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TM 9-2520-234-35
D E P A R T M E N T O F T H E A R M Y T E C H N I C A L M A N U A L
FIELD AND DEPOT MAINTENANCE MANUAL
FOR
POWER TRAIN ASSEMBLY
(8351100)
( AL L I SON MODE L XT G-411-2A)
COMPOSED OF:
TRANSFER ASSEMBLY, TRANSMISSION INPUT,
(2520-894-9535)
TRANSMISSION ASSEMBLY,
(2520-894-9533)
DRIVE ASSEMBLY, TRANSMISSION OUTPUT,
VEHICLE LEFT
(2520-894-9534)
DRIVE ASSEMBLY, TRANSMISSION OUTPUT,
VEHICLE RIGHT
This copy is a reprint with changes 1 and 2, which
includes pen and ink changes as well as remove and
insert pages.
HEADQUARTERS, DEPARTMENT OF THE ARMY
05 J UL Y 1962
TM 9-2520-234-35
C 2
CHANGE
NO. 2
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C. 31 August 1992
TECHNI CAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT
MAI NTENANCE MANUAL
POWER TRAIN ASSEMBLY (8351100) (ALLISON MODEL XTG-411-2A)
POWER TRAIN ASSEMBLY (11650290) (ALLISON MODEL XTG-411-4)
TM 9-2520-234-35, 5 July 1962, is changed as follows:
1. New or changed material is indicated by a vertical bar in the margin of the page.
2. Make a pen-and-ink change to the cover of this manual to add the XTG-411-4 model.
3. Cross out the listed End Item Applications which appear on the inside front cover. This material has been
moved to the new pages a and b to be inserted as directed in paragraph 5.
4. Pen-and-ink changes to be made are listed on pages (1 of 13) through (13 of 13/(14 blank). Fasten these
pages to the inside front cover. If there is not room in the basic manual to add pen-and-ink changes, asterisk
the basic pages to indicate there is new or revised material which must be referred to when doing maintenance
procedures.
5. Remove old pages and insert new pages as indicated below:
Remove Pages Insert Pages
None
Table of Contents pages
1 thru 24
27 and 28
None
63 thru 68
69 and 70
73 thru 76
None
111 thru 118
195 thru 198
231 thru 238
None
None
None
Warning pages a and b
i thru iii/(iv blank)
1 thru 24
27 and 28
28.1 /(28.2 blank)
63 thru 67/(68 blank)
69 and 70
73 thru 76
76.1 and 76.2
111 thru 118
195 thru 198
231 thru 238
238.1 thru 238.3/(238.4 blank)
239.1 /(239.2 blank)
241.1 /(241.2 blank)
Approved for publ i c rel ease; di stri buti on i s unl i mi ted.
MILTON H. HAMILTON
TM 9-2520-234-35, C2
None
None
None
None
None
None
None
None
None
None
None
None
None
243.1/(243.2 blank)
245.1/(245.2 blank)
247.1/(247.2 blank)
249.1/(249.2 blank)
251.1/(251.2 blank)
253.1/(253.2 blank)
255.1/(255.2 blank)
257.1/(257.2 blank)
259.1/(259.2 blank)
261.1/(261.2 blank)
263.1/(263.2 blank)
265.1/(265.2 blank)
267.1/(267.2 blank)
File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army
O f f i c i a l :
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
02511
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Di str i buti on:
To be di stri buted i n accordance wi th DA Form 12-37-E (Bl ock 1663) Di rect and General Support mai nte-
nance r equi r ements for TM9-2520-234-35.
2
REQUI RED CHANGES
NOTE
Place an asterisk by each of the referenced paragraphs in the basic
manual to show that there is a change. While using the TM, you will
then be alerted by the asterisks that you need to refer to the pen and ink
changes portion (pages 1 of 13 thru 3 of 13/(14 blank)) of Change 2
package for changed or additional information.
Page 46 is changed as follows.
Paragraph 40a. is changed to read:
a. When it is necessary to start the vehicle en-
gine by towing or pushing the vehicle (refer to the
applicable TM manual, ref. Appendix A), the man-
ual selector valve must be placed in second gear po-
sition.
Page 62 is changed as follows.
Change Chapter 3 heading to read:
PARTS, SPECIAL TOOLS,
IMPROVISED TOOLS, AND EQUIPMENT
FOR DS & GS MAINTENANCE
Change Paragraph 60 to read:
Repair parts supplied for the XTG 411-2A, -4
power trains are listed in TM 9-2520-234-34P.
Change Paragraph 61 to read:
For standard and commonly used tools and
equi pment havi ng general appl i cati on to thi s
material, refer to the Appendix B, Section 2.
Change the last sentence in Paragraph 62a to read:
For replacements, refer to TM 9-2520-234-34P.
Page 77 is changed as follows.
Paragraph 72q is now followed by new Paragraph r:
r. Pipe Plugs. When replacing pipe plugs, coat
all pipe plugs that are not pre-coated with sealing
compound MIL-S-45180, Type III before installing
new plugs.
Change the first sentence in Paragraph 73a to read as
follows:
a. This section presents the complete disassem-
bly of the XTG 411-2A, -4 transmissions, input
transfer assembly and output drive assemblies.
Add the following NOTE after Paragraph 73b:
Note. There are Change 2 supplements immedi-
ately following each fold-out. Refer to these sup-
plements to note where changes have been made
for later models. Do not use the part numbers listed
on fold-outs 2 through 15. These part numbers
have been superseded by TM 9-2520-234-34P.
Page 78 is changed as follows.
The part number for the bracket shown in Figure 39
(Step 1) is 8355697.
For later models, the lock strips shown in Figure 40
(Step 2) are superseded by lock washers.
Note: When doing Figure 40 (Step 2) and Figure
41 (Step 3), take note of the size and location of the
bolts, lock washers and spacers (if present). Make
a sketch so that the same sizes and locations are
used at assembly. Models vary configuration at
this location and it is important that the same size
and location of parts is maintained.
In Step 2, also remove spacers 157 (Fig. 373.1,
fold-out 2), if present.
For all models, change Step 3 to read:
Usi ng a 5/8-i nch wrench, remove four i nput
transfer-to-converter housi ng bol ts and l ock
washers (A). Using a 3/4-inch wrench, remove six
input transfer-to-converter housing bolts and lock
washers (A). Remove engine coupling shaft (B).
For later models, the 10 bolts removed in Step 3 are:
1/2-13 X 5-1/4 (2)
1/2-13 X 6 (4)
7/16-14 X 1/2 (4)
Change 2 (1 of 13)
Page 79 is changed as follows.
Figure 44 (Step 6) pertains to earlier models. For
later models, lock strip (A) has been superseded by
two lock washers.
Page 80 is changed as follows.
Add to Figure 50 (Step 12):
Take care not to remove freewheel race from stator
assembly as this will dislodge twelve rollers and
twelve springs contained within.
Page 81 is changed as follows.
The last sentence in Figure 53 (Step 15) should read
as follows:
Remove seal ring (E) and expander from the lockup
clutch piston.
Page 82 is changed as follows.
Figure 58 (Step 20) pertains to earlier models. For
later models, lock strip (A) has been superseded by
two lock washers.
Page 88 is changed as follows.
In Figure 82 (Step 18), coupling (C) will only be
present on some models.
Page 91 is changed as follows.
For later models, skip Figure 92 (Step 28). Later
models are not equipped with accumulator valves.
Page 95 is changed as follows.
In Figure 110 (Step 46), screws are shown at
locations (A). In later models there are bolts at
locations (A).
Page 96 is changed as follows.
The part number for the 3/4 lifting eye shown in
Figure 114 (Step 50) is 7083672.
Page 99 is changed as follows.
Reverse Figure 125 (Step 61) with Figure 126 (Step
62).
Change Step 62 to read:
Block up the turbine shaft with a wooden block (A).
Using a 7/16-inch wrench, remove one self-locking
bolt (B) and flat washer and loosen the other. Using
loosened bolt, turn pitot tube so that it clears
(2 of 13) Change 2
collector ring on high clutch assembly. Remove
remaining self-locking bolt (B) and flat washer.
Page 102 is changed as follows.
Add this information to Figure 137 (Step 9):
Later models also may have shims under lock plate
(C). If present, remove the shims.
Page 105 is changed as follows.
The part number for the wrench in Figure 144 and in
Step 83a(5) is 8355764.
Page 106 is changed as follows.
Delete Paragraph 83b (5).
Page 107 is changed as follows.
Delete Paragraph 86b (1) and the Note following it.
Page 108 is changed as follows.
Paragraph 88 is changed to read:
a. Do not remove oil seal 22 or sleeve 18 (Fig.
373, fold-out 2) from flange adapter 19 unless re-
placement is necessary. If necessary, drive the oil
seal out of the adapter.
b. If necessary to remove sleeve 18 from flange
adapter 19, drill out pins 17. Use a drill bit slightly
larger than 3/16-inch and drill only deep enough to
free the sleeve. Press the sleeve from the housing.
Add Paragraph 91c as follows:
c . If sleeve 18 (Fig. 373, fold-out 2) was re-
moved, install new replacement as follows:
(1) Mark the locations of the three original pin
holes, in the sleeve bore, on the bolt hole circle of the
housing.
(2) The pin holes to be drilled for the new
sleeve should be located 60 degrees clockwise or
counterclockwise from the original pin holes. The
two alternate pin locations are indicated by the bro-
ken line in Fig. 149.1.
(3) Install sleeve 18 (Fig. 373, fold-out 2),
pressing it flush with the housing outer surface.
(4) Using a 1.1855-0.1875 drill, drill a hole
0.410 to 0.470-inch deep at one of the alternate loca-
tions chosen. This hole should be 0.250-inch inward
from the cover mounting surface and at a 30 degree
angle to the cover mounting surface. Refer to Figure
149.1.
Page 121 is changed as follows.
(5) Drill the remaining two dowel pin holes, Change Paragraph 141a to read:
spacing them 120 degrees apart.
a. Install 1-1/4 inch plugs 35 or 36 if they were
(6) Install the three pins (Fig. 149.1), driving
removed. Torque plugs 35 and 36 to 90-110 pound-
them 0.005 to 0.015-inch below the sleeve surface.
feet. Install 1-inch plugs 33, 39 or 41 if they were
removed. Torque plugs 33, 39 and 41 to 70-90
(7) Line bore sleeve 18 (Fig. 373, fold-out 2) to
pound-feet. Install 1-1/2 inch plugs 40 if they were
6.2990-6.002 inches diameter, with a finish of 100
removed. Torque plugs 40 to 110-130 pound-feet.
RMS (Fig. 149.1).
Page 123 is changed as follows.
Page 110 is changed as follows.
Add following sentence to Paragraph 143u:
Change Paragraph 98c to read:
c. Do not remove inserts 137,140,112,113 and
122 (Fig. 373, fold-out 2), or sleeves 119,120,134,
136 or 139 from input transfer housing assembly
111 unless replacement is necessary. If necessary to
remove a bushing or insert, refer to par. 72 for the
proper procedure. If present, do not remove bush-
ing assembly 118.
Figure 151 is changed as follows:
Dimension for line bore should be added to read
7.0864-7.0876 inch diameter.
Note that later models have plugs located differently
from that shown in figure 161.
Page 124 is changed as follows.
Paragraph 146a is changed to read:
a. If removed, install l/4-inch plugs 49 and 50.
Torque plugs 49 and 50 to 96-120 pound-inches.
Install preformed packing 59 into end cover 48.
Page 127 is changed as follows.
Output coupling and coupling retainer as shown in
Figures 172 and 173 and as addressed in Steps s and t
are present only in earlier models.
Change 2 (3 of 13)
Step u is for XTG 411-2A models. For XTG 411-4
models, install 11 internal and 11 external-splined
br ake pl at es and di sks, begi nni ng wi t h an
extemal-splined brake plate (Fig. 174).
Page 128 is changed as follows.
Paragraph 148c is changed to read:
c. For earlier models, using l/2-inch wrench,
remove self-locking bolt 51 securing drive gear
shroud 48 and shroud plate 50 to the pump. Remove
the shroud and plate. Straighten and remove lock
pin 42 from gear 49. Remove the gear.
Paragraph 148e is changed to read:
e. Do not remove the needle bearing assemblies
29 and 45 or dowel pins 31 and 46 from covers 30
and 47.
Paragraphs 15lb and c are deleted.
(4 of 13) Change 2
Page 129 i s changed as fol l ows.
Del ete Pa r a gr a ph 151 m . The shr oud i s no
l on g e r r e q u i r e d .
Page 134 i s changed as fol l ows.
Par agr aph 153at i s changed to r ead:
a t . R e m o v e l e f t - b r a k e a p p l y c a m
s t a t i on a r y r i n g (f i g . 1 9 0 ). R e mov e r i n g
seal and ex pander fr om r i ng.
Par agr aph 153au i s changed to r ead:
a u . R e mov e r i g h t - b r a k e a p p l v ca m
s t a t i on a r y r i n g (f i g. 191).
seal and ex pander fr om r i ng.
Par agr aph 156a i s changed to
a . I n s t a l l a n y p l u gs i n
r e a r h ou s i n g 2 5 t h a t w e r e
Re mov e r i n g
r ead:
tr an s mi s s i on
r e mov e d f or
cl e a n i n g p u r p os e s . Tor q u e 3/8-i n ch p l u g
22 (f i g. 379, f ol d -ou t 8) t o 12-16 p ou n d -
f e e t . Tor q u e l - i n c h p l u g 2 7 t o 7 0 - 9 0
p ou n d - f e e t .
Par agr aph 156b i s changed to r ead:
b . I n s ta l l n ew r i n g s ea l a n d ex pa n der
on to r i gh t-br a k e a ppl y ca m s ta ti on a r y r i n g
(fi g. 191).
Par agr aph 156d i s changed to r ead:
d . I n s ta l l n ew r i n g s ea l a n d ex pa n der
on to l ef t-br a k e a ppl y ca m s ta ti on a r y r i n g
(fi g. 190).
Page 138 i s changed as fol l ows.
Par agr aph 156ag i s changed to r ead:
a g. I n s ta l l th e l ef t-f ol l ower l i n k s h a f t
p l u g (f i g. 198). Tor q u e t h e 3/8-i n ch p l u g
to 12-16 pou n d-f eet.
Par agr aph 156aj i s changed to r ead:
aj . I n s t a l l t h e r i g h t - f ol l ow e r l i n k
s h a f t p l u g (f i g. 200). Tor q u e t h e p l u g t o
12-16 pound-feet.
Page 139 i s changed as fol l ows.
Par agr aph 156ap i s changed as fol l ows:
a p . I nstal l the br ak e cool ant pump
i d l e r ge a r s h a f t a n d s e cu r e wi t h on e
3 /8 - 1 6 x 3 - 1 /4 ca p s cr e w (f i g . 1 7 6 ).
Torque the cap screw to 26-32
p ou n d - f e e t .
Ad d t h e f ol l ow i n g N ot e i mme d i a t e l y
bel ow Pa r a gr a ph 158 h ea di n g:
N ot e . The pi ni ons i n thi s pl anetar y
ca r r i er a r e a ma tch ed s et. Th er e-
for e, fai l ur e of one pi ni on r equi r es
r epl a cemen t of th e compl ete s et.
Page 141 i s changed as fol l ows.
C h a n g e N o t e f ol l ow i n g Pa r a g r a p h 1 6 1
headi ng to r ead:
N o t e . Ch i l l s t e e r p l a n e t a r y ca r -
r i er s pi n dl es 11 (f i g. 378, f ol d-ou t
7) i n dr y i ce for appr ox i matel y one
h ou r pr i or to i n s ta l l a ti on . Ha n dl e
chi l l ed par ts wi th gl oves.
Add thi s N o t e fol l owi ng Par agr aph 161k .
N o t e . Ch i l l i n g of s pi n dl es r es u l ts
i n "f r os t" i n i ti a l l y wh i ch u l ti ma te-
l y i s moi s tu r e. I f a r ebui l t car r i er
assembl y i s not bei ng i nstal l ed i n a
t r a n s mi s s i on i n t h e n e a r f u t u r e ,
a p p l y a c oa t i n g of oi l a r ou n d
s p i n d l e l oca t i on s t o a v oi d r u s t
ox i d a t i on .
Page 144 i s changed as fol l ows.
The part number for the compressi ng tool
i n Fi gur e 210 i s 8355784.
De l e t e b ot h N ot e s f r om Pa ge 144 f ol l ow -
i ng Steps k and 1.
Page 145 i s changed as fol l ows.
Del ete N o t e fol l owi ng Par agr aph 173a (l ).
Ch an ge 2 (5 of 13)
Page 147 i s changed as fol l ows.
Ad d t h i s N ot e i mme d i a t e l y f ol l owi n g t h e
headi ng for Par agr aph 178:
N ot e . The pi ni ons i n thi s pl anetar y
ca r r i er a r e a ma tch ed s et. Th er e-
for e, fai l ur e of one pi ni on r equi r es
r epl a cemen t of th e compl ete s et.
Change Par agr aph 178e to r ead:
Del ete the Note fol l owi ng Par agr aph 183g.
e . Pos i t i on t h e r e v e r s e - r a n ge p l a n e -
ta r y ca r r i er a s s embl y i n a pr es s . U s i n g a
s u i ta bl e pr es s i n g tool , r emov e s i x ca r r i er
s pi n dl es (f i g. 214). Remov e th e pi n i on s 14
(fi g. 377, fol d-out 6), thr ust washer s 8 and
15, s pa cer s 13, 9 a n d 11, i f pr es en t, a n d
r ol l er bear i ngs 10 and 12, i f pr esent.
Add thi s Note i mmedi atel y fol l owi ng the
h e a d i n g f o r P a r a g r a p h 1 8 8 :
C h a n g e N o t e f ol l owi n g Pa r a gr a p h 181
h e a d i n g t o r e a d :
N o t e . Ch i l l s pi n dl es 7 i n dr y i ce
a p p r ox i ma t e l y on h ou r p r i or t o
i n s t a l l a t i on . H a n d l e ch i l l e d p a r t s
wi th gl ov es .
Page 148 i s changed as fol l ows.
Change Par agr aph 181c to r ead:
c . I n s er t 22 n ew s pi n dl e r ol l er s i n to
one end of the pi ni on bor e (fi g. 215).
Del ete Pa r a gr a ph 181f .
Del ete l oos e r ol l er s s hown i n Fi gur e 216.
Page 149 i s changed as fol l ows.
Ch a n ge Pa r a gr a ph 18l l _to r ea d:
1 . I n s ta l l th e r ema i n i n g f i v e s pi n dl es
7 (fi g. 377, fol d-out 6) and pi ni ons 14, wi th
r ol l er s 10, th r u s t wa s h er s 8 a n d 15, l ock
pi n s 16 a n d s pa cer s 9 a n d 13 i n th e s a me
manner as des cr i bed i n b thr ough k , above.
Add thi s N ot e fol l owi ng Par agr aph 1811:
N o t e . Ch i l l i n g of s pi n dl es r es u l ts
i n "f r os t" i n i ti a l l y wh i ch u l ti ma te-
l y i s moi s tu r e. I f a r ebu i l t ca r r i er
a s s embl y i s n ot bei n g i n s ta l l ed i n
a tr a n s mi s s i on i n th e n ea r f u tu r e,
a p p l y a c oa t i n g of oi l a r ou n d
s p i n d l e l oca t i on s t o a v oi d r u s t
ox i dati on .
Th e pa r t n u mber f or th e compr es s i n g tool
i n Fi gur e 218 i s 8355784.
Page 150 i s changed as fol l ows.
N ot e . The pi ni ons i n thi s pl anetar y
ca r r i er a r e a ma tch ed s et. Th er e-
for e, fai l ur e of one pi ni on r equi r es
r epl a cemen t of th e compl ete s et.
C h a n g e N o t e f ol l owi n g h ea di n g f or Pa r a -
gr aph 191 to r ead:
N o t e . Chi l l spi ndl es 34 i n dr y i ce
f or a p p r ox i ma t e l y on e h ou r p r i or
t o i n s t a l l a t i on . H a n d l e ch i l l e d
par ts wi th gl oves.
Page 152 i s changed as fol l ows.
Add thi s N ot e after Par agr aph 191k .
N o t e . Ch i l l i n g of s pi n dl es r es u l ts
i n "frost" i ni ti al l y whi ch ul ti mate-
l y i s moi s tu r e. I f a r ebu i l t ca r r i er
a s s embl y i s n ot bei n g i n s ta l l ed i n
a tr a n s mi s s i on i n th e n ea r f u tu r e,
a p p l y a c oa t i n g of oi l a r ou n d
s p i n d l e l oca t i on s t o a v oi d r u s t
ox i dati on .
(6 of 13) Ch a n ge 2
Add th i s N o t e i mme d i a t e l y f ol l owi n g t h e
h e a d i n g Pa r a gr a p h 193:
N ot e . The pi ni ons i n thi s pl anetar y
ca r r i er a r e a ma tch ed s et. Th er e-
f or e, f a i l u r e of on e pi n i on r equ i r es
r epl a cemen t of th e compl ete s et.
Change Par agr aph 193d to r ead:
d . Re mov e p l a n e t a r y ca r r i e r p i n i on s ,
t h r u s t wa s h e r s , a n d b e a r i n g s f r om t h e
ca r r i er (f i g. 225).
Page 153 i s changed as fol l ows.
Ch a n ge th e N o t e f ol l owi n g th e h ea di n g of
Par agr aph 196 to r ead:
N o t e . Ch i l l s pi n dl es 19 i n dr y i ce
f or a p p r ox i ma t e l y on e h ou r p r i or
t o i n s t a l l a t i on . H a n d l e ch i l l e d
pa r ts wi th gl ov es .
Change Par agr aph 196c to r ead:
c . I n s t a l l on e t h r u s t wa s h e r 25 (f i g.
376.1, f ol d-ou t 5.1) a n d on e ca ged bea r i n g
65 onto al i ni ng tool 8351208.
Del ete Pa r a gr a ph 196d.
(1) Ch a p t e r 5 cov e r s d i s a s s e mb l y
a n d a s s e mb l y of t h e p ow e r t r a i n a n d r e -
bu i l d of s u bas s embl i es .
(2) Th e di s a s s embl y a n d a s s embl y
i n s t r u ct i on s a r e p r e s e n t e d i n a p i ct or i a l
s t e p -b y -s t e p ma n n e r , d e s i gn e d t o p or t r a y
g r a p h i c a n d e a s y - t o- f ol l ow i n s t r u ct i on s .
Th er e i s a pi ctu r e i n cor r ect s equ en ce f or
e v e r y ma i n s t e p i n t h e d i s a s s e mb l y a n d
a s s embl y pr ocedu r es . I n a ddi ti on to f i gu r e
n u mb e r , e a ch p i ct or i a l s t e p i s i d e n t i f i e d
by i ts step number . Oth er s ecti on s of th e
ma n u a l a r e comp i l e d i n t h e p a r a g r a p h -
ou tl i n e s ty l e.
d . Ch a pter 6 f or Sta n da r ds . Ch a pter
6 cov er s r epa i r a n d r ebu i l d s ta n da r ds a n d
i ncl udes a tabul ati on of wear l i mi ts.
C h a n ge 2
1
CHAP 1, SEC I
GENERAL PAR 1
2 Change 2
Figure 4. Model XTG 411-2a,XTG 411-4 power trains
*C1
*C1
*C1
*C1
*C1
PAR 1-3
G E N E R A L CHAP 1, SEC I
e . Ap p e n d i ce s a n d I n d e x . F ol l owi n g
Chapter 6 ar e Appendi x A and Appendi x B
a n d th e book i n dex . Appen di x A con ta i n s
a l i s t of cu r r en t r ef er en ces , i n cl u di n g s u p-
pl y ma n u a l s , for ms , tech n i ca l ma n u a l s a n d
ot h e r a v a i l a bl e p u bl i ca t i on s a p p l i ca bl e t o
t h e XTG 4 1 1 p ow e r t r a i n s . Ap p e n d i x B
t a b u l a t e s t h e e x p e n d a b l e s u p p l i e s a n d
ma t e r i a l s n e e d e d f or t h e r e p a i r t a s k s i n
thi s manual .
f . Fol d-ou t I l l u s tr a ti on s . Th e 15 f ol d-
ou t pa ges a n d 15 s u ppl emen t pa ges a t th e
en d of th e book i n cl u de a s ch ema ti c v i ew
of t h e h y d r a u l i c s y s t e m (f i g . 3 7 2 a n d
372.1) and 14 ex pl oded v i ews of the power
tr a i n compon en ts (f i gs . 373 th r ou gh 386.1).
Thes e pages may be fol ded out s o that the
en ti r e v i ew ex ten ds bey on d th e r i gh t edge
of ot h e r p a ge s i n t h e b ook , ma k i n g t h e
v i e w c om p l e t e l y v i s i b l e w h i l e r e a d i n g
pa r a gr a ph s con cer n i n g i t.
g. Reporti ng Equi pment I mpr ove-
me n t Re comme n d a t i on s (E I R). E I Rs wi l l
be pr epa r ed u s i n g a SF 368 (Qu a l i ty Def i -
ci en cy Repor t). I n s tr u cti on s f or pr epa r i n g
E I R s a r e p r ov i d e d i n DA PAM 7 3 8 - 7 5 0
(Ar my Ma i n t e n a n ce Ma n a ge me n t Sy s t e m).
E I Rs s h ou l d b e ma i l e d d i r e ct l y t o: Com-
m a n d e r , U . S . A r m y Ta n k -Au t omot i v e
Comma n d , ATTN : AMSTA-QRT, Wa r r e n ,
MI 48397-5000. A r epl y wi l l be f u r n i s h ed
to you.
h . L u b r i ca t i on . Re f e r t o t h e v e h i cl e
oper a tor ma n u a l a n d l u br i ca ti on or der f or
i n s tr u cti on s .
i . Mai ntenance I nstructi ons. R e f e r
t o t h e Ve h i cl e Or ga n i z a t i on a l or Di r e ct
Su ppor t/Gen er a l Su ppor t Ma i n t e n a n ce
Man u al .
F I E L D AN D DE POT MAI N TE N AN C E
AL L OCATI ON
Re f e r t o t h e ma i n t e n a n ce a l l oca t i on
ch a r t i n th e Veh i cl e Or ga n i za ti on a l Ma i n -
ten an ce Man u al .
3. FORMS, RECORDS AND REPORTS
De p a r t me n t of t h e Ar my f or ms a n d
p r oce d u r e s u s e d f or e q u i p me n t ma i n t e -
n a n ce w i l l b e t h os e p r e s cr i b e d b y DA
PAM 7 3 8 - 7 5 0 (Ar my Ma i n t e n a n ce Ma n -
a gemen t Sy s tem) (TAMMS).
Change 2
3
CHAP 1, SEC I G E N E R A L PAR 3
4
C h a n g e 2
PAR 3 G E N E R A L CHAP 1, SEC I
Change 2
5
*C1
CHAP 1, SEC I I
4. DESCRI PTI ON
PAR 4-7 GE NE RAL DE SCRI PTI ON AND DATA
Secti on I I . GE NE RAL DE SCRI PTI ON AND DATA
(3) L oca t i on a l t e r ms f or t h e ou t -
pu t dr i v e a s s embl i es cor r es pon d to f r on t,
a . Ge n e r a l . Th e Al l i s on Mod e l XTG r ear , l eft and r i ght of the v ehi cl e.
411-2A a n d XTG 411-4 power tr a i n s (f i gs .
1 thr ough 4) ar e each a combi nati on of an (4 ) R ot a t i on a l t e r ms (cl ock w i s e
i n pu t tr a n s f er (dr i v e) s ecti on a n d a ma i n or cou n t e r cl ock w i s e ) w i l l b e e s t a b l i s h e d
t r a n s mi s s i on s e ct i on . Ri gh t - a n d l e f t -ou t - by r ef er en ces i n tex t, or by th e v i ewer s
pu t dr i v e a s s embl i es a r e a v a i l a bl e a n d a r e posi ti on i n i l l ustr ati ons.
d i s cu s s e d i n t h i s p u bl i ca t i on . Th e i n p u t
tr a n s f er s ecti on i n cl u des a tor qu e con v er -
t e r a n d t r a n s mi t s e n gi n e r ot a t i on t o t h e c . Tr a n s mi s s i on Comp on e n t Gr ou p s .
mai n tr ansmi ssi on secti on. The mai n tr ans- Th e ma i n compon en ts of th e power tr a i n
mi s s i on s e ct i on i n cl u d e s r a n ge cl u t ch e s a r e i d e n t i f i e d i n f i g s . 5 A, 5 B a n d 5 C.
a n d ge a r i n g, s t e e r cl u t ch e s , s t e e r p l a n e - C h a p t e r 2 cov e r s t h e d e s cr i p t i on a n d
ta r y gea r i n g a n d v eh i cl e br a k es . Th e ou t- oper ati on of al l components i n detai l .
p u t d r i v e a s s e mb l i e s i n cl u d e r e d u ct i on
gea r pl a n eta r i es a n d pr ov i de r ev er s e-r ota -
t i n g d r i v e s t o t h e v e h i cl e t r a ck s . F ou r 5. DRI VI NG I NSTRUCTI ONS
f or wa r d a n d two r ev er s e s peeds a r e ma n -
u a l l y s e l e ct e d . Th e a x e s of t h e e n g i n e , Refer to th e v eh i cl e oper ator man u al
ma i n t r a n s mi s s i on a n d ou t p u t d r i v e s a r e
par al l el .
b . Def i n i ti on of L oca ti on a l a n d
Di r ecti on a l Ter ms
(1) L oca t i on a l t e r ms u s e d i n d e -
s cr i bi n g th e power tr a i n , a r e f r on t, r ea r ,
r i gh t a n d l ef t. Th e i n pu t tr a n s f er s ecti on
a n d ma i n t r a n s mi s s i on s e ct i on l oca t i on a l
ter ms do n ot a l wa y s cor r es pon d to v eh i cl e
l ocati onal ter ms , whi l e thos e of the output
d r i v e a s s e mb l i e s d o cor r e s p on d . I n t h e
v eh i cl e a ppl i ca ti on f or wh i ch th i s ma n u a l
i s w r i t t e n , t h e p o w e r t r a i n i s f r o n t -
mou n ted a n d th e l oca ti on a l ter ms f or th e
i n pu t tr a n s f er a n d ma i n tr a n s mi s s i on s ec-
t i on s a r e op p os i t e t h os e f or t h e v e h i cl e
and output dr i ve assembl i es (fi g. 3).
(2) Th e f r on t of th e tr a n s mi s s i on
i s a l wa y s th e l oca ti on a dj a cen t to th e en -
gi n e r ega r dl es s of th e ma n n er of mou n ti n g
i n th e v eh i cl e. Th e r ea r i s th e l oca ti on a t
w h i ch t h e b r a k e i n s p e ct i on cov e r s a r e
mou n t e d . Th e l e f t i s t h e s i d e t o w h i ch
t h e i n p u t t r a n s f e r h ou s i n g i s a t t a ch e d .
Th e r i gh t i s th e s i de on wh i ch th e br a k e
appl y shafts ar e l ocated (fi gs. 2 and 3).
f or i n s tr u cti on s .
6. TRANSMI SSI ON OI L
Oi l may be consi der ed as the l i febl ood
of a h y d r a u l i c t r a n s mi s s i on . Th e u s e of
p r op e r oi l , a n d a t t e n t i on t o k e e p i n g t h e
oi l cl e a n , i s of p a r a mou n t i mp or t a n ce .
The pr oper oi l l ev el must be mai ntai ned i n
th e tr a n s mi s s i on to obta i n ma x i mu m per -
f or ma n ce . Ch e ck t h e oi l l e v e l r e gu l a r l y .
Cl e a n t h e oi l s cr e e n s a t s p e ci f i e d i n t e r -
v al s . Be v e r y ca r e f u l t h a t n o f or e i g n
ma tter en ter s th e power tr a i n s y s tem a t
a n y t i me . Wh e n ch a n gi n g or a d d i n g oi l ,
u s e on l y t h a t s p e ci f i e d (s e e Oi l s p e ci f i -
c a t i on s Ta b l e I , TA B U L A TE D DA TA ,
p a r . 7 , b e l ow ). R e f e r t o t h e op e r a t or
ma n u a l f or p r oce d u r e s t o b e f ol l ow e d i n
ch e ck i n g t h e oi l l e v e l a n d f or ch a n gi n g
the oi l .
7. TABU L ATE D DATA
Th e f ol l ow i n g t a b l e cov e r s t e ch n i ca l
da ta a ppl i ca bl e to th e Al l i s on XTG 411-2A
and XTG 411-4 power tr ai ns.
6
Change 2
PAR 7 GE NE RAL DE SCRI PTI ON AND DATA CHAP 1, SEC I I
Table I . TABULATED DATA
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ty pe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wei ght, dr y:
I nput transfer secti on . . . . . . . . . . . . . . . . . . .
Mai n transmi ssi on secti on . . . . . . . . . . . . . . . .
Ri ght-output dr i ve assembl y. . . . . . . . . . . . . .
Left-output dr i ve assembl y. . . . . . . . . . . . . . .
Tot a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ov er al l di mensi ons (wi th output dr i v es):
L en gth . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wi dth (between ou tpu t dr i v e-to-h u l l
mounti ng faces) . . . . . . . . . . . . . . . . . . . .
Wi dth (between tr ack s pr ock et h u b
mounti ng faces) . . . . . . . . . . . . . . . . . . .
Hei gh t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Al l i son Tr ansmi ssi on Di vi si on,
Gen er a l Motor s Cor por a ti on
XTG 411-2A, XTG 411-4
X-dr i v e, tor qu e con v er ter , pl a n eta r y
gea r , a l l -tor qu e s h i f ti n g
XTG 411-2A XTG 411-4
Pou n ds Pou n ds
405 405
1,985 2,045
635 635
720 720
3,745 3,805
73.02 i n.
83.00 i n.
112.11 i n.
26.07 i n.
Name pl ate l ocati ons (model , ser i al number , par t number ):
I nput transfer secti on . . . . . . . . . . . . . . . . . . .
Mai n tr ansmi ssi on secti on. . . . . . . . . . . . . . . .
Output dr i ve assembl i es (r i ght or l eft). . . . . . .
Suspensi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R a t i n g
Maxi mum i nput torque . . . . . . . . . . . . . . . . . .
Maxi mum i nput speed . . . . . . . . . . . . . . . . . . .
Maxi mum net i nput hor sepower . . . . . . . . . . . .
Rot a t i on :
I nput (v i ewi ng mounti ng face of engi ne
a d a p t e r ). . . . . . . . . . . . . . . . . . . . . . . . . .
Ou tpu t (v i ewi n g r i gh t of power tr ai n ):
Mai n tr ansmi ssi on (for war d r anges) . . . . . .
(r ever se r ange) . . . . . . .
Output dr i v e assembl i es (for war d r anges) . .
(r ev er s e r an ge). . .
Dr i ve r anges (manual l y sel ected). . . . . . . . . . . . . .
Top, n ear r ear of th e tr an s fer h ou s i n g
Top, center of mai n housi ng
Lower r ear of s addl e, bel ow s addl e
ca p
Adapter bol ts to engi ne fl y wheel
housi ng; output dr i ve assembl i es
bol t to v ehi cl e hul l and s uppor t r ear
of mai n tr ansmi ssi on secti on; ti e bar
between engi ne and tr ansmi ssi on
XTG 411-2A XTG 411-4
880 l b ft 1200 l b ft
2300 r pm 2500 r pm
360 hp 575 hp
Cl ock wi s e
Cl ock wi s e
Cou n t e r cl ock wi s e
Cou n t e r cl ock wi s e
Cl ock wi s e
Fou r for war d, two r ev er s e
Change 2
7
CHAP 1, SEC I I GE NE RAL DE SCRI PTI ON AND DATA PAR 7
Table I . TABULATED DATA - Continued
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . 3-el emen t, s i n gl e-s ta ge, pol y ph a s e,
wi th a u toma ti c l ock u p cl u tch
Cl u t ch e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mu l ti pl a te, wet, h y dr a u l i c-a ppl i ed
Gea r i n g (con s ta n t mes h th r ou gh ou t):
I nput transfer geari ng . . . . . . . . . . . . . . . . . . 6-pi tch , s tr a i gh t-cu t, i n -l i n e s pu r
Ra n ge ge a r i n g
Low and reverse ranges . . . . . . . . . . . . . . . 8-pi tch , s tr a i gh t-cu t, pl a n eta r y
I ntermedi ate range . . . . . . . . . . . . . . . . . . 10-pi tch , s tr a i gh t-cu t, pl a n eta r y
Output transfer geari ng . . . . . . . . . . . . . . . . . 4-pi tch , s tr a i gh t-cu t, i n -l i n e s pu r
Steer geari ng . . . . . . . . . . . . . . . . . . . . . . . . . S-pi tch , s tr a i gh t-cu t, pl a n eta r y
Output dri ve geari ng . . . . . . . . . . . . . . . . . . . 5-pi tch , s tr a i gh t-cu t, pl a n eta r y
Brakes (servi ce and parki ng) . . . . . . . . . . . . . . . . . Mu l ti pl a te, wet, mech a n i ca l l y
appl i ed, s i nter ed br onze on s teel
Con tr ol (r a n ge s el ecti on , s teer i n g, br a k es ):
External . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual
I nter nal (except br akes) . . . . . . . . . . . . . . . . . Hydr aul i c
Tor qu e mu l ti pl i ca ti on r a ti os : XTG 411-2A XTG 411-4
Tor que conver ter (maxi mum at stal l ). . . . . . . . 3.3:1 3.2:1
Compl ete power tr a i n (i n pu t tr a n s f er s ecti on
and mai n tr ansmi ssi on secti on). . . . . . . . . . See tabl e bel ow
Power tr a i n r a ti os :
Gea r I nput
XTG 411-2A XTG 411-4
ou t p u t Steer Tot a l
Ra n ge
Tor qu e Tor qu e
Tr a n s f e r R a n g e Tr a n s f e r Pl a n e t a r y Me ch a n i ca l C on v e r t e r Con v e r t e r
Fi r s t 0.611:1 4.00:1 1.30:1 1.477:1 4.690:1 3.3:1 3.2:1
S e con d 0.611:1 4.00:1 1.30:1 1.000:1 3.178:1 3.3:1 3.2:1
Th i r d 0.611:1 2.00:1 1.30:1 1.000:1 1.589:1 3.3:1 3.2:1
Fou r th 0.611:1 1.00:1 1.30:1 1.000:1 0.794:1 3.3:1 3.2:1
Re v e r s e 1 0. 611: 1 4.77:1 1.30:1 1.477:1 5.60:1 3.3:1 3.2:1
Re v e r s e 2 0. 611: 1 4.77:1 1.30:1 1.000:1 3.79:1 3.3:1 3.2:1
St e e r i n g:
Ty p e :
Fi rst, reverse 1 ranges . . . . . . . . . . . . . . . Cl utch brake
Thi r d, four th, r ever se 2 r anges. . . . . . . . . . Gear ed
S e con d . . . . . . . . . . . . . . . . . . . . . . . . . . . Opti on al
Ra t i os :
Cl u tch br a k e . . . . . . . . . . . . . . . . . . . . . . I n fi n i te
Geared . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.477.1 maxi mum
Con t r ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ma n u a l l y con tr ol l ed by oper a tor ,
s teer br ak es and cl utches
h y dr a u l i ca l l y a ppl i ed
8 Change 2
PAR 7 GE NE RAL DE SCRI PTI ON AND DATA CHAP 1, SEC I I
Ta bl e I . TABU L ATED DATA - Con ti n u ed
Power tak e-offs (XTG 411-2A, 2 on i nput tr ans fer hous i ng):
Number 1 on fr ont of i nput tr ansfer housi ng. . . Empl oy s i nput tr ansfer dr i v e gear as
PTO dr i v e gea r (6-pi tch , 68-teeth ,
200 pr es s ur e angl e); dr i v e gear
r otates at en gi n e s peed an d di r ecti on
Number 2 on center l i ne of engi ne . . . . . . . . . . Rota tes cou n ter cl ock wi s e (f a ci n g
mount) at engi ne s peed; empl oy s
i nter nal spl i ne of engi ne coupl i ng as
PTO dr i v e (16/32-pi tch , 16-teeth , 30
pr essur e angl e)
Power tak e-offs (XTG 411-4, 3 on i nput tr ans fer hous i ng):
Number 1 on fr ont of i nput tr ans fer hous i ng. . . Empl oy s i nput tr ansfer dr i v e gear as
PTO dr i v e gea r (6-pi tch , 68-teeth ,
20 pr es s ur e angl e); dr i v e gear
r otates at en gi n e s peed an d di r ecti on
Number 2 on center l i ne of engi ne . . . . . . . . . . Rota tes cou n ter cl ock wi s e (f a ci n g
mount) at engi ne s peed; empl oy s
i nter nal spl i ne of engi ne coupl i ng as
PTO dr i v e (16/32-pi tch , 16-teeth , 30
pr essur e angl e)
Nu mber 3 on cen ter l i n e of tor qu e con v er ter
(opti on al ) . . . . . . . . . . . . . . . . . . . . . . . . . Rota tes cl ock wi s e (f a ci n g mou n t) a t
1.64 x en gi n e s peed empl oy s i n ter n a l
s pl i n e of con v er ter cov er as PTO
dr i v e (16/32-pi tch , 16-teeth , 30
pr essur e angl e)
Oi l pumps (5, i n 3 assembl i es):
Ty pe
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pos i ti v e di s pl a cemen t, s pu r gea r
Oi l s y s tem:
Capaci ty, i ni ti al fi l l . . . . . . . . . . . . . . . . . . . . Approx 20 U.S. gal
Capaci ty, refi l l . . . . . . . . . . . . . . . . . . . . . . . Approx 12 U.S. gal
Capaci ty, r i ght-output dr i ve . . . . . . . . . . . . . . 1-3/4 U.S. gal
Capaci ty, l eft-output dr i ve . . . . . . . . . . . . . . . 3-1/4 U.S. gal
Oi l speci fi cati ons . . . . . . . . . . . . . . . . . . . . . . . . . MI L -L -2104D; See v eh i cl e l u br i ca ti on
or der for appr ov ed gr ades
Mai n screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I ntegr al wi r e mesh
Con tr ol pr es s u r es :
Mai n pr es s u r e (i n con v er ter oper ati on ):
Neutr al , fi r st, second, thi r d . . . . . . . . . . . . 190 to 240 psi
F ou r t h . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 to 160 psi
Reverse l , reverse 2 . . . . . . . . . . . . . . . . . 300 to 360 psi
Mai n pr es s ur e (i n l ock up oper ati on):
Neutr al , fi r st, second, thi r d, four th .
. . . . . . . . 118 to 160 psi
Lockup and r ange cl utch appl y pr essur e . . . . . . . . . Same as mai n pr essur e for appl i cabl e
r an ge
Change 2 9
PAR 7
CHAP 1, SEC I I GE NE RAL DE SCRI PTI ON AND DATA
Ta bl e I . TABU L ATED DATA - Con ti n u ed
Steer cl utch and steer br ake appl y pr essur e . . . . . . 60 to 130 psi
Governor (pi tot) pressure . . . . . . . . . . . . . . . . . . . 80 to 88 psi at 2600 r pm of conv er ter
tu r bi n e
Lubri cati on pressure . . . . . . . . . . . . . . . . . . . . . . . 18 to 45 psi at 1825 to 1925 engi ne
r p m
Brake cool ant pressure . . . . . . . . . . . . . . . . . . . . . Unregul ated
Gov er n or pr es s u r e at l ock u p en gagemen t (fu l l TV)
(throttl e val ve) . . . . . . . . . . . . . . . . . . . . . . 75 to 89 psi
Ou tpu t s peed at l ock u p en gagemen t (at ou tpu t cou pl i n gs ):
Thi r d gear . . . . . . . . . . . . . . . . . . . . . . . ...0 910 to 1080 r pm
Fourth gear . . . . . . . . . . . . . . . . . . . . . . . . ..1820 to 2160 rpm
Output speed l i mi ts at whi ch downshi fts can be made:
Fourth to thi rd . . . . . . . . . . . . . . . . . . . . . . .
Second to fi rst . . . . . . . . . . . . . . . . . . . . . . . .
Fi r st to neutr al . . . . . . . . . . . . . . . . . . . . . . .
Temper a tu r es (to cool er ):
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maxi mum . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ta ch ome t e r d r i v e :
Locati on . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotati on . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ra t i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
930 to 1410 r pm
780 to 1225 r pm
600 to 1180 r pm
Appr ox 220 degr ees F
Appr ox 305 degr ees F
Left si de of tr ansmi ssi on, behi nd
l eft ou tpu t
Cou n ter cl ock wi s e (f a ci n g pa d)
Rotates at s peed equal to output
10
Change 2
PAR 8-9
CH APTE R 2
DESCRI PTI ON AND OPERATI ON
Secti on I . DE SCRI PTI ON AND OPE RATI ON OF I NPU T TRANSFE R ASSE MBL Y
8 . I NPU T TRANSFER GEARI NG
a . I n pu t Tr a n s f er Gea r i n g
a n d L ock u p Cl u tch
( 1 ) Th e t o r q u e c o n v e r t e r a n d
l ock u p cl u t ch a r e comb i n e d i n a comp a ct
s u b a s s e mb l y w h i ch s e r v e s a s t h e i n p u t
member f or th e ma i n tr a n s mi s s i on s ecti on .
Th i s combi n a t i on a ct s a s a t or qu e mu l t i -
p l i e r , a f l u i d cou p l i n g or a d i r e ct -d r i v e
cou p l i n g d e p e n d i n g u p on t h e r e q u i r e -
ment at any par ti cul ar ti me.
(2) E n gi n e t or q u e i s d e l i v e r e d t o
con v e r t e r cov e r 69 b y t r a n s f e r ge a r 67.
Con v er ter cov er , l ock u p cl u tch pi s ton 74,
r ea cti on pl a te 78 a n d con v er ter pu mp a s -
s embl y 82 r ota te a s a u n i t a n d con s ti tu te
th e dr i v e member s . Sta tor a s s embl y 94 i s
l oca t e d b e t w e e n p u mp a s s e mb l y 8 2 a n d
t u r b i n e a s s e mb l y 7 9 . Th e s t a t or i s t h e
r e a ct i on me mb e r . Tu r b i n e a s s e mb l y 7 9
and l ock up cl utch pl ate 77 r otate as a uni t
a n d w i t h con v e r t e r t u r b i n e s h a f t 2 (f i g.
375, f ol d -ou t 4). Th i s gr ou p con s t i t u t e s
th e dr i v en member s .
(3) Th e ca v i t y wi t h i n t h e a s s e m-
bl ed compon en ts i s k ept ch a r ged wi th oi l
w h i ch con t i n u a l l y ci r cu l a t e s f or cool i n g
a n d l u br i ca ti on . Rota ti on of th e con v er ter
p u mp wh i l e t h e v e h i cl e e n gi n e i s a t i d l e
s p e e d w i l l n ot t r a n s m i t a s i g n i f i c a n t
a mou n t of power h y dr a u l i ca l l y to th e con -
v e r t e r t u r b i n e . Th u s , d u r i n g e n gi n e i d l e ,
th e con v er ter a cts a s a di s en ga ged cl u tch .
