580N, 580SN, 580SNWT, 590SN Service Manual - 8

Transmission - Power Shuttle transmission internal components
Transmission drive and driven shafts - Inspect - Secondary shaft

1. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear.
2. Check the splines on the secondary shaft for wear
and damage. Check the passages in the secondary
shaft to be sure that the passages are open and free
of foreign material.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
4. Check the teeth in the synchronizer assemblies for
wear and damage. Replace as necessary.
5. Check for wear or damage to the steel rings and
the bronze rings from the synchronizer assemblies.
Check the springs in the synchronizer assemblies for
wear, cracks, heat distortion, and other damage. Re-
place as necessary.
Next operation:
Transmission drive and driven shafts - Assemble (21.154)
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Transmission drive and driven shafts - Assemble - Secondary shaft

NOTE: Before each gear is installed on the secondary shaft, make sure that the bore of the gear and the outside
diameter of the secondary shaft are completely lubricated with clean transmission oil.
NOTE: When you install snap rings on the secondary shaft, make sure that the ends of each snap ring are seated in
the snap ring groove. Do not install a snap ring so that the ends extend into an axial slot on the secondary shaft.
1. If equipped with four wheel drive, if the snap ring
was removed from the shaft, install the snap ring as
shown.
RCPH10TLB784AAL 1
2. Put the secondary shaft on the bench so that the first-

second gear end is up. You can use a vise with soft
jaws to hold the secondary shaft in position. Install
the four-wheel drive gear, if equipped.
RCPH10TLB783AAL 2
3. If equipped with four wheel drive, install the snap ring

for the four wheel drive gear.
RCPH10TLB782AAL 3
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4. Install first gear.
RCPH10TLB781AAL 4
5. This photo shows the correct relationship between

the hub and the sleeve for assembly of the first-sec-
ond synchronizer. The tabs (1) in the inside diameter
of the sleeve fit into the small recesses (2) in the out-
side diameter of the hub. The large recesses (3) in
the hub are for the detent assemblies, that are not
yet installed.
RCPH10TLB950AAL 5
6. This photo shows the correct positions of the hub, the

sleeve, the springs, the blocks, and the balls prior to
final assembly. The springs are installed in the hub,
and the blocks are on the springs. The blocks are
not yet pushed down into the sleeve and are holding
the hub up out of the sleeve. The balls are loose in
the recesses of the blocks.
RCPH10TLB951AAL 6
7. Use a punch or screwdriver to push the balls into the

blocks and to push the blocks down so that the balls
are on the flat faces of the teeth, but not into the de-
tent grooves. When all the balls are in position, push
the hub and the blocks down until the balls move into
the detent groove.
RCPH10TLB952AAL 7
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8. Install the tapered friction ring on the synchronizer

assembly.
RCPH10TLB947AAL 8
9. Use clean transmission oil to lubricate the bronze

ring (1) and the steel ring (2). Install the bronze ring
(1) and the steel ring (2)as shown.
RCPH10TLB946AAL 9
10. Install the synchronizer ring as shown. The flat sides

of the teeth must be up.
RCPH10TLB945AAL 10
11. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 11
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12. Use clean transmission oil to lubricate the bronze

ring (1) and the steel ring (2). Install the bronze ring
(1) and the steel ring (2)as shown.
RCPH10TLB946AAL 12
13. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top synchronizer ring. To
do this, you must use enough force to overcome the
strength of the detent springs and balls. When the
synchronizer ring and the sleeve are completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If
the sleeve does not engage the teeth smoothly or
does not stay in position when moved to any of the
three positions, the synchronizer assembly has dam-
aged parts or was not assembled correctly. Disas-
semble the synchronizer assembly to find the prob-
lem.
14. Install the synchronizer ring and the first-second syn-
chronizer as an assembly. Make sure the top syn-
chronizer ring is installed so that the flat sides of the
teeth are up.
RCPH10TLB780AAL 13
NOTE: There is a groove in the bore at one end of the synchronizer hub. The synchronizer assembly must be installed
so that the groove is down.
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15. Install the spacer.
RCPH10TLB779AAL 14
16. Install and second gear. The teeth in the inside diam-
eter of the spacer must engage the teeth on the bot-
tom of second gear before second gear is installed.
RCPH10TLB778AAL 15
17. Install the pin.
RCPH10TLB777AAL 16
Next operation:
Transmission drive and driven shafts - Adjust (21.154)
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Transmission drive and driven shafts - Adjust - Backlash

adjustment
1. Install the thrust washer and snap ring.
RCPH10TLB775AAL 1
2. Use a feeler gauge and measure the backlash be-

tween the gear and the thrust washer. Record this
measurement (a). Subtract the recorded measure-
ment (a) from 0.20 to 0.42 mm (0.0079 to 0.0165
inch) (b). Select the shim(s) required (c). Example:
Use 0.83 ± 0.11 mm (0.0327 ± 0.0043 inch) shim (s).
a. 1.14 mm 0.0449 inch

b. -0.31 mm 0.0122 inch
c. 0.83 mm 0.0327 inch
3. Remove the snap ring and thrust washer.
RCPH10TLB775AAL 2
4. Use clean transmission oil to lubricate the shim(s)

and the thrust washer. Install the shim(s). Install the
thrust washer on top of the shim(s). Make sure that
the side with the oil grooves is down.
RCPH10TLB776AAL 3
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5. Put the bearing race on the shaft.
RCPH10TLB774AAL 4
6. Use an acceptable driver to drive the bearing race

onto the secondary shaft until bearing race makes
contact with the snap ring.
RCPH10TLB785AAL 5
7. Turn the secondary shaft over so that second gear is

at the bottom. Use blocks to support the secondary
shaft. Install the fourth gear on the secondary shaft.
RCPH10TLB771AAL 6
8. This photo shows the correct relationship between

