Zf-wg161 Transmission Repair

TRANSMISSION
REPAIR (ZF-WG161)
PART NO. 4034066 1300 SRM 1456

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
Special Tools List .....................................................................................................................................................2
Transmission Repair ............................................................................................................................................... 3
Remove ................................................................................................................................................................ 3
Disassemble .........................................................................................................................................................7
Transmission Housing, Disassemble .............................................................................................................8
Oil Pump, Disassemble ................................................................................................................................ 15
Forward Clutch, Disassemble ...................................................................................................................... 21
Reverse Clutch, Disassemble ....................................................................................................................... 26
First Speed Clutch, Disassemble ................................................................................................................. 32
Second Speed Clutch, Disassemble ..............................................................................................................37
Third Speed Clutch, Disassemble ................................................................................................................42
Input Shaft, Disassemble ............................................................................................................................. 46
Clean and Inspect ............................................................................................................................................. 46
Housings ........................................................................................................................................................47
Oil Seals and Gaskets ...................................................................................................................................47
Bearings ........................................................................................................................................................ 47
Gears and Shafts .......................................................................................................................................... 47
Assemble ............................................................................................................................................................48
Input Shaft, Assemble .................................................................................................................................. 48
Third Speed Clutch, Assemble .....................................................................................................................48
Second Speed Clutch, Assemble ...................................................................................................................55
First Speed Clutch, Assemble ...................................................................................................................... 62
Reverse Clutch, Assemble ............................................................................................................................ 70
Forward Clutch, Assemble ........................................................................................................................... 77
Oil Pump, Assemble ..................................................................................................................................... 85
Transmission Housing, Assemble ................................................................................................................86
Transmission Oil Filter Assembly Replacement .............................................................................................95
Remove .......................................................................................................................................................... 95
Clean ..............................................................................................................................................................96
Inspect ........................................................................................................................................................... 96
Install ............................................................................................................................................................ 96
Install .................................................................................................................................................................97
Control Valve Replacement ................................................................................................................................ 102
Remove ............................................................................................................................................................ 102
Install ...............................................................................................................................................................103
Control Valve Repair ...........................................................................................................................................104
Disassemble .....................................................................................................................................................104
Clean ................................................................................................................................................................108
Inspect ............................................................................................................................................................. 108
Assemble ..........................................................................................................................................................109
This section is for the following models:
©2015 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 1456 Series Code / Model Designation Reference Table
Series Code / Model Designation Reference Table

This table consist of the following Series Codes
used in this manual.
Series Code European Model Americas Model

H019 H13.00-16.0XM-6, H300-360HD2, H360HD2-EC
H10.00-12.0XM-12EC
J007 H8.00-12.00XM-6 H190-280HD2
J019 H13.00-16.00XM-6, H300-360HD2, H360HD2-EC
H10.00-12.00XM-12EC
K007 H8.00-12.00XM-6, H10.00XMS-6 H190-280HD2, H230HDS
K019 H13.00-16.00XM-6 H210-250-48HD2, H300-360HD2
K019EC H6.00-7.00XM-12EC H360HD2-EC
L007 H8.00-12.00XM-6 H190-280HD2, H250HD2
A238 H16.00XM-9, H18XM-7.5, H360-36HD, H360-48HD
H16XM-12, H18XM-9
B238 H16.00XM-9, H18XM-7.5, H360-36HD, H360-48HD
H16XM-12, H18XM-9
1
Special Tools List 1300 SRM 1456
Special Tools List

The following list consists of the special tools re-
quired to perform the assembly procedures outlined
in this manual.
Item Figure Nomenclature Part Number
Clutch Pack Spring

1 Hyster P/N 4612858
Compression Tool
2 Holding Fixture Assembly Hyster P/N 4612859
3 Shaft Seal Mounting Tool Hyster P/N 4612860
4 Grip Handle Hyster P/N 4612861
5 Pump Seal Mounting Tool Hyster P/N 4612862
2
1300 SRM 1456 Transmission Repair
Transmission Repair
REMOVE During removal, it may be possible for the drive
shaft to split apart into two pieces. Reassemble
1. Tilt the mast fully forward. the drive shaft using the alignment mark made
prior to removal.
2. Turn the key to OFF position to shutdown the
engine. Failure to assemble and install the drive shaft
properly may lead to:
3. Apply the parking brake.
• Vibration of the drive shaft and/or truck
4. Tilt the operator compartment up to gain access • Premature failure of the universal joints on
to the transmission. See the section Opera- the drive shaft
tor's Cab 0100SRM1390.
• Excessive vibration levels in the transmis-
5. Disconnect the cables at the battery. Discon- sion
nect the ground cable first and then the posi- • Excessive vibration levels in the drive axle
tive cable.
NOTE: Use a marker of some type to indicate posi-
tion and orientation of drive shaft prior to removal.
CAUTION
The drive shaft for this truck is a two piece model, 6. Disconnect the drive shaft at the transmission.
consisting of a male splined drive shaft, a female See Figure 1.
splined slip yoke and a universal joint on both
7. Disconnect the wiring harnesses on the trans-
ends where it connects to the drive axle and
mission and wires for the sensors on the trans-
transmission.
mission. Put identification tags on the wires so
Drive shafts are balanced and configured at the they can be correctly connected again. See Fig-
time of manufacture. It is recommended that an ure 2.
alignment mark is made on the drive shaft indicat-
ing the position of the universal joint and drive
shaft prior to removal.
3
Transmission Repair 1300 SRM 1456
1. FRAME (REFERENCE) 6. TRANSMISSION

2. DIPSTICK ASSEMBLY 7. TORQUE CONVERTER
3. DRIVE SHAFT 8. CAPSCREWS
4. OUTPUT YOKE 9. CAPSCREWS
5. TRANSMISSION MOUNT
Figure 1. Transmission Arrangement
4
1. TRANSMISSION INTERNAL SPEED SENSOR 5. ENGINE SPEED SENSOR

2. TRANSMISSION TURBINE SPEED SENSOR 6. TORQUE CONVERTER TEMPERATURE SEN-
3. DIFFERENTIAL PRESSURE SWITCH SOR
4. TRANSMISSION CONTROL VALVE CONNEC-
TOR
Figure 2. Transmission Wire Connectors and Sensors
5
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
8. Place a suitable container under the transmis-

sion sump and remove the transmission sump
drain plug and drain the transmission oil [ap-
proximately 20 liter (21 qt)].
9. Disconnect the oil lines from the transmission

to the thermostat valve. Drain the oil into a
drain pan. Put plugs and caps on open lines
and fittings.
10. Disconnect the oil hoses at the hydraulic

pumps. Install plugs and caps on open lines and
fittings.
11. The hydraulic pumps are connected to the

transmission with four capscrews. Attach a lift-
ing device to hold the hydraulic pumps, remove
the capscrews, and the hydraulic pumps. The
drive shaft of the hydraulic pump is engaged in
the splines of the drive gear. The drive shaft of
the hydraulic pump will slide out of the drive 1. LIFTING EYES
gear when the hydraulic pump is removed. Figure 3. View of Transmission
12. Install blocks and a jack under the flywheel end
of the engine as a support. If the support is un-
der the engine oil sump, make sure that the
support is across the width of the oil sump so
the weight of the engine does not damage the
oil sump.
13. Connect a lifting device, with a lifting capacity

of at least 1200 kg (2650 lb), to the two lifting
eyes located on the top of the transmission. See
Figure 3.
14. Remove the access plug to gain access to the

flywheel ring gear. See Figure 4.
15. Remove the access plate to gain access to the 1. ACCESS HOLE TO ROTATE FLYWHEEL
capscrews that connect the flywheel to the 2. ACCESS PLUG
drive plates. See Figure 4. 3. CONVERTER HOUSING
4. ACCESS PLATE TO FLYWHEEL CAPSCREWS
16. Insert a flywheel rotation tool into the access
plug hole and rotate the flywheel until one of Figure 4. Access Plug for Drive Plate Capscrews
the capscrews is visible through the access
plate hole. See Figure 4.
6
17. Remove the capscrew. Rotate the flywheel and

remove the remaining capscrews until all four
of the capscrews have been removed.
18. Raise the lifting device to hold the weight of the

transmission only. Remove the twelve cap-
screws that fasten the torque converter housing
to the flywheel housing.
19. Remove the two 3/4 × 31/2-inch bolts that fas-

ten the transmission mount to the frame.
CAUTION
Keep the transmission level when the transmis-
sion is separated from the engine so the drive
plate is not damaged.
20. Make sure that all connections have been re-

moved and carefully lift the transmission as-
sembly from the frame and engine.
DISASSEMBLE
Figure 5. ZF ERGOPOWER Transmission
Figure 5 shows a view of the ZF ERGOPOWER
transmission.
7
Transmission Housing, Disassemble