Th e p r e s s u r e of t h e oi l i n t h e con v e r t e r
c a v i t y k e e p s t h e l o c k u p c l u t c h p i s t o n
p u s h e d t o i t s r e l e a s e d p os i t i on e x ce p t
wh en a h i gh er pr es s u r e i s a ppl i ed to th e
op p os i t e s i d e of t h e p i s t on . Th i s occu r s
onl y at hi gher speeds.
(4) Wh e n t h e e n gi n e i s a cce l e r a -
t e d , t h e v a n e s of t h e con v e r t e r p u mp
t h r ow oi l r a d i a l l y ou t wa r d a n d i n t o t h e
bl a des of th e tu r bi n e. Th e i mpa ct of th i s
oi l a ga i n s t th e tu r bi n e bl a des ca u s es th e
tu r bi n e to r ota te. Oi l l ea v es th e v a n es of
the tur bi ne at a poi nt near the tur bi ne hub
but fl owi ng i n a di r ecti on oppos i te to con-
v er ter r ota ti on . Th i s f l ow i n a n oppos i te
d i r e ct i on i s mos t p r on ou n ce d a t l ow e r
tu r bi n e s peeds . At h i gh er tu r bi n e s peeds ,
th e f l ow ch a n ges a n d i s mor e towa r d th e
di r ecti on of r ota ti on .
(5 ) To r e t u r n t o t h e con v e r t e r
pump, the oi l must pass between the stator
v a n e s . At l ow t u r b i n e s p e e d s , t h e oi l
s t r i k e s t h e con ca v e s i d e s of t h e s t a t or
v anes. Thi s tends to dr i v e the stator i n a
d i r e ct i on op p os i t e t o con v e r t e r r ot a t i on .
Th e s tator l ock s u p, h owev er , an d th e s ta-
tor bl a des tu r n th e f l ow of oi l a n d di r ect
i t i n th e s a me di r ecti on a s th e con v er ter
pu mp r ota tes . Th e u n ex pen ded en er gy of
th e oi l i s th u s a dded to th e mov emen t of
th e pu mp. Th i s i s th e k ey to tor qu e mu l -
t i p l i ca t i on .
( 6 ) Wh e n t u r b i n e s p e e d
pr ea ch es pu mp s peed, th e di r ecti on of oi l
f l ow f r om t u r b i n e t o p u mp ch a n ge s . Th e
r e t u r n i n g oi l s t r i k e s t h e con v e x s i d e s of
t h e s t a t or v a n e s , ca u s i n g t h e s t a t or t o
f r e e w h e e l . U n d e r t h e s e con d i t i on s , t h e
tor qu e con v er ter a cts a s a f l u i d cou pl i n g.
Ther e i s no mul ti pl i cati on of tor que.
(7 ) Wh e n t h e con v e r t e r r e a ch e s
s u f f i ci en t s peed, a n d th er e i s n o f u r th er
n e e d f or e i t h e r t or q u e mu l t i p l i ca t i on or
f l u i d dr i v e, a u toma ti c v a l v es di r ect pr es -
s u r e to th e l ock u p cl u tch pi s ton . Th e pi s -
t on comp r e s s e s t h e l ock u p cl u t ch p l a t e
a ga i n s t t h e b a ck p l a t e , l ock i n g t h e con -
v er ter tu r bi n e to th e con v er ter cov er a s -
s e mb l y . Th e r e f or e , d u r i n g l ock u p , t h e
con v er ter tu r bi n e i s dr i v en di r ectl y f r om
th e en gi n e. Th er e i s n o h y dr a u l i c a cti on
wi t h i n t h e t or q u e con v e r t e r b e ca u s e t h e
p u mp a n d t u r b i n e r ot a t e a s a u n i t . Th e
s tator fr eewh eel s to pr ev en t an y h y dr au l i c
dr ag. Ther e i s no l oss fr om sl i ppage, whi ch
12 Change 2
PAR 9-11 DESCRI PTI ON AND OPERATI ON OF
CHAP 2, SEC I I
MAI N TRANSMI SSI ON ASSEMBL Y
i s i n h e r e n t wi t h f l u i d d r i v e s a n d t or q u e
con v er ter s wi th ou t l ock u p.
10. I NPU T PRESSU RE AND SCAVENGE
OI L PUMP ASSEMBLY
a . Compon en ts (f i g. 373, f ol d-ou t 2)
(1 ) A 2 - s e ct i on , g e a r - t y p e p r e s -
s u r e a n d s ca v en ge oi l pu mp 45 i s l oca ted
on th e i n pu t tr a n s f er h ou s i n g. I t i s dr i v en
by th e i n pu t tr a n s f er gea r s a n d r ota tes a t
a n y t i me t h e v e h i cl e e n gi n e r ot a t e s . On e
s e ct i on i s t h e i n p u t p r e s s u r e p u mp . Th e
ot h e r (s ma l l e r ) s e ct i on i s t h e s ca v e n g e
pump. The assembl y i ncl udes a pump dr i ve
gea r 57, pu mp i dl er gea r 58, two s ca v en ge
pump gear s 55 and 56, pr essur e pump body
61, s ca v e n ge p u mp b od y 47, f ou r n e e d l e
bea r i n gs 53, 54, 59 a n d 60, a n d s epa r a tor
pl ate 50.
(2) Pu mp dr i v e gea r 57 a n d i dl er
gea r 58 a r e th e i n pu t pr es s u r e pu mp el e-
me n t s . Sca v e n ge p u mp ge a r 56 i s k e y e d
to th e s h aft of th e dr i v e gear 57 by k ey 51.
Gea r 55 i s mou n ted on s h a f t of gea r 58.
Th e dr i v e a n d dr i v en gea r s a r e s u ppor ted
i n th e pu mp bodi es 47 a n d 61. Sepa r a tor
pl ate 50 di vi des the pump secti ons.
b . Op e r a t i on
(1) Th e i n p u t p r e s s u r e s e ct i on of
the pump s uppl i es oi l under pr es s ur e to the
p ow e r t r a i n f or con t r ol , l u b r i ca t i on a n d
con v er ter ch a r gi n g. Th i s oi l i s pi ck ed u p
f r om t h e s u mp of t h e ma i n t r a n s mi s s i on
s e ct i on a n d p u mp e d i n t o t h e h y d r a u l i c
s y s tem, pa s s i n g f i r s t th r ou gh th e ma i n oi l
s cr een a s s embl y .
(2 ) Th e s ca v e n g e s e ct i on of t h e
p u mp p i ck s u p oi l wh i ch col l e ct s i n t h e
i n pu t tr a n s f er gea r h ou s i n g a n d con v er ter
hous i ng, and r etur ns i t to the s ump of the
ma i n tr a n s mi s s i on s ecti on . Th e s ou r ce of
thi s oi l i s l ubr i cati on of the i nput tr ansfer
gear s and bear i ngs.
(3 ) Th e p u mp a s s e mb l y r ot a t e s
a t a ppr ox i ma tel y 1.62 ti mes en gi n e s peed
and i n the same di r ecti on as the engi ne.
Secti on I I . DE SCRI PTI ON AND OPE RATI ON OF MAI N TRANSMI SSI ON ASSE MBL Y
11. H I GH -RAN GE CL U TCH AN D
GOVE RN OR
a . H i gh -r a n ge Cl u tch a n d Gov er n or
Compon en ts (f i g. 375, f ol d-ou t 4)
( 1 ) Th e h i g h - r a n g e c l u t c h i n -
cl u des a h ou s i n g a s s embl y 73, a pi s ton a s -
s e m b l y 6 7 , f ou r (X TG 4 1 1 - 2 A ) or f i v e
(XTG 411-4) pl a tes 57, f i v e pl a tes 56, r e-
a cti on pl a te 59, r etu r n s pr i n gs 66 a n d r e-
t a i n e r 65. Th e h i gh -r a n ge cl u t ch h u b i s
i n t e gr a l w i t h t h e i n t e r me d i a t e - r a n ge ca r -
r i e r a s s e mbl y 16 (f i g. 376, f ol d -ou t 5). A
gov er n or r i n g i s r i v eted or wel ded to th e
cl u tch h ou s i n g a s s embl y 73 (f i g. 375, f ol d-
out 4).
(2 ) Pi t ot t u b e 7 6 i s a g ov e r n or
compon en t. I t i s mou n ted by two bol ts 14
to tr ansmi ssi on housi ng 17. The hi gh-r ange
cl u tch an d gov er n or r i n g r otate.
b . Oper a ti on of H i gh -r a n ge Cl u tch
and Gov er nor (fi g. 375, fol d-out 4)
(1) Th e h i gh -r a n ge cl u t ch t r a n s -
mi ts tor qu e a t 1:1 r a ti o f r om th e con v er -
ter tu r bi n e s h a f t to th e h i gh -r a n ge cl u tch
h u b a n d , i n t u r n , t h r ou gh t h e l ow- a n d
i n ter medi a te-r a n ge pl a n eta r i es , wh i ch a r e
l ock ed togeth er , to th e tr a n s mi s s i on ou t-
pu t s h a f t. Wh en h y dr a u l i c pr es s u r e i s di -
r e ct e d t o t h e ca v i t y b e t w e e n p i s t on a s -
s e mbl y 67 a n d h ou s i n g a s s e mbl y 73, t h e
pi s ton compr es s es i n ter n a l -s pl i n ed 56 a n d
ex ter n a l -s pl i n ed 57 pl a tes a ga i n s t r ea cti on
pl a te 59. Th i s l ock s th e h i gh -r a n ge cl u tch
h u b (l oca t e d on t h e i n t e r me d i a t e - r a n g e
p l a n e t a r y ca r r i e r ) t o t h e cl u t ch h ou s i n g,
a n d t r a n s mi t s con v e r t e r ou t p u t t or q u e
di r ectl y to th e tr a n s mi s s i on r a n ge ou tpu t
s h a f t .
(2 ) Wh e n h y d r a u l i c p r e s s u r e i s
ex h a u s ted f r om th e cl u tch ca v i ty , s pr i n gs
Change 2 13
CHAP 2, SEC I I DESCRI PTI ON AND OPERATI ON OF PAR 11-13
MAI N TRANSMI SSI ON ASSEMBL Y
66 p u s h p i s t on a s s e mbl y 67 i n t o h ou s i n g
a s s embl y 73, a l l owi n g th e cl u tch pl a tes to
separ ate and sl i p fr eel y.
(3) Th e gov e r n or i s a f l u i d v e l o-
ci t y t y p e . Th e gov e r n or r i n g, r i v e t e d or
wel ded to the l eft end of hous i ng 73, i s k ept
f i l l e d w i t h oi l , r e t a i n e d i n t h e r i n g b y
ce n t r i f u ga l f or ce d u r i n g r ot a t i on . Th e oi l
th u s mov es a t v i r tu a l l y th e s a me s peed a s
d oe s t h e r i n g. Th e p i t ot t u b e 76 i s p os i -
t i on e d s o t h a t i t s op e n e n d f a ce s a ga i n s t
t h e mov e me n t of t h e oi l i n t h e gov e r n or
r i n g. Th e op p os i t e e n d of t h e p i t ot t u b e
con n e ct s w i t h t h e h y d r a u l i c con t r ol s y s -
t e m . Pr e s s u r e i n t h e gov e r n or l i n e t h u s
v ar i es wi th the s peed at whi ch oi l i s thr own
i nto the pi tot tube by the r otati ng r i ng.
12. I NTERMEDI ATE-RANGE CLUTCH
AN D PL AN E TARY GE ARI N G
a . I n t e r me d i a t e - r a n ge Cl u t ch
Compon en ts (f i g. 376, f ol d-ou t 5)
(1 ) I n t e r me d i a t e - r a n g e cl u t ch i n -
cl u d e s a cl u t ch h ou s i n g 3, f ou r i n t e r n a l -
s p l i n e d 4 a n d t h r e e e x t e r n a l - s p l i n e d 5
pl ates, appl y pl ate 7, spr i ng 8 pi ston 9 and
pi ston housi ng 14. Exter nal spl i nes on r i ng
gear assembl y 6 ser v e as the cl utch hub.
(2) Cl u tch h ou s i n g 3 i s a n ch or ed,
a ga i n s t r ota ti on , i n th e tr a n s mi s s i on h ou s -
i n g. Pl a t e s 5 a n d a p p l y p l a t e 7 e n ga ge
s l ots i n h ou s i n g 3. Pl a tes 4 en ga ge ex ter -
n a l s pl i n es on r i n g gea r a s s embl y 6. Pi s -
ton housi ng 14 i s anchor ed i n tr ansmi ssi on
h ou s i n g b y b ol t 42 (f i g. 375, f ol d -ou t 4).
Pi s ton 9 (f i g. 376, f ol d-ou t 5) wor k s i n a
bor e of housi ng 14 on r i ng seal s 11 and 12.
b .
(1 ) Th e l i n k a g e comp on e n t s b y
wh i ch th e s er v i ce a n d pa r k i n g ba k es a r e
a ppl i ed i n cl u de s pi n dl e a s s embl y 77, ca ge
a s s e mb l y 72, r i gh t -b r a k e a p p l y s h a f t 97,
l e f t - b r a k e a p p l y s h a f t 8 4 , r i g h t - b r a k e
a p p l y ca m a s s e mbl y 83, l e f t -br a k e a p p l y
ca m a s s e mbl y 75, s h a f t s 2 a n d 65, ca m
f ol l ower s 6 a n d 62, ca m f ol l ower l i n k s 3
and 60, l i nk assembl i es 10 and 69, adj ust-
i n g n u ts 20 (f i g. 378, f ol d-ou t 7) a n d 14
(f i g . 3 8 0 , f ol d - ou t 9 ), r a t ch e t s 2 1 (f i g .
378, f ol d-ou t 7) a n d 15 (f i g. 380, f ol d-ou t
9), spr i ngs 22 (fi g. 378, fol d-out 7) and 16
(f i g. 380, f ol d-ou t 9) a n d r eta i n er a s s em-
bl y 87 (fi g. 379, fol d-out 8).
(2) Retai ner assembl y 87, spi ndl e
assembl y 77 and cage assembl y 72 suppor t
br ak e appl y shafts 84 and 97 i n the tr ans-
mi s s i on r e a r h ou s i n g. Br a k e a p p l y ca m
a s s embl i es 75 a n d 83 a r e s pl i n ed to th ei r
r e s p e ct i v e b r a k e a p p l y s h a f t s . Ca m f ol -
l ower l i n k s 3 a n d 60 a r e pi v oted a t th ei r
upper ends on shafts 2 and 65, i nstal l ed i n
the tr ansmi ssi on r ear housi ng. Li nk assem-
bl i es 10 a n d 69 con n ect to th e l ower en ds
of t h e ca m f ol l ow e r l i n k s . Th e ca m f ol -
l ower s 6 and 62 r otate i n the cam fol l ower
l i n k s . Th e t h r e a d e d e n d s of l i n k a s s e m-
18 Change 2
PAR 18-19 DESCRI PTI ON AND OPERATI ON OF CHAP 2, SEC II
MAIN TRANSMISSION ASSEMBLY
bl i es 10 a n d 69 a r e i n s ta l l ed th r ou gh l u gs
on th e r ota ti n g br a k e a ppl y ca ms . Adj u s t-
i n g n u t s 20 (f i g. 378, f ol d -ou t 7) a n d 14
(f i g. 380, f ol d-ou t 9) a r e i n s ta l l ed on th e
thr eaded ends of l i nk assembl i es 10 and 69
(f i g . 3 7 9 , f ol d - ou t 8 ). Ra t ch e t s 2 1 (f i g .
378, f ol d-ou t 7) a n d 15 (f i g. 380, f ol d-ou t
9) ar e hel d i n engagement wi th the adj us t-
i ng nuts by spr i ngs 22 (fi g. 378, fol d-out 7)
a n d 16 (f i g. 380, f ol d -ou t 9), wa s h e r s 23
(fi g. 378, fol d-out 7) and 17 (fi g. 380, fol d-
ou t 9), a n d pi n s 24 (f i g. 378, f ol d-ou t 7)
and 18 (fi g. 380, fol d-out 9).
(3 ) Tw o a i r v a l v e p l a t e a s s e m-
bl i es 36 a n d 43 (f i g. 379, f ol d-ou t 8) a r e
pi v oted on pi n 45 i n br a ck et 40. Spr i n gs
39 and 42 hol d the val ves i n a cl osed posi -
ti on ov er passages i n the tr ansmi ssi on r ear
h ou s i n g w h e n t h e b r a k e s a r e m e c h -
an i cal l y appl i ed.
b. Oper a ti on (f i g. 379, f ol d-ou t 8)
(1 ) Wh e n e i t h e r of b r a k e a p p l y
s h a f t s 8 4 or 9 7 a r e r ot a t e d (cl ock w i s e
v i ewed f r om r i gh t of tr a n s mi s s i on ), br a k e
a ppl y ca m 75 or 83 mov es th e ca m f ol l ow-
er 6 or 62 a n d ca m f ol l ower l i n k 3 or 60
f or wa r d . L i n k a s s e mb l y 10 or 69, b e i n g
con n ected to th e ca m f ol l ower l i n k , mov es
f or wa r d . Th i s r ot a t e s t h e r ot a t i n g b r a k e
ca m cl ock wi s e, a ppl y i n g th e br a k e.
(2) Si mu l t a n e ou s wi t h r ot a t i on of
the br ak e cam to appl y pos i ti on, br ak e ai r
v a l v e 36 or 43 i s f or ced to cl os ed pos i ti on
by i ts s pr i ng. Note that the v al v es ar e hel d
open (u pwa r d) a ga i n s t s pr i n g pr es s u r e (by
th e br ak e cam ex ten s i on s ) wh en th e br ak es
a r e r e l e a s e d . Th e a i r v a l v e s con t r ol t h e
a dmi s s i on of a i r to th e i n ta k e s i de of th e
b r a k e cool a n t p u mp . Th u s , w h e n b r a k e s
a r e a ppl i ed, n o a i r i s a dmi tted a n d oi l i s
pu mped. Wh en br a k es a r e r el ea s ed, a i r i s
admi tted, pr ev enti ng the pumpi ng of oi l .
(3) Br a k e a d j u s t me n t i s ma d e b y
r ota ti n g th e br a k e a dj u s ti n g n u ts . A l a r ge
s cr ewdr i v er ca n be i n s er ted i n r a di a l s l ots
i n the nuts . The s pr i ng-l oaded r atchets r e-
tai n the nuts i n the posi ti on to whi ch they
ar e adj usted.
19. REL AY VAL VE BODY ASSEMBL Y
a . Compon en ts (f i g. 382, f ol d-ou t 11)
(1) Th e pu mp i s dr i v en by a gea r
s pl i n ed to th e l ow-r a n ge ca r r i er s h a f t a n d
i n mesh wi th gear 53 (fi g. 379, fol d-out 8),
wh i ch , i n t u r n , d r i v e s ge a r 49 (f i g. 384,
f ol d -ou t 13). Th e p u mp r ot a t e s a n y t i me
th e v eh i cl e mov es . Du r i n g f or wa r d mov e-
me n t , w h e n b r a k e s a r e r e l e a s e d , a i r i s
d r a w n i n t o t h e p u mp t h r ou g h op e n a i r
v al v es (r efer to par . 18b(2), abov e). Dur i ng
r ev er s e mov emen t (br a k es r el ea s ed), a i r i s
ex pel l ed thr ough the ai r v al v es .
(2) Wh en br a k es a r e a ppl i ed, th e
a i r v a l v e s a r e cl os e d . Th e p u mp t h e n
d r a w s oi l t h r ou g h ch e ck v a l v e w a s h e r
a s s e mb l y 6 7 . E a ch s e ct i on of t h e p u mp
t h e n d e l i v e r s oi l t o a b r a k e . Th e r i gh t
s ecti on s u ppl i es th e r i gh t br a k e; th e l ef t
secti on suppl i es the l eft br ak e.
25. OI L FI L TER AND SCREENS
a . Compon en ts (f i g. 373 a n d 374,
(1) Th e t r a n s mi s s i on l e f t ou t p u t
i s cou pl ed to th e s pl i n ed en d of s h a f t 39.
Sh a f t 39 r ot a t e s wi t h i n p i n i on a s s e mbl y
47. Th e ca r r i er i s s ta ti on a r y , ca u s i n g th e
pi n i on s to r otate i n a di r ecti on oppos i te to
th a t of s h a f t 39. Th e pi n i on s a r e i n mes h
wi th i n ter n a l gea r 23 wh i ch a l s o mu s t r o-
t a t e i n a d i r e ct i on op p os i t e t o t h a t of
s h a f t 39. Th e r ota ti on of i n ter n a l gea r 23
i s tr ansmi tted to output dr i v e shaft 4 and,
i n tur n, to the v ehi cl e tr ack s .
(2) Th e ou tpu t dr i v e th u s r ev er s es
th e di r ecti on of r ota ti on a v a i l a bl e a t th e
tr ans mi s s i on output. Speed r educti on wi th-
i n the output dr i ve i s 5.35:1.
27. L EFT-OU TPU T DRI VE ASSEMBL Y
a . C om p on e n t s (f i g . 3 8 5 , f ol d - ou t
14). Th e l ef t-ou tpu t dr i v e compon en ts a r e
i den ti cal to th os e of ti n e r i gh t-ou tpu t dr i v e
e x ce p t f or s h a f t 16 a n d s a d d l e 8. Th e s e
compon en ts a r e l on ger i n th e l ef t- ou tpu t
dr i v e.
b . Op e r a t i on (f i g. 385, f ol d -ou t 14).
Th e oper a ti on of th e l ef t-ou tpu t dr i v e a s -
sembl y i s i denti cal to the r i ght assembl y.
24 Change 2
P A R 2 8 - 3 0 OP E R AT I ON OF H Y DR AU L I C S Y S T E MS C H A P 2, S E C I V
Sect i on I V. OPERAT I ON OF HYDRAUL I C SYST EM
2 8 . PRE L I MI N ARY I N S TRU CTI ON S
a . H y d r a u l i c S c h e m a t i c s
(f i g s . 6 t h r ou g h 1 9 , a n d f i g . 3 7 2 -
f ol d - ou t 1 )
(1 ) Th e h y d r a u l i c s y s t e m , b e c a u s e of
i t s i mp or t a n ce t o t h e op e r a t i on of t h e p ow e r
t r a i n , s h ou l d b e ca r e f u l l y s t u d i e d a n d u n d e r -
s t ood . Th e r e a r e 1 4 p a r t i a l h y d r a u l i c s ch e -
ma ti cs i n col or (f i gs . 6 th r ou gh 19) a n d a f ol d-
ou t h y d r a u l i c s ch e ma t i c (f i g. 372). Th e col or -
e d s ch e ma t i cs s h ow p os i t i on s of v a l v e s a n d
mov i n g comp on e n t s , a n d t h e v a r i ou s h y d r a u l i c
ci r cu i t s a s i n d i ca t e d b y t h e ca p t i on s . Th e
f ol d -ou t s ch e ma t i c, i n b l a ck a n d wh i t e , s h ows
t h e e n t i r e h y d r a u l i c s y s t e m.
(2 ) H y d r a u l i c s ch e ma t i c v i e w s (f i g s . 6
th r ou gh 18) pa r a l l el th e tor qu e pa th s ch ema ti c
v i e ws (f i gs . 22 t h r ou gh 34) i n Se ct i on I I I of
t h i s ch a p t e r . Th e h y d r a u l i c s ch e ma t i c v i e w s
i l l u s t r a t e w h a t h a p p e n s h y d r a u l i ca l l y , w h i l e
th e tor qu e pa th s ch ema ti c v i ews i l l u s tr a te wh a t
happens mechani cal l y.
b . E x p l a n a t i on s of H y d r a u l i c S y s t e m
(1 ) I n t h e s ch e ma t i c v i e w s , a p a r t i cu -
l a r col or or col or v a r i a t i on i n f i gs . 6 t h r ou gh
18, i s con t i n u e d i n t h e s y s t e m u n t i l i t p a s s e s
th r ou gh a r egu l a tor or a n or i f i ce wh i ch ch a n ges
th e pr es s u r e of th e oi l .
(2) To a v oi d n e e d l e s s r e p e t i t i on , r e f e r -
e n ce s a r e ma d e t o i n i t i a l e x p l a n a t i on s . To
l i n k th e h y dr a u l i c a cti on wi th th e cor r es pon d-
i n g me ch a n i ca l a ct i on , r e f e r e n ce s a r e ma d e
t o t h e p a r a gr a p h s e x p l a i n i n g t h e me ch a n i ca l
a ct i on s .
2 9 . G E N E R A L I N F OR MA TI ON
a . Tor q u e C on v e r t e r a n d L ock u p Dr i v e .
R e g a r d l e s s of g e a r or s t e e r con d i t i on , d r i v e
f r om t h e v e h i cl e e n gi n e t o t h e r a n ge ge a r i n g
i s e i t h e r h y d r a u l i c (t or q u e con v e r t e r ) or me -
ch a n i ca l (l ock u p cl u t ch e n ga ge d ).
b . Tr a n s m i s s i o n O i l L e v e l s
(1) Th e h y d r a u l i c s y s t e m i s d e s i gn e d s o
th a t a f ter th e v eh i cl e en gi n e h a s been oper a t-
i n g a s h or t t i me , t wo d i s t i n ct oi l l e v e l s a r e
e s t a b l i s h e d i n t h e t r a n s mi s s i on . Th e oi l l e v e l
i n t h e t r a n s mi s s i on r e a r h ou s i n g i s comp a r a -
ti v el y l ow (f i g. 19). Th e oth er i s i n th e tr a n s -
mi s s i on s u mp , wh i ch s u r r ou n d s (bu t i s s e p a -
r a ted f r om) th e r a n ge gea r s ecti on i n th e ma i n
t r a n s mi s s i on h ou s i n g. Th e t wo l e v e l s gu a r a n -
t e e a s u f f i ci e n t oi l r e s e r v e , wh i l e ma i n t a i n i n g
t h e mos t e f f i ci e n t oi l l e v e l i n t h e op e r a t i n g
s e ct i on s of t h e t r a n s mi s s i on .
(2 ) Tw o oi l l e v e l s e x i s t b e c a u s e a i r
p u mp e d b y t h e s ca v e n g e p u mp i s d i s ch a r g e d
i n t o t h e t r a n s m i s s i o n r e a r h o u s i n g . Th i s
cr e a t e s a con s t a n t a i r p r e s s u r e on t h e oi l i n
t h i s h ou s i n g. Th e a i r p r e s s u r e f or ce s t h e oi l
l ev el down , pu s h i n g th e oi l i n to th e r es er v oi r ,
u n t i l a i r ca n e s ca p e i n t o t h e r e s e r v oi r . Th e
u pper a r ea s of th e i n pu t tr a n s f er h ou s i n g a n d
t h e ma i n t r a n s mi s s i on h ou s i n g a r e con n e ct e d .
A b r e a t h e r , l oca t e d n e a r t h e t op of t h e i n p u t
t r a n s f e r h ou s i n g, a l l ows a t mos p h e r i c p r e s s u r e
to be pr es en t i n th es e h ou s i n gs .
3 0 . H YDR AU L I C S YS TE M F U N C TI ON
N E U TR AL R AN G E (f i g . 6 )
N o t e . R e f e r t o p a r . 4 6 a n d f i g . 2 2
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
a . I n n e u t r a l r a n g e , m a i n p r e s s u r e i s
suppl i ed onl y by the i nput pr essur e pump (pump
n ot s h own i n f i g. 6; s e e f i g. 372, f ol d -ou t 1).
Th i s oi l i s di r ected to f ou r poi n ts a t a l l ti mes .
Th e s e p oi n t s a r e : t h e ma i n -p r e s s u r e r e gu l a t or
v a l v e, th e l ock u p cu tof f v a l v e, th e th r ottl e a n d
t h r ot t l e r e gu l a t or v a l v e s , a n d t h e s t e e r p r e s -
s u r e r egu l a tor v a l v e. Th i s pa r t of th e h y dr a u -
l i c ci r cu i t a l wa y s i s ch a r ge d wh e n t h e p owe r
t r a i n i s op e r a t i n g.
b . At t h e ma i n - p r e s s u r e r e gu l a t or v a l v e ,
oi l e n t e r s t h e v a l v e b or e a t t wo p oi n t s . Th e
u p p e r con n e ct i on d i r e ct s t h e oi l b e t w e e n t w o
of t h e v a l v e l a n d s . I t s u r r ou n d s t h e v a l v e
s tem a n d f l ows i n to h ol es dr i l l ed i n th e s tem,
w h i ch ca r r y t h e oi l t h r ou g h a s p r i n g - l oa d e d
b a l l ch e ck v a l v e t o t h e ca v i t y a b ov e t h e l a r ge
2 5
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6
PAR 30 DESCRI PTI ON AND OPERATI ON OF CHAP 2, SEC IV
RIGHT- AND LEFT-OUTPUT DRIVE ASSEMBLIES
t op l a n d . Pr e s s u r e i n t h i s ca v i t y p u s h e s
the v al v e downwar d agai nst a spr i ng at i ts
l ower en d. As th e v a l v e mov es down wa r d,
i t u n cov er s a por t wh i ch a dmi ts oi l to th e
l ock u p s h i f t v a l v e bor e. Wh en th e l ock u p
shi ft val ve i s hel d upwar d by i ts spr i ng, the
oi l f l ow s u n r e s t r i ct e d t o t h e t or q u e con -
v e r t e r a n d k e e p s i t ch a r ge d . Wh en th e
v a l v e i s i n th e down wa r d pos i ti on , f l ow to
t h e con v e r t e r i s l i mi t e d b y a n or i f i ce .
An oth er pa s s a ge i s bl ock ed by th e mi ddl e
l and of the l ock up shi ft v al v e.
c . Oi l e n t e r i n g t h e ma i n - p r e s s u r e
r e g u l a t or b or e a t t h e l ow e r con n e ct i on
fl ows i n to a cav i ty between th e two l ar ger
l ower l ands of ti ne v al v e. I f the oi l i s col d
or the s peed of the pump i s s uffi ci ent, the
oi l f l ow ma y e x ce e d t h e ca p a ci t y of t h e
con v e r t e r . Th e p r e s s u r e t h e n r i s e s a n d
ca u s e s t h e v a l v e t o mov e d ow n w a r d , u n -
cov er i n g a por t th r ou gh wh i ch pa r t of th e
fl ow exhausts to the sump.
d . Ma i n -p r e s s u r e r e gu l a t i on i n n e u -
t r a l (con v e r t e r op e r a t i on ) i s ma i n t a i n e d
on l y by th e compr es s i on of th e s pr i n gs a t
th e l ower en d of th e v a l v e. Sh ou l d en gi n e
s p e e d b e i n cr e a s e d s u f f i ci e n t l y t o ca u s e
l ock u p (i n cr ea s ed pi tot pr es s u r e f or ces th e
l ock u p s h i f t v a l v e down wa r d), ma i n pr es -
s u r e wou l d f l ow t o t h e l ock u p cl u t ch . At
th e s a me ti me, a br a n ch f r om th e l ock u p
cl u t ch l i n e d i r e ct s p r e s s u r e t o t h e a r e a
between th e top of th e l ock u p s h i f t v a l v e
a n d t h e b ot t om of t h e h i g h k n ock d ow n
pl u g. Th u s , i n n eu tr a l l ock u p, ma i n pr es -
s ur e i s l ower ed becaus e mor e oi l i s al l owed
t o e s ca p e i n t o t h e con v e r t e r f e e d l i n e
(and, i n some i nstances, to the sump).
e . At t h e l ock u p cu t of f v a l v e , oi l i s
d i r e ct e d t o t wo p oi n t s . On e p oi n t i s t h e
r i g h t e n d o f t h e v a l v e . Th e ot h e r i s
t h r ou gh a n or i f i ce (e a r l i e r mod e l s ; l a t e r
model s hav e no or i fi ce) to a pas s age whi ch
f eeds th e ma n u a l s el ector v a l v e. Wh en n o
s h i f t s a r e b e i n g ma d e , t h e l ock u p cu t of f
v al v e r emai ns i n the posi ti on shown. Fr om
th e l ock u p cu tof f v a l v e, ma i n pr es s u r e i s
d i r e ct e d t o t h e ma n u a l s e l e ct or v a l v e .
Th i s v a l v e i s i n n eu tr a l pos i ti on a n d does
n ot d i r e ct p r e s s u r e t o a n y of t h e r a n ge
cl u tch es . I t does , h owev er , di r ect pr es s u r e
to th e f i r s t, n eu tr a l a n d r ev er s e 1 s i gn a l
l i n e (t h r ou g h t h e h ol l ow ce n t e r of t h e
v a l v e). Pr es s u r e i n th e s i gn a l l i n e pu s h es
t h e d r i v e c l u t c h r e l a y v a l v e u p w a r d
a ga i n s t i ts s top, a l i n i n g th e h y dr a u l i c ci r -
cu i t f or d r i v e b y me a n s of t h e g e a r e d
s teer cl u tch es .
f . At th e th r ottl e a n d th r ottl e r egu -
l a tor v a l v es , ma i n pr es s u r e i s s u ppl i ed to
two poi n ts . Th e l ef t con n ecti on i s bl ock ed
a t cl os e d t h r ot t l e . Wh e n t h e t h r ot t l e i s
open ed, th e th r ottl e v al v e l ev er mov es th e
th r ottl e v a l v e to th e l ef t. Th e s pr i n g be-
tween th e th r ottl e v al v e an d th r ottl e r egu -
l ator v al v e tr ans mi ts thi s mov ement to the
th r ottl e r egu l a tor v a l v e. Wh en th e th r ottl e
r egu l ator v al v e mov es to th e l eft, a por t i s
u n cov er ed, a l l owi n g oi l to f l ow to th e TV
l i n e. A br a n ch of th e TV l i n e di r ects oi l ,
th r ou gh a n or i f i ce, to th e l ef t en d of th e
t h r ot t l e r e gu l a t or v a l v e w h e r e i t e x e r t s
s u f f i ci e n t p r e s s u r e t o ba l a n ce th e
compr es s i on of the TV s pr i ng and r egul ate
TV pr es s u r e. Th u s , th e gr ea ter th e mov e-
men t of th e th r ottl e v al v e to th e l eft, th e
g r e a t e r i s t h e c o m p r e s s i o n o f t h e TV
s pr i n g a n d, con s equ en tl y , th e gr ea ter th e
p r e s s u r e i n t h e TV l i n e . TV p r e s s u r e i s
di r ected to th e 10 l ower s i de of th e l ock u p
s h i f t v a l v e , wh e r e i t i n h i b i t s t h e i n i t i a l
down wa r d mov emen t of th e v a l v e.
g . Wh en th e l ock u p s h i f t v a l v e mov es
down wa r d a ga i n s t TV pr es s u r e f a r en ou gh
t o cl os e t h e TV p r e s s u r e p a s s a ge , i t n o
l on ger i s oppos ed by TV pr es s u r e (ex cept
at ful l thr ottl e, h , bel ow) a n d r a pi dl y com-
p l e t e s i t s d own wa r d s t r ok e . Th e ca v i t y
b e l ow t h e v a l v e e x h a u s t s t h r ou gh t h e T
pr es s u r e l i n e a n d a n or i f i ce s h own a bov e
th e th r ottl e v a l v e.
h . Wh e n t h e t h r ot t l e i s comp l e t e l y
open , th e th r ottl e v a l v e mov es f a r en ou gh
to th e l eft to u n cov er th e T pr es s u r e por t.
Change 2 27
CHAP 2, SEC IV DESCRI PTI ON AND OPERATI ON OF PAR 30
RIGHT- AND LEFT-OUTPUT DRIVE ASSEMBLIES
TV p r e s s u r e a t t h i s t i me i s a t ma x i mu m
a n d ca n f l ow i n to th e T pr es s u r e l i n e. T
p r e s s u r e i s con n e ct e d t o t h e a r e a b e l ow
th e l ock u p s h i f t v a l v e, a s i s TV pr es s u r e.
Th e e f f e ct of T p r e s s u r e i s t o d e l a y t h e
d own wa r d mov e me n t of t h e l ock u p s h i f t
v a l v e . Th u s , a t f u l l t h r ot t l e , g ov e r n or
(p i t ot ) p r e s s u r e mu s t b e h i gh e r t o ca u s e
l ock u p. H i gh er gov er n or pr es s u r e r equ i r es
hi gher tur bi ne shaft speed.
i . Th e ma i n p r e s s u r e l i n e e n t e r i n g
th e th r ottl e v al v e bor e at th e r i gh t h as n o
f u n ct i on .
j . A t t h e s t e e r p r e s s u r e r e g u l a t o r
v a l v e, ma i n pr es s u r e i s r edu ced a n d r egu -
l ated, an d pr odu ces s teer pr es s u r e.
N o t e : Th e pr es s u r e wh i ch a ppl i es
t h e ou t p u t cl u t ch e s , ge a r e d s t e e r
cl u tch es an d br ak es wh eth er for
s t e e r op e r a t i on or s t r a i gh t t r a v e l
i s a l w a y s d e s i g n a t e d "s t e e r
pressure ."
St e e r p r e s s u r e i s con s t a n t , r e ga r d l e s s of
fl uctuati ons i n mai n pr essur e.
k . St e e r p r e s s u r e i s d i r e ct e d t o t h e
s t e e r v a l v e s . I n n e u t r a l , i t s i mp l y f l ows
t h r ou gh p a s s a ge s s u r r ou n d i n g t h e s t e e r
v al v es , and i s di r ected by two dr i v e cl utch
f eed l i n es to th e dr i v e cl u tch r el a y v a l v e.
Th e dr i v e cl u tch r el a y v a l v e, h el d u pwa r d
by s i gn a l pr es s u r e, di r ects s teer pr es s u r e
t o t h e r i g h t - a n d l e f t - g e a r e d s t e e r
cl u t ch e s , Th e s e cl u t ch e s a r e t h e d r i v e
cl u t ch e s i n f i r s t ge a r . Th u s , i n n e u t r a l ,
t h e y a r e e n ga ge d a n d r e a d y t o t r a n s mi t
dr i v e when a shi ft i s made to fi r st gear .
1 . Gov e r n or (p i t ot ) p r e s s u r e i s p r o-
d u ce d i n a f l u i d v e l oci t y - t y p e gov e r n or .
Th i s con s i s t s of on l y t w o ma i n comp o-
n e n t s : a gov e r n or r i n g a n d a p i t ot t u b e .
The r i ng i s a r otati ng channel , open at i ts
i n n er ci r cu mf er en ce. I t i s a tta ch ed to th e
hi gh-r ange cl utch housi ng and r otates wi th
th e tu r bi n e ou tpu t s h a f t. Oi l i s con s ta n tl y
f ed to i t f r om th e l u br i ca ti on s y s tem a n d
centr i fugal for ce r etai ns the oi l . Ti ne pi tot
tu be i s L -s h a ped a n d i ts open en d i s i m-
me r s e d i n t h e oi l i n t h e gov e r n or r i n g.
The open end of the tube faces agai ns t the
r ot a t i on of t h e r i n g. Th e oi l , mov i n g a t
v i r t u a l l y t h e s a me s p e e d a s t h e r i n g, i s
th r own i n to th e pi tot tu be a n d i s di r ected
to th e top of th e l ock u p s h i f t v a l v e, th e
l eft end of the shi ft i nhi bi tor v al v e, and to
th e a r ea between th e l a n ds of th e l ock -u p
cu t of f v a l v e . G ov e r n or p r e s s u r e v a r i e s
wi th the s peed of the tur bi ne output s haft.
m . At t h e t op of t h e l ock u p s h i f t
v a l v e, gov er n or pr es s u r e pu s h es down wa r d
on th e v a l v e. At cl os ed th r ottl e con di ti on ,
p r e s s u r e s u f f i ci e n t t o ov e r come on l y t h e
l ock u p s h i f t v a l v e s p r i n g wi l l f or ce t h e
v a l v e d ow n w a r d . At p a r t t h r ot t l e con d i -
t i on , s p r i n g p r e s s u r e p l u s TV p r e s s u r e
(i n i t i a l l y ) m u s t b e ov e r c om e . A t f u l l
t h r ot t l e con d i t i on , s p r i n g p r e s s u r e p l u s
maxi mum TV pr essur e and T pr essur e must
b e ov e r come .
n . At t h e s h i f t i n h i b i t or v a l v e , gov -
er n or pr es s u r e pu s h es th e v al v e towar d th e
r i gh t. A s p r i n g r e s i s t s t h i s mov e me n t .
Wh en gov er n or pr es s u r e i s s u f f i ci en t, th e
r i gh t en d of th e i n h i bi tor pl u n ger wi l l be
p u s h e d a ga i n s t t h e l on ge s t p r oj e ct i on on
t h e ma n u a l s e l e ct or v a l v e l e v e r . I n n e u -
tr al , thi s i s not si gni fi cant.
o . At th e l ock u p cu tof f v a l v e, gov er -
n or p r e s s u r e i s b l ock e d e x ce p t f or b r i e f
i n ter v a l s du r i n g s h i f ti n g. Wh en s h i f ts a r e
m a d e , t h e l o c k u p c u t o f f v a l v e m o v e s
r a pi dl y to th e l ef t a n d ex h a u s ts gov er n or
pr es s u r e to th e s u mp. Th i s des tr oy s gov er -
n or pr es s u r e a n d a l l ows th e l ock u p s h i f t
v a l v e, i f down wa r d, to mov e u pwa r d a n d
r e l e a s e t h e l ock u p cl u t ch . Th i s f e a t u r e
en s u r es th a t th e l ock u p cl u tch wi l l be r e-
l eas ed ev er y ti me a r an ge cl u tch en gages .
p . Oi l r etu r n i n g f r om th e tor qu e con -
v e r t e r p a s s e s t h r ou gh a n (e x t e r n a l ) oi l
cool er a n d f l ows i n to th e a r ea a bov e th e
28 Change 2
PAR 30-31 DESCRI PTI ON AND OPERATI ON OF CHAP 2, SEC IV
RIGHT- AND LEFT-OUTPUT DRIVE ASSEMBLIES
l u b r i ca t i on r e gu l a t or v a l v e . Th e p r e s s u r e
ma i n t a i n e d a t t h i s p oi n t i s s u f f i ci e n t t o
b a l a n ce t h e comp r e s s i on of t h e s p r i n g
p u s h i n g t h e v a l v e u p wa r d . Th i s p r e s s u r e
for ces oi l thr ough the l ubr i cati on passages.
Oi l f l ow i n e x ce s s of l u b r i ca t i on r e q u i r e -
men ts r etu r n s to th e s u mp th r ou gh a n ex -
h a u s t por t a t th e r i gh t s i de of th e v a l v e
b or e .
31. H YDRAU L I C SYSTE M F U N CTI ON
FI RST GEAR (fi g. 7)
N o t e : Refer to par . 47 and fi g. 23
f or t h e t or q u e p a t h t h r ou gh t h e
power tr a i n .
a . F u n ct i on s i n f i r s t g e a r a r e t h e
same as those descr i bed for neutr al i n par .
3 0 , a b ov e , e x c e p t t h a t t h e l o w - r a n g e
c l u t c h i s e n g a g e d a n d t h e v e h i c l e i s
mov i n g.
b . Wh en th e ma n u a l s el ector v a l v e i s
mov ed to f i r s t gea r pos i ti on , a por t i s u n -
cov e r e d wh i ch d i r e ct s ma i n p r e s s u r e t o
t h e l ow - r a n g e cl u t ch Mov e me n t of t h e
ma n u a l s el ector v a l v e l ev er pu ts a l u g on
the l ev er i n a posi ti on whi ch wi l l al l ow the
s h i f t i n h i b i t or p l u n g e r t o e x t e n d a n d
pr ev en t s h i f ti n g to n eu tr a l or r ev er s e a t
h i gh er s peeds .
c . Wh e n t h e v e h i cl e i s mov i n g f or -
wa r d wi th th e br a k es r el ea s ed, th e br a k e
a i r v a l v e s (t e x t con t i n u e s on p a g e 3 1 )
Change 2 28.1/(28.2 blank)
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PAR 3 1 - 3 4 OP E R AT I ON OF H Y DR AU L I C S Y S T E MS CHAP 2, SEC I V
a r e op e n . Th e b r a k e cool a n t p u mp i s op e r a t -
i ng but ai r i s bei ng dr awn thr ough the open ai r
v al v es an d di r ected to th e br ak es . I f th e br ak es
a r e a p p l i e d (e x ce p t h y d r a u l i ca l l y i n s t e e r i n g),
th e a i r v a l v es cl os e a n d oi l i s dr a wn f r om th e
s u mp , t h r ou gh ch e ck v a l v e s , a n d d e l i v e r e d t o
t h e b r a k e p l a t e s .
d . F i g . 7 i l l u s t r a t e s p a r t i a l op e n i n g of
th e th r ottl e wh i ch pr odu ces TV pr es s u r e a t th e
t h r ot t l e r e gu l a t or v a l v e . Re f e r t o p a r . 30f , g ,
h , and i , a b ov e , f or a comp l e t e e x p l a n a t i on of
th e f u n cti on of th e th r ottl e a n d th r ottl e r egu -
l a t or v a l v e s .
32. H Y DR A U L I C S Y S TE M F U N C TI ON -
SE CON D GE AR (f i g. 8)
N o t e . R e f e r t o p a r . 4 8 a n d f i g . 2 4
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
a . Th e f u n ct i on of t h e h y d r a u l i c s y s t e m
i n s e con d g e a r i s t h e s a me a s t h a t i n f i r s t
gea r ex cept th a t dr i v e to th e power tr a i n ou t-
pu ts i s th r ou gh th e ou tpu t cl u tch es r a th er th a n
t h r ou gh t h e ge a r e d s t e e r cl u t ch e s .
b . Wh e n t h e m a n u a l s e l e c t or v a l v e i s
s h i f t e d t o t h e s e con d ge a r p os i t i on , t h e l ow -
r a n ge cl u tch i s en ga ged bu t n o s i gn a l pr es s u r e
i s p r e s e n t . Be ca u s e n o s i gn a l p r e s s u r e e x i s t s ,
th e dr i v e cl u tch r el a y v a l v e i s h el d down wa r d
by th e s pr i n g a t i ts u pper en d. Th i s a l i n es th e
h y d r a u l i c s y s t e m t o d i r e ct s t e e r p r e s s u r e t o
th e r i gh t- a n d l ef t -ou tpu t cl u tch es .
c . Fi g. 8 i l l u s tr a tes th e l ock u p s h i f t v a l v e
i n i ts down wa r d pos i ti on a n d s h ows ma i n pr es -
s u r e a p p l y i n g t h e l o c k u p c l u t c h . N o t e t h e
b r a n ch of t h e l ock u p cl u t ch l i n e t h a t d i r e ct s
p r e s s u r e t o t h e t o p o f t h e m a i n - p r e s s u r e
r e gu l a t or v a l v e . Down wa r d mov e me n t of t h e
v a l v e ex h a u s ts oi l to th e s u mp, r edu ci n g ma i n
p r e s s u r e .
