Service Manual: 580N 580SN-WT 580SN 590SN

TRANSMISSION, DRIVE AND PTO OUT - C
580N
580SN-WT
580SN
590SN
Loader Backhoe
SERVICE MANUAL
Printed in U.S.A. Part number 84393972

English
Copyright © 2010 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. October 2010
Racine Wisconsin 53404 U.S.A.
TRANSMISSION Power Shuttle - 20.C
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
TRANSMISSION Power Shuttle
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Four wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - Two wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control valve
Exploded view - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exploded view - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Shaft
Exploded view - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Exploded view - Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exploded view - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exploded view - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control valve
Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Shaft
Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Disassemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Inspect - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Assemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Disassemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Inspect - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Assemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Housing
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Assemble - Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Power Shuttle
TRANSMISSION Power Shuttle - General specification

Type of transmission oil MS-1209, Hy-Tran™ Ultra
Clutch disc clearance 2.3 - 4.3 mm (0.1 - 0.2 in)
Capacity - Two wheel drive

Total system 18.5 l (19.5 US qt)
Refill capacity with or without filter change 16 l (16.9 US qt)
Capacity - Four wheel drive

Total system 21 l (22.2 US qt)
Refill capacity with or without filter change 18.5 l (19.5 US qt)
TRANSMISSION Power Shuttle - Torque

Pipe plug in end of four-wheel drive shaft 30 N·m (265.5 lb in)
Solenoid valve in four-wheel drive valve 22.0 N·m (194.7 lb in)
Nut for solenoid coils on transmission control valve 7 - 10 N·m (62.0 - 88.5 lb in)
Fittings for four-wheel drive clutch tube 30 N·m (265.5 lb in)
Allen head screws for valve plate on front housing 23 N·m (203.6 lb in)
Test port plugs 23 N·m (203.6 lb in)
Detent plugs 80 N·m (59.0 lb ft)
Bolts for rear cover 50 N·m (36.9 lb ft)
Bolt for output flange 139 N·m (102.5 lb ft)
Allen head screws for shifter assembly 23 N·m (203.6 lb in)
Hollow cap screws for tube on front housing 40 N·m (354.0 lb in)
Bolts to fasten front and rear housings 50 N·m (36.9 lb ft)
Bolts to fasten cover below four-wheel drive flange 23 N·m (203.6 lb in)
Bolt for four-wheel drive flange 139 N·m (102.5 lb ft)
Bolts for oil pump 23 N·m (203.6 lb in)
Fitting for oil filter 50 N·m (36.9 lb ft)
Bolts to fasten four-wheel drive valve to front housing 23 N·m (203.6 lb in)
Bolts to fasten cover for oil screen 23 N·m (203.6 lb in)
Bolts for transmission control valve 23 N·m (203.6 lb in)
Drain plug 80 N·m (59.0 lb ft)
Allen head screws to fasten pump support to pump 10 N·m (88.5 lb in)
housing
Nut for four-wheel drive solenoid coil 8 N·m (70.8 lb in)
Allen head screws for modulation cover 11 N·m (97.4 lb in)
Solenoid plunger in transmission control valve 23 N·m (203.6 lb in)
Bolts to fasten pump mount to rear housing 50 N·m (36.9 lb ft)
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TRANSMISSION Power Shuttle - Special tools

380040161 - Teflon seal installation
RCPH10TLB828AAL 1
CAS-2379 Input shaft holder and spring compressor
RCPH10TLB043ABL 2
CAS-2381 Seal driver
RCPH10TLB045BL 3
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CAS-2378 transmission leg set
RCPH10TLB044ABL 4
CAS2771A - Teflon seal installation tool kit - 4 wheel drive

shaft
RCPH10TLB688AAL 5
1. CAS2771-2 Seal Expander/Protector

2. CAS2771-1 Seal Compressor
3. CAS2771-3 Spacer
4. CAS2327 Pusher
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TRANSMISSION Power Shuttle - Exploded view

1. Nut (2) 90-100 NM (67 - 73 lb-ft) 8. Backing plate
2. Transmission 9. Cap screw (4) 52-57 NM (38-42 lb-ft)
3. Bolt (12) 52-57 NM (67-73 lb-ft) 10. Bolt (4) 52-57 NM (38 - 42 lb-ft)
4. Dipstick tube 11. Nut 90-100 NM (67 - 73 lb-ft)
5. Converter 12. Rubber transmission mount (2)
6. Flex plate with caged nut 13. Constant torque clamp (4) 5.6 - 7.9 NM (50 - 50 in-lb)
7. Flex plate
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RCPH10TLB5GAL 1
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TRANSMISSION Power Shuttle - Exploded view - Four wheel drive

transmission
Four-wheel drive transmission
1. Tube 13. Breather
2. Hollow bolt 14. Breather pipe
3. Copper washer 15. PTO flange
4. Copper washer 16. O-ring
5. Plug 17. Bolt
6. Plug 18. Rear cover
7. Plug 19. Bolt
8. O-ring 20. Dowel pin
9. Fitting 21. Drain plug
10. Copper washer 22. Rear housing
11. Test port plug 23. Four-wheel drive clutch tube
12. Park brake pressure tube 24. Front housing
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RCPH10TLB020GAL 1
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TRANSMISSION Power Shuttle - Exploded view - Two wheel drive

transmission
Two-wheel drive transmission
1. Tube 11. Dowel pin
2. Hollow bolt 12. Park brake pressure tube
3. Copper washer 13. Rear cover
4. Plug 14. PTO flange
5. Copper washer 15. Bolt
6. O-ring 16. O-ring
7. Sealing washer 17. Bolt
8. Test port plug 18. Drain plug
9. Breather 19. Rear housing
10. Breather pipe 20. Front housing
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RCPH10TLB021GAL 1
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Control valve - Exploded view - Four wheel drive valve (if equipped)
Four wheel drive valve (if equipped)
1. Bolt 5. Check valve 9. Solenoid coil
2. Plug 6. Gasket 10. Connector
3. Copper washer 7. O-rings 11. Nut
4. Solenoid valve body 8. Solenoid valve body 12. Jumper wire
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RCPH10TLB026GAL 1
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Control valve - Exploded view - Transmission control valve

Transmission control valve
1. Nut 9. Gasket 17. Snap ring-not 25. Plug
removable
2. Seal 10. Plate 18. Ball 26. Spring spacer
3. O-ring 11. Outer modulation piston 19. Spring 27. Forward/reverse spool
4. Connector 12. Small spring 20. Control valve body 28. Flow divider piston
5. Solenoid coil 13. Medium spring 21. Bolt 29. Flow divider shaft
6. Solenoid plunger 14. Large spring 22. Hex head plug 30. Valve plate
7. Allen head bolt 15. Piston pin 23. Copper washer 31. Differential lock
solenoid valve
8. Modulation cover 16. Inner modulation piston 24. Allen head plug 32. Snap ring
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RCPH10TLB027GAL 1
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Shaft - Exploded view - Input shaft

Input shaft
1. Seal ring 11. Clutch plate (12) 21. Rivet
2. Snap ring 12. Lock ring 22. Gear
3. Bearing 13. Lock-spring cover 23. Bearing
4. Spacer 14. Spring 24. Snap ring
5. Needle bearing 15. Clutch sleeve 25. Seal rings
6. Gear 16. Clutch piston 26. Snap ring
7. Thrust washer 17. Seal ring 27. Bearing
8. Lock ring 18. Seal ring 28. Pump drive shaft
9. Clutch plate lock ring 19. Inner shaft 29. Seal ring
10. Clutch drive plate (14) 20. Split pin
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RCPH10TLB022GAL 1
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Shaft - Exploded view - Shift rod and forks

Shift rod and forks
1. Boot 7. O-ring 13. Detent ball 19. Shift rod for third and
fourth gear
2. Band 8. Spring 14. Detent plug 20. Shift rod for first and
second gear
3. Shift lever 9. Bushing 15. Washer 21. Roll pin
4. Pin 10. Snap ring 16. Detent spring 22. Shift fork for third and
fourth gear
5. Allen head screw 11. Shift collar 17. Bolt 23. Shift fork for first and
second gear
6. Shifter housing 12. Plate 18. Copper washer
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RCPH10TLB024GAL 1
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Shaft - Exploded view - Secondary shaft

Secondary shaft
1. Bearing 8. Steel ring 15. Sleeve 22. Thrust washer
2. Lock ring 9. Coated ring 16. Gear 23. Bearing
3. Shim 10. Tapered friction ring 17. Split pin 24. Seal
4. Thrust washer 11. Hub 18. Secondary shaft 25. Flange
5. Gear 12. Spring 19. Gear 26. Washer
6. Spacer 13. Ball 20. Clutch ring 27. O-ring
7. Synchronizer ring 14. Lock spring plate 21. Synchronizer ring 28. Bolt
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RCPH10TLB023GAL 1
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Shaft - Exploded view - Four wheel drive shaft

Four wheel drive shaft
1. Bolt 7. Bearing 13. Sleeve
2. Washer 8. Teflon sealing ring 14. Pipe plug
3. O-ring 9. Special washer 15. Shaft
4. Four-wheel drive flange 10. Snap ring 16. Four wheel drive clutch gear
5. Cover 11. Spacer
6. Seal 12. Spring
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RCPH10TLB025GAL 1
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TRANSMISSION Power Shuttle - Remove

1. Park the machine on a level surface. Put the back-
hoe in the transport position with the stabilizers
down. Also, put the loader bucket on the ground.
2. Raise the wheels off the ground high enough to re-
move the transmission. Put suitable stands under
both sides of the machine at the front and rear.
NOTE: The rear wheels can be removed to ease the transmission removal.
3. Drain the transmission oil
RCPH10TLB065AAL 1
4. Disconnect the supply line (1) from the transmission,

disconnect the return line (2) from the transmission.
RCPH10TLB167ABL 2
5. Disconnect the differential lock hose.
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6. If equipped, remove the front cab floor mat (1). Re-

move the cab front floor plate (2)
RCPH10TLB168ABL 3
7. Disconnect the return spring for the shift lever. Dis-

connect the transmission gear shift lever from the
transmission shifter mechanism .
RCPH10TLB012FAL 4
8. Disconnect the wiring harness connector for the

transmission shift solenoid.
9. Disconnect the wiring harness for the transmission
temperature sender.
10. Disconnect the wiring harness for the SAHR parking
brake.
11. If equipped, disconnect the wiring harness for the
four wheel drive solenoid.
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12. Loosen and remove the cap screw and washer (1)
for the left rear mounting bracket on front drive shaft
guard through the access hole in the fuel tank.
RCPH10TLB060AAL 5
13. Loosen and remove the bolts, washers, and nuts (2)
that fasten the left rear mounting bracket to front drive
shaft guard. Remove the left rear mounting bracket.
RCPH10TLB062AAL 6
14. Put a floor jack under the front drive shaft guard that
will hold the guard in place when the cap screws are
removed. Loosen and remove the cap screws and
washers (3) from the remaining mounting brackets
on the front drive shaft guard. Remove the front drive
shaft guard from the machine.
RCPH10TLB061AAL 7
15. If equipped, remove the retainer and bolts that fasten

the front drive shaft to the transmission output shaft
yoke. Remove the front drive shaft from the splined
pinion shaft on the front axle.
NOTE: During installation apply Loctite 243 to the bolts for
the retainer. Tighten the bolts to 33 to 39 Nm (24 to 29
pound-feet).
16. Remove the retainer and bolts that fasten the rear
drive shaft to the transmission output shaft yoke. Re-
move the rear drive shaft from the splined pinion
shaft on the rear axle.
NOTE: During installation apply Loctite 243 to the bolts for the retainer. Tighten the bolts to 33 to 39 Nm (24 to 29
pound-feet).
17. Tag and disconnect the transmission cooler inlet and
outlet hoses at the transmission. Install caps on the
transmission fittings and plugs in the hose ends.
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18. Remove the hydraulic pump.

19. Remove the starter from the engine. Remove the
access cover from the bell housing.
RCPH10TLB026AAL 8
20. Install the engine turning tool, 380000988, to turn the

flywheel for access to the cap screws.
RCPH10TLB005BAL 9
21. Loosen and remove the four cap screws that fasten
the flywheel to the flex plate.
RCPH10TLB027AAL 10
NOTE: During installation make sure that the converter is in the correct position on the transmission shaft. Align the
holes in the flex plate with the holes in the fly wheel. Install but do not tighten all four cap screws, then final torque
the cap screws to 52 to 57 Nm (38 to 42 pound-feet).
22. Use acceptable stands or blocks to secure the en-
gine in place.
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23. Loosen and remove the 12 cap screws (1) and flat
washers (2) that fasten the transmission to the en-
gine. If equipped, move the heater hose and clamps
(3) out of the way.
RCPH10TLB012FAL 11
NOTE: During installation tighten the 12 cap screws to a torque of 52 to 57 Nm (38 to 42 pound-feet)
24. Install a transmission jack under the transmission
and apply light pressure.
25. Remove both the left and right transmission mount-
ing cap screw
NOTE: During installation tighten the transmission mounting cap screws to a torque of 90 to 100 Nm (67 to 73 pound-
feet), install two nuts on the left mount.
26. Carefully slide the transmission away from the en-
gine. Lower to the floor and remove from under the
machine.
Next operation:
TRANSMISSION Power Shuttle - Install (C.20.C)
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TRANSMISSION Power Shuttle - Install

NOTE: Install the transmission is the reverse of removal.
NOTE: Rotate the torque converter through the bottom hole of the bell housing and slide it against the adapter plate.
Align the bolt hole with the bosses on the torque converter.
1. Install and hand tighten all four cap screws that fas-
ten the flywheel to the torque converter.
2. Final torque the cap screws to 52 to 57 Nm (38 to 42
pound-feet).
3. Remove the engine turning tool
4. Install the access cover on the bell housing. Install
the starter on the engine.
RCPH10TLB026AAL 1
NOTICE: Before staring the engine do the following

5. Make sure the transmission drain plug has been in-
stalled and tightened.
6. Fill the transmission, see capacities.
NOTE: If removed, install the rear wheels.

7. Remove the stands from under the machine and
lower the machine to the floor.
8. With the machine parked on level ground and the
engine running at low idle, check the transmission
oil level. The oil level must be between the ADD and
the FULL marks on the dispstick. If the oil level is at
the ADD mark, add oil as required until the oil level
is at the FULL mark.
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Control valve - Disassemble - Four wheel drive valve (if equipped)

1. Remove the nut.
RCPH10TLB734AAL 1
2. Remove the solenoid coil.
RCPH10TLB737AAL 2
3. Remove the solenoid valve.
RCPH10TLB738AAL 3
4. Remove the check valve from the solenoid valve

body. DO NOT try to disassemble the check valve.
There are no serviceable parts. If there is a problem,
use a new check valve.
RCPH10TLB740AAL 4
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5. Remove the three O-rings from the solenoid valve.
RCPH10TLB741AAL 5
Next operation:
Control valve - Assemble (C.20.C)
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Control valve - Assemble - Four wheel drive valve (if equipped)

1. Install the three new O-rings on the solenoid valve.
Use clean transmission oil to lubricate the O-rings.
RCPH10TLB741AAL 1
2. Install the check valve in the valve body as shown.
RCPH10TLB740AAL 2
3. Install the solenoid valve in the solenoid valve body.

Tighten the solenoid valve to a torque of 22 Nm (195
pound-inches).
RCPH10TLB739AAL 3
4. Install the solenoid coil on the solenoid valve.
RCPH10TLB737AAL 4
84390833 11/10/2010
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5. Install the nut.
RCPH10TLB736AAL 5
6. Tighten the nut to a torque of 8 Nm (71 pound-

inches).
RCPH10TLB735AAL 6
Next operation:
Control valve - Disassemble (C.20.C)
84390833 11/10/2010
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Control valve - Disassemble - Transmission control valve

NOTE: Some of the photos in the following procedure may not be the same as the model you are repairing. The
repair procedure is the same.
1. Remove the nut for the forward/reverse solenoid.
RCPH10TLB742AAL 1
2. Remove the seal.
RCPH10TLB744AAL 2
3. Remove the first solenoid coil.
RCPH10TLB747AAL 3
4. Remove the O-ring from the either the solenoid coil

or the solenoid plunger.
RCPH10TLB748AAL 4
84390833 11/10/2010
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5. Remove the second solenoid coil.
RCPH10TLB749AAL 5
6. Remove the O-ring from the second solenoid coil.
RCPH10TLB750AAL 6
7. The remaining O-ring can stay with either the sole-

noid coil or the solenoid plunger. Remove the re-
maining O-ring.
RCPH10TLB751AAL 7
NOTE: Step 8 to 10 are for early production N Series 2 machines, current production have a 2 wire connector per
solenoid.
8. Remove the retainer from the rear of the connector
for the solenoid coils.
RCPH10TLB005ABL 8
NOTE: Before removing any wires from the connector, you may want to record the locations of the wires for reference
during assembly.
84390833 11/10/2010
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9. Use a small punch to release the locking tab on the

terminal.
RCPH10TLB006ABL 9
10. Pull the wire and the terminal from the connector.
RCPH10TLB007ABL 10
11. Repeat steps 8 and 10 for the remaining wires and

terminals.
12. Remove the nut for the differential lock solenoid.
RCPH10TLB752AAL 11
13. Remove the solenoid coil.
RCPH10TLB753AAL 12
84390833 11/10/2010
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14. Loosen and remove the solenoid plunger.
RCPH10TLB754AAL 13
15. Remove the O-rings from the solenoid plunger.
RCPH10TLB755AAL 14
16. Loosen and remove the solenoid plunger with the

forward/reverse spool attached.
RCPH10TLB756AAL 15
17. Use a small screwdriver to push down the spring as

shown so that you can disengage the notched end of
the forward/reverse spool from the post on the end of
the solenoid plunger.
RCPH10TLB011ABL 16
84390833 11/10/2010
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18. Separate the solenoid plunger (1) , the spring (2), the
spring spacer (3) , and the forward/reverse spool (4).
RCPH10TLB009ABL 17
19. Remove the O-ring from the solenoid plunger.
RCPH10TLB010ABL 18
20. Remove the four Allen head bolts that fasten the
modulation cover to the control valve body.
RCPH10TLB754AAL 19
21. Remove the outer modulation piston (1) from the

modulation cover (2). Remove the two cover gaskets
(3) and the spacer gasket (4). Remove the check ball
(5) and spring (6) . Remove the outer modulation pis-
ton spring (7) , the inner (8) and outer spring (9) , and
the inner modulation piston pin (10) and piston (11).
RCPH10TLB758AAL 20
84390833 11/10/2010
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22. Loosen the plug at the opposite end of the bore.
RCPH10TLB759AAL 21
23. Remove the plug (1) , snap ring (2) , flow divider shaft
(3) , the spring (4) , and the flow divider piston (5)
from the bore.
RCPH10TLB764AAL 22
24. Remove the plug from the bore for the forward/re-
verse spool.
RCPH10TLB760AAL 23
25. Remove the spring from the bore for the forward/
reverse solenoid.
RCPH10TLB761AAL 24
84390833 11/10/2010
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26. Remove the spring spacer.
RCPH10TLB762AAL 25
27. Remove the four hex head plugs (1) and the Allen
head plug (2) only if the plugs are damaged or leak-
ing. There are copper washers under the plugs.
RCPH10TLB763AAL 26
Next operation:
Control valve - Inspect (C.20.C)
84390833 11/10/2010
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Control valve - Inspect - Transmission control valve

1. Use cleaning solvent to clean all metal parts.
2. Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary.
3. Inspect the spool and the pistons for damage or wear.
Make sure that the orifice in the outer modulation
piston is open. Use new parts as necessary.
4. Inspect the control valve body for cracks, corrosion,
and wear. Inspect the bores for wear. Find the bore
from which the ball was removed. There is a very
small orifice in one side of this bore. Make sure that
this orifice is open. If the control valve body is bad,
you must use a new transmission control valve.
5. Find the plate that held the ball in position. Put the
ball on the hole in the plate so that the ball is in con-
tact with the edge that has the radius. Hold the plate
and the ball up to a bright light and look at the bot-
tom side of the plate and the ball. There must be no
light visible between the plate and the ball. If light is
visible, use a new plate.
Next operation:
Control valve - Assemble (C.20.C)
84390833 11/10/2010
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Control valve - Assemble - Transmission control valve

NOTE: Some of the photos in the following procedure may not be the same as the model you are repairing. The
repair procedure is the same.
1. If the four hex head plugs (1) and the Allen head plug
(2) were removed, install the copper washers and the
plugs.
RCPH10TLB763AAL 1
2. Use clean transmission oil to lubricate the flow di-

vider shaft (1) . Install the flow divider shaft (1) . The
closed end of the flow divider piston (1) must be to-
ward the inside of the control valve body. Use clean
transmission oil to lubricate the flow divider piston (3)
. Install the spring (2) , flow divider piston (3) , and
the snap ring (4) in the bore. Install a new O-ring on
the plug (5) . Use clean transmission oil to lubricate
the O-ring on the plug (5) . Install the plug (5).
RCPH10TLB764AAL 2
3. Tighten the plug at the in the bore.
RCPH10TLB759AAL 3
4. Lubricate the new inner modulation piston (11) with

clean transmission oil. Install the new inner piston
(11) so that the end with the deeper bore is towards
the outside of the valve body. Install the spring (6)
into the small bore. Install one cover gasket (3) on
the valve body. Install the check ball (5) on top of
the spring (6) in the small bore. Install the spacer (4)
so the coined (radius) side contacts the ball. Install
the remaining cover gasket (3) onto the spacer (4) In-
stall the inner modulation piston pin (10) the inner (8)
and outer (9) spring and the outer modulation piston
spring (7) into the bore. Lubricate the outer modula-
tion piston (1) with clean transmission oil and install
the piston (1) into the modulation cover (2) with the RCPH10TLB758AAL 4
closed end towards the modulation cover.