STEP 1.
Remove the oil filter assembly and control valve
assembly from the transmission. See Transmis-
sion Oil Filter Assembly Replacement, Remove
and Control Valve Replacement, Remove.
1. OIL FILTER ASSEMBLY

2. CONTROL VALVE ASSEMBLY
3. TRANSMISSION
STEP 2.
Remove the converter pressure back-up valve and
differential pressure switch from the transmission
housing. DO NOT remove the pressure relief
valve.
1. CONVERTER PRESSURE BACK-UP VALVE

2. DIFFERENTIAL PRESSURE SWITCH
3. PRESSURE RELIEF VALVE
8
STEP 3.
Remove the engine speed sensor, and oil fill tube
with dipstick from the transmission.
1. ENGINE SPEED SENSOR

2. OIL FILL TUBE WITH DIPSTICK
STEP 4.
Remove the internal speed sensor, turbine speed
sensor, and output speed sensor from the trans-
mission.
1. INTERNAL SPEED SENSOR

2. TURBINE SPEED SENSOR
3. OUTPUT SPEED SENSOR
9
STEP 5.
Remove the torque converter from the transmis-
sion. Remove capscrews from torque converter bell
housing and transmission.
1. TORQUE CONVERTER
2. TORQUE CONVERTER BELL HOUSING
3. CAPSCREW
4. TRANSMISSION
STEP 6.
Remove the torque converter bell housing with oil
pump, and gasket from the transmission housing.
Remove the stator hollow shaft from the input
shaft.

2. GASKET
3. TRANSMISSION HOUSING
4. STATOR HOLLOW SHAFT
5. INPUT SHAFT
10
STEP 7.
Remove the oil pump from the torque converter
bell housing.
1. OIL PUMP
STEP 8.
Remove two capscrews, output flange, and output
shaft seal from the transmission housing. Discard
the seal.
1. CAPSCREW
2. OUTPUT FLANGE
3. OUTPUT SHAFT SEAL
STEP 9.
Remove the retaining ring and O-ring from the
transmission housing. Discard the O-ring.
1. RETAINING RING
2. O-RING
11
STEP 10.
Remove the PTO shaft from the housing. Remove
the retaining ring. Using a press, remove the
bearing from the PTO shaft.
1. PTO SHAFT
2. HOUSING
3. RETAINING RING
4. BEARING
WARNING
To prevent the possibility of injury to personnel, use a lifting device of sufficient lifting capacity while per-
forming the following step.
NOTE: Make sure that the guide pins have been removed before removing the rear transmission cover.
STEP 11.
Remove the capscrews, washers, and rear trans-
mission cover from the front transmission cover.
1. CAPSCREW
2. WASHER
3. REAR TRANSMISSION COVER
4. FRONT TRANSMISSION COVER
5. GUIDE PIN
12
STEP 12.
Remove capscrews, suction tube, screen, and
tubes from the front transmission cover. Remove
and discard the O-rings from the tubes.
1. CAPSCREW
2. SUCTION TUBE
3. SCREEN
4. TUBE
5. GUIDE PIN
6. O-RING
WARNING
forming the following step.
STEP 13.
Remove the clutch packs and input shaft from the
front transmission cover in the order given in the
legend.
1. CLUTCH, 3RD SPEED/OUTPUT

2. CLUTCH, 2ND SPEED
3. CLUTCH, REVERSE
4. CLUTCH, FORWARD
5. INPUT SHAFT
6. CLUTCH, 1ST SPEED
13
STEP 14.
Remove capscrews and screen from front trans-
mission cover.
1. CAPSCREW
2. SCREEN
NOTE: Perform STEP 15 only if any of the tubes are damaged.
STEP 15.
Remove the system pressure tubes from the rear
transmission cover in the order of the legend.
Prior to removal of the tubes remove the holding
segment from the tubes.

4. CLUTCH, REVERSE
5. CLUTCH, FORWARD
6. HOLDING SEGMENT
14
Oil Pump, Disassemble

STEP 1.
Remove the O-ring and capscrews from the oil
pump. Discard the O-ring.
1. O-RING
2. CAPSCREWS
3. OIL PUMP
STEP 2.
Remove the cover, inner rotor, and outer rotor
from the oil pump housing. Inspect the pump
housing, inner rotor outer rotor, and cover for
wear marks. If any wear is shown, replace the oil
pump.
1. COVER
2. INNER ROTOR
3. OUTER ROTOR
4. OIL PUMP HOUSING
15
STEP 3.
Remove and discard the shaft seal from the oil
pump housing.
1. SHAFT SEAL
2. OIL PUMP HOUSING
1. PISTON RING 12. FRICTION DISC

2. THREADED STUD 13. "L" RING
3. TAPERED ROLLER BEARING 14. GUIDE RING
4. CLUTCH SHAFT 15. COMPRESSION SPRING
5. BALL BEARING 16. OUTER O-RING
6. IDLER GEAR 17. INNER O-RING
7. NEEDLE BEARING 18. PISTON
8. RETAINING RING 19. CLUTCH PACK CARRIER
9. END SHIM 20. WASHER
10. OUTER FRICTION DISC 21. SNAP RING
11. INNER DISC
Figure 6. Forward Clutch Assembly
16
1. PISTON RING 12. INNER DISC

2. THREADED STUD 13. FRICTION DISC
3. TAPERED ROLLER BEARING 14. "L" RING
4. CLUTCH SHAFT 15. GUIDE RING
5. GEAR 16. COMPRESSION SPRING
6. NEEDLE BEARING 17. OUTER O-RING
8. BALL BEARING 19. PISTON
10. END SHIM 21. WASHER
11. OUTER FRICTION DISC 22. SNAP RING
Figure 7. Reverse Clutch Assembly
17

2. THREADED STUD 13. SNAP RING
5. AXIAL NEEDLE BEARING 16. PISTON
6. NEEDLE BEARINGS 17. INNER O-RING
7. IDLER GEAR 18. OUTER O-RING
9. END SHIM 20. SEALING CAP
10. OUTER FRICTION DISC 21. AXIAL WASHER
11. INNER DISC 22. RUNNING DISC
Figure 8. 1st Speed Clutch Assembly
18

2. THREADED STUD 13. SNAP RING
5. AXIAL NEEDLE BEARING 16. PISTON
7. NEEDLE BEARINGS 18. OUTER O-RING
9. END SHIM 20. AXIAL WASHER
10. OUTER FRICTION DISC 21. RUNNING DISC
11. INNER DISC
Figure 9. 2nd Speed Clutch Assembly
19
1. PISTON RING 14. COMPRESSION SPRING

