Hyster 897949 11 03 srm0635

FOUR-SPEED
POWERSHIFT
TRANSMISSION
REPAIR
(HR 36000)
H36.00-48.00E (H800-1050E) [D117];
RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH,
RS45-46TP, RS45-46TBP [A222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227]
PART NO. 897949 1300 SRM 635
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
Do not lift heavy parts by hand, use a lifting mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
Keep the unit clean and the working area clean and orderly.
Use the correct tools for the job.
Keep the tools clean and in good condition.
Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
Always fasten a DONOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
Be sure to follow the WARNING and CAUTION notes in the instructions.
Gasoline, Liquid PetroleumGas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Four-Speed Powershift Transmission Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Torque Converter Repair ................................................................................................................................... 2
Torque Converter, Remove ............................................................................................................................ 2
Torque Converter, Disassemble .................................................................................................................... 2
Clean and Inspect .......................................................................................................................................... 2
Torque Converter, Assemble ......................................................................................................................... 2
Torque Converter (Turbine) Housing, Disassemble..................................................................................... 5
Relief Valve for Lube Pressure, Disassemble and Assemble....................................................................... 5
Oil Sealing Rings Sleeve, Replace ................................................................................................................ 5
Torque Converter Housing, Assemble .......................................................................................................... 6
Torque Converter, Install .............................................................................................................................. 6
Transmission Repair.......................................................................................................................................... 6
Remove, Transmission Only.......................................................................................................................... 6
Remove, Transmission and Engine Assembly.............................................................................................. 7
Transmission, Disassemble........................................................................................................................... 8
Output Shaft, Disassemble and Assemble............................................................................................... 9
Fourth-Speed Shaft, Disassemble and Assemble .................................................................................... 10
Third-Speed Shaft, Disassemble and Assemble ...................................................................................... 11
Forward Shaft and Clutch, Disassemble and Assemble ......................................................................... 14
Reverse and Second-Speed Shaft and Clutch, Disassemble and Assemble ........................................... 16
First-Speed Shaft and Clutch, Disassemble and Assemble .................................................................... 18
Input Shaft, Disassemble and Assemble.................................................................................................. 20
Speed Sensor, Install ..................................................................................................................................... 20
Transmission, Clean and Inspect.................................................................................................................. 22
Transmission, Assemble................................................................................................................................ 22
Control Valve.................................................................................................................................................. 24
Clean and Inspect...................................................................................................................................... 24
Assemble and Install................................................................................................................................. 24
Install, Transmission .................................................................................................................................... 25
Install, Transmission and Engine Assembly................................................................................................ 25
Clean Oil System of Transmission after Major Repair................................................................................ 26
Automatic Powershift Control (APC 100)......................................................................................................... 26
Functional Description.................................................................................................................................. 26
Fuses .............................................................................................................................................................. 29
Transmission Control Lever.......................................................................................................................... 29
First-Speed Shaft Bearings Adjustment........................................................................................................... 32
Torque Converter Stall Speed Check................................................................................................................ 35
Transmission Oil Pressures Check ................................................................................................................... 35
Clutch Pressures Check ................................................................................................................................ 35
Torque Converter (Torque Converter Regulator) Oil Pressure Check........................................................ 35
Troubleshooting.................................................................................................................................................. 37
Diagrams, Schematics, or Arrangements......................................................................................................... 39
Figure 31. Transmission Hydraulic Diagram.......................................................................................... 40
This section is for the following models:
H36.00-48.00E (H800-1050E) [D117];
RS45-30CH, RS46-35CH, RS45-25IH, RS46-30IH,
RS45-46TP, RS45-46TBP [A222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227]
2003 HYSTER COMPANY i
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 635 General
General
This four-speed powershift transmission is an
HR-36000 series transmission manufactured by
Spicer-Clark.
This section has the repair procedures for the
torque converter, transmission, control valve, and
the oil pump for the transmission. See the section
Four-Speed Powershift Transmission Descrip-
tion and Operation 1300 SRM 634 for information
on the operation of this transmission. The transmis-
sion assembly is shown in Figure 1.
ALWAYS replace all seals, O-rings, metal seal rings,
gaskets, and snap rings with new ones. Lubricate all
seals with clean transmission oil before installation.
Lubricate metal seal rings with multipurpose grease
#2 before installation. Use care with seals especially
during installation to prevent damage.
If possible, use magnaflux to check all gears and
shafts. Check gear teeth for wear, pitting, chipping,
nicks, cracks, or scoring. If gears show spots where
hardened surface has worn through, replace gear.
Make sure shafts are not bent or the splines twisted.
1. TRANSMISSION OIL PUMP
2. FORWARD CLUTCH
3. THIRD CLUTCH
4. REAR COVER
5. FIRST CLUTCH
6. OUTPUT YOKE
7. OUTPUT GEAR
8. TRANSMISSION HOUSING
9. OIL SUMP AND PAN
10. FOURTH CLUTCH
11. SECOND CLUTCH
12. REVERSE CLUTCH
13. IMPELLER HUB GEAR
14. TORQUE CONVERTER
HOUSING
15. TURBINE OF TORQUE
CONVERTER
16. INPUT SHAFT AND GEAR
17. PUMP DRIVE GEAR
Figure 1. Transmission (HR-36000)
1
Torque Converter Repair 1300 SRM 635
Torque Converter Repair
TORQUE CONVERTER, REMOVE
The torque converter is removed during removal of
the transmission. See Remove, Transmission Only
procedures for the transmission.
TORQUE CONVERTER, DISASSEMBLE
If it is necessary to disassemble the torque converter,
do so as follows and as shown in Figure 2:
1. Remove capscrews and lockwashers that fasten
drive plates and bearing cover to impeller cover.
Remove backing ring, drive plates, bearing cover,
and O-ring.
2. Remove two rings and washer spacer that fas-
tens the turbine hub. One ring is thicker than
the hub locating ring.
NOTE: Use a drain pan for the oil in the converter
section that did not drain during initial drain of oil.
3. Remove screws and washers that fasten impeller
cover. Use a screwdriver at the slots to remove
impeller cover, turbine, and turbine hub. Re-
move large O-ring for the cover.
4. Remove locating snap ring from under turbine
hub. This ring is thinner than the retainer ring
of Step 2. Remove snap ring that fastens stator
to stator support. The stator support is fastened
to the stator with a dowel. Do not remove spacer
if stator or spacer will not be replaced.
5. Remove retainer for oil baffle (Figure 3). Use a
special removal tool to remove impeller and oil
baffle. The special removal tool is very similar to
a gear puller, but is for larger diameter parts.
6. Remove screws and washers that fasten stator
support to converter housing. Rotate stator sup-
port so there is clearance between stator support
and pump drive gear. The "cutout" in the stator
support allows this clearance.
7. Remove snap ring for the impeller hub gear (Fig-
ure 3). Remove hub gear from impeller hub. Re-
move oil baffle, oil seal, and baffle seal ring.
8. Remove screws and washers that fasten hub to
impeller. Remove backing ring. Remove impeller
from hub. Remove O-ring between hub and im-
peller.
9. Straighten locking tabs for hub bolts. Remove
turbine-to-hub bolts and washers. Remove tur-
bine hub.
If necessary, disassemble turbine and impeller cover.
Install blocks under the edges of the impeller cover to
suspend the turbine and hub. Remove bearing snap
ring and spacer. Use a drift and hammer to remove
turbine and hub from impeller cover bearing.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturers recommended safety precau-
tions.
Clean the parts of the torque converter in solvent.
Dry parts with compressed air. Inspect splines and
gear teeth for damage. Inspect shafts, bearings,
and bearing surfaces for scratches, wear, or damage.
Clean holes that have threads and capscrews where
a thread-locking compound is used.
TORQUE CONVERTER, ASSEMBLE
If the turbine and impeller cover were not disassem-
bled, go to Step 3.
If disassembled, assemble turbine and impeller cover
as follows (see Figure 2):
1. Align holes in turbine and turbine hub and in-
stall lock tabs, hub bolts, and washers. Tighten
hub bolts to 122 to 134 Nm(90 to 99 lbf ft). Bend
a corner of lock tab over bolt heads.
2. Align impeller cover over turbine and hub. In-
stall bearing for impeller cover in cover and over
turbine hub. Install new O-ring. Install spacer
on turbine hub. Install bearing rings.
2
1300 SRM 635 Torque Converter Repair
Figure 2. Torque Converter and Flywheel
3
Torque Converter Repair 1300 SRM 635
Legend for Figure 2
1. TURBINE HUB
2. SNAP RING
3. REACTION MEMBER
4. SPACER
5. BEARING
6. IMPELLER HUB
7. O-RING
8. IMPELLER
9. BACKING RING
10. BEARING COVER
11. RING
12. IMPELLER COVER
13. LOCK TAB
14. TURBINE
15. FLYWHEEL
16. DRIVE PLATES
1. SNAP RING
2. BEARING
3. BEARING SUPPORT
4. HYDRAULIC PUMP GEAR
5. TURBINE HOUSING
6. SPRING
7. PISTON RING
8. SLEEVE
9. STATOR SUPPORT
10. TUBE
11. WASHER
12. INPUT SHAFT
13. RETAINER
14. BAFFLE
15. SEAL RING
16. OIL SEAL
17. IMPELLER GEAR
Figure 3. Input Shaft and Pump Drive Gears
4
1300 SRM 635 Torque Converter Repair
3. Make sure the surface of impeller hub and holes
for screws are clean and dry. Put new O-ring on
impeller hub. If removed, use a drift or press the
same size as the bearing and install hub bearing
and snap ring in hub.