the hub and the sleeve for assembly of the third-
fourth synchronizer. The tabs (1) in the inside diam-
eter of the sleeve fit into the small recesses (2) in the
outside diameter of the hub. The large recesses (3)
in the hub are for the detent assemblies, shown in-
stalled.
RCPH10TLB811AAL 7
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9. Install the 3 sets of hub springs, hub pins, and spring

plates into the synchronizer hub. Use a punch or
screwdriver to push the spring plates as the synchro-
nizer hub is installed into the sleeve. Be sure that
the spring plates are aligned with the grooves in the
sleeve.
RCPH10TLB952AAL 8
10. Install the friction ring on each side the synchronizer

assembly.
RCPH10TLB892AAL 9
11. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assem-
bly.
RCPH10TLB891AAL 10
12. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top synchronizer ring. To
do this, you must use enough force to overcome the
strength of the detent springs and balls. When the
synchronizer ring and the sleeve are completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If
the sleeve does not engage the teeth smoothly or
does not stay in position when moved to any of the RCPH10TLB810AAL 11
three positions, the synchronizer assembly has dam-

aged parts or was not assembled correctly. Disas-
semble the synchronizer assembly to find the prob-
lem.
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13. Install the synchronizer assembly onto the shaft.
RCPH10TLB770AAL 12
14. Install the third gear on the shaft.
RCPH10TLB769AAL 13
15. Use clean transmission oil to lubricate the thrust

washer. Install the thrust washer onto the shaft.
RCPH10TLB768AAL 14
16. Put the bearing in position on the secondary shaft.

Make sure that the snap ring groove is at the top.
RCPH10TLB767AAL 15
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17. Use an acceptable driver to drive the bearing onto

the secondary shaft until the bearing makes contact
with the thrust washer.
RCPH10TLB953AAL 16
NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you
install the secondary shaft in the rear housing. To prevent this, you can install a hose clamp on the output end of the
secondary shaft. This will keep the bearing in position during installation of the secondary shaft.
18. Check for correct operation of both synchronizer as-
semblies. If they do not shift smoothly, with the teeth
on the synchronizer ring aligned with the splines on
the sleeve, the re is a problem. Disassemble as nec-
essary, and correct the problem.
Next operation:
Transmission drive and driven shafts - Disassemble (21.154)
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Transmission drive and driven shafts - Disassemble - Primary shaft

1. Put the primary shaft on the bench so that the end
with the bearing attached is up. Remove the snap
ring.
RCPH10TLB954AAL 1
2. Install a bearing separator under the gear as shown.

DO NOT install the bearing separator between the
gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the primary shaft. Use moly-
disulfide grease to lubricate the shaft protector and
the end of the puller. Pull the bearing from the pri-
mary shaft.
RCPH10TLB955AAL 2
3. Remove the bearing.
RCPH10TLB956AAL 3
4. Remove the thrust washer.
RCPH10TLB957AAL 4
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5. Install a bearing separator under the lip of the bear-

ing race as shown. Install an acceptable puller on the
bearing separator. Use a shaft protector between the
puller and the end of the primary shaft. Use moly-
disulfide grease to lubricate the shaft protector and
the end of the puller. Pull the bearing race from the
primary shaft.
RCPH10TLB958AAL 5
Next operation:
Transmission drive and driven shafts - Inspect (21.154)
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Transmission drive and driven shafts - Inspect - Primary shaft

1. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear.
2. Check the splines on the primary shaft for wear and
damage.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble - Primary shaft

1. Use an acceptable driver to drive the bearing race all
the way onto the primary shaft.
RCPH10TLB959AAL 1
2. Use clean transmission oil to lubricate the thrust

washer. Install the thrust washer so that the side
with the oil grooves is down.
RCPH10TLB957AAL 2
3. Put the bearing into position so that the snap ring

groove on the outside diameter of the bearing is at
the top.
RCPH10TLB956AAL 3
4. Use an acceptable driver to drive the bearing onto the

primary shaft until the bearing makes contact with the
thrust washer.
RCPH10TLB960AAL 4
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5. Install the snap ring.
RCPH10TLB954AAL 5
Next operation:
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Transmission drive and driven shafts - Disassemble - Reverse shaft

1. The bearings are the only serviceable parts on the re-
verse shaft. If you remove the bearings, use a shaft
protector between the puller and the end of the re-
verse shaft. Use molydisulfide grease to lubricate the
shaft protector and the end of the puller. (1)Bearing,
(2) Reverse shaft
RCPH10TLB050ABL 1
Next operation:
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Transmission drive and driven shafts - Inspect - Reverse shaft

1. Check the teeth on the gears for wear and damage.
If a tooth is badly damaged, be sure to inspect the
gear that is in mesh with the damaged gear. Check
the bearings for flat areas, pitting, and other damage.
Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble - Reverse shaft

1. Use an acceptable driver to drive each bearing onto
the reverse shaft until the bearing makes contact with
the shoulder on the reverse shaft.
Next operation:
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Transmission drive and driven shafts - Disassemble - Oil pump