84390833 11/10/2010
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5. Install the modulation cover onto the valve body. In-

stall the four Allen head bolts into the cover. Tighten
the four Allen head bolts to a torque of 11 Nm (97
pound-inches).
RCPH10TLB754AAL 5
6. Install a new O-ring on the solenoid plunger. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB010ABL 6
7. Assemble the solenoid plunger (1), the spring (2), the

spring spacer (3), and the forward/reverse spool (4)
as shown above. One side of the spring spacer (3)
has a chamfer in the bore. Install the spring spacer
(3) so that the chamfer is toward the forward/reverse
spool (4).
RCPH10TLB009ABL 7
8. Use a small screwdriver to push down the spring as

shown so that you can engage the notched end of
the forward/reverse spool with the post on the end of
the solenoid plunger. When the notched end and the
post are fully engaged, release the spring to hold the
forward/reverse spool in position.
RCPH10TLB011ABL 8
84390833 11/10/2010
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9. Install the solenoid plunger and the forward/reverse

spool in the control valve body.
RCPH10TLB757AAL 9
10. Tighten the solenoid plunger to a torque of 23 Nm

(204 pound-inches).
RCPH10TLB756AAL 10
NOTE: The following photos do not show the forward/reverse solenoid installed. The forward/reverse solenoid must
be installed before doing steps 11, 12 and 13.
11. Install the spring spacer in the bore as shown. One
side of the spring spacer has a chamfer in the bore.
Install the spring spacer so that the chamfer is toward
the inside of the control valve body. Make sure that
the end of the forward/reverse spool comes through
the hole in the spring spacer.
RCPH10TLB762AAL 11
12. Install the spring.
RCPH10TLB761AAL 12
84390833 11/10/2010
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13. Install a new O-ring on the plug. Use clean transmis-

sion oil to lubricate the O-ring. Install the plug in the
bore.
RCPH10TLB760AAL 13
14. Install new O-rings on the differential lock solenoid

plunger. Use clean transmission oil to lubricate the
O-rings.
RCPH10TLB755AAL 14
15. Install and tighten the differential lock solenoid

plunger to a torque of 15 Nm (133 pound-inches).
RCPH10TLB754AAL 15
NOTE: Step 16 to 18 are for early production N Series 2 machines, late production have a 2 wire connector per
solenoid.
16. Before inserting a terminal in the connector, use a
small screwdriver to push the locking tab out slightly
so that the locking tab will engage the plastic tab in
the connector when you insert the terminal.
RCPH10TLB008ABL 16
84390833 11/10/2010
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17. Push each terminal into the connector until the lock-
ing tab and the plastic tab engage, locking the termi-
nal into the connector.
RCPH10TLB007ABL 17
18. After all the terminals are in the connector, install the
retainer on the rear of the connector.
RCPH10TLB005ABL 18
19. Install the differential lock solenoid coil on the sole-

noid plunger.
RCPH10TLB746AAL 19
20. Install the nut. Tighten the nut to a torque of 7 to 10

Nm (62 to 89 pound-inches).
RCPH10TLB745AAL 20
84390833 11/10/2010
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21. Install a new O-ring on the solenoid plunger at the

control valve body. Use clean transmission oil to lu-
bricate the O-ring.
RCPH10TLB751AAL 21
22. Install a new O-ring in the solenoid coil. Use clean

transmission oil to lubricate the O-ring.
RCPH10TLB750AAL 22
23. Install the solenoid coil on the solenoid plunger.
RCPH10TLB749AAL 23
24. Install a new O-ring on the solenoid plunger. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB748AAL 24
84390833 11/10/2010
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25. Install the remaining solenoid coil on the solenoid

plunger.
RCPH10TLB747AAL 25
26. Install the sealing washer.
RCPH10TLB744AAL 26
27. Install the nut. Tighten the nut to a torque of 7 to 10

Nm (62 to 89 pound-inches).
RCPH10TLB743AAL 27
Next operation:
Next operation:
84390833 11/10/2010
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Shaft - Disassemble - Input shaft

NOTE: Do steps 1 and 2 before you disassemble the input shaft. This will help to locate any problems. After you
assemble the input shaft, the tests will be done again to make sure that the input shaft is working correctly.
1. Apply compressed air of approximately 620 kPa (90
psi) to the forward clutch passage. Listen to hear
the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward
gear must not turn on the input shaft. Try to move the
reverse gear. The reverse gear must turn freely on
the input shaft. If the clutches do not work correctly,
inspect the parts closely during disassembly so that
you can find and correct the problem.
psi) to the reverse clutch passage. Listen to hear
the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The reverse
forward gear. The forward gear must turn freely on
inspect the parts closely during disassembly so that
you can find and correct the problem.
3. Use the bottom piece of CAS-2379 special tool as
shown to fasten the input shaft in the vise so that the
reverse clutch is up.
RCPH10TLB786AAL 1
4. Remove the sealing ring.
RCPH10TLB788AAL 2
84390833 11/10/2010
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5. Remove the snap ring above the bearing.
RCPH10TLB787AAL 3
6. Install a bearing separator under the gear as shown.

DO NOT install the bearing separator between the
gear and the bearing. Install a puller on the bearing
separator. Use a shaft protector between the puller
and the end of the input shaft. Use molydisulfide
grease to lubricate the shaft protector and the end
of the puller. Make sure that you pull only until the
bearing is free. Pulling any farther can damage the
parts.
RCPH10TLB789AAL 4
7. Remove the bearing.
RCPH10TLB790AAL 5
8. Remove the spacer.
RCPH10TLB791AAL 6
84390833 11/10/2010
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9. Remove the gear.
RCPH10TLB792AAL 7
10. Remove the needle bearing.
RCPH10TLB793AAL 8
11. Remove the thrust washer.
RCPH10TLB794AAL 9
12. Remove the roll pin.
RCPH10TLB795AAL 10
84390833 11/10/2010
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13. Tap lightly on the thrust plate to move the thrust plate
down so that there is clearance between the snap
ring and the thrust plate.
RCPH10TLB796AAL 11
14. Tap lightly on the thrust plate to move the thrust plate
ring and the thrust plate. Remove the snap ring.
RCPH10TLB797AAL 12
15. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fas-
ten the two pieces together.
RCPH10TLB798AAL 13
16. Tighten the nuts evenly to compress the spring.

Compress the spring just enough to get access to
the snap ring.
RCPH10TLB800AAL 14
84390833 11/10/2010
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17. Remove the snap ring.
RCPH10TLB799AAL 15
18. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS-2379 special tool.
RCPH10TLB800AAL 16
19. Use pry bars to lift the thrust plate evenly.
RCPH10TLB922AAL 17
20. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB809AAL 18
84390833 11/10/2010
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21. Place a mark below the groove on the housing.
RCPH10TLB878AAL 19
22. Place a mark on each steel and friction disc and the
thrust plate. These marks will be used for reference
during the reassembly procedure.
RCPH10TLB879AAL 20
23. Place a mark on top of the thrust plate and each steel
and friction disc as they are removed. These marks
will be used for reference during the reassembly pro-
cedure.
RCPH10TLB880AAL 21
24. Remove the pressure plate and spring.
RCPH10TLB881AAL 22
84390833 11/10/2010
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25. Remove the sleeve.
RCPH10TLB807AAL 23
NOTICE: Use an air hose with a safety on/off control nozzle with 2.1 bar (30 psi) maximum at the nozzle. Wear face
protection.
26. Use compressed air in the port shown to remove the
piston.
RCPH10TLB801AAL 24
27. Remove the piston.
RCPH10TLB802AAL 25
28. Put the input shaft in the bottom piece of the CAS-
2379 special tool as shown so that the forward clutch
is up.
RCPH10TLB923AAL 26
84390833 11/10/2010
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29. Remove the four sealing rings (1)
RCPH10TLB819AAL 27
RCPH10TLB924AAL 28

gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the input shaft. Use moly-
disulfide grease to lubricate the shaft protector and
the end of the puller. Make sure that you pull only
until the bearing is free. Pulling any farther can dam-
age the parts.
RCPH10TLB925AAL 29
RCPH10TLB926AAL 30
84390833 11/10/2010
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RCPH10TLB927AAL 31
NOTE: It is possible that the gear moved partially out of the clutch pack when the bearing was removed. If this occurs,
it can be difficult to remove the roll pin. Move the gear as necessary to remove the roll pin.
34. Remove the gear.
RCPH10TLB928AAL 32
RCPH10TLB929AAL 33
RCPH10TLB930AAL 34
84390833 11/10/2010
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37. Tap lightly on the end plate to move the end plate
ring and the end plate.
RCPH10TLB932AAL 35
RCPH10TLB931AAL 36
39. Use pry bars to lift the end plate evenly. Remove the
end plate.
RCPH10TLB933AAL 37
RCPH10TLB934AAL 38
84390833 11/10/2010
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41. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fas-
ten the two pieces together.
RCPH10TLB935AAL 39
42. Tighten the nuts evenly to compress the spring.

Compress the spring just enough to get access to
the snap ring.
RCPH10TLB936AAL 40
RCPH10TLB937AAL 41
CAS-2379 special tool.
RCPH10TLB938AAL 42
84390833 11/10/2010
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45. Remove the retainer plate.
RCPH10TLB939AAL 43
46. Remove the spring.
RCPH10TLB940AAL 44
47. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB941AAL 45
48. Follow the same procedure as Step 21and Step 22for

marking the top of the thrust plate and the steel and
friction discs as they are removed from the housing.
RCPH10TLB806AAL 46
84390833 11/10/2010
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protection.
50. Use compressed air in the port shown to remove the
piston.
RCPH10TLB803AAL 47
51. Remove the piston.
RCPH10TLB802AAL 48
52. Remove the sealing ring from the OD and the ID of

each piston.
RCPH10TLB805AAL 49
Next operation:
Shaft - Inspect (C.20.C)
84390833 11/10/2010
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Shaft - Inspect - Input shaft

1. Check the springs for broken or cracked coils. Com-
pare the heights of the two springs. If the two springs
are not approximately the same height, use new
springs. The correct spring height is approximately
85.5 mm (3.4 inches). Use new parts as required.
2. Check the sealing ring grooves (large and small) for
wear and damage. Use new parts as required.
3. 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. Use
new parts as required.
4. Check the splines on the output shaft for wear and
damage. Check the passages in the output shaft
to be sure that the passages are open and free of
foreign material. Use new parts as required.
5. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
6. If the clutch discs are to be used again, keep the
clutch packs separate and record which clutch pack
goes with each clutch. Use new parts as required.
RCPH10TLB804AAL 1
RCPH10TLB942AAL 2
84390833 11/10/2010
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7. Use a straight edge to check each steel disc (1) and

each friction disc (2) to be sure each part is flat. If
a steel disc (1) or a friction disc (2) is not flat, a new
part must be installed during assembly. If the friction
discs (2) are smooth or almost smooth, use new par
ts during assembly. If the friction material is damaged
or appears burned, use new parts during assembly.
Also, check the splines for wear. Inspect the steel
discs (1) for pitting, scoring, or other damage. If there
is any damage, use new parts during assembly. If
you will be using new friction discs, soak the friction
discs in clean transmission oi l for at least an hour
before assembly. If you are using the old friction
discs, make sure that the friction surfaces are coated RCPH10TLB943AAL 3
with transmission oil before assembly.

8. Inspect the bore and the shaft in the input shaft hous-
ing for damage that will cause leakage when the
clutch is assembled. Check the slots in the side of
the input shaft housing for damage from the tangs
on the steel discs. Use new par ts as required during
assembly.
9. Inspect the end of the clutch pack housing line bore
holes, if a rivet is coming out of the housing (arrow),
replace the rivet.
RCPH10TLB818AAL 4
Next operation:
Shaft - Assemble (C.20.C)
84390833 11/10/2010
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Shaft - Assemble
1. Use clean transmission oil to lubricate the sealing
rings. Install new sealing rings in each piston.
RCPH10TLB805AAL 1
2. Slide the 380001926 piston installation tool on the

input shaft.
RCPH10TLB820AAL 2
3. Use clean transmission oil to lubricate the edge and

the bore of the piston. Install the piston. Remove
the 380001926 piston installation tool from the input
shaft.
the bore of the piston. Install the piston.
RCPH10TLB806AAL 3
84390833 11/10/2010
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RCPH10TLB940AAL 4
6. Install the retainer plate. The side that has a raised

area around the bore goes down.
RCPH10TLB939AAL 5
7. Install the top piece of the CAS-2379 special tool.

Use the three threaded rods and nuts to fasten the
two pieces together. Tighten the nuts evenly to com-
press the spring just enough to get access to the
snap ring groove in the input shaft. Install the snap
ring. Loosen the nuts to relieve the spring tension
and remove the CAS-2379 special tool. Make sure
that the outer edge of the snap ring is seated in the
groove in the retainer plate.
RCPH10TLB961AAL 6
8. Install the pin.
RCPH10TLB962AAL 7
84390833 11/10/2010
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9. Use clean transmission oil to lubricate the thrust

washer. Install the thrust washer so that the notch in
the inner edge fits over the pin. Make sure that the
side with the oil grooves is up.
RCPH10TLB963AAL 8
10. Use clean transmission oil to lubricate the needle

bearings. Install the needle bearing.
RCPH10TLB964AAL 9
11. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the refer-
ence mark on top of the plate made during disas-
sembly is facing towards the gear.
RCPH10TLB971AAL 10
12. Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one fric-
tion disc with the reference mark on top towards the
gear.
RCPH10TLB972AAL 11
NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before
assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil
before assembly.
84390833 11/10/2010
C.20.C / 68

the steel disc towards the gear.
RCPH10TLB048ABL 12
14. Repeat steps 12 and 13 until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
15. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs
are down. Put the clutch pack on the clutch housing
as shown so that the tabs with the reference marks
on the steel discs are almost ready to start into the
slot in the clutch housing with the reference mark.
RCPH10TLB965AAL 13
16. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all
the tabs are going into the slots. Make sure all of
the tabs with reference marks are aligned in the slot
in the housing with the reference mark. Also make
sure that the gear moves down with the clutch pack.
RCPH10TLB966AAL 14
17. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move
the thrust plate down evenly just far enough to get
access to the snap ring groove in the clutch housing.
RCPH10TLB967AAL 15
84390833 11/10/2010
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18. Install the snap ring.
RCPH10TLB968AAL 16
19. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When
the thrust plate is up all the way, the inner edge of
the snap ring will fit in this recess.
RCPH10TLB969AAL 17

side with the oil grooves is down.
RCPH10TLB927AAL 18
21. Use an acceptable driver to drive the bearing onto

the input shaft until the bearing makes contact with
the thrust washer.
RCPH10TLB970AAL 19
84390833 11/10/2010
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RCPH10TLB924AAL 20
NOTE: For clarity of the Teflon sealing ring installation procedure the following photos do not show the clutch pack,
gear, spacer, bearing, and snap ring installed on the input shaft. Steps 1 through 22 must be performed before in-
stalling the Teflon sealing ring on the input shaft.
23. Place the 380001929 spacer into the 380001933 ex-
pander/protector.
RCPH10TLB821AAL 21
24. Slide the 380001933 expander/protector and the

spacer onto the shaft. Heat the Teflon sealing ring
to 80° to 100° C (176° to 212° F). Install the Teflon
sealing ring onto the expander/protector.
RCPH10TLB831AAL 22
25. Install the 380001928 pusher over the expander/pro-

tector and slide the sealing ring until it reaches the
groove in the shaft. Remove the pusher, protector,
and spacer from the shaft.
RCPH10TLB838AAL 23
84390833 11/10/2010
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26. Install the end of the 380001927 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.
RCPH10TLB839AAL 24
27. 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.
RCPH10TLB840AAL 25

pander/protector.
RCPH10TLB822AAL 26
29. Slide the expander/protector and the spacer onto the

shaft. Heat the Teflon sealing ring to 80° to 100° C
(176° to 212° F). Install the Teflon sealing ring onto
the expander/protector.
RCPH10TLB832AAL 27
84390833 11/10/2010
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groove in the shaft. Remove the pusher, expander/
protector, and spacer from the shaft.
RCPH10TLB837AAL 28

RCPH10TLB839AAL 29
from the shaft.
RCPH10TLB840AAL 30

pander/protector.
RCPH10TLB823AAL 31
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RCPH10TLB833AAL 32

RCPH10TLB836AAL 33

RCPH10TLB839AAL 34
from the shaft.
RCPH10TLB840AAL 35
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pander/protector.
RCPH10TLB824AAL 36

RCPH10TLB834AAL 37

RCPH10TLB835AAL 38

RCPH10TLB839AAL 39
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from the shaft.
RCPH10TLB840AAL 40
43. Put the input shaft in the bottom piece of the

CAS2379 special tool so that the reverse clutch
housing is up. Slide the 380001926 piston installa-
tion tool on the input shaft.
RCPH10TLB825AAL 41

the bore of the piston. Install the piston. Remove the
piston installation tool.
45. Install the sleeve.
RCPH10TLB882AAL 42
46. Install the pressure plate and the spring. The raised
area around the bore of the pressure plate must go
down. The side that has the groove around the bore
should face up. The outer edge of the snap ring must
fit in the groove after the parts are assembled.
RCPH10TLB881AAL 43
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47. Install the top piece of the CAS-2379 special tool.

Use the three threaded rods and nuts to fasten the
two pieces together. Tighten the nuts evenly to com-
press the spring just enough to get access to the
snap ring groove in the input shaft. Install the snap
ring. Loosen the nuts to relieve the spring tension
and remove the CAS-2379 special tool. Make sure
that the outer edge of the snap ring is seated in the
groove in the retainer plate.
RCPH10TLB973AAL 44
48. Install the pin.
RCPH10TLB974AAL 45

side with the oil grooves is up.
RCPH10TLB975AAL 46
50. Use clean transmission oil to lubricate the needle

bearing. Install the needle bearing.
RCPH10TLB793AAL 47
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51. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the refer-
ence mark on top of the plate made during disas-
sembly is facing towards the gear.
RCPH10TLB971AAL 48
NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before
assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil
before assembly.
the steel disc towards the gear followed by one fric-
tion disc with the reference mark on top towards the
gear.
RCPH10TLB972AAL 49

the steel disc towards the gear.
RCPH10TLB048ABL 50
54. Repeat steps 52 and 53until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
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55. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs
are down. Put the clutch pack on the clutch housing
as shown so that the tabs with the reference marks
on the steel discs are almost ready to start into the
slot in the clutch housing with the reference mark.
RCPH10TLB976AAL 51
56. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all
the tabs are going into the slots. Make sure all of
the tabs with reference marks are aligned in the slot
in the housing with the reference mark. Also make
sure that the gear moves down with the clutch pack.
RCPH10TLB977AAL 52
57. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move
the thrust plate down evenly just far enough to get
access to the snap ring groove in the clutch housing.
RCPH10TLB978AAL 53
RCPH10TLB979AAL 54
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59. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When
the thrust plate is up all the way, the inner edge of
the snap ring will fit in this recess.
RCPH10TLB980AAL 55
60. Use clean transmission oil to lubricate the spacer (1)

and install the spacer (1) on the input shaft. Install the
bearing (2) onto the input shaft. Use an acceptable
driver (3) to drive the bearing onto the input shaft until
the bearing (2) makes contact with the spacer (1)
RCPH10TLB981AAL 56
RCPH10TLB919AAL 57
gear, spacer, bearing, and snap ring installed on the input shaft. Steps 43 through 61 must be performed before
installing the Teflon sealing ring on the input shaft.
pander/protector.
RCPH10TLB826AAL 58
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63. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80° to 100°
C (176° to 212° F). Install the Teflon sealing ring onto
the 380001428 expander/protector.
RCPH10TLB829AAL 59

RCPH10TLB830AAL 60

RCPH10TLB841AAL 61
from the shaft.
RCPH10TLB827AAL 62
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67. Measure the clutch disc clearance for each clutch

assembly. The end cover must be all the way up
against the snap ring. Use a feeler gauge to mea-
sure the distance between the end cover and the first
metal disc. The distance must be 2.3 to 4.3 mm (0.09
to 0.17 inch). If the distance is not within specifica-
tion, the clutch is probably assembled wrong. Clutch
plate wear will not cause the distance to be outside
the specification.
RCPH10TLB982AAL 63
NOTE: The art shows a clutch pack without the PTO through shaft, the procedures for steps 68 and 69 are the same.
psi) to the forward clutch passage. Listen to hear
the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward
reverse gear. The reverse gear must turn freely on
the input shaft . If the clutches do not work correctly,
disassemble the clutches to find the problem.
RCPH10TLB054GAL 64
Clutch pack
1. Forward clutch passage 4. Forward clutch pack 7. Input shaft
2. Reverse clutch passage 5. Reverse clutch pack
3. Forward gear 6. Reverse gear

psi) to the reverse clutch passage. Listen to hear
the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The reverse
forward gear. The forward gear must turn freely on
disassemble the clutches to find the problem.
Next operation:
Shaft - Disassemble (C.20.C)
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Shaft - Disassemble - Secondary shaft

1. Support the secondary shaft on blocks on the bench
as shown.
RCPH10TLB765AAL 1

gear and the bearing. If the bearing separator has a
beveled edge, the beveled edge must be down. Do
not tighten the bearing separator so much that the
bearing separator pushes the synchronizer down. In-
stall an acceptable puller on the bearing separator.
Use a shaft protector between the puller and the end
of the secondary shaft. Use molydisulfide grease to
lubricate the shaft protector and the end of the puller.
Make sure that you pull only until the bearing is free.
Pulling any farther can damage the parts .
RCPH10TLB766AAL 2
RCPH10TLB767AAL 3
RCPH10TLB768AAL 4
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5. Remove the third gear from the shaft.
RCPH10TLB769AAL 5
6. Remove the synchronizer assembly.
RCPH10TLB770AAL 6
7. Use a feeler gauge to measure the clearance be-

tween the clutch ring (1)and the edge of the tapered
friction ring (2). This clearance (3) should be approx-
imately 1.0 mm (0.04 inch) with used parts in good
condition. If the clearance is 0.5 mm (0.02 inch) or
less, use new parts as required. Repeat the mea-
surement for the opposite side of the synchronizer
assembly before disassembly.
RCPH10TLB810AAL 7
8. Remove the clutch ring from each side of the syn-

chronizer assembly.
RCPH10TLB817AAL 8
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9. Remove the tapered friction ring from each side of

the synchronizer assembly.
RCPH10TLB816AAL 9
10. Inspect the clutch ring teeth for wear, wear in excess
of 0.5 mm (0.02 inch) the ring must be replaced.
RCPH10TLB815AAL 10
NOTE: The parts may fly out of the hub when you do the following step. Putting the synchronizer assembly in a
cardboard box during this step can prevent loss of parts.
11. Remove the sleeve from the synchronizer hub.
When the sleeve is removed from the synchronizer
hub the spring plates, hub pins and hub springs will
be released from the synchronizer hub. Be careful
not to lose any of these parts.
RCPH10TLB893AAL 11
12. This photo shows the relationship of the balls (1) , the
spring plates (2) , the springs (3) , and the hub (4)
RCPH10TLB949AAL 12
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13. Remove fourth gear.
RCPH10TLB771AAL 13
14. Turn the secondary shaft over so that second gear is

at the top. You can use a vise with soft jaws to hold
the secondary shaft in position.
RCPH10TLB772AAL 14
15. Install a bearing separator under the bearing race as

shown. If the bearing separator has a beveled edge,
the beveled edge must be down. Do not tighten the
bearing separator so much that the bearing separa-
tor pushes the synchronizer down. Install an accept-
able puller on the bearing separator. Use a shaft
protector between the puller and the end of the sec-
ondary shaft . Use molydisulfide grease to lubricate
the shaft protector and the end of the puller. Make
sure that you pull only until the bearing race is free.
Pulling any farther can damage the parts.
RCPH10TLB773AAL 15
16. Remove the bearing race from the shaft.
RCPH10TLB774AAL 16
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17. Remove the snap ring from the shaft.
RCPH10TLB775AAL 17
18. Remove the shim(s) and the thrust washer.
RCPH10TLB776AAL 18
19. Remove the pin.
RCPH10TLB777AAL 19
20. Remove second gear.
RCPH10TLB778AAL 20
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RCPH10TLB779AAL 21
22. Remove the synchronizer ring and the first-second

synchronizer as an assembly.
RCPH10TLB780AAL 22
23. Use a feeler gauge to measure the clearance be-

tween the bottom of the teeth on the synchronizer
ring and the edge of the sleeve on the outside of
the synchronizer assembly. This clearance should
be approximately 1.0 mm (0.04 inch) with used parts
in good condition. If the clearance is 0.5 mm (0.02
inch) or less, use new parts as required. Repeat the
measurement for the opposite side of the synchro-
nizer assembly before disassembly.
24. Remove the steel ring (1) and the bronze ring (2)to-
gether.
RCPH10TLB946AAL 23
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25. Remove the tapered friction ring.
RCPH10TLB947AAL 24
26. Turn the synchronizer assembly over and remove the

synchronizer ring from the other side.
RCPH10TLB945AAL 25
27. Remove the steel ring (1) and the bronze ring (2)to-
gether.
RCPH10TLB946AAL 26
28. Remove the tapered friction ring.
RCPH10TLB947AAL 27
NOTE: The parts will fly out of the hub when you do the following step. Putting the synchronizer assembly in a
cardboard box during this step can prevent loss of parts.
84390833 11/10/2010
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29. Support the sleeve on blocks. Push down on the hub

while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB948AAL 28
30. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 29
31. Remove first gear.
RCPH10TLB781AAL 30
32. If equipped with four wheel drive, remove the snap

ring from the four wheel drive gear.
RCPH10TLB782AAL 31
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33. Remove the four wheel drive gear, if equipped. On

two-wheel drive transmissions, there is a raised area
on the shaft.
RCPH10TLB783AAL 32
34. If equipped with four wheel drive, do not remove the

snap ring for the four wheel drive gear unless the
snap ring is damaged.
RCPH10TLB784AAL 33
Next operation:
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Shaft - Inspect - Secondary shaft

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:
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Shaft - 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.
84390833 11/10/2010
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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:
Shaft - Adjust (C.20.C)
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Shaft - 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
84390833 11/10/2010
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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.
84390833 11/10/2010
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13. Install the synchronizer assembly onto the shaft.
RCPH10TLB770AAL 12
14. Install the third gear on the shaft.
RCPH10TLB769AAL 13

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:
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Shaft - 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

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-
the end of the puller. Pull the bearing from the pri-
mary shaft.
RCPH10TLB955AAL 2
RCPH10TLB956AAL 3
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-
the end of the puller. Pull the bearing race from the
primary shaft.
RCPH10TLB958AAL 5
Next operation:
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Shaft - Inspect - Primary shaft

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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Shaft - Assemble - Primary shaft

1. Use an acceptable driver to drive the bearing race all
the way onto the primary shaft.
RCPH10TLB959AAL 1

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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RCPH10TLB954AAL 5
Next operation:
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Shaft - 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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Shaft - 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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Shaft - 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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Shaft - 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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Shaft - 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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Shaft - 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
RCPH10TLB040ABL 3
4. Install the plug.
RCPH10TLB039ABL 4
84390833 11/10/2010
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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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Shaft - 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
RCPH10TLB886AAL 4
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5. Remove the special washer.
RCPH10TLB887AAL 5
6. Remove the springs.
RCPH10TLB888AAL 6
RCPH10TLB889AAL 7
8. Remove the two O-rings from the shaft.
RCPH10TLB890AAL 8
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9. Remove the two Teflon sealing rings from the shaft.
RCPH10TLB890AAL 9
Next operation:
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Shaft - 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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Shaft - 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-

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

RCPH10TLB897AAL 5

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.
CAS2771-2 expander/protector.
RCPH10TLB900AAL 9
10. Install the CAS2327 pusher over the expander/pro-

RCPH10TLB902AAL 10
11. Install the end of the CAS2771-1 seal compressor

RCPH10TLB903AAL 11
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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:
Housing - Disassemble (C.20.C)
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Housing - Disassemble
NOTE: Some photos may not represent your transmission, the procedures are the same.
1. Fasten the rear housing to acceptable support equip-
ment . It is recommended that you use equipment
that will let you rotate the transmission.
RCPH10TLB689AAL 1
2. Remove the drain plug and drain the oil from the
transmission.
RCPH10TLB690AAL 2
NOTE: The four-wheel drive transmission is shown. On two-wheel drive transmissions, the drain plug is at the rear
of the transmission.
3. Remove the two cap screws that fasten the cover for
the oil screen. Remove the cover.
RCPH10TLB693AAL 3
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4. Remove the oil screen and the O-ring.
RCPH10TLB695AAL 4
NOTE: Steps 8 through 10 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
mission, go to step 11.
5. Remove the oil filter.
RCPH10TLB698AAL 5
6. DO NOT remove the plug unless the plug is leaking.