2. PLUG 15. PISTON
3. TAPERED ROLLER BEARING 16. INNER O-RING
4. AXIAL NEEDLE BEARING 17. OUTER O-RING
5. IDLER GEAR 18. CLUTCH PACK CARRIER
6. NEEDLE BEARING 19. CLUTCH SHAFT
7. SNAP RING 20. PISTON RING
8. END SHIM 21. RUNNING DISC
9. OUTER FRICTION DISC 22. AXIAL WASHER
10. INNER DISC 23. THREADED STUD
11. FRICTION DISC 24. CAP
12. SNAP RING 25. PISTON RING
13. GUIDE RING 26. SEAL
Figure 10. 3rd Speed Clutch Assembly
20
Forward Clutch, Disassemble

NOTE: As each clutch assembly is disassembled, ensure that all of the components of that assembly are
kept separate from any other clutch assemblies to prevent the possibility of parts being assembled to an in-
correct clutch assembly.
STEP 1.
Remove the threaded stud, and unsnap piston
ring. Using a bearing puller, remove the tapered
roller bearing from the clutch shaft.
1. THREADED STUD
2. PISTON RING
3. TAPERED ROLLER BEARING
4. CLUTCH SHAFT
STEP 2.
Remove the clutch pack carrier from the clutch
shaft.
1. CLUTCH PACK CARRIER

2. CLUTCH SHAFT
21
STEP 3.
Remove the snap ring. Using a press, remove the
clutch shaft from the idler gear.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
STEP 4.
Remove snap ring and roller bearing from the id-
ler gear.
1. SNAP RING
2. ROLLER BEARING
3. IDLER GEAR
22
STEP 5.
Remove the needle bearing from the clutch shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
STEP 6.
Remove the piston ring. Using a bearing puller,
remove the tapered roller bearing from the clutch
shaft.
1. PISTON RING
3. CLUTCH SHAFT
STEP 7.
Remove the retaining ring from the clutch pack
carrier.
1. RETAINING RING
23
STEP 8.
Remove the end shim and disc set from the clutch
pack carrier.
1. END SHIM
2. DISC SET
WARNING
The spring has a force of 1700 ±147 N (382 ±33 lbf).
STEP 9.
Using a spring compression tool, Hyster P/N
4612858, compress the spring and remove the "L"
ring.
1. COMPRESSION TOOL
2. COMPRESSION SPRING
3. "L" RING
24
STEP 10.
Slowly release the compression spring and remove
the guide ring, compression spring, and washer
from the clutch pack carrier.
1. GUIDE RING
4. WASHER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 11.
Remove piston from clutch pack carrier.
1. PISTON
STEP 12.
Remove and discard inner and outer O-rings from
the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
25
Reverse Clutch, Disassemble

STEP 1.
Remove the threaded stud and piston ring. Using
a bearing puller, remove the tapered roller bear-
ing from the clutch shaft.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 2.
shaft.

2. CLUTCH SHAFT
26
STEP 3.
Remove the snap ring. Using a press, remove the
clutch shaft from the idler gear.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
STEP 4.
Remove snap ring and bearing from the idler gear.
1. SNAP RING
2. BEARING
3. IDLER GEAR
27
STEP 5.
Remove the needle bearing and snap ring from the
clutch shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
3. SNAP RING
4. GEAR
STEP 6.
shaft.
1. PISTON RING
3. CLUTCH SHAFT
28
STEP 7.
carrier.
1. RETAINING RING
STEP 8.
pack carrier.
1. END SHIM
2. DISC SET
29
WARNING
STEP 9.
4612858, compress the spring and remove the "L"
ring.
1. COMPRESSION TOOL
3. "L" RING
STEP 10.
the guide ring, compression spring and washer,
1. GUIDE RING
4. WASHER
30
STEP 11.
1. PISTON
STEP 12.
the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
31
First Speed Clutch, Disassemble

STEP 1.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 2.
Remove the retaining ring and axial bearing as-
sembly from the clutch shaft.
1. RETAINING RING
2. AXIAL BEARING ASSEMBLY (3 PIECES)
3. CLUTCH SHAFT
32
STEP 3.
Remove the idler gear, two needle bearings, and
axial bearing assembly from the clutch shaft.
1. IDLER GEAR
2. NEEDLE BEARING
4. CLUTCH SHAFT
STEP 4.
shaft.

2. CLUTCH SHAFT
33
STEP 5.
shaft.
1. PISTON RING
3. CLUTCH SHAFT
STEP 6.
carrier.
1. RETAINING RING
STEP 7.
pack carrier.
1. END SHIM
2. DISC SET
34
WARNING
STEP 8.
4612858, compress the spring and remove the
snap ring.
1. COMPRESSION TOOL
3. SNAP RING
STEP 9.
the guide ring, compression spring, and guide ring
1. GUIDE RING
35
STEP 10.
1. PISTON
STEP 11.
the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
36
Second Speed Clutch, Disassemble

STEP 1.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 2.
Remove the retaining ring and axial bearing as-
sembly from the clutch shaft.
1. RETAINING RING
3. CLUTCH SHAFT
37
STEP 3.
Remove the idler gear, two needle bearings, and
axial bearing assembly from the clutch shaft.
1. IDLER GEAR
2. NEEDLE BEARING
4. CLUTCH SHAFT
STEP 4.
shaft.

2. CLUTCH SHAFT
38
STEP 5.
shaft.
1. PISTON RING
3. CLUTCH SHAFT
STEP 6.
carrier.
1. RETAINING RING
39
STEP 7.
pack carrier.
1. END SHIM
2. DISC SET
WARNING
STEP 8.
snap ring.
1. COMPRESSION TOOL
3. SNAP RING
40
STEP 9.
1. GUIDE RING
STEP 10.
1. PISTON
STEP 11.
the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
41
Third Speed Clutch, Disassemble

STEP 1.
shaft.
1. PISTON RING
3. CLUTCH SHAFT
STEP 2.
Remove the axial bearing assembly, idler gear,
and two needle bearings from the clutch shaft.

2. IDLER GEAR
3. NEEDLE BEARING
4. CLUTCH SHAFT
42
STEP 3.
shaft.

2. CLUTCH SHAFT
STEP 4.
Remove the piston rings. Using a bearing puller,
shaft.
1. PISTON RING
3. CLUTCH SHAFT
STEP 5.
carrier.
1. RETAINING RING
43
STEP 6.
pack carrier.
1. END SHIM
2. DISC SET
WARNING
STEP 7.
snap ring.
1. COMPRESSION TOOL
3. SNAP RING
44
STEP 8.
1. GUIDE RING
STEP 9.
1. PISTON
STEP 10.
Remove and discard the inner and outer O-rings
from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
45
Input Shaft, Disassemble

STEP 1.
Remove piston ring. Using a bearing puller, re-
move two tapered roller bearings from the input
shaft.
1. PISTON RING
3. INPUT SHAFT
CLEAN AND INSPECT • Wear safe eye protection.