NOTE: Bolts (6), O-Rings, bushings and seals are the only serviceable components in the oil pump. Complete dis-
assembly of the oil pump is shown for reference only.
1. Remove the O-ring.
RCPH10TLB983AAL 1
2. Remove the two Allen head bolts that fasten the

pump support to the pump housing.
RCPH10TLB984AAL 2
3. Separate the pump support from the pump housing.
RCPH10TLB985AAL 3
4. Remove the large gear from the pump housing.
RCPH10TLB986AAL 4
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NOTE: Install a plastic plug in the bearings to keep the bearings from falling out when the small gear is removed from
the pump housing.
5. Remove the small gear from the pump housing.
RCPH10TLB987AAL 5
NOTE: Be careful when removing the plastic plug from the small gear the needle bearings will fall out. Make a record
of the number of needle bearings remove from the small gear for use during assembly.
6. Remove the seal from the pump housing.
RCPH10TLB988AAL 6
7. Turn the pump housing over and use blocks to sup-

port the pump housing. Use an acceptable driver to
drive the bushing from the bore of the pump housing.
RCPH10TLB989AAL 7
8. Support the large gear on blocks as shown. Use a

punch and a hammer to drive the bushing from the
large gear.
RCPH10TLB994AAL 8
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9. Use an acceptable driver to push the needle bearing

out of the small gear.
RCPH10TLB996AAL 9
10. Remove the shaft for the small gear only if the shaft
is damaged. The shaft will probably be difficult to
remove.
RCPH10TLB993AAL 10
11. Use a blind hole puller and a slide hammer to pull the
bushing from the shaft of the pump support.
RCPH10TLB997AAL 11
12. Remove the roll pin for the torque converter relief
valve.
RCPH10TLB999AAL 12
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13. Remove the plug, the spring, and the ball for the
torque converter relief valve.
RCPH10TLB001ABL 13
14. Remove the roll pin for the oil pump relief valve. Be
very careful because the large amount of spring ten-
sion will force the parts out when the roll pin is re-
moved.
RCPH10TLB002ABL 14
15. Remove the plug, the spring, the pin, and the plunger
for the oil pump relief valve.
RCPH10TLB038ABL 15
Next operation:
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Transmission drive and driven shafts - Inspect - Oil pump

1. Inspect the large gear and the small gear for wear
and damage. If the teeth on a gear have scoring,
excessive wear, or sharp edges, use a new gear.
Check for damage to the lugs on the large gear. If
there is damage, check the hub on the torque con-
verter for similar damage. Replace the large gear
and the torque converter as necessary.
2. Inspect the gear pockets in the pump housing for
wear or damage. If the gear pockets have scoring
or excessive wear, use a new oil pump.
3. Inspect the splines on the shaft for wear and damage.
If you find damage, inspect the part that is installed
on the shaft.
4. Inspect all passages to be sure that the passages are
open and free of foreign material.
5. Check the needle bearing for wear, pitting, or other
damage.
6. Inspect the parts of the torque converter relief valve
and the oil pump relief valve for wear and damage.
Next operation:
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Transmission drive and driven shafts - Assemble - Oil pump

1. Install the plunger for the oil pump relief valve.
RCPH10TLB042ABL 1
2. Install the pin for the oil pump relief valve. The ma-
chined end of the pin must be toward the plunger.
Make sure that the pin goes into the bore of the
plunger.
RCPH10TLB041ABL 2
3. Install the spring.
RCPH10TLB040ABL 3
4. Install the plug.
RCPH10TLB039ABL 4
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5. This step will be difficult because the spring will be

under heavy tension. Push the plug in until the plug
is to the inside of the hole for the roll pin. Install the
roll pin.
RCPH10TLB002ABL 5
6. Install the ball, the spring, and the plug for the torque
converter relief valve. Make sure that the hole in the
plug is aligned with the hole for the roll pin.
RCPH10TLB001ABL 6
7. Install the roll pin through the holes in the pump sup-
port and the hole in the plug.
RCPH10TLB003ABL 7
8. Use an acceptable driver to install a new bushing in

the shaft of the pump support.
RCPH10TLB998AAL 8
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9. Use an acceptable driver to install a new needle

bearing in the small gear. Push the needle bearing
until the needle bearing is approximately centered in
the bore of the gear.
RCPH10TLB996AAL 9
10. If the shaft for the small gear was removed, clean the
mating surfaces and apply either Loctite 640 (green)
or Loctite 642 (amber) before installation.
RCPH10TLB993AAL 10
11. Support the large gear on blocks so that the side with
the lugs is down. Use an acceptable driver to push
the new bushing to the end of the bore.
RCPH10TLB995AAL 11
12. Put a new bushing into position so that the recess (1)
in the bushing is aligned with the oil drain hole (2) in
the pump housing.
RCPH10TLB990AAL 12
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13. Use an acceptable driver to install the bushing.
RCPH10TLB992AAL 13
14. Use an acceptable driver to install a new seal in the

end of the pump housing.
RCPH10TLB991AAL 14
15. Use clean transmission oil to lubricate the small gear,

the needle bearing, and the bore in the pump hous-
ing. Install the small gear on the shaft in the pump
housing. Install the same number of needle bearings
that were removed between the small gear and the
shaft.
RCPH10TLB987AAL 15
16. Use clean transmission oil to lubricate the large gear,

the bushing in the large gear, and the bore in the
pump housing. Install the large gear so that the side
with the lugs is down.
RCPH10TLB986AAL 16
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17. Install the pump support on the pump housing. Make

sure that all the bolt holes are aligned.
RCPH10TLB985AAL 17
18. Install the two Allen head bolts to fasten the pump
support to the pump housing. Tighten the Allen head
bolts until they are just snug.
RCPH10TLB984AAL 18
19. Install a large worm gear clamp (radiator hose clamp)

around the outside of the pump housing and the
pump support. The clamp must cover the joint be-
tween the two parts and be in contact with both parts.
Tighten the clamp. Tap the housing with a soft ham-
mer. Tighten the clamp again. Tap the housing
again with a soft hammer. Tighten the clamp again.
Tighten the Allen head bolts to 10 Nm (89 pound-
inches). Remove the clamp.
20. Put the oil pump on a clean work surface so that the
pump housing is up. Insert a small screwdriver or
punch through the hole in the torque converter hub
and rotate the large gear by pushing against one of
the lugs. The large gear must rotate freely. If the
large gear does not rotate freely, loosen the Allen
head bolts and repeat step 340. If the large gear
rotates freely, fill the oil pump with clean transmission
oil and rotate the large gear three revolutions before
you install the oil pump on the transmission.
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21. Install a new O-ring.
RCPH10TLB983AAL 19
Next operation:
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Transmission drive and driven shafts - Disassemble - Four wheel

