ZF-WG211 Transmission Repair

TRANSMISSION
REPAIR (ZF-WG211)
H18XM-9, H18XMS-9, H20XM-9 (H400HD,
H400HDS, H450HD, H450HDS) [C236];
H18XM-12EC, H22XM-12EC, H23XM-12EC
(H450HD-EC, H500HD-EC) [D214];
H25-32XM-12, H25-32XMS-9, H28-32XM-16CH
(H550-700HD, H550-700HDS) [H008]
PART NO. 4121138 1300 SRM 1718

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
Special Tools List .....................................................................................................................................................1

Transmission Repair ............................................................................................................................................... 4
Remove ................................................................................................................................................................ 4
Disassemble .........................................................................................................................................................7
Transmission Housing, Disassemble .............................................................................................................8
Oil Pump, Disassemble ................................................................................................................................ 17
Forward Clutch, Disassemble ...................................................................................................................... 24
Reverse Clutch, Disassemble ....................................................................................................................... 30
First Speed Clutch, Disassemble ................................................................................................................. 36
Second Speed Clutch, Disassemble ..............................................................................................................41
Third Speed Clutch, Disassemble ................................................................................................................47
Fourth Speed Clutch, Disassemble ..............................................................................................................52
Input Shaft, Disassemble ............................................................................................................................. 57
Clean and Inspect ............................................................................................................................................. 57
Housings ........................................................................................................................................................58
Oil Seals and Gaskets ...................................................................................................................................58
Bearings ........................................................................................................................................................ 58
Gears and Shafts .......................................................................................................................................... 58
Assemble ............................................................................................................................................................58
Input Shaft, Assemble .................................................................................................................................. 59
Fourth Speed Clutch, Assemble ...................................................................................................................59
Third Speed Clutch, Assemble .....................................................................................................................67
Second Speed Clutch, Assemble ...................................................................................................................74
Reverse Clutch, Assemble ............................................................................................................................ 81
Forward Clutch, Assemble ........................................................................................................................... 89
Oil Pump, Assemble ..................................................................................................................................... 96
Transmission Housing, Assemble ................................................................................................................97
Transmission Oil Filter Assembly and Oil Fill Tube Replacement ............................................................. 109
Remove ........................................................................................................................................................ 109
Clean ............................................................................................................................................................111
Inspect ......................................................................................................................................................... 111
Install .......................................................................................................................................................... 111
Install ...............................................................................................................................................................113
Control Valve Replacement ................................................................................................................................ 116
Remove ............................................................................................................................................................ 116
Install ...............................................................................................................................................................117
Control Valve Repair ...........................................................................................................................................118
Disassemble .....................................................................................................................................................118
Clean ................................................................................................................................................................123
Inspect ............................................................................................................................................................. 123
Assemble ..........................................................................................................................................................123
This section is for the following models:
H18XM-9, H18XMS-9, H20XM-9 (H400HD, H400HDS, H450HD, H450HDS)

[C236];
H18XM-12EC, H22XM-12EC, H23XM-12EC (H450HD-EC, H500HD-EC) [D214];
H25-32XM-12, H25-32XMS-9, H28-32XM-16CH (H550-700HD, H550-700HDS)
[H008]
©2014 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 1718 Special Tools List
Special Tools List

The following list consists of the special tools
required to perform the assembly procedures
outlined in this manual.
Item Figure Nomenclature Part Number
1 Bearing Driver 4104871
2 Forcing Device 4104872
3 Grab Sleeve 4104874
1
Special Tools List 1300 SRM 1718
5 Bearing Puller 4104876
7 Driver 4104878
8 Pressure Sleeve 4104879
Clutch Pack Spring

9 4612858
Compression Tool
2
1300 SRM 1718 Special Tools List
10 Holding Fixture Assembly 4612859
11 Shaft Seal Mounting Tool 4612860
12 Grip Handle 4612861
13 Pump Seal Mounting Tool 4612862
3
Transmission Repair 1300 SRM 1718
Transmission Repair
REMOVE
CAUTION
1. Tilt the mast fully forward and lower the forks Drive shafts are balanced and configured at the
completely. time of manufacture. Prior to removal, make sure
2. Turn the key to OFF position to shutdown the an alignment mark is present on the splined stub
engine. and the slip yoke, indicating their relative posi-
tion. Always align slip yoke and splined stub cor-
3. Apply the parking brake. rectly. Failure to assemble and install the drive
shaft properly leads to excessive vibration levels
4. Tilt the operator compartment up to gain access and premature failure of components attached to
to the transmission. See the section Opera- the drive shaft.
tor's Cab 0100SRM1390.
6. Apply alignment marks on slip yoke and
5. Disconnect the cables from the battery. Discon- splined stub prior to drive shaft removal.
nect the ground cable first and then the posi-
tive cable. 7. Disconnect the drive shaft at the transmission.
See Figure 1.
1. DRIVE SHAFT 5. CAP SCREWS

2. UNIVERSAL JOINT 6. DIPSTICK ASSEMBLY
3. TRANSMISSION MOUNT 7. TRANSMISSION
4. TORQUE CONVERTOR
Figure 1. Transmission Arrangement
4
1300 SRM 1718 Transmission Repair
8. Disconnect the Frame-Powertrain connector

(CPP02) and the starter motor cable (TS13). CAUTION
See Figure 2. Disposal of lubricants and fluids must meet local
environmental regulations.
9. Place a suitable container under the transmis-

sion sump, remove the transmission sump
drain plug and drain the transmission oil [ap-
proximately 27 liter (28.5 qt)].
10. Disconnect the oil lines from the transmission

to the thermostat valve. Drain the oil into a
drain pan. Put plugs and caps on open lines
and fittings.
11. Attach a lifting device to the hydraulic pumps
12. The hydraulic pumps are connected to the

transmission with four capscrews. Attach a lift-
ing device to hold the hydraulic pumps, remove
the capscrews, and the hydraulic pumps. The
drive shaft of the hydraulic pump is engaged in
the splines of the drive gear. The drive shaft of
the hydraulic pump will slide out of the drive
gear when the hydraulic pump is removed.
13. Put a beam on the frame, that can carry the

1. FRAME-POWERTRAIN CONNECTOR weight of the hydraulic pumps.
2. STARTER MOTOR TERMINAL
14. Turn the pumps away from the transmission (±
Figure 2. Powertrain Connections 45°) towards the hydraulic tank, leaving the ho-
ses connected, and attach the hydraulic pumps
in that position to the beam. See Figure 3.
5
1. HYDRAULIC PUMPS 3. ENGINE

2. TRANSMISSION
Figure 3. Remove Transmission
15. Install blocks and a jack under the flywheel end

of the engine as a support. If the support is un-
der the engine oil sump, make sure that the
support is across the width of the oil sump so
the weight of the engine does not damage the
oil sump.
16. Connect a lifting device, with a lifting capacity

of at least 1200 kg (2650 lb), to the two lifting
eyes located at the top of the transmission. See
Figure 4.
1. LIFTING EYES
Figure 4. View of Transmission
6
17. Open the left cover to gain access to the engine 23. Raise the lifting device to hold the weight of the
area. transmission only. Remove the twelve cap-
screws that fasten the torque converter housing
18. Remove the exhaust pipe to gain access to the to the flywheel housing.
convertor housing. See Figure 5.
24. Remove the two M6 x 110 bolts that fasten the
transmission mount to the frame.
CAUTION
Keep the transmission level when the transmis-
sion is separated from the engine to avoid dam-
age to the drive plate.
25. Make sure that all connections have been re-

moved and carefully lift the transmission as-
sembly from the frame and engine.
DISASSEMBLE
Figure 6 shows a view of the ZF ERGOPOWER
transmission mounted to the Holding Fixture As-
sembly.
1. ACCESS HOLE TO ROTATE FLYWHEEL

2. ACCESS PLUG
3. EXHAUST PIPE
4. ACCESS PLATE TO FLYWHEEL CAPSCREWS
Figure 5. Access Plug for Drive Plate Capscrews
19. Remove the access plug to gain access to the

flywheel ring gear.
20. Remove the access plate to gain access to the

capscrews that connect the flywheel to the
drive plates.
21. Insert a flywheel rotation tool into the access

plug hole and rotate the flywheel until one of
the capscrews is visible through the access 1. HOLDING FIXTURE
plate hole. See Figure 5. 2. CLAMPING DEVICE
22. Remove the capscrew. Rotate the flywheel and Figure 6. ZF ERGOPOWER Transmission
remove the remaining capscrews until all four
capscrews have been removed.
7
Transmission Housing, Disassemble

