Académique Documents
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Service
Manual
Allison Transmission
AUTOMATIC MODELS
AUGUST 1996
REVISED 199907
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
• Amojell® is a registered trademark of the Amoco Oil Company.
• DEXRON® is a registered trademark of General Motors Corporation.
• Biobor® JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax
and Chemical Corporation.
• Dykem® is a registered trademark of the Dykem Company.
• Loctite® is a registered trademark of the Loctite Corporation.
• Teflon® is a registered trademark of the DuPont Corporation.
• Permatex® is a registered trademark of the Loctite Corporation.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by letter suffix to the publication number. Check with your
Allison Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be pur-
chased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of Transmis-
sions — Truck, Tractor, etc.
WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
• When checking the transmission fluid level, be sure that the parking brake and/
or emergency brakes are set and properly engaged, and the wheels are blocked.
Unexpected and possible sudden movement may occur if these precautions are
not taken.
• While conducting a stall check, the vehicle must be positively prevented from
moving. Apply the parking and service brake, and block the wheels securely.
Warn personnel to keep clear of the vehicle and its travel path. Failure to do so
can cause serious injury.
• Do not burn discarded Teflon® seals; toxic gases are produced by burning.
• Never dry bearings with compressed air. A spinning bearing can disintegrate
allowing balls or rollers to become lethal flying projectiles. Also, spinning a
bearing without lubrication can damage the bearing.
• Do not position the transmission so that its rear end is lower than its front end.
The components in the rear of the transmission are not secured. These
components could fall out and cause personal injury and/or damage to the parts.
• Certain control valve body components are spring-loaded and must be
restrained while retaining pins or bolts are removed.
• The main-pressure regulator valve spring is under approximately 65 lbs (290 kN)
compression.
• Hydraulic fluid under 40 psi (280 kPa) pressure may be trapped in the output
retarder accumulators. Personal injury can occur if this pressure is accidently
released.
• Accumulator piston springs are highly compressed. Use extreme caution during
removal of the accumulator cover. Personal injury can occur if the bolts are
removed without properly relieving the spring force.
• The retarder piston return spring is highly compressed. Use extreme caution
during removal of the spring. Personal injury can occur if proper removal
procedures are not followed.
5–12. REMOVAL OF REAR COVER (MT 640, 643, 6–7. RETARDER CONTROL VALVE ASSEMBLY
650, 653) (MTB Series Only)
a. Positioning . . . . . . . . . . . . . . . . . . . . . . . .5–9 a. Disassembly . . . . . . . . . . . . . . . . . . . . . 6–15
b. MT 640, 643 Rear Cover . . . . . . . . . . . . .5–9 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 6–16
c. MT 650, 653 Rear Cover . . . . . . . . . . . . .5–9 6–8. OIL PUMP AND FRONT SUPPORT
5–13. REMOVAL OF OUTPUT RETARDER ASSEMBLY
(MTB 643, 653) a. Disassembly . . . . . . . . . . . . . . . . . . . . . 6–16
a. Retarder Control Valve Assembly . . . . .5–10 b. Rework of Front Support Sealring
b. Retarder Housing . . . . . . . . . . . . . . . . . .5–10 Grooves. . . . . . . . . . . . . . . . . . . . . . . . . 6–18
c. Retarder Adapter Housing . . . . . . . . . . .5–12 c. Assembly . . . . . . . . . . . . . . . . . . . . . . . 6–18
6–9. FORWARD CLUTCH AND TURBINE SHAFT 6–18. OUTPUT RETARDER HOUSING
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–23 (MTB 643, 653)
b. Rework of Rotating Sealring Bore, a. Disassembly . . . . . . . . . . . . . . . . . . . . . 6–48
Forward Clutch . . . . . . . . . . . . . . . . . . . .6–24 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 6–49
c. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–26 6–19. RETARDER ADAPTER HOUSING
(MTB 643, 653)
6–10. FOURTH CLUTCH
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 6–52
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–28 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 6–55
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–28
6–20. LOW CLUTCH ADAPTER HOUSING AND
6–11. CENTER SUPPORT ASSEMBLY FIRST CLUTCH PISTON (MT(B) 650, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–30 a. Disassembly . . . . . . . . . . . . . . . . . . . . . 6–56