N o t e . I f pu mp s peed i s n ot s u f f i ci en t
to pr ov i de a l a r ger v ol u me of oi l th a n
th a t f l owi n g to th e con v er ter a n d l os t
b y l e a k a ge , t h e ma i n - p r e s s u r e r e gu -
l a t or v a l v e ma y n ot mov e d ow n w a r d
s u f f i ci e n t l y t o e x h a u s t oi l .
d . At h i g h e r s p e e d s , t h e s h i f t i n h i b i t or
p l u n ge r i s e x t e n d e d a n d p r e v e n t s s h i f t i n g t o
f i r s t , n e u t r a l or r e v e r s e g e a r s .
3 3 . H YDR AU L I C S YS TE M F U N C TI ON -
TH I RD GE AR (f i g. 9)
N o t e . R e f e r t o p a r . 4 9 a n d f i g . 2 5
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
a . I n t h i r d g e a r , t h e h y d r a u l i c s y s t e m
op e r a t e s a s i n s e con d ge a r e x ce p t t h a t ma i n
p r e s s u r e a p p l i e s t h e i n t e r me d i a t e - r a n ge cl u t ch
a n d t h a t r e v e r s e 2 , t h i r d a n d f ou r t h s i g n a l
p r e s s u r e i s d i r e ct e d t o t h e l ow e r e n d of t h e
s t e e r r e l a y v a l v e .
b . Wh e n t h e ma n u a l s e l e ct or v a l v e i s i n
t h i r d - g e a r p os i t i on , t h e i n t e r me d i a t e - r a n g e
cl u t ch i s ch a r ge d a n d s i gn a l p r e s s u r e i s d i -
r e ct e d t o t h e s t e e r r e l a y v a l v e . Si gn a l p r e s -
s u r e p u s h e s t h e v a l v e u p wa r d a ga i n s t s p r i n g
p r e s s u r e a n d a 1 i n e s t h e s t e e r c i r c u i t f o r
g e a r e d s t e e r .
c . At h i g h e r s p e e d s , t h e s h i f t i n h i b i t or
p l u n ge r wi 11 e x t e n d a n d p r e v e n t s h i f t i n g t o
l ow e r ge a r s , n e u t r a l a n d r e v e r s e ge a r s .
3 4 . H YDR AU L I C S YS TE M F U N C TI ON
F OU RTH GE AR (f i g. 10)
N o t e . R e f e r t o p a r . 5 0 a n d f i g . 2 6
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
a . C on d i t i on s i n t h e h y d r a u l i c s y s t e m
d u r i n g f ou r t h - ge a r op e r a t i on a r e t h e s a me a s
i n th i r d gea r ex cept th a t th e h i gh -r a n ge cl u tch
i s e n ga ge d i n s t e a d of t h e i n t e r me d i a t e -r a n ge
cl u t ch . Th e on l y v a l v e a t a d i f f e r e n t p os i t i on
i s t h e ma n u a l s e l e ct or v a l v e .
b . Wh e n i n t h e f ou r t h ge a r p os i t i on , t h e
ma n u a l s e l e ct or v a l v e l e v e r w i l l p e r mi t t h e
s h i f t i n h i b i t or p l u n g e r t o e x t e n d , a t h i g h e r
s p e e d s , a n d b l ock a n y s h i f t f r om f ou r t h ge a r .
c. F u l l - t h r ot t l e op e n i n g i s i l l u s t r a t e d ,
s h owi n g h ow both T a n d TV pr es s u r es a r e pr o-
du ced. Note th a t T pr es s u r e i s equ a l to ma x i -
mu m TV p r e s s u r e b u t t h a t T p r e s s u r e i s d i -
r e ct e d t o a d i f f e r e n t a r e a .
3 1
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PAR 3 4 - 3 7
OP E R AT I ON OF H Y DR AU L I C S Y S T E MS CHAP 2, SEC I V
d . I n f ou r t h g e a r , ma i n p r e s s u r e i s d i -
r ected to th e top of th e h i gh k n ock down pl u g.
Pr es s u r e a t th i s poi n t pu s h es th e h i gh k n ock -
d own p 1u g d own wa r d a ga i n s t t h e t op of t h e
ma i n - p r e s s u r e r e g u l a t or v a l v e . Th e r e i s n o
e f f e ct on ma i n p r e s s u r e w h e n l ock u p i s e n -
g a g e d b e ca u s e l ock u p a p p l y p r e s s u r e (ma i n )
i s a l r e a d y e x e r t i n g a n e q u a l d own wa r d f or ce
on t h e ma i n - p r e s s u r e r e g u l a t or v a l v e . H ow -
e v e r , i f t h e l ock u p cl u t ch s h ou l d d i s e n g a g e ,
th e h i gh k n ock down pl u g wou l d con ti n u e to pu s h
downward on the mai n-pressure regul ator
v a l v e . Th u s , ma i n p r e s s u r e i s t h e s a me i n
f ou r t h g e a r w h e t h e r op e r a t i on i s l ock u p or
con v er ter . Th i s i s th e on l y gea r i n wh i ch th i s
i s t r u e . I n a l l ot h e r ge a r s , l ock u p op e r a t i on
ca u s e s a l ow e r i n g of ma i n p r e s s u r e .
3 5 . H YDR AU L I C S YS TE M F U N C TI ON
RE VE RSE 1 GE AR (f i g. 11)
N o t e . R e f e r t o p a r . 5 1 a n d f i g . 2 7
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
a . H y d r a u l i c s y s t e m con d i t i on s i n r e -
v e r s e 1 g e a r a r e t h e s a me a s d e s cr i b e d f or
n e u t r a l i n p a r . 30, a b ov e , a n d i l l u s t r a t e d i n
f i g. 6, e x ce p t t h a t t h e r e v e r s e - r a n ge cl u t ch i s
en ga ged a n d th e v eh i cl e i s mov i n g i n r ev er s e.
b . Wh e n t h e ma n u a l s e l e ct or v a l v e i s i n
r e v e r s e 1 p os i t i on , t h e r e v e r s e - r a n g e cl u t ch
i s e n ga ge d a n d a b r a n ch of t h e cl u t ch a p p l y
l i n e di r ects ma i n pr es s u r e to th e l ower en d of
t h e r e gu l a t or p l u g. Th i s p r e s s u r e p u s h e s u p -
w a r d on t h e r e g u l a t or p l u g w h i ch , i n t u r n ,
pu s h es u pwa r d on th e ma i n -pr es s u r e r egu l a tor
v a l v e . Th u s , t h e p l u gs u p wa r d f or ce a s s i s t s
th e r egu l a tor v a l v e s pr i n gs a n d i n cr ea s es ma i n
p r e s s u r e .
c . At h i g h e r s p e e d s , t h e s h i f t i n h i b i t or
p l u n g e r w i 1 1 e x t e n d a n d b l ock a n y s h i f t t o
n e u t r a l or a f or w a r d ge a r .
d . I n r e v e r s e g e a r , t h e b r a k e c o o l a n t
p u mp r ot a t e s i n a r e v e r s e d i r e ct i on . Th u s ,
n o br a k e cool a n t ca n be pu mped.
3 6 . H YDR AU L I C S YS TE M F U N C TI ON
REVERSE 2 GEAR (f i g. 12)
N o t e . R e f e r t o p a r . 5 2 a n d f i g . 2 8
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
a . H y d r a u l i c s y s t e m con d i t i on s i n r e -
v er s e 2 gea r a r e th e s a me a s th os e f or r ev er s e
1 gear ex cept th at th e power tr ai n ou tpu t dr i v e
i s t h r ou g h t h e ou t p u t cl u t ch e s r a t h e r t h a n
t h r ou gh t h e ge a r e d s t e e r cl u t ch e s .
b . I n r e v e r s e 2 ge a r , n o s i gn a l p r e s s u r e
e x i s t s u n d e r t h e d r i v e c l u t c h r e l a y v a l v e .
Sp r i n g p r e s s u r e h ol d s t h e v a l v e d ow n w a r d , i n
w h i ch p os i t i on s t e e r p r e s s u r e i s d i r e ct e d t o
t h e r i g h t - a n d l e f t - ou t p u t cl u t ch e s . R e v e r s e
2, th i r d a n d f ou r th s i gn a l pr es s u r e i s di r ected
to th e l ower s i de of th e s teer r el a y v a l v e. Th i s
p u s h e s t h e v a l v e u p wa r d a ga i n s t s p r i n g p r e s -
s u r e a n d a l i n e s t h e s t e e r ci r cu i t f or g e a r e d
s t e e r .
3 7 . H YDR AU L I C S YS TE M F U N C TI ON -
L OW R AN G E , S TE E R
a . F i r s t G e a r , F u l l - r i g h t S t e e r
(f i g . 1 3 )
N o t e . R e f e r t o p a r . 5 3 a n d f i g . 2 9
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
(1) Th e h y dr a u l i c s y s tem wi l l f u n cti on i n
f i r s t - g e a r s t e e r i n t h e s a me ma n n e r a s d e -
s cr i b e d f or f i r s t - ge a r s t r a i gh t t r a v e l i n p a r .
31, a bov e, ex cept f or th e pos i ti on of th e s teer
v a l v es a n d th e f l ow of oi l to th e dr i v e cl u tch es
a n d b r a k e s .
(2) I n r i gh t s teer , th e s teer con tr ol s h a f t
i s r ot a t e d cl ock wi s e . Th i s r ot a t i on mov e s t h e
r i gh t- s teer v a l v e down wa r d wh i l e th e l ef t-s teer
v a l v e m o v e s u p w a r d . Th e d o w n w a r d m o v e -
me n t of t h e r i gh t -s t e e r v a l v e b l ock s t h e f l ow
of s t e e r p r e s s u r e (i n t h e u p p e r p a s s a ge ), p r e -
v e n t i n g i t s b e i n g d i r e ct e d t o t h e r i gh t -d r i v e
cl u t ch f e e d l i n e . I n t h e l owe r s t e e r p r e s s u r e
p a s s a g e , a p o r t i s u n c o v e r e d w h i c h a l l o w s
s t e e r p r e s s u r e t o e n t e r t h e s t e e r r e g u l a t or
v a l v e b or e a n d t o f l ow t o t h e r i gh t - s t e e r f e e d
l i n e. Th e pr es s u r e i n th e r i gh t-s teer f eed l i n e
i s r egu l a ted by th e a cti on of th e l ower pa r t of
t h e s t e e r v a l v e a s s e mb l y . Wh e n s t e e r p r e s -
sure enters the ri ght-steer val ve bore, i t
e x e r t s a n u p w a r d p r e s s u r e on t h e s t e e r r e gu -
l a t or v a l v e . U p w a r d mov e me n t of t h e s t e e r
r e gu l a t or v a l v e t h r ot t l e s t h e i n -f l ow of s t e e r
p r e s s u r e . Thus, the degree of downward
mov e me n t of a s t e e r v a l v e d e t e r mi n e s s t e e r
3 5
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CHAP 2, SEC I V OP E R AT I ON OF H Y DR AU L I C S Y S T E MS PAR 3 7
f e e d p r e s s u r e . Ma x i mu m d own wa r d mov e me n t
w i l l p r od u ce ma x i mu m s t e e r f e e d p r e s s u r e .
(3 ) R i g h t - s t e e r f e e d p r e s s u r e f l ow s t o
t h e s t e e r r e l a y v a l v e wh i ch d i r e ct s i t t o t h e
r i gh t b r a k e . Th e cl u tch -br a k e meth od i s u s ed
f or f i r s t -ge a r s t e e r . I n r i gh t s t e e r , t h e r i gh t
b r a k e i s a p p l i e d . F u l l - r i g h t s t e e r s t op s t h e
r i gh t ou t p u t of t h e p owe r t r a i n . Pa r t i a l -r i gh t
s teer s l ows th e r i gh t ou tpu t.
(4) U p wa r d mov e me n t of t h e l e f t -s t e e r
v a l v e does n ot i n ter r u pt th e f l ow of s teer pr es -
sure to the l eft-dri ve cl utch (geared steer
c l u t c h ). Th i s u p w a r d m o v e m e n t , h o w e v e r ,
d oe s op e n a p a s s a g e t h r ou g h w h i ch oi l ca n
f l ow, t h r ou gh a n or i f i ce , t o t h e s t e e r cool a n t
f e e d l i n e . Th e s t e e r cool a n t f e e d l i n e ca r r i e s
oi l to th e s teer r el ay v al v e, wh er e i t i s s en t to
th e r i gh t br a k e, th r ou gh th e cl u tch -br a k e s teer
cool a n t l i n e .
(5 ) A b a l l - t y p e ch e ck v a l v e i s l oca t e d
between ea ch of th e s teer f eed l i n es a n d s teer
c o o l a n t f e e d l i n e s . Th e u p p e r c h e c k v a l v e
op e n s w h e n t h e a p p l i ca t i on of r i gh t s t e e r i s
di s con ti n u ed, a n d a l l ows th e br a k e a ppl y pr es -
s u r e to ex h a u s t th r ou gh th e cl u tch -br a k e s teer
cool a n t l i n e .
(6) I n r i ght s teer i n fi r s t gear , the r i ght-
d r i v e cl u t ch (ge a r e d s t e e r cl u t ch ) i s r e l e a s e d ,
th e r i gh t br a k e i s a ppl i ed a n d cool ed, a n d th e
l e f t - d r i v e cl u t ch (ge a r e d s t e e r cl u t ch ) r e ma i n s
en ga ged a n d con ti n u es to dr i v e.
b . S e con d G e a r , F u l l - l e f t S t e e r
(f i g . 1 4 )
N o t e . R e f e r t o p a r . 5 4 a n d f i g . 3 0
for th e tor qu e path th r ou gh th e power
t r a i n .
(1) Th e h y d r a u l i c s y s t e m wi l l f u n ct i on
i n s e con d ge a r s t e e r i n t h e s a me ma n n e r a s
d e s cr i b e d f or s e con d - g e a r s t r a i g h t t r a v e l i n
p a r . 32, a b ov e , e x ce p t f or t h e p os i t i on of t h e
s t e e r v a l v e s a n d t h e f l ow of oi l t o t h e d r i v e
cl u t ch e s a n d b r a k e s .
(2) I n l ef t s teer , th e s teer con tr ol s h a f t
i s r o t a t e d c o u n t e r c l o c k w i s e . Th i s r o t a t i o n
mov es th e r i gh t- s teer v a l v e u pwa r d wh i l e, th e
l e f t -s t e e r v a l v e mov e s d ow n w a r d . F l ow t o t h e
l e f t -d r i v e cl u t ch (ou t p u t cl u t ch ) i s b l ock e d . A
r e gu l a t e d s t e e r f e e d p r e s s u r e i s s e n t t o t h e
s teer r el a y v a l v e. Th e s teer r el a y v a l v e s en ds
oi l t o t h e l e f t b r a k e t h r ou g h t h e l e f t - b r a k e
a p p l y l i n e .
(3 ) Th e f l ow t o t h e r i g h t - d r i v e cl u t ch
(output cl utch) i s not i nter r upted and the cl utch
con ti n u es to dr i v e th e r i gh t ou tpu t. Th e r i gh t-
s t e e r v a l v e s u p p l i e s s t e e r cool a n t f e e d t o t h e
l e f t b r a k e . Th e l e f t - b r a k e a p p l y p r e s s u r e ca n
ex h au s t th r ou gh th e l ower ch eck v al v e (between
s teer feed an d s teer cool an t feed l i n es ) an d th e
cl u t ch - b r a k e s t e e r cool a n t l i n e , w h e n a p p l i ca -
t i on of s t e e r i s d i s con t i n u e d .
3 8 . H YDR AU L I C S YS TE M F U N C TI ON
TH I RD AN D F OU RTH GE ARS, STE E R
a . Th i r d G e a r , F u l l - r i g h t S t e e r
(f i g . 1 5 )
N o t e . Re f e r t o p a r . 55 a n d f i g. 31
for th e tor qu e path th r ou gh th e power
t r a i n .
(1) Th e h y d r a u l i c s y s t e m wi l l f u n ct i on
i n th i r d-gea r s teer i n th e s a me ma n n er a s de-
s cr i bed i n pa r . 33, a bov e, ex cept f or th e pos i -
ti on of th e s teer v a l v es a n d th e f l ow of oi l to
t h e d r i v e cl u t ch e s a n d s t e e r cl u t ch e s .
(2 ) Dow n w a r d mov e me n t of t h e r i g h t -
s t e e r v a l v e a n d t h e r e s u l t i n g oi l f l ow i s d e -
s cr i b e d i n p a r . 37a (2), a b ov e .
(3 ) R i g h t - s t e e r f e e d p r e s s u r e f l ow s t o
t h e s t e e r r e l a y v a l v e wh i ch d i r e ct s i t t o t h e
r i gh t- gea r ed s teer cl u tch , th r ou gh th e gea r ed
s t e e r c l u t c h a p p l y l i n e . Th e g e a r e d s t e e r
me t h od i s u s e d i n t h i r d -ge a r s t e e r . I n r i gh t
s teer , th e r i gh t-gea r ed s teer cl u tch i s a ppl i ed.
F u l l -r i gh t s t e e r f u l l y a p p l i e s t h e s t e e r cl u t ch
s o th a t n o s l i ppa ge occu r s . Pa r ti a l -r i gh t s teer
a l l ow s t h e s t e e r cl u t ch t o s l i p s ome w h a t .
(4) U p wa r d mov e me n t of t h e l e f t -s t e e r
v al v e does n ot i n ter r u pt th e fl ow of s teer pr es -
s u r e t o t h e l e f t - d r i v e cl u t ch (ou t p u t cl u t ch ).
Th i s u p w a r d mov e me n t , h ow e v e r , d oe s op e n
a pa s s a ge th r ou gh wh i ch oi l ca n f l ow, th r ou gh
a n or i f i ce, to th e s teer cool a n t f eed l i n e. Th e
s teer cool a n t f eed l i n e ca r r i es oi l to th e s teer
3 8
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8
PAR 3 8 - 3 9 OP E R AT I ON OF H Y DR AU L I C S Y S T E MS CHAP 2, SEC I V
r el a y v a l v e, wh er e i t i s s en t to th e r i gh t-gea r -
ed steer cl utch, through the geared steer
cool a n t l i n e .
(5) Th e r i gh t - ge a r e d s t e e r cl u t ch i s e x -
h a u s t e d , a f t e r u s e , t h r ou g h t h e b a l l ch e ck
v a l v e (u p p e r ) l oca t e d b e t w e e n t h e s t e e r f e e d
a n d s t e e r cool a n t f e e d l i n e s .
(6 ) I n r i g h t s t e e r i n t h i r d g e a r , t h e
r i gh t - d r i v e cl u t ch (ou t p u t cl u t ch ) i s r e l e a s e d ,
t h e r i gh t - ge a r e d s t e e r cl u t ch i s e n ga ge d a n d
s u ppl i ed wi th cool a n t, a n d th e l ef t-dr i v e cl u tch
(ou t p u t cl u t ch ) i s e n g a g e d a n d con t i n u e s t o
d r i v e .
b . F ou r t h Ge a r , F u l l - l e f t St e e r (f i g. 16)
N o t e . R e f e r t o p a r . 5 6 a n d f i g . 3 2
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
(1 ) Th e h y d r a u l i c s y s t e m w i l l f u n ct i on
i n f ou r t h ge a r s t e e r i n t h e s a me ma n n e r a s
d e s cr i b e d f or f ou r t h g e a r s t r a i g h t t r a v e l i n
p a r . 34, a b ov e , e x ce p t f or t h e p os i t i on of t h e
s t e e r v a l v e s a n d t h e f l ow of oi l t o t h e d r i v e
cl u t ch e s a n d s t e e r cl u t ch e s .
(2) I n l ef t s teer , th e s teer con tr ol s h a f t
i s r o t a t e d c o u n t e r c l o c k w i s e . Th i s r o t a t i o n
mov e s t h e r i gh t -s t e e r v a l v e u p wa r d wh i l e t h e
l e f t -s t e e r v a l v e mov e s d ow n w a r d . F l ow t o t h e
l e f t -d r i v e cl u t ch (ou t p u t cl u t ch ) i s b l ock e d . A
r e g u l a t e d s t e e r f e e d p r e s s u r e i s s e n t t o t h e
s teer r el a y v a l v e. Th e s teer r el a y v a l v e s en ds
oi l to th e l ef t-gea r ed s teer cl u tch , th r ou gh th e
l e f t - ge a r e d s t e e r cl u t ch a p p l y l i n e .
(3 ) Th e f l ow t o t h e r i g h t - d r i v e cl u t ch
(output cl utch) i s not i nter r upted and the cl utch
con ti n u es to dr i v e th e r i gh t ou tpu t. Th e r i gh t-
s teer v a l v e s u ppl i es s teer cool a n t f eed to l ef t-
g e a r e d s t e e r cl u t ch . Th e l e f t - g e a r e d s t e e r
cl u tch a ppl y pr es s u r e ca n ex h a u s t th r ou gh th e
l ow e r ch e ck v a l v e (b e t w e e n s t e e r f e e d a n d
s t e e r cool a n t f e e d l i n e s ) a n d t h e ge a r e d s t e e r
cool a n t l i n e , wh e n a p p l i ca t i on of s t e e r i s d i s -
con t i n u e d .
3 9 . H YDR AU L I C S YS TE M F U N C TI ON -
R E V E R S E R A N G E , S TE E R
a . R e v e r s e 1 G e a r , F u l l - r i g h t S t e e r
(f i g . 1 7 )
N ot e . R e f e r t o p a r . 5 7 a n d f i g . 3 3
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
(1 ) Th e h y d r a u l i c s y s t e m w i l l f u n ct i on
i n r e v e r s e 1 - g e a r s t e e r i n t h e s a me ma n n e r
a s d e s cr i b e d f or r e v e r s e l - ge a r s t r a i gh t t r a v e l
i n p a r . 35, a b ov e , e x ce p t f or t h e p os i t i on of
th e s teer v al v es an d th e fl ow of oi l to th e dr i v e
cl u t ch e s a n d b r a k e s .
(2 ) R e f e r t o p a r . 3 7 a (2 ) t h r o u g h (5 ),
a bov e, f or a n ex pl a n a ti on of th e f u n cti on of th e
s teer v a l v es a n d oi l f l ow to th e dr i v e cl u tch es
a n d b r a k e s .
(3) I n r e v e r s e 1 ge a r , r i gh t s t e e r , t h e
r i gh t - d r i v e cl u t ch (ge a r e d s t e e r cl u t ch ) i s r e -
l ea s ed, th e r i gh t br a k e i s a ppl i ed a n d s u ppl i ed
wi th cool a n t, a n d th e l ef t-dr i v e cl u tch (gea r ed
s teer cl u tch ) con ti n u es to dr i v e th e l ef t-ou tpu t.
b . R e v e r s e 2 G e a r , F u l l - l e f t S t e e r
(f i g . 1 8 )
N o t e . R e f e r t o p a r . 5 8 a n d f i g . 3 4
f or th e tor qu e pa th th r ou gh th e power
t r a i n .
(1) Th e h y dr a u l i c s y s tem wi l l f u n cti on i n g
r e v e r s e 2 - g e a r s t e e r i n t h e s a me ma n n e r a s
d e s cr i b e d f or r e v e r s e 2 - g e a r s t r a i g h t t r a v e l
i n p a r . 36, a b ov e , e x ce p t f or t h e p os i t i on of
the steer val ves and oi l fl ow to the dri ve
cl u t ch e s (ou t p u t cl u t ch e s ) a n d g e a r e d s t e e r
cl u t ch e s .
(2) Re f e r t o p a r . 38b (2) a n d (3), a b ov e ,
f or a n ex pl a n a ti on of th e f u n cti on of th e s teer
v a l v e s a n d oi l f l ow t o t h e d r i v e cl u t ch e s a n d
g e a r e d s t e e r cl u t ch e s .
(3 ) I n r e v e r s e 2 g e a r , l e f t s t e e r , t h e
l e f t - d r i v e cl u t ch (ou t p u t cl u t ch ) i s r e l e a s e d ,
th e l ef t-gea r ed s teer cl u tch i s a ppl i ed a n d s u p-
p l i e d w i t h cool a n t , a n d t h e r i gh t - d r i v e cl u t ch
con ti n u es to dr i v e th e r i gh t ou tpu t.
4 3
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Figure 19
PAR 3 9
OP E R AT I ON OF H Y DR AU L I C S Y S T E MS C H A P 2, S E C I V
4 5
*C2
CHAP 2, SEC V
T OR QU E P A T H S
PAR 4 0 - 4 3
4 0 . H YDR AU L I C S YS TE M F U N C TI ON -
DU RI N G TOW OR PU SH STARTS
OF VE H I CL E (f i g. 19)
a . Wh en i t i s n eces s a r y to s ta r t th e v e-
h i cl e e n gi n e b y t owi n g or p u s h i n g t h e v e h i cl e
(r e f e r t o TM 9-2300-216-10), t h e ma n u a l s e -
l e ct or v a l v e mu s t b e p l a ce d i n s e con d g e a r
p os i t i on .
b . Th e f u n ct i on of t h e h y d r a u l i c s y s t e m
i n s econ d gea r du r i n g a tow- or pu s h -s ta r ti n g
op e r a t i on i s t h e s a me a s t h a t d e s cr i b e d f or
s econ d gea r i n pa r . 32, a bov e, a n d i l l u s tr a ted
i n f i g. 8. H ow e v e r , d u r i n g s u ch a n op e r a t i on
(u n t i l t h e e n gi n e b e gi n s t o r ot a t e ), t h e i n p u t
d r i v e n p r e s s u r e p u mp ca n n ot s u p p l y ma i n
p r e s s u r e t o t h e s y s t e m. Th e ou t p u t d r i v e n
p r e s s u r e p u m p m u s t s u p p l y m a i n p r e s s u r e
unti l the cl utches (output and l ow r ange) engage
a n d u n ti l tor qu e i s tr a n s mi tted to th e v eh i cl e
e n gi n e .
c . Th e o u t p u t d r i v e n p r e s s u r e p u m p
d r a ws oi l , t h r ou gh t h e s u mp s cr e e n , f r om t h e
power tr a i n s u mp. Th e ou tpu t of th e oi l pu mp
u n s ea ts a ch eck v a l v e a n d f l ows i n to th e ca v i ty
s u r r ou n d i n g t h e ma i n oi l s cr e e n a s s e mb l y .
Th e r e a f t e r , t h e oi l f l ow i s t h e s a me a s ma i n
p r e s s u r e oi l f l ow f or s e con d ge a r u n d e r a n y
ot h e r con d i t i on .
d . Th e pu r pos e of th e ch eck v a l v e i n th e
ou tpu t dr i v en pr es s u r e pu mp ou tpu t l i n e i s to
pr ev en t a ba ck f l ow of ma i n pr es s u r e i n to th e
ou t p u t d r i v e n p u mp . I n n e u t r a l , t h e ou t p u t
dr i v en pu mp i s n ot r ota ti n g a n d th er e i s s ome
l os s by l ea k a ge th r ou gh th e pu mp. I n r ev er s e
ge a r s , t h e p u mp r ot a t e s i n a r e v e r s e d i r e c-
t i on a n d w ou l d (e x ce p t f or t h e ch e ck v a l v e )
a ct u a l l y p u mp oi l ou t of t h e ma i n p r e s s u r e
l i n e a n d r etu r n i t to th e s u mp.
Sect i on V. TORQUE PATHS THROUGH POWER TRAI N
4 1 . G E N E R A L
a . F i gu r e 20 i s a s ch e ma t i c v i e w of t h e
p ow e r t r a i n w i t h ou t t h e ou t p u t d r i v e a s s e m-
b l i e s . Al l of t h e p r i n ci p a l comp on e n t s t h r ou gh
w h i ch t or q u e f l ow s a r e i d e n t i f i e d . F i gu r e 21
i s a cu ta wa y v i ew of th e l ef t-ou tpu t dr i v e a s -
s e mb l y , col or e d t o i n d i ca t e t h e t or q u e p a t h .
Su bs equ en t f i gu r es , 22 th r ou gh 34, a r e col or ed
s ch e ma t i c v i e ws , i l l u s t r a t i n g t h e t or q u e p a t h s
f or th e con di ti on s i n di ca ted i n ea ch v i ew. Ar -
r ow s on comp on e n t s i n d i ca t e t h e d i r e ct i on of
r ot a t i on of s u ch comp on e n t s .
b . E x p l a n a t i o n s o f h y d r a u l i c a c t i o n s
u n d e r cor r e s p on d i n g con d i t i on s a r e i n p a r s .
28 th r ou gh 40 of th i s ch a pter .
c. To a v oi d n e e d l e s s r e p e t i t i on , r e f e r -
e n c e s a r e m a d e t o p r e c e d i n g e x p l a n a t i o n s
w h e r e a p p l i ca b l e .
4 6
4 2 . TOR QU E PATH - I N PU T TR AN S F E R
GE ARI N G (f i g. 20)
Tor q u e i s t r a n s mi t t e d f r om t h e e n gi n e t o
t h e i n p u t t r a n s f e r ge a r i n g b y a s p l i n e d cou p -
l i n g s h a f t . Tw o i d l e r g e a r s t r a n s mi t t or q u e
f r om th e i n pu t tr a n s f er dr i v e gea r to th e con -
v e r t e r cov e r d r i v e g e a r . Th e i n p u t r ot a t i on
(a t cou p l i n g s h a f t ) i s cou n t e r cl ock w i s e w h e n
v i e w e d f r om t h e l e f t s i d e of t h e p ow e r t r a i n .
Rota ti on of th e tor qu e con v er ter i s cl ock wi s e,
Th e r e i s a s p e e d i n cr e a s e r a t i o of 0 . 6 1 1 t o
1.000 between th e en gi n e a n d tor qu e con v er ter .
43. TORQU E PATH S - TORQU E
C ON V E R TE R A N D L OC K U P
CL U TCH (f i g. 20)
a . Tor q u e i s t r a n s mi t t e d f r om t h e i n p u t
tr a n s f er gea r i n g to th e r a n ge gea r i n g by ei th er
t h e t or q u e con v e r t e r or l ock u p cl u t ch . Wh e n
th e l ock u p cl u tch i s r el ea s ed, tor qu e i s tr a n s -
Figure 20
PAR 4 3 - 4 4
T OR QU E P A T H S
CHAP 2, SEC V
mi t t e d h y d r a u l i ca l l y f r om t h e con v e r t e r p u mp
t o t h e con v e r t e r t u r b i n e . Wh e n t h e l ock u p
cl u t ch i s e n ga ge d , t h e p u mp a n d t u r b i n e a r e
l ock ed togeth er a n d tor qu e i s tr a n s mi tted me-
ch a n i ca l l y .
b . Wh e n t r a n s mi t t e d h y d r a u l i ca l l y , t h e
tor qu e ma y be mu l ti pl i ed a s mu ch a s 3.3 ti mes
(a t t u r b i n e s t a l l ). Wh e n t r a n s mi t t e d me ch a n i -
ca l l y , tor qu e l ea v i n g th e con v er ter i s equ a l to
t h a t e n t e r i n g i t . Th e l ock u p cl u t ch e n g a g e s
a n d r e l e a s e s a u t oma t i ca l l y .
c . At l ow e r s p e e d s , w h e n h i gh t or q u e i s
r e q u i r e d , t h e l ock u p cl u t ch i s r e l e a s e d . At
h i gh e r s p e e d s , w h e n l e s s t or q u e i s r e q u i r e d ,
t h e l ock u p cl u t ch i s e n ga ge d . L ock u p e n ga ge -
me n t ca n occu r i n e v e r y g e a r r a n g e a n d i n
n eu tr a l . I n f i gu r es 22 th r ou gh 34 th e con v er ter
ou tpu t i s i n di ca ted by y el l ow wh en th e l ock u p
cl u t ch i s r e l e a s e d ; b y r e d w h e n e n ga ge d .
4 4 . TOR QU E PATH - OU TPU T
TRAN SF E R GE ARI N G (f i g. 20)
a . Two ge a r s ma k e u p t h e ou t p u t t r a n s f e r
gea r i n g. Th e dr i v e gea r i s s pl i n ed to th e l ow-
r a n ge ca r r i er s h a f t wh i ch i s th e r a n ge gea r i n g
ou tpu t f or th e power tr a i n r ega r dl es s of wh i ch
ge a r i s e n ga ge d . Th e d r i v e ge a r me s h e s w i t h
th e dr i v en gea r a n d i mpa r ts oppos i te r ota ti on .
b . Th e d r i v e n g e a r t r a n s m i t s t o r q u e ,
th r ou gh a s pl i n ed s h a f t, to th e s teer pl a n eta r y
r i n g ge a r s on e i t h e r s i d e of t h e d r i v e n ge a r .
Th e s peed r edu cti on , a n d cor r es pon di n g tor qu e
i n cr e a s e , i s 1 . 3 0 t o 1 . 0 0 .
4 7
Figure 21
CHAP 2, SEC V
T OR QU E P A T H S PAR 4 5
Figure 21. Output drive torque path
45. TORQUE PATH OUTPUT DRI VES
(f i g . 2 1 )
a . F i g u r e 2 1 i s a cu t a w a y v i e w of t h e
l eft-ou tpu t dr i v e (mou n ts at r i gh t s i de of power
t r a i n ). Th e con s t r u ct i on of t h e r i gh t a s s e mb l y
i s i d e n t i ca l e x ce p t f or l e n g t h ; op e r a t i on i s
i d e n t i ca l .
b . Tor q u e i s t r a n s mi t t e d f r om t h e ma i n
tr a n s mi s s i on s ecti on ou tpu t to th e ou tpu t dr i v e
a s s e mb l y b y t h e ou t p u t d r i v e s u n ge a r s h a f t .
Th e i n t e gr a l s u n ge a r i mp a r t s t or q u e t o t h e
pl a n eta r y pi n i on s wh i ch a r e mou n ted i n a s ta -
t i on a r y ca r r i e r . I n t u r n , t h e p i n i on s t r a n s mi t
tor qu e to th e r i n g gea r . Th e r i n g gea r , s pl i n ed
t o t h e ou t p u t s h a f t , t r a n s mi t s t or q u e t o t h e
ou tpu t s h aft.
c . Ar r ow s i n d i ca t i n g t h e d i r e ct i on of r o-
t a t i on i l l u s t r a t e con d i t i on s w h e n t h e p ow e r
tr a i n i s oper a ti n g i n a f or wa r d gea r . I n a r e-
v e r s e ge a r , a l l r ot a t i on s w ou l d r e v e r s e . N ot e
th at th e ou tpu t dr i v e ou tpu t r otati on i s oppos i te
th a t of th e ou tpu t dr i v e i n pu t beca u s e th e r e-
a c t i on m e m b e r (s t a t i on a r y m e m b e r ) i s t h e
p l a n e t a r y ca r r i e r .
4 8
Figure 22
PAR 4 6 T O R Q U E P A T H S
CHAP 2, SEC V
4 6 . TOR QU E PA TH - N E U TR A L
t o p a r s . 42 a n d 43, a b ov e . Si n ce cl u t ch e s a r e
(f i g . 2 2 )
n ot a p p l i e d , n o t or q u e i s t r a n s mi t t e d b e y on d
t h e l ow - a n d i n t e r me d i a t e - r a n g e s u n g e a r s .
I n n e u t r a l , t or q u e i s t r a n s mi t t e d t o t h e S ome of t h e r a n g e g e a r s r ot a t e f r e e l y , b u t ,
tu r bi n e s h a f t th r ou gh th e i n pu t tr a n s f er gea r s s i n ce th er e i s n o r ea cti on , n o tor qu e i s tr a n s -
a n d tor qu e con v er ter (or l ock u p cl u tch ). Ref er m i t t e d .
4 9
Figure 23
CHAP 2, SEC V
T OR QU E P A T H S
PAR 4 7
4 7 . TOR QU E PATH F I R S T G E AR ,
C ON VE R TE R OPE R ATI ON (f i g . 2 3 )
a . I n f i r s t ge a r , t or q u e i s t r a n s mi t t e d t o
t h e t u r b i n e s h a f t t h r ou gh t h e i n p u t t r a n s f e r
ge a r i n g a n d t h e t or q u e con v e r t e r (or l ock u p
cl u t ch ). Th e l ow-r a n ge s u n ge a r i s s p l i n e d t o
t h e t u r b i n e s h a f t a n d i mp a r t s t or q u e t o t h e
l ow - r a n g e p l a n e t a r y p i n i on s . Th e l ow - r a n g e
cl u t ch i s e n ga ge d , h ol d i n g t h e l ow-r a n ge r i n g
ge a r s t a t i on a r y . Th u s , t h e l ow --r a n ge p l a n e -
ta r y pi n i on s mu s t r ota te wi th i n th e s ta ti on a r y
r i n g g e a r . Th i s d r i v e s t h e l ow - r a n g e p l a n e -
t a r y ca r r i e r a n d s h a f t i n t h e s a me d i r e ct i on
a s th e tu r bi n e s h a f t bu t a t r edu ced s peed.
b . Th e l o w - r a n g e c a r r i e r s h a f t d r i v e s
t h e ou t p u t t r a n s f e r d r i v e ge a r . I n t u r n , t h e
dr i v e gear tr an s mi ts tor qu e to th e ou tpu t tr an s -
f er dr i v en gea r , ca u s i n g i t to r ota te i n th e op-
p os i t e d i r e ct i on . Th e d r i v e n g e a r t r a n s mi t s
t o r q u e t o t h e r i g h t - a n d l e f t - g e a r e d s t e e r
p l a n e t a r y r i n g ge a r s .
c . Th e r i g h t - a n d l e f t - g e a r e d s t e e r
cl u tch es a r e en ga ged, h ol di n g th e gea r ed s teer
s u n ge a r s s t a t i on a r y . Th e ge a r e d s t e e r p l a n e -
t a r y p i n i on s , me s h e d wi t h b ot h t h e s u n ge a r s
a n d r i n g ge a r s , a r e f or ce d t o r ot a t e a r ou n d
t h e s t a t i on a r y s u n g e a r s . Th e ca r r i e r t h u s
becomes th e ou tpu t member of th e gea r ed s teer
pl a n eta r y . Rota ti on a t r edu ced s peed i s tr a n s -
mi tted to th e r i gh t- a n d l ef t-ou tpu t cou pl i n gs .
Re f e r t o p a r . 7 f or ge a r r a t i os a p p l i ca b l e t o
f i r s t g e a r .
5 0
PAR 4 8 T OR QU E P A T H S CHAP 2, SEC V
Figure 24. Second-gear torque path, lockup operation
48. TORQUE PATH SECOND GEAR, ge a r e d s t e e r p l a n e t a r y ca r r i e r s a n d s u n ge a r s
L OCKUP OPERATI ON (fi g. 24)
t oge t h e r . Wh e n t h e s e comp on e n t s a r e l ock e d
Th e tor qu e pa th i n s econ d gea r i s i den ti ca l
t oge t h e r , t h e r i n g ge a r s d r i v e t h e m a s u n i t s .
to th a t f or f i r s t gea r u n ti l i t l ea v es th e gea r ed
Th e ou tpu t s peed i s th u s equ a l to th e s peed of
s teer pl a n eta r y r i n g gea r s (r ef er to 47a a n d b ,
th e r i n g gea r s . Re f e r t o TABU L ATE D DATA,
a b ov e ). I n s e con d g e a r , t h e r i g h t - a n d l e f t -
p a r . 7 , f or g e a r r a t i os a p p l i ca b l e t o s e con d
ou t p u t cl u t ch e s a r e e n g a g e d . Th i s l ock s t h e g e a r .
5 1
CHAP 2, SEC V T OR QU E P A T H S PAR 4 9
Figure 25. Third-gear torque path, lockup operation
49. TORQUE PATH THI RD GEAR,
LOCKUP OPERATI ON (fi g. 25)
a . Tor q u e i s t r a n s mi t t e d t o t h e l ow- a n d
i n t e r me d i a t e -r a n ge p l a n e t a r y s u n ge a r s i n t h e
ma n n e r d e s cr i b e d i n p a r s . 42 a n d 43, a b ov e .
I n th i r d gea r , th e l ow- a n d i n ter medi a te-r a n ge
p l a n e t a r y g e a r s a r e comp ou n d e d t o p r od u ce
t h e d e s i r e d s p e e d r e d u ct i on r a t i o. Th e i n t e r -
me d i a t e -r a n ge cl u t ch i s e n ga ge d , h ol d i n g t h e
i n t e r me d i a t e -r a n ge r i n g ge a r s t a t i on a r y . Th e
i n t e r me d i a t e -r a n ge p l a n e t a r y p i n i on s , me s h e d
w i t h t h e i n t e r me d i a t e - r a n ge s u n ge a r , w h i ch
i s r ota ti n g, a n d th e s ta ti on a r y r i n g gea r , mu s t
r ota te wi th i n th e r i n g gea r . Th i s a cti on dr i v es
t h e i n t e r me d i a t e - r a n g e p l a n e t a r y ca r r i e r .
b . Th e l ow - r a n ge p l a n e t a r y r i n g ge a r i s
a tta ch ed to th e i n ter medi a te-r a n ge ca r r i er a n d
r ot a t e s a t a s l owe r s p e e d t h a n t h e l ow-r a n ge
s u n ge a r . Th u s , t h e f a s t e r mov i n g s u n ge a r ,
a n d s l ower mov i n g r i n g gea r , combi n e to dr i v e
t h e l ow-r a n ge p l a n e t a r y p i n i on s . Th e ou t p u t
me mb e r of t h i s comp ou n d a r r a n ge me n t i s t h e
l ow - r a n ge p l a n e t a r y ca r r i e r a n d s h a f t .
c . Th e r e ma i n d e r of t h e t or q u e p a t h i s
i d e n t i ca l t o t h a t d e s cr i b e d f or s e con d g e a r
( p a r . 4 8 , a b o v e ) . Ref er to T A B U L A T E D
DAT A, p a r . 7, f or ge a r r a t i os a p p l i ca b l e t o
t h i r d ge a r .
52
PAR 5 0
T OR QU E P A T H S
C H A P 2 S E C V
50. TORQUE PATH FOURTH
LOCKUP OPERATI ON (fi g.
GE AR,
26)
Figure 26. Fourth-gear torque path, lockup operation
a . Tor q u e i s t r a n s mi t t e d t o t h e t u r b i n e
s h a f i n t h e ma n n e r d e s cr i be d i n p a r s . 42 a n d
4 3 , a b ov e . I n f ou r t h g e a r , t or q u e i s t r a n s -
mi t t e d d i r e ct l y b y t h e h i gh -r a n ge cl u t ch a n d
t h e r e i s n o p l a n e t a r y g e a r a ct i on . E n g a g e -
men t of th e h i gh -r a n ge cl u tch l ock s th e tu r bi n e
s h a f t a n d h i gh -r a n ge cl u tch h u b togeth er . Th e
h i g h - r a n g e cl u t ch h u b i s i n t e g r a l w i t h t h e
i n t e r m e d i a t e - r a n g e p l a n e t a r y c a r r i e r . Th e
i n t e r me d i a t e -r a n ge s u n ge a r i s s p l i n e d t o t h e
t u r b i n e s h a f t . Th e r e f or e , t h e i n t e r me d i a t e -
r a n ge p l a n e t a r y ge a r i n g i s l ock e d a n d r ot a t e s
as a uni t.
b . Th e l ow-r a n ge r i n g gea r i s a tta ch ed to
t h e i n t e r me d i a t e - r a n g e p l a n e t a r y ca r r i e r . As
a r e s u l t , wh e n t h e t u r b i n e s h a f t r ot a t e s , a l l
me mb e r s of a l l r a n g e p l a n e t a r y s e t s r ot a t e
w i t h t h e t u r b i n e s h a f t , a t t h e s a me s p e e d .
Th u s , t or q u e i s t r a n s mi t t e d f r om t h e t u r b i n e
s h a f t to th e ou tpu t tr a n s f er dr i v e gea r a t 1 to
1 r a t i o.
c . Th e r e ma i n d e r of t h e t or q u e p a t h i s
i denti cal to that for thi rd gear. For gear
rati os appl i cabl e to fourth gear, refer to
T ABUL AT E D DAT A, par . 7.
5 3
CHAP 2, SEC V
T OR QU E P A T H S PAR 5 1
51. TORQUE PATH REVERSE 1 GEAR,
CONVERTER OPERATI ON (fi g. 27)
a . Tor q u e i s t r a n s mi t t e d t o t h e t u r b i n e
s h a f t i n th e ma n n er des cr i bed i n pa r s . 42 a n d
43, a b ov e . I n r e v e r s e r a n ge , t or q u e i s t r a n s -
mi t t e d f r om t h e t u r b i n e s h a f t t o t h e ou t p u t
t r a n s f e r d r i v e g e a r b y a comp ou n d a r r a n g e -
m e n t o f t h e r e v e r s e - r a n g e a n d l o w - r a n g e
p l a n e t a r y g e a r s .
b . Th e i n pu t member of th i s compou n d a r -
r a n ge me n t i s t h e l ow-r a n ge s u n ge a r . Tor q u e
i s t r a n s mi t t e d t o t h e l ow -r a n ge p i n i on s w h i ch
r ot a t e i n t h e d i r e ct i on op p os i t e t h e s u n ge a r .
Th e s l o w e r m o v i n g , l o w - r a n g e c a r r i e r , a l -
t h ou gh i t i s r ot a t i n g, i s a r e a ct i on me mb e r .
Th e l o w - r a n g e r i n g g e a r , m e s h e d w i t h i t s
p i n i on s , r ot a t e s i n t h e d i r e ct i on op p os i t e t h e
s u n ge a r . Th u s , t h e r e v e r s a l of r ot a t i on a c-
t u a l l y occu r s i n t h e l ow - r a n ge p l a n e t a r y .
Figure 27. Reverse 1-gear torque path, converter operation
c . Th e r e v e r s e - r a n g e s u n g e a r i s a t -
ta ch ed to th e l ow-r a n ge r i n g gea r a n d r ota tes
w i t h i t . Th e r e v e r s e - r a n ge cl u t ch i s e n ga ge d ,
h ol di n g th e r ev er s e-r a n ge r i n g gea r s ta ti on a r y .
Th e r e v e r s e - r a n g e p l a n e t a r y p i n i on s a r e i n
me s h w i t h b ot h t h e r i n g ge a r a n d s u n ge a r .
Th e r ot a t i on of t h e r e v e r s e - r a n g e s u n g e a r
f or ces th e pi n i on s to r ota te wi th i n th e s ta ti on -
a r y r i n g ge a r . Th i s d r i v e s t h e r e v e r s e -r a n ge
ca r r i e r i n t h e s a me d i r e ct i on a s , b u t a t a
s l ower s peed th a n , th e s u n gea r . Th e r ev er s e-
r a n ge ca r r i er , s pl i n ed to th e l ow-r a n ge pl a n e-
t a r y ca r r i e r s h a f t , d r i v e s t h e ou t p u t t r a n s f e r
d r i v e g e a r .
d . Th e r e ma i n d e r of t h e t or q u e p a t h i s
i d e n t i ca l t o t h a t d e s cr i b e d f or f i r s t g e a r i n
pa r . 47b a n d c , a b ov e . R e f e r t o TA BU L A TE D
DATA, p a r . 7 , f or g e a r r a t i os a p p l i ca b l e t o
r e v e r s e 1 g e a r .