STEP 1.
Remove electrical harness from the transmission.
Put identification tags on the wires to be able to
correctly reconnect.
1. TRANSMISSION TURBINE SPEED SENSOR

2. TRANSMISSION INTERNAL SPEED SENSOR
3. DIFFERENTIAL PRESSURE SWITCH
4. MAIN CONNECTOR
5. ENGINE SPEED SENSOR
6. TRANSMISSION CONTROL VALVE CONNEC-
TOR
7. TORQUE CONVERTER TEMPERATURE SEN-
SOR
8. TRANSMISSION OUTPUT SPEED SENSOR
STEP 2.
Remove the oil filter assembly and oil filler tube
from the transmission. See Transmission Oil Fil-
ter Assembly and Oil Fill Tube Replacement, Re-
move.
STEP 3.
Remove the control valve assembly from the
transmission. See Control Valve Replacement
8
STEP 4.
Remove the differential pressure switch for the
ZF-Micro Filter from the duct plate.
1. COMPRESSION SPRING
2. PISTON
STEP 5.
Remove the torx screws and separate the duct
plate and the gaskets from the housing front sec-
tion.
1. DUCT PLATE 3. SEAL

2. GASKET
STEP 6.
Remove the converter safety valve from the hous-
ing bore.
2. PISTON
9
STEP 7.
Remove the breather, internal speed input sensor
and turbine sensor from the transmission.
1. BREATHER
2. INDUCTIVE TRANSMITTER - N INTERNAL
SPEED INPUT
3. INDUCTIVE TRANSMITTER - N TURBINE
STEP 8.
Remove the inductive transmitter - n engine,
speed sensor and temperature sensor from the
transmission.
1. INDUCTIVE TRANSMITTER - N ENGINE

2. SPEED SENSOR - N OUTPUT (HALL SENSOR)
3. TEMPERATURE SENSOR
STEP 9.
Remove two screws and install the eye bolts. Use
a lifting tackle to remove the torque converter
from the transmission. Remove the diaphragm
from the torque converter.
1. EYE BOLTS 3. DIAPHRAGM

2. SCREW
10
STEP 10.
Remove the capscrews from the bellhousing and
remove bellhousing from transmission.
1. BELLHOUSING
2. TRANSMISSION
STEP 11.
Remove the O-ring from oil pump. Remove the
capscrews from transmission housing plate and
remove transmission housing plate.
1. O-RING
2. CAPSCREWS
3. TRANSMISSION HOUSING PLATE
STEP 12.
With a pulling device remove the stator hollow
shaft/oil pump with a lifting tackle.
1. OIL PUMP
11
STEP 13.
Remove the screws and remove the cover.
1. SCREWS
2. COVER
STEP 14.
Remove the O-ring and retaining ring. Pull the
pump shaft from the housing bore. Remove the re-
taining ring from the pump shaft.
1. O-RING 3. PUMP SHAFT

2. RETAINING RING 4. RETAINING RING
STEP 15.
Remove the retaing ring and remove the ball bear-
ing from the pump shaft.
1. RETAINING RING 3. PUMP SHAFT

2. BALL BEARING
12
STEP 16.
Remove the screws and washer from the output
flange. Remove and discard the O-ring.
1. SCREWS
2. OUTPUT FLANGE
STEP 17.
Remove the output flange and shaft seal. Drive
out both pins and remove capscrews from front
housing and rear housing sections.
1. OUTPUT FLANGE 3. PIN

2. SHAFT SEAL 4. CAPSCREWS
WARNING
To prevent the possibility of injury to personnel,
use a lifting device of sufficient lifting capacity
while performing the following step.
NOTE: Make sure that the cylindrical pins have

been removed before removing the rear transmis-
sion cover.
STEP 18.
Use a lifting device to remove the rear transmis-
sion housing from the front transmission housing.
1. REAR TRANSMISSION HOUSING

2. FRONT TRANSMISSION HOUSING
13
STEP 19.
Remove all piston rings from the clutches and in-
put shaft. Remove two capscrews from clutch
screen. Remove fluid tubes with O-rings, dicard O-
rings.
1. PISTON RING 3. CAPSCREWS

2. FLUID TUBES
WARNING
while performing the following step.
STEP 20.
Remove the clutch assemblies and input shaft
from the front transmission cover in the order
given in the legend.
1. CLUTCH, 3RD SPEED/OUTPUT

2. CLUTCH, 2ND SPEED
3. CLUTCH, 1ST SPEED
4. CLUTCH, 4TH SPEED
5. CLUTCH, FORWARD
6. CLUTCH, REVERSE
7. INPUT SHAFT
8. SCREEN
14
STEP 21.
Remove capscrews from suction pipe in the front
transmission housing.
1. CAPSCREW
2. SUCTION PIPE
STEP 22.
Remove the bearing outer rings from the front

5. CLUTCH, FORWARD
6. CLUTCH, REVERSE
7. INPUT SHAFT
15
STEP 23.
Remove the system pressure tubes from the rear
transmission housing in the order of the legend.
NOTE: Perform STEP 23 only if any of the tubes

are damaged.
1. CLUTCH, REVERSE
STEP 24.
Remove the bearing outer rings from the rear

5. CLUTCH, FORWARD
6. CLUTCH, REVERSE
7. INPUT SHAFT
16
Oil Pump, Disassemble

STEP 1.
Remove the O-ring and capscrews from the oil
pump. Discard the O-ring.
1. O-RING 3. OIL PUMP

2. CAPSCREWS
STEP 2.
Remove the cover, inner rotor, and outer rotor
from the oil pump housing. Inspect the pump
housing, inner rotor outer rotor, and cover for
wear marks. If any wear is shown, replace the oil
pump.
1. COVER
2. INNER ROTOR
3. OUTER ROTOR
4. OIL PUMP HOUSING
17
STEP 3.
Remove and discard the shaft seal from the oil
pump housing.
1. SHAFT SEAL
2. OIL PUMP HOUSING
Figure 7. Forward Clutch Assembly
18
NOTE: See Parts Manual for breakdown.
Figure 8. Reverse Clutch Assembly
19
Figure 9. 1st Speed Clutch Assembly
20
Figure 10. 2nd Speed Clutch Assembly
21
Figure 11. 3rd Speed Clutch Assembly
22
Figure 12. 4th Speed Clutch Assembly
23
Forward Clutch, Disassemble

NOTE: As each clutch assembly is disassembled, ensure that all of the components of that assembly are
kept separate from any other clutch assemblies to prevent the possibility of parts being assembled to an in-
correct clutch assembly.
STEP 1.
Remove the piston ring.
1. PISTON RING
STEP 2.
Remove the tappered roller bearing from the shaft
with the use of a forcing device and grab sleeve.
1. FORCING DEVICE
2. GRAB SLEEVE
24
STEP 3.
1. PISTON RING
STEP 4.
Remove the clutch assembly and spur gear to-
gether with the two-arm puller.
1. TWO-ARM PULLER
2. CLUTCH ASSEMBLY
STEP 5.
Remove the clutch assembly from the spur gear.
1. CLUTCH ASSEMBLY
2. SPUR GEAR
25
STEP 6.
Remove the snap ring from the clutch assembly.
1. SNAP RING
2. CLUTCH ASSEMBLY
STEP 7.
Remove the end shim and disc set from the clutch
pack carrier.
1. END SHIM
2. DISC SET
3. CLUTCH PACK CARRIER
26
WARNING
The spring has a force of 1700 ±147 N (382
±33 lbf).
STEP 8.
Using a spring compression tool, P/N 4612858,
compress the spring and remove the "L" ring.
1. COMPRESSION TOOL
3. "L" RING
STEP 9.
Slowly release the compression spring and remove
the guide ring, compression spring, and washer
from the disk carrier.
1. GUIDE RING
3. DISK CARRIER
4. WASHER
27
NOTE: Use compressed air to aid in the removal of

the piston.
STEP 10.
Remove piston from disk carrier.
1. PISTON
2. DISK CARRIER
STEP 11.
Remove and discard inner and outer O-rings from
the piston.
1. INNER O-RING 3. PISTON