drive shaft
1. There is a pipe plug at the bottom of the hole in the
end of the shaft (see arrow). DO NOT remove the
pipe plug unless the pipe plug is damaged.
RCPH10TLB883AAL 1
2. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring (see ar-
row). Remove the snap ring from the groove. Re-
lease the tension and remove the tool.
RCPH10TLB884AAL 2
NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out to provide
access to the snap ring.
3. Remove the snap ring from the shaft.
RCPH10TLB885AAL 3
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4. Remove the spacer.
RCPH10TLB886AAL 4
5. Remove the special washer.
RCPH10TLB887AAL 5
6. Remove the springs.
RCPH10TLB888AAL 6
7. Remove the sleeve.
RCPH10TLB889AAL 7
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8. Remove the two O-rings from the shaft.
RCPH10TLB890AAL 8
9. Remove the two Teflon sealing rings from the shaft.
RCPH10TLB890AAL 9
Next operation:
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Transmission drive and driven shafts - Inspect - Four wheel drive

shaft
1. Inspect the lugs on the sleeve for peening or other
damage. If you find damage to the lugs, also inspect
the four-wheel drive clutch gear.
2. Check the splines on the shaft and inside the sleeve
for wear and damage.
3. Check the passages in the shaft to be sure that the
passages are open and free of foreign material.
4. Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble - Four wheel

drive shaft
NOTE: Special tools used up to step 6 are from the tool set CAS2771A, standard transmission without rear pump
drive.
1. Install new O-rings on the shaft. Use clean transmis-
sion oil to lubricate the O-rings.
RCPH10TLB890AAL 1
2. Install the CAS2771-2 expander/protector on the

shaft.
RCPH10TLB894AAL 2
NOTE: For clarity, the following photo does not show the use of a heat resistant glove. To prevent injury be sure to
wear a heat resistant glove when installing the Teflon sealing ring.
3. Heat the Teflon sealing ring to 80° to 100° C (176°
to 212° F). Install the Teflon sealing ring onto the
CAS2771-2 expander/protector.
RCPH10TLB895AAL 3
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4. Install the CAS2327 pusher over the expander/pro-

tector and slide the sealing ring until it reaches the
groove in the shaft. Remove the pusher and ex-
pander/protector from the shaft.
RCPH10TLB896AAL 4
5. Install the end of the CAS2771-7 seal compressor

with the deep chamfer onto the shaft and over the
sealing ring. Use a back and forth twisting motion to
allow the seal compressor to slip over the top of the
sealing ring and seat the sealing ring into the groove.
Be careful not to damage the sealing ring. After the
sealing ring is seated in the groove, remove the seal
compressor from the shaft.
RCPH10TLB897AAL 5
6. Turn the seal compressor around and slide the end

with the narrow chamfer over the shaft and over the
sealing ring. Leave the seal compressor in place for
15 minutes until the sealing ring has cooled and is
properly sized and seated in the groove. After the
sealing ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB898AAL 6
7. Place the CAS2771-3 spacer against the end of the

shaft.
RCPH10TLB899AAL 7
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8. Slide the CAS2771-2 expander/protector over the

CAS2771-3 spacer. The expander/protector will stop
in the correct position to install the sealing ring in the
groove.
RCPH10TLB900AAL 8
NOTE: For clarity, the following photo does not show the use of a heat resistant glove. To prevent injury be sure to
wear a heat resistant glove when installing the Teflon sealing ring.
9. Heat the Teflon sealing ring to 80° to 100° C (176°
to 212° F). Install the Teflon sealing ring onto the
CAS2771-2 expander/protector.
RCPH10TLB900AAL 9
10. Install the CAS2327 pusher over the expander/pro-

tector and slide the sealing ring until it reaches the
groove in the shaft. Remove the pusher, expander/
protector, and spacer from the shaft.
RCPH10TLB902AAL 10
11. Install the end of the CAS2771-1 seal compressor

with the deep chamfer onto the shaft and over the
sealing ring. Use a back and forth twisting motion to
allow the seal compressor to slip over the top of the
sealing ring and seat the sealing ring into the groove.
Be careful not to damage the sealing ring. After the
sealing ring is seated in the groove, remove the seal
compressor from the shaft.
RCPH10TLB903AAL 11
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12. Turn the seal compressor around and slide the end
with the narrow chamfer over the shaft and over the
sealing ring. Leave the seal compressor in place for
sealing ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB904AAL 12
13. Install the sleeve on the shaft. Be careful not to dam-

age the Teflon sealing rings and the O-rings while in-
stalling the sleeve.
RCPH10TLB889AAL 13
14. Install the springs.
RCPH10TLB888AAL 14
15. Install the special washer.
RCPH10TLB887AAL 15
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16. Install the spacer onto the shaft.
RCPH10TLB886AAL 16
17. Install the snap ring onto the shaft.
RCPH10TLB885AAL 17
18. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring groove
(see arrow). Install the snap ring in the groove. Re-
lease the tension and remove the tool. Make sure
that the snap ring is seated in the recess in the spring
retainer.
RCPH10TLB884AAL 18
NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out.
19. If the pipe plug at the bottom of the hole in the end
of the shaft (see arrow) was removed, apply Loctite
242 or Loctite 262 to the threads of the new pipe plug
before installation. Tighten the pipe plug to a torque
of 30 Nm (266 pound-inches).
RCPH10TLB004ABL 19
Next operation:
Transmission housing - Disassemble (21.112)
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Index
Transmission - 21
Power Shuttle transmission internal components - 154