The plug is sealed with Loctite 542 or Loctite 262
and is difficult to remove. If removal is necessary,
clean all oil from the threads and apply Loctite 542
or Loctite 262 (red) before installation.
RCPH10TLB703AAL 6
7. Remove the fitting for the oil filter.
RCPH10TLB699AAL 7
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8. Remove the spool.
RCPH10TLB701AAL 8
RCPH10TLB702AAL 9
10. Use a blind hole puller to remove the four-wheel drive

priority valve.
RCPH10TLB907AAL 10
NOTE: The four-wheel drive priority valve is adjusted at the factory. DO NOT try to disassemble or adjust the four-
wheel drive priority valve. If any of the parts are damaged, use a new four-wheel drive priority valve.
11. Remove the dipstick.
RCPH10TLB908AAL 11
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12. Remove the dipstick tube.
RCPH10TLB909AAL 12
13. Remove the fitting for the dipstick tube.
RCPH10TLB808AAL 13
14. Remove the bolts that fasten the transmission control

valve to the front housing.
RCPH10TLB847AAL 14
15. Remove the transmission control valve and the gas-

ket.
16. Remove the three bolts that fasten the four-wheel
drive valve to the front housing.
RCPH10TLB848AAL 15
17. Remove the four-wheel drive valve and the gasket.
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18. Remove the seven bolts that fasten the pump mount
to the rear housing.
RCPH10TLB849AAL 16
19. Remove the pump mount housing.
RCPH10TLB850AAL 17
20. Use a plastic mallet and tap the through shaft out of
the transmission rear housing.
RCPH10TLB851AAL 18
21. Pull the shaft from the transmission.
RCPH10TLB852AAL 19
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22. Remove the seal from the shaft.
RCPH10TLB814AAL 20
23. Remove the snap ring from the pump shaft.
RCPH10TLB813AAL 21
24. Use a suitable driver and remove the bearing from

the pump drive shaft.
RCPH10TLB812AAL 22
25. Remove the pressure sensor switch from the brake

housing.
RCPH10TLB853AAL 23
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26. Remove the solenoid from the brake housing.
RCPH10TLB854AAL 24
27. Make sure the orifice remains in the brake housing.
RCPH10TLB855AAL 25
28. Remove the three Allen head bolts that fasten the
shifter housing to the rear cover. Remove the shifter
assembly and the O-ring.
RCPH10TLB856AAL 26
29. Remove the bolt and the output flange.
RCPH10TLB857AAL 27
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30. Remove the output flange.
RCPH10TLB858AAL 28
31. Remove three of the parking brake cover bolts.

Loosen the remaining three bolts evenly one turn
at a time to relieve spring pressure in the brake
housing.
RCPH10TLB859AAL 29
NOTE: Housing is under spring pressure, failure to follow instructions will result in serious injury and damage to
equipment.
32. Remove the brake discs from the brake housing.
RCPH10TLB859AAL 30
33. Remove the brake disc flange from the output shaft.
RCPH10TLB860AAL 31
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34. Remove the rear cover mounting bolts.
RCPH10TLB861AAL 32
35. At the three prying points, use pry bars and loosen
the rear cover from the transmission.
RCPH10TLB864AAL 33
36. Remove the rear cover from the transmission.
RCPH10TLB865AAL 34
37. Remove the seal from the rear cover.

38. Use a punch to remove the pins that fasten the shift
collars to the shift rods.
RCPH10TLB723AAL 35
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39. Remove the shift collars from the shift rods.
RCPH10TLB725AAL 36
40. Remove the two Allen head bolts that hold the plate
between the two shift rods.
RCPH10TLB726AAL 37
41. Remove the plate.
RCPH10TLB728AAL 38
42. Remove the two shift interlock balls from the groove
between the two shift rods.
RCPH10TLB729AAL 39
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43. Remove one of the detent plugs from the right-hand

side of the rear housing.
RCPH10TLB730AAL 40
44. Remove the detent spring.
RCPH10TLB731AAL 41
45. Remove the detent ball.
RCPH10TLB049ABL 42
46. Repeat steps 43 through 45 to remove the other de-

tent plug, spring, and ball.
NOTE: Rotate the transmission in the stand so the shafts will not fall out when the snap ring is removed.
47. Push the secondary shaft to the rear so that there is
clearance between the snap ring and the rear hous-
ing. Remove the snap ring.
RCPH10TLB732AAL 43
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NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you
remove the secondary shaft from 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 removal of the secondary shaft.
48. Remove all of the housing bolts that are fastened
from the rear housing to the front housing. There
are 13 of these bolts on the four-wheel drive and 14
on the two-wheel drive. On the two-wheel drive, two
of the bolts are longer than the others. Record the
locations of these two.
RCPH10TLB704AAL 44
49. Rotate the transmission so that the front housing is

up. On four-wheel drive transmissions only, there are
three bolts fastened from the front housing to the rear
housing. Remove these bolts.
RCPH10TLB717AAL 45
NOTE: Steps 50 through 57 are for four-wheel drive transmissions only. If you are working on a two-wheel drive
transmission, go to step 58.
50. Install two bolts in the four-wheel drive flange as
shown. Use a pry bar between the two bolts to hold
the four-wheel drive flange while you remove the bolt
from the four-wheel drive shaft.
RCPH10TLB906AAL 46
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51. Remove the washer.
RCPH10TLB705AAL 47
52. Remove the four-wheel drive flange.
RCPH10TLB706AAL 48
53. Remove the O-ring from the four-wheel drive flange.
RCPH10TLB707AAL 49
54. Remove the three bolts that fasten the cover to the
front housing.
RCPH10TLB708AAL 50
84390833 11/10/2010
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55. Remove the cover.
RCPH10TLB710AAL 51
56. Remove the O-ring from the cover.
RCPH10TLB711AAL 52
57. Remove the seal from the cover.
RCPH10TLB020ABL 53
58. Make a mark across the joint between the oil pump
and the torque converter housing so that the oil pump
can be aligned the same way during installation.
RCPH10TLB866AAL 54
84390833 11/10/2010
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59. Remove the six bolts that fasten the oil pump in po-
sition.
RCPH10TLB867AAL 55
60. Use two pry bars to lift the oil pump evenly until the
oil pump can be removed.
RCPH10TLB713AAL 56
61. Remove the oil pump.
RCPH10TLB714AAL 57
62. Pull up the input shaft to get clearance as you release

the snap ring.
RCPH10TLB715AAL 58
84390833 11/10/2010
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RCPH10TLB716AAL 59
64. Fasten acceptable lifting equipment to the front hous-

ing as shown. Use pry bars at both ends of the hous-
ings to separate the front housing from the rear hous-
ing.
RCPH10TLB718AAL 60
65. As you lift the front housing, continue to use the pry
bar to make sure that the front housing comes up
evenly. Also, it will probably be necessary to hit the
end of the four-wheel drive shaft, if so equipped, and
the end of the input shaft with a soft hammer so that
the two shafts come down out of the front housing
and stay with the rear housing.
RCPH10TLB910AAL 61
NOTE: The bearings in steps 66 and 67 are a close slip fit. If a bearing is difficult to remove, the bearing is probably
not straight in the bore or on the shaft. Push the bearing back into the installed position and try again.
66. The bearing for the primary shaft and the bearing for
the secondary shaft can stay with either the shafts or
the front housing. Remove the two bearings.
RCPH10TLB720AAL 62
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67. On machines with four-wheel drive, remove the four-

wheel drive shaft bearing from the front housing.
RCPH10TLB911AAL 63
68. Remove the tube from the front housing only if the
tube is damaged or leaking.
RCPH10TLB027ABL 64
69. Remove the three O-rings from the flange of the rear
housing.
RCPH10TLB920AAL 65
70. On machines with four-wheel drive, remove the four-

wheel drive shaft.
RCPH10TLB720AAL 66
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71. Remove the input shaft and the reverse shaft to-
gether.
RCPH10TLB921AAL 67
NOTE: Make a mark on the top end of the reverse shaft so that you can install the reverse shaft with the same end
up during assembly.
72. Rotate the rear housing so that the open side is up.
Connect acceptable lifting equipment to the top gear
on the secondary shaft.
RCPH10TLB912AAL 68
73. Use the lifting equipment to begin lifting the sec-

ondary shaft while you use your hands to lift the pri-
mary shaft. At the same time, move the primary
shaft back and forth to keep the primary shaft mov-
ing freely. It can be necessary to tap the ends of the
shift rods (from below the rear housing) so that the
shift rod and fork assemblies continue to move freely.
When the primary shaft is free of the rear housing
and the secondary shaft, remove the primary shaft.
RCPH10TLB913AAL 69
74. Continue to lift the secondary shaft until you can

move the secondary shaft out of the shift forks. Then
remove the secondary shaft.
RCPH10TLB914AAL 70
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75. Remove the shift rod and fork assembly for first and
second gear from the rear housing.
RCPH10TLB915AAL 71
76. Remove the shift rod and fork assembly for third and
fourth gear from the rear housing. Remember that
this assembly was installed in the bore nearer the
top of the rear housing.
RCPH10TLB916AAL 72
NOTE: Steps 77 and 78 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
77. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 73
RCPH10TLB917AAL 74
84390833 11/10/2010
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79. It is not necessary to remove the test port plugs (1),

the breather (2), or the temperature sender (3) from
the rear housing unless these parts are leaking or
damaged.
RCPH10TLB918AAL 75
80. Inspect the input shaft bore in the rear housing. If

there are grooves from the sealing rings, you must
use a new rear housing. Remove any sharp edges
at the ends of the input shaft bore and at the oil dis-
tribution holes.
81. Remove the four-wheel drive clutch tube (four-wheel
drive machines only) from the front housing only if
the front housing must be replaced or if the tube is
leaking or damaged.
RCPH10TLB023ABL 76
82. Remove the three Allen head bolts that fasten the
valve plate to the front housing.
RCPH10TLB025ABL 77
83. Remove the valve plate from the front housing.
RCPH10TLB024ABL 78
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84. Remove the gasket.
RCPH10TLB026ABL 79
Next operation:
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Housing - Disassemble - Shifter housing

1. Use side cutters as shown to release the catch on
the band that fastens the boot to the shifter housing.
Remove the band.
RCPH10TLB012ABL 1
2. Remove the boot from the shifter housing.
RCPH10TLB013ABL 2
3. Remove the two pins (one on either side of the shifter

housing). Use a screwdriver to lift each pin as shown
until you can reach the pin with your fingers. Then
pull the pin out.
RCPH10TLB013ABL 3
4. Remove the snap ring from the shift lever.
RCPH10TLB016ABL 4
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5. Remove the bushing from the shift lever.
RCPH10TLB019ABL 5
RCPH10TLB018ABL 6
7. Remove the shift lever from the shifter housing.
RCPH10TLB017ABL 7
Next operation:
Housing - Disassemble (C.20.C)
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Housing - Disassemble - Shift rods and shift forks

1. If disassembly is required, remove the roll pins and
separate the shift forks from the shift rods. Make sure
that you remember how the parts are assembled and
which parts go together. The forks are the only parts
that are not interchangeable. Inspect all parts for
burrs and excessive wear. Assembly is the reverse
of disassembly.
RCPH10TLB944AAL 1
Next operation:
Housing - Assemble (C.20.C)
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Housing - Assemble - Shifter housing

1. Apply lithium grease to the ball of the shift lever. In-
stall the shift lever in the shifter housing.
RCPH10TLB017ABL 1
2. The correct alignment of the shift lever and the shifter

housing is shown above. The slot (1) in the shift lever
must be toward the flat side (2) of the flange on the
shifter housing. The slots (3) on each side of the shift
lever must be aligned with the holes (4) in each side
of the shifter housing.
RCPH10TLB021ABL 2
RCPH10TLB018ABL 3
4. Install the bushing.
RCPH10TLB019ABL 4
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5. Put the snap ring on the shift lever. Use a deep

well socket to push the snap ring into the snap ring
groove.
RCPH10TLB015ABL 5
6. Install the pins through the holes in the shifter hous-

ing so that the pins engage the slots in the shift lever.
RCPH10TLB013ABL 6
7. Install the boot so that the end of the boot fits over
the ends of the pins. Be careful so that the pins do
not fall out during this step.
RCPH10TLB013ABL 7
8. Install the band or clamp on the boot. Use the side

cutters to engage the catch on the band.
RCPH10TLB012ABL 8
Next operation:
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Housing - Assemble - Transmission housing

1. If the four-wheel drive clutch tube (four-wheel drive
machine only) was removed from the front housing,
install the four-wheel drive clutch tube. Tighten the
fittings to a torque of 40 Nm (265 pound-inches).
RCPH10TLB023ABL 1
2. Install plugs (foam ear plugs work well) in the three oil
passages in the edge of the rear housing. Scrape all
sealing material from the sealing surface of the rear
housing. Prepare the sealing surface by rubbing with
a 3M Scotch-Brite fiber pad or equivalent. DO NOT
use steel wool or anything that can leave material
on the sealing surface. Flush the rear housing with
solvent.
RCPH10TLB028ABL 2
3. Install plugs (foam ear plugs work well) in the three

oil passages in the edge of the front housing. (The
plugs have not been installed in the picture above.)
Scrape all sealing material from the sealing surface
of the front housing. Prepare the sealing surface by
rubbing with a 3M Scotch-Brite fiber pad or equiv-
alent. DO NOT use steel wool or anything that can
leave material on the sealing surface. Flush the front
housing with solvent.
RCPH10TLB023ABL 3
4. Install the gasket for the valve plate on the front hous-
ing.
RCPH10TLB026ABL 4
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5. Put the valve plate into position.
RCPH10TLB024ABL 5
6. Install the three Allen head bolts to fasten the valve

plate to the front housing. Tighten the Allen head
bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB025ABL 6
7. If the test port plugs (1), the breather (2), and the
temperature sender (3) were removed from the rear
housing, install these parts. Tighten the test port
plugs (1) to a torque of 23 Nm (204 pound-inches).
RCPH10TLB918AAL 7
8. Put the bearing for the four-wheel drive shaft into
position in the rear housing.
RCPH10TLB917AAL 8
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9. Install the four-wheel drive clutch gear so that the

side with the lugs is up.
RCPH10TLB733AAL 9
10. Connect acceptable lifting equipment to the top gear

on the secondary shaft. Lift the secondary shaft over
the rear housing. Engage the shift forks with the syn-
chronizers as shown. Begin to lower the assembly
into the rear housing.
RCPH10TLB029ABL 10
11. As you lower the assembly into the rear housing, also
begin to install the primary shaft so that the gears on
the primary shaft go into mesh with the gears on the
secondary shaft. Continue to lower the parts, making
sure that each part goes into the correct bore in the
rear housing. (Remember that the shift rod and fork
assembly for third and fourth gear goes into the bore
nearer the top of the rear housing). When all of the
parts are in position, disconnect the lifting equipment.
RCPH10TLB913AAL 11
12. 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. Install the snap
ring.
RCPH10TLB732AAL 12
NOTE: In steps 13 through 15, the photos show the upper detent parts already installed. It is necessary for you to
install both the upper and lower detent parts according to the instructions in the procedure. Make sure that you start
with both shift rods in the NEUTRAL position.
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13. Install the lower detent ball.
RCPH10TLB049ABL 13
14. Install the lower detent spring.
RCPH10TLB731AAL 14
15. Install the copper washer on the detent plug. Install

the lower detent plug. Tighten the lower detent plug
to a torque of 80 Nm (59 pound-feet).
RCPH10TLB730AAL 15
16. Repeat steps 13 through 15 to install the upper de-

tent ball, spring, copper washer, and plug.
17. Install the two detent balls in the groove between the
two shift rods.
RCPH10TLB729AAL 16
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18. Install the plate over the two detent balls.
RCPH10TLB728AAL 17
19. Apply Loctite 542 or Super bond 321 to the threads

of the two Allen head bolts. Install the two Allen head
bolts to fasten the plate in position. Tighten the two
Allen head bolts to a torque of 50 Nm (37 pound-
feet).
RCPH10TLB727AAL 18
20. Install the shift collars on the shift rods.
RCPH10TLB725AAL 19
21. Install the pins to fasten the shift collars to the shift
rods.
RCPH10TLB724AAL 20
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22. Scrape all sealing material from the sealing surface

of the rear cover. Prepare the sealing surface by
rubbing with a 3M Scotch-Brite fiber pad or equiv-
alent. DO NOT use steel wool or anything that can
leave material on the sealing surface. Wipe the seal-
ing surface with Loctite Safety Solvent or equivalent.
Apply a layer of Loctite 518 or Super bond 539 to the
sealing surface.
23. Put the rear cover in position. Make sure that the
dowel is installed in the rear housing and through the
hole in the rear cover. Install the seven bolts to fasten
the rear cover to the rear housing. If necessary, tap
the rear cover with a soft faced hammer to close the
gap between the rear housing and the rear cover
before you tighten the bolts. Tighten the seven bolts
sequentially to a torque of 50 Nm (37 pound-feet).
RCPH10TLB861AAL 21
NOTE: The above photo shows the shifter installed, the shifter should not be installed at this time.
24. Install a new O-ring on the shifter assembly. Use
clean oil to lubricate the O-ring. Put the shifter as-
sembly into position on the rear cover.
RCPH10TLB722AAL 22
25. Install the three Allen head bolts to fasten the shifter
assembly to the rear cover. Tighten the three Allen
head bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB721AAL 23
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26. If the tube was removed from the front housing, in-
stall the tube now. Tighten the hollow bolts to a
torque of 40 Nm (354 pound-inches).
RCPH10TLB027ABL 24
27. Install the input shaft and the reverse shaft together
as shown. If you are using the same reverse shaft,
make sure that you install it with the same end up as
when it was removed.
RCPH10TLB921AAL 25
28. On machines with four-wheel drive, install the four-

wheel drive shaft. Use clean transmission oil to lu-
bricate the bearing surfaces on the four-wheel drive
shaft. Make sure that the four-wheel drive shaft goes
through the four-wheel drive clutch gear, the thrust
washer, and the bearing.
RCPH10TLB719AAL 26
29. Wipe the sealing surface of the rear housing and the
front housing with Loctite Safety Solvent or equiva-
lent. Apply a layer of Loctite 518 or Super bond 529
to the sealing surface of the rear housing.
RCPH10TLB030ABL 27
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30. Remove the three plugs from the oil passages in the
rear housing (see arrows). Install three new O-rings
for the oil passages. Remove the three plugs from
the oil passages in the front housing.
RCPH10TLB920AAL 28
31. Use clean transmission oil to lubricate the bearing for

the primary shaft and the bearing for the secondary
shaft. Install the bearings.
RCPH10TLB720AAL 29
32. Install the front housing on the rear housing. Make

sure that the bearings on the shafts go straight into
the bores in the front housing. Push the front housing
all the way down on the rear housing.
RCPH10TLB718AAL 30
33. Install all of the housing bolts that fasten the rear
housing to the front housing. There are 13 of these
bolts on four-wheel drive transmissions and 14 on
two-wheel drive transmissions. Tighten the bolts
evenly until the front housing and rear housing are
together, then tighten the bolts to a torque of 50 Nm
(37 pound-feet).
RCPH10TLB704AAL 31
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34. Install the three bolts that fasten from the front hous-
ing to the rear housing. Tighten the bolts to a torque
of 50 Nm (37 pound-feet).
RCPH10TLB033ABL 32
35. Use clean transmission oil to lubricate the bearing for

the four-wheel drive shaft. Install the bearing on the
four-wheel drive shaft.
RCPH10TLB034ABL 33
36. Use the CAS-2381 special tool to install a new seal in

the cover. Push just until the seal stops moving. DO
NOT use excessive force. Fill the cavity under the
lip of the seal with high temperature wheel bearing
grease.
RCPH10TLB022ABL 34
37. Install a new O-ring on the cover. Use clean trans-

mission oil to lubricate the O-ring.
RCPH10TLB711AAL 35
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38. Install the cover in the front housing.
RCPH10TLB710AAL 36
39. Install the three bolts that fasten the cover to the front
housing. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB709AAL 37
40. Install a new O-ring in the four-wheel drive flange.