2. OUTER O-RING
STEP 12.
Remove the needle bearing from the shaft.
1. NEEDLE BEARING
2. SHAFT
28
STEP 13.
Unsnap the retaining ring from the idler gear and
remove the ball bearing.
1. IDLER GEAR 3. RETAINING RING

2. BALL BEARING
STEP 14.
1. FORCING DEVICE
2. GRAB SLEEVE
STEP 15.
1. PISTON RING
29
Reverse Clutch, Disassemble

STEP 1.
1. PISTON RING
2. CLUTCH SHAFT
STEP 2.
1. FORCING DEVICE
2. GRAB SLEEVE
STEP 3.
1. SNAP RING 3. IDLER GEAR

2. CLUTCH SHAFT
30
STEP 4.
1. TWO-ARM PULLER
2. CLUTCH ASSEMBLY
STEP 5.
1. SNAP RING
2. CLUTCH ASSEMBLY
STEP 6.
pack carrier.
1. END SHIM
2. DISC SET
31
WARNING
The spring has a force of 1700 ±147 N (382
±33 lbf).
STEP 7.
1. COMPRESSION TOOL
3. "L" RING
STEP 8.
the guide ring, compression spring and washer,
from the disk carrier.
1. GUIDE RING
3. DISK CARRIER
4. WASHER
32

the piston.
STEP 9.
Remove piston from disc carrier.
1. PISTON
2. DISC CARRIER
STEP 10.
the piston.

2. OUTER O-RING
STEP 11.
With a cut-off device and pulling device remove
the idler gear from the shaft.
1. CUT-OFF DEVICE 3. SPUR GEAR

2. PULLING DEVICE
33
STEP 12.
Unsnap the retaining ring from the idler gear and
remove the ball bearing.
1. RETAINING RING 3. IDLER GEAR

2. BALL BEARING
STEP 13.
Remove the needle bearing from the shaft.
1. NEEDLE BEARING 2. SHAFT
34
STEP 14.
1. FORCING DEVICE 2. GRAB SLEEVE
STEP 15.
1. PISTON RING
35
First Speed Clutch, Disassemble

STEP 1.
1. PISTON RING
STEP 2.
1. FORCING DEVICE
2. GRAB SLEEVE
STEP 3.
Remove the retaining ring.
1. RETAINING RING
36
STEP 4.
Remove the axial bearing and idler gear.
1. AXIAL BEARING
2. IDLER GEAR
STEP 5.
Remove the needle bearing and the axial bearing.
1. NEEDLE BEARING
2. AXIAL BEARING
STEP 6.
Remove the clutch assembly with the two-arm
puller.
1. TWO-ARM PULLER
2. CLUTCH ASSEMBLY
37
STEP 7.
1. SNAP RING
2. CLUTCH ASSEMBLY
STEP 8.
pack carrier.
1. END SHIM
2. DISC SET
38
WARNING
The spring has a force of 580 ±72 N (130 ±16 lbf).
STEP 9.
1. COMPRESSION TOOL
3. "L" RING
STEP 10.
the guide ring, compression spring from the clutch
pack carrier.
1. GUIDE RING
2. CUP SPRING SET
3. DISC CARRIER
39

the piston.
STEP 11.
1. PISTON
2. DISC CARRIER
STEP 12.
the piston.

2. OUTER O-RING
STEP 13.
1. PISTON RING
2. TAPERED ROLLER BEARING
3. SHAFT
40
STEP 14.
1. FORCING DEVICE
2. GRAB SLEEVE
Second Speed Clutch, Disassemble

STEP 1.
1. PISTON RING
STEP 2.
1. FORCING DEVICE
2. GRAB SLEEVE
41
STEP 3.
Remove the retaining ring.
1. RETAINING RING
STEP 4.
1. AXIAL BEARING
2. IDLER GEAR
STEP 5.
1. NEEDLE BEARING
2. AXIAL BEARING
42
STEP 6.
puller.
1. TWO-ARM PULLER
2. CLUTCH ASSEMBLY
STEP 7.
1. RETAINING RING
2. CLUTCH ASSEMBLY
STEP 8.
pack carrier.
1. END SHIM
2. DISC SET
43
WARNING
STEP 9.
1. COMPRESSION TOOL
3. "L" RING
STEP 10.
pack carrier.
1. GUIDE RING
3. DISC CARRIER
44

the piston.
STEP 11.
1. PISTON
2. DISC CARRIER
STEP 12.
the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
45
STEP 13.
1. PISTON RING
3. SHAFT
STEP 14.
1. FORCING DEVICE
2. GRAB SLEEVE
46
Third Speed Clutch, Disassemble

STEP 1.
1. PISTON RING
STEP 2.
1. FORCING DEVICE
2. GRAB SLEEVE
47
STEP 3.
1. AXIAL BEARING
2. IDLER GEAR
STEP 4.
1. NEEDLE BEARING
2. AXIAL BEARING
STEP 5.
puller.
1. TWO-ARM PULLER
2. CLUTCH ASSEMBLY
48
STEP 6.
1. RETAINING RING
STEP 7.
pack carrier.
1. END SHIM
2. DISC SET
49
WARNING
STEP 8.
1. COMPRESSION TOOL
3. "L" RING
STEP 9.
pack carrier.
1. GUIDE RING
2. CUP SPRING SET
3. DISC CARRIER
50

the piston.
STEP 10.
1. PISTON
2. DISC CARRIER
STEP 11.
Remove and discard the inner and outer O-rings
from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
STEP 12.
Remove the piston rings.
1. PISTON RING
3. SHAFT
51
STEP 13.
1. FORCING DEVICE
2. GRAB SLEEVE
Fourth Speed Clutch, Disassemble

STEP 1.
1. PISTON RING
STEP 2.
1. FORCING DEVICE
2. GRAB SLEEVE
52
STEP 3.
1. PISTON RING
STEP 4.
1. TWO-ARM PULLER
2. CLUTCH ASSEMBLY
STEP 5.
NOTE: Input gear can NOT be dissasembled

(shrink fit).
1. AXIAL BEARING
2. IDLER GEAR
53
STEP 6.
1. NEEDLE BEARING
2. AXIAL BEARING
3. INPUT GEAR
STEP 7.
1. SNAP RING
2. CLUTCH ASSEMBLY
STEP 8.
pack carrier.
1. END SHIM
2. DISC SET
54
STEP 9.
1. COMPRESSION TOOL
3. "L" RING
STEP 10.
pack carrier.
1. GUIDE RING
2. CUP SPRING SET
3. DISC CARRIER

the piston.
STEP 11.
Use compressed air to aid in the removal of the
piston.
1. PISTON
2. DISC CARRIER
55
STEP 12.
Remove and discard the inner and outer O-rings
from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
STEP 13.
1. PISTON RING
STEP 14.
1. FORCING DEVICE
2. GRAB SLEEVE
56
Input Shaft, Disassemble

STEP 1.
Remove piston ring. Using a bearing puller, re-
move two tapered roller bearings from the input
shaft.
1. PISTON RING
3. INPUT SHAFT
CLEAN AND INSPECT • Do not use gasoline or solvents that con-

