GROUP 20

GEAR BOX /
CONVERTER
GEAR BOX DISASSEMBLY

20-3-9 EN

30 / 04 / 1999
CONTENTS

– GEAR BOX AND CONVERTER .................................................................... 5

– GEAR BOX .......................................................................................................... 6

(Details)

– GEAR BOX .......................................................................................................... 8

(Mecanism details - gears)

– GEAR BOX.......................................................................................... 10
(Electrical control valve details)

– TRANSMISSION HYDRAULIC CIRCUIT..................................................... 12

– TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT ............................ 14

– TRANSMISSION MAINTENANCE ................................................................ 15

– PRESSURE CHECKING ................................................................................. 16

– PRESSURE READING ON GEAR BOX ..................................................... 18

– SPECIAL TOOLS ............................................................................................... 19

– SHAFT AND GEAR END FLOAT TOLERANCES .................................... 20

– DIS-ASSEMBLY AND RE-ASSEMBLY ........................................................ 21

GENERAL INFORMATION ................................................................................. 22
1 - TRANSMISSION DIS-ASSEMBLY................................................................ 23
2 - INPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY................................. 28
3 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT ............ 33
4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE REVERSE IDLER SHAFT 33
5 - OUTPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY............................. 34
7 - PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY .... 38
8 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE OIL PUMP......................... 39
9 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE VALVE ............................... 40
10 - GEAR LEVER HOUSING DIS-ASSEMBLY AND RE-ASSEMBLY ............. 41
11 - TRANSMISSION RE -ASSEMBLY .............................................................. 42

– TEST PROCEDURE ........................................................................................... 51

3
4
GEAR BOX AND CONVERTER

9 8

2
3

1
7
4
5

1 – Complete gear box

2 – Converter
3 – Intermediate piece
4 – Screw
5 – Washer
6 – Converter reinforcement plate
7 – Screw
8 – Screw
9 – Washer

5
 45 47

44
46
49
GEAR BOX (Details)

18
31 3
29 19 17 4 53 50
28 3 52
30
43 40 37 27 4 16
30
39 38 26 8 54 51
3 3 13 55
42 41 4 8
4
9 12

6
3 20 48
4 3 11 59
10
4 60
36 25
35 22
58 21 7
57 56 23
4 3
61
33 34 24 62
32 14
15
6

1
2
5
GEAR BOX (Details)

1 – Transmission housing 37 – Oil temperature sensor

2 – Transmission rear case 38 – "O" ring
3 – Plug 39 – Suction trainer
4 – "O" ring 40 – Washer
5 – Screw 41 – "O" ring
6 – Stud-bolt 42 – Cover
7 – Screw 43 – Screw
8 – "O" ring 44 – Valve (Pressure regulation)
9 – Plug 45 – Seal kit
10 – Seal 46 – Over pressure valve
11 – Brake assy 47 – Seal kit
12 – Plug 48 – Upper seat
13 – "O" ring 49 – Gear lever foot
14 – Drain plug 50 – Pin
15 – "O" ring 51 – Clamp
16 – Air breather 52 – Dust cover
17 – Transmission oil pressure switch 53 – Clamp
18 – Complete electrical control valve 54 – Screw
19 – Screw 55 – Washer
20 – Plug 56 – "O" ring
21 – Filtrer housing 57 – Plate
22 – Gasket 58 – Screw
23 – Connection 59 – Oil level
24 – Oil filter 60 – "O" ring
25 – Screw 61 – Connection
26 – Ball 62 – "O" ring
27 – Spring
28 – "O" ring
29 – Plug
30 – Plug
31 – Plug
32 – Complete pump
33 – Seal
34 – "O" ring
35 – Screw
36 – Washer

7
 2 3 3 4

1 3 4

2 22

15 19 3
14 24 2
11 12 13 21 23
8 10 25 21
6 7 17 18
6 16
48 49 50 51
5 9
10 9 6 29 30 29 29 30
8 11 6 28 28
12 7 26
14 13

8
17 16 15 29 47
27 44
GEAR BOX (mécanism details - gears)

18
19 46
22 21 20 60 61 45
43 43 57
21
24
65 63 62
42
63 41 56
64
23 68 62 62 34 56
2 66 33 55
68 31
54
67 52

32 51 50
55
39 35 58
47
59
49
36 34
38 37
40
GEAR BOX (mecanism -details - gears)

1 – Reverse idler gear 41 – Synchro assy

2 – Bearing 42 – Output shaft 1st gear
3 – Shim 43 – Bearing
4 – Spacer 44 – Spacer
5 – Input shaft 45 – Coupling
6 – Seal 46 – Out put shaft drive gear
7 – Seal (inner) 47 – Seal
8 – "O" ring 48 – Coupling flange
9 – Seal (outer) 49 – "O" ring
10 – "O" ring 50 – Washer
11 – Piston 51 – Screw
12 – Clutch disc 52 – Out put shaft
13 – Friction disc 54 – Gear (37 teeth)
14 – Piece 55 – Bearing
15 – Circlips 56 – Shim
16 – Spring 57 – Spacer
17 – Bushing 58 – Spacer
18 – Circlips 59 – End yoke
19 – Thrustwasher 60 – 1st and 2nd shift rod
20 – Forward primary gear 61 – 3th and 4th shift rod
21 – Roller bearing 62 – Ball
22 – Spacer 63 – Spring
23 – Bearing 64 – Plug
24 – Stop washer 65 – "O" ring
25 – Backward primary gear 66 – 1st and 2nd shift fork
26 – Countershaft 67 – 3th and 4th shift fork
27 – Bearing 68 – Screw
28 – Bearing
29 – Shim
30 – Spacer
31 – Out put shaft
32 – 3rd gear
33 – 2nd gear
34 – Coupling sleeve
35 – Synchro assy
36 – Circlips
37 – 4th gear
38 – Washer
39 – Bearing
40 – Plug