• Wear clothing that protects skin.
WARNING • Work in a well-ventilated area.
To prevent serious eye injury, always wear safe • Do not use gasoline or solvents that con-
eye protection when performing vehicle mainte- tain gasoline. Gasoline can explode.
nance or service. • Use hot solution tanks or alkaline solutions
correctly. Carefully follow manufacturer's
WARNING instructions.
To avoid personal injury when cleaning parts,
work in a well-ventilated area, wear protective Clean all parts thoroughly using solvent type clean-
clothing (face shield or safety glasses and protec- ing fluid. It is recommended that parts be im-
tive gloves), and follow chemical manufacturer's mersed in cleaning fluid and moved up and down
recommendations for safe usage. slowly until all old lubricant and foreign material is
dissolved and parts are thoroughly cleaned.
Solvent cleaners can be flammable, poisonous,
and cause burns. Examples of solvent cleaners The importance of careful and thorough inspection
are carbon tetrachloride, emulsion-type cleaners, of all parts cannot be overstressed. Replacement of
and petroleum-based cleaners. To avoid serious all parts showing indication of wear or stress will
personal injury when using solvent cleaners, eliminate costly and avoidable failures at a later
carefully follow manufacturer's instructions and date.
these procedures:
46
Housings Bearings
Clean interior and exterior of housings, bearing

caps, etc., thoroughly. Cast parts may be cleaned in WARNING
hot solution tanks with mild alkali solution provid- Compressed air can move particles so that they
ing these parts do not have ground or polished sur- cause injury to the user or to other personnel.
faces. Parts should remain in solution long enough Make sure that the path of the compressed air is
to be thoroughly cleaned and heated. This will aid away from all personnel. Wear protective goggles
the evaporation of the cleaning solution and rinse or a face shield to prevent injury to the eyes.
water. Parts cleaned in solution tanks must be
NOTE: Do not spin the bearings when drying.
thoroughly rinsed with clean water to remove all
traces of alkali. Cast parts may also be cleaned
Remove bearings from cleaning fluid and strike flat
with steam cleaner.
against a block of wood to dislodge solidified parti-
cles of lubricant. Immerse again in cleaning fluid to
Inspect housings, covers and bearing caps to ensure
flush out particles. Repeat above operation until
that they are thoroughly clean and that mating
bearings are thoroughly clean. Dry bearings using
surfaces, bearing bores, etc., are free from nicks or
moisture-free compressed air. Be careful to direct
burrs. Check all parts carefully for evidence of
air stream across bearing to avoid spinning. Bear-
cracks or conditions which would cause subsequent
ings may be rotated slowly by hand to facilitate
oil leaks or failures.
drying process.
Oil Seals and Gaskets NOTE: Do not replace a bearing cone or cup indi-
vidually without replacing the mating cup or cone
Replacement of spring load oil seals, O-rings, metal
at the same time.
sealing rings, gaskets, and snap rings is more eco-
nomical when the unit is disassembled than prema-
Carefully inspect all rollers, cages and cups for
ture overhaul to replace these parts at a future
wear, chipping, or nicks to determine fitness of
time. Further loss of lubricant through a worn seal
bearings for further use. After inspection, dip bear-
may result in failure of other more expensive parts
ings in recommended Automatic Transmission
of the assembly. Sealing members should be han-
Fluid and wrap in clean lint-free cloth or paper to
dled carefully, particularly when being installed.
protect them until installed.
Cutting, scratching, or curling under of lips of seals
seriously impairs its efficiency. When assembling
Gears and Shafts
new metal type piston rings, these should be lubri-
cated with a coat of Vaseline to stabilize rings in
If Magna-Flux process is available, use process to
their grooves for ease of assembly of mating mem-
check parts. Examine teeth on all gears carefully
bers. Lubricate all O-rings with recommended type
for wear, pitting, chipping, nicks, cracks, or scores.
Automatic Transmission Fluid before assembly.
If gear teeth show spots where case hardening is
Prior to installation of rubber seals, lightly coat the
worn through or cracked, replace with new gear.
outer surface with mineral spirits, and coat the in-
Small nicks may be removed with suitable hone. In-
ner surface with multipurpose grease.
spect shafts and quills to make certain they are not
sprung, bent, or spline-twisted, and that shafts are
true.
47
ASSEMBLE
Input Shaft, Assemble

STEP 1.
Using a press, install two tapered roller bearings
on the input shaft until they bottom out, and in-
stall the piston ring on the input shaft.
1. PISTON RING
3. INPUT SHAFT
Third Speed Clutch, Assemble
CAUTION
Make sure that the O-rings are not deformed during installation, and DO NOT roll the O-rings onto the pis-
ton.
NOTE: Prior to installing O-rings, coat with transmission oil to make installation easier.
STEP 1.
Install new inner and outer O-rings on the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
48
NOTE: Check piston relief valve functionality prior to installation of the piston.
STEP 2.
Using the spring compression tool, Hyster P/N
4612858, install the piston into the clutch pack
carrier, as noted during disassembly, until it bot-
toms out.
1. PISTON
STEP 3.
Install the guide ring, compression spring, and
guide ring into the clutch pack carrier.
1. GUIDE RING
49
STEP 4.
4612858, depress the spring assembly and install
the snap ring into the annular groove. Remove the
spring compression tool from the clutch pack car-
rier.
1. COMPRESSION TOOL
3. SNAP RING
STEP 5.
Install the friction disk, uncoated side down toward the piston, into the clutch pack carrier. See Figure 10.
NOTE: Prior to installation, the inner and friction discs must be coated with clean automatic transmission
fluid.
STEP 6.
Install the inner discs and friction discs into the clutch pack carrier as shown in Figure 10.
STEP 7.
Install the friction disc, uncoated side up, into the clutch pack carrier. See Figure 10.
STEP 8.
Install the end shim and retaining ring into the
clutch pack carrier.
1. END SHIM
2. RETAINING RING
50
STEP 9.
Install a dial indicator as shown, and depress the
end shim with a force of 100 N (23 lbf), set the dial
indicator to zero.
1. DIAL INDICATOR
2. END SHIM
STEP 10.
Press the end shim against the retainer and deter-
mine the clearance between the end shim and the
retainer. The disk clearance is to be 2.0 to
2.3 mm (0.079 to 0.090 in.). If the clearance is not
within the limits specified a new retainer must be
installed. See the Parts Manual for the next size
retainer.
1. DIAL INDICATOR
2. END SHIM
STEP 11.
Using a press, install the tapered roller bearing on
the clutch shaft until it bottoms out, and install
the two piston rings.
1. CLUTCH SHAFT
3. PISTON RINGS
51
STEP 12.
Turn the clutch pack carrier over so that the bot-
tom of the carrier is facing up, and using a heat
gun, heat the inner diameter to 120°C (248°F).

2. HEAT GUN
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns
STEP 13.
Install the clutch pack carrier on the clutch shaft
until it bottoms out.

2. CLUTCH SHAFT
52
STEP 14.
Install the running disc chamfer side up, axial
bearing, and axial washer on the clutch shaft.
1. AXIAL BEARING
2. RUNNING DISC
3. AXIAL WASHER
NOTE: Manually align the inner teeth of the disks prior to performing STEP 15.
STEP 15.
Install the two needle bearings and idler gear on
the clutch shaft, rotating the idler gear left and
right small amounts to achieve final alignment
with the clutch pack.
1. AXIAL BEARING ASSEMBLY

2. NEEDLE BEARING
3. IDLER GEAR
4. CLUTCH SHAFT
53
STEP 16.
Install the axial washer, axial bearing, and run-
ning disc chamfer side down on the clutch shaft.
1. AXIAL WASHER
2. AXIAL BEARING
3. RUNNING DISC
STEP 17.
the piston ring.
1. PISTON RING
3. CLUTCH SHAFT
STEP 18.
Check the opening of the clutch by applying com-
pressed air at the bore. See arrow in the figure.
The opening of the clutch must be clearly audible.
54
Second Speed Clutch, Assemble
CAUTION
ton.
STEP 1.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
STEP 2.
toms out.
1. PISTON
55
STEP 3.
1. GUIDE RING
STEP 4.
4612858 and a press, depress the spring assembly
and install the snap ring into the annular groove.
Remove the spring compression tool from the
1. COMPRESSION TOOL
3. SNAP RING
STEP 5.
NOTE: Prior to installation, the inner and outer friction discs must be coated with clean automatic trans-
mission fluid.
STEP 6.
STEP 7.
Install the friction disk, uncoated side up, into the clutch pack carrier. See Figure 9.
56
STEP 8.
1. END SHIM
2. RETAINING RING
STEP 9.
indicator to zero
1. DIAL INDICATOR
2. END SHIM
STEP 10.
2.3 mm (0.079 to 0.090 in.). If the clearance is not
within the limits specified a new retainer must be
installed. See the Parts Manual for the next size
retainer.
1. DIAL INDICATOR
2. END SHIM
57
STEP 11.
the piston ring.
1. PISTON RING
3. CLUTCH SHAFT
STEP 12.