Transmission drive and driven shafts - Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Transmission drive and driven shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transmission drive and driven shafts - Assemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Transmission drive and driven shafts - Assemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Transmission drive and driven shafts - Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Transmission drive and driven shafts - Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission drive and driven shafts - Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Transmission drive and driven shafts - Disassemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Transmission drive and driven shafts - Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission drive and driven shafts - Disassemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Transmission drive and driven shafts - Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission drive and driven shafts - Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission drive and driven shafts - Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission drive and driven shafts - Exploded view - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission drive and driven shafts - Exploded view - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission drive and driven shafts - Exploded view - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission drive and driven shafts - Exploded view - Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission drive and driven shafts - Inspect - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Transmission drive and driven shafts - Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmission drive and driven shafts - Inspect - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Transmission drive and driven shafts - Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Transmission drive and driven shafts - Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Transmission drive and driven shafts - Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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Transmission - 21
Powershift transmission internal components - 155
580N
580SN WT
580SN
590SN
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Contents
Transmission - 21
Powershift transmission internal components - 155
FUNCTIONAL DATA
Shaft assemblies
Exploded view - H-Type - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch
Exploded view - H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Shaft assemblies
Disassemble - S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Disassemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Disassemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Clutch
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Back side measurement 81
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Front side measurement 86
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Dimension "D" measurement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Neutral position measure-
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check - S-Type (SPS Power Syncro) - Speed gears switches - Checking procedure . . . . . . . . . . . . . . . 95
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Transmission - Powershift transmission internal components
Shaft assemblies - Exploded view - H-Type - Reverse shaft

Reverse shaft
1. Bearing 11. Thrust plate 21. Split pin 31. Clutch drive plates
2. Bearing 12. Clutch drive plates 22. Split pin 32. Thrust plate
3. Teflon seal 13. Clutch plates 23. Teflon seal ring 33. Lock ring
4. Snap ring 14. Snap ring 24. O-ring 34. Retaining plate
5. Bearing 15.Lock washer 25. Clutch piston 35. Gear
6. Spacer 16. Spring 26. Sleeve 36. Needle cage
7. Needle cage 17. Sleeve 27. Spring 37. Retaining plate
8. Gear 18. Clutch piston 28. Lock washer 38. Bearing
9. Retaining plate 19. Teflon seal ring 29. Snap ring 39. Snap ring
10. Lock ring 20. O-ring 30. Clutch plates 40. Teflon seal ring
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RCPH10TLB019GAL 1
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Clutch - Exploded view - H-Type

1. Seal 8. Gear 15. Snap ring 22. Shaft
2. Seal 9. Lock ring 16. Retaining washer 23. Spring pin
3. Bearing 10. Thrust plate 17. Spring 24. Bearing
4. Gear 11. Clutch discs 18. Sleeve 25. Teflon seal ring
5. Lock ring 12. Reaction plates 19. Clutch piston
6. Washer 13. Washer 20. Teflon seal ring
7. Roller retainer 14. Spacer 21. Teflon seal ring
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RCPH10TLB018GAL 1
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Shaft assemblies - Disassemble - S-Type (SPS Power Synchro) -

Rear cover - shafts
NOTE: To remove shaft B and C, remove the front half-housing, the parking brake, the rear cover, the bearing snap
ring of the secondary shaft and the switches group
NOTE: Steps 3 through 5 are for machines with a parking brake.
1. Remove the input shaft (1). Remove the idler shaft
(2).
RCPH10TLB109AAL 1
2. Remove the parking brake group.
RCPH10TLB045ACL 2
3. Remove O-Ring (1)Remove the 7 screws (2). Re-

move the flange (3). Remove the assembled PTO
shaft (4)
RCPH10TLB050ACL 3
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4. Remove the 4 screws (1)and the 3 screws (2). Re-

move the rear cover (3).
RCPH10TLB049ACL 4
NOTE: Steps 6 through 8 are for machines without a parking brake.

5. Remove the 5 screws (1), the 3 screws (2)and the 2
screws (3).
RCPH10TLB255ACL 5
6. Remove the rear cover (1)and the PTO shaft (2).
RCPH10TLB256ACL 6
7. Remove PTO shaft.
RCPH10TLB193ACL 7
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8. If necessary, remove teflon seal ring. It may be nec-

essary to cut the ring.
RCPH10TLB105AAL 8
9. Remove snap ring.
RCPH10TLB257AAL 9
10. Use a suitable driver and remove the bearing from

the PTO shaft.
RCPH10TLB106AAL 10
11. Remove shims (1). Remove bearing snap ring (2).
RCPH10TLB194ACL 11
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21.155 / 10
12. Attach lifting bracket 380100088 to the shafts, re-

move them from the transmission.
RCPH10TLB145AAL 12
Next operation:
Shaft assemblies - Assemble (21.155)
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Shaft assemblies - Assemble -S-Type (SPS Power Synchro) - Rear

cover - shafts
1. Assemble the 4WD shaft. Remove the secondary
shaft and the primary shaft.
RCPH10TLB719AAL 1
2. Assemble the input shaft. Assemble the idler shaft.

Install the front half housing on the rear half housing.
Tighten the screws. Assemble the switches group.
RCPH10TLB720AAL 2
3. Push the secondary shaft toward the rear of the rear

housing so that there is clearance between the snap
ring groove and the rear housing. Assemble the
bearing snap ring on the secondary shaft Assemble
the shims on the secondary shaft.
RCPH10TLB732AAL 3
4. If you change bearing of the secondary shaft or rear

front-housing calculate the amount of shims to be
inserted between rear cover and rear half-housing.
RCPH10TLB732AAL 4
5. Rear cover. Determine the dimension Y.
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6. Rear front-housing.. Determine the dimension Z.

