Transmission service manual.pdf

7/24/2019 Transmission service manual.pdf

1/42

Issue - 1209

TRANSMISSION - DISMANTLING

1. Remove filter cartridge

3. Remove dipstick / filler tube and gasket A.

5. Unscrew mounting bolts and lift off control valvetaking care not to lose detent balls and springs.

2. Disconnect and remove clutch feed pipes. Latermachines have hoses instead of pipes whichshould be marked for position before removal.

4. Remove pump suction pipe, gasket Band Oring C.

6. Unscrew plugs from both sides of valve and liftout detent balls and springs.

Section 7 TRANSMISSION Section 7

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Issue - 1210

TRANSMISSION - DISMANTLING (contd)

7. Remove brake disconnect housing D, releasecirclips Eand remove spools. Cover Fis springloaded and care should be taken to releasespring pressure.

9. Lift off torque converter assembly.

11. To renew bearing, remove small circlip and pressout pump adapter. Release outer snap rings and

push bearing out of housing.

8. Unscrew plug and withdraw 4th speed selectorspool.

10. Unscrew bolts Gand tap off converter housing.

12. Unscrew plugs from both sides of valve and liftout detent balls and springs.


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3/42

Issue - 1211


13. Using a suitable tube, adapters and puller, pressout transmission pump housing. Take care toposition legs of puller on the strongest parts ofthe casing. Do Notuse jacking holes to withdrawhousing as damage may be caused.

15. Unscrew bolts H and lift off pump unit fromhousing.

17. Release circlip Land tap converter shaft downto clear bearings and drive gear.

14. Lift out pump and housing assembly from casing.

16. Remove converter relief valve ball and spring Jand bearing shim K.

18. Withdraw outer bearing from housing.


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4/42

Issue - 1212


19. Remove drive gear.

21. Lift out converter drive shaft

23. Make flanges of clutch shafts to ensurereplacement in correct radial position andlocation. Remvoe shaft bolts and position two

bolts in jacking holes provided.

20. Withdrae inner bearing.

22. Release bearing circlip, remove bolts andseparate pump components.

24. Tighten : jacking bolts and lift out clutch shafts.Note :Clutch shafts are fitted with different sizerestrictors and must therefore always be

replaced in their original positions.


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5/42

Issue - 1213


25. Withdraw froward/1st and reverse /2nd clutchassemblies through pump housing aperture.

27. Remove idler gear spindle.

29. Lift out 3rd/4th clutch assembly through pumphousing aperture.

26. Release idler gear circlip.

28. Collect idler gear and components from withincasing.

30. Remove plug and prise out converter relief valvecartridge. Remove circlip to separatecomponents.


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Issue - 1214


31. Remvoe both output flanges by prising offtabwashers and usscrewing bolts.

33. Prise out oil seals.

35. Tap output shaft and bearing upwards throughgear and collect spacer.

32. Use a puller to withdraw flanges from outputshaft.

34. Release circlip and remove shim.

36. Remove two sealing covers by tapping inwardson one side.


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7/42

Issue - 1215


37. Unscrew two baffle plate retaining bolts andremove top baffle.

TYPICAL CLUTCH - DISMANTLING

39. Release snap ring and withdraw backing plateand clutch plates.

41. Remove circlip, spring and spring cups.

38. Remove output gear and lower baffle throughpump housing aperture.

40. Compress piston return spring and releasecirclip.

42. Remove piston, Dismantle remaining clutchesin a similar manner.


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8/42

Issue - 1216

2. Assemble piston return spring, cups and circlip.

4. Measure thickness of one drive plate.

6. Positionthrust plate M onto carrier. Fit thrustwasher Ninto spur gear using grease to retainit in position. Place spur gear carrier with splines

resting on top of drive plate. i.e. Splines notengaged.

TYPICAL CLUTCH - ASSEMBLY

1. Fit new piston seals with sealing edge towardspressure side of piston. Coat seals with greaseand push piston into carrier.

