compressed
IW561-0010J134

Dented end leaves

IW561-0010J135

Broken
IW561-0010J136

Replace if any of the following faults exists.

・Abnormal noise
Check of bearings (ball, roller) ・Damage or deformation in balls, rollers
・Excessive play
・Decoloring

75 W561-0012E
 Maintenance standard

3.2 Transmission

Std.in Limit in
Check item Name No. Measured portion
(mm) (mm)
t=0.094 t=0.083
111 (2.38) (2.1)
146 H=0.142 H=0.126
(3.6) (3.2)
t=0.094 t=0.083
112 (2.4) (2.1)
147 H=0.102 H=0.087
(2.6) (2.2)
t=0.094 t=0.083
(2.38) (2.1)
179 t H=0.142 H=0.126
(3.6) (3.2)
t=0.094 t=0.083
(2.38) (2.1)
Wear of oil seal ring Oil seal ring 180 H
H=0.126 H=0.110
(3.2) (2.8)
t=0.122 t=0.110
119
IW561-0010J126 (3.11) (2.8)
155
H=0.114 H=0.108
186
(2.9) (2.75)
t=0.094 t=0.083
(2.38) (2.1)
208
H=0.126 H=0.110
(3.2) (2.8)
t=0.094 t=0.083
113 (2.38) (2.1)
150 H=0.126 H=0.110
(3.2) (2.8)
Wear in oil seal ring h=0 h=0.006
contact areas and 108 (0) (0.15)
oil seal ring 114 T=0.098 T=0.106
grooves h (2.5) (2.7)
h=0 h=0.006
145 (0) (0.15)
Clutch piston
151 T=0.098 T=0.106
(2.5) (2.7)
T h=0 h=0.006
(0) (0.15)
176 IW561-0010J127
T=0.098 T=0.106
(2.5) (2.7)
h=0 h=0.006
(0) (0.15)
T=0.098 T=0.106
Clutch shaft assy 111
(2.5) (2.7)
T=0.126 T=0.134
(3.2) (3.4)

76 W561-0012E
 Maintenance standard

Clutch shaft assy h=0 h=0.006

(0) (0.15)
T=0.098 T=0.106
148
(2.5) (2.7)
T=0.126 T=0.134
(3.2) (3.4)
Wear in oil seal ring h=0 h=0.006
contact areas and (0) (0.15)
oil seal ring T=0.098 T=0.106
179 h
grooves (2.5) (2.7)
T=0.126 T=0.134
(3.2) (3.4)
h=0 h=0.006
Supply cover 47
(0) (0.15)
T h=0 h=0.006
Seal carrier 15
IW561-0010J127
(0) (0.15)
h=0 h=0.006
112 (0) (0.15)
Seal carrier
149 T=0.098 T=0.106
(2.5) (2.7)
T=0.098 T=0.106
Seal race 207
(2.5) (2.7)

363-705-60000 △
0
363-506-10000 △
0

77 W561-0012E
Head Office Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785

History of revision
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