4. Align holes in impeller with hub holes. Do NOT
damage O-ring. The two dimples that are 180
degrees apart on backing ring must be installed
toward engine flywheel. Install backing ring
and install new special self-locking screws and
washers. Tighten screws to 79 to 87 Nm (58 to
64 lbf ft).
CAUTION
Make sure the total time to install and tighten
the special screws is less than 15 minutes. If
any screw is removed for any reason, it must
be replaced. The epoxy left in the hub hole
must be removed with a tap and cleaned with
solvent. Make sure the hole is dry before in-
stalling a new screw.
5. Put a thin coat of Loctite 638 on the outer di-
ameter of the oil seal of the oil baffle (Figure 3).
Press oil seal in oil baffle with lip of seal down.
6. Carefully install oil baffle on impeller without
damaging oil seal. Install a new sealing ring for
oil baffle. Install hub gear on impeller hub and
install snap ring.
TORQUE CONVERTER (TURBINE)
HOUSING, DISASSEMBLE
If necessary, disassemble converter housing assem-
bly as follows:
1. Remove snap ring for front bearing of input shaft.
Use a hammer with a soft face to lightly hit input
shaft to remove it and bearing from housing.
2. Put a mark on each pump gear for correct loca-
tion during installation. Remove bearing sup-
port screws and lockwashers for the drive (cen-
ter) gear. Remove drive gear and bearing assem-
bly. Remove other two pump gear and bearing
assemblies using the same procedure.
RELIEF VALVE FOR LUBE PRESSURE,
DISASSEMBLE AND ASSEMBLE
If the unit has this relief valve, disassemble, clean, or
replace and assemble the valve as shown in Figure 4.
1. HOUSING
2. WASHER
3. SPRING
4. SEAT
5. PLUNGER
6. VALVE SEAT
RETAINER
7. RETAINING RING
Figure 4. Relief Valve Assembly
OIL SEALING RINGS SLEEVE, REPLACE
There is a sleeve at the front end of the forward,
reverse, and fourth-gear clutch shafts. Remove the
sleeves ONLY if they are to be replaced.
1. Remove locating ring for front bearing of clutch
shaft.
2. Remove retainer plate screw, washer, and plate.
3. Remove sleeve using a puller.
4. Use a press or a driver to prevent damage to the
sleeve during installation. Make sure the notch
in the new sleeve is aligned with the sleeve lock
notch.
5. Put sleeve lock in position. Install capscrew and
washer. Tighten capscrew.
6. Install locating ring for front bearing of clutch
shaft in ring groove.
5
Transmission Repair 1300 SRM 635
TORQUE CONVERTER HOUSING,
ASSEMBLE
Assemble converter housing assembly as follows and
as shown in Figure 3:
1. Install two pump drive gears as marked during
disassembly. Install transmission pump gear at
center location. Tighten all mount capscrews.
2. Install input shaft and gear. Use a hammer with
a soft face to tap shaft so bearing snap ring can
be installed. Install snap ring and continue to tap
shaft so snap ring is against shoulder in housing.
3. Open locating ring for the front bearing of the
reverse clutch. See Figure 15. Use a hammer
with a soft face to tap shaft of the reverse and
second clutch until locating ring is completely in
groove of converter housing.
4. Open locating ring for the front bearing of the
fourth-speed clutch. See Figure 7. Use a hammer
with a soft face to tap shaft of the fourth-speed
clutch until locating ring is completely in groove
of converter housing.
5. Install the front bearing of the forward clutch.
TORQUE CONVERTER, INSTALL
The torque converter is assembled in the torque con-
verter housing and is installed with the transmis-
sion. See Install, Transmission .
Transmission Repair
REMOVE, TRANSMISSION ONLY
NOTE: The transmission can be removed from under
the lift truck or as a complete assembly with the en-
gine. If an inspection pit is not available, the truck
must be raised 500 mm (19.7 in.) from the ground to
provide easier access and removal.
1. Place truck on level surface.
2. Shut down engine.
3. Apply parking brake.
4. Operate all hydraulics to release pressure in the
system.
NOTE: When removing battery cables, remove
ground cable first.
5. Disconnect the cables at the battery.
6. Remove floor plates and covers to provide access
to the hydraulic pump and transmission.
7. Close shut-off valves on hydraulic tank.
8. Disconnect the drive shaft at the differential.
9. Remove the drive shaft between the transmis-
sion and the differential.
10. Disconnect the wiring harness on top of the
transmission.
11. Disconnect the wires at the solenoids on the
transmission control valve.
12. Disconnect the wires at the pressure and temper-
ature sending unit on the transmission.
13. Place tags on lines for identification.
14. Remove the drain plug from the transmission
sump.
15. Drain the oil.
16. Put plugs and caps on open fittings.
17. Disconnect the hoses at the hydraulic pumps.
NOTE: The hydraulic pumps are fastened to the
transmission with 4 capscrew each.
The drive shaft of the hydraulic pump is engaged in
splines in the drive gear.
The drive shaft of the hydraulic pump will slide from
the drive gear when the hydraulic pump is removed.
19. Remove the hydraulic pumps.
20. Disconnect and remove the dipstick assembly.
21. Install blocks and a jack under the flywheel end
of the engine as a support.
22. Disconnect exhaust system to avoid possible
damage.
6
1300 SRM 635 Transmission Repair
WARNING
Verify the lifting device has the minimum ca-
pacity of 725 kg (1600 lb).
23. Connect a lifting device to the transmission.
24. Remove the transmission mounts to the frame.
See Figure 5.
NOTE: RS45-30CH, RS46-35CH, RS45-25IH, RS46-
30IH (A222) SHOWN.
1. TRANSMISSION
HOUSING
2. TRANSMISSION
MOUNT
3. FRAME MOUNT
4. FRAME BRACKET
5. ISOLATOR
Figure 5. Transmission Mount
25. Remove the 8 bolts securing the drive plates to
the torque converter.
26. Remove all fasteners between engine flywheel
housing and torque convertor housing.
27. Verify all the connections have been removed.
28. Carefully slide back the transmission from the
frame approximately 40 mm (1.60 in.) to permit
the transmission to be lowered.
WARNING
The transmission is heavy, verify that the lift-
ing devices are securely positioned.
29. Carefully, to avoid damage to the flex plate, lower
the transmission assembly past the cross mem-
ber support.
REMOVE, TRANSMISSION AND ENGINE
ASSEMBLY
NOTE: The transmission can be removed from under
the lift truck or as a complete assembly with the en-
gine. If an inspection pit is not available, the truck
must be raised 500 mm (19.7 in.) from the ground to
provide easier access and removal.
1. Place truck on level surface.
2. Shut down engine.
3. Apply parking brake.
4. Operate all hydraulics to release pressure in the
system.
NOTE: When removing battery cables, remove
ground cable first.
5. Disconnect the cables at the battery.
6. Remove floor plates and covers to provide access
to the hydraulic pump and transmission.
7. Close shut-off valves on hydraulic tank.
8. Disconnect the drive shaft at the differential.
9. Remove the drive shaft between the transmis-
sion and the differential.
10. Disconnect the wiring harness on top of the
transmission.
11. Disconnect the wires at the solenoids on the
transmission control valve.
12. Disconnect the wires at the pressure and temper-
ature sending unit on the transmission.
13. Place tags on lines for identification.
14. Remove the drain plug from the transmission
sump.
15. Drain the oil.
17. Disconnect the hoses at the hydraulic pumps.
7
transmission with 4 capscrew each.
The drive shaft of the hydraulic pump is engaged in
splines in the drive gear.
The drive shaft of the hydraulic pump will slide from
the drive gear when the hydraulic pump is removed.
19. Remove the hydraulic pumps.
20. Disconnect and remove the dipstick assembly.
21. Install blocks and a jack under the flywheel end
of the engine as a support.
22. Disconnect exhaust system to avoid possible
damage.
23. Remove engine hood and ballast cover.
24. Disconnect the air cleaner intake elbow.
25. Drain coolant from the cooling system.
26. Disconnect cooling lines.
27. Remove the radiator and transmission oil cooler.
28. Remove the tubing between the engine and air
cleaner.
29. Disconnect fuel lines at the fuel filter.
30. Disconnect the throttle linkage.
31. Disconnect wires and wiring harnesses at the en-
gine.
32. Disconnect the heater hoses at the engine.
NOTE: Verify that the lifting device has a capacity of
at least 1360 kg (3000 lb).
33. Connect a lifting device to the engine.
34. Remove the capscrews that hold the engine
mount at the fan end of the engine. See Figure 6.
35. Remove the capscrews that hold the two rear en-
gine mount brackets to the frame.