3. Compress spring and secure circlip

5. Assemble one driven plate into carrier followedby the drive plate priviously meaured.


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9/42

Issue - 1217

TYPICAL CLUTCH - ASSEMBLY (contd)

7. Position assembly onto straight-edge or surfaceplate. Measure depth from face of spur gear tostraight-edge and add thickness of drive plate(operation 4). Repeat measurement with splinesof spur gear engaged in drive plate. Firstmeasurment must be greater than fullengagement of splines and drive plate.

9. Measure end float of backing plate which shouldbe 2.0 2.7mm (0.08 0.10 in). Drive plates areavailable in varying thickness to correct in asimilar manner.

Note :Before installing ball bearing into 1st speedspur gear, coat outside diameter with JCB HighStrength Retainer.

8. Remove spur gear and fit alternate driven platesand drive plates. Fit backing plate and securewith snap ring.


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10/42

Issue - 1218

2. Direct heating should not be used on inner track.Heat a round bar and place inside inner trackas shown.

4. Place output gear together with lower baffle inposition through pump housing aperture andlocate onto bearing taking care not to dislodgerollers.

6. Measure distance between end face of shaftkand shoulder of bearing land.e.g. 78.30 mm

TRANSMISSION - ASSEMBLY

(See page 1/1-3 for torque settings)

1. When fitting a new output shaft roller bearinghead up inner track to approximately 150oC (seestage 2) and press onto gear hub, shouldertowards gear.

3. Fit circlip into bearing bore and fit outer raceand rollers. Use petroleum jelly to hold rollers inposition.

5. Slide output shaft, with spacer but without frontbearing, into position within the output gear and

push fully home.


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Issue - 1219

8. If the end paly is incorrect, a shim Xshould befitted under the outer race of the roller bearing.

9. Cross section of output shaft assembly showingshim Xin position

11. Fit top baffle and secure with bolts.

TRANSMISSION - ASSEMBLY (contd)

7. Measure distance between end face of shaft andbearing inner circlip. e.g. 78.90mm.

Example : Dimension 6 = 79.30 mm

Dimension 7 = 78.90 mm

Dimension = 0.40 mm

The roller bearing must have an end play of 0.30to 0.50 mm. In the example above the end playis correct; proceed to stage 11.

10. Replace output gear and lower baffle taking carenot to dislodge rollers.


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12/42

Issue - 1220

13. Position output shaft and bearing through spacerand output gear and tap down until bearing seatsfirmly onto circlip.

15. Coat outside diameter of new oil seal with JCBMulit-Gasketand install to 22mm (0.86 in) belowend face of shaft. Repeat procedure for otherseal.

17. Assemble converter relief valve and tap intoposition at bottom of bore. Fit plug.


12. Coat outside diameter of new sealing covers withJCB Multi-Gasketand tap into position.

14. Select shim to eliminate end float when circlip isfitted. Fit shim and circlip.

16. Grease lips of seal and fit output flange. Aftertightening blots coat contact face of lockplatewith JCB Mulit-Gasket and tap into position.

Repeat for outer output flange.


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Issue - 1221


18. Lay 3rd/4th clutch thrust plate and thrust washerinto casing, checking location of ears. Greaselightly to retain in position.

20. Lay a new gasket noto clutch shaft mountingface and measure depth to bearing rollers.Subtract from this the clutch pack end float whichwhould be 0.30 0.50mm (0.012 0.019 in).

22. Move clutch pack to one side and palce selectedshim Punderneath thrust plate. Grease lightlyto hold in position.

19. Enter 3rd/4th clutch pack into casing and positioncarefully over thrust washer.

21. Measure depth from bearing thrust face on fhaftto face of mounting flange. Subtract this fromdimension calcutated at fig. 20 to establishthickness of clutch pack shim.

23. Reposition clutch pack and use mandrel, toolno. 992/10300 to align components.


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Issue - 1222


24. Apply grease to piston ring seals on shaft. Usinga new gasket coated with JCB Multi-Gasketcarefully enter shaft into bore and secure withbolts.

26. Assemble forward/1st and reverse/2nd clutchpacks into casing by repeating operations 18 to23. Install reverse/2nd clutch first and displaceradially until forward/1st clutch is installed.