9
GEAR BOX (electrical control valve details)

3
1

10
GEAR BOX (Electrical control valve details)

1 – Complete electrical control valve

2 – Solénoïd
3 – Seal kit
4 – Plug

11
 RUNNING FORWARD AND BACKWARD VALVE
4WD
PRESSURE TEST
4WD
4WD SOLENOID
CLUTCH VALVE
B B

PRESSURE C
REGULATOR FORWARD TEST REVERSE TEST
VALVE POINT POINT
(14,5 ± 1 bar) CLUTCH CLUTCH
RUNNING RUNNING
FORWARD BACKWARD
A
PUMP
TEST
POINT
CONVERTER
RELIEF VALVE
CONVERTER PRESSURE OIL
(6,5 ± 1,5 bar)
TEST POINT FILTRER

D
TORQUE
CONVERTEUR

COLD
START
VALVE
(26 bar)

LUBE
PRESSURE TEMPERATURE
TEST SENDER

12
PUMP
TRANSMISSION HYDRAULIC CIRCUIT

LUBE
SUCTION TEST
STRAINER POINT

TRANSMISSION
LUBRIFICATION

SUMP

OIL COOLER
DESCRIPTION OF THE TRANSMISSION SHAFT HYDRAULIC CIRCUIT

CLUTCH CIRCUIT

The oil is sucked into the casing via the suction strainer.
The oil leaving the pump passes into the filter and is directed towards the clutch circuit.
The filter is protected by a cold start valve calibrated to 26 bars.
On the filter outlet, the pressure regulator mark A maintains a pressure of 14 +/- 1 bar in the clutch cir-
cuit. The same regulator supplies the converter circuit.

The electrovalves mark B enable the pressure to be directed towards the front and reverse gear clutches,
and in neutral gear they enable the clutches to be decompressed towards the casing.

On the 4WD "sprung on" version, the clutch is engaged by a spring. When the 4WD electrovalve mark C
is fed, the pressure is applied on the piston which pushes the spring back and frees the 4WD clutch.

CONVERTER CIRCUIT

The oil passes into the converter circuit through the pressure regulator mark A. The pressure limiter mark
D maintains a pressure of 6.5 +/- 1.5 bar in the circuit.

COOLING AND LUBRICATION CIRCUIT

The oil returning from the converter passes via the inside of the pump's hollow shaft, heads towards the
oil cooler and then returns into the transmission shaft to lubricate the gears and the bearings on the inlet
shaft.

13
TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT

CLUTCH CLUTCH
RUNNING RUNNING
FORWARD BACKWARD

P2 P3

MODULATION
VALVE

VALVE
RUNNING FORWARD /
RUNNING BACKWARD

4WD CLUTCH
CLUTCH
PRESSURE
RELIEF VALVE
REGULATION
4WD P4
P5
VALVE
14,5 ± 1 bar 6,5 ± 1,5 bar
P1

FILTER
BY-PASS OIL TORQUE
VALVE FILTER CONVERTER
T1

COLD PUMP
START OIL COOLER

VALVE

26 BAR SUCTION
STRAINER
P6

P1 = Oil pump pressure test point(14,5 ± 1 bar).

P2 = Forward clutch pressure test point (14,5 ± 1,5 bar).
P3 = Reverse clutch pressure test point (14,5 ± 1,5 bar).
P4 = Converter relief pressure test point (6,5 ± 1,5 bar).
P5 = Four wheel drive pressure test point (14,5 ± 1,5 bar).
P6 = Lubrification pressure test point (1,5 ± 1 bar).
T1 = Temperature test.

14
TRANSMISSION MAINTENANCE

RECOMMANDED LUBRICANTS :

Oils used in this transmission must all meet the following specifications :

GRADE SPECIFICATION CLASSIFICATION

10W30 API GL 4 MIL-L-2105B

ALLISON C3

OPERATING TEMPERATURE : 85° - 90° C OIL LEVEL

In order to ensure a good lubrication and a good
operating temperature it is important to use the
specified oil and to maintain the correct level.
OIL AND FILTER CHANGING
It is recommanded to change the oil at the follo-
wing intervals :
After the first 50 hours of work.
Then every 800 hours maximum afterward.
Always clean the strainer when changing the oil.
The level must be checked always with the oil
gauge dipstick, with the engine idling.
* Do not pour oil over the upper mark as this
could cause overheating due to oil splashing
through the pinions (emulsion and deterioration
of the oil). This could also cause external leaks.
Oil changing is also necessary to eleminate the
metal particles of the transmission components.
The particles result from a normal use.

Replace the filter after the first 50 hours of work PRECAUTION

and every 400 hours afterward.
To prevent a lack of lubrication in the trans-
mission when towing the machine on long dis-
Many factors having an influence on the oil chan-
tances, it is recommended to uncouple the
ging require to increase the oil changing frequen-
gear box out put shaft.
cy.

CAPACITY (GEAR BOX only) : 15,5 L

OIL USED BY MANITOU : MANITOU oil auto-

matic transmission shaft.

1 L- Réf. 62 148
25 L- Réf. 487 655
56 L- Réf. 545 557
215 L- Réf. 490 207

15
PRESSURE CHECKING

- The transmission oil, should be at an approximate temperature of 80°C during pressure tests.

- The handbrake must be applied.

- All test ports have a 9 / 16" UNF thread.

- A manometer of 0-20 bar minimum is necessary.

- For the P / N° of pressure connections, manometers or hoses, please refer to "Gauge Box" catalogue
P / N° 547 037.

- Forward, reverse and 4WD clutch pack pressures should not be more than 1 bar lower than the oil pump
pressure.

OIL PUMP PRESSURE TEST PORT. CONVERTER RELIEF PRESSURE TEST

Pressure should be 14,5 ± 1 bar at maximum POINT.
engine speed (approx. 2500 RPM). Pressure should be 6,5 ± 1,5 bar at maximum
engine speed (approx. 2500 RPM).

FORWARD CLUTCH PRESSURE TEST REVERSE CLUTCH PRESSURE TEST POINT.