Use clean transmission oil to lubricate the O-ring.
RCPH10TLB707AAL 38
41. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB706AAL 39
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42. Install the washer.
RCPH10TLB705AAL 40
43. Install and tighten the cap screw in the four-wheel

drive shaft to a torque of 139 Nm (103 pound-feet).
RCPH10TLB906AAL 41
44. Pull the input shaft toward the front of the transmis-
sion to get clearance for the snap ring.
RCPH10TLB031ABL 42
45. Install the snap ring on the bearing.
RCPH10TLB032ABL 43
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46. It will be easier to install the oil pump if you use a

guide stud as shown above. You can make a guide
stud by cutting the head from an M8 bolt.
RCPH10TLB036ABL 44
47. Use clean transmission oil to lubricate the O-ring on

the oil pump. Install the oil pump. Make sure that the
alignment marks that you made during disassembly
are aligned.
RCPH10TLB035ABL 45
48. If you used a guide stud, remove the guide stud. In-
stall the six bolts that fasten the oil pump in posi-
tion. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB712AAL 46
49. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 47
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50. Install a reaction plate first.
RCPH10TLB876AAL 48
51. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 49
52. Install the back plate as shown.
RCPH10TLB874AAL 50
RCPH10TLB873AAL 51
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54. Install the brake housing.
RCPH10TLB872AAL 52
55. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50 Nm (37 pound feet).
RCPH10TLB871AAL 53
56. Install the flange and a new O-ring.
RCPH10TLB869AAL 54
57. Install the bolt and washer.
RCPH10TLB868AAL 55
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58. Torque bolt to 139 Nm (103 pound feet).
RCPH10TLB870AAL 56
59. Make sure the orifice is in the brake housing, install

new O-rings.
RCPH10TLB855AAL 57
60. Install the brake solenoid, torque the solenoid to 20

Nm (15 pound feet).
RCPH10TLB854AAL 58
61. Install the pressure sensor switch into the brake

housing.
RCPH10TLB853AAL 59
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62. Slide the expander/protector onto the pump drive

shaft.
RCPH10TLB842AAL 60

380001428 expander/protector.
RCPH10TLB843AAL 61

RCPH10TLB844AAL 62

RCPH10TLB845AAL 63
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from the shaft.
RCPH10TLB846AAL 64
67. Install the bearing and snap ring on the pump drive
shaft, install the shaft in the rear housing.
68. Install the PTO shaft into the transmission.
RCPH10TLB850AAL 65

of the pump mount and rear cover. Prepare the sea
ling surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or any-
thing that can leave material on the sealing surface.
Wipe the sealing surface with Loctite Safety Solvent
or equivalent. Apply a layer of Loctite 518 or Super
bond 539 to the sealing surface.
70. Install the pump mount on the rear housing, torque
bolts to 50 Nm (37 pound-feet).
RCPH10TLB849AAL 66
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71. Install the fitting for the dipstick tube.
RCPH10TLB808AAL 67
72. Install the dipstick tube.
RCPH10TLB909AAL 68
73. Install the dipstick.
RCPH10TLB908AAL 69
NOTE: The following photo shows the four-wheel drive priority valve installed and is for reference for the plug only.
74. If the plug was removed, make sure that the threads
are clean and apply Loctite 543 or Loctite 262 (red)
to the threads before installation. Tighten the plug to
a torque of 40 Nm (354 pound-inches).
RCPH10TLB703AAL 70
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75. Install the four-wheel drive priority valve in the oil filter
bore.
RCPH10TLB037ABL 71
RCPH10TLB702AAL 72
77. Install the spool.
RCPH10TLB701AAL 73
78. Install the fitting for the oil filter. Tighten the fitting to
a torque of 50 Nm (37 pound-feet).
RCPH10TLB700AAL 74
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79. Use clean transmission oil to lubricate the gasket on

the oil filter. Install the oil filter.
RCPH10TLB698AAL 75
80. Install the gasket for the four-wheel drive valve.
RCPH10TLB905AAL 76
81. Put the four-wheel drive valve in position on the gas-

ket.
RCPH10TLB697AAL 77
82. Install the three bolts that fasten the four-wheel drive
valve to the front housing. Tighten the bolts to a
torque of 23 Nm (204 pound-inches).
RCPH10TLB696AAL 78
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83. Install a new O-ring on the oil screen. Use clean

transmission oil to lubricate the O-ring. Install the oil
screen and O-ring.
RCPH10TLB695AAL 79
84. Install the cover for the oil screen. Install the two bolts
that fasten the cover for the oil screen. Tighten the
bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB694AAL 80
85. Install the gasket for the transmission control valve.

Put the transmission control valve in position on the
gasket.
RCPH10TLB692AAL 81
86. Install the bolts that fasten the transmission control

valve to the front housing. Tighten the bolts in a
pattern alternating from front to back and side to side
until all the bolts are at a torque of 23 Nm (204 pound-
inches).
RCPH10TLB691AAL 82
NOTE: The following photo shows the drain plug for four wheel drive machines.
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87. Install a new O-ring on the drain plug. Lubricate the

O-ring with clean transmission oil. Install the drain
plug. Tighten the drain plug to a torque of 80 Nm (59
pound-feet).
RCPH10TLB690AAL 83
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Index

Control valve - Assemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control valve - Assemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Control valve - Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control valve - Disassemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control valve - Exploded view - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control valve - Exploded view - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Control valve - Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Housing - Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Housing - Assemble - Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Housing - Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Housing - Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Shaft - Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Shaft - Assemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Shaft - Assemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Shaft - Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Shaft - Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Shaft - Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Shaft - Disassemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Shaft - Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Shaft - Disassemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Shaft - Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Shaft - Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Shaft - Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Shaft - Exploded view - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Shaft - Exploded view - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Shaft - Exploded view - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shaft - Exploded view - Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Shaft - Inspect - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Shaft - Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Shaft - Inspect - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Shaft - Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Shaft - Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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Shaft - Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
TRANSMISSION Power Shuttle - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMISSION Power Shuttle - Exploded view - Four wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION Power Shuttle - Exploded view - Two wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION Power Shuttle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION Power Shuttle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TRANSMISSION Power Shuttle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TRANSMISSION Power Shuttle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION Power Shuttle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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TRANSMISSION Powershift - 20.E
580N
580SN WT
580SN
590SN
84390833 11/10/2010
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Contents
TECHNICAL DATA
TRANSMISSION Powershift
General specification - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General specification - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special tools - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUNCTIONAL DATA
Exploded view - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exploded view - H-type - 1st, 3rd, 4th gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Exploded view - H-type - transmission assembly - 4 wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exploded view - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exploded view - S-type (SPS Power Synchro) - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Exploded view - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exploded view - S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exploded view - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exploded view - S-Type (SPS Power Synchro) - Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Exploded view - S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exploded view - S-type (SPS power synchro) - Shaft A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Exploded view - S-Type (SPS Power Synchro) - Shafts B - C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Exploded view -S-type (SPS power synchro) - transmission assembly - 4 wheel drive shaft . . . . . . . . . 40
Exploded view - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Shaft
Exploded view - H-Type - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Clutch and gear
Exploded view - H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SERVICE
Disassemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Assemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassemble - S-type (SPS power synchro)- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assemble - S-type (SPS power synchro) Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Remove - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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Install - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassemble - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cleaning - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Inspect - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Assemble - H-type - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Control valve
Disassemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Assemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Shaft
Disassemble - S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Disassemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Assemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Disassemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Assemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Disassemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Assemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Disassemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Assemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Clutch and gear
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Back side measurement 250
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Front side measurement 255
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Dimension "D" measurement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Neutral position measure-
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Check - S-Type (SPS Power Syncro) - Speed gears switches - Checking procedure . . . . . . . . . . . . . . 264
Housing
Disassemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Assemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Electronic control
Disassemble S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Assemble - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
TRANSMISSION Powershift - General specification - S-type (SPS

Power Synchro)
Type Carraro TLB1 2WD & 4WD SPS - SAHR Parking Brake
Lubricant - Carraro TLB1 2WD& 4WD SPS - SAHR Parking Brake

Total system capacity 19.5 l (20.6 US qt)
Refill capacity with or without filter change 16 l (16.9 US qt)
Type of fluid Case AKCELA Hy-Tran™ Ultra (CASE MS1209) (CNH
MAT 3505)
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TRANSMISSION Powershift - Torque - S-type (SPS Power Synchro)

(1) 28 N·m (20.7 lb ft)
(2) 23 N·m (17.0 lb ft)
(3) 40 N·m (29.5 lb ft)
(4) 50 N·m (36.9 lb ft)
(5) 139 N·m (102.5 lb ft)
(6) 50 N·m (36.9 lb ft)
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RCPH10TLB145GAL 1
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TRANSMISSION Powershift - General specification - H-type - 4WD

only
Type Carraro TLB2 PB CD 4WD 2WS
Lubricant
Total system capacity 17.9 l (18.9 US qt)
Refill capacity with or without filter change 11.3 l (11.9 US qt)
Type of fluid Case AKCELA Hy-Tran™ Ultra
TRANSMISSION Powershift - Special tools - H-type - 4WD only

380040161 - Teflon seal installation kit
RCPH10TLB828AAL 1
380002211 - Handle
RCPH10TLB059AAL 2
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380040161 - Teflon seal ring protector and shims - 1st,

3rd, 4th, and 4WD shafts
RCPH10TLB080AAL 3
380100081 - Teflon seal ring protector and shims - 2nd

gear
RCPH10TLB073AAL 4
380100082 - Teflon seal ring sizer - 2nd gear
RCPH10TLB074AAL 5
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380100083 - Teflon seal ring protector - 1st gea r
RCPH10TLB072AAL 6
380100084 - Teflon seal ring sizer - 1st gear
RCPH10TLB078AAL 7
380100085 - Teflon seal ring protector and shim - 1st gear

bushing
RCPH10TLB079AAL 8
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380100086 - Teflon seal ring sizer - 1st gear bushing
RCPH10TLB075AAL 9
380100087 - Holder bushing - 4WD shaft
RCPH10TLB076AAL 10
380100088 - Shaft puller/installer
RCPH10TLB077AAL 11
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CAS2379 - Holder and spring compressor
RCPH10TLB043ABL 12
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TRANSMISSION Powershift - Torque - H-type - 4WD only
RCPH10TLB14GAL 1
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RCPH10TLB15GAL 2
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TRANSMISSION Powershift - Exploded view - Powershift H-type

1. Nut (2) 90-100 NM (67-73 lb-ft) 8. Flex plate
2. Transmission 9. Backing plate
3. Bolt (12) 52-57 NM (38-42 lb-ft) 10. Cap screw (4) 52-57 NM (38 - 42 lb-ft)
4. Dipstick tube 11. Bolt (4) 52-57 NM (38 - 42 lb-ft)
5. Bolt (2) 27-31 NM (20-23 lb-ft) 12. Nut 90-100 NM (67-73 lb-ft)
6. Converter 13. Rubber transmission mount (2)
7. Flex plate with caged nut 14. Constant torque clamp (4) 5.6 - 7.9 NM (50-70 in-lb)
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RCPH10TLB6GAL 1
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TRANSMISSION Powershift - Exploded view - H-type - 1st, 3rd, 4th

gear shaft
1st, 3rd, 4th gear shaft
1. Bearing 15. Teflon seal ring 29. 4th gear clutch 43. O-ring
2. Thrust washer 16. Seal rings 30. Thrust plate 44. Bushing
3. Gear 17. Plug 31. Lock ring 45. O-ring
4. Lock ring 18. Spring pin 32. Gear 46. Roller bearing
5. Thrust plate 19. Spring pin 33. Roller retainer 47. Bushing
6. 3rd gear clutch 20. Gear 34. Gear 48. Teflon seal ring
7. Roller retainer 21. Teflon seal ring 35. Lock ring 49. Teflon seal ring
8. Thrust washer 22. Teflon seal ring 36. Thrust plate 50. Teflon seal ring
9. Snap ring 23. Clutch piston 37. 1st gear clutch 51. Gear
10. Retaining plate 24. Bushing 38. Lock ring 52. Roller bearing
11. Spring 25. Spring 39. Retaining plate 53. Bushing
12. Bushing 26. Retaining plate 40. Spring 54. Thrust bearing
13. Clutch piston 27. Lock ring 41. Clutch piston 55. Bearing
14. Teflon seal ring 28. Thrust washer 42. Teflon seal ring
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RCPH10TLB17GAL 1
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TRANSMISSION Powershift - Exploded view - H-type - transmission

assembly - 4 wheel drive shaft
Transmission Assembly
1. Bearing 13. Plug
2. Ring 14. Counter disk
3. Shim 15. Clutch pack
4. Washer 16. Thrust plate
5. Bellville washers 17. Lock ring
6. Bushing 18. Gear
7. O-ring 19. Needle bearing
8. Clutch piston 20. Spacer
9. O-ring 21. Bearing
10. Pin 22. Seal ring
11. O-ring 23. Seal ring
12. Clutch housing
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RCPH10TLB16GAL 1
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TRANSMISSION Powershift - Exploded view - S-Type (SPS Power

Synchro) - Filters
Filters
1. Drain plug 6. Spin-on filter
2. Cap screws 7. Connector
3. Cover 8. Cap screws
4. O-ring 9. Support
5. Oil filter 10. O-ring
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RCPH10TLB152GAL 1
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TRANSMISSION Powershift - Exploded view - S-type (SPS Power

Synchro) - Oil pump
Oil pump
1. Seal ring 3. Oil pump
2. Screws 4. O-ring
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RCPH10TLB153GAL 1
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Synchro) - Switches and sensors
Switches and sensors
1. Screws 9. Washer seal
2. Gaskets 10. Speed sensor
3. Pipe 11. Screw
4. Temperature sensor and thermostat 12. Bracket
5. Wiring harness 13. Switch gear
6. Regulating pressure valve 14. O-ring
7. Washer 15. Spring
8. Pressure switch 16. Switch detents
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RCPH10TLB154GAL 1
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Synchro) - Hydraulic control valve
Hydraulic control valve
1.Screw 7. Valve
2. Gasket 8. Valve
3 Control valve 9. Valve
4. Screws 10,11,12. O-ring
5. Screws 13. Screws
6. Valve
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RCPH10TLB155GAL 1
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Synchro) - Front housing
Front housing
1. O-ring 12. Gears
2. Retaining screw 13. Gears
3. Washer 14. Nut
4. O-ring 15. Oil pump
5. Flange 16. Screws
6. Cap screws 17. Housing
7. Cover 18. Primary shaft
8. O-ring 19. Secondary shaft
9. Seal 20. Front housing
10. Bearing 21. Drain plug
11. O-rings 22. Four-wheel drive clutch tube
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RCPH10TLB156GAL 1
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Synchro) - Rear cover
Rear cover
1. O-ring 11. Shims
2. Screws 12. Bearing snap ring
3. Flange 13. Screws
4. Rear cover 14. Drain plug
5. Teflon seal ring 15. Pin
6. PTO shaft 16.Rear front housing
7. Bearing 17. Housing
8. Snap ring 18. Screws
9. Screws 19. Parking brake
10. Screws 20. O-ring
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RCPH10TLB157GAL 1
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Synchro) - Gear pistons
Gear pistons
1. Screws 13. Screws
2. Plate 14. O-ring
3. Plugs 15. Drain plug
4. O-ring 16. Neutral piston
5. Plugs 17. O-ring
6. O-ring 18. 3rd gear piston
7. Shims 19. Seal ring
8. Screws 20. 1st gear piston
9. Neutral piston 21. O-ring
10. O-ring 22. 2nd gear piston
11. Screw 23. 4th gear piston
12. Oil circuit plate
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RCPH10TLB158GAL 1
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TRANSMISSION Powershift - Exploded view - S-type (SPS power

synchro) - Shaft A - D
Shafts A - D
1. Seal ring 11. Clutch plate lock ring 21. Teflon seal ring 31. Split pin
2. Snap ring 12. Needle cage 22. Teflon seal ring 32. Spring cover
3. Bearing 13. Spring cover 23. Snap ring 33. Snap ring
4. Spacer 14. Snap ring 24. Bearing 34. Spring
5. Sleeve 15. Spring 25. Thrust washer 35. Clutch drive plate
6. Gear 16. Shaft bearing 26. Gear 36. Clutch plate
7. Needle cage 17. Clutch drive plate 27. Sleeve 37. Shaft bearing
8. Thrust washer 18. Clutch plate 28. Thrust washer 38. Clutch piston
9. Split pin 19. Clutch piston 29. Lock ring 39. Teflon seal ring
10. Lock ring 20. Teflon seal ring 30. Teflon seal ring 40. Snap ring
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RCPH10TLB002GAN 1
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Synchro) - Shafts B - C
Shafts B - C
1. Bearing 12. Fourth speed gear 23. First/second speed 34. Springs
synchronizer assembly
2. Thrust washer 13. Snap ring 24. Steel ring 35. Hub
3. Third speed gear 14.4WD gear 25. Tapered friction ring 36.
4. Speed synchronizer 15. Outer race bearing 26. Sintered ring 37. First speed gear
assembly
5. Clutch ring 16. Snap ring 27. Synchronizer ring 38. Snap ring
6. Tapered friction ring 17. Thrust washer 28. Tapered friction ring 39. Inner race bearing
7. Sleeve 18. Second speed gear 29. Steel ring 40. Bearing
8. Plates 19. Split pin 30. Sintered ring 41. Shaft
9. Balls 20. Shims 31. Sleeve
10. Hub springs 21. Shaft 32. Balls
11. Synchronizer hub 22. Synchronizer ring 33. Plates
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RCPH10TLB160GAL 1
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TRANSMISSION Powershift - Exploded view -S-type (SPS power

synchro) - transmission assembly - 4 wheel drive shaft
Shaft E - 4WD
1. Snap ring 7. Four wheel drive clutch tube
2. Washer 8. Teflon sealing rings
3. Spacer 9. O-ring
4. Springs 10. Four wheel drive clutch gear
5. Sleeve 11. Bearing
6. O-ring
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RCPH10TLB161GAL 1
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Synchro) - Shift rails - forks
Shift rails - forks
1. Shift forks - 1st and 2nd gear 3. Shift rail
2. Shift forks - 3rd and 4th gear 4. Spring pins
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RCPH10TLB162GAL 1
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Shaft - 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 and gear - 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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TRANSMISSION Powershift - Disassemble - S-Type (SPS Power

Synchro) - Filters
transmission
RCPH10TLB081AAL 1
2. Remove the two cap screws (1)which fasten the

cover for the oil screen. Remove the cover (2).
RCPH10TLB082AAL 2
3. Remove the oil filter (1)and the O-ring (2). Handle

and washer the filter according to authorized proce-
dures. In case of replacement, use only authorized
disposal procedures.
RCPH10TLB083AAL 3
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4. Remove the filter
RCPH10TLB249AAL 4
5. If necessary remove the connector for the filter.
RCPH10TLB092AAL 5
Next operation:
TRANSMISSION Powershift - Assemble (C.20.E)
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TRANSMISSION Powershift - Assemble - S-Type (SPS Power

Synchro) - Filters
Prior operation:
TRANSMISSION Powershift - Disassemble (C.20.E)
1. Assemble the O-Ring (1). Assemble the support

(2). Assemble the two screws (3)which fasten the
support of the spin-on filter. Torque to TRANSMIS-
SION Powershift - Torque (C.20.E) TRANSMIS-
SION Powershift - Torque (C.20.E)
RCPH10TLB035ACL 1
2. Assemble the connector (1)of the spin-on filter

(2). Torque wrench TRANSMISSION Powershift -
Torque (C.20.E).
RCPH10TLB034ACL 2
NOTE: Put a thin coat of oil transmission on the filter gasket, turn clockwise until the gasket makes contact with the
base, continue to turn the filter 2/3 turn.
3. Assemble filter and O-ring after having washed or
replaced it.
RCPH10TLB250AAL 3
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4. Assemble cover and screws Tightening torque 50

N·m (36.9 lb ft).
RCPH10TLB082AAL 4
5. Assemble plug (1). Tightening torque 139 N·m

(102.5 lb ft).
RCPH10TLB081AAL 5
Next operation:
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TRANSMISSION Powershift - Disassemble - S-type (SPS power

synchro)- Oil pump
1. Remove the screws.
RCPH10TLB094AAL 1
2. Remove the pump using the two levers.
RCPH10TLB251AAL 2
3. Remove the oil pump.
RCPH10TLB252AAL 3
84390833 11/10/2010
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4. If replacement is necessary, remove the O-ring.
RCPH10TLB095AAL 4
5. Remove the seal ring, if replacement is necessary.
RCPH10TLB096AAL 5
Next operation:
TRANSMISSION Powershift - Assemble (C.20.E)
84390833 11/10/2010
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TRANSMISSION Powershift - Assemble - S-type (SPS power

synchro) Oil pump
Prior operation:
1. Use a soft faced hammer and special tool CAxxxxx

to assemble new seal ring (1)on oil pump (2).
RCPH10TLB014ACL 1
2. Install O-ring.
RCPH10TLB095AAL 2
3. Prior to oil pump assembly, ensure marks line up

between oil pump and half-case.
RCPH10TLB098AAL 3
84390833 11/10/2010
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4. Grease the ring to keep it centered to the shaft slot

center line to help fit the pump.
RCPH10TLB099AAL 4
5. Apply a thin film of transmission oil on the coupling

seat with the front half-case. Assemble the oil pump.
RCPH10TLB099AAL 5
6. Install screws (1)and torque to TRANSMISSION

Powershift - Torque (C.20.E)
NOTE: Ensure the marks on the oil pump and bellhouse line up.
Next operation:
Electronic control - Disassemble (C.20.E)
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TRANSMISSION Powershift - Remove - Powershift H-type

1. Park the machine on a level surface. Put the back-
hoe in the transport position with the stabilizers
down. Also put the loader bucket on the floor.
2. Raise the wheels off the floor high enough to re-
move the transmission. Put suitable stands under
both sides of the machine at the front and rear.
NOTE: The rear wheels can be removed to ease the transmission removal.
3. Loosen and remove the cap screw and washer (1)
for the left rear mounting bracket on front drive shaft
guard through the access hole in the fuel tank.
RCPH10TLB060AAL 1
4. Loosen and remove the bolts, washers, and nuts (2)

that fasten the left rear mounting bracket to the front
drive shaft guard. Remove the left rear mounting
bracket.
RCPH10TLB062AAL 2
5. Put a floor jack under the drive shaft guard that will
hold the guard in place when the cap screws are
removed. Loosen and remove the cap screws and
washers (3)from the remaining mounting brackets on
the front drive shaft guard. Remove the front drive
shaft guard from the machine.
RCPH10TLB061AAL 3
NOTE: Powershift transmission have spacers and O-rings on the bolts, they are required for assembly.
6. Remove the retainer and bolts that fasten the front
move the front drive shaft from the splined pinion
shaft on the front axle.
pound-feet).
84390833 11/10/2010
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7. Remove the retainer and bolts that fasten the rear

move the rear drive shaft from the splined pinion
shaft on the rear axle.
RCPH10TLB069AAL 4
pound-feet).
8. Put a container under the drain plug that will hold
approximately 22 liters (6 U.S. gallons). Remove the
fill plug and the drain plug.
RCPH10TLB070AAL 5
9. Remove hydraulic pump from the transmission.