28. Assemble oil pump components, fit shaft andsecure with circlip.

25. Position idler gear and thrust washers insidecasing and using a new gasket coated with JCBMulti-Gasket enter spindle into casing. Fitretaining washer, pin and circlip before finallytightening bolts and nuts.

27. Grease piston ring seals on shafts and fit usingnew gaskets coated with JCB Multi-Gasket.Tighten securing bolts.Note :Ensure that shafts are fitted correctly intheir original bores.

29. Grease piston ring on converter drive shaft andpush shaft fully down into pump housing.


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15/42

Issue - 1223


30. Tap inner bearing fully into its bore.

32. Tap outer bearing into position and secure withcirclip L.

34. Measure depthof counterbore in pump body andsubtract from bearing outer race dimension (fig.33)

31. Slide gear into position then tap converter driveshaft upwards to engage splines.

33. Laya new gasket onto pump flange and measurefrom bearing outer race to gasket. Ensurebearing outer race is pushed fully down.

35. Subtract bearing end float 0.30 to 0.50 mm(0.012 to 0.019 in) from final dimension (fig.34) to establish thickness of shim K. position

shim over bearing and assemble relief ball andspring J.


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Issue - 1224


36. Assemble pump to housing and tighten bolts H.

38. Using a new flange gasket coated with Multi-Gasketcarefully tap pump housing into casingwhilst checking that drive gear teeth mesh withclutch spur gears.

40. Fit converter housing and secure with bolts G.

37. Apply JCB Multi-Gasket to pressure ports ofpump housing and casing as shown.

39. Coat outside diameter of new oil seal Qwith JCBMulti-Gasketand tap down flush with housing.Smear lips of seal with grease.

41. Assemble loader pump drive bearing into flangewhilst holding snap rings open. Fit drive hubthrough bearing and secure with small circlip.


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17/42

Issue - 1225

43. Carefully lower torque converter into positionwhilst turning it to engage splines.

45. Assemble main valve block ensuring that spoolseals are fitted with lips facing inward.

47. Place sandwich plate in position with a newgasket each side then position check valve ballsand spring as shown.


42. Fit loader pump drive to casing using a newgasket coated with JCB Multi-Gasket.

44. Assemble 4th speed selector spool and refit plugusing a new sealing washer.

46. Apply grease to detent balls and spring to holdthem in position. Secure with plugs.


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Issue - 1226


48. Lower valve block into position taking care notto disturb the ball and springs. Tighten securingbolts in a diagonal sequence to 25 Nm(18.4 lbf ft).

50. Coat new gasket Awith JCB Multi-Gasketandfit dipstick/filler tube.

52. Smear seal of new filter cartridge with oil andscrew into position.

49. Apply JCB Multi-Gasketto a new gasket Band,using a new O ring C, fit pump suction pipe.

51. Fit clutch feed pipes using new sealing washers.Later machines are fitted with hoses instead ofpipes.


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19/42

Issue - 1227


7-65 7-65

1. ELECTRO - HYDRAULIC

GEARSHIFT SYSTEMSee also Illustrated Table Page 13 and 15

Control valve assembly with 2-stage control pressurevalve, 4 magnets and breather valve.

(AI-Gearshift housing) AI = Aluminium

1.1 Disassembly

Remove delivery line (1st speed to the 2-stage valve).

Loosen socket head screws and remove control valveassembly.

Remove gasket and intermediate plate.

Remove delivery lines, loosen socket head screwsand separate channel plate from gear case.

Note: Pay attention to the released balls and springs!Use two adjusting screws!

(S) Adjusting screws (M 8) 5870 204 011

Remove delivery line.

1

2

3

4


20/42

Issue - 1228


7-66 7-66

5

6

7

8

Relax spring clip and remove cover.

Pull off cable shoes and remove cable harness.

Loosen socket head screws and remvoe solenoidvalves.

Remove components, see Figure 1

Loosen socket head screws and fix gearshift housingprovisionally, using Special Tool (S).

Now, loosen the remaining socket head scews andseparate the gearshift housing (is spring-loaded).from the valve body by loosening the nuts (S) evently.

(S) Adjusting scerws (M 5) 5870 204 036


21/42

Issue - 1229


7-67 7-67

10

11

9

Dismantle pressure control valve.