POINT. Pressure should be 14,5 ± 1,5 bar at maximum
Pressure should be 14,5 ± 1,5 bar at maximum engine speed (approx. 2500 RPM).
engine speed (approx. 2500 RPM).

16
LUBRICATION PRESSURE TEST POINT. FOUR WHEEL DRIVE PRESSURE TEST
Pressure should be 1,5 ± 1 bar at maximum POINT.
engine speed (approx. 2500 RPM). Pressure should be 14 ± 1,5 bar at maximum
engine speed (approx. 2500 RPM).

STALLING SPEED OF TORQUE CONVERTER : 1600 ± 50 tr/mn

17
PRESSURE READING ON GEAR BOX

MACHINE TYPE and N° : ................................................... N° of HOURS : ..........................................

GEAR BOX TYPE and N° : ................................................
(To be carried out with gear box oil at 80° mini).

NEUTRAL FORWARD REVERSE

GEAR GEAR

Mini r.p.m. .......................

PUMP
Maxi r.p.m. .......................

Mini r.p.m. .......................

CONVERTER
Maxi r.p.m. .......................

Mini r.p.m. .......................

DRAINAGE
Maxi r.p.m. .......................

FORWARD Mini r.p.m. .......................

GEAR Maxi r.p.m. .......................

REVERSE Mini r.p.m. .......................

GEAR Maxi r.p.m. .......................

Mini r.p.m. .......................

4 WD
Maxi r.p.m. .......................

COMMENTS : .............................................................................................................................................

.....................................................................................................................................................................

* BREAKDOWN AT THE ORIGIN : ...........................................................................................................

.....................................................................................................................................................................

* DETERMINED CAUSE OF THE BREAKDOWN : ..................................................................................

.....................................................................................................................................................................

18
SPECIAL TOOLS

NUMBER DESIGNATION

- 479307 Hand press.

- 479309 Input & Rev. Idler shaft brg. removal collet.
- 563390 4WD brg removal collet.
- 563391 Out put shaft front brg. removal collet.
- 563392 C / shaft and output shaft rear brg. removal collet.
- 563394 C / shaft front bearing removal collet.
- 563393 Input shaft spring compressor.
- 563395 Shimming Adapter

RECOMMENDED TUBE SIZES FOR REPLACING BEARINGS.

Ø INTERIOR Ø EXTERIOR

C / shaft, Output shaft rear & 4WD brg. 41 mm 47 mm

Reverse idler, output shaft front & input shaft brgs. 36 mm 41 mm

Output shaft 1st gear brg. sleeve 50,5 mm 55 mm

The dummy plug for re-fitting inner detent spring & ball can be made using a piece of bar 18mm dia. x 25
mm long.

19
SHAFT AND GEAR END FLOAT TOLERANCES

SHAFT END FLOATS.

All shaft end floats should be 0,0254 à 0,0762 mm.

GEAR END FLOATS.

Input shaft forward and reverse primary gears : 0,061 à 0,41 mm.

Output shaft gears :

4th Gear : 0,20 à 0,56 mm.

3rd Gear : 0,38 à 0,84 mm.
2nd Gear : 0,36 à 0,56 mm.
1st Gear : 0,33 à 0,51 mm.

4 wheel drive : 0,051 à 0,28 mm.

20
DIS-ASSEMBLY
RE-ASSEMBLY

21
GENERAL INFORMATION
We recommend that the procedures as outlined
in this manual be followed when performing main-
tenance work on this transmission.
TOOLS
This transmission can be repaired with ordinary
mechanics hand tools however this procedure is
not only slow but may damage otherwise servi-
ceable parts. To reduce maintenance costs and
vehicle downtime, we recommend that the spe-
cial tools listed in this manual be procured from a
tool manufacturer, as stated.
CLEANLINESS
Transmission should be steam cleaned external-
ly prior to disassembly. Seal all opening before
cleaning to prevent entry of dirt and water which
can damage serviceable parts. Dirt is abravise
and will cause premature wear and failure of clut-
ch plates, hydraulic valves and bearings.
* Due to the nature of opération of the hydraulic
system cleanliness is of prime importance and
the following guidelines should be observed :
1 – Not lint or cotton rags should be used in order
to prevent any possible clogging.
2 – When fitting new clutch plates they should be
soaked in clean new oil as recommended for
3 hours.
3 – All parts should be thoroughly cleaned and
lubricated with new oil prior to reassembly.
22
BEARINGS
When a transmission is removed at relativity low
mileage, bearings should be removed with pullers
designed for the purpose. Wrap the bearings to
keep our dirt.
Clean, inspect and lubricate all bearings just prior
to reassembly. If accumulated mileage is over
1500 hours we suggest that all bearings be repla-
ced.
REPLACEMENT PARTS
The exploded views of sub-assemblies which are
incorporated in this manuel are for the mecha-
nic’s convenience and show the latest material.
The parts are arranged in their correct order and
may also be used as a reference for assembly or
disassembly of this unit.
SHIMS
When inserting shim packs, it is essential that the
thinnest shims are placed between the thicker
shims to prevent any possible damage to the
shims.
SEALS
The seals which have been removed on the
disassembly shall be replaced by new on reas-
sembly.
1 - TRANSMISSION DIS-ASSEMBLY

1-1 1-2

Invert the transmission on a suitable bench. For Remove 4 capscrews and withdraw the direc-
convenience the bench top should have a hole tion control valve.
in it to accommodate the input shaft and pump.
Remove 3 screws and withdraw the gear shift
lever assembly.

1-3 1-4

Remove the Converter Relief Valve. Remove the Pressure Regulator Valve.

1-5 1-6

Remove the cold start housing, spring and ball Remove the temperature sender.

23
 1-7 1-8

Remove the bolt, washer and "O"ring and with- 4WD VERSION : Remove the bolt, washer and
draw the output yoke. "O"ring and withdraw the 4 wheel drive yoke
and spacer. (Not fitted on 2 wheel drive model).