tain gasoline. Gasoline can explode.
WARNING • Use hot solution tanks or alkaline solutions
correctly. Carefully follow manufacturer's
To prevent serious eye injury, always wear safe
instructions.
eye protection when performing vehicle mainte-
nance or service.
Clean all parts thoroughly using solvent type clean-
ing fluid. It is recommended that parts be im-
WARNING mersed in cleaning fluid and moved up and down
To avoid personal injury when cleaning parts, slowly until all old lubricant and foreign material is
work in a well-ventilated area, wear protective dissolved and parts are thoroughly cleaned.
clothing (face shield or safety glasses and protec-
tive gloves), and follow chemical manufacturer's The importance of careful and thorough inspection
recommendations for safe usage. of all parts cannot be overstressed. Replacement of
all parts showing indication of wear or stress will
Solvent cleaners can be flammable, poisonous, eliminate costly and avoidable failures at a later
and cause burns. Examples of solvent cleaners date.
are carbon tetrachloride, emulsion-type cleaners,
and petroleum-based cleaners. To avoid serious
personal injury when using solvent cleaners,
carefully follow manufacturer's instructions and
these procedures:
• Wear safe eye protection.
• Wear clothing that protects skin.
• Work in a well-ventilated area.
57
Housings NOTE: Do not spin the bearings when drying.
Clean interior and exterior of housings, bearing Remove bearings from cleaning fluid and strike flat
caps, etc., thoroughly. Cast parts may be cleaned in against a block of wood to dislodge solidified parti-
hot solution tanks with mild alkali solution provid- cles of lubricant. Immerse again in cleaning fluid to
ing these parts do not have ground or polished sur- flush out particles. Repeat above operation until
faces. Parts should remain in solution long enough bearings are thoroughly clean. Dry bearings using
to be thoroughly cleaned and heated. This will aid moisture-free compressed air. Be careful to direct
the evaporation of the cleaning solution and rinse air stream across bearing to avoid spinning. Bear-
water. Parts cleaned in solution tanks must be ings may be rotated slowly by hand to facilitate
thoroughly rinsed with clean water to remove all drying process.
traces of alkali. Cast parts may also be cleaned
with steam cleaner. NOTE: Do not replace a bearing cone or cup indi-
vidually without replacing the mating cup or cone
Inspect housings, covers and bearing caps to ensure at the same time.
that they are thoroughly clean and that mating
surfaces, bearing bores, etc., are free from nicks or Carefully inspect all rollers, cages and cups for
burrs. Check all parts carefully for evidence of wear, chipping, or nicks to determine fitness of
cracks or conditions which would cause subsequent bearings for further use. After inspection, dip bear-
oil leaks or failures. ings in recommended Automatic Transmission
Fluid and wrap in clean lint-free cloth or paper to
Oil Seals and Gaskets protect them until installed.
Replacement of spring load oil seals, O-rings, metal Gears and Shafts
sealing rings, gaskets, and snap rings is more eco-
nomical when the unit is disassembled than prema- If Magna-Flux process is available, use process to
ture overhaul to replace these parts at a future check parts. Examine teeth on all gears carefully
time. Further loss of lubricant through a worn seal for wear, pitting, chipping, nicks, cracks, or scores.
may result in failure of other more expensive parts If gear teeth show spots where case hardening is
of the assembly. Sealing members should be han- worn through or cracked, replace with new gear.
dled carefully, particularly when being installed. Small nicks may be removed with suitable hone. In-
Cutting, scratching, or curling under of lips of seals spect shafts and quills to make certain they are not
seriously impairs its efficiency. When assembling sprung, bent, or spline-twisted, and that shafts are
new metal type piston rings, these should be lubri- true.
cated with a coat of Vaseline to stabilize rings in
their grooves for ease of assembly of mating mem- ASSEMBLE
bers. Lubricate all O-rings with recommended type
Automatic Transmission Fluid before assembly.
Prior to installation of rubber seals, lightly coat the
outer surface with mineral spirits, and coat the in-
ner surface with multipurpose grease.
Bearings
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
58
Input Shaft, Assemble

STEP 1.
Using a press, install two tapered roller bearings
on the input shaft until they bottom out, and in-
stall the piston ring on the input shaft.
1. PISTON RING
3. INPUT SHAFT
Fourth Speed Clutch, Assemble
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns
STEP 1.
With a heat gun, heat the tappered roller bearing
inner diameter to 120°C (248°F).
NOTE: Install the bearing inner ring subsequently

after cooling down.
1. TAPPERED ROLLER BEARING

2. HEAT GUN
59
WARNING
prevent burns
STEP 2.
Install the tappered roller bearing onto the shaft
until contact and install the piston ring.

2. PISTON RING
STEP 3.
If neseccary, freeze the shaft to -80°C (-112°F) and
heat the input gear with a heat gun to
120°C (248°F) and mount them until contact.
1. SHAFT
2. INPUT GEAR
STEP 4.
If neseccary, install the retaining ring onto the
shaft.
NOTE: Prior to installing bearings, coat with

transmission oil. Upper and lower axial bearings
are identical.
1. RETAINING RING
60
STEP 5.
Install the lower axial bearing then the needle
bearing followed by the upper axial bearing.
1. AXIAL BEARING
2. NEEDLE BEARING
3. SHAFT
STEP 6.
Install and oil the needle bearing to the shaft.
1. NEEDLE BEARING
2. SHAFT
STEP 7.
Install the idler gear to the shaft.
1. IDLER GEAR
61
NOTE: Install the chamfer of the running disc

showing towards the needle bearing.
STEP 8.
Install the axial bearing, needle bearing, and run-
ning disc.
1. AXIAL BEARING
2. NEEDLE BEARING
3. RUNNING DISC
4. SHAFT
CAUTION
Make sure that the O-rings are not deformed dur-
ing installation, and DO NOT roll the O-rings onto
the piston.
NOTE: Prior to installing O-rings, coat with trans-

mission oil to make installation easier.
STEP 9.
Install outer O-ring and inner O-ring to the pis-
ton.
NOTE: Check function of drain valve. Ball must re-

main free and not become jammed.
1. INNER O-RING
2. OUTER O-RING
3. DRAIN VALVE BALL
STEP 10.
Using the spring compression tool, P/N 4612858,
install the piston into the clutch pack carrier, as
noted during disassembly, until it bottoms out.
1. PISTON
2. DISC CARRIER
62
STEP 11.
Install the cup spring set and "L" ring into the
disc carrier. Preload the spring with assembly aid
and pressure piece until "L" ring has snapped into
annular groove.
NOTE: Use a NEW "L" ring on installation.
1. CUP SPRING SET

2. "L" RING
3. DISC CARRIER
STEP 12.
Install the friction disk, uncoated side down toward the piston, into the clutch pack carrier. See Figure 12.
NOTE: Prior to installation, the inner and friction discs must be coated with clean automatic transmission
fluid.
STEP 13.
Install the inner discs and friction discs into the clutch pack carrier as shown in Figure 12.
STEP 14.
Install the friction disc, uncoated side up, into the clutch pack carrier. See Figure 12.
STEP 15.
Install the end shim and retaining ring into the
clutch pack carrier.
1. END SHIM
2. RETAINING RING
63
STEP 16.
Install a dial indicator as shown, and depress the
end shim with a force of 100 N (23 lbf ft), set the
dial indicator to zero.
1. DIAL INDICATOR
2. END SHIM
STEP 17.
Press the end shim against the retainer and deter-
mine the clearance between the end shim and the
retainer. The disk clearance is to be 1.35 to
1.65 mm (0.053 to 0.064 in.). If the clearance is
not within the limits specified a new retainer
must be installed. See the Parts Manual for the
next size retainer.
1. DIAL INDICATOR
2. END SHIM
WARNING
prevent burns
STEP 18.
Turn the clutch pack carrier over so that the bot-
tom of the carrier is facing up, and using a heat
gun, heat the inner diameter to 120°C (248°F).

2. HEAT GUN
64
WARNING
prevent burns
STEP 19.
Install the clutch pack carrier onto the shaft with
short left-hand/right-hand rotations to seat the
discs.
STEP 20.
Install the piston ring onto the shaft.
1. PISTON RING
2. CLUTCH ASSEMBLY
WARNING
prevent burns
STEP 21.

2. HEAT GUN
65
WARNING
prevent burns
STEP 22.
until contact and install the stud bolt. Tighten the
stud bolt to 17 N•m (12.5 lbf ft).

2. STUD BOLT
STEP 23.
Check the opening of the clutch by applying com-
pressed air at the bore. See arrow in the figure.
The opening of the clutch must be clearly audible.
66
Third Speed Clutch, Assemble
WARNING
prevent burns
STEP 1.
NOTE: Install the bearing inner ring subsequently

after cooling down.

2. HEAT GUN
WARNING
prevent burns
STEP 2.

2. PISTON RING
67
CAUTION
the piston.

STEP 3.
ton.

1. INNER O-RING 3. DRAIN VALVE BALL
2. OUTER O-RING
STEP 4.
install the piston into the disc carrier, as noted
during disassembly, until it bottoms out.
1. PISTON
2. DISC CARRIER
STEP 5.
annular groove.
1. CUP SPRING SET 3. DISC CARRIER

2. "L" RING
68
STEP 6.
fluid.
STEP 7.
STEP 8.
STEP 9.
1. END SHIM
2. RETAINING RING
STEP 10.
end shim with a force of 100 N (23 lbf), set the dial
indicator to zero.
1. DIAL INDICATOR
2. END SHIM
69
STEP 11.
next size retainer.
1. DIAL INDICATOR
2. END SHIM
STEP 12.