Remove components.

Remove stop plate (Arrows) and detent blocks (2 x).


22/42

Issue - 1230


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12

13

14

1.2 Reassembly

Note :Inspect all componenst for damage and renewif necessay.

check free travel of the moving parts in the housingprior to the installation.

Spools can be exchanged individually !

Lubricate components prior to the reassembly ! inthe following Reassembly Instructions, empiricalvalues are indicated for several shims ! If deviationsare encountered during the final test bench run,correct by means of corresponding shims!

Close the bores by means of ball (8pieces, 4, 5mim).

Introduce detent blocks (1 and 2) in the bores andfix them by means of the stop plates (3 and 4).

Install detent block (5).

Note : The illustration on the left shows theinstallationposition of the components.

Install components.

1 = Spool (Total length 86,00mm)2 = Spring (Lo = 53,40mm)

Note :Lo = Length of the unloaded spring !


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Issue - 1231


7-69 7-69

15

16

17

18

Reset valve :

Install components.1 = Spool2 = Washer (s) (empirical value = 5,20mm)3 = Spring (Lo = 58,00mm)4 = Spring (Lo = 65,40mm)

Pressure control valve :

Install components :

1 = Spool2 = Spring (Lo = 132,40mm)3 = Spring (Lo = 76,70mm)4 = Spool

Control pressure valve :


1 = Spring2 = Spring (Lo = 132,40mm)3 = Washer (s) (Lo = 76,70mm)4 = Washer (s)5 = Spool6 = Sleeve

Pre-assemble 2-stage pressure control valve withbreather valve (Figure 18-20) :

Install orifice (D = 0,70mm).

Note :Wet threads of orifice with Loctite (Type No.270)!


24/42

Issue - 1232


7-70 7-70

20

21

22


1 = Intermediate plate2 = Valve3 = Compression spring (Lo = 29,90 mm)4 = Straight pin (4 h 8 x 25 mm)5 = Cylinder6 = Spool7 = Spring (Lo = 70,90 mm)8 = Washer(s) (Empirical value s = 3,00 mm)9 = Screw plug (install new O-Ring)

Note :Insert compression spring (3) and valve (2) inthe bore, preload and fix by means of straight pin(4)!

Close bore (Arrow) by means of ball (5 mm).

Install components and fix by means of socket headscrews and !I~t ~a_shers (Figure 21 and 22) :

1 = Gasket2 = Block assembly3 = Ring4 = Spool5 = Gasket 6 = Cover7 = O-Ring8 = Screw plug

Note :Pay attention to the different thickness of therings (3) !

Empirical value s = 6,00 mm!

Torque limit (M 5/8.8) 5, 5 Nm


19

23

4

5

6

78

9

1

12

34

5678


25/42

Issue - 1233


7-71 7-71


1 = Spring (Lo = 53,40 mm)2 = Spool3 = Spring (Lo = 53,40 mm)4 = Spool5 = Spool (Reducing valve)6 = Spring (Lo = 37,10 mm)7 = Retaining plate8 = Socket head screw9 = Spring (Lo = 53,40 mm)10 = Spool

Note :Pay attention to the installation position of thecomponents, see Figure 23!

Torque limit (M 5/8.8) 5,5 Nm

Insert solenoid valves and fix them by means ofretaining plate and socket head screws.

Torque limit ( M 5/8.8) 3,5 Nm

Note: Pay attention. to the radial installation positionof the sole:noid valves, see Figure 26 !

Install cable harness.

Note :Install new gasket 1

Pay attention to the position of the projection, seeArrow!

23

24

25

1

2

3

4

5

6

78

9

10


26/42

Issue - 1234

2

1

Connect solenoid valves according to the Figure onthe left.

Install new O-Ring (164,2 x 6,7 mm) see Arrow andfix cover by means of spring clip.

Install delivery line, control pressure sensor

(accord!ng to the design) and screw plug.

Note :Install new seal rings and O-Rings !