1-9 1-10

Remove 17 screws and using a suitable hoist 4WD VERSION : Remove the 4 wheel drive
take off the rear transmission case. shaft assembly. (Not fitted on 2 wheel drive
Note : The bearing cones and shims may fall model).
from the rear case during removal.

1-11 1-12

Tilt the countershaft and withdraw the input Remove the reverse idler shaft assembly.
shaft assembly.

24
1-13 1-14

Remove the outer detent plug, spring and ball. Ensure both synchronisers are in the neutral
position then remove the 1st / 2nd shift fork
screw.

1-15 1-16

Withdraw the 1st / 2nd shift rod from the hou- Remove the 3rd / 4th shift fork screw.
sing. Then using a magnetic probe remove the Safety Note : before attempting to remove the
interlock ball from the detent bore. 3rd / 4th shift rail, replace the detent plug as the
ball and spring may shoot out and cause injury.

1-17 1-18

Turn the 3rd / 4th shift rod through 90 degrees Remove the detent plug, inner detent ball and
and withdraw from the housing. spring.

25
1-19 1-20

Remove the counter shaft assembly. Remove the 1st / 2nd and 3rd / 4th shift forks.

1-21 1-22

Remove the output shaft assembly. Remove the 4th gear lock out screw. (If fitted).

1-23 1-24

Remove 2 screws and withdraw the strainer Using a strap wrench remove and discard the oil
cover, "O"ring, spacer and strainer. filter.

26
1-25 1-26

Remove 2 bolts and withdraw oil filter housing 4WD VERSION : Remove the 4 wheel drive
and gasket. solenoid coil and retaining nut.

1-27 1-28

4WD VERSION : Remove the 4 wheel drive Remove and discard the expansion plug from
solenoid spool. the shimming access hole.

1-29

Invert the case. Remove 4 screws and copper

washers then withdraw the pump assembly and
sealing ring.

27
2 - INPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY

DIS-ASSEMBLY
2-1 2-2

Position the shaft in a soft jawed vice as shown. Remove and discard the 3 sealing rings.

2-3 2-4

Using the appropiate bearing puller remove the Remove the thrust washer and needle bearing.
rear bearing.

2-5 2-6

Remove the reverse primary gear. Remove the bearing, spacer, bearing and thrust
washer.

28
 2-7 2-8

Remove the clutch pack retaining ring. Remove the clutch pack retaining plate.

2-9 2-10

Remove the clutch pack. Using the appropriate tool compress the piston
spring and release the circlip.

2-11 2-12

Remove the circlip, retainer and spring. Using pliers, as shown, pull the piston out of the
drum.

29
2-13 2-14

Invert the shaft and remove the sealing ring. Remove and discard the piston sealing rings
Repeat steps 2,3 to 2,12 to dismantle the for- and "O"rings.
ward clutch pack.

RE-ASSEMBLY
2-15 2-16

Re-new the piston sealing rings and "O"rings. Using transmission fluid to lubricate the seals
To assist assembly bend the inner sealing ring push the piston into the drum.
into a heart shape as shown.

2-17 2-18

Replace the spring, retainer and circlip as Using the appropriate tool compress the spring
shown. and locate the circlip ingo its groove.

30
 2-19 2-20

Replace an externally splined (plain) disc and Replace the clutch pack retaining plate and re-
then an internally splined (friction) disc alterna- fit the retaining clip.
tely until six of each have been replaced.
NOTE: New friction discs should be soaked in transmis-
sion fluid for a minimum of 3 hours prior to assembly.

2-21 2-22

Replace the thrust washer, bearing, spacer and Line up the clutch plate splines and replace the
bearing. primary gear. Then replace the needle bearing
anhd thrust washer as shown.

2-23 2-24

Using an appropriately sized tube replace the Invert the shaft and repeat steps 2:15 to 2:23.
bearing as shown. Then fit a new sealing ring as shown.

31
2-25

Finally fit 3 new sealing rings to the rear of the

shaft as shown.

32
3 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT
4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE REVERSE IDLER
SHAFT DIS-ASSEMBLY
3-1 3-2

The countershaft assembly. Using the appropriate bearing puller remove the
countershaft front and rear bearings.

RE-ASSEMBLY
3-3 4-1

Using an appropriately sized tube replace the The reverse idler assembly.
countershaft front and rear bearings.

DIS-ASSEMBLY RE-ASSEMBLY
4-2 4-3

Using the appropriate bearing puller remove the Using an appropriately sized tube replace the
front and rear bearings. front and rear bearings.

33
5 - OUTPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY

DIS-ASSEMBLY
5-1 5-2

Position the shaft assembly in a soft-jawed vice Using the appropriate bearing puller remove the
as shown. front bearing.

5-3 5-4

Remove the thrust washer and 4th gear. Remove the 3rd / 4th synchro assembly.

5-5 5-6

Remove the circlip and synchro hub. Remove the 3rd gear.

34
 5-7 5-8

Invert the shaft and using the appropriate bea- 4WD VERSION : Remove the 4 wheel drive
ring puller remove the rear bearing. gear.
2WD VERSION : On 2 wheel drive models a
spacer is fitted in place of a gear.

5-9 5-10

Remove the 1st gear. Remove the needle bearings and spacer.

5-11 5-12

Remove the 1st / 2nd synchroniser assembly. Using a suitable bearing puller or press.
Remove the bearing sleeve , synchro hub and
2nd gear.

35
 RE-ASSEMBLY
5-13 5-14

Removal of the bearing sleeve, synchro hub Replace the 2nd gear and synchro hub.
and 2nd gear.

5-15 5-16

Using an appropriately sized tube refit the 1st Replace the 1st / 2nd synchroniser assembly.
gear bearing sleeve.

5-17 5-18

Replace the 1st gear needle bearings and spa- Replace the 1st gear.
cer as shown.

36
5-19 5-20

Replace the 4 wheel drive gear using stop Using an appropriately sized tube refit the rear
threaded product (P / N° 548110). bearing.
Note : The gear should be fitted with the fluted
boss against the 1st gear. (On 2 wheel drive
models a spacer is fitted in place of the gear).