NOTE: Verify all the connections to the engine or
transmission have been removed.
36. Carefully lift the engine and transmission as-
sembly from the frame.
1. REAR MOUNT (FAN END OF ENGINE)
2. FRONT MOUNT
Figure 6. Engine Mounts
TRANSMISSION, DISASSEMBLE
Make sure to keep the parts for each clutch together
during disassembly. Make a note of the order of the
friction discs and separator plates of each clutch.
Also make a note of which way each bearing seal
is facing for correct installation. Disassemble the
transmission as follows:
1. Remove torque converter assembly from trans-
mission. If necessary, disassemble torque con-
verter as described in Torque Converter, Disas-
semble.
2. Remove solenoid dust cover from transmission
control valve. Remove screws and lockwashers
that fasten control valve cover. Remove cover as-
sembly of control valve, seal plate, and inner and
outer gaskets. Remove control valve housing and
gasket.
3. Remove screws that fasten stator support. Ro-
tate stator support so curved "cutout" section is
aligned with pump drive gear to allow removal.
See Figure 3. Remove stator support.
4. Use a crane and sling to support torque con-
verter housing. Remove capscrews that fasten
torque converter housing to transmission case.
Remove torque converter housing with the
reverse/second- and fourth-speed clutch assem-
blies attached.
5. Remove snap ring that fastens front bearing for
the fourth clutch to the torque converter housing.
8
It can be necessary to use a prybar to remove the
fourth-speed clutch assembly from housing.
6. Remove snap ring that fastens the front bearing
for the second and reverse clutch to the torque
converter housing. See Figure 15. It can be nec-
essary to use a prybar to remove the second and
reverse clutch assembly from housing.
7. Remove output shaft nut, washers, yoke, seal,
and yoke from output shaft. Remove seal and
spacer. Remove bearing cap nuts and lockwash-
ers for rear bearing of output shaft. Remove
bearing cap and O-ring. See Figure 7.
8. Remove bearing cap nuts and lockwashers for
bearing of the third-speed shaft. Remove bearing
cap, O-ring, rings, and washer. See Figure 10.
9. Remove bearing cap nuts and lockwashers for the
bearing of the first-speed (low) shaft. Remove
bearing cap, shims, O-ring, and ring. See Fig-
ure 17. Keep cap and shims together. If cap,
clutch, front or rear bearings, transmission case,
or rear cover are not replaced, the same shims
will be used during assembly.
10. Remove clutch pressure and lube tubes and
O-rings at the holes under bearing cap for the
first-speed shaft bearing.
11. Remove locating rings for the rear bearings of the
third-speed and output shafts.
12. Remove nuts, screws, and lockwashers that fas-
ten the rear cover of the transmission. Remove
oil screen plug and oil screen. Tap on the end of
the output shaft and clutch shafts while prying
cover off to remove cover. Using aligning studs
can help in the removal. Remove cover gasket.
13. Remove retaining ring for the fourth-speed hub.
Remove hub. Remove three retaining rings for
the second-speed hub. Remove hub.
14. Use a bearing puller to remove the rear bearing
of the output shaft. Remove first-speed clutch
and output shaft simultaneously. Remove front
bearing for output shaft.
15. Remove clutch assembly of the third-speed
clutch.
16. Remove oil baffle screws, lockwashers, and oil
baffle from cover. Remove bolts and lockwashers
of the suction tube. Remove suction tube and
O-ring.
17. Have another person release the bearing snap
ring for the rear bearing of the forward shaft.
Use a hammer that has a soft face to tap the end
of the shaft for removal.
18. Remove forward clutch assembly. See Figure 12.
Remove outer race of the rear bearing of the in-
put shaft. Remove bearing cup and oil baffle
spacer of the first-speed shaft.
Output Shaft, Disassemble and Assemble
NOTE: The following procedures describe the disas-
sembly of each of the shaft assemblies and clutches.
These assemblies have been removed fromthe trans-
mission as assemblies in the previous procedures.
Disassemble only the shaft or clutch assembly nec-
essary to make repairs.
CAUTION
Inspect all bearings for damage and wear.
Bearings are normally replaced during a ma-
jor disassembly and assembly such as this.
Inspect clutch plates for wear of friction mate-
rial and damage to the separator plates.
Make sure to keep all parts of each clutch as-
sembly together. Some of these parts look the
same, but are not. Using the wrong part can
cause incorrect operation or damage.
Always use new seals, seal rings, and snap
rings during assembly. Apply a thin coat of
multipurpose grease #2 to all seals before in-
stallation. Fill all seal grooves with this same
grease.
The following procedure describes the disassembly
and assembly of the output shaft. See Figure 7:
1. Remove inner race of the front bearing of the out-
put shaft.
2. Remove front retaining ring for the output gear.
Remove spacers and gear from shaft. If neces-
sary, remove rear retaining ring.
9
1. SEPARATOR DISC (TEETH
OUTSIDE)
2. FRICTION DISC (TEETH
INSIDE)
3. BACKING PLATE
4. RING
5. SEAL
6. SPRING
7. SPRING RETAINER
8. HUB
10. BEARING
11. RETAINER
12. SPACER
13. OUTPUT GEAR
14. REAR COVER
15. CLUTCH DRUM AND GEAR
FOR FOURTH SPEED
16. PISTON
17. OUTPUT SHAFT
18. BEARING CAP
19. O-RING
20. PLUG
21. YOKE
Figure 7. Fourth-Speed Shaft and Output Shaft
3. If removed, install rear retaining ring on output
shaft. Install spacers and gear with long hub
toward rear. Install front retaining ring.
4. Install retainer and press front bearing on out-
put shaft with race shoulder facing gear. Install
bearing and outer race on inner race.
5. Install clutch hub on shaft using retaining rings.
Fourth-Speed Shaft, Disassemble and
Assemble
and assembly of the fourth-speed shaft: See Figure 7
and Figure 8.
1. Remove oil sealing rings from the fourth-clutch
shaft. Remove snap ring for front bearing and
remove bearing using a bearing puller. Remove
other ring.
10
2. Remove snap ring for the backing plate of the
clutch disc and remove backing plate. Remove
all friction and separator discs.
3. Remove seal. Compress wave spring and remove
retaining ring from its groove. Release wave
spring and remove snap ring and retainer for the
spring. Remove wave spring and thrust washer.
Turn assembly over and tap shaft on a block of
wood to remove seals and piston.
4. Make sure the bleed valve is clean in the piston
removed in Step 3. Install inner and outer seal
rings on piston. Lock ring joint and apply grease
to stabilize it in the ring groove. Carefully posi-
tion piston in drum without damaging seal rings.
5. Install seal, thrust washer, wave spring, spring
retainer, and retainer snap ring on shaft. Com-
press wave spring and install retainer snap ring
in shaft groove. Install a separator disc (teeth on
outside) in clutch drum.
6. Alternately install six friction discs and the other
five separator discs in drum. The last disc must
be a friction disc.
7. Install backing plate and snap ring in drum.
8. Press front bearing against shoulder on shaft
with snap ring groove toward drum. Install snap
ring. Install grease in groove for seal rings and
install seals in grooves.
Third-Speed Shaft, Disassemble and
Assemble
and assembly of the third-speed shaft (see Figure 9
and Figure 10):
1. Remove sealing ring from shaft. Remove snap
ring for rear bearing. Use a bearing puller to
remove rear bearing.
2. Remove retaining ring for outer bearing of the
third gear. Use a hammer that has a soft face
to tap the third gear with the outer bearing from
clutch drum.
3. Remove snap ring for clutch backing plate. Re-
move backing plate.
1. HUB
2. RING
3. SPRING RETAINER
4. SPRING
5. SEAL
6. BACKING PLATE
7. FRICTION DISC
(TEETH INSIDE)
8. SEPARATOR DISC
(TEETH OUTSIDE)
9. PISTON
10. CLUTCH SHAFT,
DRUM, AND GEAR
FOR FOURTH
SPEED
11. BEARING
Figure 8. Fourth-Speed Clutch
11
1. SPRING RETAINER
2. SPRING
3. RETAINING RING
4. RING
5. BEARING
6. GEAR AND HUB
7. SNAP RING
8. BACKING PLATE
9. FRICTION DISC
(TEETH INSIDE)
10. SEPARATOR DISC
(TEETH OUTSIDE)
11. PISTON
12. SEAL
13. CLUTCH SHAFT,
DRUM, AND GEAR
FOR THIRD SPEED
Figure 9. Third-Speed Clutch Assembly
4. Use a bearing puller to remove inner bearing for
the third-speed gear. Remove snap ring for inner
bearing.
5. Remove all friction and separator discs. Com-
press wave spring and remove retaining ring
from its groove. Release wave spring and re-
move snap ring and retainer for the spring.
Remove wave spring.
6. Remove clutch piston and seals.
7. Make sure the bleed valve is clean in the piston
removed in Step 6. Install inner and outer seal
rings on piston. Lock ring joint and apply grease
to stabilize it in ring groove. Carefully position
piston in drum without damaging seal rings.