1 = Delivery .line

2 = Control pressure sensor, resp. screw plug

Torque limit (M 12 x 1,5) 40 Nm

1.3 Pre-Assemble channel plate :

Install orifice for the backfeed D = 1,00 mm (Arrow1), set screw M 5 x 6 mm (Arrow 2) and secure bycaulking


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26

27

28

29


27/42

Issue - 1235

Install connecting socket (3 x) and screw plug (Arrow).

Note :Use the O-Rings!

The occupation of the connecting sockets may bedifferent according to the design!

Insert the two check valves (composed of balls andsprings) with grease in the countersinking of thechaooel plate (see Arrows).

1.4 Attach channel plate and gearshift system :

Install components.

Install housing gasket, intermediate plate and 2nd

gasket.


Assemble AI=Channel plate and fasten it by meansof socket head screws.

Torque limit (M 8/8.8 DIN 912) 23 NmTorque limit (M 8/8.8 DIN 6912) 16 Nm

(Flat head)

Item 1 = Socket head screws 3 pieces M 8 x 30(DIN 6912)

Remaining socket head screws 9 pieces M8 x 40(DIN 6912)

30

31

32

33


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Issue - 1236

Assemble 1 st gasket.

Note : Pay attention to the different gaskets. seeFigure 34 (Arrow) and Figure 35 !

Assemble intermediate plate (Arrow) and 2nd gasket.

Place control valve assembly against shoulder andfasten it by means of socket head screws.

Note :Use flat washers !

Pay attention to the location of the different sockethead head screws (lengths)!

Torque limit 20 Nm

Install delivery lines according to Figure 37 and 38.

See also Draft, Page 17.

Note :Use new O-Rings !

34

35

36

37


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29/42

Issue - 1237

Install connecting line KV to K1, see Arrow !

38


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Issue - 1241


7-79 7-79

2. GEAR BOX

2.1 Disassembly

2.1.1 Converter - Drive:

Illustration on the right shows the Version with sheet-metal converter (gearshift system already removed).

Remove suction and filler pipe (Arrows). Removeadapter, resp. filter

(S) Assembly car 5870 350 000(S) Clamping bracket 5870 350_014(S) Clamping bracket 5870 350 036(S) Lifting device 5870 350 041

Tilt housing 90.

Remove orifice.

Note :Screws are covered with Loctite!

Remove the converter.

2.1.2 Converter charge and control pressurepump :

Loosen screwed connection and remove enginecompartment.

40

41

42

43


31/42

Issue - 1242


7-80 7-80

44

45

46

47

Loosen hex. head screws on the bearing cap. Tapbearing cap loose and separate it from the oil supply

flange.

Fasten back-off device by means of hex. head screws

on the oil supply flange.Pull converter charge and control pressure pump(compl.) out of the housing bore.

(S) Back-off device 5870 000 062

Loosen hex. head screws and separate pump fromoil supply flange.

Note :Pay attention to the released converter reliefvalve (ball and spring)!

Remove rectangular ring (1) and circlip (2).

21


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Issue - 1243


7-81 7-81

48

49

50

51

Press shaft in direction of the Arrow out of the pumpcasing.

Loosen hex. head screws, remove pump cover andremove gear set.

Note :If traces of wear are encountered in the pumpcasing as well as in the pump cover, resp. if theadmitted end play would be > 0,05 mm (Figure 50),the complete pump must be renewed !

Now, complete the pump again.

(S) Depth gauge 5870 200 072

Remove converter relief valve (ball and spring) andsqueeze out circlip.


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Issue - 1244


7-82 7-82

52

53

54

55

Press drive shaft in direction of the Arrow until thespur gear gets free.

Pry roller bearing out of the bore. remove released

spur gear.

(S) Adjusting spanner 5870 400 001

Remove drive shaft in direction of the Arrow.

Pull roller bearing out of the bore.

(S) Internal puller 5870 300 005(S) Back-up tool 5870 300 003


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Issue - 1245


7-83 7-83

56

57

58

59

2.1.3 Converter control valve and power take off:

Remove screw plug and temperature adapter(Arrow)

Squeeze out circlip and take out Converter controlvalve.

Tilt gear case 180.

Loosen hex. head screws, rasp. hex. nuts. Lift powertake-off out of the case.