2. HEAT GUN
WARNING
NOTE: Manually align the inner teeth of the disks prior to performing STEP 13.
58
STEP 13.
Install the clutch pack carrier until it bottoms out.

2. CLUTCH SHAFT
STEP 14.
Install the running disk chamfer side up, axial
1. AXIAL BEARING
2. RUNNING DISK
3. AXIAL WASHER
59
STEP 15.
Install two needle bearings and the idler gear on
the clutch shaft, rotate the idler gear left and
right small amounts to achieve final alignment
with the clutch pack.
1. IDLER GEAR
2. NEEDLE BEARINGS
3. AXIAL BEARING ASSEMBLY
4. CLUTCH SHAFT
STEP 16.
Install the axial washer, axial bearing and run-
ning disc, chamfer side down on the clutch shaft.
1. AXIAL WASHER
2. AXIAL BEARING
3. RUNNING DISK
60
STEP 17.
Install the retaining ring on the clutch shaft.
1. RETAINING RING
2. CLUTCH SHAFT
STEP 18.
the clutch shaft until it bottoms out, piston ring,
and threaded stud.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
61
STEP 19.
First Speed Clutch, Assemble
CAUTION
ton.
STEP 1.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
62
STEP 2.
toms out.
1. PISTON
STEP 3.
1. GUIDE RING
63
STEP 4.
4612858, depress the spring assembly and install
the snap ring into the annular groove. Remove the
spring compression tool from the clutch pack car-
rier.
1. COMPRESSION TOOL
3. SNAP RING
STEP 5.
mission fluid.
STEP 6.
STEP 7.
STEP 8.
1. END SHIM
2. RETAINING RING
64
STEP 9.
indicator to zero.
1. DIAL INDICATOR
2. END SHIM
STEP 10.
2.75 mm (0.096 to 0.108 in.). If the clearance is
not within the limits specified a new retainer
must be installed. See the Parts Manual for the
next size retainer.
1. DIAL INDICATOR
2. END SHIM
STEP 11.
the piston ring.
1. PISTON RING
3. CLUTCH SHAFT
65
STEP 12.

2. HEAT GUN
WARNING
NOTE: Manually align the inner teeth of the disks prior to performing the step below.
STEP 13.
Install the clutch pack carrier on the clutch shaft
until it bottoms out.

2. CLUTCH SHAFT
66
STEP 14.
Install the running disc chamfer side up, axial
1. RUNNING DISK
2. AXIAL BEARING
3. AXIAL WASHER
STEP 15.
Install the axial bearing assembly, two needle
bearings, and idler gear on the clutch shaft, rotat-
ing the idler gear left and right small amounts to
achieve final alignment with the clutch pack.
1. IDLER GEAR
2. NEEDLE BEARING
4. CLUTCH SHAFT
67
STEP 16.
Install the axial washer, axial bearing, and run-
ning disc, chamfer side down on the clutch shaft.
1. AXIAL WASHER
2. AXIAL BEARING
3. RUNNING DISC
STEP 17.
Install the retaining ring on the clutch shaft.
1. RETAINING RING
2. CLUTCH SHAFT
68
STEP 18.
and threaded stud.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 19.
69
Reverse Clutch, Assemble
CAUTION
ton.
STEP 1.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
NOTE: Check piston relief valve functionality prior to installation.
STEP 2.
toms out.
1. PISTON
NOTE: Installation tool, Hyster P/N 4612859, consists of two parts: an inner installer and pressure piece.
70
STEP 3.
Install the inner installer on the clutch pack car-
rier.
Install the washer, compression spring, guide ring,

and new "L" ring into the clutch pack carrier.
1. WASHER
3. GUIDE RING
4. "L" RING
STEP 4.
4612858, and pressure piece, depress the spring
assembly until the "L" ring has engaged the annu-
lar groove. Remove the spring compression tool,
pressure piece, and inner installer from the clutch
pack carrier.
1. COMPRESSION TOOL
2. INSTALLATION TOOL
STEP 5.
mission fluid.
STEP 6.
71
STEP 7.
STEP 8.
1. END SHIM
2. RETAINING RING
STEP 9.
end shim with a force of 100 N (23 lbf). Set the
dial indicator to zero.
1. DIAL INDICATOR
2. END SHIM
STEP 10.
next size retainer.
1. DIAL INDICATOR
2. END SHIM
72
STEP 11.
the piston ring.
1. PISTON RING
3. CLUTCH SHAFT
STEP 12.
Using a heat gun, heat the inner diameter of the
gear to 120°C (248°F).
1. GEAR
2. HEAT GUN
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns.
WARNING
Cold parts. Wear protective clothing and gloves.
73
STEP 13.
Cool the clutch shaft to -60°C (-76°F) and install
the gear on the clutch shaft making sure that the
chamfered side is facing up and the gear is bot-
tomed out. Install the snap ring and needle bear-
ing on the clutch shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
3. SNAP RING
4. GEAR
STEP 14.
Install the bearing and snap ring into the idler
gear.
1. SNAP RING
2. BEARING
3. IDLER GEAR
74
STEP 15.
Using a press, install the idler gear onto the
clutch shaft until it bottoms out. Install the snap
ring on the clutch shaft.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
STEP 16.

2. HEAT GUN
WARNING
NOTE: Manually align the inner teeth on the discs prior to performing STEP 17.
75
STEP 17.
Install the clutch pack carrier, rotating the clutch
pack left and right small amounts to achieve final
alignment on the clutch shaft until it bottoms out.

2. CLUTCH SHAFT
STEP 18.
and threaded stud.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
76
STEP 19.
Forward Clutch, Assemble
CAUTION
ton.
STEP 1.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
77
STEP 2.
toms out.
1. PISTON
NOTE: Installation tool, Hyster P/N 4612859, consists of two parts; an inner installer and pressure piece.
STEP 3.
Install the inner installer on the clutch pack car-
rier.
Install the washer, compression spring, guide ring,

and new "L" ring into the clutch pack carrier.
1. WASHER
3. GUIDE RING
4. "L" RING
78
STEP 4.
4612858, and pressure piece, depress the spring
assembly until the "L" ring has engaged the annu-
lar groove. Remove the spring compression tool,
pressure piece, and inner installer from the clutch
pack carrier.
1. COMPRESSION TOOL
2. INSTALLATION TOOL
STEP 5.
STEP 6.
STEP 7.
STEP 8.
1. END SHIM
2. RETAINING RING
79
STEP 9.
end shim with a force of 100 N (23 lbf). Set the
dial indicator to zero.
1. DIAL INDICATOR
2. END SHIM
STEP 10.
next size retainer.
1. DIAL INDICATOR
2. END SHIM
80
STEP 11.
the piston ring.
1. PISTON RING
3. CLUTCH SHAFT
STEP 12.
Install the needle bearing on the clutch shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
81
STEP 13.
Install the bearing and snap ring into the idler
gear.
1. SNAP RING
2. BEARING
3. IDLER GEAR
STEP 14.
Using a press, install the idler gear onto the
clutch shaft until it bottoms out. Install the snap
ring on the clutch shaft.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
82
STEP 15.

2. HEAT GUN
WARNING
NOTE: Manually align the inner teeth on the discs prior to performing STEP 16.
STEP 16.
Install the clutch pack carrier, rotating the clutch
pack left and right small amounts to achieve final
alignment on the clutch shaft until it bottoms out.