7. Prescribed end float (between rear cover and rear
half-housing) --> 0 ÷ 0,1 mm. Select an amount of
shims S , among the range of available shims see ta-
ble in next step), to make sure there is the prescribed
end float. S= Y-Z mm
RCPH10TLB257ACL 5
8. Select the shim of thickness value (S) among the

range of available shims. Note: choose the shim
(S) so that is guaranteed an end float of 0 ÷ 0.1 mm
between rear cover and rear half-housing
RCPH10TLB078ACL 6
9. Assemble the shims.
RCPH10TLB257ACL 7
10. Heat the bearing to 60 - 80 °C (140.0 - 176.0 °F)for

5 minutes. Assemble bearing on the shaft PTO.
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11. Assemble snap ring..
RCPH10TLB257AAL 8
12. For the assembly of teflon seal ring follow operations

from step 19 to step 23 using the following tools.
CA716225 (without shim) CA715497 CA715356.
RCPH10TLB087ACL 9
NOTE: Steps 13 through 15 are for machines without the parking brake.
13. Assemble PTO shaft (1)into the rear cover (2).
RCPH10TLB193ACL 10
14. Apply a thin film of sealant on the edge of the rear

cover. Assemble the rear cover group. Make sure
that the pin is correctly installed both in the rear hous-
ing and through the hole in the rear cover.
RCPH10TLB256ACL 11
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15. Tighten the 5 screws (1)the 3 screws (2)and the 2

screws (3)to fasten the rear cover to the rear half
housing. If necessary, tap the rear cover with a soft
faced hammer to close the gap between the rear
half housing and the rear cover before tightening
the screws. Tightening torque Powershift transmis-
sion - Torque (21.113). Assemble the O-Ring (4).
RCPH10TLB255ACL 12
NOTE: Steps 16 through 22 are for machines with the parking brake.
16. Clean the cover (1). Apply a thin film of sealant on
the edge of the rear cover.
RCPH10TLB168ACL 13
17. Clean the rear half-housing. Assemble the O-Ring

(1)on the rear half-housing.
RCPH10TLB057ACL 14
18. Make sure that the pin (1)is correctly installed both
in the rear housing and through the hole in the rear
cover. Tighten the 4 screws (2)and the 3 screws
(3)to fasten the rear cover to the rear half hous-
ing. Tightening torque Powershift transmission -
Torque (21.113).
RCPH10TLB049ACL 15
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19. Clean the flange.
RCPH10TLB166ACL 16
20. Apply a thin film of sealant on the edge of the flange.
RCPH10TLB167ACL 17
21. Assemble the assembled PTO shaft (1)into the trans-

mission. Assemble the flange (2). Tighten the 7
screws (3)to fasten the flange to the cover. Tighten
torque Powershift transmission - Torque (21.113).
Assemble the O-Ring (4).
RCPH10TLB002AAN 18
22. Assemble the parking brake group.
RCPH10TLB001AAN 19
Next operation:
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Shaft assemblies - Disassemble (21.155)
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Shaft assemblies - Disassemble -S-Type (SPS Power Synchro)

- Gear pistons
NOTE: To remove gear and neutral piston, remove the parking brake group and rear cover and secondary shaft
lubrication pipe.
1. Remove the O-Rings.
RCPH10TLB062ACL 1
NOTE: O-rings cannot be re-used. Replace O-rings during assembly.

2. Remove 2nd (1)and 4th (2) gear pistons.
RCPH10TLB063ACL 2
NOTE: Use a M4 screw to remove the pistons. If replacement of pistons is needed see following step.
3. If dimension difference between the new piston and
the replaced one is more than 0.07 mm, shift rails
and switches adjustment is required.
RCPH10TLB217ACL 3
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4. 4th gear pistons - ø36 mm. If the replacement is

needed cut the seal ring and remove it. Remove the
O-Ring
RCPH10TLB251ACL 4
5. 2nd gear pistons- ø42 mm. If the replacement is

needed cut the seal ring and remove it. Remove the
O-Ring
RCPH10TLB251ACL 5
6. If one of the following parts is replaced : synchro-

nizer, shift rails, forks, secondary shaft, secondary
shaft gears or half-housings, the shims adjusting
must be revised. Remove the screw (1). Remove
the bushing (2). Collect the shims (3).
RCPH10TLB064ACL 6
7. Remove the screws (1). Remove the locking plugs.

(2).
RCPH10TLB065ACL 7
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21.155 / 19
8. Remove the plugs (1). See next step.
RCPH10TLB058ACL 8
9. Remove the screws (1). Remove the oil circuit plate

(2). Remove the O-Rings (3). Remove plugs by
blowing in air (just enough to pull out the plugs)
through the hole as shown in figure (see arrows).
RCPH10TLB081ACL 9
NOTE: Possible oil leakage. Carefully follow all the safety procedures indicated in this manual and in the vehicle
manual.
10. Plug (3). ø52 mm. Remove the O-Ring.
RCPH10TLB172ACL 10
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11. Plug (5). ø47 mm. Remove the O-Ring.
RCPH10TLB172ACL 11
12. Remove the NEUTRAL pistons.
RCPH10TLB059ACL 12
NOTE: Use a M4 screw to remove the pistons. If the replacement is needed remove the seal and O-Ring. See step
4 to disassemble the seals. If replacement of pistons is needed see step 15.
13. Remove 1st (1)and 3rd (2)gear pistons. If replace-
ment of pistons is needed see following step.
RCPH10TLB060ACL 13
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21.155 / 21
14. If dimension difference between the new piston and

the replaced one is more than 0.07 mm, shift rails
and switches adjustment is required.
RCPH10TLB217ACL 14

(1)must be revised. If necessary remove the screw
(2)and collect the shims (1). If the replacement is
needed remove the seal and O-Ring (3). See step 4
and 5 to disassemble the seals.
RCPH10TLB066ACL 15

(1)must be revised. Remove the screw (2). Remove
the bushing (3). Collect the shims (1).
RCPH10TLB061ACL 16
Next operation:
Shaft assemblies - Assemble (21.155)
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Shaft assemblies - Assemble -S-Type (SPS Power Synchro) - Gear

pistons
1. 4th gear pistons - ø36 mm. Assemble the O-Ring
into the piston.
RCPH10TLB233ACL 1
2. Assembly seal ring (1)into the piston (2).
RCPH10TLB048ACL 2
3. Slide the expander/protector tool onto the piston (1).