10. Tag and disconnect the transmission cooler inlet and
outlet hoses at the transmission. Install caps on the
transmission fittings and plugs in the hose ends.
11. Disconnect the electrical connector for the transmis-
sion control valve harness, remove the mounting bolt
for the connector mounting bracket.
RCPH10TLB067AAL 6
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12. Disconnect the supply line (1) from the transmission,

disconnect the return line (2) from the transmission.
RCPH10TLB167ABL 7
13. Disconnect the electrical connector for the SAHR

parking brake.
14. Disconnect the hose for the differential lock.
15. Remove the starter from the engine. Remove the
access cover from the bell housing.
RCPH10TLB026AAL 8
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16. Install the engine turning tool, 380000988, to turn the

flywheel for access to the cap screws.
RCPH10TLB005BAL 9
17. Loosen and remove the four cap screws that fasten
the flywheel to the flex plate.
RCPH10TLB027AAL 10
NOTE: During installation make sure that the converter is in the correct position on the transmission shaft. Align the
hole sin the flex plate with the holes in the flywheel. Install but do not tighten all four cap screws, then final torque the
cap screws to 52 to 57 Nm (38 to 42 pound-feet).
18. Use acceptable stands or blocks to secure the en-
gine in place.
19. Install a transmission jack under the transmission
and apply light pressure.
20. Loosen and remove the 12 cap screws and flat wash-
ers that fasten the transmission to the engine.
21. Remove both the left and right transmission mount-
ing cap screw.
NOTE: During installation tighten the transmission mounting cap screws to a torque of 90 to 100 Nm (67 to 73 pound-
feet), install two nuts on the left mount.
22. Carefully slide the transmission away from the en-
gine. Lower to the ground and remove from under
the machine.
Next operation:
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TRANSMISSION Powershift - Install (C.20.E)
84390833 11/10/2010
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TRANSMISSION Powershift - Install - Powershift H-type

NOTE: Install the transmission in reverse of removal.
1. Mount the transmission to the engine, torque the
mounting bolts to 52 to 57 Nm (38 to 42 pound-feet).
NOTE: Rotate the torque converter through the bottom hole of the bell housing and slide it against the adapter plate.
Align the bolt hole with the bosses on the torque converter.
2. Install and hand tighten all four cap screws that fas-
ten the flywheel to the torque converter.
3. Final torque the cap screws to 52 to 57 NM (38 to 42
pound-feet).
4. Remove the engine turning tool.
5. Install the access cover on the bell housing. Install
the starter on the engine.
RCPH10TLB026AAL 1
NOTICE: Before starting the engine, do the following.

6. Make sure the transmission drain plug has been in-
stalled and tightened.
7. Fill the transmission.
NOTE: If removed, install the rear wheels.

8. Remove the stands from under the machine and
lower the machine to the ground.
9. With the machine parked on level ground and the
engine running at low idle, check the transmission
oil level. The oil level must be between the ADD and
the FULL marks on the dipstick. If the oil level is at
the ADD mark, add oil as required until the oil level
is at the FULL mark.
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TRANSMISSION Powershift - Disassemble - H-type

1. Clean exterior of the transmission and place on a
suitable stand.
transmission.
RCPH10TLB081AAL 1
3. Remove the two cap screws which fasten the cover

for the oil suction filter.
RCPH10TLB082AAL 2
4. Remove the cover, filter, and O-ring.
RCPH10TLB083AAL 3
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5. Remove the filter.
RCPH10TLB249AAL 4
6. If necessary remove the connector for the filter.
RCPH10TLB092AAL 5
7. Loosen the oil filter bypass valve.
RCPH10TLB084AAL 6
8. Remove the filter bypass valve.
RCPH10TLB085AAL 7
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9. Remove the breather from the transmission only if

the breather is damaged or leaking.
RCPH10TLB086AAL 8
10. Remove forward clutch test port plug if O-ring is leak-

ing, replace O-ring and torque to 30 Nm (22 pound
feet).
RCPH10TLB087AAL 9
11. Remove reverse clutch test port plug if O-ring is leak-

ing, replace O-ring and torque to 30 Nm (22 pound
feet).
RCPH10TLB088AAL 10
12. Remove lubrication pressure test port plug if O-ring

is leaking, replace O-ring and torque to 30 Nm (22
pound feet).
RCPH10TLB089AAL 11
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13. Remove the speed sensor.
RCPH10TLB090AAL 12
14. Remove the thermostat.
RCPH10TLB091AAL 13
15. Remove the torque converter from the transmission.
RCPH10TLB093AAL 14
16. Remove the cap screws securing the pump in the

transmission.
RCPH10TLB094AAL 15
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17. Loosen the pump from the transmission with two pry
bars.
RCPH10TLB251AAL 16
18. Remove the pump from the transmission.
RCPH10TLB252AAL 17
19. Remove the O-ring from the pump.
RCPH10TLB095AAL 18
20. Remove the seal from the pump.
RCPH10TLB096AAL 19
84390833 11/10/2010
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21. Tag and remove the lubrication tube.
RCPH10TLB100AAL 20
22. Tag and remove the 4th gear tube (1), 2nd gear tube
(2), 3rd gear tube (3), and the 1st gear tube (4.)
RCPH10TLB101AAL 21
23. Tag and remove the lubrication tube.
RCPH10TLB254AAL 22
24. Loosen the front flange cap screw.
RCPH10TLB596AAL 23
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25. Remove the cap screw and the front flange.
RCPH10TLB102AAL 24
26. Remove the seal from the housing.
RCPH10TLB103AAL 25
Parking Brake
27. Loosen the flange bolt.
RCPH10TLB596AAL 26
28. Remove the flange bolt and washer.
RCPH10TLB868AAL 27
84390833 11/10/2010
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29. Remove the O-ring and flange.
RCPH10TLB869AAL 28
NOTE: The transmission was removed from the machine for clarity only, it is not necessary to remove the transmis-
sion.
30. Loosen brake housing bolts.
RCPH10TLB871AAL 29
31. Remove bolts (A), and alternately loosen bolts (B) to

release the load of bellville washers.
RCPH10TLB594AAL 30
NOTICE: The housing is under spring pressure, failure to follow these instructions could damage the transmission.
84390833 11/10/2010
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32. Remove the brake cover from the transmission.
RCPH10TLB872AAL 31
33. Remove and discard the O-ring.
RCPH10TLB873AAL 32
34. Remove back plate.
RCPH10TLB874AAL 33
35. Remove the springs and remove the friction disc.
RCPH10TLB875AAL 34
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36. Remove the reaction plates.
RCPH10TLB876AAL 35
37. Remove the hub.
RCPH10TLB877AAL 36
38. Remove the retaining plate.
RCPH10TLB599AAL 37
39. Remove and discard the O-rings and backup ring

from the retaining plate.
RCPH10TLB600AAL 38
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40. Use CAS2379 to compress the bellville washers, re-

move the retaining ring.
RCPH10TLB601AAL 39
41. Remove the piston from the brake housing.
RCPH10TLB602AAL 40
42. Remove and discard the O-rings and backup rings

from the piston.
RCPH10TLB603AAL 41
43. Remove the bellville washers from the brake hous-

ing.
RCPH10TLB604AAL 42
84390833 11/10/2010
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44. Remove the seal from the brake housing.
RCPH10TLB605AAL 43
45. Remove and discard the O-ring from the brake hous-
ing.
RCPH10TLB606AAL 44
PTO Shaft
46. Remove the mounting screws for the pump flange.
RCPH10TLB255AAL 45
47. Remove the flange from the transmission.
RCPH10TLB104AAL 46
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48. Remove the PTO shaft from the transmission.
RCPH10TLB256AAL 47
49. Remove the teflon seal ring from the PTO shaft.
RCPH10TLB105AAL 48
50. Remove the snap ring from the PTO shaft.
RCPH10TLB257AAL 49

the PTO shaft.
RCPH10TLB106AAL 50
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Housing separation
52. Remove the cap screws that fasten the front and rear
housings together.
RCPH10TLB258AAL 51
53. Use pry bars in the slots to loosen the front housing
from the rear housing.
RCPH10TLB259AAL 52
54. Attach suitable lifting equipment to the front housing

and remove it from the transmission.
RCPH10TLB260AAL 53
55. Remove and discard the O-rings from the rear hous-
ing.
RCPH10TLB107AAL 54
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56. Pull the input shaft and reverse shaft together.
RCPH10TLB109AAL 55
57. Remove the cap screws and the shield from the 4
wheel drive clutch pack.
RCPH10TLB144AAL 56
58. Attach lifting bracket 380100088 to the shafts, re-

move them from the transmission.
RCPH10TLB145AAL 57
Input shaft
59. Remove the teflon seal ring.
RCPH10TLB110AAL 58
84390833 11/10/2010
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RCPH10TLB111AAL 59
61. Install a bearing puller under the gear as shown, do

not install the bearing puller between the gear and
the bearing. Insert a shaft protector between the
puller and the end of the input shaft.
RCPH10TLB112AAL 60
RCPH10TLB113AAL 61
RCPH10TLB114AAL 62
84390833 11/10/2010
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RCPH10TLB115AAL 63
RCPH10TLB116AAL 64
RCPH10TLB262AAL 65
RCPH10TLB262AAL 66
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68. Remove the lock ring.
RCPH10TLB117AAL 67
69. Use pry bars to lift and remove the thrust plate.
RCPH10TLB118AAL 68
70. Remove the clutch plates and the clutch discs.
RCPH10TLB119AAL 69
71. Place a mark below a groove on the clutch housing.
RCPH10TLB120AAL 70
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72. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 71
73. 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 72
RCPH10TLB264AAL 73
CAS2379 special tool (not shown).
RCPH10TLB121AAL 74
84390833 11/10/2010
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RCPH10TLB122AAL 75
RCPH10TLB265AAL 76
78. Use compressed air in the piston pressure port to

remove the piston.
RCPH10TLB123AAL 77
protection.
84390833 11/10/2010
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79. Remove the piston seal rings and backup rings.
RCPH10TLB266AAL 78
80. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 79
RCPH10TLB267AAL 80
82. Insert a shaft protector between the puller and the

end of the input shaft. Remove the bearing.
RCPH10TLB125AAL 81
84390833 11/10/2010
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83. Remove the bearing and thrust washer.
RCPH10TLB126AAL 82
RCPH10TLB303AAL 83
RCPH10TLB127AAL 84
86. Repeat steps 68 to 78 and disassemble the clutch.
84390833 11/10/2010
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Reverse shaft
end of the reverse shaft. Remove the bearing.
RCPH10TLB128AAL 85
88. Turn the shaft over and insert a shaft protector be-
tween the puller and the end of the reverse shaft.
Remove the bearing.
RCPH10TLB268AAL 86
Primary shaft
89. Remove the teflon seal ring from the primary shaft.
RCPH10TLB272AAL 87
84390833 11/10/2010
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90. Install a puller on the gear as shown.
RCPH10TLB273AAL 88
91. Remove the bearing and gear.
RCPH10TLB146AAL 89
RCPH10TLB274AAL 90
RCPH10TLB147AAL 91
84390833 11/10/2010
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RCPH10TLB275AAL 92
RCPH10TLB148AAL 93
96. Remove the needle bearings and thrust washer.
RCPH10TLB149AAL 94
97. Remove the roll pin and spacer.
RCPH10TLB150AAL 95
84390833 11/10/2010
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98. Drive the thrust plate down away from the lock ring.
RCPH10TLB276AAL 96
RCPH10TLB277AAL 97
100. Remove the thrust plate from the clutch pack.
RCPH10TLB151AAL 98
101. Remove discs and plates from the clutch pack.
RCPH10TLB278AAL 99
84390833 11/10/2010
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RCPH10TLB152AAL 100
RCPH10TLB279AAL 101
RCPH10TLB152AAL 102
105. Remove the retaining ring and spring.
RCPH10TLB153AAL 103
84390833 11/10/2010
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RCPH10TLB154AAL 104
107. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB155AAL 105
RCPH10TLB266AAL 106
RCPH10TLB156AAL 107
84390833 11/10/2010
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110. Use a puller and remove the bearing from the shaft.
RCPH10TLB157AAL 108
1st, 3rd, and 4th gear shaft

111. Use a puller and remove the bearing.
RCPH10TLB172AAL 109
112. Remove the bushing.
RCPH10TLB173AAL 110
113. Remove the gear and clutch from the shaft.
RCPH10TLB174AAL 111
84390833 11/10/2010
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114. Push down on the thrust plate.
RCPH10TLB284AAL 112
RCPH10TLB285AAL 113
116. Remove the thrust plate.
RCPH10TLB175AAL 114
RCPH10TLB176AAL 115
84390833 11/10/2010
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fasten the two pieces together, remove the snap ring.
RCPH10TLB286AAL 116
RCPH10TLB177AAL 117
120. Remove the snap ring, retaining ring, and spring.
RCPH10TLB287AAL 118
121. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB304AAL 119
84390833 11/10/2010
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122. Remove the teflon ring and O-ring from the piston.
RCPH10TLB178AAL 120
123. Remove the teflon seal ring and O-ring from the
clutch housing.
RCPH10TLB179AAL 121
124. Use a puller and remove the gear.
RCPH10TLB180AAL 122
125. Remove the needle bearings and spacer.
RCPH10TLB181AAL 123
84390833 11/10/2010
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126. Remove the O-rings from inside the spacer.
RCPH10TLB182AAL 124
127. Remove the teflon rings from the outside of the

spacer.
RCPH10TLB183AAL 125
RCPH10TLB288AAL 126
RCPH10TLB184AAL 127
84390833 11/10/2010
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RCPH10TLB071AAL 128
RCPH10TLB310AAL 129
RCPH10TLB185AAL 130
RCPH10TLB289AAL 131
84390833 11/10/2010
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RCPH10TLB186AAL 132
RCPH10TLB187AAL 133
RCPH10TLB121AAL 134
RCPH10TLB264AAL 135
84390833 11/10/2010
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RCPH10TLB121AAL 136
RCPH10TLB188AAL 137
140. Used compressed air to remove the piston.
RCPH10TLB305AAL 138
141. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 139
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RCPH10TLB266AAL 140
143. Turn the shaft over and remove the teflon seal rings.
RCPH10TLB190AAL 141
RCPH10TLB191AAL 142
RCPH10TLB192AAL 143
84390833 11/10/2010
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RCPH10TLB193AAL 144
147. Remove the needle bearing and thrust washer.
RCPH10TLB194AAL 145
RCPH10TLB290AAL 146
RCPH10TLB310AAL 147
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RCPH10TLB185AAL 148
RCPH10TLB289AAL 149
RCPH10TLB186AAL 150
RCPH10TLB187AAL 151
84390833 11/10/2010
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RCPH10TLB121AAL 152
RCPH10TLB264AAL 153
RCPH10TLB121AAL 154
RCPH10TLB188AAL 155
84390833 11/10/2010
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158. Used compressed air to remove the piston.
RCPH10TLB305AAL 156
159. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 157
RCPH10TLB195AAL 158
84390833 11/10/2010
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4 wheel drive shaft

161. Remove the teflon seals.
RCPH10TLB221AAL 159
162. Use a puller and remove the bearing, remove the

spacer.
RCPH10TLB297AAL 160
RCPH10TLB222AAL 161
RCPH10TLB298AAL 162
84390833 11/10/2010
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165. Locally fabricate a pipe with notch to access the snap

ring as shown. Remove the snap ring.
RCPH10TLB223AAL 163
166. Remove shims and thrust washer.
RCPH10TLB299AAL 164
167. Remove the bellville washers and spacer.
RCPH10TLB224AAL 165
168. Push down on the thrust plate and remove the lock
ring.
RCPH10TLB225AAL 166
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169. Remove thrust plate, discs, and plates from the

clutch pack.
RCPH10TLB226AAL 167
RCPH10TLB227AAL 168
171. Use a punch and remove the pistons.
RCPH10TLB228AAL 169
172. Remove the O-rings from the piston.
RCPH10TLB603AAL 170
84390833 11/10/2010
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173. Remove the O-rings from the pistons.
RCPH10TLB229AAL 171
Next operation:
TRANSMISSION Powershift - Cleaning (C.20.E)
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TRANSMISSION Powershift - Cleaning - H-type - 4WD only

Cleaning
1. Clean all parts thoroughly using solvent type clean-
ing fluid. It is recommended that parts be immersed
in cleaning fluid and moved up and down slowly until
all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned .
Bearings
2. Remove bearings from cleaning fluid and strike flat
against a block of wood to dislodge solidified par-
ticles of lubricant. Immerse again in cleaning fluid
to flush out particles. Repeat above operation until
bearings are thoroughly clean. Dry bearings using
moisture-free compressed air. Be careful to direct
air stream across bearing to avoid spinning. Do not
spin bearings when drying. Bearings may be rotated
slowly by hand to facilitate drying process.
Housings
3. Clean interior and exterior of housings, bearing caps,
etc., thoroughly. Cast parts may be cleaned in hot so-
lution tanks with mild alkali solutions providing these
parts do not have ground or polished surfaces. Parts
should remain in solution long enough to be thor-
oughly cleaned and heated. This will aid the evapo-
ration of the cleaning solution and rinse water. Parts
cleaned in solution tanks must be thoroughly rinsed
with clean water to remove all traces of alkali. Cast
parts may also be cleaned with steam cleaner. All
parts cleaned must be thoroughly dried immediately
by using moisture-free compressed air or soft, lint
free absorbent wiping rags free of abrasive materials
such as metal fillings, contaminated oil, or lapping
compound.
Next operation:
TRANSMISSION Powershift - Inspect (C.20.E)
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TRANSMISSION Powershift - Inspect - H-type - 4WD only

Inspection
1. The importance of careful and thorough inspection
of all parts cannot be overstressed. Replacement
of all parts showing indication of wear or stress will
eliminate costly and avoidable failures at a later date.
Bearings
2. Carefully inspect all rollers, cages and cups for wear,
chipping, or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup
individually without replacing the mating cup or cone
at the same time. After inspection, dip bearings in
clean transmission fluid and wrap in clean lint free
cloth or paper to protect them until installed.
Oil Seals, Gaskets, etc.

3. Replacement of spring load oil seals, O-rings, metal
sealing rings, gaskets, and snap rings is more eco-
nomical when uni t is disassembled than premature
overhaul to replace these parts at a future time. Fur-
ther loss of lubricant through a worn seal may result
in failure of other more expensive parts of the assem-
bly. Sealing members should be handled carefully,
particularly when being installed. Cutting, scratch-
ing, or curling under of lip of seal seriously impairs its
efficiency. When assembling new metal type sealing
rings, same should be lubricated with coat of chassis
grease to stabilize rings in their grooves for ease of
assembly of mating members. Lubricate all O-rings
and seals with recommended type transmission fluid
before assembly.
Gears and Shafts

4. Examine teeth on all gears carefully for wear, pit-
ting, chipping, nicks, cracks, or scores. If gear teeth
show spots where case hardening is worn through
or cracked, replace with new gear. Small nicks may
be removed with suitable hone. Inspect shafts and
quills to make certain they are not sprung, bent, or
splines twisted, and that shafts are true.
Housing, Covers, etc.

5. Inspect housings, covers and bearing caps to be cer-
tain they are thoroughly clean and that mating sur-
faces, bearing bores, etc., are free from nicks or
burrs. Check all parts carefully for evidence of cracks
or condition which would cause subsequent oil leaks
or failures.
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Clutches
6. Verify the total thickness of the clutch kit is within the
wear limits, if not, replace the clutch kit. Verify that
all the clutch plates do not appear burned or that the
friction material is not damaged and the splines are
intact. If using new clutch kit, soak the clutch plates
in clean transmission fluid for at least one hour before
assembly.
Forward and Reverse Clutch Kits

Number of clutch plates 6
Number of steel plates 6
Nominal clutch plate thickness 2.40 ± 0.05 MM (0.095 ± 0.002 INCHES)
Maximum clutch plate wear 0.25 MM (0.010 INCHES)
Nominal clutch kit thickness *29.00 - 29.20 MM (1.14 to 1.14 INCHES)
Maximum clutch kit wear 3.0 MM (0.12 INCHES)
*Measured under a load of 163 KG (360 Pound force)
1st Gear Clutch Kit

Maximum clutch kit wear 1.8MM (0.07 INCHES)
2nd Gear Clutch Kit

3rd Gear Clutch Kit

4th Gear Clutch Kit

84390833 11/10/2010
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4WD Gear Clutch Kit

Maximum clutch kit wear 2.7 MM (0.11 INCHES)
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TRANSMISSION Powershift - Assemble - H-type -

1. Install new seal rings on clutch piston.
RCPH10TLB603AAL 1
2. Install new O-rings on the pins.
RCPH10TLB229AAL 2
3. Install the pins on the clutch piston.
RCPH10TLB300AAL 3
4. Lubricate the piston and pin O- rings with transmis-

sion fluid.
RCPH10TLB301AAL 4
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5. Use a soft faced hammer and drive the clutch piston

into the clutch housing.
RCPH10TLB230AAL 5
6. Turn the clutch housing over, install the counter disk

in the clutch housing with the tapered edge facing
down.
RCPH10TLB231AAL 6
7. Install the clutch kit starting with a drive plate followed

by a clutch disc, continue to install until all clutch
plates and discs are installed.
RCPH10TLB232AAL 7
8. Install the thrust plate.
RCPH10TLB233AAL 8
84390833 11/10/2010
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9. Install the retaining ring.
RCPH10TLB234AAL 9
10. Align the clutch discs using a screwdriver then install

the gear.
RCPH10TLB235AAL 10
11. Install the needle bearing and the spacer.
RCPH10TLB236AAL 11
12. Use a suitable driver and install the bearing.
RCPH10TLB237AAL 12
84390833 11/10/2010
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13. Turn the clutch pack over. Make sure that the disk/
counter disk pack and the piston are seated.
RCPH10TLB238AAL 13
14. Install the spacer and washer.
RCPH10TLB239AAL 14
15. Using a thickness gauge measure the gap between

the washer and lock ring (X).
RCPH10TLB240AAL 15
16. Subtract from X a known value of S1 (S1=1.80MM),

the result is S for the shim thickness required.
(X-1.80)=Shims required.
RCPH10TLB241AAL 16
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17. Select the shim thickness value among the range of

available shims.
RCPH10TLB242AAL 17
NOTE: Make sure there will be a stroke of 1.70 to 1.90 MM after shims are installed.
18. Remove the lock ring and washer from the shaft.
RCPH10TLB243AAL 18
19. Install the bellville washers, the washer must be in-

stalled with the outer rings touching and the inner
rings have a gap.
RCPH10TLB302AAL 19
20. Install the washer and the shim(s) that was deter-
mined in step 16.
RCPH10TLB244AAL 20
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21. Locally fabricate a pipe with notch to access the snap

ring as shown. Compress the bellville washers and
install the lock ring.
RCPH10TLB245AAL 21
RCPH10TLB246AAL 22
23. Use pusher 380001928 to install the teflon seal rings.