5 4
PAR 5 2 T OR QU E P A T H S
CHAP 2, SEC V
Figure 28. Reverse 2-gear torque path, converter operation
52. TORQUE PATH - REVERSE 2 GEAR,
ou tpu t tr a n s f er dr i v e gea r a s des cr i bed i n pa r .
CONVERTER OPERATI ON (fi g. 28)
51c a n d d , a bov e. Th e r ema i n der of th e tor qu e
p a t h i s i d e n t i ca l t o t h a t d e s cr i b e d i n p a r . 48,
Tor qu e i s tr a n s mi tted to th e tu r bi n e s h a f t
a b ov e , f or s e con d ge a r . Re f e r t o TABU L ATE D
a s des cr i bed i n pa r s . 42 a n d 43, a bov e. Tor qu e
DATA, p a r . 7 , f or g e a r r a t i os a p p l i ca b l e t o
i s tr a n s mi tted th r ou gh th e r a n ge gea r i n g to th e
r e v e r s e 2 g e a r .
5 5
CHAP 2, SEC V
T OR QU E P A T H S PAR 5 3
Figure 29. First-gear, full-right-steer torque path, converter operation
53. TORQUE PATH FI RST GE AR,
FUL L -RI GHT STEER, CONVERTER
OPERATI ON (fi g. 29)
a . To r q u e i s t r a n s m i t t e d t o t h e s t e e r
p l a n e t a r y r i n g ge a r s i n t h e s a me ma n n e r a s
t h a t f or f i r s t ge a r , a s d e s cr i b e d i n p a r . 47a
a n d b , a b ov e . F r om t h i s p oi n t , t o t h e p owe r
t r a i n ou t p u t s , t h e t or q u e p a t h s f or t h e r i gh t
a n d l e f t s i d e s a r e d i f f e r e n t .
b . Th e cl u t ch - b r a k e me t h od i s u s e d f or
f i r s t - g e a r s t e e r . S t e e r i n g r e s u l t s w h e n t h e
b r a k e i s a p p l i e d a t on e s i d e wh i l e t h e d r i v e
cl u t ch i s e n g a g e d a t t h e op p os i t e s i d e . Th e
d r i v e cl u t ch i s t h e g e a r e d s t e e r cl u t ch . Th e
v e h i cl e s t e e r s t ow a r d t h e b r a k e d s i d e .
c . I n r i gh t s t e e r , i n f i r s t ge a r , t h e r i gh t
5 6
b r a k e i s a p p l i e d w h i l e t h e r i gh t - d r i v e cl u t ch
i s r e l e a s e d . Th e d r i v e cl u t ch on t h e l e f t s i d e
i s s t i l l e n ga ge d a n d con t i n u e s t o d r i v e . H y -
d r a u l i c a ct i on , con t r ol l e d b y t h e s t e e r con t r ol
v a l v e , r e l e a s e s t h e d r i v e cl u t ch a n d a p p l i e s
th e br a k e. An oppos i te mov emen t of th e s teer
con tr ol v a l v e wi l l r el ea s e th e l ef t-gea r ed s teer
cl u tch (th e dr i v e cl u tch ), a ppl y th e l ef t br a k e,
a n d r es u l t i n l ef t s teer .
d . I n f u l l s t e e r , t h e a p p l i e d b r a k e l ock s
t h e s t e e r p l a n e t a r y ca r r i e r a n d r ot a t i on s t op s
a t t h a t s i d e . I n p a r t i a l s t e e r , t h e a p p l i e d
b r a k e on l y s l ow s t h e s i d e t ow a r d w h i ch t h e
t u r n i s m a d e . Th e d e g r e e o f s t e e r i s c o n -
tr ol l ed by th e degr ee of mov emen t of th e s teer
c o n t r o l . R e f e r t o TA B U L A TE D DA TA , p a r .
7, for the gear r ati os whi ch appl y to fi r s t gear ,
ful l -ri ght steer.
PAR 5 4 T OR QU E P A T H S
CHAP 2, SEC V
Figure 30. Second-gear, full-left-steer torque path, lockup operation
54. TORQUE PATH SE COND GE AR,
FUL L -L E FT STE E R, L OCKUP
OPERATI ON (fi g. 30)
a . To r q u e i s t r a n s m i t t e d t o t h e s t e e r
p l a n e t a r y r i n g ge a r s i n t h e s a me ma n n e r a s
t h a t f or f i r s t g e a r , a s d e s cr i b e d i n p a r . 4 7 a
a n d b , a b ov e . F r om t h i s p oi n t , t o t h e p owe r
t r a i n ou t p u t s , t h e t or q u e p a t h s f or t h e r i gh t
a n d l e f t s i d e s a r e d i f f e r e n t .
b . Th e cl u t ch - b r a k e me t h od i s u s e d f or
s e con d - g e a r s t e e r . I n t h i s me t h od , s t e e r i n g
r e s u l t s wh e n t h e b r a k e i s a p p l i e d a t on e s i d e
wh i l e th e dr i v e cl u tch i s en gaged at th e oppos i te
s i d e . I n s e con d ge a r , t h e d r i v e cl u t ch i s t h e
ou t p u t cl u t ch . Th e v e h i cl e s t e e r s t owa r d t h e
s i de on wh i ch th e br a k e i s a ppl i ed.
c . I n l e f t s t e e r , i n s e con d ge a r , t h e l e f t
b r a k e i s a p p l i e d w h i l e t h e l e f t -ou t p u t cl u t ch
i s r e l e a s e d . Th e d r i v e cl u t ch (ou t p u t cl u t ch )
on th e r i gh t s i de i s s ti l l en ga ged a n d con ti n u es
t o d r i v e . H y d r a u l i c a ct i on , con t r ol l e d b y t h e
s t e e r con t r ol v a l v e , r e l e a s e s t h e d r i v e cl u t ch
a n d a p p l i e s t h e b r a k e . An op p os i t e mov e me n t
of t h e s t e e r con t r ol v a l v e w i l l r e l e a s e t h e
r i gh t-ou tpu t cl u tch , a ppl y th e r i gh t br a k e, a n d
r e s u l t i n r i gh t s t e e r .
d . F u l l a n d p a r t i a l s t e e r i n s e con d ge a r
i s con t r ol l e d a s e x p l a i n e d i n p a r . 53d , a b ov e .
R e f e r t o T A B U L A T E D D A T A , p a r . 7 , f or
g e a r r a t i o s a p p l i c a b l e t o s e c o n d g e a r , l e f t
s t e e r .
5 7
CHAP 2, SEC V T OR QU E P A T H S PAR 5 5
55.
Figure 31. Third-gear, full-right-steer torque path, converter operation
TORQUE PATH THI RD GEAR,
FUL L -RI GHT STEER, CONVERTER
OPERATI ON (fi g. 31)
a . To r q u e i s t r a n s m i t t e d t o t h e s t e e r
p l a n e t a r y r i n g ge a r s i n t h e s a me ma n n e r a s
d e s c r i b e d i n p a r . 4 9 a a n d b , a b o v e . F r o m
t h i s p oi n t , t o t h e p ow e r t r a i n ou t p u t s , t h e
t or q u e p a t h s f or t h e r i gh t a n d l e f t s i d e s a r e
d i f f e r e n t .
b . Th e g e a r e d s t e e r me t h od i s u s e d f or
t h i r d - g e a r s t e e r . I n t h i s m e t h o d , s t e e r i n g
r e s u l t s w h e n t h e g e a r e d s t e e r cl u t ch i s e n -
ga ged a t on e s i de wh i l e th e dr i v e cl u tch (ou t-
pu t cl u tch ) i s a ppl i ed a t th e oppos i te s i de. Th e
v e h i cl e s t e e r s t owa r d t h e s i d e on wh i ch t h e
ge a r e d s t e e r cl u t ch i s e n ga ge d .
c . I n r i gh t s teer , i n th i r d gea r , th e r i gh t-
gea r ed s teer cl u tch i s a ppl i ed wh i l e th e r i gh t-
ou tpu t cl u tch i s r el ea s ed. Th e dr i v e cl u tch on
th e l ef t s i de i s s ti l l en ga ged a n d con ti n u es to
d r i v e . H y d r a u l i c a ct i on , con t r ol l e d b y t h e
s t e e r con t r ol v a l v e , r e l e a s e s t h e d r i v e cl u t ch
a n d a p p l i e s t h e ge a r e d s t e e r cl u t ch . An op -
pos i te mov emen t of th e s teer con tr ol v a l v e wi l l
r el ea s e th e l ef t-ou tpu t cl u tch , en ga ge th e l ef t-
ge a r e d s t e e r cl u t ch , a n d r e s u l t i n l e f t s t e e r .
d . I n f u l l s t e e r , t h e a p p l i e d ge a r e d s t e e r
cl u t ch l ock s t h e g e a r e d s t e e r p l a n e t a r y s u n
g e a r a n d s l ow s t h e g e a r e d s t e e r p l a n e t a r y
c a r r i e r . I n p a r t i a l s t e e r , t h e g e a r e d s t e e r
cl u t ch i s on l y p a r t i a l l y a p p l i e d a n d s l ows t h e
ou tpu t to a l es s er degr ee. Th e degr ee of s teer
i s con tr ol l ed by th e degr ee of mov emen t of th e
s t e e r con t r ol . R e f e r t o TA BU L A TE D DA TA ,
p a r . 7, f or t h e ge a r r a t i os a p p l i ca b l e t o t h i r d
g e a r , r i g h t s t e e r .
5 8
PAR 5 6
T OR QU E P A T H S CHAP 2, SEC V
Figure 32. Fourth-gear, full-left-steer torque path, lockup operation
a n d l e f t s i d e s a r e 56. TORQUE PATH FOURTH GE AR, t or q u e p a t h s f or t h e r i gh t
FUL L -L E FT STE E R, L OCKUP d i f f e r e n t .
OPERATI ON (fi g. 32)
b . I n f ou r t h g e a r , s t e e r i n g i s i d e n t i ca l
a . To r q u e i s t r a n s m i t t e d t o t h e s t e e r to th a t f or th i r d gea r , a s des cr i bed i n pa r . 55b,
p l a n e t a r y r i n g ge a r s i n t h e s a me ma n n e r a s c and d, above. Refer to ABULATED DATA,
d e s c r i b e d i n p a r . 5 0 a a n d b , a b o v e . F r o m p a r . 7 , f or g e a r r a t i os a p p l i ca b l e t o f ou r t h
t h i s p oi n t , t o t h e p ow e r t r a i n ou t p u t s , t h e g e a r , r i g h t s t e e r .
5 9
CHAP 2, SEC V T OR QU E P A T H S PAR 5 7
57.
Figure 33. Reverse 1-gear, full-right-steer torque path, converter operation
TORQUE PATH REVERSE 1 GEAR, p a r . 5 1 a , b a n d c , a b ov e . F r om t h i s p oi n t ,
FUL L -RI GHT STEER, CONVERTER to th e power tr a i n ou tpu ts , th e tor qu e pa th i s
OPERATI ON (fi g. 33) a s d e s cr i b e d f or f i r s t - g e a r s t e e r (p a r . 5 3 b ,
c a n d d , a b ov e ) e x ce p t t h a t r ot a t i on s of t h e
Th e t or q u e p a t h f r om t h e e n gi n e t o t h e comp on e n t s a r e op p os i t e . R e f e r t o T A B U -
ge a r e d s t e e r p l a n e t a r y r i n g ge a r s i s i d e n t i ca l L AT E D DAT A, pa r . 7, f or gea r r a ti os a ppl i -
t o t h a t f or r e v e r s e 1 g e a r , a s d e s cr i b e d i n ca b l e t o r e v e r s e 1 ge a r , r i gh t s t e e r .
6 0
PAR 5 8 T OR QU E P A T H S CHAP 2, SEC V
58.
Figure 34. Reverse 2-gear, full-left-steer torque path,converter operation
TORQUE PATH REVERSE 2 GEAR, t r a i n ou t p u t s , t h e t or q u e p a t h i s t h e s a me a s
FUL L -L E FT STE E R, CONVE RTE R d e s cr i b e d f or t h i r d g e a r (p a r . 5 5 b , c a n d d ,
OPERATI ON (fi g. 34) a b ov e ) e x ce p t t h a t r ot a t i on s a r e op p os i t e a n d
t h a t t h e s t e e r i n g a ct i on i s on t h e l e f t s i d e of
Th e t or q u e p a t h f r om t h e e n gi n e t o t h e th e power tr a i n i n s tea d of th e r i gh t s i de a s de-
s t e e r p l a n e t a r y r i n g ge a r s i s i d e n t i ca l t o t h a t s cr i b e d f or t h i r d ge a r . Refer to T ABUL AT E D
f or r e v e r s e 1 ge a r a s d e s cr i b e d i n p a r . 51a , D A T A , p a r . 7 , f or g e a r r a t i os a p p l i ca b l e t o
b and c , a b ov e . F r om t h i s p oi n t , t o t h e p owe r r e v e r s e 2 g e a r , l e f t s t e e r .
61
*C2
* C2
*C2
*C2
PAR 5 9 - 6 2
CHAPTER 3
PARTS, SPECIAL TOOLS, IMPROVISED TOOLS, AND EQUIPMENT
FOR FIELD AND DEPOT MAINTENANCE
5 9 . G E N E R A L
Tool s a n d e q u i p me n t a n d ma i n t e n a n ce
p a r t s , ov e r a n d a b ov e t h os e a v a i l a b l e t o t h e
u s i n g or ga n i z a t i on , a r e s u p p l i e d t o Or d n a n ce
f i e l d ma i n t e n a n ce u n i t s a n d d e p ot s h op s f or
mai ntai ni ng, repai ri ng, and/or rebui l di ng
t h e ma t e r i e l .
6 0 . R E PA I R PA R TS
Re p a i r p a r t s s u p p l i e d f or t h e XTG-411-
2A p owe r t r a i n a r e l i s t e d i n TM 9-2520-234-
3 5 P.
6 1 . C OMMON TOOL S AN D E QU I PME N T
St a n d a r d a n d common l y u s e d t ool s a n d
e q u i p me n t h a v i n g ge n e r a l a p p l i ca t i on t o t h i s
ma t e r i e l a r e l i s t e d i n ORD 6 SN L J -8, s e c-
t i on 18; ORD 6 SN L J -9, s e ct i on s 2 a n d 9;
SM 9-4-4910-J8-13; SM 9-4-4910-J9-1, -8,
- 1 5 , - 1 6 , - 1 7 , - 2 1 , - 2 7 a n d - 4 4 ; a n d S M 9 -
4-5180-A58, a n d a r e a u t h or i z e d f or i s s u e b y
TA a n d TOE .
6 2 . S PE C I AL AN D I MPR OVI S E D TOOL S
AN D E QU I PME N T
a . S p e ci a l Tool s a n d E q u i p me n t (f i g s .
35 and 36). Cer ta i n tool s a n d equ i pmen t s pe-
ci f i ca l l y des i gn ed f or f i el d a n d depot ma i n te-
n a n ce , r e p a i r , a n d ge n e r a l u s e wi t h t h e ma -
ter i el a r e l i s ted i n Ta bl e I I , bel ow, f or i den ti -
f i ca t i on on l y . Th i s l i s t i s n ot to be u s ed f or
r e q u i s i t i on i n g r e p l a ce me n t s . F or r e p l a ce -
me n t s , r e f e r t o TM 9 - 2 5 2 0 - 2 3 4 - 3 5 P.
Figure 35. Power train special tools group 1
6 2
PAR 62 TOOL S AND EQU I PMENT CHAP 3
Fi gur e 36. Power tr ai n s peci al tool s Gr oup 2
Change 2 63
CHAP 3 TOOL S AND EQU I PMENT PAR 62
b . I m p r o v i s e d To o l s a n d E q u i p m e n t Pr i n c i p a l d i m e n s i on s a n d d e t a i l s a r e
(f i g s . 3 7 a n d 3 8 ). C e r t a i n i mp r ov i s e d s u p p l i e d t o p e r mi t f a b r i ca t i on of t h e s e
tool s a n d equ i pmen t, h el pf u l i n DS & GS i t e ms . Th e s e t ool s a r e n ot a v a i l a b l e f or
m a i n t e n a n c e a r e l i s t e d i n Ta b l e I I . i s s u e.
Fi gu r e 38. Power tr a i n i mpr ov i s ed tool s
64 Change 2
PAR 62 TOOLS AND EQUIPMENT CHAP 3
Table II. SPECIAL TOOLS AND EQUIPMENT
Fig. Item Item Part NO. (CAGEC)
No. No. Name NSN Use
Fig. Para.
Ref. Ref.
35 Lifting sling 7081593 (19207) Lifting transmission 39 74
4910-00-473-7556
35 Lifting sling 7083778 (19207) Lifting transmission 40, 49, 74, 75,
4910-00-708-3778 components 55, 89,
96, 101
76, 227,
228, 229
35
36
36
Mechanical 7082201 (19207) Removing spindles 59, 62 74
puller 5120-00-473-7352 from input transfer
at t achment housing
1 Pressure oil 8356176 (19207) Check oil pressures 368, 231, 232
t es t er 6685-00-572-8612 369 233
2 Guide bolt 8351231 (19207) Alining brake and 164, 146,
5120-00-722-3917 geared steer clutch 170 227
anchor rings
36 3 Splined 8351386 (19207) Applying right brake 91, 75, 227,
wrench, brake 5210-00-733-8909 297 234
adjusting
36 4 Splined 8351387 (19207) Applying left brake 81, 75, 227,
wrench, brake 5210-00-733-8912 298 234
adjusting
36 5 Spindle 8351492 (19207) Adapting 205 158, 161
repl acer 4910-00-757-1960 5120-00-733-8908
pl at e replacer to geared
steer planetary carrier
36 6 Output 8351496 (19207) Lifting right-and 104, 75, 143,
carrier sling 4910-00-757-1959 left-output carriers 157, 146, 227
171
36
36
7 Sling chain 8351888 (19207) Lifting low- and 49, 125, 74, 75,
hooks 4030-00-757-1961 clutch reverse-range 244, 227
piston housing 260
8 Bearing 8355744 (19207) Removing roller 238 223
remover 5120-00-034-0873 bearing from output
drive output shaft
36 9 Face spanner 8355764 (19207) Removing or 144 83, 86
wrench 5120-00-950-9566 replacing converter
carrier bearing
retaining nut
Change 2 65
CHAP 3 TOOLS AND EQUIPMENT
Table II. SPECIAL TOOLS AND EQUIPMENT (cont)
PAR 62
Fig. Item Item Part NO. (CAGEC)
No. No. Name NSN
36 10
36 11
36 12
36 13
36 14
36 15
36 16
Brake
adjusting gage
Dial pressure
g a g e
Mechanical
adapter
Headless
straight pin
Pinion
alining tool
Headless
straight pin
Spindle
replacer
Use
8351213 (19207) Gaging brake
5210-00-733-5005 clearance
7950330 (19207) Checking oil
6620-00-795-0330 pressures
7082774 (19207) Used with
5120-00-708-2774 5120-00-473-7352
puller
8351208 (19207) Alining intermediate-
5315-00-733-8904 and reverse-range
planetary carrier
pinions and rollers;
used with
5120-00-733-8908
replacer
8351214 (19207) Alining steer
5120-00-738-1644 planetary carrier
pinions and rollers;
used with
5120-00-733-8908
replacer
8351209 (19207) Alining low-range
5315-00-733-8905 planetary carrier
pinions and rollers;
used with
5120-00-733-8908
replacer
8351266 (19207) Removing or
5120-00-733-8908 installing pinion
spindles in low-,
intermediate-,
reverse-range and
output planetary
carriers; used with
4910-60-757-1960
plate,
5120-00-733-8904
alining tool,
5120-00-733-8905
alining tool and
5120-00-738-1644
alining tool
Fig. Para.
Ref. Ref.
296 234
232
219, 181,
221 196
215 161
215 191
205,
217,
222,
226
158, 161,
181, 191,
196
66 Change 2
PAR 62 TOOLS AND EQUIPMENT CHAP 3
Fig. Item Item Part No. (CAGEC)
No. No. Name NSN
36
36
36
36
36
37
38
38
17
18
19
20
21
Table II. SPECIAL TOOLS AND EQUIPMENT (cont)
Spring
compressing
tool
Plain encased 8351932 (19207) Installing output drive
seal replacer 5120-00-034-0872 output shaft oil seal
Oil seal
replacer
8351210 (19207) Installing transmis-
5120-00-893-3745 sion output shaft and
input transfer
adapter oil seals
Eye bolt
Transmission
lifting
bracket
Disassembly
and assembly
table
Output final
drive repair
stand
Headless
guide bolt,
7/8-14 x 10-
inch
Use
8355784 (19207) Compressing springs
5120-00-996-2119 and retainers in
reverse-, low-, high-
range and output
clutches
7083672 (19207) Removing low-range
5306-00-708-3672 planetary carrier and
related components
8355697 (19207) Lifting transmission;
4910-00-977-5580 used with
4910-00-473-7556
lifting sling
Fabricated Disassembling and
assembling power
train and subassemblies
Fabricated Supporting output
final drive during
rebuild operations
Fabricated Alining final drive
saddle and planetary
carrier
Fig.
Ref.
210, 168, 171,
218, 183, 186,
229 198, 201
239 226
149,
91, 131,
162 146, 206
114 75
39 74
74, 75,
227, 228
358
160
229
229
Para.
Ref.
Table III deleted)
Change 2 67/(68 blank)
PAR 63-65
CHAPTER 4
TROUBLESHOOTI NG
Section I . GENERAL
6 3 . PU R POS E
N o t e : I n f or ma ti on i n th i s ch a pter
i s f or u s e b y Or d n a n ce ma i n t e -
n a n ce p e r s on n e l , i n con j u n ct i on
wi t h a n d a s a s u p p l e me n t t o t h e
tr ou bl es h ooti n g s ecti on i n th e a p-
pl i ca bl e TM-20 ma n u a l . I t pr ov i des
con ti n u a ti on of i n s tr u cti on s wh er e
a r emedy i n the Uni t l ev el mai nte-
n a n ce ma n u a l r e f e r s t o Or d n a n ce
m a i n t e n a n c e p e r s o n n e l f o r c o r -
r e ct i v e a ct i on .
Op e r a t i on of a d e a d l i n e d v e h i cl e wi t h ou t
a p r e l i mi n a r y e x a mi n a t i on ca n ca u s e f u r -
th er da ma ge to a di s a bl ed compon en t a n d
p os s i b l e i n j u r y t o p e r s on n e l . By ca r e f u l
i n s pecti on a n d tr ou bl es h ooti n g, s u ch da m-
age and i nj ur y can be avoi ded. I n addi ti on,
th e ca u s es of f a u l ty oper a ti on of a v eh i cl e
or comp on e n t ca n of t e n b e d e t e r mi n e d
wi th ou t ex ten s i v e di s a s s embl y .
64. GE N E RAL I N STRU CTI ON S AN D
PR OC E DU R E S
N ot e : Th i s ch a p t e r con t a i n s
i n s p e ct i on a n d t r ou bl e s h oot i n g
p r oce d u r e s t o b e p e r f or me d w h i l e
a d i s a b l e d c o m p o n e n t i s s t i l l
mou n ted i n th e v eh i cl e a s wel l a s
after i t has been r emov ed.
a . Th e i n s p e ct i on s ma d e w h i l e t h e
compon en t i s mou n ted i n th e v eh i cl e a r e,
f or t h e mos t p a r t , v i s u a l a n d a r e t o b e
p e r f or me d b e f or e a t t e mp t i n g t o op e r a t e
t h e v e h i cl e . Th e ob j e ct of t h e s e i n s p e c-
t i on s i s t o d e t e r mi n e t h e con d i t i on of
th es e compon en ts a n d, i f f ou n d def ecti v e,
to tak e pr ecau ti on s to pr ev en t an y fu r th er
d a ma ge .
b . Th e t r o u b l e s h o o t i n g p e r f o r m e d
wh i l e t h e comp on e n t i s mou n t e d i n t h e
v eh i cl e i s th a t wh i ch i s bey on d th e s cope
of t h e u s i n g or g a n i z a t i on . C h e c k t h e
t r ou b l e s h oot i n g s e ct i on of t h e a p p l i ca b l e
TM-20 ma n u a l , t h e n p r oce e d a s ou t l i n e d
i n thi s chapter .
c . I f th e compon en t a l on e i s r ecei v ed
by th e Or dn a n ce es ta bl i s h men t, i n s pecti on
i s per f or med to v er i f y th e di a gn os i s ma de
wh en th e compon en t was i n th e v eh i cl e, to
u n cov e r f u r t h e r d e f e ct s , or t o d e t e r mi n e
ma l f u n ct i on s . Th i s i n s p e ct i on i s p a r t i cu -
l a r l y i mp or t a n t b e ca u s e i t i s of t e n t h e
onl y means of deter mi ni ng the mal functi on
w i t h ou t c om p l e t e l y d i s a s s e m b l i n g t h e
comp on e n t .
Section I I . TROUBLESHOOTI NG PROCEDURES
65. OPE RATI N G CH ARACTE RI STI CS a . C on s t r u ct i on F e a t u r e s . R e f e r t o
p a r s . 8 t h r ou g h 2 7 f or d e s cr i p t i on a n d
To p e r f o r m e f f e c t i v e t r o u b l e s h o o t - oper a ti on of tr a n s mi s s i on compon en ts .
i n g, t h e me ch a n i c mu s t h a v e a t h or ou gh
k n ow l e d g e of t h e con s t r u ct i on f e a t u r e s b . F u n ct i on s of C omp on e n t s . R e f e r
a n d o p e r a t i n g c h a r a c t e r i s t i c s of the to pa r s . 28 th r ou gh 58 f or ex pl a n a ti on s of
p owe r t r a i n . Pa r t i cu l a r a t t e n t i on s h ou l d p o w e r t r a i n h y d r a u l i c o p e r a t i o n s a n d
b e a c c o r d e d t o t h e s u b j e c t s o u t l i n e d power f l ow th r ou gh th e power tr a i n com-
b e l o w . pon en ts .
Change 2 69
CHAP 4, SEC I I TROU BL E SH OOTI N G PROCE DU RE S PAR 65-69
c . Op e r a t i n g I n s t r u ct i on s . R e f e r t o
t h e a p p l i ca bl e TM-10 ma n u a l f or i n s t r u c-
ti on s on oper a ti n g th e tr a n s mi s s i on wh i l e
dr i vi ng the vehi cl e i n whi ch i t i s i nstal l ed.
d . Oi l Su ppl y .
s u ppl y i n for ma ti on .
Ref er to pa r . 6 f or oi l
e . Pow e r Tr a i n Ad j u s t me n t s . R e f e r
to par . 234 f or a dj u s tmen t pr ocedu r es .
f . Oi l Pr e s s u r e s . R e f e r t o TA B U -
L A TE D DA TA i n p a r . 7 f or t h e p ow e r
tr ai n oi l pr essur e schedul e.
66. TROU BL E SH OOTI N G BE F ORE
RE MOVAL OR OPE RATI ON
a . Do n ot op e r a t e t h e v e h i cl e p r i or
to compl eti n g th e pr ocedu r es des cr i bed i n
t h i s p a r a gr a p h . Re f e r t o p a r . 63, a b ov e ,
f or t h e p u r p os e of t h e s e i n s p e ct i on s . I n -
s p e ct f or oi l l e a k a ge . Vi s u a l l y i n s p e ct a l l
s pl i t l i n es , con n ecti on s , v a l v e bodi es , a n d
p l u gs f or oi l l e a k s . Oi l l e a k a ge a t s p l i t
l i n e s ma y b e ca u s e d b y l oos e mou n t i n g
b ol t s or d e f e ct i v e g a s k e t s . Ti g h t e n a l l
bol ts wh er e l ea k a ge i s f ou n d. I f mou n ti n g
b ol t s a r e t i gh t a n d oi l con t i n u e s t o l e a k ,
i nstal l a new gask et.
N o t e : I n s p e ct p ow e r t r a i n a ga i n
f or oi l l e a k a ge a f t e r s t a r t i n g t h e
v e h i cl e e n gi n e . Re f e r t o p a r . 67,
b e l ow .
b . I n s p e ct t h e p owe r t r a i n f or l oos e
c o m p o n e n t s a n d l i n k a g e . I n s p e c t f o r
d a ma ge d or b r ok e n e x t e r n a l comp on e n t s .
Ch e ck f or t h e p r op e r op e r a t i on of s t e e r ,
r a n ge s e l e ct or a n d b r a k e con t r ol s b e f or e
s ta r ti n g th e v eh i cl e en gi n e. Ref er to pa r .
234.
6 7 .
66,
TROU BL E SH OOTI N G BE F ORE
REMOVAL AND DU RI NG
OPE RATI ON
a . Ge n e r a l . I f t h e i n s p e ct i on i n p a r .
a b ov e , d oe s n ot r e v e a l t h e ca u s e of
t h e f a i l u r e , a n d t h e v e h i cl e i s op e r a b l e ,
f u r t h e r t r ou b l e s h oot i n g i s n e ce s s a r y . Do
n ot r emov e th e power tr a i n f r om th e v e-
h i cl e u n ti l th e ca u s es of tr ou bl e, l i s ted i n
Ta b l e I V, TR OU BL E S H OOTI N G , b e l ow ,
a r e ch eck ed. Ref er to pa r . 63, a bov e, f or
t h e p u r p os e a n d s cop e of t h e s e t r ou b l e -
s h oot i n g p r oce d u r e s . I n or d e r t o ma k e a
th or ou gh tes t of th e power tr a i n wh i l e i t
i s mounted i n the v ehi cl e, be s ur e that the
en gi n e i s pr oper l y tu n ed a n d th a t th e oi l
l ev el i n th e power tr a i n i s cor r ect (r ef er
t o p a r . 6 ). I n s p e ct a g a i n f or oi l l e a k s
after s tar ti ng the engi ne.
b . Tr ou b l e s h oot i n g Ta b l e . Th i s t r ou -
b l e s h oot i n g i n f or ma t i on wi l l a s s i s t me ch -
a n i cs i n di a gn os i n g a n d cor r ecti n g power
tr a i n ma l f u n cti on s . U s e Ta bl e I V, TROU -
BLESHOOTI NG, bel ow, i n conj uncti on wi th
pa r s . 233 a n d 234, TESTS AND ADJ U ST-
ME N TS. I n Ta b l e I V, t h e l e t t e r s s h own
op p os i t e t h e m a l f u n c t i on i n d i c a t e t h e
pr oba bl e ca u s es of tr ou bl e i n th e or der i n
w h i ch t h e y s h ou l d b e ch e ck e d . Th e i n -
s t r u ct i on s i n t h e l a s t col u mn a r e t o b e
f ol l owed i n cor r ecti n g th e ma l f u n cti on .
68. TROU BL ESH OOTI NG TESTS
Al l of t h e t e s t p r e s cr i b e d a f t e r r e -
bu i l d ma y be a ppl i ed to a power tr a i n i n
w h i ch a ma l f u n ct i on i s s u s p e ct e d (p a r .
233).
69. TROU BL E SH OOTI N G P OWE R
TRAI N REMOVED FROM VEH I CL E
Wh en th e ma l f u n cti on of a power tr a i n i s
n ot a s ce r t a i n e d b y t e s t s b e f or e r e mov a l
f r om th e v eh i cl e, th e power tr a i n s h ou l d
be mou n ted i n a tes t s ta n d a n d ch eck ed.
Re f e r t o p a r s . 2 3 3 a n d 2 3 4 . Pa r t i cu l a r
a t t e n t i on s h ou l d b e gi v e n t o cor r e ct a d -
j u s t me n t a n d p r op e r oi l l e v e l i n e v e r y
power tr ai n tes t.
70 Change 2
par. 234c
par. 6
par. 233e
pars. 70-75 and 227, 228
pars. 70-76 and 227-229
par. 234c
pars. 70-75 and 227, 228
pars. 70-75 and 227, 228
par. 6
par. 6
par. 234a
refer to vehicle TM
refer to vehicle TM
T R OU B L E S H OOT I NG CH AP 4, S E C I I
Ta b l e I V . TR OU B L E S H OOTI N G
(C on t i n u e d on n e x t p a g e )
7 1
par. 233e
pars. 70-75 and 227, 228
pars. 77-81
par. 234e
par. 233e
pars. 102-106
pars. 701-74, 82-86 and 228
pars. 70-75 and 227, 228
pars. 107-111
par. 234e
pars. 102-106
pars. 102-106
pars. 107-111
par. 233e
par. 234c
par. 234d
par. 233e
pars. 75, 76, 227 and 229
par. 234c
T R O U B L E S H O O T I N G
Ta b l e I V - C o n t i n u e d CH AP 4, SEC I I
(Con ti n u ed on n ex t pa ge)
7 2
par. 234d
par. 234a
par. 233e
pars. 75, 227
pars. 75, 142 through 146 and 227
par. 234d
pars. 75, 227
pars. 75, 227
pars. 75, 142
see vehicle TM
par. 223e
pars. 107-111
par. 234a and b
pars. 75, 227
PAR 69 TROU BL E SH OOTI N G PROCE DU RE S CHAP 4, SEC I I
Tabl e I V - Conti nued
73
PAR 70-71
CH APTE R 5
REPAI R AND REBU I L D
Secti on I . PREL I MI NARY I NSTRU CTI ONS FOR POWER TRAI N OVERH AU L
7 0 . G E N E R AL
a . Pr ov i de Pr oper E qu i pmen t. Pr oper
e q u i p me n t mu s t b e a v a i l a b l e b e f or e r e -
bui l d i s star ted. Thi s equi pment i ncl udes a
h oi s t of a t l e a s t 2 - t on c a p a c i t y , a d e -
qu a te h a n d tool s (pa r . 62) (a n d i mpr ov i s ed
t ool s , w h e r e a v a i l a b l e ). w ood b l ock s . r e -
cepta cl es f or s ma l l pa r ts , l i n t-f r ee wi pi n g
cl ot h s , oi l -s ol u b l e gr e a s e a n d n on h a r d e n -
i n g ga s k e t ce me n t . Ref er to Ta bl e I I a n d
p a r . 62 f or l i s t i n g of s p e ci a l a n d i mp r o-
v i s ed tool s .
WARN I N GS
G
G
G
Wh i te l ea d i s tox i c. To a v oi d i n j u r y ,
do not use whi te l ead.
Tr a n s mi s s i on a n d t r a n s mi s s i on com-
pon en ts a r e h ea v y a n d ca n cr u s h y ou .
H a v e a gr ou n d gu i de ch eck s l i n gs a n d
l i f t i n g d e v i ce s f or cu t s , b r e a k s or
w e a r b e f o r e a n d d u r i n g h o i s t i n g .
Sl i n gs a n d l i f t i n g d e v i ce s ca n b r e a k
a n d ca u s e i n j u r y or d e a t h . To a v oi d
i n j u r y , d o n ot s t a n d u n d e r t r a n s mi s -
s i on or components when l i fti ng them.
Fu mes f r om bu r n i n g Tef l on ca n ca u s e
s e r i o u s i n j u r y o r d e a t h . Beca u s e
cl u tch pi s ton s ea l r i n gs a n d s tep-j oi n t
s ea l r i n gs a r e ma de of Tef l on , do n ot
get r i d of them by bur ni ng.
b . Pa r t s t o Di s ca r d . At t r a n s mi s s i on
assembl y, al l pi ston seal s, seal r i ngs, pack -
i n gs , l ock wa s h er s , l ock n u ts , cotter pi n s ,
l ock wi r es , l ock s tr i ps a n d ga s k ets s h ou l d
b e r e mov e d a n d d i s ca r d e d . N e w p a r t s
s h ou l d a l wa y s be s u ppl i ed to r epl a ce s u ch
i t e ms .
c . Av oi d C omp on e n t Da ma g e . Us e
ca r e a v oi d d a ma ge t o t r a n s mi s s i on com-
p on e n t s d u r i n g d i s a s s e mbl y , cl e a n i n g, i n -
s p e ct i on , r e p a i r a n d r e a s s e mb l y . N i ck s ,
s cr a t ch e s a n d d e n t s r e s u l t i n g f r om ca r e -
l e s s h a n d l i n g ma y ca u s e oi l l e a k a ge or
i mpr oper f u n cti on i n g. Th i s cou l d r es u l t i n
t r a n s mi s s i on f a i l u r e . Al l d e f e ct i v e p a r t s
m u s t b e r e p l a c e d . H a n d l i n g of h e a v y
comp on e n t s wi t h s l i n gs a n d h ook s , a n d
b l ock i n g t h e t r a n s mi s s i on f or s u p p or t i n
v a r i ou s pos i ti on s , i s i mpor ta n t f or s a f ety
and to pr ev ent damage.
d. Torque. Al l pl ugs, bol ts, nuts and
s cr ews mu s t be i n s ta l l ed a t th e pr es cr i bed
tor qu e t i g h t n e s s t o en s u r e p r op e r
a s s embl y . Pr oper u s e of a tor qu e wr en ch ,
a n d ca r ef u l a tten ti on to pr es cr i bed tor qu e,
wi l l h el p pr ev en t di s tor ti on , oi l l ea k s a n d
s tr i pped th r ea ds . Al l tor qu e r equ i r emen ts
for pl ugs, bol ts, scr ews and nuts ar e found
i n the per ti nent r ebui l d secti on and i n the
a s s e mb l y s t e p p r oce d u r e s (s e c. XXXI I I )
wh i ch fol l ow.
71. CL E AN I N G RE COMME N DATI ON S
a . G e n e r a l . Cl e a n l i n e s s i s of p a r a -
mou n t i mpor ta n ce i n s er v i ci n g a tr a n s mi s -
s i on . Al l comp on e n t s mu s t b e t h or ou gh l y
cl ea n ed a n d k ept cl ea n th r ou gh ou t th e r e-
bu i l d pr oces s . Di r t ca n ca u s e ma l f u n cti on
a n d p os s i b l e f a i l u r e of t h e t r a n s mi s s i on .
Refer to th e Appen di x A, Secti on 4b.
b . Cl e a n i n g Pa r t s
WARNI NG
Compr es s ed s h op a i r wi l l n ot ex ceed
30 psi (pounds per squar e i nch). Regu-
l a t or a s s e mb l y mu s t b e a t t a ch e d t o
compr es s or . To a v oi d i n j u r y , u s e on l y
wi th ef f ecti v e ch i p-gu a r di n g a n d per -
s on a l p r ot e ct i v e e q u i p me n t (goggl e s /
f a ces h i el d, gl ov es , etc.).
74 Change 2
PAR 71-72 PRELI MI NARY I NSTRUCTI ONS FOR CHAP 5, SEC I
POWER TRAI N OVERHAUL
WARNI NG
Dr y Cl ea n i n g Sol v en t P-D-680 i s tox i c
a n d f l a mma bl e. To a v oi d i n j u r y , wea r
pr otecti v e goggl es a n d gl ov es a n d u s e
i n a w e l l -v e n t i l a t e d a r e a . Av oi d con -
ta ct wi th s k i n , ey es , a n d cl oth es , a n d
d o n ot b r e a t h e v a p or s . Do n ot u s e
n ea r open f i r e or ex ces s i v e h ea t. Th e
f l a s h p oi n t f or Ty p e I d r y cl e a n i n g
s ol v en t i s 100 F (38 C), a n d f or Ty pe
I I i s 138 F (50 C). I f you become di zzy
wh i l e u s i n g dr y cl ea n i n g s ol v en t, get
f r es h a i r i mmedi a tel y a n d get medi ca l
a i d . I f con t a ct w i t h e y e s i s ma d e ,
wa s h y ou r e y e s wi t h wa t e r a n d ge t
medi ca l a i r i mmedi a tel y .
(1 ) E v e r y comp on e n t s h ou l d b e
th or ou gh l y cl ea n ed a f ter th e tr a n s mi s s i on
i s d i s a s s e mbl e d . Cl e a n i n g i s n e ce s s a r y t o
en s u r e ef f ecti v e i n s pecti on f or wea r , da m-
a ge a n d s er v i cea bi l i ty of compon en ts .
( 2 ) A b r a s i v e s , f i l e s , s c r a p e r s ,
wi r e br u s h es a n d s h a r p tool s s h ou l d n ev er
be u s ed on s u r f a ces wh er e f i n i s h i s i mpor -
ta n t to th e oper a ti on or s ea l i n g of pa r ts ,
ex cept wh er e s peci f i ca l l y r ecommen ded.
(3) Gu m or v a r n i s h d e p os i t s ma y
b e r e mov e d b y s oa k i n g i n d r y cl e a n i n g
s ol v e n t or mi n e r a l s p i r i t s a n d u s i n g a
s of t - b r i s t l e b r u s h . C r ocu s cl ot h ma y b e
u s e d t o r e mov e mi n or s u r f a ce i r r e gu l a r i -
t i e s . L a p p i n g comp ou n d ma y b e u s e d , i f
r e q u i r e d , i n v a l v e b od y b or e s t o p r e v e n t
v a l v es f r om s ti ck i n g. Cl ea n th or ou gh l y to
r emov e compou n d a f ter u s e.
(4) A s of t w i r e (b r a s s or cop p e r )
ma y be u s ed to cl ea n oi l pa s s a ges . Al wa y s
fl ush such passages thor oughl y after cl ean-
i n g.
(5) I f s tea m cl ea n i n g i s u s ed, dr y
t h e cl e a n e d p a r t s i mme d i a t e l y w i t h com-
pr es s ed a i r a n d a ppl y a f i l m of oi l to pr e-
v e n t r u s t i n g. N e v e r u s e l y e or ca u s t i cs
wh i ch wi l l cor r ode or etch metal s u r faces .
(6 ) Do n ot c l e a n t h e l u b r i c a n t
f r om n e w b e a r i n gs . K e e p n e w b e a r i n g s
w r a p p e d u n t i l t h e y a r e t o b e i n s t a l l e d .
Soa k bea r i n gs wh i ch h a v e been i n s er v i ce
i n dr y cl ea n i n g s ol v en t or mi n er a l s pi r i ts
to l oos en depos i ts of di r t. Do n ot s pi n th e
bea r i n gs du r i n g cl ea n i n g or dr y i n g. Af ter
cl e a n i n g, t u r n t h e b e a r i n gs b y h a n d a n d
n ot e a n y e v i d e n ce of gr i t . Re cl e a n t h e m
i f gr i t i s pr es en t. Re f e r t o TM 9-214 f or
fur ther i nfor mati on on cl eani ng bear i ngs.
72. I NSPECTI ON AND REPAI R
RE COMME N DATI ON S
N ot e . Just befor e or dur i ng assem-
b l y , l u b r i ca t e a l l s e a l s , s h a f t s ,
gea r s , bea r i n gs , v a l v es , a n d oth er
mov i n g p a r t s w i t h t r a n s mi s s i on
oi l . Th i s l u b r i ca t i on wi l l p r ot e ct
t h e p a r t s d u r i n g s t or a ge a n d a t
i n i ti al s tar t-u p.
a . Ca s ti n gs , For gi n gs , Ma ch i n ed
Su r f a ce s
(1) I n s p e ct a l l ca s t i n gs a n d f or g-
i n gs for br eak s , cr ack s an d wear or s cor i n g
t h a t wou l d i mp a i r s e r v i ce a b i l i t y . Re mov e
n i ck s a n d s ma l l s u r f a ce i r r egu l a r i ti es wi th
cr ocu s cl oth or a s oft s ton e.
(2 ) I n s p e ct a l l oi l p a s s a g e s f or
obs tr u cti on s a n d di r t. Recl ea n pa s s a ges i f
n eces s a r y .
(3 ) I n s p e c t m ou n t i n g f a c e s f or
n i ck s , s cr a tch es a n d s cor es . Remov e mi n or
def ects wi th cr ocu s cl oth or a s of t h on i n g
s ton e. Repl a ce a n y pa r ts i n wh i ch def ects
t h a t ca n n ot b e cor r e ct e d wi l l i mp a i r t h e
oper a ti on of th e tr a n s mi s s i on .
(4) I n s pect th r ea ded open i n gs f or
da ma ged th r ea ds . Ch a s e da ma ged th r ea ds
wi th th e cor r ect s i ze u s ed tap.
Note. A n ew tap wi l l cu t ov er s i ze.
I f thr eads ar e str i pped, di scar d the
pa r t u n l es s i t ca n be s a ti s f a ctor i l y
r epai r ed by i nstal l i ng an i nser t.
(5 ) R e p l a c e h o u s i n g s o r o t h e r
cas t par ts th at ar e cr ack ed or br ok en .
b . Rol l e r or Ba l l Be a r i n gs . Re f e r t o
TM 9-214 f or pr oper cl ea n i n g a n d i n s pec-
ti on pr ocedu r es .
c . N e e d l e - t y p e R ol l e r Be a r i n g s . I n -
s p e ct t h e b e a r i n gs f or f r e e a n d s moot h
r ot a t i on , b r ok e n or mi s s i n g r ol l e r s , a n d
Change 2 75
CHAP 5, SEC I
PRELI MI NARY I NSTRUCTI ONS FOR PAR 72
POWER TRAI N OVERHAUL
ti gh tn es s of f i t i n th e bor e. I f def ects a r e
fou n d, r epl ace th e bear i n g u s i n g th e pr oper
r e p l a ce r .
N o t e . Do n ot r emov e n eedl e bea r -
i n gs u n l e s s r e p l a ce me n t i s n e ce s -
s a r y , s i n ce r emov a l u s u a l l y r es u l ts
i n des tr ucti on of the bear i ng.
d . Bu s h i n gs , Bu s h i n g-ty pe Bea r i n gs
-
a n d Th r u s t Wa s h e r s
(1) I n s pect bu s h i n gs a n d bu s h i n g-
ty pe bea r i n gs f or s i ze, s cor i n g a n d ou t-of -
r oundnes s , bur r s , s har p edges and ev i dence
of s ei zi n g. Mi n or s cor es , s h a r p edges a n d
s cr a t ch e s ma y b e r e mov e d w i t h cr ocu s
cl ot h . Ou t - of - r ou n d , d e e p l y s cor e d or
wor n par ts shoul d be di scar ded.
N ot e . Do n ot r e mov e b u s h i n g s
b u s h i n g - t y p e b e a r i n g s u n l e s s
r e p l a ce me n t i s n e ce s s a r y , a s r e -
m o v a l u s u a l l y d a m a g e s t h e s e
par ts .
(2) Remov e bu s h i n gs a n d bu s h i n g-
t y p e b e a r i n gs b y u s i n g a p u l l e r or p r e s s
wh e n p os s i b l e . Bu s h i n gs i n b l i n d h ol e s
ma y r equ i r e r emov a l by s a wi n g or th e u s e
of a nar r ow cape chi sel .
C a u t i on . I f neces s ar y to cut out a
b u s h i n g, d o n ot d a ma ge t h e b or e
i nto whi ch i t fi ts.