2. CLUTCH SHAFT
83
STEP 17.
the clutch shaft until it bottoms out, piston ring
and threaded stud.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 18.
84
Oil Pump, Assemble

NOTE: Lubricate the shaft seal with mineral spirits on the outside and multipurpose grease on the inside of
the seal.
STEP 1.
Using pump seal mounting tool Hyster P/N
4612862 with handle Hyster P/N 4612861, install
the new shaft seal, lip facing down, into the oil
pump housing.
1. SHAFT SEAL
2. OIL PUMP HOUSING
STEP 2.
Install the outer rotor with the chamfer facing
down, inner rotor with the threads facing up, and
cover on the oil pump housing.
1. COVER
2. INNER ROTOR
3. OUTER ROTOR
4. OIL PUMP HOUSING
85
CAUTION
ton.
STEP 3.
Install new O-ring and capscrews on the oil pump.
Tighten the capscrews until contact is made, then
loosen 180 degrees.
1. O-RING
2. CAPSCREWS
3. OIL PUMP
Transmission Housing, Assemble

NOTE: Perform STEP 1 only if tubes have been removed.
STEP 1.
Install the system pressure tubes into the rear
transmission cover in the order of the legend.
Tighten the locking nuts to 42 N•m (31 lbf ft). Af-
ter installation of the tubes, install the holding
segment on the tubes. Tighten screw to
23 N•m (17 lbf ft).
1. CLUTCH, FORWARD
2. CLUTCH, REVERSE
6. HOLDING SEGMENT
86
STEP 2.
Install screen and capscrews into the front trans-
mission cover. Tighten capscrews to
23 N•m (17 lbf ft).
1. CAPSCREW
2. SCREEN
WARNING
forming STEP 3.
CAUTION
During installation of the clutch packs, make sure that the piston rings are properly aligned. If they are
not properly aligned, serious damage to the transmission will occur.
STEP 3.
To help insure proper installation, make sure the
piston rings are aligned, and use Vaseline to keep
them in place.
Install the clutch packs in the order given in the

legend.

2. INPUT SHAFT
3. CLUTCH, FORWARD
4. CLUTCH, REVERSE
87
STEP 4.
Install new O-rings on the tubes. Install tubes,
capscrews, and suction tube into the front trans-
23 N•m (17 lbf ft).
Install screen and capscrews into the front trans-

9.5 N•m (84 lbf in).
1. CAPSCREW
2. SUCTION TUBE
3. SCREEN
4. TUBE
5. GUIDE PIN
6. O-RING
WARNING
forming STEP 5.
CAUTION
During installation of the rear transmission cover, make sure that the piston rings are properly aligned. If
they are not properly aligned, serious damage to the transmission will occur.
STEP 5.
Coat the mounting flange of the front cover with
Loctite™574, Install the rear transmission cover,
and position the rear cover over the clutch packs.
Install guide pins, washers, and capscrews on the
front transmission cover. Tighten capscrews to
46 N•m (34 lbf ft).
1. CAPSCREW
2. WASHER
4. FRONT TRANSMISSION COVER
5. GUIDE PIN
88
STEP 6.
Coat the outer surface of the shaft seal with a
light coat of mineral spirits; fill the shaft seal be-
tween the dust lip and sealing lip with multipur-
pose grease. Install the shaft seal, using shaft seal
mounting tool Hyster P/N 4612860, with the lip
facing inward.
1. SHAFT SEAL
2. SHAFT SEAL MOUNTING TOOL
STEP 7.
Install output flange, washer, and two new cap-
screws on transmission housing. Tighten cap-
screws to 34 N•m (25 lbf ft).
1. CAPSCREW
2. OUTPUT FLANGE
3. OUTPUT SHAFT SEAL
STEP 8.
Using a press, install the bearing on the PTO
shaft, and install the retaining ring. Install the
PTO shaft in the housing.
1. PTO SHAFT
2. HOUSING
3. RETAINING RING
4. BEARING
89
STEP 9.
Install the power take-off retaining ring and new
O-ring on transmission housing.
1. RETAINING RING
2. O-RING
STEP 10.
Install two alignment pins and the stator hollow
shaft.
1. ALIGNMENT PINS
2. STATOR HOLLOW SHAFT
STEP 11.
Install the converter safety valve into the trans-
mission cover until it bottoms out.
1. CONVERTER SAFETY VALVE

2. TRANSMISSION COVER
90
STEP 12.
Install two additional alignment pins and install a
new gasket on the transmission cover.
1. ALIGNMENT PINS
2. GASKET
3. TRANSMISSION COVER
STEP 13.
Install the torque converter bell housing on the
transmission housing.

2. GASKET
4. INPUT SHAFT
91
STEP 14.
Install the oil pump into the torque converter bell
housing.
1. OIL PUMP
NOTE: Capscrews used for the oil pump have an O-ring instead of a washer and the O-ring must coated
with clean transmission oil.
STEP 15.
Install capscrews on the torque converter bell
housing and transmission housing. The bell hous-
ing will align the oil pump. Install the oil pump
capscrews. Tighten all capscrews to
46 N•m (34 lbf ft). Install the torque converter
into the torque converter bell housing.
1. TORQUE CONVERTER
3. CAPSCREW
92
STEP 16.
Install the oil fill tube with dipstick, oil drain plug
80 N•m (59 lbf ft), engine speed sensor
30 N•m (22 lbf ft), torque converter temperature
sensor 25 N•m (18 lbf ft), and breather
12 N•m (106 lbf in).
1. BREATHER
2. ENGINE SPEED SENSOR
3. TORQUE CONVERTER TEMPERATURE SEN-
SOR
4. OIL DRAIN PLUG
5. OIL FILL TUBE WITH DIPSTICK
STEP 17.
Install the converter pressure backup valve and
differential pressure switch in the transmission
housing. Tighten the plug for the converter pres-
sure backup valve to 100 N•m (74 lbf ft), differen-
tial pressure switch 30 N•m (22 lbf ft). The pres-
sure relief valve should not have been removed.
1. CONVERTER PRESSURE BACKUP VALVE

2. DIFFERENTIAL PRESSURE SWITCH
3. PRESSURE RELIEF VALVE
93
STEP 18.
Install the output speed sensor 23 N•m (17 lbf ft),
turbine speed sensor 30 N•m (22 lbf ft), and inter-
nal speed sensor 30 N•m (22 lbf ft).
1. INTERNAL SPEED SENSOR

2. TURBINE SPEED SENSOR
3. OUTPUT SPEED SENSOR
STEP 19.
Install the control valve assembly and oil filter as-
sembly. See Transmission Oil Filter Assembly Re-
placement, Install and Control Valve Replace-
ment, Install.
1. OIL FILTER ASSEMBLY

3. TRANSMISSION
94
TRANSMISSION OIL FILTER ASSEMBLY

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

2. TRANSMISSION OIL FILTER HEAD
95
STEP 3.
Remove two capscrews and the transmission oil
filter head from the transmission. Remove and
discard two O-rings from the transmission oil fil-
ter head.
1. CAPSCREW
3. O-RING
Clean Inspect
Clean the transmission oil filter head with cleaning Inspect the mating surfaces for scratches, gouges,
solvent. abrasions or cracks. Replace the filter head if dam-
aged.
Install
STEP 1.
Coat two new O-rings with clean transmission oil
and install into the transmission oil filter head.
Using two capscrews mount the transmission oil
filter head on the transmission. Tighten capscrews
to 23 N•m (21 lbf ft).
1. CAPSCREW
3. O-RING
96
STEP 2.
Coat the gasket located on the top of the transmis-
sion oil filter with a light coat of transmission oil.
Install transmission oil filter on the transmission
oil filter head, by hand, until the gasket fully con-
tacts the transmission oil filter head and tighten
1/3 to 1/2 turn more.
1. TRANSMISSION OIL FILTER

INSTALL
1. Connect a lifting device, with a lifting capacity
of at least 1200 kg (2650 lb), to the two lifting
eyes located on the top of the transmission. See
Figure 11.
CAUTION
Keep the transmission level when the transmis-
sion is separated from the engine so the drive
plate is not damaged.
2. Carefully lower the transmission into position

on the frame and engine.
3. Install two 3/4 × 31/2-inch bolts that fasten the

transmission mount to the frame.
4. Still supporting the weight of the transmission

with the lifting device, install twelve capscrews
that fasten the torque converter housing to the
flywheel housing. Torque to 46 N•m (34 lbf ft).
5. Insert a flywheel rotational tool into the access

plug hole and rotate the flywheel until one of 1. LIFTING EYES
the capscrew mounting holes is visible through
the access plate hole. See Figure 12. Figure 11. Left Side View of Transmission
97
10. Remove the blocks and jack that are supporting

the flywheel end of the engine.
11. Attach a lifting device to the hydraulic pumps.