8. Put retainer for wave spring, wave spring, wave
spring retainer, and snap ring for retainer on
shaft. Compress wave spring and install retainer
ring for spring into groove of shaft. Make sure re-
tainer ring is completely in groove.
9. Install snap ring for inner bearing on shaft. In-
stall a separator disc (teeth on outside) in clutch
drum.
10. Alternately install 12 friction discs and the other
11 separator discs in drum. The last disc must be
a friction disc.
12. Install inner bearing for the third-speed gear.
This bearing does not have an oil shield. Care-
fully install the third gear and hub. Make sure
the hub splines engage the splines of all friction
discs. To avoid damage, do not force the hub
through the discs.
13. Install outer bearing of the third gear. This bear-
ing has an oil shield. The oil shield must face
away from the gear. Install retaining ring for
bearing.
14. Install rear bearing on shaft. The groove in the
bearing must be toward the end of the shaft. In-
stall snap ring for bearing. Install oil seal ring in
the groove near the end of the shaft. Use grease
to hold the oil seal ring in place.
12
2. REAR COVER
3. BEARING
4. WASHER
5. RING
6. O-RING
7. BEARING CAP
8. PLUG
9. HUB AND GEAR
10. RETAINING RING
11. SPRING
12. SPRING RETAINER
13. BACKING PLATE
14. FRICTION DISC (TEETH INSIDE)
15. SEPARATOR DISC (TEETH OUTSIDE)
16. PISTON
17. SEAL
18. CLUTCH DRUM, SHAFT, AND GEAR
Figure 10. Third-Speed Shaft
13
Forward Shaft and Clutch, Disassemble
and Assemble
and assembly of the forward shaft and clutch (see
Figure 11 and Figure 12):
1. Remove piston rings from forward clutch shaft.
Remove retainer ring for inner race of front bear-
ing. Use prybars to remove bearing inner race.
Remove retainer ring for outer bearing.
2. Use prybars to remove clutch gear/hub and outer
bearing together.
3. Use a bearing puller to remove inner bearing for
hub.
4. Remove retainer ring for clutch backing plate.
Remove backing plate. DO NOT LOSE THE
BALL AND SPRING OF THE BACKING
PLATE. Remove all friction and separator discs.
5. Compress disc springs and remove retaining
rings from grooves. Release disc springs and
remove snap ring and retainer for spring. Re-
move disc springs. Make sure to keep these disc
springs together and with the other clutch parts.
Remove clutch piston and seals.
6. Remove retainer ring and thrust washer for rear
bearing. Not all units have the thrust washer.
Use a bearing puller to remove rear bearing.
7. Get a section of pipe that has approximately the
same outer diameter as the bearing outer race.
Use the pipe and a hammer or a press to install
rear bearing. The groove in the bearing must
be toward the end of the shaft. If installed, put
thrust washer on shaft. Install retaining ring for
rear bearing.
8. Install inner and outer seal rings on piston. Lock
ring joint and apply grease to stabilize it in ring
groove. Carefully position piston in drum with-
out damaging seal rings.
9. Install one friction disc (teeth on inner diame-
ter). Install one separator disc, then alternately
install the other 10 friction discs and the other
nine separator plates. The first and last clutch
disc must be a friction disc. This is the sequence
of installation when the clutch has an iron pis-
ton.
1. RETAINER
2. SPRING
3. RING
4. BEARING
5. CLUTCH HUB AND
GEAR
6. PISTON RING
7. CLUTCH DRUM
AND GEAR
8. SEAL
9. PISTON
10. SEPARATOR DISC
(TEETH OUTSIDE)
11. FRICTION DISC
(TEETH INSIDE)
12. BACKING PLATE
13. SNAP RING
Figure 11. Forward Clutch Assembly
14
1. RETAINER
2. SPRING
3. RING
4. BEARING
5. CLUTCH HUB AND GEAR
6. PISTON RING
8. SEAL
9. PISTON
12. BACKING PLATE
13. SNAP RING
Figure 12. Forward Clutch and Shaft Assembly
10. Install detent spring and ball in backing plate.
See Figure 13. Install backing plate in clutch
drum making sure not to lose the spring or ball.
Compress clutch discs and disc springs and in-
stall retainer ring for backing plate.
11. Install disc springs and retainer for piston. Make
sure the disc spring with the large diameter is
toward the piston.
12. Compress disc springs and install rings fully in
grooves. Install inner bearing and ring. This
bearing does not have a shield in it. Carefully
install hub and gear in drum. Make sure hub
splines engage splines of all friction discs. To
avoid damage, do not force hub through the discs.
1. CLUTCH PLATE
2. RETAINER RING
3. DETENT SPRING
4. DETENT BALL
5. CLUTCH DRUM
Figure 13. Detent
15
13. Install rings in outer bearing with shield toward
gear. Install inner race of front bearing. The
large diameter must be toward gear. Install re-
tainer for front bearing.
14. Put grease in groove for piston rings. Install pis-
ton rings in grooves. Align piston rings at center
of groove.
Reverse and Second-Speed Shaft and
Clutch, Disassemble and Assemble
and assembly of the reverse and second-speed shaft
and clutch (see Figure 14 and Figure 15):
1. Remove piston rings at the reverse clutch end of
shaft. Remove retaining ring for front bearing.
Use prybars to move front bearing enough to in-
stall bearing puller. Use bearing puller to remove
front bearing.
2. Remove retainer ring for outer bearing of hub
gear. Use pry bars to carefully pry hub gear up
for clearance to install a gear puller. Remove hub
gear and outer bearing.
3. Remove retainer ring for clutch backing plate.
Remove backing plate. DO NOT LOSE THE
BALL AND SPRING OF THE BACKING
PLATE.
4. Remove all clutch discs. Use a bearing puller to
remove inner bearing.
5. Compress disc springs and remove retaining ring
from its groove. Release disc springs and re-
move retainer ring and retainer for spring. Re-
move disc springs. Make sure to keep these disc
springs together and with the other clutch parts.
Remove clutch piston.
6. Put a coat of grease on seal rings and install
seal rings on piston. Carefully position piston in
drum without damaging seal rings.
7. Install disc springs for piston. Make sure disc
spring with the large diameter is toward piston.
Install retainer ring for disc springs. Install re-
tainer for spring retainer ring. Compress disc
springs and install retainer ring fully in groove.
Use a press to install inner bearing. This bearing
does not have a shield in it.
1. SEAL
2. PISTON
3. SEPARATOR DISC
(TEETH OUTSIDE)
4. FRICTION DISC
(TEETH INSIDE)
5. BACKING PLATE
6. SNAP RING
7. RETAINER
8. SPRING
9. RING
10. BEARING
11. CLUTCH HUB AND
GEAR
12. PISTON RING
13. CLUTCH DRUM
AND GEAR
Figure 14. Reverse and Second-Speed Clutch
16
1. PISTON RING
2. RING
3. BEARING
4. SNAP RING
5. REVERSE CLUTCH HUB AND GEAR
6. SPRING
7. SPRING RETAINER
8. BACKING PLATE
11. PISTON
12. SEAL
14. HUB AND GEAR FOR SECOND-SPEED CLUTCH
Figure 15. Reverse and Second-Speed Shaft
8. Install one friction disc (teeth on inner diame-
ter). Install one separator disc, then alternately
install the other 10 friction discs and the other
nine separator plates. The first and last clutch
disc must be a friction disc. This is the sequence
of installation when the clutch has an iron pis-
ton.
9. Install detent spring and ball in backing plate.
See Figure 13. Install backing plate in clutch
drum making sure not to lose the spring or ball.
Compress clutch discs and disc springs and in-
stall retainer ring for backing plate.
10. Carefully install hub and gear in drum. Make
sure hub splines engage splines of all friction
discs. To avoid damage, do not force hub through
the discs.
11. Install outer bearing with shield toward gear. In-
stall retainer ring for outer bearing. Install front
17
bearing. The groove in the bearing must be to-
ward gear. Install retainer ring for front bearing.
12. Put grease in groove for sealing rings. Install
sealing rings in grooves. Align sealing rings at
center of groove.
13. Remove snap ring for backing plate of second
clutch. Remove backing plate and all clutch
discs.
14. Compress wave spring and remove retaining ring
from its groove. Release wave spring and remove
snap ring and retainer for spring. Remove wave
spring and thrust washer. Remove second clutch
piston.
15. Make sure the bleed valve is clean in the second-
gear piston removed in Step 14. Install inner and
outer seal rings on piston. Lock ring joint and
apply grease to stabilize it in ring groove. Care-
fully position second-gear piston in drumwithout
damaging seal rings.
16. Put thrust washer, wave spring, wave spring re-
tainer, and snap ring for retainer on shaft. Com-
press wave spring and install retainer ring for
spring into the groove of the shaft. Make sure
retainer ring is completely in groove.
17. Install a separator disc (teeth on outside) in
clutch drum. Alternately install the six friction
discs and the other five separator discs in drum.
The clutch disc next to the piston is a separator
disc. The last clutch disc is a friction disc.