Squeeze out circlips, at the same time tap thecomplete driving pin loose (direction of Arrow) anddrive it out.


35/42

Issue - 1246


7-84 7-84

60

61

62

2.1.4 Remove the multi-disk clutches KV/K1 KR/K2, layshaft and K3/K4 :

Loosen hex. nuts, resp. screws of both axles (KV/ K1and KR/K2) and remove connections, see Arrow.

Now, pull the two axles out of the clutches, resp. thegear case,-using special device.

(S) Puller device 5870 000 069

Remove the two clutches.

Note :Pay attention to the released washers andbearing rollers !

(S) Lifting device 5870 281 035

The Illustration on the left shows the clutch KR/K2


36/42

Issue - 1247


7-85 7-85

63

64

65

Layshaft with reverse gear :

Remove hex. head screws from reverse gear, removewasher.

Note :Screw is secured with Loctite !

Loosen screws of the Layshaft and remove itdownwards.

Take off spur gear upwards.

If necessary, remove angle ring.

Note :Pay attention to the released bearing rollers.

Remove clutch K3/K4 (Figure 60 and 61) accordingly.

The Illustration on the right shows the removed multi-disk clutch K3/K4.


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Issue - 1248


7-86 7-86

67

68

69

70

2.1.5 Multi-disk clutches:

Remove spur gear and take out the releasedcomponents.

Squeeze out snap ring.

Remove plate stack.On the opposite side, disassemble clutch KVaccordingly.

Preload compression spring.

Remove circlip and components.

(S) Assembly jig 5870 345 028


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Issue - 1249


7-87 7-87

71

72

Remove piston by means of clampi~ pliers.

Note :A slight rotation would help to remove thepiston !

If necessary, remove the needle bearing from thepiston carrier.

Note :Carry out the disassembly of clutch KV, KR/K2 and K3/K4 accordingly.


39/42

Issue - 1251


7-89 7-89

82

84

85

Rotate gear case 180.

Remove lock plate and loosen screws.

Pull off output flange.

(S) Two-leg puller 5870 970 006

Tap loose output shaft and drive it out of the gearcase.

Take second half of the baffle plate and spur gearout of the case.

83


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Issue - 1252


7-90 7-90

86

87

Remove shaft seal and circlip.

Drive roller bearing out of the case.

Loosen hex. head screws in the housing inside and

press the~two anchor pins out of the gear case, usingpry bars.

Note :Hex. head screws are installed with Loctite!

(S) Puller device 5870 000 066(S) Pry bar 5870 345 036


41/42

Issue - 1253


7-91 7-91

95

96

97

98

2.2 Reassembly

2.2.1 Gear case :Install studs according to the Illustration on the right.

Torque limit (M 8/8.8) 9 Nm

Note :Use Loctite Type - No. 270 !

Tilt gear case 180o.

Fasten baffle plate for breather in the area of the oil

filter, resp. adapter by means of hex. head screws(see Arrow).

Note :Secure hex. head screws with Loctite Type-No. 270 !

Torque limit (M 8/8.8). 23 Nm

Install screw plug with seal ring (see Arrows).

2.2.2 Parking brake :

Insert a-Ring (3) s = 25,3 x 2,4 in the anchor pin .(1) and install it in the housing bore.

Start pin from the inside along with shim (4)s = 6mm, flat washer and hex. head screw, cover itwith Loctite Type - No. 270 and fasten.

Torque limit 49 Nm

Grease 2nd a-Ring (3) and insert it in the anchor pingroove (2) and with assembled brake cam into the

housing bore (see also Draft. Page 34).

32

1


42/42

Introduce oil baffle plate (4) through the large housingbore and lay it upon the roller bearing (3) see Draft.

Note :Pay attention to the location of the oil baffleplate !

Insert spur gear with replaced bearing inner race(5) (see Arrow) through the housing bore in thealready installed bearing outer race (3).

Squeeze circlip (6) into the lower groove of thehousing.

Mount heated speedometer drive worm (7), resp.spacing tube (according to the Version) upon the driveshaft.


7-93 7-93

100

101

102

103

Transmission service manual.pdf

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Transcript of Transmission service manual.pdf