5-21 5-22

Invert the shaft and refit the 3rd gear, synchro Re-fit the 3rd / 4th synchroniser assembly.
hub and circlip.

5-23 5-24

Refit the 4th gear and thrust washer as shown. Using an appropriately sized tube replace the
front bearing.

37
7 - PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY

DIS-ASSEMBLY
7-1 7-2

The permanent 4 wheel drive shaft. Using the appropriate bearing puller remove the
front and rear bearings.

RE-ASSEMBLY
7-3 7-4

Remove the 4 wheel drive gear. Replace the 4 wheel drive gear using stop
threaded product (P / N° 548110), on the shaft
splines . Then using a suitably sized tube re-fit
the front and rear bearings.

38
8 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE OIL PUMP

Note : Individual components of the oil pump 8-1

are non serviceable. The pump may, however,
be stripped for cleaning and examination pur-
poses.

View showing a dismantled pump assembly.

8-2

The pump oil seal may be replaced using an

approprietely sized tube.

39
9 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE VALVE

Nota : Dis-assembly of the control valve is not 9-1

generally recommended as, with the
exception of the solenoids, individual
parts are non serviveable. It may howe-
ver be dismantled for cleaning and exa-
mination.

The retaining nut, coil and washers removed.

9-2 9-3

The modulation components removed. There are 4 "O"rings fitted to the underside of
the valve which may be re-newed if necessary.

40
10 - GEAR LEVER HOUSING DIS-ASSEMBLY AND RE-ASSEMBLY

10-1 Nota : Before re-assembly remove all traces of

old sealant from the joint faces.

Remove the plastic ties from the rubber gaiter

and pull the assembly apart as shown.

10-2 10-3

Apply a airtightness product (P / N° 562228) to Lubricate the ball seating with a light grease
the sealing face as shown. and push the two halves of the assembly toge-
ther. Secure the rubber gaiter with two new
plastic ties.

41
11 - TRANSMISSION RE-ASSEMBLY

Note : All shafts and bearing should be lubri- 11-1

cated with transmission fluid prior to
assembly.
To prevent possible contamination of
hydraulic parts lint or cotton rags should
not be used.

4WD VERSION : Position the front case as shown

and using a suitably sized tube fit a new 4 wheel drive
output shaft oil seal to a depth of 6mm below the hou-
sing face. Fill the seal lip with light grease.

11-2 11-3

Re-fit the oil pump assembly and sealing ring. If previously removed, replace the two plug and
Tighten 4 bolts to a torque of 13-23 Ib / ft. New "O"ring assemblies as shown and tighten to a
copper washers must be fitted under the bolt torque of 30 to 40 Ibs /ft.
heads.

11-4 11-5

Invert the case and then re-fit the bearing cups Using a suitable tool push the inner detent
if previously removed. spring and ball into the case and secure in place
with a dummy plug as shown. (ø 18 mm, lg. 25
mm).

42
 11-6 11-7

Dummy plug in place Replace the countershaft and reverse idler shaft
assemblies.

11-8 11-9

Slide the 1st / 2nd fork onto the 3rd / 4th rail then refit Push the interlock ball into the detent bore.
the 3rd / 4th shift fork and tighten the screw to a
torque of 13 to 18 Ibs / ft. Hold the forks and rail in
place on the output shaft then re-fit the complete
assembly into the case. The shift rail should displace
the dummy plug as it enters the bore.
Note : Check that the inner detent spring and ball
have not become displaced and remove the loose
dummy plug from the case sump.

11-10 11-11

Re-fit the 1st / 2nd shift rail and tighten the shift Replace the outer detent ball and spring.
fork screw to a torque of 13 to 18 Ibs / ft. Check Tighten the plug to a torque of 30 to 40 Ibs /ft.
that the interlock ball is correctly positioned in
between the two rails.

43
11-12
4WD VERSION : Replace the 4 wheel drive
shaft assembly. Lubricate the rear seal with a
light grease.
11-14
Rear case with all shaft assemblies fitted.
11-16
Invert the case and replace the shim packs and bea-
ring cups. The 2mm thick spacer shim should be fit-
ted into the case first, then fit the remaining shims fol-
lowed by the bearing cup. A light grease may be used
to help hold the cups in the case.
44
11-13
Lubricate the input shaft front and rear seals a
light grease and re-fit the shaft assembly into
the case.
11-15
Position the rear case as shown and using a
suitably sized tube fit a new output shaft oil seal
to a depth of 6mm below the housing face. Fill
the seal lip with a light grease.
11-17
Re-fit the rear case, (without sealant at this
stage), and secure with at least 6 equally spa-
ced bolts. When fitting the rear case be careful
to avoid damaging the input shaft sealing rings.
11-18
Position a D.T.I. on the end of the input shaft as
shown, and using a suitable pry bar through the
side access hole, measure and note the shaft
end float.
11-20
Attach a suitable shimming tool, (with a 12mm
thread), to the end of the countershaft. Position
a D.T.I. as shown, and using a pry bar lift the
shaft, then measure and note the end float .
11-22
4WD VERSION : Attach a suitable shimming tool,
(with a 12mm thread), to the end of the 4 wheel drive
shaft. Position a D.T.I. as shown, and using a pry bar
lift the shaft, then measure and note the end float.
45
11-19
Attach a suitable shimming tool, (with a 12mm
thread), to the end of the reverse idler shaft.
Position a D.T.I. as shown, and using a pry bar
lift the shaft, then measure and note the end
float.
11-21
Attach a suitable shimming tool, (with a 12 mm
thread), to the end of the output shaft. Position
a D.T.I. as shown, and using a pry bar lift the
shaft, then measure and note the end float.
Remove the rear case and add or remove shims
as necessary to give .001" to .003" end float on
all shafts.
Repeat steps 11.17 to 11.22 until all shaft end
floats are correct.
11-23 11-24

Replace the 4 "O"rings in the front case. (There Re-fit the rear case using an approved liquid
are only 3 fitted on the 2 wheel drive model). gasket Taking care not to damage the input
shaft sealing rings. Tighten the 17 bolts to a
torque of 33 to 47 Ibs / ft.