2. HEAT GUN
WARNING
prevent burns
STEP 13.
Install the clutch pack carrier on the clutch shaft
until it bottoms out.

2. CLUTCH SHAFT
70
NOTE: Install the chamfer of the running disc

showing towards the needle bearing.
STEP 14.
Install the axial bearing, needle bearing, and run-
ning disc.
1. AXIAL BEARING 3. RUNNING DISC

2. NEEDLE BEARING 4. SHAFT
STEP 15.
Install the two needle bearings and idler gear on
the clutch shaft, rotating the idler gear left and
right small amounts to achieve final alignment
with the clutch pack.
1. AXIAL BEARING AS- 3. IDLER GEAR

SEMBLY 4. CLUTCH SHAFT
2. NEEDLE BEARING
71
STEP 16.
Install the running disc chamfer side up, needle
bearing, and axial bearing on the clutch shaft.
1. NEEDLE BEARING 3. AXIAL BEARING

2. RUNNING DISC
WARNING
prevent burns
STEP 17.

2. HEAT GUN
72
WARNING
prevent burns
STEP 18.
until contact and install the stud bolt.
STEP 19.
73
Second Speed Clutch, Assemble
WARNING
prevent burns
STEP 1.

2. HEAT GUN
WARNING
prevent burns
STEP 2.

2. PISTON RING
CAUTION
the piston.

STEP 3.
ton.

1. INNER O-RING
2. OUTER O-RING
3. DRAIN VALVE BALL
74
STEP 4.
install the piston into the disc carrier, as noted
during disassembly, until it bottoms out.
1. PISTON
2. DISC CARRIER
STEP 5.
annular groove.
1. CUP SPRING SET

2. "L" RING
3. DISC CARRIER
STEP 6.
fluid.
STEP 7.
STEP 8.
75
STEP 9.
1. END SHIM
2. RETAINING RING
STEP 10.
end shim with a force of 100 N (23 lbf), set the dial
indicator to zero.
1. DIAL INDICATOR
2. END SHIM
STEP 11.
next size retainer.
1. DIAL INDICATOR
2. END SHIM
76
STEP 12.

2. HEAT GUN
WARNING
prevent burns
STEP 13.
Install the clutch pack carrier on the clutch shaft
until it bottoms out.

STEP 14.
Install the running disc chamfer side up, needle
bearing, and axial bearing on the clutch shaft.
1. NEEDLE BEARING 3. AXIAL BEARING

2. RUNNING DISC
77
STEP 15.
Install two needle bearings and the idler gear on
the clutch shaft, rotate the idler gear left and
right small amounts to achieve final alignment
with the clutch pack.
1. IDLER GEAR
2. NEEDLE BEARINGS
3. AXIAL BEARING ASSEMBLY
4. CLUTCH SHAFT
STEP 16.
Install the axial washer, axial bearing and run-
ning disc, chamfer side down on the clutch shaft.
1. AXIAL WASHER 3. RUNNING DISK

2. AXIAL BEARING
78
STEP 17.
Install the retaining ring on the clutch shaft.
1. RETAINING RING
2. CLUTCH SHAFT
WARNING
prevent burns
STEP 18.

2. HEAT GUN
79
WARNING
prevent burns
STEP 19.
1. STUD BOLT
STEP 20.
80
Reverse Clutch, Assemble
WARNING
prevent burns
STEP 1.

2. HEAT GUN
WARNING
prevent burns
STEP 2.

2. PISTON RING
81
STEP 3.
Install the needle bearing onto shaft and oil the
needle bearing.
1. NEEDLE BEARING
2. SHAFT
STEP 4.
Install the stud bolt to the shaft and tighten the
1. STUD BOLT
82
STEP 5.
Install the bearing and snap ring into the idler
gear.
1. SNAP RING 3. IDLER GEAR

2. BEARING
WARNING
prevent burns.
STEP 6.
Using a heat gun, heat the inner diameter of the
idler gear bearing to 120°C (248°F).
1. IDLER GEAR
2. HEAT GUN
WARNING
prevent burns.
STEP 7.
Install the idler gear until contact is made.
1. IDLER GEAR
83
CAUTION
the piston.

STEP 8.
ton.

1. INNER O-RING 3. DRAIN VALVE BALL
2. OUTER O-RING
STEP 9.
1. PISTON
2. DISC CARRIER
STEP 10.
annular groove.
1. CUP SPRING SET 3. DISC CARRIER

2. "L" RING
84
STEP 11.
fluid.
STEP 12.
STEP 13.
STEP 14.
1. END SHIM
2. RETAINING RING
STEP 15.
1. DIAL INDICATOR
2. END SHIM
85
STEP 16.
next size retainer.
1. DIAL INDICATOR
2. END SHIM
WARNING
prevent burns
STEP 17.

2. HEAT GUN
WARNING
prevent burns
STEP 18.
discs.
86
STEP 19.
1. PISTON RING
2. CLUTCH ASSEMBLY
WARNING
prevent burns
STEP 20.

2. HEAT GUN
87
WARNING
prevent burns
STEP 21.
1. SHAFT
STEP 22.
88
Forward Clutch, Assemble
WARNING
prevent burns
STEP 1.

2. HEAT GUN
WARNING
prevent burns
STEP 2.
1. PISTON RING
89
STEP 3.
Install the needle bearing onto shaft and oil the
needle bearing.
1. NEEDLE BEARING
2. SHAFT
STEP 4.
Install the stud bolt to the shaft and tighten the
1. STUD BOLT
STEP 5.
Install the bearing and snap ring into the idler
gear.
1. IDLER GEAR
2. SNAP RING
3. BEARING
90
WARNING
prevent burns.
STEP 6.
Using a heat gun, heat the inner diameter of the
idler gear bearing to 120°C (248°F).
1. IDLER GEAR
2. HEAT GUN
WARNING
prevent burns.
STEP 7.
Install the idler gear until contact is made.
1. IDLER GEAR
CAUTION
the piston.

STEP 8.
ton.

1. INNER O-RING
2. OUTER O-RING
3. DRAIN VALVE BALL
91
STEP 9.
1. PISTON
2. DISC CARRIER
STEP 10.
annular groove.
1. CUP SPRING SET

2. "L" RING
3. DISC CARRIER
STEP 11.
fluid.
STEP 12.
STEP 13.
92
STEP 14.
1. END SHIM
2. RETAINING RING
STEP 15.
1. DIAL INDICATOR
2. END SHIM
STEP 16.
next size retainer.
1. DIAL INDICATOR
2. END SHIM
93
WARNING
prevent burns
STEP 17.

2. HEAT GUN
WARNING
prevent burns
STEP 18.
discs.
STEP 19.
1. PISTON RING
2. CLUTCH ASSEMBLY
94
WARNING
prevent burns
STEP 20.

2. HEAT GUN
WARNING
prevent burns
STEP 21.
1. SHAFT
STEP 22.
95
Oil Pump, Assemble

NOTE: Lubricate the shaft seal with mineral spirits on the outside and multipurpose grease on the inside of
the seal.
STEP 1.
Using pump seal mounting tool, P/N 4612862,
with handle, P/N 4612861 install the new shaft
seal, lip facing down, into the oil pump housing.
1. SHAFT SEAL
2. OIL PUMP HOUSING
STEP 2.
Install the outer rotor with the chamfer facing
down, inner rotor with the threads facing up, and
cover on the oil pump housing.
1. COVER
2. INNER ROTOR
3. OUTER ROTOR
4. OIL PUMP HOUSING
96
CAUTION
the piston.
STEP 3.
Install new O-ring and capscrews on the oil pump.
Tighten the capscrews until contact is made, then
loosen 180 degrees.
1. O-RING
2. CAPSCREWS
3. OIL PUMP
Transmission Housing, Assemble

NOTE: Perform STEP 1 only if tubes have been removed.
STEP 1.
Install the system pressure tubes into the rear
transmission cover in the order of the legend.
Tighten the hollow bolts to 40 N•m (29.5 lbf ft).
1. CLUTCH, REVERSE
97
STEP 2.
Install the bearing outer rings with grease to the
front transmission housing.

5. CLUTCH, FORWARD
6. CLUTCH, REVERSE
7. INPUT SHAFT
STEP 3.
Install the bearing outer rings with grease to the
rear transmission housing.