Using spacer and protector for the inner ring and
spacer for the outer ring from kit 380040161. Size
the seal rings using sizer 380001427.
RCPH10TLB247AAL 23
24. Mount a dial indicator as shown. Apply 10 Bar (145

psi) to the piston port, the stroke should be between
2.3 to 2.4 MM (0.090 to 0.095 inches).
RCPH10TLB248AAL 24
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1st Gear Clutch Pack

25. On the 1st gear clutch, install a new teflon seal ring
using protector 380100083 and pusher 380001928.
Install a new O-ring.
RCPH10TLB196AAL 25
26. Size the teflon seal ring using sizer 380100084.
RCPH10TLB197AAL 26
27. Install a new teflon seal ring and O-ring on the clutch
piston.
RCPH10TLB198AAL 27
28. Apply clean transmission fluid to the seal rings, install

the piston.
RCPH10TLB291AAL 28
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29. Insert the spring, thrust washer, and snap ring.
RCPH10TLB199AAL 29
30. Place the clutch in CAS2379 special tool (not

shown), and compress the spring.
RCPH10TLB177AAL 30
31. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB286AAL 31
32. Remove the top plate of the spring compressor

CAS2379.
RCPH10TLB200AAL 32
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33. Starting with a reaction plate, install 6 reaction plates

and 6 friction discs. Then install the thrust plate into
the clutch housing.
RCPH10TLB201AAL 33
34. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB285AAL 34
35. Apply air pressure to the clutch pack to seat the thrust
plate against the retaining ring and release the air
pressure. Use a feeler gauge and measure the dis-
tance between the thrust plat and the first clutch disc,
a measurement of 1.725 to 2.375 mm (0.068 to 0.094
inches) should be obtained. If the distance is not
within specification, check the clutch assembly.
RCPH10TLB202AAL 35
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4th Gear Clutch Pack

36. Install new O-rings and backup rings on the 4th gear
piston.
RCPH10TLB266AAL 36
37. Apply a thin film of grease on the piston rings.
RCPH10TLB160AAL 37
38. Use 380001926 clutch pack piston installer to protect

the inner seal and install the clutch piston.
RCPH10TLB280AAL 38
39. Install the spring sleeve.
RCPH10TLB161AAL 39
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40. Install the spring and thrust washer.
RCPH10TLB203AAL 40

RCPH10TLB162AAL 41
erly seated.
RCPH10TLB163AAL 42

CAS2379.
RCPH10TLB162AAL 43
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44. Install a new roll pin in the shaft.
RCPH10TLB204AAL 44
45. Apply a thin coat of grease to the bottom of the thrust

washer to keep the washer in place while turning the
shaft.
RCPH10TLB292AAL 45
46. Align the slot in the thrust washer with the roll pin.
RCPH10TLB293AAL 46

and 9 friction discs.
RCPH10TLB205AAL 47
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48. Install the needle bearing and the thrust plate.
RCPH10TLB206AAL 48
is properly seated.
RCPH10TLB207AAL 49
pressure. Align the clutch disc splines.
RCPH10TLB208AAL 50
51. Use a feeler gauge and measure the distance be-

tween the thrust plat and the first clutch disc, a mea-
surement of 1.50 to 1.95 mm (0.060 to 0.075 inches)
should be obtained. If the distance is not within spec-
ification, check the clutch assembly.
RCPH10TLB209AAL 51
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52. Install the clutch hub into the clutch pack, make sure
the clutch hub seats completely.
RCPH10TLB210AAL 52
Assembling 1st Gear Onto The Shaft

53. Put 1st gear clutch hub onto the shaft.
RCPH10TLB294AAL 53
54. Put 1st gear clutch pack onto 1st gear clutch hub,
make sure the clutch hub seats completely.
RCPH10TLB174AAL 54
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55. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB211AAL 55
56. Remove the old teflon seal rings from the bushing.
RCPH10TLB212AAL 56
57. Install new teflon seal rings on the bushing with

protector and shim set 380100085, use pusher
380001928.
RCPH10TLB307AAL 57
58. Size the teflon seal rings using 380100086 sizer.
RCPH10TLB308AAL 58
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59. With the reference marks up, install the bushing into
the clutch pack.
RCPH10TLB213AAL 59
60. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB214AAL 60
RCPH10TLB215AAL 61
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3rd Gear Clutch Pack

62. Install new O-rings and backup rings on the piston.
RCPH10TLB266AAL 62
RCPH10TLB160AAL 63

RCPH10TLB280AAL 64
RCPH10TLB216AAL 65
84390833 11/10/2010
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RCPH10TLB295AAL 66

RCPH10TLB162AAL 67
erly seated.
RCPH10TLB163AAL 68

CAS2379.
RCPH10TLB162AAL 69
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70. Install a new roll pin.
RCPH10TLB296AAL 70

RCPH10TLB205AAL 71
72. Install the thrust plate.
RCPH10TLB206AAL 72
is properly seated.
RCPH10TLB207AAL 73
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RCPH10TLB281AAL 74

RCPH10TLB209AAL 75
76. Install the thrust washer and roller bearing.
RCPH10TLB217AAL 76
77. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB218AAL 77
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78. Install the thrust washer.
RCPH10TLB219AAL 78
RCPH10TLB220AAL 79
80. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB140AAL 80
2nd Gear Clutch Pack

RCPH10TLB158AAL 81
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82. Install the teflon seal ring. Use protector and shims
as required from 380040161 and pusher 380001928.
Size the seal rings using sizer 380001427.
RCPH10TLB159AAL 82
RCPH10TLB266AAL 83
RCPH10TLB160AAL 84

RCPH10TLB280AAL 85
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RCPH10TLB216AAL 86
RCPH10TLB295AAL 87

RCPH10TLB162AAL 88
erly seated.
RCPH10TLB163AAL 89
84390833 11/10/2010
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CAS2379.
RCPH10TLB162AAL 90

RCPH10TLB164AAL 91
92. Install the spacer and the roll pin.
RCPH10TLB165AAL 92
93. Align the slot on the thrust washer with the roll pin,
install the thrust washer and the needle bearing.
RCPH10TLB166AAL 93
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94. Install the thrust plate and drive it down evenly to the
clutch disc.
RCPH10TLB167AAL 94
is properly seated.
RCPH10TLB168AAL 95
RCPH10TLB281AAL 96
97. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB169AAL 97
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98. Install the roll pin.
RCPH10TLB170AAL 98
install the thrust washer and the snap ring.
RCPH10TLB282AAL 99

RCPH10TLB209AAL 100
101. Install the gear with the large hub down, use a suit-
able driver and install the bearing.
RCPH10TLB283AAL 101
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102. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB171AAL 102
Reverse Shaft
103. Use a suitable driver and install a bearing on one end
of the shaft.
RCPH10TLB141AAL 103
104. Turn the shaft over and install a bearing on the other
end of the shaft.
RCPH10TLB142AAL 104
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Forward and Reverse Clutch Packs

RCPH10TLB266AAL 105
RCPH10TLB160AAL 106

RCPH10TLB280AAL 107
RCPH10TLB216AAL 108
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RCPH10TLB295AAL 109

RCPH10TLB162AAL 110
erly seated.
RCPH10TLB163AAL 111

CAS2379.
RCPH10TLB162AAL 112
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113. Install the roll pin.
RCPH10TLB129AAL 113
install the thrust washer.
RCPH10TLB130AAL 114
115. Install the needle bearing.
RCPH10TLB131AAL 115
116. Place the clutch hub on a bench, install the thrust

plate on the hub.
RCPH10TLB132AAL 116
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117. Starting with a friction disc, install 6 friction discs and

6 reaction plates.
RCPH10TLB133AAL 117
118. Install the clutch pack in the clutch housing.
RCPH10TLB134AAL 118
is properly seated.
RCPH10TLB269AAL 119
120. Install the spacer.
RCPH10TLB114AAL 120
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121. Heat the bearing to 80° to 100° C (176° to 212° F),

use a suitable driver and install the bearing.
RCPH10TLB135AAL 121
RCPH10TLB136AAL 122

pander/protector.
RCPH10TLB826AAL 123
124. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80° to 100°
C (176° to 212° F). Install the Teflon sealing ring onto
the 380001428 expander/protector.
RCPH10TLB829AAL 124
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RCPH10TLB830AAL 125

RCPH10TLB840AAL 126
from the shaft.
RCPH10TLB827AAL 127

RCPH10TLB137AAL 128
129. Turn the shaft over and repeat steps 104to 118and
assemble the other clutch pack.
84390833 11/10/2010
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130. Install the roll pin, align the slot on the thrust washer
with the roll pin, install the thrust washer.
RCPH10TLB270AAL 129
RCPH10TLB138AAL 130
RCPH10TLB139AAL 131

pander/protector.
RCPH10TLB821AAL 132
84390833 11/10/2010
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spacer onto the shaft. Heat the Teflon sealing ring
to 80° to 100° C (176° to 212° F). Install the Teflon
sealing ring onto the expander/protector.
RCPH10TLB831AAL 133

groove in the shaft. Remove the pusher, protector,
and spacer from the shaft.
RCPH10TLB838AAL 134

RCPH10TLB839AAL 135
from the shaft.
RCPH10TLB840AAL 136
84390833 11/10/2010
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pander/protector.
RCPH10TLB822AAL 137

RCPH10TLB832AAL 138

RCPH10TLB837AAL 139

RCPH10TLB839AAL 140
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from the shaft.
RCPH10TLB840AAL 141

pander/protector.
RCPH10TLB823AAL 142

RCPH10TLB833AAL 143

RCPH10TLB836AAL 144
84390833 11/10/2010
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RCPH10TLB839AAL 145
from the shaft.
RCPH10TLB840AAL 146

pander/protector.
RCPH10TLB824AAL 147

RCPH10TLB834AAL 148
84390833 11/10/2010
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RCPH10TLB835AAL 149

RCPH10TLB839AAL 150
from the shaft.
RCPH10TLB840AAL 151
Transmission Housings
153. Lubricate the bores of the transmission housing that
house teflon sealing rings.
RCPH10TLB143AAL 152
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154. Attach lifting bracket 380100088 to the three shafts

as shown, install the shafts into the housing.
RCPH10TLB145AAL 153
155. Install the 4WD clutch cover as shown, apply Loctite

542 to the threads and torque cap screws to 50 Nm
(37 pound feet).
RCPH10TLB144AAL 154
156. Install the forward and reverse clutch pack and the
reverse shaft into the housing as an assembly.
RCPH10TLB109AAL 155
157. Start the bearing of the reverse shaft into its bore in
the housing and mesh the gears at the same time.
RCPH10TLB271AAL 156
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158. Apply a thin coat of Loctite 510 to the mating surface

of the transmission housing.
RCPH10TLB261AAL 157
159. Install new O-rings in the housing.
RCPH10TLB107AAL 158
160. Lubricate the bores of the front transmission housing

that house teflon sealing rings.
161. Attach lifting equipment to the front housing, lower
the front housing onto the rear housing.
RCPH10TLB260AAL 159
NOTE: Do not bind the shafts to prevent damaging the teflon seal rings.
84390833 11/10/2010
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162. Install and hand tighten all of the transmission hous-

ing cap screws.
RCPH10TLB108AAL 160
163. Torque the housing cap screws to 50 Nm (37 pound

feet).
RCPH10TLB258AAL 161
PTO Shaft
164. Slide the expander/protector onto the pump drive
shaft.
RCPH10TLB842AAL 162

380001428 expander/protector.
RCPH10TLB843AAL 163
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RCPH10TLB844AAL 164

RCPH10TLB845AAL 165
from the shaft.
RCPH10TLB846AAL 166
169. Install the bearing and snap ring on the PTO shaft.
170. Put the PTO shaft into the transmission.
RCPH10TLB256AAL 167
84390833 11/10/2010
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of the pump mount and rear cover. Prepare the seal-
ing surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or any-
thing that can leave material on the sealing surface.
Wipe the sealing surface with Loctite Safety Solvent
or equivalent. Apply a layer of Loctite 518 or Super
bond 539 to the sealing surface.
172. Clean the housing, use Loctite 518 sealer on the mat-
ing surfaces.
RCPH10TLB104AAL 168
173. Install the pump mount on the rear housing, torque

bolts to 50 Nm (37 pound-feet).
RCPH10TLB255AAL 169
Parking Brake
174. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 170
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175. Install the bellville washers as shown.
RCPH10TLB595AAL 171
176. Install the backup ring, install the seal ring.
RCPH10TLB608AAL 172
NOTE: Make sure that the seal ring does not twist during installation.
177. Lubricate the piston seals with transmission fluid, in-
stall the piston into the brake housing.
RCPH10TLB602AAL 173
178. Use CAS2379 and compress the bellville washers,

install the retaining ring.
RCPH10TLB601AAL 174
NOTICE: Make sure the retainer is properly seated before removing spring compressor.
84390833 11/10/2010
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179. Install new O-rings and backup ring in the retaining

plate.
RCPH10TLB600AAL 175
180. Lubricate the O-rings on the retaining plate, install

the plate into the brake housing.
RCPH10TLB599AAL 176
181. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 177
182. Install a reaction plate first.
RCPH10TLB876AAL 178
84390833 11/10/2010
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183. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 179
184. Install the back plate as shown.
RCPH10TLB874AAL 180
RCPH10TLB873AAL 181
186. Install the brake housing.
RCPH10TLB872AAL 182
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187. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50 Nm (37 pound feet).
RCPH10TLB871AAL 183
188. Install the flange and a new O-ring.
RCPH10TLB869AAL 184
189. Install the bolt and washer.
RCPH10TLB868AAL 185
190. Torque bolt to 139 Nm (103 pound feet).
RCPH10TLB870AAL 186
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Lubrication and Clutch Tubes

191. Install tubes and torque to 30 Nm (22 pound-feet).
RCPH10TLB254AAL 187
Pump
RCPH10TLB095AAL 188
193. Install the seal.
RCPH10TLB097AAL 189
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194. When installing the pump align the pump holes.
RCPH10TLB098AAL 190
195. Lubricate the teflon seal ring with clean transmission

fluid.
RCPH10TLB253AAL 191
196. Lubricate the O-ring with clean transmission fluid.
RCPH10TLB099AAL 192
197. Push the pump into position.
RCPH10TLB252AAL 193
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198. Install and torque bolts to 23 Nm (17 pound-feet).
RCPH10TLB094AAL 194
199. Install the torque converter.
RCPH10TLB093AAL 195
200. Install a new suction filter.
RCPH10TLB250AAL 196
201. Install the cover and torque the bolts to 23 Nm (17

pound-feet).
RCPH10TLB082AAL 197
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202. Install and torque drain plugs to 80 Nm (59 pound-

feet).
RCPH10TLB081AAL 198
203. Install and torque the filter bypass to 23 Nm (17

pound-feet).
RCPH10TLB085AAL 199
204. Install and torque the speed sensor to 50 Nm (37

pound-feet).
RCPH10TLB090AAL 200
205. Install and torque the thermostat to 30 Nm (22 pound-

feet).
RCPH10TLB091AAL 201
206. Install a new oil filter.
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207. Fill transmission with approved fluid, see specifica-

tions.
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Control valve - Disassemble S-Type (SPS Power Synchro) -

Hydraulic control valve
1. Disconnect all electrical wires and drain the transmis-
sion.
2. Remove the screws (1) and remove the control valve
(2).
RCPH10TLB152ACL 1
3. Remove the gasket (1).
RCPH10TLB153ACL 2
4. Remove the screws (1) and the HDL and 4WD valves
(2).
RCPH10TLB154ACL 3
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HDL and FWD valves positions:
RCPH10TLB155ACL 4
HDL and FWD valves dimensions:
RCPH10TLB040ACL 5
5. Remove the O-rings as needed.
RCPH10TLB158ACL 6
6. Remove the screws and the REV and FWD valves.
RCPH10TLB154ACL 7
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REV and FWD valves positions:
RCPH10TLB156ACL 8
REV and FWD valves dimensions:
RCPH10TLB041ACL 9
7. Remove the O-rings (1) as needed.
RCPH10TLB159ACL 10
8. Remove the S2 and S4 solenoid valves.

S2 and S4 solenoid valves positions:
RCPH10TLB160ACL 11
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S2 and S4 solenoid valves dimensions:
RCPH10TLB042ACL 12
9. Unscrew the nut.
RCPH10TLB192ACL 13
10. Remove the nut.
RCPH10TLB191ACL 14
11. Remove the solenoid.
RCPH10TLB190ACL 15
84390833 11/10/2010
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12. Remove the washer.
RCPH10TLB190ACL 16
RCPH10TLB189ACL 17
14. Unscrew the solenoid tube.
RCPH10TLB188ACL 18
15. Remove the solenoid tube. Remove the O-rings as

needed.
RCPH10TLB187ACL 19
16. Remove the S1 (1st and 2nd gear) and S3 (3rd and
4th gear) solenoid valves.
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S1 and S3 solenoid valves positions:
RCPH10TLB252ACL 20
S1 and S3 solenoid valves dimensions:
RCPH10TLB043ACL 21
17. Unscrew the nut.
RCPH10TLB186ACL 22
18. Remove the nut.
RCPH10TLB185ACL 23
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RCPH10TLB184ACL 24
20. Unscrew the solenoid tube.
RCPH10TLB183ACL 25
21. Remove the solenoid tube. Remove the O-rings as

needed.
RCPH10TLB182ACL 26
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22. Remove the screws, circuit plate, and O-Rings. (1).
RCPH10TLB080ACL 27
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Control valve - Assemble S-Type (SPS Power Synchro) - Hydraulic

control valve
NOTE: Some of the following images may not represent your transmission, the procedures are the same.
1. Lubricate and install the O-rings, oil circuit plate, and
screws. .
RCPH10TLB080ACL 1
2. Lubricate and install the O-rings on the solenoid tube

for the S1 and S3 solenoid valves.
3. Install the solenoid tube.
RCPH10TLB182ACL 2
4. Tighten the solenoid tube to specifications.
RCPH10TLB183ACL 3
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5. Install the solenoid.
RCPH10TLB184ACL 4
6. Install the nut.
RCPH10TLB185ACL 5
7. Tighten the nut to specifications. TRANSMISSION

Powershift - Torque (C.20.E)
RCPH10TLB180ACL 6
8. Lubricate and install the O-rings for the S2 and S4

solenoid valves.
9. Install the solenoid tube.
RCPH10TLB187ACL 7
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10. Tighten the solenoid tube to specifications.
RCPH10TLB181ACL 8
RCPH10TLB189ACL 9
RCPH10TLB189ACL 10
RCPH10TLB190ACL 11
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14. Install the nut.
RCPH10TLB191ACL 12
15. Tighten the nut to specifications TRANSMISSION

Powershift - Torque (C.20.E).
RCPH10TLB179ACL 13
16. Lubricate and install the O-rings for the REV and
FWD valves.
17. Install the valves.
RCPH10TLB159ACL 14
18. Lubricate and install the O-rings for the HDL and
4WD valves.
19. Install the valves.
RCPH10TLB158ACL 15
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20. Install the screws for the HDL, 4WD, REV and FWD
valves. Tighten the screws to specifications.
RCPH10TLB253ACL 16
21. Lubricate and install the gasket (1).
RCPH10TLB153ACL 17
22. Install the control valve (1) and the screws (2).
Tighten the screws to specifications. TRANSMIS-
SION Powershift - Torque (C.20.E)
RCPH10TLB152ACL 18
23. Disconnect all electrical wires and drain the transmis-

sion.
Next operation:
Housing - Disassemble (C.20.E)
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Shaft - 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

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

move them from the transmission.
RCPH10TLB145AAL 12
Next operation:
Shaft - Assemble (C.20.E)
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Shaft - 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.

6. Rear front-housing.. Determine the dimension Z.
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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 TRANSMISSION Power-
shift - Torque (C.20.E). 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 housing. Tight-
ening torque TRANSMISSION Powershift - Torque
(C.20.E).
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

transmission. Assemble the flange (2). Tighten the
7 screws (3)to fasten the flange to the cover. Tighten
torque TRANSMISSION Powershift - Torque
(C.20.E). Assemble the O-Ring (4).
RCPH10TLB002AAN 18
22. Assemble the parking brake group.
RCPH10TLB001AAN 19
Next operation:
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Shaft - Disassemble (C.20.E)
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Shaft - 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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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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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:
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Shaft - 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 CAxxxxxx expander/protector onto the pis-

ton (1). The expander/protector will stop in the cor-
rect position 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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5. Install the CAxxxxxx pusher over the expander/pro-

tector and slide the seal ring until it reaches the
groove in the shaft. Remove the pusher, ex-
pander/protector, and spacer from the shaft.
RCPH10TLB197ACL 5
6. Install the end of the CAxxxxxx seal compressor with

the deep chamfer onto the piston and over the seal-
ing ring. Use a back and forth twisting motion to allow
the seal compressor to slip over the top of the seal-
ing ring and seat the sealing ring into the groove. Be
careful not to damage the seal ring. After the seal-
ing ring is seated in the groove, leave the seal com-
pressor in place for 15 minutes until the sealing ring
has cooled and is properly sized and seated in the
groove. After the 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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9. For the installation of the seal ring (1), repeat the

operations from sequence 3 to sequence 6, using
the following tools: CAxxxxxx - expander/protector
CAxxxxxx - pusher CAxxxxxx - gauger
RCPH10TLB234ACL 9

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

semble 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 special tool CAxxxxxx.
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 TRANSMISSION Powershift -
Torque (C.20.E).
RCPH10TLB270ACL 15
16. Engage the 3rd speed gear and check that the bush-
ing top is in range.
84390833 11/10/2010
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must be revised.
RCPH10TLB047ACL 16
18. Assemble special tool CAxxxxxx on the shift rail. As-

semble the shims (1). Assemble the bushing (2). As-
semble 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 TRANSMISSION Powershift - Torque
(C.20.E).
RCPH10TLB147ACL 19
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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

TRANSMISSION Powershift - Torque (C.20.E).
RCPH10TLB219ACL 22
24. Use special tool CAxxxxxx to insert 3rd gear pistons

(1). Use special tool CAxxxxxx 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 in your seat using a soft tool material.
Remove the special tool CAxxxxxx and CAxxxxxx.
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
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
RCPH10TLB196ACL 30
32. 3N4 piston . Use special tool CAxxxxxx to insert the

NEUTRAL pistons . 1N2 piston . Use special tool
CAxxxxxx to insert the NEUTRAL pistons.
RCPH10TLB170ACL 31
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33. Push the piston in your seat using a soft tool material.
Remove the special tool CAxxxxxx.
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
84390833 11/10/2010
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37. Assemble the plug.
RCPH10TLB173ACL 36
38. Assemble the locking plugs (2). Tighten the screws

(1)Tightening torque TRANSMISSION Powershift -
Torque (C.20.E).
RCPH10TLB065ACL 37
39. Assemble group (B).
RCPH10TLB174ACL 38
40. Rear cover side: Use special tool CAxxxxxx and

CAxxxxxx 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
84390833 11/10/2010
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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 tool CAxxxxxx and CAxxxxxx.
RCPH10TLB145ACL 40
42. Assemble the O-Rings.
RCPH10TLB062ACL 41
43. Assemble the rear cover.
RCPH10TLB049ACL 42
Next operation:
Clutch and gear - Measure (C.20.E)
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts A - D

(2).
RCPH10TLB109AAL 1
RCPH10TLB110AAL 2
RCPH10TLB111AAL 3
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
84390833 11/10/2010
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RCPH10TLB113AAL 5
RCPH10TLB117AAL 6
7. Remove the gear.
RCPH10TLB115AAL 7
RCPH10TLB116AAL 8
84390833 11/10/2010
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RCPH10TLB262AAL 9
RCPH10TLB262AAL 10
11. Remove lock ring.
RCPH10TLB117AAL 11
12. Use pry bars to lift and to remove the thrust plate.
RCPH10TLB118AAL 12
84390833 11/10/2010
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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
RCPH10TLB121AAL 16
84390833 11/10/2010
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RCPH10TLB264AAL 17
RCPH10TLB121AAL 18
RCPH10TLB122AAL 19
RCPH10TLB265AAL 20
84390833 11/10/2010
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21. Use compressed air in the piston pressure port to

remove the piston.
RCPH10TLB123AAL 21
RCPH10TLB266AAL 22
23. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 23
RCPH10TLB267AAL 24
84390833 11/10/2010
C.20.E / 208

end of the input shaft. Remove the bearing.
RCPH10TLB125AAL 25
26. Remove the bearing and thrust washer.
RCPH10TLB126AAL 26
27. Remove gear.
RCPH10TLB303AAL 27
RCPH10TLB127AAL 28
29. Repeat steps 9 to 22 to disassemble the clutch.
84390833 11/10/2010
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30. Check the sealing ring grooves (large and small) for
wear and damage if necessary. Use new parts as
required.
31. Check on the output shaft for wear and damage.
Check oil passages in the output shaft to be sure that
the passages are open and free of foreign material.
Use new parts as required.
32. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
33. If the clutch discs are to be used again, keep the
clutch packs in the same previous assembly order
separate and record which clutch pack goes with
each clutch. Use new parts as required.
RCPH10TLB804AAL 29
34. Use a straight edge to check each clutch drive plate

and each clutch plate to be sure each part is flat. If
they are not flat a new part must be installed dur-
ing assembly. If the clutch plates are smooth or al-
most smooth, use new parts during assembly. If the
friction material is damaged or appears burned, use
new parts during assembly. Also, check the splines
for wear. Inspect the clutch drive plate for pitting,
scoring, or other damage. If there is any damage,
use new parts during assembly. If you will be us-
ing new clutch plates, soak the clutch plates in clean
transmission oil for at least an hour before assem-
bly. If you are using the old clutch plates, make sure
that the contact surfaces are coated with transmis- RCPH10TLB943AAL 30
sion oil before assembly, check the wear conditions