While lifting the hydraulic pumps into position,
carefully slide the drive shaft of the hydraulic
pump into the drive gear, making sure to prop-
erly align the splines of the drive shaft into the
drive gear.
12. Install the hydraulic pumps to the transmission

with four capscrews. Tighten capscrews to
25 N•m (18 lbf ft).
1. ACCESS HOLE TO ROTATE FLYWHEEL
2. ACCESS PLUG 13. Remove plugs and caps from hydraulic oil hoses
3. CONVERTER HOUSING and fittings. Connect hydraulic oil hoses to the
4. ACCESS PLATE TO FLYWHEEL CAPSCREWS hydraulic pumps.
Figure 12. Access Plug for Drive Plate Capscrews
14. Remove plugs and caps from transmission oil
hoses and fittings. Connect oil hoses from the
6. Install a capscrew. Rotate flywheel and install
thermostat valve to the transmission.
the remaining capscrews until all four cap-
screws have been installed. Torque to 15. Insert a funnel into the transmission dipstick
115 N•m (85 lbf ft). tube. Fill the transmission with 20 liter (21 qt)
of ZF TE-ML03 fluid.
7. Install access plate to converter housing. See
Figure 12. 16. Connect the transmission wiring harness and
connectors for the transmission sensors as
8. Install flywheel ring gear access plug. See Fig-
marked during removal. See Figure 13.
ure 12.
9. Remove the lifting device from the two lifting

eyes of the transmission.
98
1. TRANSMISSION INTERNAL SPEED SENSOR 5. ENGINE SPEED SENSOR

2. TRANSMISSION TURBINE SPEED SENSOR 6. TORQUE CONVERTER TEMPERATURE SEN-
3. DIFFERENTIAL PRESSURE SWITCH SOR
4. TRANSMISSION CONTROL VALVE CONNEC-
TOR
Figure 13. Transmission Wire Connectors and Sensors
99
• Excessive vibration levels in the drive axle

CAUTION
The drive shaft for this truck is a two piece model, NOTE: Use marks created during removal to aid in
consisting of a male splined drive shaft, a female installing drive shaft in proper position and orien-
splined slip yoke and a universal joint on both tation.
ends where it connects to the drive axle and 17. Connect the drive shaft to the transmission.
transmission. See Figure 14.
Drive shafts are balanced and configured at the 18. Connect the battery cables. First the ground ca-
time of manufacture. It is recommended that an ble, then the positive cable.
alignment mark is made on the drive shaft indicat-
ing the position of the universal joint and drive 19. Tilt the Operator's compartment down. See the
shaft prior to removal. section Operator's Cab 0100SRM1390.
During removal, it may be possible for the drive 20. Apply the parking brake.
shaft to split apart into two pieces. Reassemble
the drive shaft using the alignment mark made 21. Turn the key to ON position and start truck
prior to removal. with the transmission in neutral, allow engine
to idle for 2-3 minutes.
Failure to assemble and install the drive shaft
properly may lead to: 22. Check transmission fluid levels on the dipstick.
At operating temperature 80 to 90°C (176 to
• Vibration of the drive shaft and/or truck
194°F), the fluid level should measure in the
• Premature failure of the universal joints on HOT zone on the dipstick. Add transmission
the drive shaft fluid as needed to bring fluid level to the proper
• Excessive vibration levels in the transmis- level on the dipstick.
sion
100
1. FRAME (REFERENCE) 6. TRANSMISSION

2. DIPSTICK ASSEMBLY 7. TORQUE CONVERTER
3. DRIVE SHAFT 8. CAPSCREWS
4. OUTPUT YOKE 9. CAPSCREWS
5. TRANSMISSION MOUNT
Figure 14. Transmission Arrangement
101
Control Valve Replacement 1300 SRM 1456
Control Valve Replacement
REMOVE
STEP 1.
Disconnect the vehicle negative battery terminal.
STEP 2.
Disconnect the electrical connector from the trans-
mission control valve.
STEP 3.
Remove two screws, one at each end at the top of
the control valve, and install two alignment
screws in their place.
1. TORX SCREWS
NOTE: During removal of the sealing plates and gasket; note the position of the sealing plates as they are
very different from each other.
NOTE: The intermediate plate can be reused if it is not damaged.
STEP 4.
Remove the remaining mounting screws, control
valve assembly, front sealing plate, intermediate
plate and rear sealing plate from the transmis-
sion. Discard sealing plates.

2. FRONT SEALING PLATE
3. INTERMEDIATE PLATE
4. REAR SEALING PLATE
102
1300 SRM 1456 Control Valve Replacement
INSTALL
NOTE: The intermediate plate can be reused if it is not damaged.
STEP 1.
Install the new rear sealing plate, intermediate
plate, and new front sealing plate, as noted during
removal, onto the alignment pins. Install the con-
trol valve assembly, and torx mounting screws
onto the transmission. Tighten the torx mounting
screws in a opposite pattern to 9.5 N•m (84 lbf in).

2. FRONT SEALING PLATE
3. INTERMEDIATE PLATE
4. REAR SEALING PLATE
STEP 2.
Remove the two alignment screws. Install two
torx screws, one at each end at the top of the con-
trol valve in their place. Tighten to
9.5 N•m (84 lbf in).
1. TORX SCREWS
STEP 3.
Connect the electrical connector from the trans-
mission control valve.
STEP 4.
Connect the vehicle negative battery terminal.
103
Control Valve Repair 1300 SRM 1456
Control Valve Repair
DISASSEMBLE
STEP 1.
Remove the control valve assembly from the transmission. See Control Valve Replacement, Remove.
STEP 2.
Place a match mark on the cover and the valve
block on both ends of the control valve to assist in
proper assembly of these components.
1. COVER
2. VALVE BLOCK
STEP 3.
Remove the torx screws from the duct plate.
1. TORX SCREWS
2. DUCT PLATE
3. CONTROL VALVE BODY
104
1300 SRM 1456 Control Valve Repair
STEP 4.
Remove the duct plate and sealing plate from the
control valve body. Discard the sealing plate.
1. DUCT PLATE
2. SEALING PLATE
STEP 5.
Remove the retaining clamp, capscrews, cover,
and gasket from the housing. Discard gasket. Re-
move capscrews, cover, and gasket from the oppo-
site end of the control valve. Discard the gasket.
1. RETAINING CLAMP
2. CAPSCREW
3. COVER
4. GASKET
STEP 6.
Remove the wiring harness from the housing.
1. WIRING HARNESS
2. CAP SCREW
3. FIXING PLATE
4. PRESSURE REGULATOR
105
STEP 7.
Remove three capscrews, three fixing plates, and
three pressure regulators from the housing.
1. CAPSCREW
2. FIXING PLATES
4. HOUSING
WARNING
The housing is under spring pressure, use care during removal of the housing.
STEP 8.
Remove two capscrews and install two alignment
screws in their place in the housing. Remove the
remaining capscrews from the housing.
1. CAPSCREW
2. ALIGNMENT SCREW
3. HOUSING
4. GASKET
106
STEP 9.
Remove the pressure reducing valve with spring,
three vibration dampers with springs, and three
follow-on slides with springs.
1. PRESSURE REDUCING VALVE WITH SPRING