(3 ) I n s p e c t t h r u s t w a s h e r s f or
w e a r , d i s t or t i on , s cor e s a n d b u r r s . C o r -
r ect mi n or def ects bu t r epl a ce pa r ts th a t
a r e wor n , s cor ed or def or med.
e . Oi l Sea l s , Pr ef or med Pa ck i n gs
an d Ga s k e t s
(1 ) I n s p e ct h ook - t y p e s e a l r i n g s
f or w e a r , d i s t or t i on a n d b r ok e n h ook s .
R e p l a ce d e f e ct i v e s e a l r i n g s . I n s t a l l a
n ew h ook -ty pe s ea l r i n g i f th e r i n g s h ows
a n y wea r on th e ou ts i de ci r cu mf er en ce, or
i f th er e i s ex ces s i v e s i de wea r . Th e s i des
of t h e s e a l r i n g mu s t b e s moot h wi t h i n
0.005-i n ch ma x i mu m s i de wea r . Th e s i des
of t h e s h a f t g r oov e (or t h e b or e ) i n t o
wh i ch th e s ea l r i n g f i ts s h ou l d be s mooth
w i t h i n 5 0 m i c r oi n c h e s e q u i v a l e n t a n d
s q u a r e wi t h t h e a x i s of r ot a t i on wi t h i n
0 . 0 0 2 - i n ch . I f t h e s i d e s of t h e g r oov e s
h a v e t o b e r e w or k e d , i n s t a l l a n e w s e a l
r i n g.
(2 ) I n s p e ct m e t a l - e n c a s e d l i p -
ty pe s ea l s f or cr a ck s , wea r , cu ts a n d br i t-
t l e n e s s . I n s p e ct s p r i n gs a n d s e a l s h e l l s .
Repl a ce a n y s ea l s f ou n d def ecti v e.
N o t e . An y t i me a me t a l -e n ca s e d
l i p -t y p e s e a l i s r e mov e d , i t mu s t
be r epl aced wi th a new seal .
f . G e a r s
(1) I n s pect gea r s f or bu r r s , wea r ,
pi tti n g a n d br ok en teeth a t tooth con ta ct
ar eas .
(2 ) I n s p e c t b o r e s o f p l a n e t a r y
p i n i on s f or we a r a n d p i t t i n g of b e a r i n g
con ta ct a r ea s .
(3 ) R e m ov e b u r r s u s i n g a s of t
h o n i n g s t o n e . R e p l a c e g e a r s t h a t a r e
ex ces s i v el y wor n or pi tted.
g . Spl i n ed Par ts
(1 ) I n s p e ct s p l i n e d p a r t s f or
t w i s t e d or b r ok e n s p l i n e s , b u r r s a n d e x -
ces s i v e wea r .
(2 ) R e m ov e b u r r s u s i n g a s of t
h on i n g s t on e . Re p l a ce p a r t s wh i ch h a v e
t wi s t e d or b r ok e n s p l i n e s a n d e x ce s s i v e
w e a r .
h . C l u t c h Pl a t e s
(1 ) I n s p e c t f r i c t i o n - f a c e d s t e e l
p l a t e s f or b u r r s , e mb e d d e d me t a l p a r -
t i cl e s , s e v e r e l y p i t t e d f a ce s , e x ce s s i v e
w e a r , c r a c k s , d i s t o r t i o n a n d d a m a g e d
s pl i n ed teeth . Remov e bu r r s u s i n g a s of t
h on i n g s t on e . Re p l a ce p l a t e s wh i ch h a v e
oth er def ects .
(2) I n s pect s teel pl a tes f or bu r r s ,
s cor i n g, e x ce s s i v e w e a r , d i s t or t i on , e m-
bedded meta l , ga l l i n g, cr a ck s , br ea k s a n d
d a ma ge d s p l i n e t e e t h . Re mov e b u r r s a n d
mi n or s u r f a ce i r r e gu l a r i t i e s u s i n g a s of t
h on i n g s t on e . Re p l a ce p l a t e s wh i ch h a v e
oth er def ects .
76 Change 2
PAR 72 PRELI MI NARY I NSTRUCTI ONS FOR CHAP 5, SEC I
POWER TRAI N OVERHAUL
i . Th r e a d e d Pa r t s
(1) I n s pect a l l th r ea ded pa r ts f or
str i pped or damaged thr eads and bur r s.
(2) Re p l a ce a l l p a r t s wh i ch h a v e
s tr i pped th r ea ds or da ma ge wh i ch ca n n ot
be r epa i r ed by ch a s i n g th e th r ea ds wi th a
tap or di e of th e pr oper s i ze.
N ot e . Ch a s e t h r e a d s wi t h a u s e d
t a p or d i e . A n e w t a p ma y cu t
ov er s i ze, wh i l e a n ew di e ma y cu t
u n der s i ze.
j . Sn a p Ri n gs . I n s pect s n a p r i n gs f or
n i ck s , bu r r s , di s tor ti on a n d wea r . Di s ca r d
def ecti v e s n a p r i n gs .
k . Spr i n gs . I n s pect s pr i n gs f or wea r ,
d i s t or t i on , b r e a k s , e v i d e n ce of ov e r h e a t -
i n g, a n d l os s of t e n s i on or comp r e s s i on .
Di s ca r d def ecti v e s pr i n gs .
l . Sh afts an d Spi n dl es
(1) I n s pect s h a f ts a n d s pi n dl es f or
e x ce s s i v e w e a r , b e n d i n g, s cor e s , cr a ck s ,
bur r s and obstr ucted oi l passages.
(2) Re mov e b u r r s a n d mi n or s u r -
f a ce i r r egu l a r i ti es wi th cr ocu s cl oth or a
s of t h on i n g s t on e . Re mov e ob s t r u ct i on s
b y p r ob i n g w i t h s of t w i r e or w i t h com-
pr es s ed a i r . Di s ca r d def ecti v e pa r ts .
m . Ba l l -ty pe Va l v es
(1) I n s p e ct ba l l s f or r u s t , p i t t i n g
or gr oov i n g. Di s ca r d ba l l s wh i ch wi l l n ot
s ea t pr oper l y .
(2 ) I n s p e ct b a l l s e a t s f or w e a r
a n d p i t t i n g. Re s e a t b y l a p p i n g wi t h t h e
p r op e r s i z e b a l l . Di s ca r d p a r t s i n wh i ch
th e s eat can n ot be r es tor ed.
n . Sp ool - t y p e Va l v e s
(1) I n s pect v a l v es f or wea r , bu r r s ,
s c o r i n g a n d e v i d e n c e o f s t i c k i n g . Tr y
v a l v e s i n t h e i r b or e s . Al l v a l v e s s h ou l d
mov e i n thei r bor es by thei r wei ght al one.
Do n ot f or ce v a l v es .
Change 2 76.1/(76.2 blank)
*C2
*C2
*C2
PAR 7 2 - 7 3 DI S AS S E MB L Y CH AP 5, SEC I I
(2) I n s pect th e edges of a l l v a l v e l a n ds .
Al l e d ge s s h ou l d b e s q u a r e a n d s h a r p . Do n ot
d e s t r oy t h e s e s h a r p e d ge s i n cl e a n i n g or r e -
pa i r oper a ti on s . Th e s h a r p edges h el p pr ev en t
t h e a ccu mu l a t i on of s u b s t a n ce s w h i ch mi g h t
ca u s e th e v a l v e to s ti ck i n i ts bor e.
(3) Remov e bur s wi th a s oft honi ng s tone.
Re cl e a n v a l v e s i f n e ce s s a r y t o r e mov e gu m or
d i r t d e p os i t s . Di s ca r d d e f e ct i v e v a l v e s .
o. Sheet Metal Parts
(1) I n s pect s h eet meta l pa r ts f or ben ds ,
cr a ck s , d i s t or t i on , i n t e r f e r e n ce wi t h a d j a ce n t
p a r t s , a n d l oos e - w e l d e d p oi n t s .
(2) St r a i gh t e n b e n t p a r t s . We l d cr a ck s
or l oos e w e l d s .
(3 ) Di s ca r d g ov e r n or oi l col l e ct or r i n g
i f a n y da ma ge i s ev i den t.
p . Th r e a d e d I n s e r t s
(1) I n s p e ct i n s e r t f or
a ge d t h r e a d s a n d b u r s .
s t r i p p e d or d a m-
(2 ) I f n e ce s s a r y t o r e mov e a n i n s e r t ,
t h e b ol t wh i ch wa s r e mov e d f r om t h e i n s e r t
ca n be u s ed wi th a n u t of th e s a me s i ze.
(3) Gr i n d a s h ou l d e r on on e e n d of t h e
nut wi de enough to al l ow the nut to s eat agai ns t
th e i n s er t a n d n ot con ta ct th e a dj a cen t mou n t-
i n g s u r f a ce .
(4) Th r ea d th e n u t on to th e bol t, s h ou l -
d e r s i d e of t h e n u t a w a y f r om t h e b ol t h e a d ,
a n d i n s t a l l t h e b ol t i n t o t h e i n s e r t t o b e r e -
mov e d .
(5) Lock th e bol t to th e i n s er t by ti gh ten -
i n g t h e n u t a ga i n s t t h e i n s e r t . Tu r n t h e b ol t
t o r e mov e t h e i n s e r t .
q . Do w e l Pi n s
(1 ) I n s p e c t p i n s f o r e x c e s s i v e w e a r ,
b e n d i n g or b u r s .
(2) Re mov e b u r s a n d mi n or s u r f a ce i r -
r egu l a r i ti es wi th cr ocu s cl oth or a s of t h on i n g
s t on e . Di s ca r d p i n s w i t h ot h e r d e f e ct s .
(3 ) To r e mov e a d ow e l p i n , d r i l l a n d
ta p a h ol e i n th e dowel to be r emov ed.
(4 ) Ob t a i n a s l e e v e w h i ch w i l l e x t e n d
a bou t a n i n ch a bov e th e top of th e dowel wh en
the sl eeve i s pl aced over the dowel . The
s l e e v e mu s t h a v e s q u a r e e n d s a n d t h e i n s i d e
di a meter of th e s l eev e mu s t be s l i gh tl y l a r ger
th a n th e ou ts i de di a meter of th e dowel pi n .
(5) Pl a ce t h e s l e e v e ov e r t h e d ow e l t o
be r emov ed a n d i n s ta l l a wa s h er on th e s l eev e.
(6) U s i n g a bol t a n d n u t t h e s a me s i z e
a s th e th r ea ded h ol e i n th e dowel , i n s ta l l th e
n u t on t h e b ol t a n d t h r e a d t h e b ol t i n t o t h e
d ow e l p i n .
(7) Hol d the bol t and tur n the nut agai nst
th e wa s h er to r emov e th e dowel .
Section II. DI SASSEMBLY OF POWER TRAI N I NTO SUBASSEMBLI ES
7 3 . G E N E R A L ,
a. Thi s secti on presents the compl ete
d i s a s s e mb l y of t h e XTG-411-2A t r a n s mi s s i on ,
i n p u t t r a n s f e r a s s e mb l y a n d ou t p u t d r i v e a s -
s e m b l i e s . Th e d i s a s s e m b l y p r oc e d u r e s a r e
p r e s e n t e d i n p i ct or i a l s t e p - b y - s t e p i l l u s t r a -
t i o n s . D i r e c t l y b e n e a t h e a c h p i c t u r e a r e
s i mp l e d i s a s s e mb l y i n s t r u ct i on s , k e y e d t o t h e
p i ct u r e s b y l e t t e r ca l l ou t s .
b . Re f e r t o f i gs . 373 t h r ou gh 386 (f ol d -
ou ts 2 th r ou gh 15 i n ba ck of ma n u a l ) f or pa r ts
i d e n t i f i ca t i on a n d l oca t i on .
c . Dr a i n t h e t r a n s mi s s i on oi l . Re f e r t o
TM 9 - 2 3 0 0 - 2 1 6 - 1 0 f or d r a i n i n g p r oce d u r e s
7 7
*C2
*C2
CHAP 5, SEC I I
DI S AS S E MB L Y
PAR 74, STEPS 1 - 4
7 4 . DI S AS S E MBL Y S TE PS
I N PU T TR AN S F E R AS S E MBL Y
Fi gur e 39 (Step 1)
U s i n g h oi s t (A), s l i n g (B), a n d b r a ck e t (C ),
p os i t i on t h e p ow e r t r a i n a s s e mb l y on b l ock s
(D) on t h e f l oor or d i s a s s e mb l y t a b l e , R e -
mov e th e s l i n g a n d br a ck et.
Fi gu r e 40 (Step 2) Re mov e i n p u t t r a n s f e r a s s e mb l y (A) a n d ga s -
Atta ch s l i n g (A) to th e i n pu t tr a n s f er h ou s i n g.
U s i n g a 5 /8 - i n c h w r e n c h , r e m ov e 1 6 i n p u t
t r a n s f e r - t o- con v e r t e r h ou s i n g b ol t s a n d l ock
w a s h e r s (B).
7 8
Fi gu r e 41 (Step 3)
U s i n g a 5 /8 - i n c h w r e n c h , r e m ov e 1 0 i n p u t
transfer-to-converter housi ng bol ts and
10 l ock wa s h e r s (A). Re mov e e n gi n e cou p l i n g
s h aft (B).
Fi gu r e 42 (Step 4)
k e t (B). U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e
11 bol ts a n d l ock wa s h er s (C) r eta i n i n g i n pu t
a n d s ca v e n g e oi l p u mp a s s e mb l y . I f n e ce s -
s a r y , u s e t w o mou n t i n g b ol t s a s j a ck s cr e w s ,
i n h ol es (D).
*C2
P AR 74, ST EPS 5 - 8
DI S AS S E MB L Y
CH AP 5, SEC I I
Fi gu r e 43 (Step 5)
Remov e i n pu t a n d s ca v en ge oi l pu mp a s s embl y
(A) a n d ga s k et (B). Remov e s ea l r i n g (C) f r om
i n p u t t r a n s f e r h ou s i n g a s s e mb l y .
Fi gu r e 44 (Step 6)
St r a i gh t e n cor n e r s of l ock s t r i p (A). U s i n g a
9 /1 6 - i n ch w r e n ch , r e mov e t w o b ol t s (B). R e -
mov e l ock s t r i p (A) a n d s t r a p (C ) r e t a i n i n g
i d l e r cl u s t e r ge a r s p i n d l e (D).
Fi gu r e 45 (Step 7)
U s i n g t wo 3/8-16 bol t s a n d f l a t wa s h e r s , a t -
t a ch s l i n g (A) t o i n p u t t r a n s f e r h ou s i n g (B).
Pos i t i on t h e h ou s i n g a s s e m b l y on t h e d i s -
a s s e mb l y t a b l e , s u p p or t i n g t or q u e con v e r t e r
(C), a n d k eepi n g th e tr a n s f er h ou s i n g a s s embl y
l e v e l .
Fi gu r e 46 (Step 8)
U s i n g a 9/16-i n ch w r e n ch , r e mov e e i gh t b ol t s
a n d l ock wa s h e r s (A) f r om con v e r t e r b e a r i n g
cov e r (B). Re mov e cov e r (B) a n d ga s k e t (C).
7 9
CHAP 5, SEC I I
DI S AS S E MB L Y PAR 74, STEPS 9 - 1 2
Fi gu r e 47 (Step 9)
U s i n g a s of t h a mmer , a n d wh i l e r a i s i n g tr a n s -
f er h ou s i n g (A), ta p l i gh tl y on th e tor qu e con -
v e r t e r a s s e mb l y (B) t o r e mov e i t f r om t h e
h ou s i n g .
Fi gu r e 48 (Step 10)
U s i n g a l /2 - i n c h w r e n c h , l oos e n 2 4 t or q u e
con v e r t e r cov e r - t o- p u mp a s s e mb l y n u t s (A),
a n d r e mov e a l l b u t t w o, 180 d e gr e e s a p a r t .
8 0
Fi gu r e 49 (Step 11)
Tu r n t h e con v e r t e r ov e r a n d r e mov e t h e t w o
r e ma i n i n g n u t s . U s i n g t h r e e 3/8-24 b ol t s (A)
a s j a ck s cr ews , s epa r a te l ock u p cl u tch r ea cti on
p l a t e (B) f r om cov e r (C). U s i n g s l i n g (D) a n d
h ook s (E ), r e mov e p u mp a s s e mb l y (F ).
Fi gu r e 50 (Step 12)
Re mov e t or q u e con v e r t e r s t a t or a s s e mb l y (A).
*
C2
PAR 74, STEPS 1 3 - 1 6
DI S AS S E MB L Y
CH AP 5, S E C i i
Fi gu r e 51 (Step 13)
U s i n g t w o s cr e w d r i v e r s (A ), r e mov e t or q u e
con v e r t e r t u r b i n e a s s e mb l y (B).
Fi gu r e 53 (Step 15)
Re mov e l ock u p cl u t ch p i s t on (A) b y b u mp i n g
con v er ter cov er a s s embl y (B) l i gh tl y on wooden
b l ock s (C ). R e mov e h ook - t y p e s e a l r i n g (D)
f r om h u b of th e cov er a s s embl y . Do n ot r e-
mov e s e a l r i n g (E ) a n d e x p a n d e r f r om t h e
l ock u p cl u t ch p i s t on u n 1 e s s r e p l a ce me n t i s
n e c e s s a r y .
Fi gu r e 52 (Step 14)
Remov e l ock u p cl u tch r ea cti on pl a te (A), l ock -
u p cl u t ch p l a t e (B) a n d t h r e e j a ck s cr e w s (C)
f r om con v e r t e r cov e r a s s e mb l y (D).
Fi gu r e 54 (Step 16)
U s i n g a 5 /8 - i n c h w r e n c h , r e m ov e 2 0 s e l f -
l ock i n g b ol t s (A) a n d f l a t w a s h e r s r e t a i n i n g
f l a n ge a d a p t e r (B).
8 1
CHAP 5, S E C 1]
DI S AS S E MB L Y P A R 74, ST EPS 1 7 - 2 0
Fi gure 55 (Step 17)
I nstal l three mounti ng bol ts (A) i n jackscrew
hol es. Attach sl i ng (B) and remove adapter (C)
and gear (D). Remove gasket (E). Cauti on:
Whi l e l i fti ng adapter, be careful t o prevent
gear from droppi ng.
Fi gure 56 (Step 18)
I f i nput transfer dri ve gear (A) remai ned wi th
fl ange adapter assembl y (B), posi ti on the as-
sembl y i n a press. Press gear (A) and i ts
beari ngs, as an assembl y, from the adapter.
Fi gure 57 (I l tep 19)
Remove pl ug (,4), gasket (B) and oi l screen ((C)
from i nput tramsfer h o I I s i n g (D). Usi ng a
5/8-i nch wrenc:h, remov(! sel f- l ocki ng bol t (E)
and fl at washer (F).
*m
Fi gure 58 (f3tep 20)
Usi ng a hammer and chi sel , strai ghten l ock
stri p (A). Re:move two bol ts (B), l ock stri p
(A) and strap (C).
82
PAR 74, STEPS 2 1 - 2 4 DI S AS S E MB L Y CH AP 5, SEC I I
Fi gu r e 61 (Step 23)
R e m o v e s e a l r i n g s (A ) f r o m i n p u t t r a n s f e r
cl u s t e r ge a r s p i n d l e (B).
Fi gu r e 59 (Step 21)
U s i n g p u l l e r (A), r e mov e cl u s t e r ge a r s p i n d l e
(B). N o t e . S u p p or t t h e cl u s t e r g e a r i n t h e
t r a n s f e r h ou s i n g w h e n r e mov i n g s p i n d l e (B).
Fi gu r e 60 (Step 22)
Remov e s pa cer (A) a n d cl u s ter gea r a n d bea r -
i n g a s s e mb l y (B).
Fi gu r e 62 (Step 24)
U s i n g p u l l e r (A), r e mov e i d l e r cl u s t e r g e a r
spi ndl e (B). Remove seal ri ng (C) from
s p i n d l e (B). N o t e . Su p p or t t h e i d l e r cl u s t e r
ge a r a s s e mb l y w h e n r e mov i n g t h e s p i n d l e .
8 3
CHAP 5. SEC I I DI SASSEMBL Y
75.
Fi gu r e 63 (Step 25)
R e mov e i d l e r cl u s t e r g e a r a n d b e a r i n g a s -
s e mb l y (A).
PAR 7 4 - 7 5
DI SASSE MBL Y STE PS
MAI N TRAN SMI SSI ON ASSE MBL Y
Fi gu r e 65 (Step 1)
U s i n g a l /2-i n ch wr e n ch , r e mov e 18 b ol t s (A)
a n d f l a t wa s h e r s (B) r e t a i n i n g r e gu l a t or a n d
l ock u p s h i f t con t r ol v a l v e b od y a s s e mb l y (C).
Fi gu r e 64 (Step 26)
R e mov e i n p u t oi l p u mp d r i v e g e a r (A) f r om
h ou s i n g (B).
8 4
Fi gu r e 66 (Step 2)
R e m o v e r e g u l a t o r a n d l o c k u p s h i f t c o n t r o l
v a l v e b od y a s s e mb l y (A) a n d ga s k e t (B).
P A R 7 5 S T E P S 3 - 6
DI S AS S E MB L Y
CH AP 5, SEC I I
Fi gu r e 67 (Step 3)
R e m o v e r e g u l a t o r a n d l o c k u p s h i f t c o n t r o l
v al v e body oi l tr ans fer pl ate (A) and gas k et (B).
Fi gu r e 68 (Step 4)
U s i n g a l /2-i n ch wr e n ch , r e mov e 28 b ol t s (A)
a n d l ock w a s h e r s (B) r e t a i n i n g ma i n con t r ol
v a l v e b od y a s s e mb l y (C).
Fi gu r e 69 (Step 5)
Re mov e ma i n con t r ol v a l v e b od y a s s e mb l y (A)
a n d ga s k et (B).
Fi gu r e 70 (Step 6)
U s i n g a l /2 - i n ch w r e n ch , r e mov e f ou r b ol t s
(A) a n d l ock wa s h er s (B) a n d f ou r s el f -l ock i n g
bol ts (C) wi th f l a t wa s h er s r eta i n i n g ma i n con -
tr ol v a l v e body oi l tr a n s f er pl a te a s s embl y (D).
8 5
CH AP 5, SEC I I DI S AS S E MB L Y PAR 75, STEPS 7 - 1 0
Fi gu r e 71 (Step 7)
Re mov e con t r ol v a l v e b od y oi l t r a n s f e r p l a t e
a s s e mb l y (A) a n d ga s k e t (B).
Fi gu r e 73 (Step 9)
R e m o v e s t e e r c o n t r o l v a l v e b o d y a s s e m b l y
(A) a n d ga s k et (B).
Fi gu r e 72 (Step 8)
U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e 1 5 b ol t s
(A) a n d l ock w a s h e r s (B) r e t a i n i n g s t e e r con -
t r ol v a l v e b od y a s s e mb l y (C).
8 6
Fi gu r e 74 (Step 10)
U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e 2 8 b ol t s
(A) a n d l ock wa s h er s (B) r eta i n i n g r el a y v a l v e
b od y a s s e mb l y (C ).
PAR 75, STEPS 1 1 - 1 4
DI S AS S E MB L Y CH AP 5, SEC I I
Fi gu r e 75 (Step 11)
Re mov e r e l a y v a l v e b od y a s s e mb l y (A), ga s k e t
(B) a n d two n y l on ba l l s (C).
Fi gu r e 76 (Step 12)
U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e 2 2 b ol t s
(A) a n d l ock wa s h er s (B), r eta i n i n g r el a y v a l v e
b od y oi l t r a n s f e r p l a t e (C).
Fi gu r e 77 (Step 13)
Re mov e oi l t r a n s f e r p l a t e (A) a n d ga s k e t (B).
Fi gu r e 78 (Step 14)
U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e 2 0 b ol t s
(A) a n d l ock wa s h e r s (B) r e t a i n i n g t r a n s mi s -
s i on top cov er pl a te (C).
8 7
CH AP 5, SEC I I DI S AS S E MB L Y PAR 75, STEPS 1 5 - 1 8
Fi gu r e 79 (Step 15)
Re mov e t r a n s mi s s i on t op cov e r p l a t e (A). Re -
mov e f ou r s e l f - l ock i n g b ol t s (B), b a f f l e (C )
a n d ga s k et (D).
F i g u r e 8 1 ( S t e p 1 7 )
U s i n g wr e n ch (A), a p p l y t h e t r a n s mi s s i on l e f t
br ak e.
Fi gu r e 80 (Step 16)
U s i n g a 9/16- i n ch w r e n ch , r e mov e t h r e e b ol t s
(A) a n d l ock w a s h e r s r e t a i n i n g oi l s cr e e n a s -
s embl y (B). U s i n g two bol ts (A) a s j a ck s cr ews ,
l oos e n a n d r e mov e s cr e e n a s s e mb l y (B).
Fi gu r e 82 (Step 18)
U s i n g a 1-i n ch wr en ch , a n d wi th th e l ef t br a k e
a p p l i e d , r e m o v e t h e l e f t - o u t p u t s h a f t s e l f -
l ock i n g b ol t (A). R e mov e l ock p l a t e (B) a n d
cou pl i n g (C).
8 8
P AR 75 ST EPS 1 9 - 2 2 DI S AS S E MB L Y CH AP 5, SEC I I
Fi gu r e 85 (Step 21)
Re mov e ou t p u t oi l p u mp d r i v e n ge a r (A) a n d
k e y (B). U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e
f ou r s e l f -l ock i n g b ol t s (C) r e t a i n i n g oi l p u mp
(D). R e mov e oi l p u mp (D).
Fi gu r e 83 (Step 19)
U s i n g a 5/8-i n ch wr en ch , r emov e 13 bol ts (A),
l ock wa s h er s (B) a n d l i f ti n g br a ck et (C).
Fi gu r e 84 (Step 20)
Re mov e l e f t - ou t p u t s u p p or t a s s e mb l y (A), ga s -
k e t (B) a n d ou t p u t oi l p u mp d r i v e ge a r (C).
Remov e s n a p r i n g (D) r eta i n i n g oi l pu mp dr i v en
ge a r (E ).
Fi gu r e 86 (Step 22)
U s i n g a 5 /8 - i n c h w r e n c h , r e m o v e f i v e c o n -
v e r t e r - t o- ma i n t r a n s mi s s i on h ou s i n g a s s e m-
b l y b ol t s (A) a n d f l a t w a s h e r s (B). U s i n g a
9 /1 6 - i n ch w r e n ch , r e mov e s i x b ol t s (C ) a n d
l ock wa s h er s (D) r eta i n i n g oi l s cr een cov er (E ).
8 9
CH AP 5, SEC I I
DI SASSEMBL Y PAR 75, ST EPS 2 3 - 2 6
Fi gu r e 89 (Step 25)
F i g u r e 8 7 (S t e p 2 3 )
U s i n g l i f ti n g s l i n g (A), r emov e con v er ter h ou s -
i n g a s s e mb l y (B) a n d ga s k e t (C) f r om t r a n s -
mi s s i on h ou s i n g (D). U s e j a ck s cr e w s (E ), t o
s e p a r a t e h o u s i n g s R e m o v e t r a n s m i s s i o n
l e f t - ou t p u t s h a f t (F ). Re mov e O- r i n g s e a l (G)
f r om h ou s i n g (B).
R e m o v e s c r e e n c o v e r ( A ) , g a s k e t ( B ) a n d
o i l s c r e e n ( C ) .
Fi gu r e 88 (Step 24)
Fi gu r e 90 (Step 26)
U s i n g a 5/8-i n ch w r e n ch , r e mov e t h e r e ma i n -
i n g con v e r t e r - t o- ma i n t r a n s mi s s i on h ou s i n g
b ol t s (A) a n d l ock w a s h e r s (B).
9 0
U s i n g a 1-i n ch wr en ch , a n d wh i l e a ppl y i n g th e
l e f t b r a k e , l oos e n b ol t (A).
P AR 75. ST EPS 2 7 - 3 0
Dl SASSEMBLY
CH AP 5, SEC I I
Fi gu r e 91 (Step 27)
Fi gu r e 93 (Step 29)
Atta ch s l i n g (A), a n d, u s i n g a 5/8-i n ch wr en ch ,
r e mov e 27 b ol t s (B), f ou r b ol t s (C) a n d t h r e e
b ol t s (D) a n d 34 l ock wa s h e r s . Re mov e l i f t i n g
b r a c k e t (E ). U s e t h r e e b o l t s (B ) a s j a c k -
s cr ews i n h ol es (F), to l oos en ou tpu t h ou s i n g.
U s i n g w r e n ch (A), a p p l y t r a n s mi s s i on r i g h t
b r a k e . U s i n g a l - i n ch w r e n ch , r e mov e b ol t
(B), l ock pl a te (C) a n d ou tpu t cou pl i n g (D).
Fi gu r e 94 (Step 30)
Fi gu r e 92 (Step 28)
U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e s i x b ol t s
(A) a n d l ock wa s h er s (B) r eta i n i n g a ccu mu l a tor
b od y (C). Re mov e a ccu mu l a t or b od y a n d ga s -
k et (D).
Remov e r i gh t-ou tpu t h ou s i n g a s s embl y (A) a n d
g a s k e t (B). R e mov e ou t p u t t r a n s f e r d r i v e
s h a f t (C ). U s i n g a 1 - i n c h w r e n c h , r e m ov e
b ol t (D) a n d l ock p l a t e (E ) r e t a i n i n g b r a k e
cool a n t oi l p u mp d r i v e ge a r (F ).
9 1
CH AP 5, SEC I I
DI S AS S E MB L Y PAR 75, STEPS 3 1 - 3 4
Fi gu r e 95 (Step 31)
Remov e br a k e cool a n t oi l pu mp dr i v e gea r (A)
a n d s p a ce r (B).
Fi gu r e 97 (Step 33)
R e m o v e t h r e e r e a r - t o - m a i n t r a n s m i s s i o n
h ou s i n g bol ts (A) a n d f l a t wa s h er s .
Fi gu r e 96 (Step 32)
U s i n g s l i n g (A), r a i s e t h e t r a n s mi s s i on a n d
b l ock i t a s s h own . U s i n g a 9/16-i n ch wr e n ch ,
r e mov e 19 b ol t s (B) a n d l ock w a s h e r s (C) r e -
t a i n i n g b r a k e cool a n t oi l p u mp a n d ma n i f ol d
a s s e mb l y (D). Re mov e a s s e mb l y (D) a n d ga s -
k e t (E ). Do n ot r e mov e t h r e e b ol t s (F ).
9 2
Fi gu r e 98 (Step 34)
U s i n g a 3/4- i n ch w r e n ch , r e mov e t h r e e s e l f -
l ock i n g (A) a n d f ou r s ta n da r d (B) r ea r -to-ma i n
t r a n s mi s s i on h ou s i n g b ol t s wi t h l ock wa s h e r s
(C) a n d f l a t wa s h er s (D).
PAR 75, ST EPS 3 5 - 3 8
DI S AS S E MB L Y CH AP 5, S E C I I
Fi gu r e 99 (Step 35)
Re mov e l e f t - s t e e r p l a n e t a r y r e t a i n i n g b ol t (A)
a n d l ock pl a te (B).
Fi gu r e 100 (Step 36)
R e mov e r e ma i n i n g r e a r - t o- ma i n t r a n s mi s s i on
h ou s i n g b ol t s a n d l ock wa s h e r s . Two b ol t s (A)
r e q u i r e a 3/4- i n ch w r e n ch . Bol t (B) r e q u i r e s
a 15/16-i n ch wr e n ch . Th e r e ma i n d e r wi l l r e -
q u i r e a 5 /8 - i n ch w r e n ch .
Fi gu r e 101 (Step 37)
U s i n g s l i n g (A ), r e m ov e t r a n s m i s s i on r e a r
h ou s i n g (B) f r om ma i n t r a n s mi s s i on h ou s i n g
(C). Re mov e s h i ms (D) a n d ga s k e t (E ).
R e m o v e s p a c e r ( A ) . R e m o v e t w e n t y l e f t -
b r a k e p l a t e s (B).
9 3
CH AP 5, SEC I I
DI SASSEMBL Y P AR 75, ST EPS 3 9 - 4 2
Fi gu r e 103 (Step 39)
U s i n g s l i n g (A), p os i t i on t r a n s mi s s i on ma i n
h ou s i n g on d i s a s s e mb l y t a b l e , b l ock i n g a s -
s e mb l y s o t u r b i n e s h a f t (B) cl e a r s t h e t a b l e .
Fi gu r e 104 (Step 40)
U s i n g h oi s t a n d s l i n g (A), r e mov e t h e l e f t -
b r a k e h u b a n d s t e e r p l a n e t a r y a s s e mb l y (B).
U s i n g a 5/8-i n ch wr e n ch , r e mov e 18 b ol t s (C)
f r om l e f t - b r a k e a n ch or (D).
9 4
Fi gu r e 105 (Step 41)
Re mov e l e f t - b r a k e a n ch or a s s e mb l y (A),
Fi gu r e 106 (Step 42)
U s i n g t h r e e 7 /1 6 - 1 4 - i n c h b ol t s (A ), a t t a c h
s l i n g (B) to l ef t-cl u tch r ea cti on pl a te a s s embl y
(C). Re mov e t h e r e a ct i on p l a t e a s s e mb l y .
*C2
PAR 75, ST EPS 4 3 - 4 6
D I S A S S E MB L Y CH AP 5, SEC I I
Fi gu r e 107 (Step 43)
Re mov e t wo b ol t s 180 a p a r t , f r om l e f t -ou t p u t
cl u t ch a s s e mb l y (A). At t a ch s l i n g (B) a n d r e -
mov e l e f t -ou t p u t cl u t ch a s s e mb l y (A). Re mov e
s p a ce r (C ).
Fi gu r e 108 (Step 44)
Re mov e n i n e s t e e r cl u t ch r e l e a s e s p r i n gs (A),
cl u t ch p l a t e s (B). At t a ch l i f t i n g s l i n g 7083778
a t t h r e e h ol e s (C) i n s t e e r cl u t ch a n ch or . Re -
mov e t h e a n ch or .
Fi gu r e 109 (Step 45)
R e mov e l e f t - s t e e r cl u t ch p i s t on (A). U s i n g a
9 /1 6 - i n ch w r e n ch , r e mov e e i g h t s e l f - l ock i n g
b ol t s (B) f r om ou t p u t b e a r i n g r e t a i n e r (C ).
Remov e r eta i n er (C) a n d bea r i n g a s s embl y (D).
Re mov e b e a r i n g (D) f r om r e t a i n e r .
Fi gu r e 110 (Step 46)
R e m o v e t w o s c r e w s (A ) r e t a i n i n g r e v e r s e -
r a n ge b e a r i n g s u p p or t a n d ca r r i e r (B).
9 5
*C2
CH AP 5, SEC I I
DI SASSEMBL Y P AR 75, ST EPS 4 7 - 5 0
Fi gu r e 111 (Step 47)
F i g u r e 1 1 3 ( S t e p 4 9 )
U s i n g a w ood e n b l ock (A) a n d s cr e w d r i v e r ,
p r y u p on r e v e r s e - r a n ge s u p p or t h ou s i n g a n d
ca r r i e r a s s e mb l y (B) e n ou g h t o a t t a ch s l i n g
(C) wi t h t wo b ol t s a n d n u t s . Re mov e s u p p or t
h ou s i n g a n d ca r r i e r a s s e mb l y (B).
R e m o v e r e v e r s e - r a n g e r i n g g e a r a s s e m b l y
(A) a n d on e i n t e r n a l - s p l i n e d cl u t ch p l a t e (B)
U s i n g a 9 /1 6 - i n c h w r e n c h , r e m o v e r e v e r s e -
r a n c e a n c h o r b o l t (C ), a n d l o c k w a s h e r a n d
f l a t w a s h e r . R e m o v e r e m a i n i n g r e v e r s e -
r a n g e cl u t ch p l a t e s (D)
Fi gu r e 112 (Step 48)
Remov e s pa cer (A) a n d th r u s t wa s h er (B) f r om
r e v e r s e - r a n ge s u n ge a r (C).
Fi gu r e 114 (Step 50)
U s i n g h oi s t a n d l i f t i n g e y e (A), r e mov e l ow -
a n d i n t e r me d i a t e -r a n ge ca r r i e r s , a n d l ow a n d
r e v e r s e -r a n ge cl u t ch p i s t on h ou s i n g a s a n a s -
s e m b l y (B ). C a u t i o n : Be ca r e f u l t h a t l ow -
range cl utchpl ates (C) do not fal l out wi th re-
mov a l of a s s e mb l y (B).
9 6
PAR 75, STEPS 5 1 - 5 4
DI SASSEMBL Y
CH AP 5, SEC I I
Fi gu r e 115 (Step 51)
Pos i ti on th e a s s embl y on th e di s a s s embl y ta bl e
a n d r e mov e t h e h oi s t a n d l i f t i n g e y e . Re mov e
l ow- a n d r e v e r s e -r a n ge cl u t ch p i s t on h ou s i n g
a s s e mb l y (A).
Fi gu r e 116 (Step 52)
Re mov e s n a p r i n g (A) r e t a i n i n g r e v e r s e -r a n ge
s u n ge a r (B). Re mov e r e v e r s e - r a n ge s u n ge a r .
Fi gu r e 117 (Step 53)
R e mov e l ow - r a n g e ca r r i e r a n d s h a f t a s s e m-
bl y (A). Remove thrust washer (B) from
c a r r i e r .
Fi gu r e 118 (Step 54)
Re mov e f ou r e x t e r n a l - (A) a n d f ou r i n t e r n a l -
(B) s p l i n e d l ow - r a n g e cl u t ch p l a t e s . U s i n g a
1 5 /1 6 - i n ch w r e n ch , r e mov e l ow - r a n g e cl u t ch
a n ch or n u t (C) a n d f l a t wa s h er .
9 7
CH AP 5, SEC I I
DI S AS S E MB L Y PAR 75, ST EPS 5 5 - 5 8
Fi gu r e 119 (Step 55)
Re mov e l ow - r a n ge cl u t ch a n ch or b ol t (A). Re -
m ov e c l u t c h a n c h or (B ). U s i n g a 9 /1 6 - i n c h
w r e n c h , r e m o v e i n t e r m e d i a t e - r a n g e c l u t c h
a n ch or b ol t (C), l ock w a s h e r a n d f l a t w a s h e r .
Fi gu r e 120 (Step 56)
R e m o v e i n t e r m e d i a t e - r a n g e c l u t c h p i s t o n
h ou s i n g a s s embl y (A) a n d Bel l ev i l l e s pr i n g (B).
Fi gu r e 121 (Step 57)
Re mov e i n t e r me d i a t e -r a n ge cl u t ch a p p l y p l a t e
(A). Re mov e r i n g ge a r a s s e mb l y (B) wi t h on e
e x t e r n a l -s p l i n e d (C) a n d on e i n t e r n a l -s p l i n e d
(D) cl u tch pl a te.
Fi gu r e 122 (Step 58)
R e mov e r e ma i n i n g t w o e x t e r n a l - s p l i n e d (A)
a n d i n t e r n a l --s p l i n e d (B) cl u t ch p l a t e s . U s i n g
a 1 5 /1 6 - i n ch w r e n ch , r e mov e i n t e r me d i a t e -
r a n ge cl u tch a n ch or n u t (C) a n d f l a t wa s h er .
9 8
*C2
*C2
PAR 75, STEPS 5 9 - 6 2
DI SASSEMBL Y
CH AP 5, SEC I I
Fi gu r e 123 (Step 59)
R e m o v e i n t e r m e d i a t e - r a n g e c 1 u t c h a n c h o r
b ol t (A). R e mov e cl u t ch a n ch or (B) a n d oi l
col l e ct or (C ).
F i g u r e 1 2 5 (S t e p 6 1 )
U s i n g s l i n g (A) a n d h ook s (B), r e mov e h i gh -
r a n ge cl u t ch a s s e mb l y (C).
Fi gu r e 124 (Step 60)
Re mov e s n a p r i n g (A) r e t a i n i n g l ow - r a n ge s u n
ge a r (B). Re mov e l ow - (B) a n d i n t e r me d i a t e -
(C) r a n ge s u n ge a r s .
F i gu r e 126 (St e p 62)
Bl ock up the tur bi ne shaft wi th a wooden bl ock
(A). U s i n g a 7/16-i n ch wr en ch , r emov e two
sel f-l ock i ng bol ts (B) and fl at washer s.
9 9
CH AP 5, SEC I I DI S AS S E MB L Y
76.
Fi gu r e 127 (Step 63)
Re mov e p i t ot t u b e a s s e mb l y (A).
Fi gu r e 128 (Step 64)
U s i n g s l i n g (A), l i f t t h e t r a n s mi s s i on h ou s i n g
a n d r e mov e con v e r t e r t u r b i n e s h a f t a s s e mb l y
(B). Pos i t i on t h e t r a n s mi s s i on h ou s i n g on i t s
b ot t om s i d e .
PAR 75- 76
DI SASSEMBLY STEPS LEFT- AND
RI GHT-OUTPUT DRI VE ASSEMBLI ES
N o t e . Th e l ef t- a n d r i gh t-ou tpu t dr i v e
a s s embl i es a r e i den ti ca l wi th th e ex -
cepti on of th e l en gth of two compon -
ents. The l eft-i nput shaft and l eft-
s a d d l e a s s e mb l y a r e l on ge r t h a n t h e
correspondi ng components of the
r i g h t - o u t p u t d r i v e a s s e m b l y . Th e
d i s a s s e mb l y p r oce d u r e s a r e t h e s a me
f or b ot h a s s e mb l i e s . Wi t h t h e e x ce p -
ti on of Step 2, th e f ol l owi n g i l l u s tr a -
t i on s s h ow t h e d i s a s s e m b l y p r oc e -
d u r e s f or t h e r i gh t - ou t p u t d r i v e a s -
s e mb l y . S t e p 2 i l l u s t r a t e s t h e l e f t -
ou tpu t dr i v e a s s embl y , a n d s h ows th e
di f f er en ce i n s i ze of th e i n pu t s h a f ts
a n d s a d d l e a s s e mb l i e s of t h e r i g h t -
a n d l e f t -ou t p u t a s s e mb l i e s .
Fi gu r e 129 (Step 1)
U s i n g a 9 /1 6 - i n ch w r e n ch , r e mov e s i x b ol t s
(A) a n d l ock w a s h e r s . R e mov e ou t p u t d r i v e
cou p l i n g ca p (B). R e mov e s e a l (C ) f r om ca p
(B ). R e m ov e a l i n e m e n t r i n g (D) a n d i n p u t
s h aft (E).
1 0 0
PAR 76, ST EPS 2 - 5 DI SASSEMBL Y CH AP 5, SEC I I
Fi gu r e 130 (Step 2)
R e mov e t h e i n p u t s h a f t (A) f r om l e f t - ou t p u t
d r i v e a s s e mb l y (B).
Fi gu r e 132 (Step 4)
U s i n g s l i n g (A) a n d t wo 3/8-24 x 1 bol t s (B)
a n d f l a t w a s h e r s , p l a ce t h e a s s e mb l y i n a n
i mp r ov i s e d s t a n d (C).
Fi gu r e 131 (Step 3)
U s i n g l i f t i n g e y e (A) a n d s l i n g (B) t o p r e v e n t
t h e d r i v e a s s e mb l y f r om t u r n i n g, a n d u s i n g a
1-1/8-i nch wrench, l oosen 24 bol ts (C).
Fi gu r e 133 (Step 5)
Re mov e t w e n t y - t w o b ol t s (A) a n d w a s h e r s (B),
l ea v i n g two of th e bol ts (C), 180 degr ees a pa r t.
R e mov e t h r e e s cr e w s (D).
1 0 1
*C2
CH AP 5, SEC I I DI SASSEMBL Y
P AR 76, ST EPS 6 - 9
Fi gu r e 136 (Step 8)
Fi gu r e 134 (Step 6)
Pl a ce a n i n d e x ma r k (A) a cr os s ou t p u t d r i v e
s a d d l e (B)- t o- h ou s i n g (C ) s p l i t l i n e . R e mov e
s a d d l e (B).
Fi gu r e 135 (Step 7)
Pos i t i on ou t p u t d r i v e s a d d l e a s s e mb l y (A) on
w o o d e n b l o c k s (B ). R e m o v e r e m a i n i n g t w o
b ol t s (C) a n d wa s h e r s (D).
U s i n g s l i n g (A) a n d t wo 7/8-14 x 6-i n ch b ol t s
(B), r a i s e th e a s s embl y a n d dr i v e ou tpu t dr i v e
p l a n e t a r y ca r r i e r (C ) f r om s a d d l e a s s e mb l y
(D). Pl a ce i n d e x ma r k s (E ) on t h e s a d d l e a n d
c a r r i e r a s s e m b l y , t h e n r e m o v e s a d d l e a s -
s e mb l y (D).
F i g u r e 1 3 7 ( S t e p 9 )
St r a i gh t e n t h e t a b s on l ock s t r i p s (A). U s i n g
a 1 5 /1 6 - i n ch w r e n ch , r e mov e f ou r b ol t s (B),
l ock s tr i ps (A) a n d l ock pl a te (C).
1 0 2
PAR 76, STEPS 1 0 - 1 3
DI S AS S E MB L Y CH AP 5, SEC I I
Fi gu r e 138 (Step 10)
Atta ch s l i n g (A) to th e ou tpu t dr i v e pl a n eta r y
ca r r i e r r i n g g e a r a s s e mb l y (B) a n d r e mov e
t h e a s s e mb l y .
Fi gu r e 139 (Step 11)
At t a ch s l i n g (A) t o ou t p u t d r i v e h ou s i n g (B).
Re mov e l ock w i r e (C) f r om b ol t s (D).
Fi gu r e 140 (Step 12)
U s i n g a 5 /8 - i n ch w r e n ch , r e mov e e i g h t b ol t s
(A) f r om ou tpu t h ou s i n g (B) th r ou gh h ol e pr o-
v i ded i n ou tpu t s h a f t a s s embl y (C).
Fi gu r e 141 (Step 13)
R e mov e ou t p u t d r i v e h ou s i n g a s s e mb l y (A).
Re mov e s p a ce r (B) a n d ga s k e t (C).
1 0 3
CH AP 5, SEC I I I I NP U T P R E S S U R E , S CAVE NGE OI L P U MP R E B U I L D P AR
Secti on Il l , I NPUT PRESSURE AND SCAVENGE OI L PUMP ASSEMBL YREBUI L D
7 7 . DE S C R I PTI ON
Ref er to pa r . 10 f or des cr i pti on of th e i n -
pu t pr es s u r e a n d s ca v en ge oi l pu mp a s s embl y .