5. CLUTCH, FORWARD
6. CLUTCH, REVERSE
7. INPUT SHAFT
98
STEP 4.
Install screen and capscrews into the front trans-
mission cover. Tighten capscrews to
23 N•m (17 lbf ft).
1. SCREEN
2. CAPSCREW
STEP 5.
Install the threaded tube with spigot and O-ring
and tighten to 10 N•m (7.3 lbf ft). Install the
threaded tube and O-ring and tighten to
23 N•m (16.9 lbf ft).
1. THREADED TUBE WITH SPIGOT

2. THREADED TUBE
STEP 6.
Install the diverse screw plugs and insert the seal-
ing cap until contact. Tighten screw plug
(M16x1.5) to 40 N•m (29.5 lbf ft). Tighten screw
plug (M10x1.5) to 25 N•m (18.4 lbf ft).
NOTE: Apply Loctite™262 to the outer diameter of

the sealing caps.
1. SCREW PLUG (M16X1.5)

2. SCREW PLUG (M10X1.5)
3. SEALING CAP
99
STEP 7.
Install the sealing caps until contact. Attach lift-
ing eye.

the sealing caps.
1. SEALING CAPS
2. LIFTING EYE
WARNING
while performing STEP 8.
CAUTION
During installation of the clutch packs, make sure
that the piston rings are properly aligned. If they
are not properly aligned, serious damage to the
transmission will occur.
STEP 8.
To help insure proper installation, make sure the
1. CLUTCH, FORWARD
piston rings are aligned, and use grease to keep 2. INPUT SHAFT
them in place. 3. CLUTCH, REVERSE
Install the clutch packs in the order given in the
legend.
STEP 9.
piston rings are aligned, and use grease to keep
them in place.
Install the 4th speed clutch pack.
100
STEP 10.
them in place.
Slightly lift the 4th speed clutch and install the 1st
speed clutch pack.

STEP 11.
Install new O-rings on the tube. Install tube with
capscrews into the front transmission cover.
Tighten capscrews to 23 N•m (17 lbf ft).
1. SUCTION TUBE
STEP 12.
them in place.
Install the 2nd speed clutch pack.
101
STEP 13.
Install the 3rd speed clutch with screen. Use
grease and install piston ring to 3rd speed clutch.
1. CLUTCH, 3RD SPEED

2. SCREEN
STEP 14.
Secure screen with capscrews and tighten to
23 N•m (16.9 lbf ft). Install fluid tubes with O-
rings into the front housing.

the fluid tubes.
1. CAPSCREWS 3. FLUID TUBE

2. SCREEN 4. FLUID TUBE
STEP 15.
Install, grease and align the piston rings on
clutches, forward, reverse, 1st speed, 2nd speed,
and 4th speed. Install the ring on clutch 3rd speed
and input shaft.
1. CLUTCH, 3RD SPEED

4. INPUTSHAFT
5. CLUTCH, FORWARD
6. CLUTCH, REVERSE
102
WARNING
while performing STEP 16.
CAUTION
During installation of the rear transmission cover,
make sure that the piston rings are properly
aligned. If they are not properly aligned, serious
damage to the transmission will occur.
STEP 16.
Coat the mounting flange of the front cover with
1. REAR TRANSMISSION COVER
Loctite™574, Install the rear transmission cover, 2. FRONT TRANSMISSION COVER
and position the rear cover over the clutch packs.
Install guide pins, washers, and capscrews on the
front transmission cover. Tighten capscrews to
46 N•m (34 lbf ft).
STEP 17.
Coat the outer surface of the shaft seal with a
light coat of mineral spirits; fill the shaft seal be-
tween the dust lip and sealing lip with multipur-
pose grease. Install the shaft seal, using shaft seal
mounting tool, P/N 4612860, with the lip facing
inward.
1. SHAFT SEAL
2. SHAFT SEAL MOUNTING TOOL
STEP 18.
Install O-ring, output flange, washer, and two
new capscrews on transmission housing. Tighten
capscrews to 46 N•m (33.9 lbf ft).
1. WASHER
2. CAPSCREW
103
STEP 19.
Using a press, install the bearing on the PTO
shaft, and install the retaining ring. Install the O-
ring and PTO shaft in the housing.
1. BALL BEARING
2. PTO SHAFT
3. RETAINING RING
STEP 20.
Install the power take-off retaining ring and new
O-ring on transmission housing.
1. PTO SHAFT
2. RETAINING RING
3. O-RING
STEP 21.
Install the cover plate with screws and tighten to
115 N•m (84.8 lbf ft).
1. SCREWS
2. COVER PLATE
104
STEP 22.
Install two alignment pins and the stator hollow
shaft.
1. ALIGNMENT PINS
2. STATOR HOLLOW SHAFT
STEP 23.
Oil the slide bearing and install the oil pump onto
the stator hollow shaft.
NOTE: Observe the hole pattern of the oil pump

and align the mount holes.
1. OIL PUMP
2. SLIDE BEARING
STEP 24.
Install capscrews with O-rings to the oil pump
and tighten to 46 N•m (33.9 lbf ft), apply Loc-
tite™574 to the webs of the mounting surface.
NOTE: Capscrews used for the oil pump have an

O-ring instead of a washer and the O-ring must
coated with clean transmission oil.
1. CAPSCREWS
2. OIL PUMP
3. MOUNTING SURFACE WEBS
105
STEP 25.
Install two additional alignment pins and install
the transmission housing plate. Tighten cap-
screws to 46 N•m (33.9 lbf ft).
1. ALIGNMENT PINS
2. TRANSMISSION COVER
3. CAPSCREWS
STEP 26.
Install the torque converter bell housing on the
transmission housing and tighten capscrews to
46 N•m (33.9 lbf ft)
1. TORQUE CONVERTER BELL HOUSING

2. CAPSCREWS
3. INPUT SHAFT
STEP 27.
Install the diaphragms to the torque converter
with screws and washers. Tighten screws to
115 N•m (84.8195 lbf ft).
NOTE: Apply Loctite™262 to the threads of

screws.
1. SCREW
2. WASHER
106
STEP 28.
Use a lifting tackle to install the torque converter
until contact. Remove the eye bolts and fasten the
diaphragms with screws.
1. EYE BOLTS
2. SCREWS
3. DIAPHRAGM
STEP 29.
Install the breather 12 N•m (8.8 lbf ft), internal
speed sensor 30 N•m (22 lbf ft), and N turbine
sensor 30 N•m (22 lbf ft).
1. BREATHER
2. INDUCTIVE TRANSMITTER - N INTERNAL
SPEED INPUT
3. INDUCTIVE TRANSMITTER - N TURBINE
STEP 30.
Install the N engine sensor 30 N•m (22 lbf ft),
Hall sensor 23 N•m (16.9 lbf ft), and temperature
sensor 25 N•m (18.4 lbf ft).
1. INDUCTIVE TRANSMITTER - N ENGINE

2. SPEED SENSOR - N OUTPUT (HALL SENSOR)
3. TEMPERATURE SENSOR
107
STEP 31.
Install the converter safety valve to the housing
bore.
2. PISTON
STEP 32.
Install four adjusting screws and mount the seal,
gasket, and duct plate to the housing front section
with screws. Tighten screws to 9.5 N•m (7 lbf ft).
1. DUCT PLATE
2. SEAL
3. GASKET
STEP 33.
Install the differential pressure switch for the ZF-
Micro Filter to the duct plate and tighten to
30 N•m (22 lbf ft).
2. PISTON
108
STEP 34.
Install the control valve assembly and oil filter as-
sembly and oil fill tube. See Transmission Oil Fil-
ter Assembly and Oil Fill Tube Replacement, In-
stall and Control Valve Replacement, Install.
STEP 35.
Reconnect electrical harness to the transmission.
1. TRANSMISSION TURBINE SPEED SENSOR

2. TRANSMISSION INTERNAL SPEED SENSOR
4. MAIN CONNECTOR
5. ENGINE SPEED SENSOR
6. TRANSMISSION CONTROL VALVE CONNEC-
TOR
7. TORQUE CONVERTER TEMPERATURE SEN-
SOR
8. TRANSMISSION OUTPUT SPEED SENSOR
TRANSMISSION OIL FILTER ASSEMBLY