First-Speed Shaft and Clutch, Disassemble
and Assemble
and assembly of the first-speed shaft and clutch (see
Figure 16 and Figure 17):
1. Remove seal rings near end of shaft at tapered
roller bearing. Use prybars to carefully move ta-
pered roller bearing for clearance to use a bearing
puller. Use the bearing puller to remove tapered
roller bearing. Remove bearing thrust washer.
2. Use a gear puller to remove first-speed gear with
outer bearing.
1. BEARING
2. WASHER
3. HUB AND GEAR
4. RING
5. SPACER
6. RING
7. SPRING WASHERS
8. BACKING PLATE
9. FRICTION DISC
(TEETH INSIDE)
10. SEPARATOR DISC
(TEETH OUTSIDE)
11. PISTON
12. PISTON SEAL
13. SEAL
14. CLUTCH SHAFT,
DRUM, AND GEAR
FOR FIRST SPEED
15. THIRD-SPEED
GEAR
Figure 16. First-Speed Clutch
18
2. REAR COVER
3. O-RING
4. BEARING CAP
5. RING
6. SHIM SET
7. PLUG
8. BACKING PLATE
9. SPRING WASHERS
10. SPACER
11. BEARING
12. HUB AND GEAR
13. WASHER
14. THIRD-SPEED GEAR
15. CLUTCH SHAFT, DRUM, AND GEAR FOR FIRST
SPEED
16. SEAL
17. PISTON SEAL
18. PISTON
Figure 17. First-Speed Shaft
19
3. Remove snap ring for backing plate. Remove
backing plate and all clutch discs.
4. Use a bearing puller to remove inner bearing of
the first-speed gear. Remove spacer.
5. Compress wave spring and remove retaining ring
from its groove. Release wave spring and remove
snap ring and retainer for spring. Remove wave
spring and the other wave spring ring. Remove
piston and seals for the first-speed clutch.
6. Use a gear puller to remove driven gear together
with front bearing.
7. Install driven gear on clutch shaft with long hub
of gear toward end of shaft. Use a press to install
tapered roller bearing. The small diameter of the
bearing must be toward the end of the shaft.
8. Install inner and outer seal rings on clutch pis-
ton. Lock ring joint and apply grease to stabi-
lize it in the ring groove. Carefully position the
first-speed piston in drumwithout damaging seal
rings.
9. Put retainer for wave spring, wave spring, wave
spring retainer, and snap ring for retainer on
shaft. Compress wave spring and install retainer
ring for spring into the groove of shaft. Make
sure retainer ring is completely in groove.
10. Install a separator disc (teeth on outside) in
clutch drum. Alternately install the 10 friction
discs and the other nine separator discs in the
drum. The last disc is a friction disc. Install
backing plate and snap ring in drum.
11. Install gear spacer and inner bearing. The bear-
ing does not have an oil shield. Use a press to in-
stall bearing. Carefully install hub gear. Make
sure hub splines engage splines of all friction
discs. To avoid damage, do not force the hub
through the discs.
12. Install outer bearing for hub gear. This bearing
has an oil shield. The shield must be toward the
end of the shaft. Install washer. Use a press to
install tapered roller bearing. The small diame-
ter of the bearing must be toward end of shaft.
NOTE: The two oil seal rings at the end of the shaft
will be installed after the clearance adjustment for
the tapered roller bearings is complete.
Input Shaft, Disassemble and Assemble
and assembly of the input shaft (see Figure 3):
1. Remove piston ring from input shaft.
2. Remove bearing snap ring and bearing washer.
3. Use prybars to move bearing enough to install
a bearing puller. Use bearing puller to remove
bearing. Use a press to install bearing with
groove in bearing away from gear.
4. Install bearing washer and snap ring. Fill groove
for piston ring with grease. Install piston in cen-
ter of groove.
SPEED SENSOR, INSTALL
Temporarily install bushings for speed sensors. Use
a depth micrometer to measure the depth at each
speed sensor bushing. Add shims to get the correct
dimensions as shown in Figure 18. Clean threads of
bushing and housing using Loctite cleaner. Install
shims under the head of the bushing. Use Loctite
number 270 or number 262 on both the bushing and

housing threads. Install shims and tighten bushings
to 61 to 68 Nm (45 to 50 lbf ft). After the Loctite
has set, install speed sensors and tighten them to

54 Nm (40 lbf ft).
20
1. SPEED SENSOR LOCATION
2. TRANSMISSION
3. SHIM LOCATION
4. DEPTH MICROMETER
5. BUSHING
Figure 18. Speed Sensor Installation
21
TRANSMISSION, CLEAN AND INSPECT
WARNING
tions.
Clean the parts of the transmission in solvent. Dry
parts with compressed air. Inspect splines and gear
teeth for damage. Inspect shafts, bearings, and
bearing surfaces for scratches, wear, or damage.
Make sure separator plates are smooth. Inspect fric-
tion discs for burned or damaged friction material.
Clean holes that have threads and capscrews where
a thread-locking compound is used.
TRANSMISSION, ASSEMBLE
NOTE: If a new transmission or converter housing
will be used, install speed sensors in new housing.
See the procedure in Speed Sensor, Install and Fig-
ure 18.
1. Install new O-ring on suction tube for transmis-
sion pump. Install tube in transmission case.
Install screws and washers for suction tube.
Tighten screws.
2. Set oil baffle in transmission case. Install and
tighten oil baffle screws.
3. Set froward clutch assembly into rear bearing
bore of transmission case. Push rear bearing
through bore far enough to install outer locating
ring. Push bearing back in bore until locating
ring is against shoulder of bore.
4. Install third-speed clutch assembly.
5. Install locating ring in front bearing bore for low
clutch bearing. Install spacer (oil baffle) and
front bearing cup as shown in Figure 19.
NOTE: The first-speed clutch and the output shaft
must be installed simultaneously. Another person
can be helpful during this installation.
6. Install the first-speed clutch and output shaft in
transmission housing. Make sure they are fully
in position in the housing. Install rear bearing
on output shaft. The groove in the bearing for
the snap ring must be toward the rear.
1. LOCATING RING
2. SPACER (OIL BAFFLE)
3. BEARING CUP
Figure 19. Bearing Installation Detail
7. Install new gasket and O-ring on rear of trans-
mission housing. A thin coat of grease will help
hold gasket in place on housing. Install align-
ing studs to help align rear cover. Install rear
cover, tapping cover with a hammer that has a
soft face. Install cover screws and washers and
tighten screws.
8. Install locating ring for bearing outer race of out-
put shaft. Install spacer for output flange on out-
put shaft.
9. Apply a thin coat of Loctite
683 (green) on outer

diameter of oil seal. Press seal in bearing cup
of output shaft with lip of seal toward bearing.
Use new O-rings and install bearing cap for the
output shaft bearing. Install lockwashers and
nuts and tighten nuts.
10. Install output flange, O-ring, washer, and elas-
tic flange nut. Use a bar to prevent flange from
turning and tighten flange nut to torque speci-
fied in Table 1.
Table 1. Flange Nut Torque
Thread Size Nm lbf ft
1" - 20 203 - 271 150 - 200
1 1/4" - 18 271 - 339 200 - 250
1 1/2" - 18 407 - 474 300 - 350
1 1/4" - 12 543 - 610 400 - 450
22
11. Install locating ring for rear bearing of the third-
speed shaft. Install new O-ring on bearing cap.
Install bearing cap, lockwashers, and nuts on
studs. Tighten nuts.
12. Install screen assembly for oil sump and in-
stall plug. Tighten plug to 13 to 20 Nm (10 to
15 lbf ft).
13. Make sure the shim pack is correct for the bear-
ings of the first-speed clutch as described in
First-Speed Shaft Bearings Adjustment. In-
stall new O-rings on clutch pressure and lube
transfer tubes and install tubes in rear cover
of transmission at rear bearing of first-speed
clutch. Fill grooves of oil sealing rings with
grease. Install sealing rings and move sealing
rings to the center of the grooves. Install shim
pack on studs and install bearing cap, washers,
and nuts. Tighten nuts.
14. Turn transmission housing so that rear cover is
to the rear. Install disc hub of the second-speed
clutch on shaft of the first-speed clutch. Install
retainer ring for hub. Install retainer for retainer
ring. Install snap ring for retainer ring of re-
tainer. See Figure 20.
1. DISC HUB
2. SNAP RING FOR RETAINER OF RETAINER
RING
3. HUB RETAINER RING
4. CLUTCH SHAFT
5. RETAINER FOR RETAINER RING
Figure 20. Retainer Ring Detail
15. Install bearing outer race for input shaft. Install
a new converter housing gasket and O-rings on
transmission housing. A thin coat of grease will
help hold the gasket in place on the housing.
16. Install pilot bearing for the second and third
clutches on the shafts. Use grease to keep bear-
ings in position.
17. Leave the passage for the first-speed clutch
open for internal lube tube installation. Install
plug for external lube tube installation. See
Figure 21. Tighten plug to 9.5 to 13.5 Nm (7 to
10 lbf ft).