7 8 . DI S AS S E MBL Y (f i g . 3 7 3 , f ol d - ou t 2 )
a . U s i n g a 9 /1 6 - i n c h w r e n c h , r e m o v e
f ou r s e l f -l ock i n g b ol t s 52 f r om p u mp a s s e m-
bl y 45.
b . R e mov e s ca v e n g e oi l p u mp b od y 4 7 ,
gea r s 55 a n d 56 a n d Woodr u f f k ey 51.
c . Do n ot r e mov e t h e t w o n e e d l e b e a r -
i n gs 53 a n d 54 f r om s ca v e n ge p u mp b od y 47
u n l e s s r e p l a c e m e n t i s n e c e s s a r y . R e m o v e
b e a r i n gs wi t h a n e x p a n d i n g s l i d e h a mme r r e -
mov e r t ool . I f s u ch a t ool i s n ot a v a i l a b l e ,
t h e b e a r i n gs w i l l h a v e t o b e cu t ou t w i t h a
b u r r gu n .
d . Re mov e p u mp s e p a r a t or p l a t e a s s e m-
bl y 48.
e . Re mov e p r e s s u r e p u mp d r i v e ge a r 57
a n d i dl er gea r 58 f r om pu mp body 61.
f . Do n ot r emov e th e two n eedl e bea r i n gs
5 9 a n d 6 0 f r om t h e p r e s s u r e p u mp b od y 6 1
u n l e s s r e p l a c e m e n t i s n e c e s s a r y . R e m o v e
b e a r i n gs wi t h a n e x p a n d i n g s l i d e h a mme r r e -
mov e r t ool . R e f e r t o c , a b o v e .
g . Do n ot r e mov e t h e t w o d ow e l p i n s 49
f r om t h e p u mp s e p a r a t or p l a t e 50 u n l e s s r e -
p l a c e m e n t i s n e c e s s a r y . I f n e c e s s a r y , r e -
mov e t h e d ow e l s .
7 9 . C L E A N I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n -
d a t i on s .
8 0 . I N S PE C TI ON AN D R E PAI R
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
7 7 - 8
a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e -
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
a n ces a n d wea r l i mi ts a r e i n di ca ted by s ma l l ,
l ow e r c a s e l e t t e r s i n f i g , 3 7 3 , f ol d - ou t 2 .
Ref er to pa r . 236 f or wea r l i mi ts i n f or ma ti on .
8 1 . AS S E MBL Y (f i g . 3 7 3 , f ol d - ou t 2 )
a . I f th e two dowel pi n s 49 wer e r emov ed
f r omp u mp s e p a r a t or p l a t e 50, p r e s s i n n e w
pi n s , l ea v i n g on e en d of ea ch wi th i n 0.420 i n ch
of th e pl a te s u r f a ce.
b . I f t h e t wo n e e d l e b e a r i n gs 59 a n d 60
w e r e r e mov e d f r om p r e s s u r e p u mp b od y 6 1 ,
i n s t a l l n e w r e p l a ce me n t s . Pr e s s t h e b e a r i n g,
a ga i n s t th e n u mber ed s i de of th e bea r i n g ca ge,
0.060 to 0.100 i n ch bel ow th e s u r f a ce a dj a cen t
to th e bea r i n g bor e.
c . I f t h e t wo n e e d l e b e a r i n gs 53 a n d 54
w e r e r e mov e d f r om s ca v e n g e p u mp b od y 4 7 ,
i n s t a l l n e w r e p l a ce me n t s . Pr e s s t h e b e a r i n g,
a ga i n s t th e n u mber ed s i de of th e bea r i n g ca ge
a n d f r om th e i n s i de of th e body , 0.010 to 0.040
i n ch bel ow th e s u r f a ce a dj a cen t to th e bea r i n g
b o r e .
d . I n s ta l l i n pu t pr es s u r e pu mp dr i v e gea r
57 a n d i dl er gea r 58 i n to i n pu t pr es s u r e pu mp
b od y 61.
e . I n s t a l l p u mp s e p a r a t or p l a t e a s s e m-
bl y 48.
f . I n s ta l l Woodr u f f k ey 51 on to i n pu t pr es -
s u r e p u mp d r i v e ge a r 57.
g . I n s ta l l s ca v en ge pu mp gea r s 55 a n d 56
onto i nput pump dr i v e gear 57 and i dl er gear 58.
h . I n s t a l l s ca v e n ge p u mp bod y a s s e mbl y
47 a n d s e cu r e wi t h f ou r 3/8-16 x 2-1/4 s e l f -
l ock i n g b ol t s 5 2 . Tor q u e t h e b ol t s t o 3 6 - 4 3
p ou n d -f e e t . Af t e r a s s e mb l y , t h e p u mp s h ou l d
r o t a t e f r e e l y .
1 0 4
P AR 8 2 - 8 3
T OR QU E CONVE R T E R R E B U I L D
S ect i on I V. T OR QUE CONVE R T E R R E B UI L D
CHAP 5, SEC I V
8 2 . DE S C R I PTI ON
Re f e r t o p a r . 9 f or d e s cr i p t i on of t h e
t or q u e con v e r t e r a s s e mb l y .
(5) U s i n g s p a n n e r wr e n ch 8351495, r e -
mov e th e con v er ter l ock n u t (f i g. 144).
(6) Re mov e t h e d ou b l e -r ow b a l l b e a r i n g
f r om th e h u b of th e con v er ter cov er .
83. DI SASSE MBL Y (f i g. 373, f ol d -ou t 2)
N o t e . Al l r e l a t e d i t e ms n ot cov e r e d
i n a th r ou gh d , b e l ow , w e r e r e mov e d
f r om t h e t r a n s mi s s i on a s ou t l i n e d i n
p a r . 7 4 , s t e p s 1 t h r o u g h 2 5 . N o
f u r t h e r d i s a s s e mb l y of t h os e p a r t s
i s r e q u i r e d .
a . To r q u e C o n v e r t e r C o v e r
(1 ) U s i n g a 5 /8 - i n c h w r e n c h , r e m ov e
24 s e l f -l ock i n g b ol t s r e t a i n i n g t h e i n p u t d r i v e
t r a n s f e r g e a r (f i g . 1 4 2 ). R e mov e t h e g e a r .
(2) Re mov e t h e r e t a i n i n g r i n g f r om t h e
t or q u e con v e r t e r s u p p or t b e a r i n g.
(3) Re mov e t h e b e a r i n g s u p p or t s l e e v e .
(4 ) U s i n g a h a mme r a n d p u n ch , b e n d
th e l i p of th e con v er ter l ock n u t away fr om th e
n ot ch e s i n t h e h u b of t h e t or q u e con v e r t e r
cov e r (f i g. 143).
Fi gure 143. Strai ghteni ng l i p of torque converter
l ock nut
Fi gure 142. Removi ng (or i nstal l i ng) i nput dri ve
transfer gear Fi gure 144. Removi ng (or i nstal l i ng) converter l ock nut
1 0 5
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CHAP 5, SEC I V.
T OR QU E CONVE R T E R R E B U I L D PAR 8 3
b . To r q u e C o n v e r t e r P u m p
(1) Str a i gh ten th e ta bs of l ock s tr i ps on
th e con v er ter pu mp h u b (f i g. 145).
(2 ) U s i n g a 7 /1 6 - i n ch w r e n ch , r e mov e
e i g h t s e l f - l ock i n g b ol t s a n d f ou r l ock s t r i p s
r etai n i n g th e tor qu e con v er ter pu mp h u b i n th e
con v e r t e r p u mp . Re mov e t h e h u b .
(3) Remov e two h ook -ty pe s ea l r i n gs 87
(f i g. 373, f ol d -ou t 2) f r om p u mp n u b 88.
(4) Re mov e r e t a i n i n g r i n g 92 r e t a i n i n g
b e a r i n g 91 i n con v e r t e r p u mp h u b 88. Pr e s s
th e bea r i n g f r om th e h u b.
c. Tor q u e C on v e r t e r Tu r b i n e
(1) Do n ot r emov e th e ba l l bea r i n g f r om
t h e t u r b i n e a s s e mb l y , u n l e s s r e p l a ce me n t i s
n e ce s s a r y (f i g . 1 4 6 ).
Fi gure 145. Strai ghteni ng corners of converter pump
hub l ock stri p
(2) I f n e ce s s a r y t o r e mov e t h e b e a r i n g,
pr y i t f r om th e tu r bi n e h u b.
d . Tor q u e C on v e r t e r S t a t or
(1) Rot a t i n g t h e s t a t or f r e e wh e e l r a ce
i n a cl ock wi s e d i r e ct i on , r e mov e i t f r om t h e
s t a t or a s s e mb l y (f i g. 147).
Fi gure 146. Torque converter turbi ne assembl y
Fi gure 147. Removi ng stator freewheel race and
thrust beari ng assembl y from stator
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PAR 8 3 - 8 6 T OR QU E CONVE R T E R R E B U I L D
CHAP 5, SEC I V
(2 ) R e m o v e 1 2 s t a t o r r o l l e r b e a r i n g s
a n d s p r i n gs f r om t h e s t a t or (f i g. 147).
(3 ) R e m o v e t h e r o l l e r t h r u s t b e a r i n g
a s s e m b l y f r o m t h e f r e e w h e e l r a c e . R e m o v e
r ol l er th r u s t wa s h er f r om th e s ta tor (f i g. 147).
I f ei th er bea r i n g or th r u s t wa s h er i s da ma ged,
r e p l a ce b ot h p a r t s .
(4) Remov e th e f r on t a n d r ea r r eta i n i n g
r i n gs , two l a r ge th r u s t wa s h er s a n d two s ma l l
t h r u s t w a s h e r s f r om t h e s t a t or a s s e m b l y .
Ma r k t h e s t a t or ca m a n d s t a t or a s s e mb l y f or
r e f e r e n ce i n r e a s s e mb l y . Pr e s s ou t t h e ca m.
8 4 . C L E A N I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n -
d a t i o n s .
8 5 . I N S PE C TI ON AN D R E PAI R
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e -
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
a n ce s a n d we a r l i mi t s a r e i n d i ca t e d b y s ma l l ,
l ow e r ca s e l e t t e r s i n f i g. 373, f ol d - ou t 2. Re -
f e r t o p a r . 236 f or we a r l i mi t s i n f or ma t i on .
8 6 . A S S E M B L Y
a . To r q u e C o n v e r t e r C o v e r
(f i g. 373, f ol d -ou t 2)
(1) I n s t a l l d ou b l e -r ow b a l l b e a r i n g 143,
r e t a i n i n g r i n g gr oov e ou t w a r d , on t h e h u b of
t or q u e con v e r t e r cov e r 69. Pr e s s t h e b e a r i n g
u n ti l i t i s f i r ml y s ea ted on th e h u b.
(2) U s i n g s p a n n e r wr e n ch 8351495 (f i g.
36), i n s t a l l con v e r t e r l ock n u t 144 (f i g. 373,
f ol d - ou t 2). Tor q u e t h e n u t t o 75 p ou n d - f e e t .
Def or m th e l i p of th e n u t i n to th e two gr oov es
i n th e h u b of con v er ter cov er 69.
(3) I n s t a l l b e a r i n g s u p p or t s l e e v e 104.
I n s ta l l th e r eta i n i n g r i n g on th e bea r i n g.
(4) I n s ta l l th e i n pu t dr i v e tr a n s f er gea r
a n d , u s i n g a 5/8-i n ch wr e n ch , s e cu r e i t wi t h
t we n t y -f ou r 7/16-20 x 1 s e l f -l ock i n g b ol t s (f i g.
1 4 2 ). Ti g h t e n t h e b ol t s t o 6 4 - 7 7 p ou n d - f e e t
t or q u e .
b . To r q u e C o n v e r t e r Pu m p
(f i g. 373, f ol d -ou t 2)
(1) I f scr ew 85 and bol t 86 or wei ghts 84
w e r e r e mov e d f r om t h e con v e r t e r p u mp , i n -
s t a l l n e w r e p l a ce me n t s .
N o t e . B e s u r e t o i n s t a l l c o r r e c t
w e i g h t s a t t h e l oca t i on s p r e v i ou s l y
i d e n t i f i e d .
(2) I n s t a l l ba l l be a r i n g 91 i n con v e r t e r
pu mp h u b 88.
(3) I n s t a l l r e t a i n i n g r i n g 92, r e t a i n i n g
bear i n g 91 i n pu mp h u b 88.
(4) I n s t a l l t wo h ook -t y p e s e a l r i n gs 87
on con v er ter pu mp h u b 88.
(5) I n s t a l l con v e r t e r p u mp h u b 88 wi t h
compon en t pa r ts i n con v er ter pu mp 83 a n d s e-
cu r e w i t h f ou r l ock s t r i p s 89 a n d e i gh t s e l f -
l ock i n g b ol t s 9 0 . Ti g h t e n t h e b ol t s t o 9 - 1 1
p ou n d - f e e t t or q u e . Be n d a cor n e r of e a ch l ock
s tr i p 89 a ga i n s t th e h ea d of ea ch bol t 90.
c . To r q u e C o n v e r t e r Tu r b i n e . I f b a l l
b e a r i n g (f i g . 1 4 6 ) w a s r e mov e d , p r e s s a n e w
b e a r i n g on t h e h u b of t h e con v e r t e r t u r b i n e .
Be s ur e the bear i ng i s fi r ml y s eated on the hub.
d . Tor q u e C on v e r t e r S t a t or
(1 ) I n s t a l l r e t a i n i n g r i n g 9 3 (f i g . 3 7 3 ,
f ol d -ou t 2) i n t o s t a t or a s s e mb l y 94. Th i s r i n g
mu s t b e i n s t a l l e d i n t o t h e gr oov e a t t h e r e a r
of th e s tator (r ear i den ti fi ed by th e s h ar p edges
of s t a t or v a n e s ).
(2 ) I n s t a l l r e a r w a s h e r 9 5 , p u s h i n g i t
thr ough the s tator unti l i t s eats on the r etai ni ng
r i n g. I n s t a l l t h r u s t wa s h e r 96, s e a t i n g i t on
t h e i n w a r d s u r f a ce of w a s h e r 95.
(3) Pr es s s ta tor ca m 99 i n to th e s ta tor ,
pos i ti on i n g i t to ma tch th e ma r k s ma de a t di s -
a s s e m b l y .
N o t e . Cam 99 must be i nstal l ed i n the
s a me pos i ti on i t h a d pr i or to r emov a l .
Th e s t a t or a s s e mb l y mu s t f r e e w h e e l
i n th e di r ecti on of con v er ter r ota ti on .
1 0 7
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CHAP 5, SEC V F L ANGE ADAP T E R R E B U I L D
PAR 8 6 - 9 1
(4) I n s ta l l th r u s t wa s h er 100 a n d f r on t-
wa s h er a s s embl y 81. I n s ta l l r eta i n i n g r i n g 80.
(5 ) I n s t a l l t h r u s t w a s h e r 1 0 3 i n t o t h e
s t a t or a s s e mb l y .
(6) I n s t a l l t h r u s t b e a r i n g a s s e mb l y 102
on t o f r e e w h e e l r a c e 1 0 1 , u s i n g oi l - s ol u b l e
gr ea s e to r eta i n i t.
(7) U s i n g a h e a v y oi l -s ol u b l e gr e a s e t o
r e t a i n t h e m , p os i t i on t h e 1 2 b e a r i n g s a n d
s pr i n gs i n th e 12 s ta tor ca m pock ets . Fi g. 148
s h ows th e l oca ti on of th e bea r i n gs a n d s pr i n gs
i n r e s p e ct t o t h e s t a t or a s s e mb l y . I n s t a l l a
s p r i n g i n t o t h e d e e p e n d of t h e ca m p ock e t .
Pl a ce a bea r i n g i n th e s h a l l ow en d of th e ca m
p ock e t b e s i d e t h e s p r i n g . I n s t a l l r e ma i n i n g
11 bea r i n gs a n d s pr i n gs i n th e s a me ma n n er .
(8) I n s t a l l f r e e wh e e l r a ce 101 (f i g. 373,
f ol d-ou t 2) wi th bea r i n g 102 i n to th e s ta tor a s -
s e m b l y .
Fi gure 148. Torque converter stator
Sect i on V. F L ANGE ADAPT ER ASSEMBL YREBUI L D
8 7 . D E S C R I P T I O N
R e f e r t o p a r . 8 f o r t h e d e s c r i p t i o n o f t h e
f l a n g e a d a p t e r a s s e m b l y .
8 9 . C L E A N I N G
Ref er to pa r . 71 f or cl ea n i n g r ecommen d-
a t i o n s .
9 0 . I N S PE C TI ON AN D R E PAI R
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e -
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
a n ce s a n d we a r l i mi t s a r e i n d i ca t e d b y s ma l l
l e t t e r s i n f i g. 373, f ol d - ou t 2. Re f e r t o p a r .
236 f or we a r l i mi t s i n f or ma t i on .
1 0 8
9 1 . A S S E M B L Y
a . I f t h e oi l s e a l wa s r e mov e d f r om t h e
f l a n ge a da pter , i n s ta l l a n ew r epl a cemen t u s i n g
oi l s e a l r e p l a ce r 8351210 (f i g. 149).
b . I n s t a l l oi l s e a l , l i p s i d e d own , p r e s s -
i n g t h e s e a l u n t i l i t i s s e a t e d a g a i n s t i t s
s h ou l der i n th e a da pter (f i g. 149).
Fi gure 149. I nstal l i ng oi l seal i n fl ange adapter
PAR 9 2 - 9 6 l NP U T T R ANS F E R GE AR I NG R E B U I L D CHAP 5, SEC V I
Secti on VI. I NP UT T R ANS F E R GE AR I NGR E B UI L D
9 2 . DE S C R I PTI ON
Ref er to pa r . 8 f or th e des cr i pti on of th e
i n p u t t r a n s f e r ge a r i n g.
9 3 . DI S A S S E MB L Y
a . Dr i v e G e a r A s s e m b l y
(f i g. 373, f ol d -ou t 2)
(1) Do n ot r e mov e s i n gl e - r ow b a l l b e a r -
i n gs 24 a n d 27 f r om i n pu t tr a n s f er dr i v e gea r
25 u n l e s s r e p l a ce me n t i s n e ce s s a r y .
(2 ) I f n e ce s s a r y , u s e a b e a r i n g p u l l e r
t o r e mov e t h e t w o b e a r i n g s 2 4 a n d 2 7 f r om
d r i v e ge a r 25.
b . C l u s t e r I d l e r G e a r As s e mb l y
(f i g. 373, f ol d -ou t 2)
(1) Do n ot r emov e dou bl e-r ow ba l l bea r -
i n g 35 f r om i d l e r cl u s t e r ge a r 34 u n l e s s r e -
p l a ce me n t i s n e ce s s a r y .
(2) I f n e ce s s a r y t o r e mov e b e a r i n g 35,
r e mov e r e t a i n i n g r i n g 3 6 a n d p r e s s b e a r i n g
ou t of gea r 34.
c . C l u s t e r G e a r A s s e m b l y
(f i g. 373, f ol d -ou t 2)
(1 ) Do n ot r e mov e r ol l e r b e a r i n g s 3 8
a n d 4 0 f r om i n p u t t r a n s f e r cl u s t e r g e a r 4 1
u n l e s s r e p l a ce me n t i s n e ce s s a r y .
(2) I f n e ce s s a r y t o r e mov e b e a r i n gs 38
a n d 40, r emov e r eta i n i n g r i n g 37 a n d pr es s
bea r i n gs 38 a n d 40 a n d s pa cer 39 f r om cl u s ter
gear 41.
9 4 . C L E A N I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n -
d a t i on s .
9 5 . I N S PE C TI ON AN D R E PAI R
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
a n d r e p a i r r e comme n d a t i on s . R e p a i r a n d r e -
b u i l d p oi n t s of me a s u r e me n t s f or f i t s , cl e a r -
a n ce s a n d we a r l i mi t s a r e i n d i ca t e d b y s ma l l ,
l ow e r ca s e l e t t e r s i n f i g. 373, f ol d - ou t 2. Re -
f e r t o p a r . 236 f or we a r l i mi t s i n f or ma t i on .
9 6 . A S S E M B L Y
a . Dr i v e G e a r A s s e m b l y
(f i g . 3 7 3 , f ol d - ou t 2 )
(1) I n s ta l l s i n gl e-r ow ba l l bea r i n g 24 on
th e i n pu t tr a n s f er dr i v e gea r , pr es s i n g a ga i n s t
th e n u mber ed s i de of th e bea r i n g ca ge. Be s u r e
b e a r i n g i s f i r ml y s e a t e d a ga i n s t i t s s h ou l d e r
on gear 25.
(2) I n s ta l l s i n gl e-r ow ba l l bea r i n g 27 on
th e i n pu t tr a n s f er dr i v e gea r , pr es s i n g on th e
n u mber ed s i de of th e bea r i n g ca ge. Be s u r e th e
b e a r i n g i s f i r ml y s e a t e d a ga i n s t i t s s h ou l d e r
on gear 25.
b . C l u s t e r I d l e r G e a r As s e mb l y
(f i g . 3 7 3 , f ol d - ou t 2 )
(1 ) I n s t a l l d ou b l e - r ow b a l l b e a r i n g 3 5
i n t o t h e i n p u t t r a n s f e r c l u s t e r i d l e r g e a r ,
p r e s s i n g a g a i n s t t h e n u m b e r e d s i d e of t h e
b e a r i n g on t h e ou t e r r a ce . Be s u r e t h e b e a r -
i n g i s f i r ml y s e a t e d a g a i n s t i t s s h ou l d e r i n
ge a r 34.
(2) I n s t a l l r e t a i n i n g r i n g 36.
c . C l u s t e r G e a r A s s e m b l y
(f i g. 373, f ol d -ou t 2)
(1) I n s ta l l r ol l er bea r i n g 40 i n to cl u s ter
ge a r 41, p r e s s i n g a ga i n s t t h e n u mb e r e d s i d e
of t h e b e a r i n g ca ge . Be s u r e t h e b e a r i n g i s
s ea ted f i r ml y a ga i n s t i ts s h ou l der i n th e gea r .
(2) I n s t a l l s p a ce r 39.
(3) I n s t a l l be a r i n g 38, p r e s s i n g a ga i n s t
t h e s i d e op p os i t e t h e n u mb e r e d s i d e of t h e
b e a r i n g ca g e .
(4) I n s t a l l r e t a i n i n g r i n g 37.
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C H A P 5, S E C V l l I NP U T T R ANS F E R H OU S I NG R E B U I L D PAR 9 7 - 9 9
Secti on VII. I NP UT T R ANS F E R HOUS I NGR E B UI L D
9 7 . DE S C R I PTI ON
Ref er to pa r . 8 f or th e des cr i pti on of th e
i n p u t t r a n s f e r h ou s i n g.
9 8 . DI S AS S E MBL Y (f i g . 3 7 3 , f ol d - ou t 2 )
a . U s i n g a 9/16-i n ch wr e n ch , r e mov e 10
b ol t s a n d l ock wa s h e r s t h a t r e t a i n t h e p owe r
t a k e - of f cov e r (f i g . 1 5 0 ). R e mov e t h e cov e r
a n d ga s k e t .
b . U s i n g 9 /1 6 - i n c h w r e n c h , r e m o v e
t w e l v e 3 /8 - 2 4 x 1 - l /4 - i n c h b ol t s w i t h l oc k
w a s h e r s . Re mov e t r a n s f e r h ou s i n g cov e r a n d
ga s k e t (f i g. 150).
c . Do n ot r e mov e i n s e r t s 137, 140, 112,
1 1 3 a n d 1 2 2 (f i g . 3 7 3 , f ol d - ou t 2 ), b u s h i n g
a s s e mb l y 118, or s l e e v e s 119, 120, 134, 136,
or 139 f r om i n p u t t r a n s f e r h ou s i n g a s s e mb l y
1 1 1 , u n l e s s r e p l a c e m e n t i s n e c e s s a r y . I f
n eces s a r y to r emov e a bu s h i n g or i n s er t, r ef er
t o p a r . 72 f or t h e p r op e r p r oce d u r e . Bu s h i n g
a s s embl y 118 i s th r ea ded a n d ma y be r emov ed
wi th a wr en ch .
d . I f i t i s n e ce s s a r y t o r e mov e s l e e v e s ,
r e mov e a l l of t h e s l e e v e s i n t h e h ou s i n g, b y
p r e s s i n g or cu t t i n g ou t , e x ce p t s l e e v e 139.
Figure 150. I nput transfer housing
1 1 0
e. I f n eces s a r y to r emov e th e i n pu t tr a n s -
f e r d r i v e g e a r s u p p or t s l e e v e 1 3 9 , d r i l l ou t
p i n s 138. U s e a d r i l l b i t s l i gh t l y l a r ge r t h a n
3/16-i n ch a n d d r i l l on l y d e e p e n ou gh t o f r e e
th e s l eev e. Pr es s th e s l eev e f r om th e h ou s i n g.
f . R e mov e a n y p i p e p l u g s (f i g . 1 5 0 ), i f
necessar y , to ai d i n the cl eani ng of the oi l pas-
s a ges i n th e h ou s i n g.
9 9 . C L E A N I N G
d a t i on s .
R e f e r t o p a r . 7 1 f o r c l e a n i n g r e c o m m e n -
Figure 151. Location of input transfer drive gear
support sleeve retaining pins
PAR 100-103 MAIN-PRESSURE REGULATOR AND CHAP 5, SEC VIII
LOCKUP SHIFT VALVE ASSEMBLYREBUILD
100. I NSPECTI ON AND REPAI R
Refer to par . 72 for gener al i nspec-
ti on and r epai r r ecommendati ons. Repai r
and r ebui l d poi nts of measur ements for
fi ts, cl e a r a n ce s a n d we a r l i mi t s a r e
i ndi cated by smal l , l ower case l etter i n
fi g. 373, fol d-out 2. Refer to par . 236 for
wear l i mi ts i nfor mati on.
101. ASSEMBLY (fi g. 373, fol d-out 2)
a . I n s tal l n ew r epl acemen t i n s er ts
137, 140, 112, 113 and 122 fr om 0.005-i nch
to one turn bel ow the housi ng surface.
b . I f 1-i nch pl ug 114 was r emoved,
i nstal l i t. Torque pl ug 114 to 70-90 pound-
feet. I f 1/8-i nch pl ug(s) 115, 116 or 131
wer e r emoved, i nstal l them. Tor que pl ugs
115, 116 and 131 to 50-60 pound-i nches. I f
l /4-i n ch p l u g(s ) 117 or 123 we r e r e -
moved, i nstal l them. Torque pl ugs 117 and
123 to 96-120 pound-i nches. I f 1/16- i nch
pl u g 9 was r emov ed, i n s tal l i t. Tor qu e
pl ug 9 to 35-50 pound-i nches.
c. I nstal l sl eeves 119, 120, 134 and
136, pr essi ng them unti l they ar e fi r ml y
seated agai nst the housi ng.
d . I f i nput transfer dri ve gear beari ng
suppor t sl eeve 139 was r emoved, i nstal l
new r epl acement as fol l ows:
(1) Ma r k t h e l oca t i on s of t h e
thr ee or i gi nal pi n hol es, i n the sl eeve bor e,
on the bol t hol e ci rcl e of the housi ng.
(2) The pi n hol es to be dr i l l ed for
t h e n e w s l e e v e s h ou l d be l oca t e d 60
degr ees cl ock wi s e or cou n ter cl ock wi s e
f r om t h e or i gi n a l p i n h ol e s . Th e t wo
al ter nate pi n l ocati ons ar e i ndi cated by
the br oken l i ne i n fi g. 151.
N ot e . Be sur e that the pi n hol es
to be dr i l l ed do not i nter fer e wi th
the oi l hol es l ocated on the k ni t
hol e ci r cl e (fi g. 151).
(3) I n s tal l s l eev e 139 (fi g. 373,
fol d-out 2), pressi ng i t fl ush wi th the hous-
i ng outer surface.
(4) Us i n g a 0.1855-0.1875 dr i l l ,
dr i l l a hol e 0.410 to 0.470-i nch deep at one
of th e al ter n ate l ocati on s ch os en . Th i s
hol e shoul d be 0.250-i nch i nward from the
cover mounti ng surface and at a 30 degree
angl e to the cover mounti ng sur face. Ref-
er to fi gure 151.
(5) Dr i l l the r emai ni ng two dowel
pi n hol es, spaci ng them 120 degrees apart.
(6) I n s tal l th e th r ee pi n s (fi g.
151), dr i vi ng them 0.005 to 0.015-i nch be-
l ow the sl eeve sur face.
(7) Li ne bor e sl eeve 139 (fi g. 373,
fol d-out 2) to 7.0864-7.0876 i nches di am-
eter, wi th a fi ni sh of 100 RMS (fi g. 151).
e . I n s tal l th e power tak e-off cov er
(fi g. 150) and gask et. Secur e the cover
wi th ten 3/8-24 x 1-1/4 bol ts an d l ock
washer s. Tor que the bol ts to 33-40 pound-
feet.
Section VIII. MAIN-PRESSURE REGULATOR AND
LOCKUP SHIFT VALVE ASSEMBLYREBUILD
102. DESCRI PTI ON c. Remove seal ri ng 8 from pl ug 7.
Refer to par. 22 for the descri pti on of d . Us i n g a l /2-i n ch s ock et wr en ch ,
the mai n-pr essur e r egul ator and l ock up r emove si x bol ts 29 and l ock washer s 28
shi ft val ve assembl y. retai ni ng val ve cover assembl y 23.
103. DI SASSEMBLY (fi g. 383, fol d-out 12) e . Remov e cov er a s s embl y 23 a n d
gas k et 22. Remov e pl u g 19 fr om cov er
a . Remove r etai ni ng r i ng 6 that r e- assembl y 23.
tai ns val ve retai ner pl ug 7.
f . Remove l ock up shi ft val ve spr i ng
b . Remove pl ug 7, val ve 9 and spri ng 27 and val ve 26.
1 0 .
Change 2 111
CHAP 5, SEC IX CONTROL VALVE ASSEMBLY AND PAR 103-108
OI L TRANSFER PLATEREBUI LD
g . R e m o v e ma i n -p r e s s u r e r e gu l a t or
v a l v e s pr i n gs 20 a n d 21 a n d v a l v e a s s em-
bl y 14. Remov e pl u g 13.
h . R e m o v e h e x a g o n - h e a d p l u g 1 1
f r om v a l v e body 12.
104. CL E AN I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e com-
me n d a t i on s .
105. I NSPECTI ON AND REPAI R
Re f e r t o p a r . 72 f or ge n e r a l i n s p e c-
t i on a n d r e p a i r r e comme n d a t i on s . Re p a i r
and r ebui l d poi nts of measur ement for fi ts,
cl e a r a n ce s a n d we a r l i mi t s a r e i n d i ca t e d
b y s ma l l , l owe r ca s e l e t t e r s i n f i g. 383,
f ol d -ou t 12. Re f e r t o p a r . 246, f or we a r
l i mi ts i n for mati on .
106. ASSEMBL Y (f i g. 383, f ol d-ou t 12)
a . I n s ta l l h i gh -r a n ge k n ock down pl u g
13, pl a i n en d f i r s t, i n to th e l a r ges t of th e
th r ee bor es i n th e ma i n -pr es s u r e r egu l a tor
a n d l ock u p s h i f t v a l v e body 12. Pos i ti on i t
i n t h e s ma l l b or e a t t h e b ot t om of t h e
l a r ge bor e.
b . I n t o t h e s a me bor e , i n s t a l l ma i n -
p r e s s u r e r e gu l a t or v a l v e 14, s ma l l e r e n d
fi r s t.
c . I n s t a l l t wo ma i n -p r e s s u r e r e gu l a -
tor val ve spr i ngs 20 and 21.
d . I n s ta l l l ock u p s h i f t v a l v e 26, s h or t
l and end fi r st, i nto val ve body 12.
e . I nstal l l ock up shi ft val ve spr i ng 27.
f . I n s ta l l pl u g 19 i n to s l eev e 24. I n -
s t a l l - v a l v e b od y cov e r a s s e mb l y 2 3 a n d
gask et 22 and secur e wi th si x 5/16-18 bol ts
29 a n d l ock wa s h er s 28. Tor qu e bol ts 29
to 13-16 pou n d-f eet.
g . I n s ta l l l /8-i n ch h ex a gon -h ea d pl u g
11. Tor que pl ug 11 to 10-12 pound-feet.
h . I nstal l seal r i ng 8 on val ve r etai ner
pl ug 7.
i . I n s ta l l l u be r egu l a tor v a l v e s pr i n g
10, val ve 9 (l ar ge l and end fi r st) and pl ug 7.
j . I n s tal l r etai n i n g r i n g 6.
Section I X. CONTROL VALVE ASSEMBLY AND OI L TRANSFER PLATEREBUI LD
107. DE SCRI PTI ON
Refer to par . 21 for th e des cr i pti on of
the contr ol v al v e assembl y and oi l tr ansfer
p l a t e .
108. DI SASSEMBL Y (f i g. 383, f ol d-ou t 12)
a . Remov e bol t 45, wa s h er 46 a n d r e-
t a i n i n g r i n g 47 f r om t h r ot t l e v a l v e s h a f t
as s embl y 58.
b . R e mov e t h r ot t l e v a l v e s h a f t a s -
s e mb l y 58 f r om v a l v e b od y 54.
c . R e mov e s e a l r i n g 5 7 f r om s h a f t
as s embl y 58.
d . R e mov e r e t a i n i n g r i n g 4 8 f r om
s el ector s h a f t a s s embl y 56.
e . L i f t of f s h i f t i n di ca tor 49 a n d i n -
di ca tor s pa cer 50.
f . R e m o v e s e l e c t o r s h a f t a s s e m b l y
56, d e t e n t b a l l 59 a n d d e t e n t s p r i n g 60
fr om val ve body 54.
g . R e m o v e p r e f o r m e d p a c k i n g 5 1
fr om val ve body 54.
h . U s i n g a 1/2-i n ch wr e n ch , r e mov e
ni ne bol ts 70 and 71, and l ock washer s 69
a n d 72 r eta i n i n g con tr ol v a l v e body cov er
73.
i . Re mov e v a l v e b od y cov e r 73 a n d
gas k et 74.
j . R e mov e t h r ot t l e r e g u l a t or v a l v e
s p r i n g 6 8 , v a l v e a s s e mb l y 6 3 , t h r ot t l e
v al v e spr i ng 62 and thr ottl e v al v e 61.
112 Change 2
PAR 108-111 CONTROL VALVE ASSEMBLY AND CHAP 5, SEC IX
OI L TRANSFER PLATEREBUI LD
k . Re mov e s h i f t i n h i b i t or v a l v e 76,
spr i ng 78 and pl unger 79.
l . R e m o v e r e t a i n i n g r i n g 7 7 f r o m
i nhi bi tor pl unger 79.
m. Remov e l ock u p cu tof f v a l v e 80.
n . R e mov e s e l e ct or v a l v e a s s e mb l y
7 5 .
o . Do n o t r e m o v e n e e d l e b e a r i n g
a s s e mb l i e s 53 a n d 55 f r om con t r ol v a l v e
b od y 54 u n l e s s r e p l a ce me n t i s n e ce s s a r y .
I f n eces s a r y , pr es s bea r i n g a s s embl i es ou t
of the v al v e body .
p . R e mov e a n y p i p e p l u g s 8 1 f r om
th e con tr ol v al v e body , i f n eces s ar y , to ai d
i n cl eani ng.
q . I f p r e s e n t , d o n ot r e mov e ch e ck
val ve 41 fr om oi l tr ansfer pl ate 43.
r . Pl u g 42 ma y be r emov ed, i f n eces -
sar y , for cl eani ng pur poses.
109. CL E AN I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e com-
men dati on s .
110. I NSPECTI ON AND REPAI R
Re f e r t o p a r . 72 f or ge n e r a l i n s p e c-
t i on a n d r e p a i r r e comme n d a t i on s . Re p a i r
a n d r e b u i l d p oi n t s of me a s u r e me n t f or
f i t s , c l e a r a n c e s a n d w e a r l i m i t s a r e
i n d i ca t e d b y s ma l l , l owe r ca s e l e t t e r s i n
f i g. 383, f ol d -ou t 12. Re f e r t o p a r . 246
f or wea r l i mi ts i n f or ma ti on .
111. ASSEMBL Y (f i g. 383, f ol d-ou t 12)
a . I f n e e d l e b e a r i n g a s s e mb l i e s 5 3
a n d 55 w e r e r e mov e d f r om con t r ol v a l v e
body 54, i n s ta l l n ew r epl a cemen ts .
b . I n s ta l l bea r i n g a s s embl y 53, pr es s -
i ng agai nst the number ed si de of the bear -
i n g ca ge, 0.200-i n ch bel ow th e s u r f a ce a d-
j acen t to th e bear i n g bor e.
c . I n s t a l l b e a r i n g a s s e mb l y 55 f r om
t h e i n s i d e of t h e v a l v e b od y , p r e s s i n g
a ga i n s t th e n u mber ed s i de of th e bea r i n g
ca g e , 0 . 0 5 0 - i n ch b e l ow t h e s u r f a ce a d -
j acen t to th e bear i n g bor e.
d . I n s ta l l a n y pi pe pl u gs 81 r emov ed
f r om con t r ol v a l v e b od y 54 f or cl e a n i n g
p u r p os e s . Tor q u e p i p e p l u gs 81 t o 50-60
pou n d-i n ch es .
e . I n s ta l l s el ector v a l v e a s s embl y 75,
l on g s t e m e n d f i r s t , i n t o con t r ol v a l v e
body 54.
f . I n s ta l l l ock u p cu tof f v a l v e 80, l on g
l and end fi r st, i nto the v al v e body .
g . I n s ta l l r eta i n i n g r i n g 77 on to s h i f t
i nhi bi tor pl unger 79.
h . I nstal l spr i ng 78 onto pl unger 79.
i . I n s t a l l t h e p l u n g e r a n d r e l a t e d
par ts i nto the v al v e body .
j . I n s ta l l th r ottl e v a l v e 61, l on g s tem
end fi r s t, i nto the v al v e body .
k . I nstal l thr ottl e val ve spr i ng 62.
Ri n g As s e mb l i e s
N o t e . Th e l e f t - a n d r i gh t -b r a k e a n ch or
r i n g a s s e m b l i e s a r e i d e n t i c a l , t h e r e -
f or e t h e f ol l ow i n g a s s e mb l y p r oce d u r e s
a p p l y t o e i t h e r a s s e mb l y .
(1) I nstal l the br ak e r etur n gui de pi n and
s pr i n g i n th e br a k e a n ch or r i n g (f i g. 207).
( 2 ) U s i n g a C - c l a m p , c o m p r e s s t h e
b r a k e r e t u r n s p r i n g, a n d i n s t a l l t h e r e t a i n i n g
r i n g (f i g. 207).
(3) I n s ta l l th e r ema i n i n g ei gh t br a k e r e-
t u r n gu i d e p i n s , s p r i n gs a n d r e t a i n i n g r i n gs
i n the same manner as descr i bed i n (1) and (2),
a b ov e .
Section
1 6 7 . DE S C R I PTI ON
Ref er to pa r . 16 f or
b . L e f t - a n d R i g h t - cl u t ch R e a ct i on
Pl a t e A s s e m b l i e s
N ot e . Th e l e f t - a n d r i gh t - cl u t ch r e -
a ct i on p l a t e a s s e mb l i e s a r e i d e n t i ca l ,
th er ef or e th e f ol l owi n g a s s embl y pr o-
c e d u r e s a p p l y t o e i t h e r a s s e m b l y .
H owe v e r , t h e f ol l owi n g d e s cr i b e s t h e
a s s e mb l y of t h e l e f t - cl u t ch r e a ct i on
p l a t e a s s e mb l y .
(1 ) I n s t a l l t w o p r e f or me d p a ck i n g s 7 0
(f i g. 377, f ol d -ou t 6) on s l e e v e 71.
(2 ) I n s t a l l s l e e v e 7 1 w i t h p r e f or m e d
pa ck i n gs 70 i n cl u tch r ea cti on pl a te 67.
(3) Se cu r e s l e e v e 71 w i t h t h r e e 5/16- 18
x 1 s e l f -l ock i n g b ol t s 72. Tor q u e t h e b ol t s t o
17-20 p ou n d -f e e t .
XXI . L EF T - AND RI GHT - OUT PUT CL UT CHES REBUI L D
th e des cr i pti on of th e
l e f t - a n d r i gh t - ou t p u t cl u t ch e s .
168. DI SASSE MBL Y (f i gs . 377 a n d 381,
f ol d -ou t s 6 a n d 10)
N o t e . Th e l e f t - a n d r i gh t - ou t p u t cl u t ch
a s s e mb l i e s a r e i d e n t i ca l , t h e r e f or e t h e
f ol l owi n g d i s a s s e mb l y p r oce d u r e s a p p l y
t o e i t h e r a s s e m b l y . A l l r e f e r e n c e s t o
e x p l od e d v i e ws a r e t o f i g. 377, f ol d -ou t
6, i l l u s t r a t i n g t h e l e f t a s s e mb l y .
a . Re mov e t w o h ook - t y p e s e a l r i n gs f r om
the hub of the output cl utch assembl y (fi g. 208).
b . U s i n g a h a mme r a n d p u n ch , f l a t t e n
t h e cor n e r s of t h e l ock p l a t e s on t h e ou t p u t
cl u t ch a s s e mb l y (f i g. 208).
Figure 208. Straightening corners of output clutch
lock plates
1 4 3
*C2
*C2
*C2
CHAP 5, SEC X X I L E F T , R I GH T OU T P U T CL U T CH E S R E B U I L D PAR 168- 169
Figure 209. Removing (or installing) geared steer sun
gear assembly
c . U s i n g a l /2 - i n ch w r e n ch , r e mov e 1 2
bol ts , s i x l ock pl a tes a n d th r ee r eta i n er s f r om
t h e cl u t ch a s s e mb l y (f i g. 208).
d . U s i n g t w o 5 /1 6 - 2 4 b ol t s , r e mov e t h e
g e a r e d s t e e r s u n g e a r a s s e m b l y f r o m t h e
cl u tch pl a te a n d h u b a s s embl y (f i g. 209).
N o t e . Th e s u n g e a r a s s e mb l y ma y
bi nd i n the hub, due to the pr efor med
p a ck i n g. I f s o, p r y i t l oos e .
e . R e mov e t h e p r e f or me d p a ck i n g f r om
ge a r e d s t e e r s u n ge a r a s s e mb l y (f i g. 209).
f . Do n ot r emov e th e bea r i n g a n d r eta i n -
i n g r i n g f r om t h e s u n ge a r a s s e mb l y u n l e s s
r e p l a ce me n t of t h e b e a r i n g i s n e ce s s a r y (f i g.
209). I f n e ce s s a r y , r e mov e t h e r e t a i n i n g r i n g
a n d pr es s ou t th e bea r i n g.
g. Remove the output cl utch hub and
cl u tch pl a tes f r om th e cl u tch pl a te h u b a s s em-
b l y (f i g. 209).
h. Usi ng a hydraul i c press and com-
pr es s i n g tool (f i g. 38) a ga i n s t th e pi s ton r etu r n
1 4 4
Figure 210. Removing (or installing) retaining ring for
piston return spring retainer
s pr i n g r eta i n er , compr es s th e s pr i n gs a n d r e-
mov e th e r eta i n i n g r i n g (f i g. 210).
i . Re mov e r e t a i n e r 43 (f i g. 377, f ol d -ou t
6) a n d ei gh teen pi s ton r etu r n s pr i n gs 44.
j . Tu r n th e cl u tch pl a te a n d h u b a s s embl y
ov er , a n d bu mp th e cl u tch pi s ton f r om th e h u b
(f i g. 210).
k . Re mov e r i n g s e a l 38 a n d e x p a n d e r 39
(f i g. 377, f ol d -ou t 6) f r om cl u t ch p i s t on 41.
l . Re mov e r i n g s e a l 37 a n d e x p a n d e r 36
f r om cl u tch pl a te a n d h u b a s s embl y 35.
1 6 9 . C L E A N I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n -
d a t i on s .
*C2
PAR 170- 173 CL U T CH P I S T ONS AND H OU S I NGS R E B U I L D CHAP 5, SEC XXI I
170. I N SPE CTI CON AN D RE PAI R
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e -
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
a n ces a n d wea r l i mi ts a r e i n di ca ted by s ma l l ,
l owe r ca s e l e t t e r s i n f i gs . 377 a n d 381, f ol d -
ou ts 6 a n d 10. Ref er to pa r s . 240 a n d 244 f or
we a r l i mi t s i n f or ma t i on .
i n g t ool (f i g. 38) a ga i n s t t h e s p r i n g r e t a i n e r ,
compr es s th e pi s ton r etu r n s pr i n gs a n d i n s ta l l
t h e r e t a i n i n g r i n g (f i g. 210).
f . I n s ta l l th e ou tpu t cl u tch h u b (f i g. 209).
g . I n s t a l l s e v e n i n t e r n a l - a n d s e v e n e x -
ter n a l -s pl i n ed ou tpu t cl u tch pl a tes a l ter n a tel y ,
begi n n i n g wi th a n i n ter n a l -s pl i n ed cl u tch pl a te
(f i g. 209).
171. ASSE MBL Y (f i gs . 377 a n d 381,
h . I f t h e b e a r i n g wa s r e mov e d f r om t h e
fol d-ou ts 6 an d 10)
gea r ed s teer s u n gea r , pr es s i n a n ew bea r i n g
u n t i l f i r ml y s e a t e d . I n s t a l l t h e r e t a i n i n g r i n g
N o t e . Th e l ef t- a n d r i gh t-ou tpu t cl u tch es
(f i g. 209).
a r e i d e n t i ca l , t h e r e f or e t h e f ol l ow i n g
a s s e m b l y p r o c e d u r e s a p p l y t o e i t h e r
i . I n s t a l l t h e p r e f or me d p a ck i n g on t h e
a s s e m b l y .
ge a r e d s t e e r s u n ge a r a s s e mb l y (f i g. 209).
a . I n s t a l l e x p a n d e r 36 a n d r i n g s e a l 37
j . U s i n g t w o 5 /1 6 - 2 4 - i n ch b ol t s , i n s t a l l
on cl u tch pl a te a n d h u b a s s embl y 35.
th e gea r ed s teer s u n gea r a s s embl y (f i g. 209).
b . I n s t a l l e x p a n d e r 39 a n d r i n g s e a l 38
k . I n s t a l l t h r e e r e t a i n e r s a n d s i x l ock
on cl u tch pi s ton 41.
p l a t e s (f i g. 208).
c . I n s t a l l t h e cl u t ch p i s t on i n t h e cl u t ch
l . I n s t a l l t w e l v e 5 /1 6 - 2 4 b ol t s . Tor q u e
p l a t e a n d h u b a s s e mb l y (f i g. 210).
t h e b ol t s t o 1 4 - 1 8 p ou n d - f e e t . Be n d cor n e r s
of the l ock s tr i ps agai ns t the heads of the bol ts
d . I n s t a l l e i gh t e e n p i s t on r e t u r n s p r i n gs
(f i g. 208).
44 (f i g. 377, f ol d -ou t 6) a n d r e t a i n e r 43.
m . I n s ta l l two h ook -ty pe s ea l r i n gs on th e
e. U s i n g a h y dr a u l i c pr es s a n d compr es s - h u b of th e ou tpu t cl u tch a s s embl y (f i g. 208).
m . I n s ta l l bea r i n g 20 i n r ev er s e-r a n ge
ca r r i e r s u p p or t 18. I n s t a l l r e t a i n i n g r i n g 21.
n . I n s t a l l r e v e r s e - r a n g e p l a n e t a r y ca r -
r i e r a s s e mb l y 6 i n t h e ca r r i e r s u p p or t 1 8 .