AND OIL FILL TUBE REPLACEMENT
Remove
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
109
STEP 1.
Remove the drain plug from the transmission, and
drain the transmission oil into a suitable con-
tainer with a capacity of 20 liter (21 qt).
1. DRAIN PLUG
2. O-RING
STEP 2.
Using a strap wrench, remove the transmission oil
filter from the transmission oil filter head, and
dispose of the oil into the container used in the
previous step.
1. TRANSMISSION OIL FILTER

STEP 3.
Remove two capscrews and the transmission oil
filter head from the transmission. Remove and
discard two O-rings from the transmission oil fil-
ter head.
1. CAPSCREW
2. TRANSMISSION OIL FILTER HEAD
3. O-RING
110
STEP 4.
Remove hexagon screw from oil fill tube. Remove
two capscrews from the oil fill tube seal and re-
move oil fill tube with mount plate from the trans-
mission.
1. HEXAGON SCREW 3. OIL FILL TUBE

2. CAPSCREW 4. SEAL
Clean
Clean the transmission oil filter head with cleaning solvent.
Inspect
Inspect the mating surfaces for scratches, gouges, abrasions or cracks. Replace the filter head if damaged.
Install
STEP 1.
Coat two new O-rings with clean transmission oil
and install into the transmission oil filter head.
Using two capscrews mount the transmission oil
filter head on the transmission. Tighten capscrews
to 23 N•m (21 lbf ft).
1. CAPSCREW
2. TRANSMISSION OIL FILTER HEAD
3. O-RING
111
STEP 2.
Coat the gasket located on the top of the transmis-
sion oil filter with a light coat of transmission oil.
Install transmission oil filter on the transmission
oil filter head, by hand, until the gasket fully con-
tacts the transmission oil filter head and tighten
1/3 to 1/2 turn more.
1. TRANSMISSION OIL FILTER
STEP 3.
Coat the seal with a light coat of transmission oil
and install the seal and oil fill tube on the trans-
mission. Using two capscrews mount the oil fill
tube on the transmission. Tighten capscrews to
34 N•m (25 lbf ft). Secure strap of oil fill tube with
hexagon screw to the transmission housing.
Tighten hexagon screw to 46 N•m (34 lbf ft).
1. HEXAGON SCREW
2. CAPSCREW
3. OIL FILL TUBE
4. SEAL
STEP 4.
Coat the O-ring with a light coat of transmission
fluid and install with drain plug to the transmis-
sion and tighten to 80 N•m (59 lbf ft).
1. DRAIN PLUG
2. O-RING
112
INSTALL
1. Connect a lifting device, with a lifting capacity
of at least 1200 kg (2650 lb), to the two lifting
eyes located on the top of the transmission. See
Figure 13.
1. ACCESS HOLE TO ROTATE FLYWHEEL

2. ACCESS PLUG
3. EXHAUST PIPE
4. ACCESS PLATE TO FLYWHEEL CAPSCREWS
Figure 14. Access Plug for Drive Plate Capscrews
6. Install a cap screw. Rotate flywheel and install

the remaining cap screws until all four cap
screws have been installed. Torque to
1. LIFTING EYES 50 N•m (38 lbf ft).
Figure 13. Left Side View of Transmission 7. Install access plate to converter housing. See
Figure 14.
8. Install flywheel ring gear access plug. See Fig-

CAUTION ure 14.
Keep the transmission level when the transmis- 9. Remove the lifting device from the two lifting
sion is attached to the engine to avoid damage to eyes of the transmission.
the drive plate.
10. Remove the blocks and jack that are supporting
2. Carefully lower the transmission into position the flywheel end of the engine.
on the frame and engine.
11. Attach a lifting device to the hydraulic pumps.
3. Install two M16 x 110 bolts that fasten the While lifting the hydraulic pumps into position,
transmission mount to the frame. carefully slide the drive shaft of the hydraulic
4. Still supporting the weight of the transmission pump into the drive gear, making sure to prop-
with the lifting device, install twelve cap screws erly align the splines of the drive shaft into the
that fasten the torque converter housing to the drive gear.
flywheel housing. Torque to 40 N•m (30 lbf ft). 12. Install the hydraulic pumps to the transmission
5. Insert a flywheel rotational tool into the access with four cap screws. Tighten cap screws to
plug hole and rotate the flywheel until one of 66 N•m (49 lbf ft).
the cap screw mounting holes is visible through 13. Remove plugs and caps from hydraulic oil hoses
the access plate hole. See Figure 14. and fittings. Connect hydraulic oil hoses to the
hydraulic pumps.
113
14. Remove plugs and caps from transmission oil

hoses and fittings. Connect oil hoses from the CAUTION
thermostat valve to the transmission. Drive shafts are balanced and configured at the
time of manufacture. It is recommended that an
15. Insert a funnel into the transmission dipstick alignment mark is made on the drive shaft indicat-
tube. Fill the transmission with 27 li- ing the position of the universal joint and drive
ter (28.5 qt) of Dexron III. shaft halves prior to removal.
16. Connect the transmission wiring harness and During removal, it is possible that splined shaft
connectors for the transmission sensors as and slip yoke separate. Reassemble the drive
marked during removal. See Figure 15. shaft using the alignment mark made prior to re-
moval.
Failure to assemble and install the drive shaft

properly may lead to:
• Excessive vibration levels in the drive shaft,
transmission and truck.
• Premature failure of the universal joints on
the drive shaft
NOTE: Use marks created during removal to aid in

installing drive shaft in proper position and orien-
tation.
17. Connect the main connector (CPS160) and the

starter motor cable (TS13) to the transmission.
See Figure 16.
18. Connect the drive shaft to the transmission.

See Figure 16.
1. FRAME-POWERTRAIN CONNECTOR
2. STARTER MOTOR TERMINAL
Figure 15. Powertrain Connections
114
1. DRIVE SHAFT 5. CAP SCREWS

2. UNIVERSAL JOINT 6. DIPSTICK ASSEMBLY
3. TRANSMISSION MOUNT 7. TRANSMISSION
4. TORQUE CONVERTOR
Figure 16. Transmission Arrangement
115
Control Valve Replacement 1300 SRM 1718
19. Connect the battery cables. Connect the posi- 22. Turn the key to ON position and start truck
tive cable first and then connect the ground ca- with the transmission in neutral, allow engine
ble. to idle for 2-3 minutes.
20. Tilt the Operator's compartment down. See the 23. Check transmission fluid levels on the dipstick.
section Operator's Cab 0100SRM1390. At operating temperature 80 to 90°C (176 to
194°F), the fluid level should reach the HOT
21. Apply the parking brake. zone on the dipstick. Add transmission fluid as
required.
Control Valve Replacement
REMOVE
STEP 1.
Disconnect the vehicle negative battery terminal.
STEP 2.
Disconnect the electrical connector from the trans-
mission control valve.
STEP 3.
Remove two screws, one at each end at the top of
the control valve, and install two alignment
screws in their place.
1. CONTROL VALVE ASSEMBLY

2. TORX SCREWS
116
1300 SRM 1718 Control Valve Replacement
STEP 4.
Remove the remaining mounting screws, control
valve assembly, and sealing plate from the trans-
mission. Discard sealing plate.

2. SEALING PLATE
3. ALIGMENT PINS
INSTALL
STEP 1.
Install the new sealing plate onto the alignment
pins. Install the control valve assembly, and torx
mounting screws onto the transmission. Tighten
the torx mounting screws in a opposite pattern to
9.5 N•m (84 lbf in).

2. SEALING PLATE
3. ALIGMENT PINS
117
Control Valve Repair 1300 SRM 1718
STEP 2.
Remove the two alignment screws. Install two
torx screws, one at each end at the top of the con-
trol valve in their place. Tighten to
9.5 N•m (84 lbf in).