11-25 11-26

Replace the shaft end plug and "O"ring assem- Fit a new expansion plug to the shimming
blies. Note the special breather plug es fitted in access hole using an approved sealant. Stop
the reverse idler position. Tighten to a torque of threaded product (P / N° 562227).
30 to 40 Ibs / ft.

11-27 11-28

Replace the output yoke, "O"ring, washer and 4WD VERSION : Replace the spacer, 4WD
bolt. Then tighten to a torque of 50 to 65 Ibs / ft. yoke, "O"ring, washer and bolt. Then tighten to
a torque of 50 to 65 Ibs / ft.

46
11-29
Re-fit the cold start ball, spring and housing.
Then tighten to a torque of 34 to 44 Ibs / ft.
11-31
Lubricate the seals with transmission fluid then
re-fit the converter regulator valve and tighten to
a torque of 17 to 22 Ibs / ft.
11-33
Ensure the 4 "O"ring are in place then re-fit the
control valve assembly and tighten the 4 caps
crews to a torque of 5.0 to 6.3 Ibs / ft. The valve
can only be fitted one way round as it is located
by a small dowel pin.
47
11-30
Lubricate the seals with transmission fluid then
re-fit the pressure regulator valve and tighten to
a torque of 34 to 44 Ibs / ft.
11-32
Re-fit the temperature sender and tighten to a
torque of 15 to 20 Ibs / ft.
11-34
Re-fit the strainer, spacer, "O"ring and cover
plate. Then tighten the two screws to a torque of
13 to 23 Ibs / ft.
11-35 11-36

Re-fit the drain plug and "O"ring assembly. Re-fit the 4th gear lock out screw, (when this
Tighten to a torque of 25 to 40 Ibs / ft. feature is not required a shorter blanking screw
is fitted). On some applications an additionnal
sealing plug may be fitted.

11-37 11-38

Apply a bead of RTV joint compound (P / N° Re-fit the gear lever assembly and tighten the
562228) to the gear case as shown. three bolts to a torque of 12 to 18 Ibs / ft.

11-39 11-40

Re-fit the filter housing and gasket. Tighten the Lubricate the seals with a light grease and
two bolts to a torque of 33 to 47 Ibs / ft. screw on a new oil filter.

48
11-41 11-42

4WD VERSION : Lubricate the seals with a light 4WD VERSION : Re-fit the 4 wheel drive sole-
grease and re-fit the 4 wheel drive solenoid noid coil and nut. Tighten to a torque of 4 Ibs / ft
spool. Tighten to a torque of 15 to 20 Ibs / ft. maximum.

11-43

4WD VERSION : If previously removed re-fit the

4 wheel drive clutch supply pipe, apply air tight-
ness product (P / N° 62175) to threads and
thighten nuts to a torque of 5 to 7.5 Ibs / ft.

49
50
TEST PROCEDURE

51
COMPACT PLUS TEST PROCEDURE
TROUBLESHOOTING

Whenever the transmission shaft is observed to malfunction, prior to dismantling anything or operating on
the transmission shaft, you should first carry out a thorough inspection so as to determine the cause of
the failure. The table below has been drawn up to make this task easier for you.

When checking pressures, please consult the section "CHECKING PRESSURES".

FAULT DIAGNOSIS HYDRAULIC SYSTEM

FAULT POSSIBLE CAUSES

Transmission fails to drive in either
direction.
Low or no pump pressure.
Low or no oil in transmission.
Mechanical failure in transmission.
Worn or broken input shaft sealing rings.
Pressure regulator valve faulty.
Direction control valve not operating.
Blockage in oil ports restricting flow.

Transmission drives in one direc- Low oil pressure to clutch pack.

tion only. Clutch pack excessively worn.
Direction valve or coil faulty.
Mechanical failure in transmission.
Blockage in oil ports restricting flow.
Worn or damaged input shaft sealing ring.

Delay in taking up drive. Low converter pressure.

Low oil level.
Low clutch pressure.
Faulty modulation in direction control valve .
Blockage in direction valve.
Blockage in oil ports restricting flow.

No drive from 4WD 4WD solenoid valve or coil not operating.

Mechanical failure in transmission .
Low pressure 4WD clutch pack pressure.
4WD clutch pack worn.

Transmission overheating. Oil level too high or low.

Restriction in cooler flow.
Low oil pressure.
Clutch packs slipping due to low pressure or wear.
Mechanical failure in transmission.
Excessive stall operation.

52
 FAULT POSSIBLE CAUSES
Difficult gear selection. Fwd or Rev. clutch pack pressurised when not selected.
Direction valve faulty.
Input shaft sealing rings leaking.
Mechanical failure in transmission.
Fwd or Rev. clutch pack not releasing due to mechanical failure.

Vehicle moves with direction valve See" Difficult gear selection".

in neutral position.

High stall speed. Low oil level.

Air in oil.
Clutch plates slipping due to low pressure or wear.
Torque converter faulty.
Converter relief valve faulty.

Low stall speed. Poor engine performance.

Torque converter defective.

Low pump pressure. Worn or broken pump.

Leaking pump sealing ring or oil seal.
Blocked oil strainer or filter.
Blockage in oil ports between transmission sump and oil pump.
Pressure regulator valve stuck open.
Cold start valve stuck open.

High pump pressure. Pressure regulator valve faulty.

Has normal operating oil temperature been reached ?

Low forward or reverse clutch pack Faulty direction control valve or coil.
pressure. Piston seal or "O"ring leaking.
Input shaft sealing ring leaking.

High forward / reverse clutch pack Pressure regulator valve faulty.

pressure.

Converter pressure low. Converter relief valve faulty.

Leak in converter, oil cooler or connecting hoses.
Pump oil seal leaking.