Pr es s on th e ca r r i er a s s embl y u n ti l i t bottoms
i n th e s u ppor t.
Sect i on XXI V. L OW- AND REVERSE- RANGE PI ST ONS AND HOUSI NG REBUI L D
1 8 2 . DE S C R I PTI ON
Th e l ow - a n d r e v e r s e - r a n ge cl u t ch p i s t on s
a r e con t a i n e d i n a common , ma ch i n e d s t e e l
h ou s i n g . Th e p i s t on s , p i s t on r e t u r n s p r i n g s ,
r e t a i n e r s , r i n g s e a l s , s e a l r i n g e x p a n d e r s a n d
r e t a i n e r r i n g s con t a i n e d i n t h i s h ou s i n g f or
l ow- a n d r ev er s e-r a n ge a r e i den ti ca l a n d i n ter -
ch a n g e a b l e .
1 8 3 . DI S AS S E MBL Y (f i g . 3 7 6 , f ol d - ou t 5 )
a . Pos i t i on t h e l ow - a n d r e v e r s e - r a n g e
c l u t c h p i s t on h ou s i n g a s s e m b l y i n a p r e s s
(f i g. 218).
b . U s i n g a c om p r e s s i n g t ool (f i g . 3 8 ),
r emov e th e r eta i n i n g r i n g r eta i n i n g th e pi s ton
r e t u r n s p r i n g r e t a i n e r (f i g . 2 1 8 ). R e m o v e
t h e r e t a i n e r .
c . I n s t a l l e i gh t e e n p i s t on r e t u r n s p r i n gs
49 (f i g. 376, f ol d -ou t 5).
d . R e mov e t h e l ow - r a n g e cl u t ch p i s t on
( f i g . 2 1 8 ) .
e . Re mov e r i n g s e a l 52 a n d e x p a n d e r 51
(f i g . 3 7 6 , f ol d - ou t 5 ) f r om l ow - r a n g e cl u t ch
p i s t on 50.
f . Re mov e r i n g s e a l 53 a n d e x p a n d e r 54
f r om p i s t on h ou s i n g 55.
g . R e m o v e r e v e r s e - r a n g e c l u t c h p i s t o n
60, p i s t on r e t u r n s p r i n gs 61, r e t a i n e r 62, r e -
ta i n i n g r i n g 63, r i n g s ea l s 57 a n d 58, a n d ex -
pa n der s 56 a n d 59 i n th e s a me ma n n er a s de-
s cr i b e d f or l ow - r a n ge i n b t h r ou gh f , a b ov e .
Sect i on XXV. L OW- RANGE PL ANET ARY AND OUT PUT SHAF T REBUI L D
1 8 7 . DE S C R I PTI ON
R e f e r t o p a r . 1 3 f or d e s cr i p t i on of t h e
l ow-r a n ge pl a n eta r y a n d ou tpu t s h a f t a s s embl y .
1 8 8 . DI S AS S E MBL Y (f i g . 3 7 6 , f ol d - ou t 5 )
a . U s i n g a h a mmer a n d pu n ch , r emov e
t h e f ou r p l a n e t a r y s p i n d l e l ock p i n s r e t a i n i n g
t h e p l a n e t a r y s p i n d l e s (f i g. 219).
b . U s i n g a p r e s s , a n d a s u i t a b l e p r e s s
t ool , r e mov e f ou r p l a n e t a r y ca r r i e r s p i n d l e s
(f i g. 220).
c . Re mov e p l a n e t a r y p i n i on 30 (f i g. 376,
f ol d-ou t 5), s pa cer s 32 a n d 29, th r u s t wa s h er s
33 an d 28, an d r ol l er s 31.
d . Re mov e t h e t h r e e r e ma i n i n g p l a n e t a r y
pi n i on s 30 a n d r el a ted pa r ts .
1 8 9 . C L E A N I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n -
d a t i on s .
1 5 0
1 9 0 . I N S PE C TI ON AN D R E PAI R
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e -
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
a n ces a n d wea r l i mi ts a r e i n di ca ted by s ma l l ,
l ow e r ca s e l e t t e r s i n f i g. 376, f ol d - ou t 5. Re -
f e r t o p a r . 239 f or we a r l i mi t s i n f or ma t i on .
191.
i n a
ASSE MBL Y (f i g. 376, f ol d -ou t 5)
N o t e . Ch i l l s pi n dl es 34 i n dr y i ce f or
a p p r ox i ma t e l y on e h ou r p r i or t o i n -
s t a l l a t i on .
a . Pl a ce l ow - r a n ge s h a f t a n d ca r r i e r 27
p r e s s .
b . Gr e a s e t h e i n s i d e d i a me t e r of p l a n e -
t a r y ca r r i e r p i n i on a s s e mb l y 30.
c . I n s e r t 20 s p i n d l e r ol l e r s i n t o t h e p i n -
i on b or e . Re f e r t o f i g. 215.
d . Pl a ce a t h r u s t w a s h e r a n d s p a ce r on
a l i n i n g t ool 8351209. Re f e r t o f i g. 215.
PAR 1 9 1 L OW P L ANE T AR Y AND OU T P U T S H AF T R E B U I L D CHAP 5, SEC X X V
Figure 221. Alining pinion and component parts in
planetary carrier
Figure 219. Removing spindle lock pin
Figure 222. I nstalling planetary carrier spindle
Figure 220. Removing planetary carrier spindle
e . I n s er t a l i n i n g tool 8351209, wi th wa s h -
er a n d s pa cer , i n to th e pi n i on .
f . I n s t a l l a s p a c e r 2 9 or 3 2 (f i g . 3 7 6 ,
f ol d-ou t 5) ov er th e a l i n i n g tool , th en a th r u s t
w a s h e r 28 or 33. Re mov e t h e a l i n i n g t ool .
g . Sl i d e p i n i on 30 a n d i t s r e l a t e d p a r t s
i n t o l oca t i on i n ca r r i e r 27 f r om wh i ch i t wa s
r e mov e d . U s i n g a l i n i n g t ool 8 3 5 1 2 0 9 , a l i n e
t h e p i n i o n , w a s h e r s a n d r o l l e r s . R e f e r t o
f i g. 221. Re mov e t h e a l i n i n g t ool .
h . I n s t a l l s p i n d l e r e p l a c e r 8 3 5 1 2 6 6 on
1 5 1
*C2
*C2
*C2
CHAP 5, SEC X X V I I NT E R ME D I AT E P L ANE T AR Y , L OW R I NG GE AR R E B U I L D PAR 191-195
th e pl a n eta r y ca r r i er a n d pos i ti on th e s pi n dl e
f or i n s t a l l a t i on . Se e f i g. 222.
N o t e . Be s u r e t h a t t h e s l ot on t h e
s p i n d l e i s i n d e x e d p r op e r l y w i t h i t s
l ock pi n bor e i n th e ca r r i er .
i . Wi th a press and spi ndl e repl acer
8351266, i n s ta l l pl a n eta r y ca r r i er s pi n dl e (f i g.
222). Th e s pi n dl e r epl a cer wi l l bottom a ga i n s t
th e ca r r i er wh en th e s pi n dl e i s pr oper l y pos i -
t i on e d i n t h e ca r r i e r .
j . U s i n g a h a m m e r a n d p u n c h , i n s t a l l
t h e p l a n e t a r y ca r r i e r s p i n d l e l ock p i n (f i g .
2 1 9 ). Dr i v e t h e p i n i n 0 . 0 3 0 t o 0 . 0 6 0 b e l ow
t h e s u r f a ce of t h e ca r r i e r . St a k e me t a l ov e r
th e pi n .
S ect i on XXVI . I NT E R ME DI AT E - R ANGE P L ANE T AR Y AND L OW- R ANGE RI NG GEAR REBUI LD
1 9 2 . DE S C R I PTI ON
Ref er to pa r s . 12 a n d 13 f or th e des cr i p-
t i on of t h e i n t e r me d i a t e -r a n ge p l a n e t a r y a n d
l ow - r a n ge r i n g ge a r .
1 9 3 . DI S AS S E MBL Y (f i g . 3 7 6 , f ol d - ou t 5 )
N o t e . Al l r e l a t e d i t e ms n ot cov e r e d
i n a th r ou gh d , b e l ow , w e r e r e mov e d
f r om t h e t r a n s mi s s i on a s ou t l i n e d i n
p a r . 75, s t e p s 116, 123 a n d 124. N o
f u r t h e r d i s a s s e mb l y of t h e s e p a r t s i s
r e q u i r e d .
a . Remov e r eta i n i n g r i n g th a t r eta i n s th e
i n t e r me d i a t e - r a n g e p l a n e t a r y ca r r i e r a s s e m-
b l y i n t h e l ow -r a n ge r i n g ge a r (f i g. 223). Re -
mov e t h e ca r r i e r a s s e mb l y .
b . U s i n g a h a mme r a n d p u n ch , r e mov e
f ou r p l a n e t a r y ca r r i e r s p i n d l e l ock p i n s (f i g.
2 2 4 ).
c . U s i n g a p r e s s a n d a p i e ce of 3/8-i n ch
dr i l l r od a ppr ox i ma tel y 6 i n ch es l on g, or oth er
s u i t a b l e p r e s s t ool , r e mov e f ou r p l a n e t a r y
s p i n d l e s f r om t h e ca r r i e r (f i g. 225).
d . R e mov e p l a n e t a r y ca r r i e r p i n i on s ,
s pa cer s , th r u s t wa s h er s a n d bea r i n g r ol l er s
fr om the car r i er (fi g. 225).
1 5 2
1 9 4 . C L E A N I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n -
d a t i on s .
1 9 5 . I N S PE C TI ON AN D R E PAI R
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
Figure 223. Removing (or installing) retaining ring
that retains intermediate-range planetary carrier assembly
*C2
*C2
*C2
PAR 195- 196
I NT E R ME D I AT E P L ANE T AR Y , L OW R I NG GE AR R E B U I L D
CHAP 5, SEC X X V I
Figure 224. Removing spindle lock pin
a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e -
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
a n ces a n d wea r l i mi ts a r e i n di ca ted by s ma l l ,
l ow e r c a s e l e t t e r s i n f i g . 3 7 6 , f ol d - ou t 5 .
Ref er to pa r . 239 f or wea r l i mi ts i n f or ma ti on .
1 9 6 . AS S E MBL Y (f i g . 3 7 6 , f ol d - ou t 5 )
N o t e . Ch i l l s p i n d l e s 1 9 i n d r y i ce
f or a p p r ox i ma t e l y on e h ou r , p r i or t o
i n s t a l l a t i on .
a . Pl a ce i n t e r me d i a t e - r a n g e p l a n e t a r y
carri er, l ong-spl i ned end down, i n a press
(f i g. 226).
b . Gr e a s e t h e i n s i d e d i a me t e r of p l a n e -
t a r y ca r r i e r p i n i on 2 2 , f i g . 3 7 6 , f ol d - ou t 5 .
c . I n s e r t 2 2 s p i n d l e r ol l e r s 2 3 i n t o t h e
p i n i on b or e . Re f e r t o f i g. 215.
e . I n s er t a l i n i n g tool 8351208 th r ou gh th e
p i n i on .
Figure 225. Removing intermediate-range planetary
carrier spindle
Figure 226. Installing intermediate-range planetary
carrier spindle
1 5 3
*C2
*C2
*C2
*C2
CHAP 5, SEC XXVI I HI GH CL UT CH RE BUI L D PAR 196- 198
f . Pl a c e a s p a c e r 2 1 or 2 4 a n d t h r u s t
wa s h er 20 or 25 ov er th e oth er en d of a l i n i n g
t ool . R e mov e a l i n i n g t ool .
g . Sl i d e t h e p i n i on , wi t h i t s r e l a t e d p a r t s
i n to th e l oca ti on i n th e ca r r i er 18 f r om wh i ch
i t wa s r e mov e d . U s i n g a l i n i n g t ool 8351208,
a l i n e th e pi n i on , r ol l er s , s pa cer s a n d wa s h er s .
Re f e r t o f i g. 221. Re mov e t h e a l i n i n g t ool .
th e
f o r
h . I n s t a l l s p i n d l e r e p l a c e r 8 3 5 1 2 6 6 on
p l a n e t a r y ca r r i e r a n d p os i t i on t h e s p i n d l e
i n s t a l l a t i on (f i g. 226).
N ot e . Be s u r e t h a t t h e s l ot on t h e
s p i n d l e i s i n d e x e d p r op e r l y w i t h i t s
l ock pi n bor e i n th e ca r r i er (f i g. 226).
i . Wi th a press and spi ndl e repl acer
8351266, i n s t a l l t h e p l a n e t a r y ca r r i e r s p i n d l e
(f i g. 226). Pr es s i n th e s pi n dl e to wi th i n 0.010
i n ch of t h e ca r r i e r s u r f a ce .
j . I n s ta l l a l ock pi n , u s i n g a h a mmer a n d
pu n ch (f i g. 224). Dr i v e th e pi n 0.030 to 0.060
b e l o w t h e a d j a c e n t c a r r i e r s u r f a c e . S t a k e
meta l ov er th e pi n .
k . I n s t a l l t h e r e ma i n i n g t h r e e s p i n d l e s
19 (f i g. 376, f ol d -ou t 5) a n d p i n i on s 22, wi t h
r ol l e r s 23, s p a ce r s 21 a n d 24, t h r u s t wa s h e r s
20 and 25 and l ock pi ns 17 i n the same manner
a s des cr i bed i n b t h r ou gh j , a b ov e .
l . I n s t a l l t h e i n t e r me d i a t e - r a n g e p l a n e -
t a r y ca r r i e r a s s e mb l y on t o t h e l ow-r a n ge r i n g
ge a r . I n s t a l l t h e r e t a i n i n g r i n g (f i g. 223).
Sect i on XXVI I . HI GH-RANGE CLUTCH REBUI LD
1 9 7 . DE S C R I PTI ON
Ref er to pa r . 11 f or th e des cr i pti on of th e
h i gh -r a n ge cl u t ch .
1 9 8 . DI S AS S E MBL Y (f i g . 3 7 5 , f ol d - ou t 4 )
N o t e . Al l r e l a t e d i t e ms n ot cov e r e d
i n a t h r ou gh i , b e l ow , w e r e r e mov e d
f r om t h e t r a n s mi s s i on a s ou t l i n e d i n
p a r . 75, s t e p s 126 a n d 127. N o f u r -
t h e r d i s a s s e mb l y of t h e s e p a r t s i s
r e q u i r e d .
a . Remov e th e r eta i n i n g r i n g th a t r eta i n s
th e h i gh -r a n ge cl u tch r ea cti on pl a te (f i g. 227).
Re mov e t h e r e a ct i on p l a t e .
b . R e mov e t h e h i g h - r a n g e cl u t ch p l a t e s
(f i g. 227).
c . U s i n g b e a r i n g p u l l e r , r e mov e t h e b e a r -
i ng fr om the hub of the hi gh-r ange cl utch hous -
i n g (f i g. 228).
1 5 4
Figure 227. Removing (or installing) retaining ring that
retains high-range clutch reaction plate
*C2
*C2
PAR 198- 199 HI GH CL UT CH RE BUI L D C H A P 5, S E C X X V I I
d . U s i n g a comp r e s s i n g t ool , comp r e s s f . R e mov e t h e h i g h - r a n g e cl u t ch p i s t on
th e h i gh -r a n ge cl u tch pi s ton r etu r n s pr i n g r e-
f r om t h e cl u t ch h ou s i n g (f i g. 230).
tai ner , and r emov e the r etai ni ng r i ng (fi g. 229).
g . Do n ot r e mov e t h e s e a l r i n g a n d e x -
e . R e mov e t h e r e t a i n e r (f i g . 2 2 9 ) a n d 1 3
h i gh - r a n ge cl u t ch p i s t on r e t u r n s p r i n gs f r om
th e cl u tch h ou s i n g.
Figure 228. Removing bearing from high-range clutch
housing
pa n der f r om th e ou ts i de di a meter of th e pi s ton
u n l e s s r e p l a ce me n t i s n e ce s s a r y .
h . Re mov e t h e h ook - t y p e s e a l r i n g f r om
th e h u b of th e h i gh -r a n ge cl u tch h ou s i n g (f i g.
230). Do n ot r emov e th e s l eev e f r om th e cl u tch
h ou s i n g u n l e s s r e p l a ce me n t i s n e ce s s a r y .
i . Do n ot r e mov e t h e r ol l e r b e a r i n g f r om
th e cl u tch h ou s i n g, u n l es s pa r ts r epl a cemen t i s
n e ce s s a r y . I f n e ce s s a r y , r e mov e t h e r e t a i n -
i n g r i n g a n d "h ook " th e bea r i n g ou t (f i g. 231).
N o t e . Th e be a r i n g a s s e mbl y wi l l be
d e s t r oy e d i f r e mov e d f r om t h e h ou s -
i n g . Th e b e a r i n g r ol l e r s ma y b e r e -
mov ed by r emov i n g th e r ol l er r eta i n -
i n g r i n g (f i g. 231).
1 9 9 . C L E A N I N G
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n -
d a t i on s .
Figure 229. Removing (or installing) retaining ring
that retains piston return spring retainer
Figure 230. Removing (or installing) piston from
high-range clutch housing
1 5 5
*C2
*C2
*C2
CHAP 5, SEC XXVI I HI GH CL UT CH R E B U I L D PAR 2 0 0 - 2 0 1
c . I f t h e s l e e v e w a s r e mov e d f r om t h e
cl u tch h ou s i n g, i n s ta l l th e s l eev e 3/4-i n ch be-
l ow th e top edge of th e h ou s i n g (f i g. 230).
d . I n s t a l l a h ook - t y p e s e a l r i n g on t h e
h u b of th e h i gh -r a n ge cl u tch h ou s i n g (f i g. 230).
e . I f s e a l r i n g a n d e x p a n d e r w e r e r e -
mov e d f r om h i gh -r a n ge cl u t ch p i s t on , i n s t a l l
n e w r e p l a ce me n t s (f i g. 230).
f . I n s t a l l t h e p i s t on i n t h e h i g h - r a n g e
cl utch housi ng (fi g. 230).
g . I n s t a l l 13 cl u t ch p i s t on r e t u r n s p r i n gs
Figure 231. High-range clutch housing
66 (f i g. 375, f ol d -ou t 4).
2 0 0 . I N S PE C TI ON AN D R E PAI R h . I n s t a l l t h e h i g h - r a n g e cl u t ch p i s t on
r e t u r n s p r i n g r e t a i n e r (f i g. 229).
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e - i . U s i n g a c om p r e s s i n g t ool (f i g . 3 8 ),
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
compr ess pi ston r etur n spr i ngs and i nstal l the
a n t e s a n d we a r l i mi t s a r e i n d i ca t e d b y s ma l l ,
l ow e r ca s e l e t t e r s i n f i g. 375, f ol d - ou t 4. Re -
f e r t o p a r . 238 f or we a r l i mi t s i n f or ma t i on .
2 0 1 . AS S E MBL Y (f i g . 3 7 5 , f ol d - ou t 4 )
a . I f t h e b e a r i n g wa s r e mov e d f r om t h e
h i gh -r a n ge cl u t ch h ou s i n g, i n s t a l l a n e w r e -
p l a ce me n t . Pr e s s t h e b e a r i n g i n u n t i l f i r ml y
s e a t e d i n t h e h ou s i n g . I n s t a l l t h e r e t a i n i n g
r i n g (f i g. 231).
b . I f on l y b e a r i n g r ol l e r s w e r e r e mov e d
f r om t h e cl u t ch h ou s i n g f or cl e a n i n g, gr e a s e
t h e r ol l e r s l i gh t l y a n d i n s t a l l i n t h e b e a r i n g
r a ce . I n s t a l l t h e r ol l e r r e t a i n i n g r i n g (f i g .
2 3 1 ).
r e t a i n i n g r i n g t h a t r e t a i n s t h e r e t a i n e r (f i g.
2 2 9 ).
j . I n s t a l l t h e b e a r i n g on t h e h u b of t h e
h i g h - r a n g e cl u t ch h ou s i n g (f i g . 2 2 7 ). Pr e s s
th e bea r i n g i n n er r a ce u n ti l i t i s f i r ml y s ea ted
on the hub.
k . I n s ta l l f i v e i n ter n a l - a n d f ou r ex ter n a l -
s p l i n e d h i g h - r a n g e cl u t ch p l a t e s , b e g i n n i n g
wi t h a n i n t e r n a l -s p l i n e d p l a t e (f i g. 227).
l . I n s t a l l t h e h i gh -r a n ge cl u t ch r e a ct i on
p l a t e (f i g. 227).
m . I n s ta l l th e r eta i n i n g r i n g th a t r eta i n s
h i gh -r a n ge cl u t ch r e a ct i on p l a t e (f i g. 227).
1 5 6
*C2
PAR 2 0 2 - 2 0 3 T R ANS MI S S I ON H OU S I NG R E B U I L D CHAP 5, SEC XXVI I I
Sect i on XXVI I I . T RANSMI SSI ON HOUSI NG REBUI L D
2 0 2 . DE S C R I PTI ON
Th e t r a n s mi s s i on ma i n h ou s i n g i s a ca s t
a l u mi n u m a l l oy h ou s i n g . I t h ou s e s a n d s u p -
p or t s t h e r a n ge ge a r i n g, r a n ge cl u t ch e s , l e f t -
s t e e r p l a n e t a r y ca r r i e r , b r a k e , s t e e r cl u t ch
a n d ou t p u t cl u t ch a s s e mbl i e s . Th e ma i n h ou s -
i n g a l s o s er v es a s th e oi l s u mp f or th e tr a n s -
m i s s i on .
2 0 3 . DI S AS S E MBL Y (f i g . 3 7 5 , f ol d - ou t 4 )
a . Re mov e t w o h ook - t y p e s e a l r i n gs f r om
th e h u b of th e di a ph r a gm (f i g. 232).
b . Re mov e t h e t h r u s t w a s h e r (f i g. 232).
c . R e mov e t w o p r e f or me d p a ck i n g s f r om
t h e t r a n s mi s s i on h ou s i n g (f i g. 232).
Figure 232. Removing hook-type seal ring from hub of
diaphragm assembly
d . R e m o v e r e t a i n i n g r i n g t h a t r e t a i n s
bear i n g (fi g. 232).
e . I f n e ce s s a r y t o r e mov e t h e d i a p h r a gm
a s s e mb l y , u s e a 9 /1 6 - i n ch w r e n ch t o r e mov e
f ou r s e l f - l ock i n g b ol t s r e t a i n i n g d i a p h r a g m.
Pos i ti on h ou s i n g i n a pr es s , a n d pr es s ou t th e
d i a p h r a g m. R e f e r t o f i g . 2 3 3 .
f . I f t h e d i a p h r a g m a s s e m b l y w a s r e -
mov e d , r e mov e t h e d i a p h r a g m cl a mp p l a t e .
Re f e r t o f i g. 232.
g . Re mov e t h e ga ge r od ca p f r om t h e oi l
f i l l e r a s s e mb l y . R e f e r t o f i g . 2 3 3 .
h . U s i n g a 9 /1 6 - i n c h w r e n c h , r e m o v e
f ou r bol ts a n d l ock wa s h er s f r om th e oi l f i l l er
t u b e a s s e m b l y . R e mov e t h e oi l f i l l e r t u b e
a s s e mb l y . R e f e r t o f i g . 2 3 3 .
i . U s i n g a 9/16-i n ch wr e n ch , r e mov e s i x
ca p s cr e w s (t w o d i f f e r e n t l e n g t h s ) a n d l ock
wa s h er s th a t r eta i n th e a ccu mu l a tor body . Re-
mov e th e a ccu mu l a tor body . Ref er to f i g. 233.
Figure 233. Transmission main housing
1 5 7
*C2
CHAP 5, SEC XXVI I I
T R ANS MI S S I ON H OU S I NG R E B U I L D
PAR 2 0 3 - 2 0 6
Figure 234. Removing transmission output coupling
and bearing
j . Pos i t i on t h e t r a n s mi s s i on h ou s i n g t o
r e s t on i t s b ot t om. U s i n g a h a mme r a n d s of t
d r i f t , d r i v e ou t t h e ou t p u t cou p l i n g a n d b a l l
b e a r i n g (f i g. 234). Figure 235. Transmission output coupling and bearing
r emoved
k . R e mov e t h e b e a r i n g f r om t h e ou t p u t
cou p l i n g (f i g. 235).
2 0 5 . I N S PE C TI ON AN D R E PAI R
l . Do n ot r e mov e t h e i n t e r n a l - r e t a i n i n g
R e f e r t o p a r . 7 2 f or g e n e r a l i n s p e ct i on
r i n g f r om t h e ou t p u t cou p l i n g u n l e s s r e p l a ce - a n d r e p a i r r e comme n d a t i on s . Re p a i r a n d r e -
me n t i s n e ce s s a r y (f i g . 2 3 5 ). I f n e ce s s a r y ,
b u i l d p oi n t s of me a s u r e me n t f or f i t s , cl e a r -
r e mov e t h e r e t a i n i n g r i n g.
a n ces a n d wea r l i mi ts a r e i n di ca ted by s ma l l ,
l ow e r ca s e l e t t e r s i n f i g. 375. f ol d - ou t 4. Re -
m . Do n ot r e mov e t h e oi l s e a l f r om t h e
f e r t o p a r . 238 f or we a r l i mi t s i n f or ma t i on .
t r a n s mi s s i on h ou s i n g u n l e s s r e p l a ce me n t i s
n e ce s s a r y (f i g . 2 3 5 ). I f n e ce s s a r y , d r i v e t h e
2 0 6 . AS S E MBL Y (f i g . 3 7 5 , f ol d - ou t 4 )
oi l s ea l ou t of th e h ou s i n g.
a . I n s t a l l a n y p l u gs r e mov e d f r om t h e
n . I f n e ce s s a r y , t h e v a r i ou s p l u g s ma y tr a n s mi s s i on ma i n h ou s i n g (fi gs . 233 a n d 235).
b e r e mov e d f r om t h e h ou s i n g t o a i d i n t h e
cl e a n i n g of t h e oi l p a s s a g e s i n t h e h ou s i n g b . Pos i t i on t h e t r a n s mi s s i on h ou s i n g on
(f i gs . 233 a n d 235). i t s s i d e . U s i n g r e p l a ce r 8351210, i n s t a l l t h e
oi l s ea l , l i p s i de u p, i n i ts tr a n s mi s s i on h ou s -
i n g bor e (f i g. 235). Be s u r e th e s ea l i s f i r ml y
2 0 4 . C L E A N I N G s ea ted a ga i n s t i ts s h ou l der i n th e h ou s i n g.
Re f e r t o p a r . 71 f or cl e a n i n g r e comme n - c. I n s t a l l t h e b e a r i n g on t o t h e ou t p u t
d a t i on s . cou p l i n g (f i g. 235).
1 5 8
PAR 206- 211 T U R B I NE S H AF T R E B U I L D CHAP 5, SEC X X I X
d. I nstal l the output coupl i ng wi th the
bear~ng i nto the transmi ssi on housi ng. I nstal l
the retai ni ng ri ng (fi g. 232).
$c~ e. Po~i ~i on the tr an s mi s s i on h ou s i n g on
i ts b~ttom si de. I nstal l the accumul ator bcdy
and gasket. Secure the body wi th four 3/8- 16
x 1-l /2 and two 3/8-16x 2-1/2-i nch cap screws
wi th l ock washers (fi g. 233).
+@ $ I nstal l the oi l fi l l er tube assembl y and
gasket. Secure the assembl y wi th four 3/8- 16
x 1 cap screws wi th l ock washers. I nstal l the
gage rod cap.
~. I nstal l the di aphragm assembl y i n i ts
housi ng bore (fi g. 233).
#C~h. I nstal l the,i i aphragmcl amp pl ate over
the h=b of the di ap:magm assembl y (fi g. 232).
Al i ne the bol t hol es i n the pl ate wi th the di a-
phragm :Lssembl y. I nstal l four 3/8-24x 2- l /2-
i nch sel f -l ocki ng d i aphra.gm bol ts (fi g. 233).
i . 1 ns t a 11 two preformed packi ngs on
transmi ssi on housi ng (fi g. 232 ).
~ I nstal l two hook-type seal ri ngs on hub
of di aphragm assembl y (fi g. 232).
Section XXIX. TURBINE SHAFT REBUILIJ
207. DESCRI PTI ON
The turbi ne shaft, of machi ned s t e e 1,
serves as the torque converter output shaft.
I t i s the i nput dri ve member to the transmi s-
.. , si on range geari ng, and i s spl i ned to the hi gh-
range cl utch hub, i ntermedi ate-range and l ow-
range sun gears. The shaft i s spl i ned to the
turbi ne of the torque converter assembl y.
208. DI SASSEMBLY (fi g. 375, fol d-out 4)
a. Remove four seal ri ngs 1 and 3 from
turb~e shaft 2.
~. Usi ng a sl eeve whi ch wi l l contact the
i nner race of thebeari ng, support the assem-
bl y i n a press. Press the shaft out of the
beari ng (fi g. 236).
209. CLEANI NG
Refer to par. 71 for cl eani ng recommen-
dati ons.
210. I NSPECTI ON AND REPAI R
-.
Refer to par. 72 for general i nspecti on
and repai r recommendati ons. Repai r and re-
bui l d poi nts of measurement for fi ts, cl ear-
ances and wear l i mi ts are i ndi cated by smal l ,
l ower case l etters i n fi g. 375, fol d-out 4.
Refer to par. 238 for wear l i mi ts i nformati on.
211. ASSEMBLY (fi g.
a. I nstal l beari ng
:375, fol d-out 4)
5 onto turbi ne shaft 2.
Pres= the beari ng i m& race unti l i t i s fi rml y
seated agai nst i t; shoul der on the shaft.
-
~. I nstal l three hook-type seal ri ngs 3
and one seal ri ng 1 ontcl turbi ne shaft 2.
ml
,!
Figure 236. Removing bearing jrom turbine shu/t
159
CHAP 5, SEC X X X L E F T , R I GH T OU T P U T
Section XXX. LEFT- AND RIGHT-OUTPUT
212. DESCRI PTI ON
Refer to pars. 26 and 27 for the descri p-
ti on of the output dri ve pl anetary assembl i es.
213. DI SASSEMBLY
*C*
a. Left-output Dri ve Pl anetary Carri er
Assembl y (18, fi g. 385, fol d-out 14)
(1) Remove three spi ndl e l ock pi ns 21
from output dri ve pl anetary carri er 20. Dri ve
pi ns tmvard the center of the carri er.
(2) Usi ng a sui tabl e pressi ng tool , re-
move three spi ndl es 19 from carri er 20.
(3) R e move three pl anetary carri er
pi ni ons 24, wi th washers 22 and 27, spacers
23 and 26 and rol l ers 25. Pl ace parts i n sepa-
rate contai ners and i denti fy them wi th thei r
l ocati on i n carri er 20. Pl ace the spi ndl es i n
the same contai ners.
b. Ri ~ht-outmt Dri ve Pl anetarv Carri er
Assembl y (41, f{g. 386, fol d-out 15). The
l eft- and ri ght-output dri ve pl anetary assem-
bl i es are i denti cal , therefore the di sassembl y
procedure i s the same as descri bed i n a(1)
bough 2(3), above.
214. CLEANI NG
Refer to par. 71
dati ons.
for cl eani ng recommen-
215. I NSPECTI ON AND REPAI R
Refer to par. 72 for general i nspecti on
and repai r recommendati ons. Repai r and re-
bui l d poi nts of measurements for fi ts, cl ear-
ances and wear l i mi ts are i ndi cated by smal l
l etters i n fi gs. 385 and 386, fol d-outs 14 and
15. Refer to par. 248 and 249 for wear l i mi ts
i nfor mati on.
160
P L AN ETARIES REBUI L D
DRIVE PLANETARY
216. ASSEMBLY
PAR 212- 216
ASSEME LIES - REBUILD
a. Left-output Dri ve Pl anetary Carri er
Asserr@~.g. 385, fol d-ou t 147
Note. Chi l l spi ndl es 19 i n dry i ce
for o n e hour, i f p[wsi bl e, pri or to
assembl y.
(1) Coat the bore;; of pi ni ons 24 wi th
gr ease.
Note. I f any one of the pi ni ons must
b e repl aced because of cl ef ects o r
damage, i t wi l l be r,ecessary to r e-
pl ace a 11 three pi ni ons wi th a new
matched assembl y.
(2) I nstal l a pi ni on al i ni ng tool i nto a
pi ni on 24.
Note. A sui tabl e al :.ni ng tool can be
i mprovi sed by gri nd:ng an unservi ce-
abl e spi ndl e to O. 005 i nch undersi ze
and brazi ng a handk to one end.
(3) Pl ace a spacer 23 ancl thrust washer
22 on one si de of pi ni o~ Y?4.
(4) I nstal l 20 needl e rol l ers 25 i nto the
pi ni on bore i n the space a:?ound the al i ni ng toed.
(5) I nstal l a seconc. spacer 26 and thrust
washer 27. Remove the al i ni ng tool .
(6) I nstal l the I i ni on, wi th the two
spacers, two washers ar.d 20 rol l ers i nto the
carri er. Al i ne i ts bore wi th the spi ndl e bore
i n the carri er, usi ng the al i ni ng tool .
(7) Pl ace the carl i er i n a press, wi th
the l arger outsi de di ameter si de of the carri er
up. Remove the al i ni ng tool .
(8) Start a spi ndl e 19 i nto the bore of
the carri er. The spi ndl t: must be accuratel y
al i ned so that i ts l ock pi n groove wi l l be paral -
l el wi th the l ock pi n hol e i n the carri er.
_____ _
PAR 216- 221 LEFT, RI GHT OUTPUT HOUSI NGS REBUI LD CHAP 5, SEC XXX!
(9) Press spi ndl e 19 i nto carri er 20 wi th cornpcment pa rts as outl i ned i nq(l ) through
unti l i t i s fl ush to O. 010 i nch bel ow the car-
ri er surface.
~$bove.
Ri ght-out put Dri ve Pl anetary Carri er
.>
(10) I nstal l spi ndl e l ock pi n 21. Dri ve
Assemb~(~-g. 386, f o i d-out 1~~
l eft- and ri ght - output dri ve pl anetary assem-
the pi n i n bel ow the top edge of the bore.
bl i es are i denti c;l l , therefore the assembl y
procedure i s the same as descri bed i n ~(i )
(11) I nstal l the remai ni ng two pi ni ons through a( 11), ab(]ve.
Section XXXI.
217. DESCRI PTI ON
Refer to pars. 26 and
LEFT-
27 for
ti on of the output dri ve housi ngs.
and RIGHT-OUTPUT DRIVE HOU5 INGS -- REBUILD
the descri p-
218. DI SASSEMBLY
a. Left-output Dri ve Housi ng Assembl y
219. CLEANI NG
Refer to par.
dati ons.
71 for cl eani ng recommen-
220. I NSPECTI ON ANI D REPAI R
Refer to pa:?. 72 for general i nspecti on
and repai r recorrl rnendati ons. Repai r and re-
bui l d poi nts of measurements for fi ts, cl ear-
ances ;and wear .i mi ts are i ndi cated[ by smal l
l etters i n fi gs. 385 and 386, fol d-outs 14 and
15. Refer to par~;. 248 and 249 for wear l i mi ts
i nfor mati on.
221. ASSEM.BL[
)/0
a. Left-out mt Dri ve Housi n@i ssembl y
-
~38, fi g. 385, fol d-out 14)
-_
(1) I f out~ r race of rol l er beari ng 34
was removed from housi ng assembl y 38, i n-
stal l a. new repl Zcement. Press the race i n
housi ng unti l i t i ~~ f l ush wi th the top of i ts bore.
Note. I nstal l i nner race of repl ace-
224. CLEANING
Refer to par, 71 for cleaning recommen-
dations.
Figure 237. Removing pipe plugs from output shaft
assembly
162
225. INSPECTION AND REPAIR
Refer to par. 72 for general inspection
and repair recoin mendat. ens. .Repair and re-
build points of measuren]ents for fits, clear-
ances and wear lilmits a::e indicated by small
letters in figs. 385 and :~86, fold-outs 14 and
15. Refer to pars, 248 ar d 249 for wear limits
information.
II J Ill I
l--
BEARING REMOVER
(IMPROVISED TOOL)
l--
WRING
+-Figure .238. Remoz ing beari ag, retainer and seal from
otiput shaft c ssembly
*~iwre2.W. l~stalling seal onto output shaft spacer
PAR 226-227 AS S E MB L Y
CHAP 5, SEC XX XIII
226. ASSEMBLY Note. Press o n the extreme outer
&
Note. The following assembly steps
for the XTG-411 -2A power train are
to be used in the same manner as the
disassembly steps, Refer to par, 73~
and b.
(1 ) C h e c k t h e t r a n s m i s s i on oi l
l ev el (f i g. 366). Add oi l a s r equ i r ed to ob-
tai n th e cor r ect oi l l ev el for a s afe s tar t.
(2) Sta r t th e en gi n e (or tes t s ta n d
motor ) a n d s h i f t th e tr a n s mi s s i on i n to 4th
g e a r . Ap p l y t h e b r a k e s , a n d a l l ow t h e
tr a n s mi s s i on to oper a te a t a n i n pu t s peed
of 1200 t o 1500 r p m f or 3 t o 8 mi n u t e s ,
u n t i l n or ma l op e r a t i n g t e mp e r a t u r e (a p -
pr ox i matel y 220 degr ees F) i s r eached.
(3 ) S h i f t t h r ou g h a l l r a n g e s s e -
v e r a l t i me s t o i n s u r e t h a t t h e h y d r a u l i c
s y s tem i s f u l l y ch a r ged. Redu ce th e i n pu t
s peed to mak e s h i fts fr om a for war d r an ge
to a r ev er s e r a n ge, or f r om r ev er s e r a n ge
to a for war d r ange.
( 4 ) S h i f t t h e t r a n s m i s s i o n t o
n e u t r a l r a n ge , a p p l y t h e b r a k e s , a n d i n -
cr ea s e th e i n pu t s peed to 1200-1500 r pm
a n d ma i n t a i n f or t h r e e mi n u t e s . s t op
e n gi n e , wa i t t we n t y mi n u t e s , t h e n ch e ck
t h e t r a n s mi s s i on oi l l e v e l . Ad d or d r a i n
th e oi l u n ti l oi l l ev el i s a t th e top of th e
OP E R A TI N G R A N G E m a r k i n g o n t h e
i n di ca tor (fi g. 366).
c . L e a k Ch e ck . Du r i n g t h e w a r m- u p
per i od, i nspect the tr ansmi ssi on for oi l
l ea k s a t s pl i t l i n es a n d a r ou n d bol ts a n d
p l u gs . I f l e a k a ge i s p r e s e n t , ch e ck b ol t s
a n d p l u gs f or t i gh t n e s s . I f l e a k a ge con -
ti n u es , r e p l a ce ga s k e t s w h e r e r e q u i r e d .
L ea k a ge of oi l , i n ma n y ca s es , ca n ca u s e
faul ty oper ati on of the tr ansmi ssi on.
d . Oi l Pr e s s u r e s . Al l n e ce s s a r y oi l
p r e s s u r e t e s t s ca n b e ma d e d u r i n g t h e
f u n cti on a l tes ts ou tl i n ed i n e , bel ow, an d
i n fi g. 367. Fi g. 368 i l l u s tr a tes a n d i den -
ti f i es th e tr a n s mi s s i on oi l pr es s u r e ch eck
poi n ts .
e . F u n ct i on a l Te s t s
(1) Th e t e s t d a t a l og s h e e t (f i g.
367) can be used as a gui de for mak i ng the
pr oper tes ts , as wel l as pr ov i di ng s paces to
r e cor d a ct u a l t e s t s r e s u l t s . I n a d d i t i on ,
the nor mal pr es s ur es ar e i ncl uded for com-
par i son wi th test r esul ts.
(2) I n a l l t e s t s , t h e t r a n s mi s s i on
oi l mu s t be a t n or ma l oper a ti n g temper a -
tu r e (a ppr ox i ma tel y 220 degr ees F). Con -
n ect th e pr es s u r e ga ge to th e ch eck poi n t
i n d i ca t e d , f or t h e t e s t b e i n g ma d e (f i g.
369).
(3) Reduce the speed of the
t r a n s mi s s i on i n p u t t o e n gi n e i d l e s p e e d
b e f or e e n ga gi n g t h e d e s i r e d r a n ge . Th e n
s l ow l y i n cr e a s e t h e s p e e d t o t h e d e s i r e d
i n pu t s peed. Recor d th e r ea di n gs f or ea ch
tes t.
(4) Do n ot a t t e mp t t o r e mov e or
i n s t a l l g a g e s w h i l e t h e t r a n s mi s s i on i s
oper a ti n g. Re i n s t a l l p l u g s i mme d i a t e l y
upon r emov i ng the gage.
(5 ) Wh e n ma k i n g t h e t e s t s f or
s teer cl u tch pr es s u r e, mov e th e s teer con -
tr ol fr om Cen ter to Fu l l s teer s l owl y wh i l e
obs er v i n g th e pr es s u r e r i s e. I t s h ou l d r i s e
to ma x i mu m a s th e con tr ol i s mov ed f u l l y
to s teer pos i ti on.
(6 ) I n t e s t s f or l ock u p e n g a g e -
me n t , i n cr e a s e s p e e d s l owl y u n t i l l ock u p
a p p l y p r e s s u r e r e gi s t e r s . Re cor d l ock u p
p r e s s u r e a n d i n p u t s p e e d . Re cor d gov e r -
n or p r e s s u r e a t l ock u p e n ga ge me n t (f u l l
TV).
Change 2 197
CHAP 5, SEC XXXI V TEST AND ADJ USTMENTS P A R 233
Fi gu r e 368. Tr a n s mi s s i on oi l pr es s u r e ch eck poi n ts a n d con tr ol s
Fi gu r e 369. Ch eck i n g tr a n s mi s s i on
oi l pr es s u r e
(7 ) I n t e s t s f or l ock u p r e l e a s e ,
fi r s t i n cr eas e th e i n pu t s peed to abov e th e
Poi n t wh e r e l ock u p occu r s . Th e n s l owl y
r edu ce th e s peed, wh i l e obs er v i n g l ock u p
cl u t ch a p p l y p r e s s u r e , u n t i l l ock u p p r e s -
s ur e dr ops qui ck l y . At thi s moment, r ecor d
gov er n or pr es s u r e an d i n pu t s peed.
(8 ) Du r i n g a l l t e s t s , w h e n t h e
output coupl i ngs at the r i ght and l eft si des
of th e power tr a i n a r e di s con n ected f r om
t h e ou t p u t d r i v e a s s e mb l i e s , ob s e r v e t h e
cou p l i n gs t o ch e ck t h e i r r ot a t i on . Rot a -
ti on shoul d be as outl i ned i n f , bel ow.
f . Rota ti on of Power Tr a i n Ou tpu ts
(1 ) I n a l l f or w a r d a n d r e v e r s e
g e a r s , b o t h t h e o u t p u t c o u p l i n g s w i l l
t e n d t o r o t a t e e v e n a t e n g i n e i d l e
s peeds . A l i g h t a p p l i c a t i o n o f t h e
198 Change 2
P AR 2 3 3 - 2 3 4 T E S T S A N D A D J U S T M E N T S C H A P 5, SEC X X X I V
br a k es wi l l s top s u ch r ota ti on wh en th e power
t r a i n i s f u n ct i on i n g p r op e r l y .
(2) I n a l l f ou r f or wa r d ge a r s , wh e n n o
s teer i s appl i ed, the power tr ai n outputs s houl d
r ot a t e cl ock w i s e , a s v i e w e d f r om t h e r i g h t
s i de of th e power tr a i n .
(3) I n both r ev er s e gea r s , wh en n o s teer
i s a ppl i ed, th e power tr a i n ou tpu ts s h ou l d r o-
t a t e c o u n t e r c l o c k w i s e , a s v i e w e d f r o m t h e
r i gh t s i de of th e power tr a i n .
(4) I n f or w a r d ge a r s (f i r s t a n d s e con d ),
i n c l u t c h - b r a k e f u l l - r i g h t s t e e r , t h e r i g h t
power tr a i n ou tpu t s h ou l d s top wh i l e th e l ef t-
ou t p u t r ot a t e s cl ock wi s e , a s v i e we d f r om t h e
r i gh t s i de of th e power tr a i n .
(5) I n f or w a r d ge a r s (f i r s t a n d s e con d ),
i n cl u t ch -b r a k e f u l l -l e f t s t e e r , t h e l e f t -p owe r
tr a i n ou tpu t s h ou l d s top wh i l e th e r i gh t ou tpu t
r ot a t e s cl ock w i s e , a s v i e w e d f r om t h e r i g h t
s i de of th e power tr a i n .
(6) I n f or w a r d ge a r s (t h i r d a n d f ou r t h ),
i n g e a r e d f u l l - r i g h t s t e e r , b ot h p ow e r t r a i n
ou t p u t s s h ou l d r ot a t e cl ock w i s e , a s v i e w e d
Figure 370. Right- and left-brake adjusting wrenches,
properly positioned
f r om t h e r i g h t s i d e of t h e p ow e r t r a i n . Th e
l e f t ou t p u t s h ou l d r ot a t e 0 . 4 7 7 t i me s f a s t e r
th a n th e r i gh t.
(7) I n f or w a r d ge a r s (t h i r d a n d f ou r t h ),
i n gea r ed f u l l -l ef t s teer , both power tr a i n ou t-
p u t s s h ou l d r ot a t e cl ock w i s e , a s v i e w e d f r om
t h e r i gh t s i d e of t h e p owe r t r a i n . Th e r i gh t
ou t p u t s h ou l d r ot a t e 0. 477 t i me s f a s t e r t h a n
th e l eft.
( 8 ) I n r e v e r s e 1 , cl u tch -br a k e f u l l -
s teer , th e r i gh t ou tpu t s h ou l d s top wh en s teer -
i n g r i g h t . Th e l e f t ou t p u t s h ou l d s t op w h e n
s t e e r i n g l e f t . Th e op p os i t e ou t p u t s h ou l d r o-
t a t e c o u n t e r c l o c k w i s e , a s v i e w e d f r o m t h e
r i gh t s i de of th e power tr a i n .
(9) I n r e v e r s e 2, ge a r e d f u l l -s t e e r , t h e
r i gh t ou t p u t s h ou l d s l ow d u r i n g r i gh t s t e e r .
Th e l ef t ou tpu t s h ou l d s l ow du r i n g l ef t s teer .
R ot a t i on of b ot h ou t p u t s s h ou l d b e cou n t e r -
cl ock w i s e , a s v i e w e d f r om t h e r i g h t s i d e of
t h e p ow e r t r a i n .