The expander/protector will stop in the correct posi-
tion to install the seal ring in the groove.
RCPH10TLB234ACL 3
4. Heat the Teflon seal ring (1)to 60 - 80 °C (140.0 -

176.0 °F)for 5 minutes. Install the teflon seal ring
onto the expander/protector.
RCPH10TLB196ACL 4
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21.155 / 23
5. Install the pusher tool over the expander/protector

and slide the seal ring until it reaches the groove in
the shaft. Remove the pusher, expander/protector,
and spacer from the shaft.
RCPH10TLB197ACL 5
6. Install the end of the seal compressor with the deep

chamfer onto the piston and over the sealing ring.
Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the sealing ring and
seat the sealing ring into the groove. Be careful not to
damage the seal ring. After the sealing ring is seated
in the groove, leave the seal compressor in place for
seal ring has cooled, remove the seal compressor
from the piston.
RCPH10TLB140ACL 6
7. 2nd gear pistons - ø42 mm. Assemble the O-Ring

into the piston.
RCPH10TLB233ACL 7
8. Assembly seal ring (1)into the piston (2).
RCPH10TLB048ACL 8
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21.155 / 24
9. For the installation of the seal ring (1), repeat the

operations from sequence 3 to sequence 6, using
the following tools: expander/protector, pusher, and
gauger service tool.
RCPH10TLB234ACL 9

must be revised.
RCPH10TLB046ACL 10
11. Assemble the special tool on the shaft rail. Assemble

the shims.
RCPH10TLB266ACL 11
12. Assemble the bushing (1). Assemble the bushing as

shown in figure.
RCPH10TLB267ACL 12
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13. Bushing figure.
RCPH10TLB067ACL 13
14. Remove the special tool.
RCPH10TLB269ACL 14
15. Check the switches have been proper assembled

and adjust the control gear shaft and than assem-
ble the screw (1)with sealant. Tighten the screws
(1)Tightening torque Powershift transmission -
Torque (21.113).
RCPH10TLB270ACL 15
16. Engage the 3rd speed gear and check that the bush-
ing top is in range.
47365539 08/07/2012
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must be revised.
RCPH10TLB047ACL 16
18. Assemble the special tool on the shift rail. Assemble

the shims (1). Assemble the bushing (2). Assemble
the bushing as shown in figure.
RCPH10TLB146ACL 17
19. Assemble as shown.
RCPH10TLB068ACL 18
20. Check the switches have been properly assembled

adjust control gear shaft and then assemble the
screw (1)with sealant. Tighten the screws (1)Tight-
ening torque Powershift transmission - Torque
(21.113).
RCPH10TLB147ACL 19
47365539 08/07/2012
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21. Engage the 4th speed gear and check that bushing
top is in the range as shown in next figure.
RCPH10TLB148ACL 20

must be revised. Assemble the shims onto the
screw . Assemble the screw with sealant.
RCPH10TLB066ACL 21
23. Tighten the screws into the piston. Tightening torque

Powershift transmission - Torque (21.113).
RCPH10TLB219ACL 22
24. Use a special tool to insert 3rd gear pistons (1). Use
a special tool to insert 1st gear pistons (2).
RCPH10TLB235ACL 23
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RCPH10TLB069ACL 24
26. Assemble 3rd and 1st gear pistons.
RCPH10TLB236ACL 25
27. Push the piston into the seat using a soft tool mate-
rial. Remove the special tools.
RCPH10TLB237ACL 26
28. Assemble as shown. Seal ring into the NEUTRAL

piston (16).
RCPH10TLB048ACL 27
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29. Assemble the O-Ring (1)into the NEUTRAL piston

. For the introduction of the seal ring , repeat the
operations from sequence 3 to sequence 6, using
the following tools: expander/protector, pusher and
gauger service tool.
RCPH10TLB196ACL 28
30. Seal ring into the NEUTRAL piston.
RCPH10TLB048ACL 29
31. Assemble the O-Ring into the NEUTRAL piston . For

the introduction of the seal ring , repeat the opera-
tions from sequence 3 to sequence 6, using the fol-
lowing tools: expander/protector, pusher and gauger
RCPH10TLB196ACL 30
32. 3N4 piston . Use special tool to insert the NEUTRAL

pistons . 1N2 piston . Use a special tool to insert the
NEUTRAL pistons.
RCPH10TLB170ACL 31
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21.155 / 30
33. Push the piston in your seat using a soft tool material.
Remove the special tool.
RCPH10TLB171ACL 32
RCPH10TLB070ACL 33
35. Plug (3). ø52 mm. Assemble the O-Ring.
RCPH10TLB172ACL 34
36. Plug (5). ø47 mm. Assemble the O-Ring.
RCPH10TLB172ACL 35
47365539 08/07/2012
21.155 / 31
37. Assemble the plug.
RCPH10TLB173ACL 36
38. Assemble the locking plugs (2). Tighten the screws