2. TORX SCREWS
STEP 3.
Connect the electrical connector from the trans-
mission control valve.
STEP 4.
Connect the vehicle negative battery terminal.
Control Valve Repair
DISASSEMBLE
STEP 1.
Remove the control valve assembly from the transmission. See Control Valve Replacement, Remove.
STEP 2.
Place a match mark on the cover and the valve
block on both ends of the control valve to assist in
proper assembly of these components.
1. COVER
2. VALVE BLOCK
118
1300 SRM 1718 Control Valve Repair
STEP 3.
Remove the torx screws from the duct plate.
1. TORX SCREWS
2. DUCT PLATE
STEP 4.
Remove the duct plate and sealing plate from the
control valve body. Discard the sealing plate.
1. DUCT PLATE
2. SEALING PLATE
3. CONTROL VALVE BODY
STEP 5.
Remove the retaining clamp, capscrews, cover,
and gasket from the housing. Discard gasket. Re-
move capscrews, cover, and gasket from the oppo-
site end of the control valve. Discard the gasket.
1. RETAINING CLAMP
2. CAPSCREW
3. COVER
4. GASKET
119
STEP 6.
Remove the wiring harness from the housing.
1. WIRING HARNESS
2. HOUSING
STEP 7.
Remove three capscrews, three fixing plates, and
three pressure regulators from the housing.
1. CAPSCREW
2. FIXING PLATES
3. PRESSURE REGULATOR
4. HOUSING
WARNING
The housing is under spring pressure, use care during removal of the housing.
120
STEP 8.
Remove two capscrews and install two alignment
screws in their place in the housing. Remove the
remaining capscrews from the housing.
1. CAPSCREW
2. ALIGNMENT SCREW
3. HOUSING
4. GASKET
STEP 9.
Remove the pressure reducing valve with spring,
three vibration dampers with springs, and three
follow-on slides with springs.
1. PRESSURE REDUCING VALVE WITH SPRING

2. VIBRATION DAMPER WITH SPRING
3. FOLLOW-ON SLIDE WITH SPRING
121
STEP 10.
Remove three capscrews three fixing plates, and
three pressure regulators from the housing.
1. CAPSCREW
2. FIXING PLATE
4. HOUSING
WARNING
The housing is under spring pressure, use care during removal of the housing.
STEP 11.
Remove two capscrews and install two alignment
screws in their place in the housing. Remove the
remaining capscrews from the housing.
1. CAPSCREW
2. ALIGNMENT SCREW
3. HOUSING
4. GASKET
122
STEP 12.
Remove the main pressure valve with spring,
three vibration dampers with springs, and three
follow-on slides with springs from the control
valve body.
1. MAIN PRESSURE VALVE WITH SPRING

CLEAN INSPECT
Clean all metal components, except as noted below, Inspect the control valve components for any signs
with cleaning solvent and dry with compressed air. of wear. If components show signs of wear replace
those components. If the valve body shows signs of
The main pressure valve, vibration damper, and wear, replace the entire control valve assembly.
follow-on-slides are specially coated aluminum
parts. If cleaning is required; these components are
to be cleaned using transmission oil only.
ASSEMBLE
NOTE: Perform STEP 1 only if a new valve body is being used.
STEP 1.
Place the control valve body on a clean, flat sur-
face. Install the orifices concave side up until con-
tact as shown.

2. ORIFICES
NOTE: Coat all parts with clean transmission oil prior to installation.
123
STEP 2.
Install the three follow-on slides with springs,
three vibration dampers with springs, and main
pressure valve with spring, into the control valve
body.
1. MAIN PRESSURE VALVE WITH SPRING

STEP 3.
Install two adjusting screws on either end of the
control valve body. Compress the follow-on slides
and springs and lock them in position using an
M5 capscrew.
1. M5 CAPSCREW
2. ADJUSTING SCREW
STEP 4.
Install a new gasket and the housing on the two
adjusting screws. Install the capscrews into the
housing. Remove the adjusting screws and insert
two cap screws. Tighten all capscrews to
5.5 N•m (48.7 lbf in), and remove the M5 cap-
screws from the control valve body.
1. CAPSCREW
2. ADJUSTING SCREW
3. HOUSING
4. GASKET
NOTE: Install the fixing plates with the neck facing downward.
124
STEP 5.
Install three pressure regulators, three fixing
plates, and three capscrews into the housing.
Tighten the capscrews to 5.5 N•m (48.7 lbf in).
1. CAPSCREW
2. FIXING PLATE
4. HOUSING
STEP 6.
Install three follow-on slides with springs, three
vibration dampers with springs, and pressure re-
ducing valve with spring.
1. PRESSURE REDUCING VALVE WITH SPRING

STEP 7.
Install two adjusting screws on either end of the
control valve body. Compress the follow-on slides
and springs and lock them in position using an
M5 capscrew.
1. M5 CAPSCREW
2. ADJUSTING SCREW
125
STEP 8.
Install a new gasket and the housing on the two
adjusting screws. Install the capscrews into the
housing. Remove the adjusting screws and insert
two cap screws. Tighten all capscrews to
5.5 N•m (48.7 lbf in), and remove the M5 cap-
screws from the control valve body.
1. CAPSCREW
2. ADJUSTING SCREW
3. HOUSING
4. GASKET
STEP 9.
Install three pressure regulators, three fixing
plates, three capscrews, and the wiring harness in
the housing. Tighten the capscrews to
5.5 N•m (48.7 lbf in).
1. WIRING HARNESS
2. CAPSCREW
3. FIXING PLATE
STEP 10.
Using the match marks applied before removal,
install a new gasket, cover, capscrews and the re-
taining clamp on the housing. Tighten the cap-
screws to 5.5 N•m (48.7 lbf in).
1. RETAINING CLAMP
2. CAPSCREW
3. COVER
4. GASKET
126
STEP 11.
Install two adjusting screws on the control valve
body.
1. ADJUSTING SCREW
STEP 12.
Install the screens, facing up, in the new sealing
plate as shown.
1. SEALING PLATE
2. SCREEN
STEP 13.
Install the new sealing plate and the duct plate on
the control valve body.
1. DUCT PLATE
2. SEALING PLATE
127
STEP 14.
Install the 23 torx screws into the duct plate.
Tighten the torx screws to 10.5 N•m (93 lbf in)
1. TORX SCREWS
2. DUCT PLATE
STEP 15.
Install the control valve assembly on the transmission. See Control Valve Replacement, Install.
128
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1300 SRM 1718 10/14

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TRANSMISSION

PART NO. 4121138 1300 SRM 1718

Special Tools List .....................................................................................................................................................1

This section is for the following models:

H18XM-9, H18XMS-9, H20XM-9 (H400HD, H400HDS, H450HD, H450HDS)

©2014 HYSTER COMPANY i

Special Tools List

Item Figure Nomenclature Part Number

1 Bearing Driver 4104871

2 Forcing Device 4104872

3 Grab Sleeve 4104874

4 Grab Sleeve 4104875

Item Figure Nomenclature Part Number

5 Bearing Puller 4104876

6 Grab Sleeve 4104877

8 Pressure Sleeve 4104879

Clutch Pack Spring

Item Figure Nomenclature Part Number

10 Holding Fixture Assembly 4612859

11 Shaft Seal Mounting Tool 4612860

12 Grip Handle 4612861

13 Pump Seal Mounting Tool 4612862

1. DRIVE SHAFT 5. CAP SCREWS

8. Disconnect the Frame-Powertrain connector

9. Place a suitable container under the transmis-

10. Disconnect the oil lines from the transmission

11. Attach a lifting device to the hydraulic pumps

12. The hydraulic pumps are connected to the

13. Put a beam on the frame, that can carry the

1. HYDRAULIC PUMPS 3. ENGINE

Figure 3. Remove Transmission

15. Install blocks and a jack under the flywheel end

16. Connect a lifting device, with a lifting capacity

Figure 4. View of Transmission

25. Make sure that all connections have been re-

1. ACCESS HOLE TO ROTATE FLYWHEEL

19. Remove the access plug to gain access to the

20. Remove the access plate to gain access to the

21. Insert a flywheel rotation tool into the access

Transmission Housing, Disassemble

1. TRANSMISSION TURBINE SPEED SENSOR

1. DUCT PLATE 3. SEAL

1. INDUCTIVE TRANSMITTER - N ENGINE

1. EYE BOLTS 3. DIAPHRAGM

1. O-RING 3. PUMP SHAFT

1. RETAINING RING 3. PUMP SHAFT

1. OUTPUT FLANGE 3. PIN

NOTE: Make sure that the cylindrical pins have

1. REAR TRANSMISSION HOUSING

1. PISTON RING 3. CAPSCREWS

1. CLUTCH, 3RD SPEED/OUTPUT

1. CLUTCH, 3RD SPEED/OUTPUT

NOTE: Perform STEP 23 only if any of the tubes

1. CLUTCH, 3RD SPEED/OUTPUT

Oil Pump, Disassemble

1. O-RING 3. OIL PUMP

Figure 7. Forward Clutch Assembly

NOTE: See Parts Manual for breakdown.