2 3 4 . A DJ U S TME N TS
a . B r a k e L i n k a g e
(1) Di s con n ect th e v eh i cl e br a k e l i n k a ge
f r om t h e t r a n s mi s s i on . Ch e ck v e h i cl e l i n k a ge
to see that i t i s not bi ndi ng.
(2 ) Pos i t i on t h e v e h i cl e b r a k e con t r ol
i n f u l l y r el ea s ed pos i ti on . Adj u s t v eh i cl e l i n k -
age u n ti l i t can be fr eel y con n ected to th e tr an s -
m i s s i on . Se cu r e t h e l i n k a ge .
b . B r a k e s
(1) Powe r t r a i n i n s t a l l e d i n v e h i cl e a n d
i n s e r v i ce .
( a ) Br a k e l i n k a g e mu s t b e p r op e r l y
a d j u s t e d a s ou t l i n e d i n a , a b ov e , b e f or e a t -
tempti n g th i s br a k e a dj u s tmen t wh en th e br a k e
a ppl y l ev er s (compon en ts of br a k e l i n k a ge) a r e
con n e ct e d .
( b ) I f b r a k e a p p l y l e v e r s a r e con n e ct -
e d , p e r ma n e n t l y s cr i b e or t e mp or a r i l y ma r k
b ot h l e v e r s s o t h a t t h e ma r k s a l i n e wi t h t h e
Rel eas e mar k on the bear i ng r etai ner (fi g. 370).
1 9 9
CHAP 5, SEC X X X I V T E S T S AND ADJ U S T ME NT S P A R 2 3 4
( c ) Wi t h t h e br a k e s f u l l y a p p l i e d , ob- ( d ) I n s t a l l i n s p e ct i on cov e r g a s k e t s ,
s er v e th e pos i ti on of th e ma r k s on th e l ev er s i n s p e ct i on cov e r s , l ock w a s h e r s a n d b ol t s .
i n r el ati on to the mar k s on the bear i ng r etai ner .
( d ) I f t h e i n d e x ma r k s on t h e l e v e r s
r ot a t e t o t h e Ap p l y ma r k on t h e r e t a i n e r b u t
not to the Readj us t mar k , the br ak es ar e s ati s -
f a ct or i l y a d j u s t e d .
( e ) I f t h e i n d e x ma r k s on t h e l e v e r s
do n ot r ota te to th e Appl y ma r k or i f th ey r o-
ta te to th e Rea dj u s t ma r k , th e br a k es mu s t be
r e a d j u s t e d .
(f ) To a d j u s t t h e b r a k e s , r e mov e t h e
i n s pecti on cov er s a t th e r ea r of th e tr a n s mi s -
s i on r ea r h ou s i n g a n d r ota te th e a dj u s ti n g n u ts
by i n s er ti n g a s cr ewdr i v er i n th e s l ots i n th e
n u t s (r e f e r t o f i g . 3 7 1 ). C l ock w i s e r ot a t i on
wi l l s h or ten th e l ev er tr a v el (ti gh ten br a k es ).
C ou n t e r cl ock w i s e r ot a t i on w i l l l e n g t h e n t h e
l ever travel (l oosen brakes). Adjust both
b r a k e s u n i f or ml y s o t h a t , w i t h b r a k e s f u l l y
a p p l i e d , b ot h ma r k s on t h e l e v e r s a l i n e wi t h
t h e Ap p l y ma r k on t h e b e a r i n g r e t a i n e r . Re -
p l a ce i n s p e ct i on cov e r s .
N o t e . I f th e br a k e l i n k a ge i s n ot i n -
s t a l l e d , t h e b r a k e s ma y b e a d j u s t e d
u s i n g t h e s a me p r oce d u r e s a s ou t -
l i ned i n (a ) th r ou gh (f ), a b ov e , e x ce p t
t h a t wr e n ch e s 8351386 a n d 8351387
ma y be u s ed to a ppl y th e br a k es (f i g.
3 7 0 ). Th e b r a k e s s h ou l d b e a p p l i e d
w i t h a p p r o x i m a t e l y 9 0 p o u n d - f e e t
t or q u e .
(2 ) N e w or r e b u i l t p ow e r t r a i n n ot i n
v e h i cl e .
(a ) Re mov e i n s p e ct i on cov e r s f r om t h e
r e a r of t h e t r a n s mi s s i on r e a r h ou s i n g.
( b ) I n s e r t ga ge 8351213 i n t o t h e s l ot
i n t h e b r a k e a n ch or , r i n g , a n d b e t w e e n t h e
b r a k e a p p l y -r ot a t i n g r i n g a n d t h e f i r s t b r a k e
p l a t e (f i g. 371).
(c ) Rota te th e a dj u s ti n g n u t u n ti l ga ge
8351213 i s s n u g be t we e n t h e a p p l y r i n g a n d
b r a k e p l a t e . Th e a d j u s t me n t mu s t n e i t h e r
b i n d t h e ga ge n or l e a v e i t l oos e . Ad j u s t b ot h
b r a k e s b y t h i s me t h od .
c. Sh i f t Con t r ol L i n k a ge
(1) Th e l i n k a ge , con n e ct i n g t h e s e l e ct or
v a l v e s h a f t (f i g. 368) wi th th e oper a tor s s h i f t
con t r ol , s h ou l d b e a d j u s t e d ca r e f u l l y . Wh e n
t h e d e t e n t i n t h e con t r ol v a l v e a s s e mb l y i s
s eated, th e power tr ai n i s i n th e r an ge to wh i ch
th e s h i f t i n di ca tor poi n ts . Th e oper a tor s con -
t r ol mu s t b e i n a cor r e s p on d i n g p os i t i on .
(2) To a d j u s t t h e l i n k a ge , d i s con n e ct i t
at one poi nt. Pl a ce th e con tr ol v a l v e i n n eu tr a l
s o th at th e deten t s eats an d pl ace th e oper ator s
s h i f t con t r ol i n n e u t r a l p os i t i on . Ad j u s t t h e
l i n k a ge s o t h a t i t ca n b e r e con n e ct e d wi t h ou t
mov i n g e i t h e r t h e con t r ol v a l v e or op e r a t or s
shi ft control . Tr y t h e con t r ol t h r ou g h a l l
r a n ge p os i t i on s , ma k i n g s u r e t h a t t h e d e t e n t
s eats i n each .
d . S t e e r C on t r ol L i n k a g e
(1) Pr oper a dj u s tmen t of th e s teer l i n k -
Figure 371. Adjusting transmission brake
2 0 0
PAR 2 3 4
T E S T S AND ADJ U S T ME NT S CHAP 5, SEC X X X I V
a ge w i l l i n s u r e t h a t t h e op e r a t or s s t e e r con -
t r ol wi l l h a v e f u l l a n d e q u a l t r a v e l f or r i gh t
a n d l e f t s t e e r .
(2 ) Th e s t e e r v a l v e b od y a s s e mb l y i n -
cl u d e s a d e t e n t a r r a n ge me n t wh i ch s e a t s on l y
wh en th e s teer v a l v e i s i n th e No Steer pos i -
t i on . Th e op e r a t or s con t r ol w h e e l (or T b a r )
mu s t be i n a cen tr a l , or No Steer pos i ti on , a t
th a t ti me. Adj u s t th e l i n k a ge s o th a t i t ca n be
con n ected wi th th e con tr ol a n d v a l v e i n th e No
St e e r p os i t i on . Ch e ck t o s e e t h a t f u l l t r a v e l
f or r i gh t a n d l ef t s teer ca n be obta i n ed.
e . Th r o t t l e V a l v e L i n k a g e . To o b t a i n
ma x i mu m p e r f or ma n ce a n d f u e l e con omy , t h e
t h r ot t l e v a l v e l i n k a g e mu s t b e p r op e r l y a d -
j u s t e d . Th e t h r ot t l e l e v e r mov e s 17 48' f r om
a cl os e d - t h r ot t l e p os i t i on t o f u l l - t h r ot t l e p os i -
t i on . A p os i t i v e s t op , l oca t e d i n t h e s e l e ct or
val ve body, i ndi cates a ful l -throttl e val ve
t r a v e l (f i g. 372, f ol d - ou t 1). To p r op e r l y a d -
j u s t t h e t h r ot t l e l i n k a ge , p r oce e d a s f ol l ow s :
(1) Wi th th e r od en d di s con n ected a t th e
t h r ot t l e v a l v e l e v e r , r ot a t e t h e t h r ot t l e v a l v e
l e v e r cl ock w i s e u n t i l r ot a t i on i s s t op p e d . (An
i n ter n a l ma ch i n ed s top i s pr ov i ded i n th e v a l v e
b o d y . )
(2) Wh i l e h ol di n g th e th r ottl e v a l v e l ev er
a t f u l l cl ock w i s e r ot a t i on , mov e t h e e n g i n e
t h r ot t l e l i n k a g e t o t h e f u l l - t h r ot t l e p os i t i on
(engi ne governor).
(3) Ad j u s t l i n k a ge t o p r ov i d e f u l l r ot a -
t i on of t h e t h r ot t l e v a l v e l e v e r a t f u l l -e n gi n e
thr ottl e by al i ni ng the hol e i n the r od end wi th
th e h ol e i n th e th r ottl e v a l v e l ev er .
(4) Pr i or to con n ecti n g th e l i n k a ge ch eck
t o i n s u r e :
( a ) Th a t f u l l -en gi n e th r ottl e i s obta i n -
e d . (Ad d i t i on a l t r a v e l s h ou l d b e a v a i l a b l e b y
u t i l i z i n g t h e t h r ot t l e con t r ol y i e l d l i n k . )
( b ) Th a t t h e t h r ot t l e v a l v e l e v e r w i l l
a l l ow th e l i n k a ge to r etu r n to th e cl os ed-th r ot-
t l e p os i t i on .
(5) Con n e ct l i n k a ge .
2 0 1
*C2
P A R 2 3 5
CHAPTER 6
REPAIR AND REBUILD STANDARDS
2 3 5 . G E N E R A L
a . We a r L i mi t s a n d Poi n t s of Me a s u r e -
men t. Da ta cov er i n g th e s i zes a n d f i ts of n ew
pa r ts a n d wea r l i mi ts i n f or ma ti on , i s gi v en i n
pa r s . 236 th r ou gh 249, bel ow. Poi n ts of mea s -
u r e me n t of a l l cr i t i ca l d i me n s i on s a r e i n d i -
ca t e d b y s ma l l l e t t e r s i n t h e e x p l od e d v i e w
p a r t s gr ou p s , f i gs . 373 t h r ou gh 386, f ol d -ou t s
2 th r ou gh 15.
b . T- Ti g h t , L - L oos e . Th e "S i z e a n d F i t
of New Pa r ts " col u mn i n cl u des th e ma n u f a ctu r e
di men s i on s a n d tol er a n ces , a n d th e f i ts of ma t-
i n g pa r ts . T den otes a ti gh t (i n ter f er en ce) f i t;
L d e n ot e s a l oos e (cl e a r a n ce ) f i t .
c . Me a n i n g of We a r L i mi t s
(1) Th e wea r l i mi ts i n di ca te th e di men -
s i on s to wh i ch a pa r t ma y wea r bef or e i t mu s t
b e r e p l a ce d . N or ma l l y , a n y p a r t n ot w or n b e -
y on d i t s w e a r l i mi t w i l l b e a p p r ov e d f or con -
ti n u ed u s e, i f i t i s n ot oth er wi s e da ma ged.
(2 ) A s i n g l e a s t e r i s k (*) i n t h e w e a r
l i mi ts col u mn i n di ca tes th a t th e pa r t s h ou l d be
r e p l a ce d w h e n w or n b e y on d t h e l i mi t s s t a t e d
i n "Si ze a n d Fi t of New Pa r ts " col u mn .
(3 ) A d ou b l e a s t e r i s k (**) i n d i ca t e s a
l i mi t a ppl y i n g to th e f i t between ma ti n g pa r ts .
I n s u ch ca s e s , we a r i s a l l owe d on e i t h e r or
both ma ti n g pa r ts s o l on g a s th e f i t i s wi th i n
t h e s p e ci f i e d l i mi t .
d . S t a n d a r d Tor q u e L i s t i n g s . S t a n d a r d
tor qu e to wh i ch bol ts , n u ts a n d s cr ews a r e to
be ti gh ten ed i s l i s ted i n pa r . 250 u n der Ta bl e
V. S TAN DAR D TOR QU E S PE C I F I C ATI ON S .
Th e s e a r e n o r m a l t o r q u e v a l u e s s p e c i a l
tor qu es a r e l i s ted i n th e copy per ti n en t to th e
a p p l i ca b l e p a r t s .
2 0 2
*C2
*C2 pg. 203-229
PAR 2 3 6 R E P AI R AND R E B U I L D S T AND AR D S
236. I NPUT TRANSFER HOUSI NG. TORQUE CONVERTER, AND I NPUT PRESSURE
AND SCAVENGE OI L PUMP REPAI R AND REBUI LD STANDARDS
CHAP 6
2 0 3
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S PAR 2 3 6
2 0 4
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S P AR 2 3 6
2 0 5
*C2
PAR 2 3 6 R E P AI R AND R E B U I L D S T AND AR D S CHAP 6
2 0 6
*C2
*C2
PAR 2 3 6 - 2 3 7 R E P AI R AND R E B U I L D S T AND AR D S
CHAP 6
237. TORQU E CON VE RTE R H OU SI N G, OI L SCRE E N ASSE MBL Y, AN D L E F T- OU TPU T
DR I VE C OU PL I N G RE PAI R AN D RE BU I L D STAN DARDS
2 0 7
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S
238. TRANSMI SSI ON H OU SI NG, AND H I GH -RANGE CL U TCH
RE PAI R AN D RE BU I L D STAN DARDS
PAR 2 3 7 - 2 3 8
2 0 8
*C2
PAR 2 3 8 R E P AI R AND R E B U I L D S T AND AR D S
C H A P 6
2 0 9
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S
PAR 2 3 8 - 2 3 9
239. I NTERMEDI ATE- AND LOW-RANGE CLUTCHES AND PLANETARI ES -
REPAI R AND REBUI LD STANDARDS
2 1 0
*C2
PAR 2 3 9 R E P AI R AND R E B U I L D S T AND AR D S C H A P 6
2 1 1
*C2
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S PAR 2 3 9 - 2 4 0
240. REVERSE-RANGE CLUTCH AND PLANETARY, LEFT- STEER AND OUTPUT
CLUTCHES - REPAIR AND REBUILD STANDARDS
212
*C2
P A R 2 4 0 R E P AI R AND R E B U I L D S T AND AR D S
C H A P 6
2 1 3
*C2
*C2
CHAP 6 RE P AI R AND RE BUI L D S T ANDARDS PAR 2 4 0 - 2 4 1
2 4 1 . L E F T- S TE E R P L A N E TA R Y , A N D B R A K E - R E P A I R A N D R E B U I L D S TA N D A R D S
2 1 4
*C2
PAR 2 4 1 - 2 4 2 RE P AI R AND RE BUI L D S T ANDARDS
CH AP 6
242. TRANSMI SSI ON REAR H OU SI NG AND REL ATED PARTS -
RE PAI R AND RE BU I L D STANDARDS
2 1 5
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S P A R 2 4 2
2 1 6
*C2
PAR 2 4 2 R E P AI R AND R E B U I L D S T AND AR D S CHAP 6
2 1 7
*C2
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S PAR 2 4 2 - 2 4 3
243. RI GH T BRAKE , AND STE E R PL ANE TARY - RE PAI R AND RE BU I L D STANDARDS
2 1 8
*C2
PAR 2 4 3 - 2 4 4 R E P AI R AND R E B U I L D S T AND AR D S CHAP 6
244. RI GH T-STEER CL U TCH , OU TPU T CL U TCH , AND END COVER -
R E P A I R A N D R E B U I L D S T A N D A R D S
2 1 9
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S
P A R 2 4 4
2 2 0
*C2
PAR 2 4 4 - 2 4 5 R E P AI R AND R E B U I L D S T AND AR D S
C H A P 6
2 4 5 . S TE E R , AN D R E L AY VAL VE BODY AS S E MBL I E S -
R E PA I R A N D R E B U I L D S TA N DA R DS
221
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S P A R 2 4 5
2 2 2
*C2
PAR 2 4 5 - 2 4 6 R E P AI R AND R E B U I L D S T AND AR D S
246. MAI N -PRE SSU RE RE GU L ATOR AN D L OCKU P SH I F T, AN D CON TROL
VAL VE BODY ASSE MBL I E S - RE PAI R AN D RE BU I L D STAN DARDS
CHAP 6
2 2 3
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S P A R 2 4 6
2 2 4
*C2
PAR 2 4 6 R E P AI R AND R E B U I L D S T AND AR D S C H A P 6
2 2 5
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S PAR 2 4 6 - 2 4 7
247. OU TPU T PRE SSU RE , AND BRAKE COOL ANT OI L PU MP ASSE MBL I E S -
REPAI R AND REBUI LD STANDARDS
2 2 6
*C2
*C2
PAR 2 4 7 - 2 4 8 R E P AI R AND R E B U I L D S T AND AR D S
CHAP 6
248. L E F T- OU TPU T DRI VE ASSE MBL Y - RE PAI R AN D RE BU I L D STAN DARDS
2 2 7
*C2
*C2
CHAP 6 R E P AI R AND R E B U I L D S T AND AR D S
PAR 2 4 8 - 2 4 9
2 4 9 . R I G H T- O U TP U T D R I V E A S S E M B L Y - R E P A I R A N D R E B U I L D S TA N D A R D S
2 2 8
*C2
PAR 2 4 9 R E P AI R AND R E B U I L D S T AND AR D S C H A P 6
2 2 9
PAR 2 5 0
2 5 0 . TOR QU E S PE C I F I C ATI ON S f i ca t i on s f or b ol t s , n u t s a n d s cr e ws . Sp e ci a l
tor qu e s peci f i ca ti on s a r e i n cl u ded i n a ppl i ca bl e
F ol l ow i n g a r e t h e s t a n d a r d t or q u e s p e ci - r e b u i l d a n d a s s e mb l y s e ct i on s .
Ta b l e V. S TAN DAR D TOR QU E S PE C I F I C ATI ON S
2 3 0
APPENDI X A
REFERENCES
1. PU BL I CATI ON I NDEXES
Th e f ol l owi n g i n dex s h ou l d be con s u l ted f r equ en tl y f or l a tes t ch a n ges or r ev i s i on s of
r ef er en ce gi v en i n th i s a ppen di x a n d f or n ew pu bl i ca ti on s r el a ti n g to ma ter i a l cov er ed i n
th i s man u al .
Consol i dated I ndex of Ar my Publ i cati ons and Bl ank For ms. . . . . DA Pam 25-30
2. SU PPL Y MAN U AL S
a . Repa i r or Rebu i l d
Author i zed Abbr evi ati ons and Br evi ty Codes. . . . . . . . . . . . . . . AR 310-50
Di cti onar y of Uni ted States Ar my Ter ms . . . . . . . . . . . . . . . . . AR 310-25
Pr i nci pl es of Automoti ve Vehi cl es . . . . . . . . . . . . . . . . . . . . . . TM 9-8000
Change 2 231
b . Cl ea n i n g, I n s pecti on , Repa i r , a n d Pa i n ti n g
I nspecti on, Car e and Mai ntenance of Anti fr i cti on Bear i ngs . . . . TM 9-214
Wel di ng Theor y and Appl i cati on. . . . . . . . . . . . . . . . . . . . . . . . TM 9-237
Mater i al s Used for Cl eani ng, Pr eser v i ng, Abr adi ng and
Cementi ng Or dnance Mater i al . . . . . . . . . . . . . . . . . . . . . . TM 9-247
Use and Care of Hand Tool s . . . . . . . . . . . . . . . . . . . . . . . . . .. TM 9-243
Pai nti ng I nstr ucti ons for Fi el d Use. . . . . . . . . . . . . . . . . . . . . . TM 43-0139
c. Sh i pmen t a n d L i mi ted Stor a ge
I n s tr u cti on Gu i de: Or dn a n ce Pr es er v a ti on , Pa ck a gi n g,
Packi ng, Stor age and Shi ppi ng. . . . . . . . . . . . . . . . . . . . . . TM 9-200
Pr eser v ati on, Pack agi ng and Pack i ng of Mi l i tar y Suppl i es
and Equi pment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 38-230-1 and -2
232 Change 2
APPENDI X B
EXPENDABLE SUPPLIES AND MATERIALS LIST
Section I . I NTRODUCTI ON
1. SCOPE
Thi s appendi x l i sts ex pendabl e suppl i es and mater i al y ou wi l l need to oper ate and
mai ntai n the tr ansmi ssi on. These i tems ar e author i zed to y ou by CTA 50-970, Ex pendabl e
I tems (Ex cept Medi cal , Cl ass V, Repai r Par ts and Her al di c I tems).
2. EXPL ANATI ON OF COL U MNS
a. Col umn (1) - I tem Number . Thi s number i s assi gned to the entr y i n the l i sti ng and
may be r efer en ced to i den ti fy th e mater i al (e.g., "Petr ol atu m [ I tem 14, Appen di x C] ").
b. Col u mn (2) - L ev el . Th i s i tem i den ti f i es th e l owes t l ev el of ma i n ten a n ce th a t
r equi r es the l i sted i tem.
F - Di r ect Su ppor t Ma i n ten a n ce
H - Gener al Suppor t Mai ntenance
c. Col umn (3) - Nati onal Stock Number . Thi s i s the Nati onal Stock Number assi gned
to the i tem; us e i t to r eques t or r equi s i ti on the i tem.
d. Col umn (4) - Descr i pti on. I ndi cates the Feder al i tem name and, i f r equi r ed, a
des cr i pti on to i den ti f y th e i tem. Th e l a s t l i n e f or ea ch i tem i n di ca tes th e Commer ci a l
an d Gov er n men t En ti ty Code (CAGEC) i n par en th es es fol l owed by th e par t n u mber .
e. Col umn (5) - Uni t of Meas ur e (U/M). I ndi cates the meas ur e us ed i n per for mi ng
th e a ctu a l ma i n ten a n ce f u n cti on . Th i s mea s u r e i s ex pr es s ed by a two-ch a r a cter a l ph a -
beti cal abbr ev i ati on (e.g., EA, I N, PR). I f the uni t of meas ur e di ffer s fr om the uni t of
i ssue, r equi si ti on the l owest uni t of i ssue that wi l l sati sfy y our r equi r ements.
Change 2 233
Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST
(1) (2) (3) (4) (5)
ITEM LEVEL NATIONAL STOCK DESCRIPTION U/M
NUMBER NUMBER
1
2
3 6830-00-247-0619
4 5350-00-221-0872
5 8305-00-286-5461
6 F 6850-90-285-8011
7
8
9
10
11
12
13
14
15
8010-01-053-2647
8010-01-309-0328
9150-00-944-8953
9150-00-189-6727
5510-00-220-6194
5510-00-220-6178
9150-00-250-0926
7920-00-205-1711
8030-00-291-1787
Blocks, wooden, 2 x 4 x 16 inches
Make from item 11
Blocks, wooden, 4 x 4 x 16 inches
Make from item 12
Carbon Dioxide, technical (dry ice)
(81348), BB-C-104
Cloth, abrasive, crocus,
50 sheet pkg (81348), P-C-458
Cloth, batiste, lint-free, white,
39-1/2 inches wide (81349),
MIL-C-4919
Dry-cleaning Solvent, Type II
(813481, P-D-680
Epoxy, gloss, white (CARC)
(81349), MIL-C-22750
Epoxy Primer Coating (CARC)
(813491, MIL-P-53022
Grease, aircraft (81349),
MIL-G-3545A
Lubricating Oil, engine
(81349), MIL-L-2104D
Lumber, softwood, 2 x 4 x 8 ft
(81348), MM-L-751
Lumber, softwood, 4 x 4 x 8 ft
(81348), MM-L-751
Petrolatum, technical (petroleum
jelly) (81348), VV-P-236
Rag, wiping, 50-lb bale (58536),
A-A-531
Sealing Compound, gasket,
hydrocarbon, fluid and water
resistant (813491, MIL-S-45180
234 Change 2
EA
EA
LB
SH
YD
GL
QT
KT
LB
QT
BF
BF
LB
YD
OZ
I NDEX
MODEL XTG 411-2A and XTG 411-4
Paragraph
A
Ad j u s t me n t s :
Brake l i nkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shi ft control l i nkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steer control l i nkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttl e val ve l i nkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendi ces, i ndex (expl ai ned) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendi x A, references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendi x B, expendabl e suppl i es and materi al s . . . . . . . . . . . . . . . . . . . . .
Appl i cati ons, end i tems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembl y of power tr ai n fr om subassembl i es:
Assembl y steps mai n tr ansmi ssi on assembl y (Steps 1 thr u 88) . . . . . .
Assembl y steps i nput tr ansfer assembl y (Steps 1 thr u 28) . . . . . . . . .
Assembl y steps l eft- and ri ght-output dri ve assembl i es
(Steps 1 thr u 10) . . . . . . . . . . . . . .. ...... . . . . . ..... . ........
Assembl y steps (see Assembl y of power tr ai n fr om subassembl i es)
B
Brake l i nkage, adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C
Chapter content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Char ts and tabl es (see Tabl es)
Check s and tes ts (s ee Tes ts )
Cl eani ng recommendati ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common tool s, equi pment (general ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compon en ts , des cr i pti on a n d oper a ti on of (s ee Des cr i pti on a n d oper a ti on
of comp on e n t s )
Components, tr ansmi ssi on, wher e i denti fi ed . . . . . . . . . . . . . . . . . . . . . . .
Contents, over al l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
Cross-secti ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fi nal dri ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I nput dr i ve . . . . . . . . . . . . . . . . . . . . . . .. . . . ... . ......... ....
Transmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
D
DA publ i cati ons references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data and descri pti on of power trai n .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data l og sheet, test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data, tabul ated (Tabl e I ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defi ni ti on of l ocati onal and di r ecti onal ter ms . . . . . . . . . . . . . . . . . . . . . .
Depot, fi el d mai ntenance al l ocati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Descri pti on and data of power trai n .. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 e
227
228
229
234
1
71
61
4 c
T
3
3
3
3
7
4 b
2
Page
199
199
200
200
201
3
231
233
b
163
185
192
199
1
7 4
6 2
6
1
5
5
4
231
6
196
6
6
3
6
Change 2 235
Paragraph
D (cont)
Des cr i pti on a n d oper a ti on of compon en ts
I n pu t tr a n s f er a s s embl y :
I nput oi l pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I nput tr ansfer gear i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque converter, l ockup cl utch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mai n tr an s mi s s i on as s embl y :
Br a k e cool a n t pu mp, ma n i f ol d . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake l i nkage, ai r val ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control val ve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hi gh cl utch, governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I ntermedi ate cl utch, pl anetary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L ow cl u tch , pl a n eta r y . . . . . . . . . . . . . . . . .... . ......... . . . .
Mai n-pr essur e r egul ator and l ockup shi ft val ve body . . . . . . . . . . . . .
Oi l fi l ter and scr eens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output oi l pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output tr ansfer gear s, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rel a y v a l v e body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse cl utch, pl anetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ri ght- and l eft-s teer pl anetar i es , output and s teer cl utches . . . . . . .
Ri gh t, l ef t br a k es , a ppl y ca ms . . . . . . . . . . . . . . . . . . . . . . . . .
Steer val ve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oper a ti on of h y dr a u l i c s y s tem:
Fu n cti on neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
l st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
2nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
reverse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
reverse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . . . . . . . .. . . . . . . .
l ow, steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd, 4th steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
reverse steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
tow, push starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General i nformati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prel i mi nary i nstructi ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ri gh t- a n d l ef t-ou tpu t dr i v e a s s embl i es :
Left-output dri ve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ri ght- output dri ve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tor que paths thr u power tr ai n:
Gear s and steer i ng neutral . . . . . . . . . . . . . . . . . . . . . . . . . . .
l st gear, converter . . . . . . . . . . . . . . . . . . . .
2nd gear, l ockup . . . . . . . . . . . . . . . . . . . . . .
3rd gear, l ockup . . . . . . . . . . . . . . . . . . . . . .
4th gear, l ockup . . . . . . . . . . . . . . . . . . . . . .
reverse 1, converter . . . . . . . . . . . . . . . . . . .
reverse 2, converter . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .
l st gear, ri ght steer . . . . . . . . . . . . . . . . . . .
2nd gear, l eft steer . . . . . . . . . . . . . . . . . . . .
3rd gear, ri ght steer . . . . . . . . . . . . . . . . . . .
4th gear, l eft steer . . . . . . . . . . . . . . . . . . . .
reverse 1 gear, ri ght steer. . . . . . . . . . . . . . .
reverse 2 gear, l eft steer . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I nput transfer geari ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
8
9
24
18
21
11
12
13
22
25
23
15
19
14
16
17
20
30
31
32
33
34
35
36
37
38
3 9
40
29
28
27
26
46
47
48
49
50
51
52
53
54
55
56
57
58
41
42
Page
13
11
11
23
18
20
13
14
14
21
23
22
16
19
15
16
17
20
25
28
31
31
31
35
35
35
38
4 3
4 6
25
25
24
2 4
4 9
50
51
52
53
5 4
55
56
57
58
59
60
61
46
46
236 Change 2
D (cont)
Tor que paths thr u power tr ai n (conti nued):
Output dri ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ou tpu t tr a n s f er gea r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Torque converter, l ockup cl utch . . . . . . . . . . . . . . . . . . . . . . . . . .
Di r ecti onal and l ocati onal ter ms defi ned . . . . . . . . . . . . . . . . . . . . . . . .
Di s a s s embl y of power tr a i n i n to s u ba s s embl i es :
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Di sassembl y steps i nput tr ansfer assembl y (Steps 1 thr u 26) . . . . . . .
Di sassembl y steps mai n tr ansmi ssi on assembl y (Steps 1 thr u 64) . . . .
Di sassembl y steps l ef t- a n d r i gh t-ou tpu t dr i v e a s s embl i es
(Steps 1 thr u 13)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Di sassembl y steps (see Di sassembl y of power tr ai n i nto subassembl i es)
Dri vi ng i nstructi ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E
End i tem appl i cati ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E q u i p me n t
Common tool s (gen er a l ) . . . . . . . . . . . . . . . . . . . . . . . . . .
I mpr ovi sed tool s (Tabl e I I ) . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Speci al tool s (Tabl e I I ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error reporti ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ex pen da bl e s u ppl i es a n d ma ter i a l s . . . . . . . . . . . . . . . . . . . . . . . . .
E x pl oded v i ews (s ee f ol d-ou ts )
F
Fi el d, depot mai ntenance al l ocati on . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fi nal dri ves cross-secti ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fol d-ou t i l l u s tr a ti on s (ex pl a i n ed) . . . . . . . . . . . . . . . . . . . . . . .
Fol d-ou ts (ba ck of book ):
Sch e ma t i c
Paragraph
1 Model XTG 411-2A hydr aul i c system . . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . .
Ex pl oded v i ews
2
3
4
5
6
7
8
9
Tr ansmi ssi on i nput tr ansfer assembl y. . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tor que conver ter housi ng, r el ated par ts . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmi ssi on housi ng, rel ated parts . . . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
I nter medi ate and l ow cl utches, pl anetar i es . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rev er s e cl utch, pl anetar y ; l eft s teer , output cl utches . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left-steer pl anetary, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tr ansmi ssi on r ear housi ng, r el ated par ts. . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ri ght brake, steer pl anetary . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Ri ght-steer cl utch, output cl utch, end cover . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
44
43
4 b
7 3
7 4
75
76
5
61
62 b
62 a
1 g
2
3
l f
Page
48
4 7
46
6
7 7
7 8
84
100
6
b
62
6 3
62
3
233
3
5
3
239
239.1
241
241.1
243
243.1
245
245.1
2 4 7
247.1
249
249.1
251
251.1
253
253.1
255
255.1
257
257.1
Change 2 237
Paragraph Page
F (cont)
Fol d-ou ts (back of book ) (con ti n u ed):
Ex pl oded v i ews (conti nued)
11 Steer, rel ay val ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Mai n-pr es s ur e r egul ator and l ock up s hi ft, contr ol v al v e bodi es . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Output pr essur e, br ake cool ant pumps . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 L ef t-ou tpu t dr i v e a s s embl y . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 Ri gh t-ou tpu t dr i v e a s s embl y . . . . . . . . . . . . . . . . . . . . . . . .
Addendum for l ater model s . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forms, records, reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functi onal tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 3 3 e
H
H y dr a u l i c s ch ema ti c (s ee Fol d-ou ts )
I
I mpr ovi sed tool s, equi pment (Tabl e I I ) . . . . . . . . . . . . . . . . . . . . . ...
6 2 b
I n dex , a ppen di ces (ex pl a i n ed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 e
I nput dri ve cross-secti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
I ns pecti on, r epai r r ecommendati ons . . . . . . . . . . . . . . . . . . . . . . . . . . 72
I nstructi ons for dri vi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
L
L ea k ch eck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 3 3 c
L i n k a ge a dj u s tmen ts (s ee Adj u s tmen ts )
7
62
7
2 3 1 c
231
233
233e
2 3 3 c
2 3 3 d
2 3 3 a
2 3 3 f
2 3 3 b
2 3 4 e
61
62
4
3
231
6
6 7
66
6 3 - 6 4
69
65-69
68
200
65
200
i i
7
65
71
6
195
196
195
195
197
197
197
195
198
197
201
i
62
65
6
4
195
6
70
7 0
6 9
7 0
6 9
71
70
238.2 Change 2
V
Vehi cl e dri vi ng i nstructi ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vi ews , s ch ema ti c a n d ex pl oded (s ee Fol d-ou ts )
Paragraph Page
5 6
W
Warm up, test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 3 3 b
Warni ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
197
a
Change 2 238.3/(238.4 blank)
Addendum to Fold-out 1
The hy dr aul i c sy stem for l ater model s of XTG 411-2A and XTG 411-4 i s the same as shown
i n Fi gur e 372 (fol d-out 1) ex cept as shown i n Fi gur e 372.1.
Fi gur e 372.1. Model XTG 411-4 tr ansmi ssi on and l ater model s of XTG 411-2A
a r ea of h y dr a u l i c s y s tem ch a n ges .
Change 2 239.1/(239.2 blank)
Addendum to Fold-out 2
For l atest part numbers, refer to TM 9-2520-234-34P.
Changes to Fi gure 373 (fol d-out 2) are as fol l ows:
2-Change to Lock washer (2) for l ater model s (see Fi g. 373.1)
30-Lock washers -Change quanti ty from (10) to (4) (shi p l oose)
83-Del eted (not a servi ceabl e subassembl y)
84-Del eted (not a servi ceabl e subassembl y)
85-Del eted (not a servi ceabl e subassembl y)
86-Del eted (not a servi ceabl e subassembl y)
118-Change to pi pe pl ug (shi ppi ng onl y)
125-Del eted for l ater model s
127-Del eted for l ater model s
128-Del eted for l ater model s
129-Del eted for l ater model s
130-Del eted for l ater model s
132-Del eted for l ater model s
141-Lockwasher-Change quanti ty from (16) to (12) (shi p l oose)
142-Capscrew-Change quanti ty from (16) to (12) (shi p l oose)
150-Change to Lock washer (2); for l ater model s (see Fi g. 373.1)
155-Add Hexagon cap screw (shi p l oose) (4) (see Fi g. 373.1)
156-Add Lock washer (shi p l oose) (4) (see Fi g. 373.1)
157-Add Spacer (shi p l oose) (4) (see Fi g. 373.1)
Fi gure 373.1. Addendum to Fi gure 373 (fol d-out 2)
Change 2 241.1/(241.2 blank)
Addendum to Fold-out 3
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 374 (fol d-out 3) ar e as fol l ows:
3 Del eted for l ater model s
4 Del eted f or l a ter model s
5 Del eted for l ater model s
42 Super seded (see fi g. 374.1)
43 Super seded (see fi g. 374.1)
44 Super seded (see fi g. 374.1)
45 Super seded (see fi g. 374.1)
46 Super seded (see fi g. 374.1)
47 Su per s eded (s ee f i g. 374.1)
48 Su per s eded (s ee f i g. 374.1)
49 Su per s eded (s ee f i g. 374.1)
50 Super seded (see fi g. 374.1)
51 Super seded (see fi g. 374.1)
52 Su per s eded (s ee f i g. 374.1)
53 Super seded (see fi g. 374.1)
54 Super seded (see fi g. 374.1)
55 Su per s eded (s ee f i g. 374.1)
56 Super seded (see fi g. 374.1)
57 Super seded (see fi g. 374.1)
58 Super seded (see fi g. 374.1)
59 Super seded (see fi g. 374. 1)
72 Del eted for l ater model s
80 Add H ex a gon -h ea d ca p s cr ew (3)
(see fi g. 374.1)
81 Add Lock washer (3) (see fi g. 374.1)
82 Add Fl ui d pr essur e fi l ter (see fi g. 374.1)
83 Add Fi l ter head (see fi g. 374.1)
84 Add Fi l ter el ement (see fi g. 374.1)
85 Add Sel f -l ock i n g n u t (s ee f i g. 374.1)
86 Add Pr ef or med pa ck i n g (s ee f i g. 374.1)
Fi gu r e 374.1. Adden du m to Fi gu r e 374 (f ol d-ou t 3)
Change 2 243.1/(243.2 blank)
Addendum to Fold-out 4
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 375 (fol d-out 4) ar e as fol l ows:
7 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
8 Del eted (not a ser v i ceabl e subassembl y )
19 Del eted for l ater model s
21 Del eted for l ater model s
26 Change qty to (2) (see fi g. 375.1)
26A Ch a n ge Pi pe pl u g (s ee f i g. 375.1)
30 Change qty to (3) (see fi g. 375.1)
32 Change qty to (1) (see fi g. 375.1)
34 Del eted for l ater model s
49 Del eted for l ater model s
50 Del eted for l ater model s
51 Del eted for l ater model s
52 Del eted for l ater model s
53 Del eted for l ater model s
54 Del eted for l ater model s
57 Change qty to (4, XTG 411-2A; 5, XTG 411-4)
99 Add Spacer (5) (see fi g. 375.1)
100 Add Lock washer (5) (see fi g. 375.1)
101 Add Hex agon Head Cap Scr ew,
7/16-14 UNC - 2A x 1-3/4 i nch (5) (see fi g. 375.1)
Fi gu r e 375.1. Adden du m to Fi gu r e 375 (f ol d-ou t 4)
Change 2 245.1/(245.2 blank)
Addendum to Fold-out 5
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 376 (fol d-out 5) ar e as fol l ows:
21 Ear l i er model s onl y
22 Ear l i er model s onl y
23 Ear l i er model s onl y
24 Ear l i er model s onl y
64- Add Pi ni on assembl y (matched set of 4) (l ater model s) (see fi g. 376.1)
65 Add Rol l er bear i ng assembl y (4) (l ater model s) (see fi g. 376.1)
Fi gu r e 376.1. Adden du m to Fi gu r e 376 (f ol d-ou t 5)
Change 2 247.1/(247.2 blank)
Addendum to Fold-out 6
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 377 (fol d-out 6) ar e as fol l ows:
11 Not us ed i n l ater model s . Note that onl y two s pacer s ar e us ed per pi ni on i n thi s
pl anetar y i n l ater model s (see fi g. 377.1)
12 Not u s ed i n l ater model s . Note th at th er e ar e 22 n eedl e bear i n g r ol l er s per pi n i on
i n thi s pl anetar y i n l ater model s (see fi g. 377.1)
67 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
68 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
9 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
Fi gur e 377.1. Addendum to Fi gur e 377 (fol d-out 6)
Change 2 249.1/(249.2 blank)
Addendum to Fold-out 7
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Ther e ar e no changes to Fi gur e 378 (fol d-out 7).
Change 2 251.1/(251.2 blank)
Addendum to Fold-out 8
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 379 (fol d-out 8) ar e as fol l ows:
22 Change qty to (1)
23 Del eted for l ater model s
56 Del eted for l ater model s
73 Del eted (not a ser v i ceabl e subassembl y )
74 Del eted (not a ser v i ceabl e subassembl y )
Change 2 253.1/(253.2 blank)
Addendum to Fold=out 9
For latest part numbers, refer to TM 9-2520-234-34P.
There are no changes to Figure 380 (fold-out 9).
.
-.
Change 2 255.:1/(255.2 blank)
Addendum to Fold-out 10
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 381 (fol d-out 10) ar e as fol l ows:
11 Del eted (not a ser v i ceabl e subassembl y )
12 Del eted (not a ser v i ceabl e subassembl y )
13 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
47 Not s er v i cea bl e
49, 50 I n l ater model s, al l four pl ugs ar e the same par t number
51 Del eted for l ater model s
52 Del eted f or l a ter model s
53 Del eted f or l a ter model s
54 Del eted f or l a ter model s
55 Del eted for l ater model s
56 Del eted f or l a ter model s
78 Del eted f or l a ter model s
79 Del eted f or l a ter model s
80 Del eted f or l a ter model s
Change 2 257.1/(257.2 blank)
Addendum to Fold-out 11
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 382 (fol d-out 11) ar e as fol l ows:
15 Del eted (not a ser v i ceabl e subassembl y )
16 Del eted (not a ser v i ceabl e subassembl y )
17 Del eted (not a ser v i ceabl e subassembl y )
18 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
61 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
62 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
Change 2 259.1/(259.2 blank)
Addendum to Fold-out 12
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 383 (fol d-out 12) ar e as fol l ows:
15 Del eted (not a ser v i ceabl e subassembl y )
16 Del eted (not a ser v i ceabl e subassembl y )
17 Del eted (not a ser v i ceabl e subassembl y )
18 Del eted (not a ser v i ceabl e subassembl y )
24 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
25 Del eted (not a ser v i ceabl e subassembl y )
41 Del eted f or l a ter model s
64 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
65 Del eted (not a ser v i ceabl e subassembl y )
66 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
67 Del eted (not a ser v i ceabl e subassembl y )
Change 2 261.1/(261.2 blank)
FIGURE 384 (fold-out 13)
I Hexagon-head, sel f -l ocki ng bol ts (4) $1409031
2Snap ri ng770803 2
3Rol ]er 8348$40
4--Pump dri ve gear8 3 J 1604
$--output pressure pump assembl y8 3 J 1672
6Pump body assembl y8 3 J 16 JO
7Needl e rol l er beari ng709414
8pump body83 f 1642
9Bal l 4\ 3606
10Shaft77 10734
1 l +i l pump dri ve gear83 $1671
12Oi l pump i dl er gear assemb]y83 47878
13Needl e rol l er beari ng7 13822
14--Oi l pump i dl er gear8 347877
1 \Round-head scr ew (2)1139$6
16Pump cover assembl y8 3$1641
17Needl e rol l er beari ng7094 14
18Pi n443767
19Pump cover83 J 1634
20Brake cool ant pump assembl y8 3$ I \ 07
2 l Pump i dl er gear770998 f
22I dl er gear shaft7709994
23Pump separator pl ~te assembl y77t0132
24Pump separator pl ate7709988
2 $Needl e rol l er beari ng709428
26pump i dl er gear770998 J
27Hexagon-head, sel f-l ocki ng bol t (7) 940901 2
2 Spump cover issemblyzz 10144
29Needl e ro]l er beari ng (2) 709488
}0Pump cover7709989
3 I Dowel pin (2) 443767
32Pump body83 fl $06
33Pump dri ve geor7709986
34Key96906-3f7f6- 17
3 $Retai ni ng r i ng (2)7710031
3 6Pump separator pl ate assembl y7710132
37Needl e rol l er beari ng709428
3 8Pump separator pl ate7709988
39Retai ni ng r i ng (2)771003 1
40Pump dri ve shaft7709997
41 Key96906-3\7J6-17
42Lock pi n1 41123
43Pump dri ve gear7709986
44Pump cover assembl y77 10148
4$Needl e rol l er beari ng (2) 709428
46Dowel pi n (2) 443767
47Pump cover770999 1
48Pump dri ve gear shroud771 0212
49External -dri ve gear771 0141
$ OGear shroud pl ate77 10821
J I Hexagon-head, sel f-l ocki ng bol t-9409010
$2Hexagon-head, sel f-l ocki ng bol t (7) 9409012
\ 3Hexagon-head, sel f-l ocki ng bol t ( 3 ) 94o9o 30
\4--Pump bottom gasket83 \ 1708
\ JPump mani fol d gasket83 \ 1678
$6Pump mani fol d7710210
\7Lock washer ( 1 \) 96906-3J338-8
\8Hexagon-head cap screw ( 1 J )96906-3 \29J-63
\9Lock washer (3) 96906-3$338-8
60Hexagon-head cap screw ( 3 ) 96906-3 $29f-61
6] Hexagon-head cap screw (4) 96906-3J29\-68
62Lock washer (4) 96906-3J338-8
63Sl eeve (2) 83498JJ
6+-Val ve stem (2)83$0$13
6\ Check va[ve spri ng (2) 83J1 J02
66Washer (2)83$170$
67Check wsl ve washer assembl y (2) 83 JO!31
68Check val ve gr ommet (2) 8347930
Small lower case letters, in the exploded view at right, refer to repair and
rebnild points of measurement for fits, clearances and wear limits. See Chapter 6.
\
a
a
BRAKE COOLANT 011
h
/-
PUMP
48 ,9
//!O
4
,, ,,
63
w
1
62
6,=+
ORD E 32803
Figure 384. Fo l d o u t 1 3 output pressure and brake caolanl oil pump as s[,m I)lie.< szploded view
263
Addendum to Fold-out 13
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 384 (fol d-out 13) ar e as fol l ows:
20 Later model s do not i ncl ude shr oud 48
29 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
30 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
31 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
45 Del eted (not a ser v i ceabl e subassembl y )
46 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
47 Del eted (n ot a s er v i cea bl e s u ba s s embl y )
48 Del eted for l ater model s
50 Del eted for l ater model s
51 Del eted for l ater model s
68 Del eted f or l a ter model s
Change 2 263.1/(263.2 blank)
Addendum to Fold-out 14
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 385 (fol d-out 14) ar e as fol l ows:
1-5, 10, 11 Refer to fi g. 385.1 for mi ssi ng ar t cal l outs
51 Add Shi m (see fi g. 385.1)
Fi gu r e 385.1. Adden du m to Fi gu r e 385 (f ol d-ou t 14)
Change 2 265.1/(265.2 blank)
A d d e n d u m t o F o l d - o u t 1 5
For l a tes t pa r t n u mber s , r ef er to TM 9-2520-234-34P.
Changes to Fi gur e 386 (fol d-out 15) ar e as fol l ows:
51 Add Shi m (see fi g. 386.1)
Fi gu r e 386.1. Adden du m to Fi gu r e 386 (f ol d-ou t 15)
+ U.S. GOVERNMENT PRINTING OFFICE : 1994 0 - 300-421 (03147)
Change 2 267.1/(267.2 blank)
B Y ORDE R OF T HE SE CRE TARY OF THE AR M Y:
Official:
J. C. LAMBERT,
Major General, United States Army,
The Adjutant General.
G. H. DECKER,
General, United States Army,
Chief of Staff.
THE METRIC SYSTEM AND EQUIVALENTS
PIN: 028708-002
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