(1)Tightening torque Powershift transmission -
Torque (21.113).
RCPH10TLB065ACL 37
39. Assemble group (B).
RCPH10TLB174ACL 38
40. Rear cover side: Use dealer supplied special tools

to insert 2nd and 4th gear pistons . Put the piston
into the tool and push out about 3 mm to allow the
centering on half housing.
RCPH10TLB144ACL 39
47365539 08/07/2012
21.155 / 32
41. Place the tool with piston on the half-housing. Push

the piston in its seat using a soft tool material. Re-
move the special tools.
RCPH10TLB145ACL 40
42. Assemble the O-Rings.
RCPH10TLB062ACL 41
43. Assemble the rear cover.
RCPH10TLB049ACL 42
Next operation:
Clutch - Measure (21.155)
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Shaft assemblies - Disassemble - S-Type (SPS Power Synchro)

- Shafts A - D
1. Remove the input shaft (1). Remove the idler shaft
(2).
RCPH10TLB109AAL 1
2. Remove the teflon seal ring.
RCPH10TLB110AAL 2
RCPH10TLB111AAL 3
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4. Install a bearing separator under the gear as shown

(do not install the bearing separator between the
gear and the bearing). Use a puller on the bearing
separator and insert a shaft protector between the
puller and the end of the input shaft.
RCPH10TLB112AAL 4
5. Remove the bearing.
RCPH10TLB113AAL 5
6. Remove the spacer.
RCPH10TLB117AAL 6
7. Remove the gear.
RCPH10TLB115AAL 7
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8. Remove the needle bearing.
RCPH10TLB116AAL 8
9. Remove the thrust washer.
RCPH10TLB262AAL 9
10. Remove the roll pin.
RCPH10TLB262AAL 10
11. Remove lock ring.
RCPH10TLB117AAL 11
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12. Use pry bars to lift and to remove the thrust plate.
RCPH10TLB118AAL 12
13. Remove the clutch plates and the clutch discs.
RCPH10TLB119AAL 13
14. Place a mark below the groove on the clutch housing.
RCPH10TLB120AAL 14
15. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 15
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16. Install the top piece of the CAS2379 special tool (not
shown). Use the three threaded rods and nuts to
fasten the two pieces together.
RCPH10TLB121AAL 16
RCPH10TLB264AAL 17
18. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB121AAL 18
19. Remove the pressure plate and spring.
RCPH10TLB122AAL 19
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20. Remove the sleeve.
RCPH10TLB265AAL 20
21. Use compressed air in the piston pressure port to

remove the piston.
RCPH10TLB123AAL 21
22. Remove the piston seal rings and backup rings.
RCPH10TLB266AAL 22
23. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 23
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24. Remove the snap ring.
RCPH10TLB267AAL 24
25. Insert a shaft protector between the puller and the

end of the input shaft. Remove the bearing.
RCPH10TLB125AAL 25
26. Remove the bearing and thrust washer.
RCPH10TLB126AAL 26
27. Remove gear.
RCPH10TLB303AAL 27
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580N, 580SN, 580SNWT, 590SN Service Manual - 8

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580N, 580SN, 580SNWT, 590SN Service Manual - 8

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Transmission - Power Shuttle transmission internal components

Transmission drive and driven shafts - Inspect - Secondary shaft

Transmission drive and driven shafts - Assemble - Secondary shaft

2. Put the secondary shaft on the bench so that the first-

3. If equipped with four wheel drive, install the snap ring

4. Install first gear.

5. This photo shows the correct relationship between

6. This photo shows the correct positions of the hub, the

7. Use a punch or screwdriver to push the balls into the

8. Install the tapered friction ring on the synchronizer

9. Use clean transmission oil to lubricate the bronze

10. Install the synchronizer ring as shown. The flat sides

11. Turn the synchronizer assembly over and install the

12. Use clean transmission oil to lubricate the bronze

13. Install the top synchronizer ring on the synchronizer

15. Install the spacer.

17. Install the pin.

Transmission drive and driven shafts - Adjust - Backlash

2. Use a feeler gauge and measure the backlash be-

a. 1.14 mm 0.0449 inch

3. Remove the snap ring and thrust washer.

4. Use clean transmission oil to lubricate the shim(s)

5. Put the bearing race on the shaft.

6. Use an acceptable driver to drive the bearing race

7. Turn the secondary shaft over so that second gear is

8. This photo shows the correct relationship between

9. Install the 3 sets of hub springs, hub pins, and spring

10. Install the friction ring on each side the synchronizer

11. Use clean transmission oil to lubricate and install the

12. Install the top synchronizer ring on the synchronizer

three positions, the synchronizer assembly has dam-

13. Install the synchronizer assembly onto the shaft.

14. Install the third gear on the shaft.

15. Use clean transmission oil to lubricate the thrust

16. Put the bearing in position on the secondary shaft.

17. Use an acceptable driver to drive the bearing onto

Transmission drive and driven shafts - Disassemble - Primary shaft

2. Install a bearing separator under the gear as shown.

3. Remove the bearing.

4. Remove the thrust washer.

5. Install a bearing separator under the lip of the bear-

Transmission drive and driven shafts - Inspect - Primary shaft

Transmission drive and driven shafts - Assemble - Primary shaft

2. Use clean transmission oil to lubricate the thrust

3. Put the bearing into position so that the snap ring

4. Use an acceptable driver to drive the bearing onto the

5. Install the snap ring.

Transmission drive and driven shafts - Disassemble - Reverse shaft

Transmission drive and driven shafts - Inspect - Reverse shaft

Transmission drive and driven shafts - Assemble - Reverse shaft

Transmission drive and driven shafts - Disassemble - Oil pump

2. Remove the two Allen head bolts that fasten the

3. Separate the pump support from the pump housing.

4. Remove the large gear from the pump housing.

7. Turn the pump housing over and use blocks to sup-

8. Support the large gear on blocks as shown. Use a

9. Use an acceptable driver to push the needle bearing

Transmission drive and driven shafts - Inspect - Oil pump