Converter pressure high. Converter relief valve faulty.

Blockage or restriction in oil cooler.

Low 4WD clutch pack pressure. 4WD piston seals leaking.

4WD shaft sealing ring leaking.
Leak from 4WD clutch supply pipe.
Faulty 4WD Solénoïd.
Blockage or restriction in 4WD clutch supply pipe.

High 4WD clutch pack pressure. Pressure regulator valve faulty.

53
 FAULT POSSIBLE CAUSES
Low lubrication pressure. Blockage or restriction in oil cooler.
Input shaft front sealing ring leaking.

FAULT DIAGNOSIS MECHANICAL SYSTEM

FAULT POSSIBLE CAUSES

Noise Vehicle Driveline Problem :
Axles, Propshafts, Engine, Engine mounts.
Mis-alignment of transmission / engine.
Bearings worn or damaged.
Gear teeth damaged or brocken.
Excessive end float of shafts or gears.
Clutch plate failure forward, reverse or 4WD.
Incorrect grade of oil in transmission.
Low oil level.
Gear or thrust washer beginning to seize.

Difficult gear selection. Shift rods worn or bent.

Synchroniser assemblies worn or damaged.
Clutch pack not releasing due to mechanical fault.
Clutch pack not releasing due to hydraulic fault.
Gear shift stub lever worn or damaged.
Incorrect grade of oil in transmission.
Low oil level.

Jumping out of Gear. Detent springs worn or broken.

Synchroniser or gear dog teeth worn or damaged.
Synchroniser assemblies worn or damaged.
Shift forks worn, loose or twisted.
Restriction or wear in gear linkage or stub lever assy. not allowing
gears to be fully selected.
Excess end float on output shaft assembly or gears.

54
BEVEL GEAR DISASSEMBLY

20-3-11 EN

30 / 04 / 1999
BEVEL GEAR MAINTENANCE

RECOMMENDED LUBRICANTS

Oil used by MANITOU

Oil MANITOU Mechanical transmission for axles and box SAE 80W90

Capacity
2.5 l

For good lubrication and a good operating temperature, it is very important to use an specified
oil and to maintain the correct lever.

Oil replacing
It is recommended to change the oil in the following working periods :

After first 50 hours services.

Every 800 hours max.

Many factors having an influence on the oil changing require to increase the oil changing
frequency.

Oil level

The level must be checked with the oil gauge dipstick, the oil must be located between
both mini. and maxi marks.

* Do not fill above the maxi. level , then this could lead to an increase in temperature,
because of the oil splash lubrication by the drive gears (emulsion and destruction of
oil). This could also provoke outer leaks.

The purpose of drains is also to eliminate metallic particles of intern components, these
metallic particles being the result of normal use.

3
 42

43
44

45
46 16
21
BEVEL GEAR (DETAILS)

27 26 23

22

14
15 24
25
12 13
10 29
1 30

4
2 1
3
5 32
6 20 33
8 34
9 13 19
11 17 10
18 31
4

40
35 41
36

37
38 39
BEVEL GEAR

1 - Shim 25 - Drive shaft

2 - Flange 26 - Roller bearing
3 - Screw 27 - Seal
4 - Bearing 29 - Bearing
5 - Seal 30 - Spacer
6 - Coupling flange 31 - Flange
7 - O ring 32 - Screw
8 - Washer 33 - Bearing
9 - Screw 34 - Seal
10 - Shim 35 - Flange
11 - Spacer 36 - O ring
12 - Bearing 37 - Flange
13 - Bevel gear assy 38 - Washer
14 - Key 39 - Screw
15 - Axle 40 - Lock washer
16 - Housing 41 - Nut
17 - Sludge door 42 - Bevel gear
18 - Screw 43 - Gauge
19 - Plug 44 - O ring
20 - Seal 45 - Plug
21 - Plug 46 - Seal
22 - Seal
23 - Air breather
24 - Key

5
REMOVE

-1-

MAIN HOUSING DISASSEMBLY PROCEDURE

- Remove 6 bolts retaining the drive plate. ( 17

mm socket ).

-2-

- Remove the drive plate.

-3-

- Remove 6 bolts retaining the input shaft

housing. ( 17 mm socket ).

-4-

- Separate the input shaft housing using the

levering slots if required.

6
 -5-

- Remove the input shaft housing and shims.

-6-

- Remove the 6 bolts retaining the output shaft

housing. ( 17 mm socket ).

-7-

- Remove the output shaft housing and shims.

-8-

- Using a suitable lever, remove the input shaft

oil seal from the case.

7
 -9-

- Using a suitable sized drift, drive the input

shaft needle bearing out of the case.

- 10 -

INPUT SHAFT DISASSEMBLY

- Undo the input flange retaining bolt ( 17 mm

socket ).

- 11 -

- Remove the bolt, washer and o-ring.

- 12 -

- Remove the input flange assembly.

8
 - 13 -

- Remove the housing from the shaft assembly.

- 14 -

- Remove the shims and bearing spacer from

the shaft.

- 15 -

- Using a suitable press, drive the shaft through

the bearing and gear to remove them. Then
remove the woodruff key from the slot.

- 16 -

- Using a suitable lever remove the oil seal from

the input shaft housing.

9
 - 17 -

- Remove the outer bearing cone.

- 18 -

- Remove the bearing cups from the housing

using a suitable drift.

- 19 -

OUTPUT SHAFT DISASSEMBLY

- Flatten the tab washer and undo the output

flange retaining nut. ( 46 mm socket ).

- 20 -

- Remove the nut and tab washer.

10
 - 21 -

- Remove the o-ring.

- 22 -

- Remove the output flange.

- 23 -

- Remove the housing from the output shaft.

- 24 -

- Remove the shims and bearing spacer.

11
 - 25 -

- Using a suitable press drive the shaft through

the bearing and gear to remove them. Then
remove the woodruff key from the slot.

- 26 -

- Using a suitable lever remove the output shaft

oil seal from the housing.