1. CONVERTER HOUSING
2. PASSAGE OPEN FOR INTERNAL LUBE
INSTALLATION
Figure 21. Low-Speed Clutch Lube Passage
18. Install alignment studs and install converter
housing on transmission housing while rotat-
ing output shaft. Rotation of the output shaft
will help the clutch hub (Step 14) and discs to
align correctly. Do NOT push the two housings
together too hard. Allow hub to align and enter
clutch discs. Install and tighten bolts that fasten
housings together.
19. Fill the groove for the oil sealing ring of the sta-
tor support using grease. Install sealing ring. In-
stall inner race of impeller hub bearing on stator
support. Align notch in stator support with pump
gear and install support on input shaft. Align
mount holes of stator support with holes in hous-
ing and install and tighten screws to fasten sta-
tor support.
23
20. Install impeller and oil baffle assembly in con-
verter housing. Install retaining ring for oil baf-
fle. Make sure the turbine and dowel pin are in
place and install turbine on stator support. In-
stall snap ring (thicker snap ring) to fasten the
reaction member.
21. Install turbine snap ring (thinner snap ring). In-
stall new impeller O-ring on impeller cover. In-
stall impeller cover and turbine assembly on in-
put shaft. Install impeller cover, lockwashers,
and screws that fasten impeller cover. Tighten
screws.
22. Install snap ring (thickest snap ring) for tur-
bine hub. Install new O-ring on bearing cap
for impeller. Stack drive plates so that all the
fingers are aligned. Concave sides are toward
flywheel and the weld nuts are toward the cover.
Align holes of backing ring and drive plates. In-
stall drive plates, backing ring, and place bolts.
Tighten the 0.4375-inch place bolts to 71 to
77 Nm (52 to 57 lbf ft). Tighten the 0.3750-inch
place bolts to 45 to 49 Nm (33 to 36 lbf ft).
CONTROL VALVE
Clean and Inspect
WARNING
tions.
Clean all parts in solvent. Inspect spools, bores, and
springs for damage. Make sure spools move freely in
the bores.
Assemble and Install
Lubricate all parts with transmission oil. Always use
new O-rings and gaskets. During assembly, make
sure all spools move freely in their bores. Connect
wires to solenoids as marked during removal.
1. Put gasket for control valve on converter housing
on alignment studs. Install control valve assem-
bly on studs. Install the two valves to housing
screws.
CAUTION
Make sure mount screws for control valve are
installed in the correct location to prevent
damage. All of the screws are not the same.
2. Install a seal plate gasket, seal plate, and the
other seal plate gasket on studs against control
valve. Install control valve cover and screws.
Items 1, 2, 3, 4, and 5 are 3/8 - 16 x 4-1/4 inch
capscrews. Items 12, 13, and 14 are 3/8 - 16 x
1 inch capscrews. Items 6 and 7 are flanged 12
point 3/8 - 16 x 3 inch capscrews. Items 8, 9,
10, and 11 are flanged 12 point 3/8 - 16 x 1-1/4
inch capscrews. Tighten screws in the sequence
(A through N) shown in Figure 22.
3. Install solenoid protection cover, washers, and
nuts. Tighten stud nuts in the sequence shown
in Figure 22.
Figure 22. Control Valve Installation (Bottom
View)
24
4. Install new O-ring on housing for pressure regu-
lator valve. Install regulator valve and charging
pump on converter housing. Install lockwash-
ers and screws. Tighten screws. Install suc-
tion tube, O-ring, adapter fitting, adapter flange,
flange screws, and lockwashers. Tighten screws.
INSTALL, TRANSMISSION
1. Install the mounts on transmission housing. See
Figure 5. Connect a lifting device with a mini-
mum capacity of 725 kg (1600 lb) to the lifting
eyes on the transmission.
2. Install two 89 mm(3.5 in.) long guide studs in the
engine flywheel housing. Rotate engine flywheel
to align a mounting hole for the drive plates with
the access hole of flywheel housing. Check end
play of flywheel.
3. Install a 102 mm (4 in.) locating stud in a drive
plate nut. Align locating stud of drive plate with
flywheel screw hole at the access hole.
4. Use the lifting device to put transmission as-
sembly into the approximate position. Align
drive plates on flywheel and converter housing
with flywheel housing. Install housing screws to
fasten converter and flywheel housings together.
Remove housing studs and install all housing
screws. Tighten all screws.
5. Install nuts and bolts for transmission mounts.
Tighten nut for transmission mount to 120 Nm
(90 lbf ft).
6. Remove locating stud in drive plates. Install
screw to fasten drive plates to flywheel. A screw-
driver or pry bar can be used to hold the drive
plates against the flywheel to install the screw.
Rotate flywheel and install each drive plate
screw in turn. After all screws are installed,
tighten all M10 screws to 61 Nm (48 lbf ft).
Check that flywheel end play is within 0.03 mm
(0.001 in.) of the end play of Step 2.
7. Connect drive shafts to transmission. Make sure
to align the marks. Tighten capscrews for input
yoke to 68 Nm (50 lbf ft). Tighten capscrews for
output yoke to 163 Nm (120 lbf ft).
8. Connect oil lines and dipstick tube at transmis-
sion. Connect wiring harness at transmission.
INSTALL, TRANSMISSION AND ENGINE
ASSEMBLY
NOTE: Verify that the lifting device has a capacity of
at least 1360 kg (3000 lb).
1. Connect a lifting device to the engine.
2. Carefully lower the engine and transmission into
the frame.
3. Install the capscrews that hold the 2 rear engine
mount brackets to the frame.
4. Install the capscrews that hold the engine mount
at the fan end of the engine. See Figure 6.
5. Connect the heater hoses at the engine.
6. Connect wires and wiring harnesses at the en-
gine.
7. Connect the throttle linkage.
8. Connect the fuel lines at the fuel filter.
9. Install the tubing between the engine and air
cleaner.
10. Install the radiator and transmission oil cooler.
11. Connect cooling lines.
12. Fill cooling system with coolant.
13. Connect the air cleaner intake elbow.
14. Install engine hood and ballast cover.
15. Connect exhaust system.
16. Connect and install dipstick assembly.
NOTE: The drive shaft of the hydraulic pump will
slide into the drive gear before the hydraulic pumps
are installed.
17. Install the drive shaft of the hydraulic pump.
transmission with 4 capscrews.
18. Install hydraulic pumps.
19. Remove plugs and caps on open fittings.
20. Connect the hoses at the hydraulic pumps.
21. Remove identification tags on lines.
25
Automatic Powershift Control (APC 100) 1300 SRM 635
22. Replace the drain plug from the transmission
sump.
23. Replace the transmission oil.
24. Connect the wires at the pressure and tempera-
ture sending unit on the transmission.
25. Connect the wires at the solenoids on the trans-
mission control valve.
26. Connect the wiring harness on top of the trans-
mission.
27. Replace the drive shaft between the transmission
and the differential.
28. Connect the drive shaft at the differential.
29. Open shut-off valves on the hydraulic tank.
30. Replace floor plates and covers.
NOTE: When replacing battery cables, replace the
ground cable last.
31. Connect the cables to the battery.
32. Start engine.
33. Operate hydraulic functions and check for leaks.
CLEAN OIL SYSTEM OF TRANSMISSION
AFTER MAJOR REPAIR
NOTE: The complete oil system of the transmission
must be cleaned after every major repair. This clean-
ing is necessary to make sure the transmission oper-
ates correctly.
Clean the system as follows:
1. Drain the entire system completely.
2. Disconnect and clean all oil lines for the trans-
mission. If possible, remove oil lines completely
to clean them.
3. Remove filter elements and clean filter can. In-
stall new filter elements.
4. Use oil and compressed air with flowopposite the
normal direction to flush the oil cooler. Do NOT
use flushing compounds.
5. Assemble all components and oil lines. Fill trans-
mission with the correct oil to the LOW mark
(dipstick or lower fill plug). Install new gaskets
and hydraulic pumps for the hydraulic systems of
the lift truck to the flange on the transmission.
Connect hydraulic lines as necessary. See the
Hydraulic System. Fill hydraulic tank of lift
truck with correct amount and type of hydraulic
oil.
6. Operate engine at idle speed for two minutes
to fill all hydraulic lines and filters. Check
for leaks. Check oil level of transmission with
engine operating. Add oil as necessary to the
LOW mark. If necessary, install the fill and level
plugs.
7. Operate engine at stall until oil is 82 to 93 C (180
to 200 F) and check for leaks. See Torque Con-
verter Stall Speed Check.
Automatic Powershift Control (APC 100)
FUNCTIONAL DESCRIPTION
The APC 100 control unit performs the following
functions (see Figure 23 and Table 2):
Direction Change Protection
FORWARD to REVERSE/REVERSE to FOR-
WARD - When the gear selector direction is re-
versed, throttle reduction is automatically applied,
setting engine speed to idle. The transmission will
downshift as the vehicle slows until first gear
is obtained. The transmission will then change
directions and shift to first gear.
NEUTRAL to FORWARD or REVERSE - Nei-
ther forward nor reverse can be selected when the
engine speed is too high (more than 1000 rpm).
FORWARD, NEUTRAL, FORWARD - When
driving in a certain direction and when putting the
gear selector in NEUTRAL and back in the same
direction, NEUTRAL will be selected until the
engine speed is low enough (less than 1000 rpm).