(see chart below). If it is 50% compared to the nom-
inal value it is suggested its replacement.
35. Inspect the bore and the shaft in the input shaft hous-
ing for damage that will cause leakage when the
clutch is assembled. Check the slots in the side of
the input shaft housing for damage from the tangs
on the clutch drive plates. Use new parts as required
during assembly.
FWD-RVS Gear Clutch *Under load of 163 kg (359.4 lb)

Clutch pack CA149306
Number of clutch steel plates 6
Nominal clutch plate thickness 2.4 ±0.05 mm
Nominal clutch kit thickness *29.00 - 29.20 mm
Maximum clutch plate wear (each side) 0.35 mm
84390833 11/10/2010
C.20.E / 210

end of the reverse shaft. Remove the bearing.
RCPH10TLB128AAL 31
37. Turn the shaft over and insert a shaft protector be-
tween the puller and the end of the reverse shaft.
Remove the bearing.
RCPH10TLB268AAL 32
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts A - D

1. Assemble new teflon ring and relevant inner O-rings,
respectively into the piston outer and inner seats.
RCPH10TLB266AAL 1
2. Apply a thin film of transmission oil on the sealing

rings just inserted.
RCPH10TLB198AAL 2
3. Insert clutch piston with 380001926 clutch pack pis-

ton installer.
RCPH10TLB931AAL 3
4. Assemble sleeve.
RCPH10TLB116AAL 4
84390833 11/10/2010
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5. Assemble spring and lock spring cover.
RCPH10TLB122AAL 5
6. Lower the lock spring cover. Insert lock ring Use tool
380100109 or CAS2379.
RCPH10TLB121AAL 6
7. Insert pin.
RCPH10TLB129AAL 7
8. Insert thrust washer.
RCPH10TLB130AAL 8
84390833 11/10/2010
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9. Insert needle cage.
RCPH10TLB131AAL 9
10. To assemble the clutch pack start with the gear on

the bench. Install the clutch plate lock ring so that
the reference mark on top of the plate made during
disassembly is facing towards the gear.
RCPH10TLB132AAL 10
11. Assemble clutch plates and clutch drive plates on the

gear . The assembled clutch pack must contain six
clutch drive plates and six clutch plates.
RCPH10TLB133AAL 11
12. Locate the pack assembly by means of two screw-

drivers.
RCPH10TLB134AAL 12
84390833 11/10/2010
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13. Assemble lock ring and washer.
RCPH10TLB135AAL 13
14. Heat the bearing to ] 80 - 100 °C (176.0 - 212.0 °F)

Assemble bearing.
RCPH10TLB135AAL 14
RCPH10TLB136AAL 15
gear, spacer, bearing, and snap ring installed on the input shaft.
84390833 11/10/2010
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16. Install the spacer and protector from kit 380040161

onto the input shaft with the chamfered end facing in.
RCPH10TLB140AAL 16
17. Slide the 380001428 expander/protector onto the in-

put shaft and over the spacer. The expander/protec-
tor will stop in the correct position to install the seal
ring in the groove.
RCPH10TLB826AAL 17
18. Heat the Teflon seal ring to 60 - 80 °C (140.0 - 176.0

°F) for 5 minutes. Install the teflon seal ring onto the
expander/protector.
RCPH10TLB826AAL 18

RCPH10TLB830AAL 19
84390833 11/10/2010
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seal ring. Use a back and forth twisting motion to
RCPH10TLB831AAL 20
seal ring. Leave the seal compressor in place for
seal ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB841AAL 21
NOTE: Repeat steps 1 through 13 for the other shaft

side with the oil grooves is down.
RCPH10TLB170AAL 22
23. Heat the bearing to 80 - 100 °C (176.0 - 212.0 °F)Use

a suitable driver to drive the bearing onto the input
shaft until the bearing makes contact with the thrust
washer.
RCPH10TLB211AAL 23
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24. Assemble snap ring. Using two pry bars lift the bear-
ings toward the snap ring to have clearance between
gear and bearing.
RCPH10TLB169AAL 24
25. Assemble the teflon seal rings as follows: place

the 380001929 spacer into the 380001933 ex-
pander/protector.
RCPH10TLB897AAL 25

spacer onto the shaft. The expander/protector will
stop in the correct position to install the seal ring in
the groove.
RCPH10TLB899AAL 26
27. Heat the Teflon seal ring to 60 - 80 °C (140.0 - 176.0

°F) for 5 minutes. Install the teflon seal ring onto the
expander/protector.
RCPH10TLB902AAL 27
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Be careful not to damage the seal ring. After the
RCPH10TLB904AAL 28
seal ring. Leave the seal compressor in place for
seal ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB904AAL 29
NOTE: For the introduction of the other three teflon rings, repeat the operations from sequence 27 to sequence 31,
using the following spacer rings: 380001931 for the 2nd teflon ring, 380001930 for the 3rd teflon ring, 380001929 for
the 4th teflon ring.
31. See the illustration. Apply compressed air of approx-
imately 6 bar to the forward clutch passage. Listen
to hear the forward piston moving to lock the forward
clutch pack. Try to move the forward gear. The for-
ward gear must not turn on the input shaft. Try to
move the reverse gear. The reverse gear must turn
freely on the input shaft. If the clutches do not work
correctly, disassemble the clutches to find the prob-
lem. RCPH10TLB054GAL 30
32. Apply compressed air of approximately 6 bar to the

reverse clutch passage. Listen to hear the reverse
piston moving to lock the reverse clutch pack. Try to
move the reverse gear. The reverse gear must not
turn on the input shaft. Try to move the forward gear.
The forward gear must turn freely on the input shaft.
If the clutches do not work correctly, disassemble the
clutches to find the problem.
RCPH10TLB054GAL 31
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33. Carry out the end float-check procedure of the clutch

pack on the both sides of the FWD-RVS GEAR
CLUTCH. In order to eliminate the end float position
the shaft on a suitable support(s) and apply a load
on the clutch counterdisk surface with a suitable
driver, as indicated in figure.
RCPH10TLB149ACL 32
34. In order to verify the end float feed the piston cham-
ber with compressed air at 6 bar (87.0 psi) and check
with a dial gauge located as shown in the photo the
real stroke “X”. Measure the end float X (see next
figure and figure 33 )
RCPH10TLB150ACL 33
35. Check the stroke of the piston. The end float value
must be: X= 1.60÷2.45 mm If the distance is not
within the range specified the clutch could be assem-
bled wrongly. Turn the clutch and repeat the same
operation for the other clutch pack (steps 33, 34 and
35).
RCPH10TLB004BAN 34
36. Assemble D shaft bearing using a suitable driver.
RCPH10TLB125ACL 35
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37. Assemble the input shaft (1). Assemble the idler

shaft (2).
RCPH10TLB177ACL 36
38. The operation is correct only if the two shafts are

fitted at the same time.
RCPH10TLB136ACL 37
Next operation:
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts B- C

1. Use approved lifting equipment to begin lifting the
secondary shaft while you use your hands to lift the
primary shaft. At the same time, move the primary
shaft back and forth to keep the primary shaft moving
freely. It can be necessary to tap the ends of the
shift rods (from below the rear housing) so that the
shift rod and fork assemblies continue to move freely.
When the primary shaft is free of the rear housing
and the secondary shaft, remove the primary shaft.
RCPH10TLB913AAL 1
2. Remove the shift rod and fork assembly.
RCPH10TLB915AAL 2
3. Remove bearing by means of an extractor.
RCPH10TLB113AAL 3
4. Remove thrust washer and third speed gear.
RCPH10TLB779AAL 4
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RCPH10TLB172AAL 5
6. Remove the bushing.
RCPH10TLB173AAL 6
NOTE: Take care during removal of sleeve, this will free the spring plates, hub pins and hub springs.
7. Remove the gear and clutch from the shaft.
RCPH10TLB174AAL 7
RCPH10TLB284AAL 8
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9. This figure shows the relationship between the plates

(1), the balls (2), the hub springs (3), and the syn-
chronizer hub (4). The synchronizer hub contains 3
plates,3 pins, and 3 springs.
RCPH10TLB076ACL 9
10. Remove fourth speed gear.
RCPH10TLB288AAL 10
RCPH10TLB184AAL 11
12. Remove the inner race bearing with a suitable ex-

tractor.
RCPH10TLB098ACL 12
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RCPH10TLB785AAL 13
14. Remove the shims (1)and the thrust washer (2).
RCPH10TLB137ACL 14
RCPH10TLB187AAL 15
16. Remove second speed gear.
RCPH10TLB193AAL 16
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17. Remove the first/second speed synchronizer assem-

bly.
RCPH10TLB101ACL 17
18. Remove synchronizer ring.
RCPH10TLB051ACL 18
19. Remove the steel ring (1)and the ring (2)together.
RCPH10TLB052ACL 19
20. Remove the tapered friction ring (1).
RCPH10TLB053ACL 20
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21. Turn the synchronizer assembly over and remove the

synchronizer ring (1)from the other side.
RCPH10TLB054ACL 21
22. Remove the steel ring (1)and the sintered ring (2).
RCPH10TLB055ACL 22
23. Remove the tapered friction ring (1).
RCPH10TLB056ACL 23
24. Support the sleeve on blocks. Push down on the hub

while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB079ACL-2 24
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25. This photo shows the relationship between the balls,

the plate, the spring, and the hub.
26. Remove first speed gear.
RCPH10TLB102ACL 26
RCPH10TLB103ACL 27
28. Remove the 4WD gear.
RCPH10TLB104ACL 28
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RCPH10TLB105ACL 29
30. Remove the inner race bearing (1)with an extractor.
31. Turn the shaft. Remove bearing.
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts B- C

1. 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 snap ring as shown.
RCPH10TLB105ACL 1
2. Assemble 4WD gear.
RCPH10TLB104ACL 2
3. Assemble the snap ring.
RCPH10TLB103ACL 3
4. Assemble the first speed gear.
RCPH10TLB102ACL 4
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5. Assemble the first/second speed synchronizer. This

photo shows the correct positions of the hub, the
sleeve, the springs, the plates, and the balls prior to
final assembly. The springs are installed in the hub,
and the plates are on the springs. The plates 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 plates.
RCPH10TLB951AAL 5
6. Use a punch or screwdriver to push the balls into the

plates and to push the plates down so that the balls
are on the flat faces of the teeth, but not into the
detent grooves. When all the balls are in position,
push the hub and the plates down until the balls move
into the detent groove.
RCPH10TLB952AAL 6
7. Install the tapered friction ring on the synchronizer

assembly.
RCPH10TLB056ACL 7
8. Use clean transmission oil to lubricate the sintered

ring and the steel ring. Install the sintered ring and
the steel ring as shown in figure.
RCPH10TLB946AAL 8
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9. Install the synchronizer ring as shown in figure. The

flat sides of the teeth must be up.
RCPH10TLB945AAL 9
10. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 10
11. Use clean transmission oil to lubricate the sintered

ring and the steel ring. Install the sintered ring and
the steel ring as shown. Install the top synchronizer
ring on the synchronizer assembly. Make sure that
the teeth on the top synchronizer 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 syn-
chronizer 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 engaged, the detent must hold the
sleeve in this position. Push the sleeve back down
to the neutral position, turn the synchronizer assem-
bly over, and repeat the procedure with the bottom RCPH10TLB946AAL 11
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 damaged parts or was not assembled
correctly. Disassemble the synchronizer assembly to
find the problem.
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12. Install the top synchronizing ring (1)so that the flat
sides of the teeth are up. Install the first/second
speed synchronizer assembly (2).
RCPH10TLB101ACL 12
13. Assemble the second speed gear.
RCPH10TLB100ACL 13
14. Assemble roll pin.
RCPH10TLB099ACL 14
15. Assemble thrust washer (1)and shims (2).
RCPH10TLB107ACL 15
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16. Assemble snap ring. Measure the backlash X be-

tween gear and thrust washer: the value must be be-
tween 0.2 -0.42 mm.
17. Use a thickness gauge.
RCPH10TLB108ACL 17
18. If backlash X is more than the value prescribed re-

move the snap ring and the washer from their seat
and, using the shims shown in the chart reach the
prescribed value. Assemble shims between thrust
washer and snap ring.
RCPH10TLB137ACL 18
19. Heat the inner race of the bearing (1)to 80 - 100 °C

(176.0 - 212.0 °F). Assemble the inner race of the
bearing (1).Use a suitable driver.
RCPH10TLB082ACL 19
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20. Assemble the outer race bearing.
RCPH10TLB097ACL 20
21. Turn the shaft. Assemble the fourth speed gear.
RCPH10TLB135ACL 21
22. Assemble the third/fourth speed synchronizer This

figure shows the correct positions of the hub (1), the
sleeve (2), the springs (3), the plates (4), and the
balls (5)prior to final assembly. The springs are in-
stalled in the hub, and the plates are on the springs.
The plates are not yet pushed down into the sleeve
and are holding the hub up out of the sleeve. The
pins are loose in the recesses of the plates.
RCPH10TLB077ACL 22
23. 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 23
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24. Install the tapered friction ring on each side the syn-
chronizer assembly.
RCPH10TLB083ACL 24
25. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assem-
bly. Install the top synchronizer ring on the synchro-
nizer assembly. Make sure that the teeth on the top
synchronizer 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 over-
come the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are com-
pletely engaged, the detent must hold the sleeve in
this position. Push the sleeve back down to the neu-
tral position, turn the synchronizer assembly over,
and repeat the procedure with the bottom synchro- RCPH10TLB134ACL 25
nizer 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 damaged parts or was not assembled correctly.
Disassemble the synchronizer assembly to find the
problem.
26. Install the third/fourth speed synchronizer assembly
onto the shaft.
RCPH10TLB106ACL 26
84390833 11/10/2010
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washer. Assemble third speed gear and the thrust
washer onto the shaft.
RCPH10TLB084ACL 27
28. Heat the bearing (1)to 80 - 100 °C (176.0 - 212.0 °F).

Assemble bearing (1). Use a suitable driver.
RCPH10TLB085ACL 28
29. Heat the inner race of the bearing (1)to 80 - 100 °C

(176.0 - 212.0 °F). Assemble the inner race of the
bearing. Use a suitable driver.
RCPH10TLB086ACL 29
30. Turn the shaft. Heat the bearing to 80 - 100 °C (176.0

- 212.0 °F). Assemble bearing. Use a suitable driver.
RCPH10TLB088ACL 30
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31. Fit the pre assembled forks 3rd and 4th speed and
1st and 2nd as shown in the photo.
RCPH10TLB163ACL 31
32. Assemble the 4WD shaft Remove the secondary

shaft and the primary shaft. Use suitable lifting
apparatus.
RCPH10TLB178ACL 32
33. Position the group with care paying attention to the

location of fork pins in their seats.
RCPH10TLB164ACL 33
Next operation:
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD)

1. Remove shaft E.
RCPH10TLB719AAL 1
2. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 2
NOTE: Make a mark on the top end of the reverse shaft so that you can install the reverse shaft with the same end
up during Assembly.
3. Remove bearing.
RCPH10TLB917AAL 3
RCPH10TLB188AAL 4
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5. Remove sleeve.
RCPH10TLB889AAL 5
6. Remove the two O-rings and sealing rings from the

shaft.
RCPH10TLB890AAL 6
7. Remove the four-wheel drive clutch tube (7) from the

front housing only if the front housing must be re-
placed or if the tube is leaking or damaged.
RCPH10TLB027ABL 7
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD)

1. Assemble the O-Rings on the shaft. Lubricate with
oil transmission.
RCPH10TLB090ACL 1
2. Assemble sleeve.
RCPH10TLB129ACL 2
3. Assemble springs.
RCPH10TLB128ACL 3
4. Install spacer.
RCPH10TLB127ACL 4
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5. Position washer (1)and snap ring (2).
RCPH10TLB092ACL 5
6. Use a suitable tool to press the springs retainer down

until you have access to the snap ring. Install the
snap ring in the groove. Release the tension and
remove the tool. Make sure that the snap ring is
seated in the recess in the spring retainer.
RCPH10TLB091ACL 6
7. Place the protector CAxxxxxx onto the shaft. The

expander/protector will stop in the correct position to
install the teflon sealing ring in the groove. Heat the
teflon sealing ring to 60 - 80 °C (140.0 - 176.0 °F)
Install it onto the expander/protector.
RCPH10TLB093ACL 7

RCPH10TLB094ACL 8
84390833 11/10/2010
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RCPH10TLB095ACL 9
from the shaft.
RCPH10TLB095ACL 10
11. Assemble protector 380001933. Repeat the opera-

tions from sequence 7 to sequence 10 for the intro-
duction of the second teflon ring. Lubricate the seals
with oil transmission.
RCPH10TLB096ACL 11
12. Apply air compressed at about 6 bar (87.0 psi)to

4WD clutch oil passage (see arrow) by plugging the
opposite hole with a finger. The sleeve should be
moving when compressing the springs . The 4WD
gear should move freely on 4WD shaft. If the opera-
tion is incorrect, dismantle to find the problem.
RCPH10TLB164GAL 12
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13. Install bearing.
RCPH10TLB124ACL 13
14. Install gear.
RCPH10TLB123ACL 14
15. Assemble shafts B and C. Assemble shaft E.
RCPH10TLB122ACL 15
16. If the four-wheel drive clutch tube (1)was removed

from the front housing, install the four-wheel drive
clutch tube. Torque wrench setting TRANSMISSION
Powershift - Torque (C.20.E). Assemble the front
half housing on the rear half housing
RCPH10TLB130ACL 16
Next operation:
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shift rails

- forks
1. Remove the secondary shaft and the primary shaft .
Use suitable lifting device.
RCPH10TLB178ACL 1
2. Remove shift forks 1st and 2nd gear (1)and shift rail
(2).
RCPH10TLB143ACL 2
3. Remove shift forks 3rd and 4th gear (1)and shift rail
(2).
RCPH10TLB142ACL 3
4. If disassembly is required, remove the spring pins

(1)and separate the shift forks from the shift rails.
Make sure that you remember how the parts are as-
sembled and which parts go together. Inspect all
parts for burrs and excessive wear.
RCPH10TLB198ACL 4
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shift rails - forks

1. Pay attention to the proper forks assembly on the
shift rails holes. The shift rails are equal
RCPH10TLB141ACL 1
2. Assemble shift forks 1st and 2nd gear (1)onto the

shift rail (2). Dimension A: about 46 mm
RCPH10TLB073ACL 2
3. Assemble shift forks 3rd and 4th gear (1)onto the shift
rail (2). Dimension B: about 62 mm
RCPH10TLB074ACL 3
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4. Pay attention to the proper assembly
RCPH10TLB075ACL 4
5. Position the roll pin.
RCPH10TLB198ACL 5
6. 1st and 2nd gear shift fork. Assemble the spring pin
to lock the fork to the shift rail.
RCPH10TLB071ACL 6
7. 3rd and 4th gear shift fork. Assemble the spring pin
to lock the fork to the shift rail.
RCPH10TLB072ACL 7
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8. Assemble shift forks 3rd and 4th gear and shift rail
on the synchronizer.
RCPH10TLB142ACL 8
9. Assemble shift forks 1st and 2nd gear and shift rail
on the synchronizer.
RCPH10TLB143ACL 9
10. Assemble the 4WD shaft on the rear half-housing.

Assemble the secondary shaft and the primary shaft.
Use suitable lifting equipment.
RCPH10TLB178ACL 10
11. Position the group with care paying attention to the

location of fork pins in their seats.
RCPH10TLB164ACL 11
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Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed

gears shift rails adjustment - Back side measurement
1. Operate on the front side. Remove the screw and
the front engagement bushing with shims.
RCPH10TLB213ACL 1
2. Assemble the special tool CAXXXXXX for the load

application.
RCPH10TLB242ACL 2
3. Pull the special tool in order to apply a 2 kg load.
RCPH10TLB241ACL 3
4. Control and note the calibrated length A of the special

tool CAXXXXXX (calibrated length A= 115 mm)
RCPH10TLB263ACL 4
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5. Operate on the rear side. Assemble the special tool

CAXXXXXX and use it as a guide for the special tool
.
RCPH10TLB258ACL 5
6. Assemble the special tool CAXXXXXX..
RCPH10TLB259ACL 6
7. Assemble the special tool CAXXXXXX.
RCPH10TLB260ACL 7
8. Assemble the special tool CAXXXXXX for the splined

shaft blocking.
RCPH10TLB261ACL 8
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9. Measure the distance from the special tool shoulder

to the upper shaft end by using a depth gauge. Note
the measured value M(R)
RCPH10TLB262ACL 9
10. Calculate the dimension C value: C= M(R)- A [ m m ]
RCPH10TLB026ACL 10
11. Measure the rear engagement bushing outer length

and note the measured value LE(R).
RCPH10TLB264ACL 11
12. Measure the rear engagement bushing depth and

note the measured value LI(R).
RCPH10TLB265ACL 12
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13. Calculate total shim SR value for the rear engage-

ment bushing: S(R)= C - (LE(R)- LI(R)) [ m m ]
RCPH10TLB016ACL 13
14. Operate on the rear side. Remove the special tool

and assemble the special tool to the upper shaft.
Assemble the shims by using the special tool as a
guide.
RCPH10TLB266ACL 14
15. Assemble the rear engagement bushing by using the

special tool as a guide, in order to assemble the
shims too.
RCPH10TLB268ACL 15
NOTE: The bushing external slots must be positioned as shown in figure.