- 27 -

- Remove the bearing cone.

- Then using a suitable drift remove the bearing

cups from the housing.

12
NOTES

- 28 -

- The bevel gears are manufactured in matched

pairs and should not be replaced individually.

- Pairs are marked with a three figure

identification number.

- The correct mounting distance (in millimetres)

is also marked on the gears.

- 29 -

- The input gear can be easily identified as it has

a machined groove and the output gear does
not.

- 30 -

- The tooth marked "X" on the input gear.

- 31 -

- Must be fitted between the two teeth marked

"X" on the output gear.

13
 - 32 -

INPUT SHAFT REASSEMBLY

- Using suitable sized tubes, refit the bearing

cups into the input shaft housing.

- 33 -

- Refit the inner bearing cone.

- 34 -

- Using suitable equipment measure the

distance from the input housing mounting face
to the rear of the inner bearing.
Measurement A :

- 35 -

- Using a suitable press refit the input gear to

the shaft taking care to correctly align the
woodruff key with the keyway.

14
 - 36 -

- Using a suitable tube press the inner bearing

cone onto the shaft.

- 37 -

- Refit the housing to the input shaft assembly.

- 38 -

- Refit the bearing spacer and shim pack.

- 39 -

- Refit the outer bearing cone.

15
 - 40 -

- Refit the input flange, washer and bolt.

- Torque to : 81 - 108 Nm.

- 41 -

- Check the torque required to rotate the shaft. It

should be 1.14 - 1.70 Nm.

- If necessary adjust the shim pack to give

correct torque.

- 42 -

- When the correct shim pack has been found,

remove the shaft.

- Assembly from the housing and using a

suitable tool.

- Replace the input shaft oil seal to a depth of

1.5 mm below the housing face.

- 43 -

- Rebuild as previously described.

- On final assembly fit the o-ring under the

flange retaining washer and use stop threaded
to secure the bolt (Ref : 466222).

16
 - 44 -

- Measure and note the diameter of the input

shaft.
Measurement B :

- 45 -

OUTPUT SHAFT REASSEMBLY

- Using suitable sized tubes, refit the bearing

cups into the output shaft housing.

- 46 -

- Refit the inner bearing cone.

- 47 -

- Using suitable equipment measure the

distance from the output housing mounting
face to the rear of the inner bearing.
Measurement C :

17
 - 48 -

- Using a suitable press refit the output gear to

the shaft taking care to correctly align the
woodruff key with the keyway.

- 49 -

- Using a suitable tube press the inner bearing

cone onto the shaft.

- 50 -

- Refit the housing to the output shaft assembly.

- 51 -

- Refit the bearing spacer and shim pack.

18
 - 52 -

- Refit the outer bearing cone.

- 53 -

- Refit the output flange, tab washer and nut.

- Torque to : 81 - 108 Nm.

- 54 -

- Check the torque required to rotate the shaft. It

should be 1.14 - 1.70 Nm.

- If necessary adjust the shim pack to give

correct torque.

- 55 -

- When the correct shim pack has been found,

remove the shaft.

- Assembly from the housing and using a

suitable tool

- Replace the output shaft oil seal to a depth of

1.5 mm below the housing face.

19
 - 56 -

- Rebuild as previously described.

- On final assembly fit the o-ring under the tab

washer.

- 57 -

- Retorque the flange retaining nut and bend the

tab washer using a suitable tool.

- 58 -

- Measure and note the diameter of the output

shaft.
Measurement D :

- 59 -

MAIN HOUSING REASSEMBLY

- Using a suitable tool refit the output shaft

needle bearing.

- Into the case to a depth of 1.5 mm below the

housing face.

20
 - 60 -

- Refit the output shaft rear oil seal.

- Into the case to a depth of 1.5 mm below the

housing face using a suitable tool.

- 61 -

- Refit the output shaft assembly and shim pack

into the case.

- Secure with 2 bolts. Do not use any sealant at

this stage.

- 62 -

- Measure the distance from the input housing

mounting face to the previously measured
diameter on the output shaft.
Measurement E :

- 63 -

- Remove the output shaft assembly then refit

the input shaft assembly and shim pack into
the case.

- Secure with two bolts. Do not use any sealant

at this stage.

21
 - 64 -

- Measure the distance from the output housing

mounting face to the previously measured
diameter on the input shaft.
Measurement F :

SHIM PACK CALCULATIONS :

- For this formula the mounting dimensions marked on gears will be called (See fig. 28).
• Input gear = Dimension G
• Output gear = Dimension H

- The shim pack thickness required for the Input shaft assembly is calculated as follows :
D x 0.5 + E = J
A + G - J = Required shim pack thickness.

- The shim pack thickness required for the output shaft assembly is calculated as follows :
B x 0.5 + F = K
C + H - K = Required shim pack thickness.

- Select the shims required to give the thickness calculated and refit input and output shaft
assemblies into the case.

- Torque the 12 bolts to 39 - 58 Nm.

- 65 -

- To aid assembly it may be helpful to highlight

the teeth marked "X" with a suitable dye.

22
 - 66 -

- Using a dial gauge and a bolt and nut fitted to

the inpu flange.

- Check the backlash of the bevel gears.

Nota : The output shaft should be stationary

during this measurement.

- The backlash when measured by this method

should be 0.12 - 0.18 mm.
If necessary adjust both the shim packs equally
to achieve the correct backlash.

- Once the correct backlash has been achieved

remove and refit the input and output shaft
assemblies using golden hermatite or an
equivalent sealant between the housings, shim
packs and case.

- 67 -

- Refit the drive plate.

Torque the bolts to 39 - 58 Nm.

- 68 -

- Photo showing breather, dipstick and filler plug.

23
 - 69 -

- Photo showing drain plug.

Nota : - Oil seal lips should be lubricated with a light grease on assembly.
- Bearings should be lubricated with an appropriate oil on assembly.
- Drain, filler, and oil level plugs should be torqued to 20 - 30 Nm.

24