Overspeed Control
No shifts will be made that can cause overspeeding
of the transmission or the engine. A light on the
instrument panel indicates overspeeding.
Turbine Sensor Failure
Since automatic shifting is based on a speed ratio,
a failure of the torque converter turbine results in
a speed ratio of zero, causing the transmission to
downshift. The control unit prevents downshifts
26
1300 SRM 635 Automatic Powershift Control (APC 100)
that would cause excess speed while driving due to
a turbine failure.
Automatic Shifting
An automatic shift to a higher gear is made when
the throttle pedal is pressed, the turbine speed ex-
ceeds a minimum speed, and the speed ration has
reached a certain value. No upshifts are allowed in
the braking mode (throttle pedal released).
An automatic shift to a lower gear is made when
the tractive effort in the lower gear exceeds the
tractive effort in the higher gear.
Declutch
The transmission shifts to neutral under certain
conditions for load handling procedures.
The following paragraphs describe the pin connec-
tions at the APC 100 control unit.
1. Diagnostic LEDs (See Figure 23)
a. RED LED - ON when internal failure pre-
vents correct operation.
b. GREEN LED - Light reflects the position of
the idle/not idle switch (pin no. 23). When
the throttle is at idle, the light is OFF. The
light is ON when the throttle is pressed.
c. YELLOW LED - ON when turbine rpm=0
(truck not moving) or when engine rpm=0
(engine stopped).
2. Switch Descriptions
a. Idle/Not Idle (pin no. 23). Switch open -
throttle pedal is depressed. Switch closed -
engine is idling, throttle pedal released.
b. Automatic/Manual (pin no. 9). Switch open
- APC 100 is shifting automatically. Switch
closed - APC 100 in manual mode, operator
decides when to shift. Downshifts or direc-
tion changes at high speeds are inhibited.
c. Declutch Request (pin no. 8). Switch open -
no declutch is applied. Switch closed - when
declutch is requested, the control unit will
shift the transmission to NEUTRAL when
vehicle speeds are less than a preset value,
depending on the unit. When the request is
dropped, the direction is engaged again.
d. Parking Brake request (pin no. 27). Switch
open - parking brake is not applied. Switch
closed - when parking brake is applied, con-
trol unit will shift the transmission to NEU-
TRAL.
e. Second Gear Start Request (pin no. 7). 24
volts applied - transmission starts in first
gear when transmission control lever is set
for second gear or lower. No voltage applied
- transmission starts in second gear when
transmission control lever is set for fourth
gear.
A. FRONT COVER B. REAR COVER
1. INDICATOR LIGHTS
RED - INTERNAL MALFUNCTION
YELLOW - ZERO RPM, ENGINE OR TORQUE
CONVERTER
GREEN - THROTTLE PEDAL DEPRESSED
2. CONNECTOR FOR LIFT TRUCK HARNESS
3. CONNECTOR FOR CHECKOUT KIT
Figure 23. APC 100 Control Unit
27
Table 2. APC 100 Control Module (Pin Connections)
Pin No. Function Pin No. Function
1 Forward Switch (input) 17-19 Not Used
2 Range Switch 1 (input) 20 Reverse Switch (input)
3 Range Switch 3 (input) 21 Range Switch 2 (input)
4-6 Not Used 22 Not Used
7 Second Gear Start 22* Third Gear Limit - Twist Locks (input)
8 Declutch Request (input) 23 Idle/Not Idle
9 Manual/Automatic 24-25 Not Used
10-11 Not Used 26 Checkout Speed Ratio Display Request
11* Ground 27 Parking Brake
12 Forward Solenoid (output) 28, 29 Engine Speed Sensor (input)
13 Reverse Solenoid (output) 30, 31 Turbine Speed Sensor (input)
14 Range Solenoid 1 (output) 32-35 Not Used
15 Range Solenoid 2 (output) 34* 24 km/h (15 mph) limit (output)
16 Range Solenoid 3 (output) 36 Throttle Reduction (output)
17* 24-volt Supply 37 Overspeed Warning Light (output)
*A227 units only.
28
FUSES
The APC 100 uses two fuses to protect its circuits.
See Figure 24. The 315 mA fuse is located behind the
front cover. To check or replace the 10A fuse, remove
the rear cover and pull out the circuit board. Be sure
to replace the fuses with the same type.
1. 315 mA FAST ACTING
2. 10A FAST FUSE
Figure 24. APC 100 Control Unit Fuses
Location
TRANSMISSION CONTROL LEVER
The transmission control lever (Figure 25) is in-
stalled on the steering column. If the unit does not
operate correctly, check the wiring and connectors.
See the schematic in Figure 26 and Figure 27 and
Table 3. Check the operation of the APC 100 control
unit. If the control lever does not operate, install a
new lever.
NOTE: RS45-30CH, RS46-35CH, RS45-25IH,
RS46-30IH (A222) SHOWN.
Figure 25. Transmission Control Lever
29
Figure 26. Transmission Control Electrical Schematic
30
Legend for Figure 26
NOTE: H36.00-48.00E [H800-1050E (D117)] SHOWN.
NOTE: *CLARK GEAR SELECTOR SHOWN. HOBBS GEAR SELECTOR SHOWN IN FIGURE 27.
NOTE: HOBBS GEAR SELECTOR USED ON MODEL H36.00-48.00E [H800-1050E (D117)].
Figure 27. Electrical Schematic for Hobbs Gear Selector
Table 3. Hobbs Gear Selector Connections
Contact Description Wire
F Forward DE
N Neutral DH
R Reverse DA
SW1 Direction Selector Switch
SW2 Neutral Switch
SW3 Speed Selector Switch
SW4 Speed Selector Switch
31
First-Speed Shaft Bearings Adjustment 1300 SRM 635
Table 3. Hobbs Gear Selector Connections (Continued)
Contact Description Wire
1 First Gear Position DJ, DG, and DC
2 Second Gear Position DJ and DG
3 Third Gear Position DJ
4 Fourth Gear Position None
Supply +12 to 24 VDC CB and DB
First-Speed Shaft Bearings Adjustment
If the cap, clutch, front or rear bearings, transmis-
sion case, or rear cover is replaced, the clearance for
the bearings must be adjusted using shims at the cap.
If none of these parts were replaced, the old shim set
can be used without doing this procedure.
Adjust the bearings as follows:
1. Move transmission assembly so rear of transmis-
sion is up. If the bearing cap for the first-speed
shaft is installed, remove bearing cap. Make sure
the cap O-ring, clutch pressure sleeve, and oil
seal ring are removed.
2. Use a micrometer depth gauge C to measure the
thickness of the bearing cap at positions A and B
as shown in Figure 28. Thickness Dis dimension
E minus dimension F. Add the two dimensions (D
at A and B) together and divide by 2 to get the
average thickness of the bearing cap.
Example: 22.12 mm (0.871 in.)
+22.17 mm (0.873 in.)
44.29 mm (1.744 in.)
2 = 22.14 mm (0.872 in.)
For the example, average thickness is 22.14 mm
(0.872 in.).
3. Lubricate the bearing and the bore of the bearing
cap. Install bearing cap on studs. Install all four
nuts.
4. Rotate the output shaft to help seat the
tapered roller bearings while the nuts are
tightened. Tighten the nuts in a cross sequence
to 20 to 27 Nm (15 to 20 lbf ft). Use a soft-faced
hammer to lightly hit the rear cover of the trans-
mission while tightening nuts.
5. Remove the two nuts from cover that are 180
apart. These nuts are NOT the nuts G shown
in Figure 28. Loosen the other two nuts (G) until
they can be rotated with your fingers.
6. Set the micrometer depth gauge C firmly against
raised machined surfaces A and B of the bearing
cap as shown in Figure 28.
7. Use a torque wrench to alternately tighten
nuts G from 1.13 Nm (10 lbf in) to 11.3 Nm
(100 lbf in) in 1.13 Nm (10 lbf in) steps. Rotate
output shaft while tightening nuts. Measure the
depth at A and B at each step. The difference be-
tween A and B must not be greater than 0.13 mm
(0.005 in.) at any step. If the difference is greater
at any step, start over at the beginning of this
step. Add the two measurements and divide by 2
to get the average depth. Use the following chart
to record the average measurement at each step.
See Table 4.
32
1300 SRM 635 First-Speed Shaft Bearings Adjustment
Table 4. Example Torque Values at
Dimensions Shown
Torque Value Gap Dimension
Nm lbf in mm in.