2. VIBRATION DAMPER WITH SPRING
3. FOLLOW-ON SLIDE WITH SPRING
STEP 10.
Remove three capscrews three fixing plates, and
three pressure regulators from the housing.
1. CAPSCREW
2. FIXING PLATE
4. HOUSING
WARNING
The housing is under spring pressure, use care during removal of the housing.
107
STEP 11.
Remove two capscrews and install two alignment
screws in their place in the housing. Remove the
remaining capscrews from the housing.
1. CAPSCREW
2. ALIGNMENT SCREW
3. HOUSING
4. GASKET
STEP 12.
Remove the main pressure valve with spring,
three vibration dampers with springs, and three
follow-on slides with springs from the control
valve body.
1. MAIN PRESSURE VALVE WITH SPRING

CLEAN INSPECT
Clean all metal components, except as noted below, Inspect the control valve components for any signs
with cleaning solvent and dry with compressed air. of wear. If components show signs of wear replace
those components. If the valve body shows signs of
The main pressure valve, vibration damper, and wear, replace the entire control valve assembly.
follow-on-slides are specially coated aluminum
parts. If cleaning is required; these components are
to be cleaned using transmission oil only.
108
ASSEMBLE
NOTE: Perform STEP 1 only if a new valve body is being used.
STEP 1.
Place the control valve body on a clean, flat sur-
face. Install the orifices concave side up until con-
tact as shown.

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

109
STEP 3.
Install two adjusting screws on either end of the
control valve body. Compress the follow-on slides
and springs and lock them in position using an
M5 capscrew.
1. M5 CAPSCREW
2. ADJUSTING SCREW
STEP 4.
Install a new gasket and the housing on the two
adjusting screws. Install the capscrews into the
housing. Remove the adjusting screws and insert
two cap screws. Tighten all capscrews to
5.5 N•m (48.7 lbf in), and remove the M5 cap-
screws from the control valve body.
1. CAPSCREW
2. ADJUSTING SCREW
3. HOUSING
4. GASKET
110
NOTE: Install the fixing plates with the neck facing downward.
STEP 5.
Install three pressure regulators, three fixing
plates, and three capscrews into the housing.
Tighten the capscrews to 5.5 N•m (48.7 lbf in).
1. CAPSCREW
2. FIXING PLATE
4. HOUSING
STEP 6.
Install three follow-on slides with springs, three
vibration dampers with springs, and pressure re-
ducing valve with spring.
1. PRESSURE REDUCING VALVE WITH SPRING

111
STEP 7.
Install two adjusting screws on either end of the
control valve body. Compress the follow-on slides
and springs and lock them in position using an
M5 capscrew.
1. M5 CAPSCREW
2. ADJUSTING SCREW
STEP 8.
Install a new gasket and the housing on the two
adjusting screws. Install the capscrews into the
housing. Remove the adjusting screws and insert
two cap screws. Tighten all capscrews to
5.5 N•m (48.7 lbf in), and remove the M5 cap-
screws from the control valve body.
1. CAPSCREW
2. ADJUSTING SCREW
3. HOUSING
4. GASKET
STEP 9.
Install three pressure regulators, three fixing
plates, three capscrews, and the wiring harness in
the housing. Tighten the capscrews to
5.5 N•m (48.7 lbf in).
1. WIRING HARNESS
2. CAPSCREW
3. FIXING PLATE
112
STEP 10.
Using the match marks applied before removal,
install a new gasket, cover, capscrews and the re-
taining clamp on the housing. Tighten the cap-
screws to 5.5 N•m (48.7 lbf in).
1. RETAINING CLAMP
2. CAPSCREW
3. COVER
4. GASKET
STEP 11.
Install two adjusting screws on the control valve
body.
1. ADJUSTING SCREW
STEP 12.
Install the screens, facing up, in the new sealing
plate as shown.
1. SEALING PLATE
2. SCREEN
113
STEP 13.
Install the new sealing plate and the duct plate on
the control valve body.
1. DUCT PLATE
2. SEALING PLATE
STEP 14.
Install the 23 torx screws into the duct plate.
Tighten the torx screws to 10.5 N•m (93 lbf in)
1. TORX SCREWS
2. DUCT PLATE
STEP 15.
Install the control valve assembly on the transmission. See Control Valve Replacement, Install.
114
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1300 SRM 1456 12/15 (8/15)(4/14)(11/13)(8/12)(8/11)

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TRANSMISSION

PART NO. 4034066 1300 SRM 1456

This section is for the following models:

©2015 HYSTER COMPANY i

Series Code / Model Designation Reference Table

Series Code European Model Americas Model

Special Tools List

Item Figure Nomenclature Part Number

Clutch Pack Spring

2 Holding Fixture Assembly Hyster P/N 4612859

3 Shaft Seal Mounting Tool Hyster P/N 4612860

4 Grip Handle Hyster P/N 4612861

5 Pump Seal Mounting Tool Hyster P/N 4612862

1. FRAME (REFERENCE) 6. TRANSMISSION

Figure 1. Transmission Arrangement

1. TRANSMISSION INTERNAL SPEED SENSOR 5. ENGINE SPEED SENSOR

Figure 2. Transmission Wire Connectors and Sensors

8. Place a suitable container under the transmis-

9. Disconnect the oil lines from the transmission

10. Disconnect the oil hoses at the hydraulic

11. The hydraulic pumps are connected to the

13. Connect a lifting device, with a lifting capacity

14. Remove the access plug to gain access to the

17. Remove the capscrew. Rotate the flywheel and

18. Raise the lifting device to hold the weight of the

19. Remove the two 3/4 × 31/2-inch bolts that fas-

20. Make sure that all connections have been re-

Transmission Housing, Disassemble

1. OIL FILTER ASSEMBLY

1. CONVERTER PRESSURE BACK-UP VALVE

1. ENGINE SPEED SENSOR

1. INTERNAL SPEED SENSOR

1. TORQUE CONVERTER BELL HOUSING

1. CLUTCH, 3RD SPEED/OUTPUT

NOTE: Perform STEP 15 only if any of the tubes are damaged.

1. CLUTCH, 3RD SPEED/OUTPUT

Oil Pump, Disassemble

1. PISTON RING 12. FRICTION DISC

Figure 6. Forward Clutch Assembly

1. PISTON RING 12. INNER DISC

Figure 7. Reverse Clutch Assembly

1. PISTON RING 12. FRICTION DISC

1. PISTON RING 12. FRICTION DISC

Figure 9. 2nd Speed Clutch Assembly

1. PISTON RING 14. COMPRESSION SPRING

Figure 10. 3rd Speed Clutch Assembly

Forward Clutch, Disassemble

1. CLUTCH PACK CARRIER

Reverse Clutch, Disassemble

1. CLUTCH PACK CARRIER

NOTE: Use compressed air to aid in the removal of the piston.

First Speed Clutch, Disassemble

1. CLUTCH PACK CARRIER

NOTE: Use compressed air to aid in the removal of the piston.

Second Speed Clutch, Disassemble

1. CLUTCH PACK CARRIER

Third Speed Clutch, Disassemble

1. AXIAL BEARING ASSEMBLY (3 PIECES)

1. CLUTCH PACK CARRIER

Input Shaft, Disassemble