16. Shaft-bushing coupling: the bushing rotation stop
tooth must be coupled with the slot on the upper
shaft.
RCPH10TLB025ACL 16
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17. Operate on the front side. Remove the special tool

for the load application. Operate on the rear side.
Assemble the special tool to the upper shaft.
RCPH10TLB243ACL 17
Next operation:
84390833 11/10/2010
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gears shift rails adjustment - Front side measurement
1. Operate on the front side. Assemble the special tool
and use it as a guide for the special tool . Assemble
the special tool . Assemble the special tool.
RCPH10TLB210ACL 1
2. Operate on the rear side. Pull the special tool in order

to apply a 2 kg load to the upper shaft.
RCPH10TLB243ACL 2
3. Operate on the front side. Measure the distance from

the special tool shoulder to the upper shaft end by
using a depth gauge. Note the measured value M(F).
RCPH10TLB210ACL 3
4. Calculate the dimension B value: B= M(F)- A [ m m

] Where A is the calibrated length on the special tool
(calibrated length A= 115 mm)
RCPH10TLB027ACL 4
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5. Measure the front engagement bushing outer length

and note the measured value LE(F).
RCPH10TLB264ACL 5
6. Measure the front engagement bushing depth and

note the measured value LI(F).
RCPH10TLB265ACL 6
7. Calculate total shim SF value for the rear engage-

ment bushing: SF= C - ( LE(F)- LI(F)) [mm]
RCPH10TLB016ACL 7
8. Operate on the front side. Remove the special tool

and assemble the special tool to the upper shaft.
Assemble the shims by using the special tool as a
guide.
RCPH10TLB211ACL 8
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9. Assemble the front engagement bushing by using

the special tool as a guide, in order to assemble the
shims too.
RCPH10TLB212ACL 9
NOTE: The bushing external slots must be positioned as shown

10. Remove the special tool . Assemble the bushing
fastening screw.
RCPH10TLB213ACL 10
11. Tighten the bushing fastening screw to the requested

torque TRANSMISSION Powershift - Torque
(C.20.E).
RCPH10TLB214ACL 11
Next operation:
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gears shift rails adjustment - Dimension "D" measurement
1. Operate on the rear side. Push the special tool (t1)
in order to apply a 2 kg load as shown in figure.
RCPH10TLB244ACL 1
2. Operate on the front side. Measure the distance D(1)

from the ledge to the upper shaft end by using a
depth gauge. Note the measured value D(1).
RCPH10TLB215ACL 2
3. Measure the depth D(2) from the ledge to the pistons

seat end by using a depth gauge. Note the measured
value D(2).
RCPH10TLB028ACL 3
4. D(2) measurement.
RCPH10TLB216ACL 4
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5. Calculate and note the dimension D value: D = D(2)-

D(1) [ m m ]
RCPH10TLB029ACL 5
Next operation:
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gears shift rails adjustment - Neutral position measurement
1. Remove the bolt from the front piston.
RCPH10TLB219ACL 1
2. Control and note the front piston length P (P= 19 mm)
RCPH10TLB247ACL 2
3. Measure and note the screw head height T.
RCPH10TLB247ACL 3
4. Operate on the front side. Measure and note the

depth D(1) from the ledge to the first shoulder into
the upper shaft pistons seat.
RCPH10TLB218ACL 4
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5. Measure and note the depth D(3). Calculate the

depth D(4): D(4)= D(2)- D(3) [ mm]
RCPH10TLB030ACL 5
6. - D4 is the dimension calculated in the previous step;

- D is the dimension calculated in the previous para-
graph.
RCPH10TLB031ACL 6
7. Calculate the value of the total shim S(V) that have to

be positioned under the screw (8) head: S(V)= D(4)-
(D/2) - P -T [ mm ]
RCPH10TLB032ACL 7
8. Assemble the screw and the shims to the front piston.
RCPH10TLB245ACL 8
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9. Stop the piston with a suitable open-end wrench then

tighten the screw to the requested torque.
RCPH10TLB219ACL 9
10. Verify the indicated distance: P+S(V)+ T [ mm ]
RCPH10TLB248ACL 10
11. Operate on the rear side. Engage the “neutral” posi-

tion by using the special tool.
RCPH10TLB243ACL 11
12. Remove the special tool. Assemble the bushing fas-

tening screw to the shift rail.
RCPH10TLB208ACL 12
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13. Tighten the rear bushing fastening screw to the re-

quested torque.
RCPH10TLB209ACL 13
14. Assemble the pistons.
RCPH10TLB015ACL 14
15. Proceed with the speed gear switches check proce-

dure.
RCPH10TLB033ACL 15
Next operation:
Clutch and gear - Check (C.20.E)
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Clutch and gear - Check - S-Type (SPS Power Syncro) - Speed gears
switches - Checking procedure
1. Prepare the special tool CAXXXXXX , composed by
the threaded tie-rod, the regulation nut, the spacer
and by the two reference pistons.
RCPH10TLB109ACL 1
2. Operate on the back side. Assemble to the transmis-

sion the special tools CAXXXXXX , and CAXXXXXX
as shown in figure.
RCPH10TLB220ACL 2
3. If not assembled, insert the switch detents and the

relative springs into the gear switches holes.
RCPH10TLB221ACL 3
4. If not assembled, assemble the gear switches.
RCPH10TLB222ACL 4
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5. Assemble the upper gear switches. (3rd) 3rd gear

switch; (4th) 4th gear switch; and the lower: (1st) 1st
gear switch; (2nd) 2nd gear switch.
RCPH10TLB151ACL 5
6. Tighten the switches to the specified torque TRANS-

MISSION Powershift - Torque (C.20.E).
RCPH10TLB223ACL 6
7. To tighten the 2nd and 4th gear switch, use a wrench.
RCPH10TLB224ACL 7
8. Prepare the data control electronic box CAXXXXXX

for the switches regulation: the electronic box must
be similar to the one schematic shown in figure. The
box must have four pilot light, each one correspond-
ing to a different engagement switch, that light when
the gear is engaged (in figure the pilot lights are
marked with “SW” followed by the gear number). The
simultaneous lighting of two pilot lights correspond-
ing to switches installed on the same shaft, corre-
spond to the neutral gear engagement (in figure the
neutral position is marked with “N”).
RCPH10TLB018ACL 8
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9. Connect the switches cables to data control the elec-

tronic box.
RCPH10TLB225ACL 9
10. Connect the switches cables as shown in figure: A

- 3rd gear switch; B - 4th gear switch; C - 1st gear
switch; D - 2nd gear switch.
RCPH10TLB024ACL 10
11. Operate on the front side. Remove the screw from

bushing.
RCPH10TLB213ACL 11
NOTE: The gear switches check procedure starts with the switches assembled on the upper shaft (3rd and 4th gear
switches).
12. Assemble the special tool CAXXXXXX to the upper
shaft, by screwing it to the shaft.
RCPH10TLB232ACL 12
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13. Push the special tool CAXXXXXX until the end of

stroke, in order to engage the third gear. Fix the
spacer on the special tool to the transmission by us-
ing two M8 screws.
RCPH10TLB226ACL 13
14. Operate on the back side. Assemble a comparator

for linear measurement and position the comparator
stylus tip on contact with the upper shaft end.
RCPH10TLB227ACL 14
15. Positioning of the stylus tip on contact with the upper

shaft.
RCPH10TLB227ACL 15
16. It is possible to make the measurements with a depth

gauge instead of the comparator.
RCPH10TLB231ACL 16
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17. In the actual assembly position, on the electronic

box, must be lighted the pilot light corresponding to
the third gear engagement.
RCPH10TLB229ACL 17
NOTE: Set the comparator to zero.

18. Operate on the front side. Proceed to the switches
check for the FORWARD STROKE as indicated on
the following steps, by regulating the upper shaft
position with the regulation nut installed on the
CAXXXXXX special tool. Turn the nut in order to
move the upper shaft toward the fourth gear en-
gagement (front side).
RCPH10TLB230ACL 18
19. During the checking procedure compile the check ta-

ble and compare the measured values with the refer-
ence ones. Insert the measured values on the “MEA-
SURED VALUE” column.
RCPH10TLB019ACL 19
20. The actual position (third gear engaged at end of the

stroke and SW3 light switched to ON) corresponds
to the “zero” position and is indicated in table with “0”
(THIRD GEAR ENGAGED).
RCPH10TLB020ACL 20
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NOTE: Reminder: The procedure starts with the upper shaft switch check (third and fourth gear), so the involved pilot
lights are the ones relative to SW3 and SW4 switches.
21. Operate slowly on the regulation nut as shown in step
[19], until the SW3 pilot light turns to OFF. Note on the
table the value measured by the comparator (THIRD
GEAR - MEASURE 1)
RCPH10TLB230ACL 21
22. Electronic box status in the current position.
RCPH10TLB018ACL 22
23. Operate slowly on the regulation nut, until the SW4

pilot light turns to ON. Note on the table the value
measured by the comparator (NEUTRAL POSITION
- MEASURE 2).
RCPH10TLB230ACL 23
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RCPH10TLB022ACL 24

- MEASURE 3).
RCPH10TLB230ACL 25
26. Electronic box status in the current position (neutral

position).
RCPH10TLB021ACL 26
27. Operate slowly on the regulation nut until the SW4

pilot light turns to OFF. Note on the table the value
- MEASURE 4).
RCPH10TLB230ACL 27
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RCPH10TLB020ACL 28
29. Operate slowly on the regulation nut until the SW3

pilot light turns to OFF. Note on the table the value
- MEASURE 5).
RCPH10TLB230ACL 29
RCPH10TLB018ACL 30

measured by the comparator (FOURTH GEAR -
MEASURE 6).
RCPH10TLB230ACL 31
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RCPH10TLB022ACL 32
33. Operate slowly on the regulation nut, until the end of

the stroke and note on the table the value measured
by the comparator (FOURTH GEAR - MEASURE 7)
RCPH10TLB230ACL 33
RCPH10TLB022ACL 34
35. Operate on the front side. Proceed to the switches

check for the BACKWARD STROKE by carrying out
backwards the steps from [21] to [34] and note the
measured values on the check table. Turn the nut in
order to move the upper shaft toward the third gear
engagement (back side).
RCPH10TLB230ACL 35
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36. Proceed with the lower shaft switches check (first

and second gear). Repeat the operations from step
[12] to step [34], where it must be used SW1 instead
of SW3 and SW2 instead of SW4. Carry out the
same measure by using the linear comparator and
note the values in the relative column on the checking
table.
RCPH10TLB230ACL 36
37. Compare the measured values obtained from the

procedure with the reference values.
RCPH10TLB023ACL 37
38. If the check results are not positive, adjust the shims
to obtain the prescribed tolerance range. Carry out
the switches check procedure again.
RCPH10TLB017ACL 38
Third and fourth gear check list

Stroke Gear Measure SW3 SW4 Measured Reference Result
Value (mm) Value (mm)
- ON OFF 0 Engaged
3rd
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
7.6/8.8
3 OFF ON OFF ON
Forward Neutral
4 OFF ON OFF ON
11.4/12.6
5 OFF OFF
6 OFF ON 18.7/19.6
4th
7 OFF ON End of stroke
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Third and fourth gear check list

- OFF ON Engaged
4th
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
7.6/8.8
3 OFF ON OFF ON
Backward Neutral
4 OFF ON OFF ON
11.4/12.6
5 OFF OFF
3rd 6 ON OFF 18.7/19.6
7 ON OFF End of stroke
First and second gear check list

Stroke Gear Measure SW1 SW2 Measured Reference Result
Value (mm) Value (mm)
- ON OFF 0 Engaged
1st
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
8.1/9.3
3 OFF ON OFF ON
Forward Neutral
4 OFF ON OFF ON
11.8/13.0
5 OFF OFF
6 OFF ON 19.6/20.5
2nd
7 OFF ON End of stroke
- OFF ON Engaged
2nd
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
8.1/9.3
3 OFF ON OFF ON
Backward Neutral
4 OFF ON OFF ON
11.8/13.0
5 OFF OFF
1st 6 ON OFF 19.6/20.5
7 ON OFF End of stroke
Next operation:
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Housing - Disassemble - S-Type (SPS Power Synchro) - Front

housing
1. Remove the cap screws that fasten the front and rear
housings together.
RCPH10TLB258AAL 1
2. Remove bearing snap ring
RCPH10TLB176ACL 2
3. Untighten and remove flange retaining screw. Use a

screwdriver and two screws to avoid flange rotation.
RCPH10TLB110ACL 3
4. Remove washer.
RCPH10TLB111ACL 4
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5. Remove flange (1)and O-ring (2).
RCPH10TLB112ACL 5
6. Remove the three cap screws.
RCPH10TLB113ACL 6
7. Remove the cover.
RCPH10TLB114ACL 7
8. Remove the O-ring from the cover.
RCPH10TLB115ACL 8
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9. Remove the seal from the cover.
RCPH10TLB116ACL 9
10. Remove screws.
RCPH10TLB132ACL 10
11. Remove screws.
RCPH10TLB117ACL 11
12. Use lever to remove the front half housing. Lift the
front half housing by means of two hooks.
RCPH10TLB133ACL 12
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13. Use a plastic mallet to detach the half housing if nec-

essary.
RCPH10TLB200ACL 13
NOTE: Do not lift the shafts of the transmission; remove the shaft from relative seats could produce seal rings damage.
14. The outer rings of the bearings for the primary shaft
(1)and for the secondary shaft (2)can stay with ei-
ther the shafts or the front housing. Remove the two
bearings.
RCPH10TLB119ACL 14
15. Remove the bearings of the primary shaft (1), and

secondary shaft (2) from the front half housing and
assemble all the bearings on the relative shaft.
RCPH10TLB250ACL 15
NOTE: Do not overturn the bearings; the bearings must be assembled in the same position.
16. Remove the 4WD shaft (1) with a plastic mallet.
RCPH10TLB206ACL 16
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17. Remove bearing.
RCPH10TLB118ACL 17
(2).
RCPH10TLB177ACL 18
19. Remove the four-wheel drive clutch tube (1)from the

front housing only if the front housing must be re-
placed or if the tube is leaking or damaged.
RCPH10TLB044ACL 19
20. Replace O-rings (N° 6), if necessary.

21. Close all oil pipe holes with rubber plugs.
RCPH10TLB249ACL 20
Next operation:
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Housing - Assemble (C.20.E)
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Housing - Assemble - S-Type (SPS Power Synchro) - Front housing

NOTE: Thoroughly inspect the transmission prior to assembly.
1. Remove the oil from the rear housing edge. Examine
with care the housing and the inner parts to check
the presence of any impurity (dirty, file dust or chips).
Clean with care to remove all the impurities.
RCPH10TLB161ACL 1
2. Remove all the old sealant from the rear housing cou-
pling surface with a suitable tool.
RCPH10TLB202ACL 2
3. Use a sealant solvent.
RCPH10TLB201ACL 3
4. Clean the O-Rings seats. Degrease and dry the cou-

pling surface of the rear housing.
RCPH10TLB203ACL 4
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5. Apply the prescribed sealant on the coupling surface

of the rear housing .
RCPH10TLB204ACL 5
6. Spread the sealant in a film of uniform thickness.
RCPH10TLB162ACL 6
NOTE: Do not put the sealant in the O-Ring seats.

7. Clean the O-Ring seats.
RCPH10TLB205ACL 7
8. Assemble the 6 O-rings.
RCPH10TLB254ACL 8
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9. Push the 6 O-Rings into their seats.
RCPH10TLB254ACL 9
10. Clean and assemble the 4WD shaft.
RCPH10TLB719AAL 10
11. Use clean transmission oil to lubricate the bearing

for the primary shaft (1)and the bearing for the sec-
ondary shaft (2). Install the bearings.
RCPH10TLB250ACL 11
12. If the four-wheel drive clutch tube (1)was removed

from the front housing, install the four-wheel drive
clutch tube. Torque to TRANSMISSION Powershift
- Torque (C.20.E).
RCPH10TLB044ACL 12
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13. Install the front half housing on the rear half housing.
Make sure that the bearings on the shafts go straight
into the bores in the front half housing. Push the
front half housing all the way down on the rear half
housing.
RCPH10TLB169ACL 13
14. Assemble screws (16). Torque to 100 N·m (73.8 lb

ft).
RCPH10TLB259AAL 14
15. Assemble screws (16). Tightening torque 50 N·m

(36.9 lb ft).
RCPH10TLB258AAL 15
16. Use clean transmission oil to lubricate the bearing

for the 4WD shaft. Install the bearing (1)on the 4WD
shaft. Use tool CAxxxxxx.
RCPH10TLB089ACL 16
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17. The seal ring must be installed to the end of its seat
into the cover, if necessary push the seal ring to the
end of its seat with the special tool CAxxxxxx and a
hammer.
RCPH10TLB115ACL 17
18. Use the special tool CAxxxxxx and a hammer to in-

stall a new seal (1)in the cover (2).
RCPH10TLB120ACL 18
19. Use the special tool CAxxxxxx to push the seal just
to the end. After the assembly, lubricate the seal ring
lip with grease
RCPH10TLB013ACL 19
20. Assemble the O-Ring.
RCPH10TLB115ACL 20
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21. Install the cover in the front housing.
RCPH10TLB114ACL 21
22. Install the three cap screws which fasten the cover
to the front housing. Tightening torque TRANSMIS-
SION Powershift - Torque (C.20.E).
RCPH10TLB113ACL 22
23. Install a new O-ring in the four-wheel drive flange.
RCPH10TLB112ACL 23
24. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB121ACL 24
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RCPH10TLB111ACL 25
26. Assemble screw. Use screwdriver to avoid flange ro-

tation. Tightening torque TRANSMISSION Power-
shift - Torque (C.20.E).
RCPH10TLB110ACL 26
27. Assemble the bearing snap ring. Assemble the oil

pump TRANSMISSION Powershift - Assemble
(C.20.E).
RCPH10TLB176ACL 27
28. Assemble the groups.
RCPH10TLB175ACL 28
Next operation:
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Electronic control - Disassemble S-Type (SPS Power Synchro)

- Switches and sensors
NOTE: Some of the following images may not represent your transmission, the procedures are the same.
1. Drain the oil from the transmission hydraulic circuit.
Remove screws, (1)Remove pipe (3) Remove gas-
kets (2)
RCPH10TLB131ACL 1
2. Remove the wiring harness (1)Remove the temper-

ature sensor and thermostat (2)
RCPH10TLB036ACL 2
3. Remove the male pressure switch (2)and washer

(1)Remove the regulating pressure valve (3)Remove
the speed sensor (4)and washer seal (5)
RCPH10TLB037ACL 3
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4. Remove the screw (1)and bracket (2). Remove the

switch gear (3)and O-rings (4).
RCPH10TLB038ACL 4
5. If necessary, remove the O-rings and the back-up

rings from the valve.
RCPH10TLB242ACL 5
NOTE: Seal rings must not be re-used

6. Remove springs (1)and pins (2)
RCPH10TLB241ACL 6
Next operation:
Electronic control - Assemble (C.20.E)
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Electronic control - Assemble - S-Type (SPS Power Synchro) -

Switches and sensors
Prior operation:
Electronic control - Disassemble (C.20.E)
1. Assemble the switch detents (1)and springs (2). Use

a magnet, if necessary.
RCPH10TLB003BAN 1
2. Remove the screw (1) and bracket (2). Remove the

switch gears (3) and O-rings (4). Torque to TRANS-
MISSION Powershift - Torque (C.20.E)
RCPH10TLB038ACL 2
3. Assemble the switch gears as shown.
RCPH10TLB151ACL 3
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4. Use special tool CAxxxxx to assemble the 2nd and

4th gear switches.
RCPH10TLB157ACL 4
5. Assemble new O-rings and back-up rings on the

valve.
RCPH10TLB242ACL 5
6. Assemble the male pressure switch (1) with washer

(2). Assemble the regulating pressure valve (3).
Remove the speed sensor (4) with washer seal (5).
Torque to TRANSMISSION Powershift - Torque
(C.20.E)
RCPH10TLB037ACL 6
7. Assemble the temperature sensor and thermo-

stat (1). Torque to TRANSMISSION Powershift -
Torque (C.20.E). Assemble the wiring harness (2).
RCPH10TLB036ACL 7
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8. Assemble pipe (3)and screws (1)Replace gaskets

(2)and torque to TRANSMISSION Powershift -
Torque (C.20.E)
RCPH10TLB131ACL 8
Next operation:
Control valve - Disassemble (C.20.E)
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Index

Clutch and gear - Check - S-Type (SPS Power Syncro) - Speed gears switches - Checking procedure . . . . . . 264
Clutch and gear - Exploded view - H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Back side mea-
surement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Dimension "D"
measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Front side mea-
surement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Neutral position
measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Control valve - Assemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . 172
Control valve - Disassemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . 164
Electronic control - Assemble - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . 290
Electronic control - Disassemble S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . 288
Housing - Assemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Housing - Disassemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Shaft - Assemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Shaft - Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Shaft - Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Shaft - Assemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Shaft - Disassemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Shaft - Disassemble - S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Shaft - Exploded view - H-Type - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TRANSMISSION Powershift - Assemble - H-type - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
TRANSMISSION Powershift - Assemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 50
TRANSMISSION Powershift - Assemble - S-type (SPS power synchro) Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TRANSMISSION Powershift - Cleaning - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
TRANSMISSION Powershift - Disassemble - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
TRANSMISSION Powershift - Disassemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . 48
TRANSMISSION Powershift - Disassemble - S-type (SPS power synchro)- Oil pump . . . . . . . . . . . . . . . . . . . . . . 52
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TRANSMISSION Powershift - Exploded view - H-type - 1st, 3rd, 4th gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION Powershift - Exploded view - H-type - transmission assembly - 4 wheel drive shaft . . . . . . . . . 20
TRANSMISSION Powershift - Exploded view - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . 22
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . 30
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . 34
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . 28
TRANSMISSION Powershift - Exploded view - S-type (SPS Power Synchro) - Oil pump . . . . . . . . . . . . . . . . . . . . 24
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Rear cover . . . . . . . . . . . . . . . . . 32
TRANSMISSION Powershift - Exploded view - S-type (SPS power synchro) - Shaft A - D . . . . . . . . . . . . . . . . . . . 36
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Shafts B - C . . . . . . . . . . . . . . . . 38
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . 42
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . 26
TRANSMISSION Powershift - Exploded view -S-type (SPS power synchro) - transmission assembly - 4 wheel drive
shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TRANSMISSION Powershift - General specification - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMISSION Powershift - General specification - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION Powershift - Inspect - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
TRANSMISSION Powershift - Install - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
TRANSMISSION Powershift - Remove - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TRANSMISSION Powershift - Special tools - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMISSION Powershift - Torque - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION Powershift - Torque - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Service Manual: 580N 580SN-WT 580SN 590SN

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TRANSMISSION, DRIVE AND PTO OUT - C

Printed in U.S.A. Part number 84393972

TRANSMISSION Power Shuttle - 20.C

TRANSMISSION, DRIVE AND PTO OUT - C

TRANSMISSION Power Shuttle - 20.C

TRANSMISSION Power Shuttle - General specification

Capacity - Two wheel drive

Capacity - Four wheel drive

TRANSMISSION Power Shuttle - Torque

TRANSMISSION Power Shuttle - Special tools

CAS-2379 Input shaft holder and spring compressor

CAS-2381 Seal driver

CAS-2378 transmission leg set

CAS2771A - Teflon seal installation tool kit - 4 wheel drive

1. CAS2771-2 Seal Expander/Protector

TRANSMISSION Power Shuttle - Exploded view

TRANSMISSION Power Shuttle - Exploded view - Four wheel drive

TRANSMISSION Power Shuttle - Exploded view - Two wheel drive

Control valve - Exploded view - Transmission control valve

Shaft - Exploded view - Input shaft

Shaft - Exploded view - Shift rod and forks

Shaft - Exploded view - Secondary shaft

Shaft - Exploded view - Four wheel drive shaft

TRANSMISSION Power Shuttle - Remove

4. Disconnect the supply line (1) from the transmission,

5. Disconnect the differential lock hose.

6. If equipped, remove the front cab floor mat (1). Re-

7. Disconnect the return spring for the shift lever. Dis-

8. Disconnect the wiring harness connector for the

15. If equipped, remove the retainer and bolts that fasten

18. Remove the hydraulic pump.

20. Install the engine turning tool, 380000988, to turn the

TRANSMISSION Power Shuttle - Install

NOTICE: Before staring the engine do the following

NOTE: If removed, install the rear wheels.

Control valve - Disassemble - Four wheel drive valve (if equipped)

2. Remove the solenoid coil.

3. Remove the solenoid valve.

4. Remove the check valve from the solenoid valve

5. Remove the three O-rings from the solenoid valve.

Control valve - Assemble - Four wheel drive valve (if equipped)

2. Install the check valve in the valve body as shown.

3. Install the solenoid valve in the solenoid valve body.

4. Install the solenoid coil on the solenoid valve.

5. Install the nut.

6. Tighten the nut to a torque of 8 Nm (71 pound-

Control valve - Disassemble - Transmission control valve

2. Remove the seal.

3. Remove the first solenoid coil.

4. Remove the O-ring from the either the solenoid coil

5. Remove the second solenoid coil.

6. Remove the O-ring from the second solenoid coil.

7. The remaining O-ring can stay with either the sole-

9. Use a small punch to release the locking tab on the

11. Repeat steps 8 and 10 for the remaining wires and

13. Remove the solenoid coil.

14. Loosen and remove the solenoid plunger.

15. Remove the O-rings from the solenoid plunger.