1.1 10 23.39 0.921
2.3 20 23.32 0.918
3.4 30 23.27 0.916
4.5 40 23.22 0.914
5.6 50 23.16 0.912
6.8 60 23.14 0.911
7.9 70 23.06 0.908
9.1 80 22.99 0.905
10.2 90 22.96 0.904
11.3 100 22.91 0.902
8. Draw a straight line through the points on the
chart as shown in Figure 29. The value where the
line crosses the zero line minus the average value
recorded for the thickness of the bearing cap of
Step 2 is the no-end-play, no-preload shimdimen-
sion. Add 0.15 0.02 mm (0.006 0.001 in.) to
this dimension for the final shim gap dimension
(total shim thickness). See the example chart
(Figure 29). In the example, the line crosses
the zero line at 23.42 mm (0.922 in.). The av-
erage thickness of the bearing cap is 22.14 mm
(0.872 in.). Subtracting the thickness from the
zero point value equals 1.28 mm (0.050 in.) for
the shim gap with no preload or end play. Add
0.15 0.02 mm (0.006 0.001 in.) to this dimen-
sion for the final shim gap dimension (total shim
thickness) of 1.41 to 1.45 mm (0.055 to 0.057 in.).
NOTE: There is a blank graph included for plotting
the actual measured values. If you need more, copy
the graphs before using them. See Figure 30.
9. Select shims for the total shimthickness found in
Step 8. Measure the thickness of the shim pack
to make sure it is correct.
10. Remove bearing cap. Install a new oil sealing
ring and new O-rings on clutch pressure sleeve
and bearing cap. Install pressure sleeve. In-
stall the correct shim pack and bearing cap on
studs. Install lockwashers and nuts. Alternately
tighten nuts to 55.6 to 61.0 Nm (41 to 45 lbf ft).
Rotate output shaft to make sure bearings are
seated and check the torque of the nuts again.
11. Install lubrication line from bearing cap to check
port for lubricating pressure in front housing.
Figure 28. Adjusting Bearing Clearance
33
First-Speed Shaft Bearings Adjustment 1300 SRM 635
Figure 29. Example Values Chart
Figure 30. Plotting Chart
34
1300 SRM 635 Transmission Oil Pressures Check
Torque Converter Stall Speed Check
This stall check is a measurement of maximum en-
gine rpm with the engine working against the torque
converter at full stall. This test will help find prob-
lems in the transmission, torque converter, or engine.
1. Make sure the coolant level in the cooling system
is correct. Make sure the oil level in the trans-
mission is correct.
2. Put the lift truck against a wall or other object
that cannot move. The parking brake can also
be applied and blocks installed at the wheels to
prevent wheel movement. The wheels must not
turn during this test.
3. Connect a tachometer to the engine. Make sure
the parking brake is engaged. Also apply the
brakes.
CAUTION
Do not keep the lift truck in a stall condition for
more than 30 seconds at a time. Transmission
damage will occur at 120 C (250 F).
4. Select the highest gear. With the engine running
in FORWARD or REVERSE, slowly increase
engine speed to approximately one-half throttle
and hold that throttle position for no more than
30 seconds at a time. Repeat this process un-
til the oil temperature of the transmission (con-
verter outlet) is 83 to 94 C (180 to 200 F).
5. The correct stall speed is approximately
1900 rpm.
6. If the reading is 50 to 200 rpm below the speci-
fications, the engine does not produce full power.
The problem can be the engine, fuel system, or
other engine systems.
7. If the reading is 50 to 200 rpm above the specifi-
cations, the transmission or torque converter can
be the problem. A high reading in only one direc-
tion or speed range indicates a problem in that
clutch assembly.
Transmission Oil Pressures Check
NOTE: If the correct pressure cannot be reached, see
the Troubleshooting at the end of this section. Dur-
ing all pressure checks, the drive wheels must be
raised from the floor.
Attach pressure gauges to the check ports. Check
that the oil level in the transmission is correct. Op-
erate the transmission in all ranges and directions
until the oil in the transmission is 83 to 94 C (180 to
200 F). Connect a tachometer to the engine. Be sure
to use the hydraulic schematic shown in Figure 31.
CLUTCH PRESSURES CHECK
1. Connect gauges to port S. See Table 5.
2. Run the engine at idle (400 to 600 rpm) and 83
to 94 C (180 to 200 F) transmission oil tempera-
ture, with brake pedals up and park brake set.
All clutch pressures must be within 34.5 kPa
(5 psi) of each other.
3. Operate the transmission in both directions and
at each of the speed ranges. The correct oil pres-
sure is 1655 to 2068 kPa (240 to 300 psi) for all
of the direction and range clutches.
4. If a clutch pressure is not within the specifica-
tions of Step 2, repair that clutch.
TORQUE CONVERTER (TORQUE
CONVERTER REGULATOR) OIL
PRESSURE CHECK
1. Connect a gauge to the check port.
2. Make sure the transmission oil temperature is
83 to 94 C (180 to 200 F), the brake pedals are
up, and the park brake is set. The correct oil
pressure is 172 kPa (25 psi) min. @ 2000 rpm
and 483 kPa (70 psi) @ governed speed.
35
Transmission Oil Pressures Check 1300 SRM 635
Table 5. Transmission Pressures
Port Pressure Check Pressure
FC (@ Control Valve) Forward Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
RC (@ Control Valve) Reverse Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
S (Top of Transmission) First-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
2C (@ Control Valve) Second-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
S (Top of Transmission) Third-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
S (Top of Transmission) Fourth-Gear Clutch Pack 1655 to 2068 kPa (240 to 300 psi)*
R (AQ to Heat Exchanger) Torque Converter Regulator 172 kPa (25 psi) min @ 2000 rpm
483 kPa (70 psi) @ gov. speed**
*At engine idle (400 to 600 rpm) and 83 to 94 C (180 to 200 F) transmission oil temp., brake pedals up, and
park brake set. All clutch pressures must be within 34.5 kPa (5 psi) of each other or repair clutch.
** 83 to 94 C (180 to 200 F) transmission oil temp., brake pedals up, and park brake set.
1. Port S
2. Port R
36
1300 SRM 635 Troubleshooting
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Transmission oil tempera-
ture is too hot.
Type of oil is not correct or oil level is
not correct.
Check oil type and level.
Oil cooler or oil lines have a restric-
tion.
Check and clean oil lines and oil
cooler.
Clutches do not engage completely. Check oil pressure and repair as nec-
essary.
Torque converter does not operate
correctly.
Check stall speed and repair as nec-
essary.
Bearings or shafts in the transmis-
sion are damaged.
Replace damaged parts.
Lift truck is operating in the wrong
speed range for a long period of time.
Have operator change operation.
One or more clutches do not
engage or engage slowly.
Oil level is not correct or oil is the
wrong type.
Friction discs in the clutch are worn. Replace damaged parts.
Transmission has internal oil leaks. Check oil pressure to locate problem.
Oil pressure is not correct. Check oil pressure to locate problem.
Control valve does not operate cor-
rectly.
Repair control valve.
Solenoid(s) or electrical circuit is
damaged.
Install new solenoid or repair wiring.
Gears in transmission are damaged. Replace damaged parts.
External oil line(s) is damaged, has
a restriction, or is disconnected.
Check and repair oil lines.
Main oil pressure is low. There is a restriction in the oil filter. Install new oil filter.
Regulator for torque converter cir-
cuit does not operate correctly.
Check and adjust regulator.
Oil level is not correct or oil is the
wrong type.
37
Troubleshooting 1300 SRM 635
Main oil pressure is low.
(Cont.)
Oil pump is worn or damaged. Repair oil pump.
There is a leak between the oil pump
and the regulator.
Check for and repair internal leaks.
Torque converter is too hot,
or performance is not to spec-
ifications.
Oil pressure is not correct. Check oil pressure to locate problem.
There is a restriction in the cooling
circuit.
Check and repair cooling circuit.
Lift truck is operating in the wrong
speed range for a long period of time.
Have operator change operation.
Torque converter makes too
much noise.
Bearings are damaged. Replace damaged parts.
Torque converter drive plate is loose
or damaged.
Repair or replace drive plate.
Oil pressure in the torque
converter circuit is low.
Transmission pump is worn. Replace pump.
Relief valve for torque converter is
open.
Check and repair.
Oil pressure in the torque
converter circuit is high.
There is a restriction in the torque
converter circuit.
Check passages for restrictions.
TRANSMISSION CONTROLLER (APC 100)
None of the display LEDs are
on when key switch is on.
There is no power to the controller. Check and repair wiring as neces-
sary.
Fuse in controller is damaged. Replace fuse.
The red light is on continu-
ously.
There is no power to the controller. Check and repair wiring as neces-
sary.
The wiring harness is damaged. Repair wiring as necessary.
The controller is damaged. Replace controller.
38
1300 SRM 635 Diagrams, Schematics, or Arrangements
The transmission remains in
NEUTRAL when power is
available to the controller.
The 10-amp fuse is damaged. Replace fuse.
The transmission remains in
a certain gear.
The transmission controller is dam-
aged.
Override the controller and drive the
vehicle manually.
39
Diagrams, Schematics, or Arrangements 1300 SRM 635
40
1300 SRM 635 Diagrams, Schematics, or Arrangements
Figure 31. Transmission Hydraulic Diagram
41
NOTES
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42
TECHNICAL PUBLICATIONS
1300 SRM 635 11/03 (4/03)(1/00)(9/98) Printed in U.S.A.

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What safety precautions should be followed when working on lift trucks?

What are the main components discussed in the document?

FOUR-SPEED

number 270 or number 262 on both the bushing and

has set, install speed sensors and tighten them to

683 (green) on outer

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