b. Rework Center Support Anchor Bolt b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 6–57
Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–30 6–21. TRANSMISSION HOUSING
c. Rework of Center Support for One a. Disassembly . . . . . . . . . . . . . . . . . . . . . 6–57
Piece Thrust Bearing Race Assembly. . .6–31 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 6–58
d. Rework of Non-Eccentric Center 6–22. GOVERNOR
Support to Eccentric Support . . . . . . . . . 6-31 a. Disassembly . . . . . . . . . . . . . . . . . . . . . 6–59
e. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–32 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 6–59
6–12. GEAR UNIT AND MAIN SHAFT ASSEMBLY 6–23. CLUTCH STACK MEASUREMENT
(MT(B) 650, 653) a. Methods . . . . . . . . . . . . . . . . . . . . . . . . 6–59
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–34 b. Forward Clutch . . . . . . . . . . . . . . . . . . . 6–60
b. Installing Replacement Sun Gear Shaft c. Fourth Clutch . . . . . . . . . . . . . . . . . . . . 6–60
Bushings . . . . . . . . . . . . . . . . . . . . . . . . .6–36 d. Low Clutch — MT 650, 653 . . . . . . . . 6–60
e. First Clutch . . . . . . . . . . . . . . . . . . . . . . 6–60
c. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–36
f. Second and Third Clutches. . . . . . . . . . 6–61
6–13. GEAR UNIT AND MAIN SHAFT ASSEMBLY 6–24. PLANETARY CARRIER ASSEMBLIES
(MT 640, 643)
a. Assembly Inspection. . . . . . . . . . . . . . . 6–61
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–39 b. Removal of Pinion Components. . . . . . 6–62
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–39 c. Replacing Bushing in Front and Low
6–14. GEAR UNIT AND MAIN SHAFT ASSEMBLY Planetary Carrier Assemblies . . . . . . . . 6–62
(MTB 643) d. Rework Center Carrier for Non-Rotating
Thrust Washers . . . . . . . . . . . . . . . . . . . 6–65
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–41
e. Installation of Pinion Components . . . . 6–65
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–42
6–15. OUTPUT SHAFT (MT 650, 653) Section 7. ASSEMBLY OF TRANSMISSION
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–42
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–43 7–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
6–16. REAR COVER ASSEMBLY (MT 650, 653) 7–2. GENERAL INFORMATION FOR
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . 7–1
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–43
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–45 7–3. INSTALLATION OF CLUTCHES, CENTER
SUPPORT, PLANETARY GEARING, AND
6–17. REAR COVER ASSEMBLY (MT 640, 643) REAR COVER OR RETARDER
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .6–47 a. Selecting Center Support Snapring . . . . 7–1
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .6–47 b. Second Clutch Clearance . . . . . . . . . . . . 7–2
SCHEMATIC VIEWS
Foldout
EXPLODED VIEWS
Foldout
1. The organization or individual has the required a. Number of Speeds. The MT(B) 640, 643 have
knowledge of the task through: four forward speeds and one reverse. The MT(B) 650,
653 have five forward speeds and one reverse. Shifting
• Formal instruction in an Allison or within the forward ranges selected by the operator is
Distributor training facility. fully automatic.
• On-the-job instruction by an Allison or b. Torque Converter and Lockup Clutch. An
Distributor representative. Allison three-element torque converter (Foldout 1 or
• Experience in performing the task. 2) transmits power from the engine to the transmission
gearing. The torque converter serves as both a fluid
2. The work environment is suitable to prevent coupling and a torque multiplier. MT 600 Series
contamination or damage to transmission parts transmissions also include a lockup clutch in the
or assemblies. torque converter assembly.
BREATHER
TRANSMISSION
HOUSING
REAR COVER
MOUNTING PAD
PARKING BRAKE
MOUNTING PAD
OUTPUT SHAFT
NEUTRAL START
SWITCH PLUG
SPEEDOMETER
DRIVE OPENING
SELECTOR SHAFT
GOVERNOR PRESSURE
GOVERNOR FILTER
FILL TUBE OPENING MODULATOR OIL PAN
ACTUATOR OPENING
H00042.01
TORQUE
TO COOLER PORT CONVERTER
PTO COVER
FROM
COOLER
PORT
NAMEPLATE
CONVERTER
RESTRAINING
DRAIN PLUG STRAP
FILL TUBE OPENING OIL PAN
H00041
TRANSMISSION HOUSING
ADAPTER HOUSING
BREATHER SPEEDOMETER
DRIVE OPENING
REAR COVER
FLANGE NUT
PARKING BRAKE
SELECTOR SHAFT MOUNTING PAD
GOVERNOR FILTER
NEUTRAL START
SWITCH PLUG GOVERNOR COVER
MAIN PRESSURE
MODULATOR
FILL TUBE OPENING ACTUATOR
OPENING
GOVERNOR PRESSURE
H00001.01
TO COOLER
MOUNTING PAD
PTO COVER
BRAKE MOUNTING
PAD
NAMEPLATE
DRAIN PLUG
OIL PAN
FILL TUBE OPENING H00002
TO RETARDER
CLUTCH
ADAPTER HOUSING FROM CONVERTER
RETARDER HOUSING
FROM EXTERNAL
FILTER TO LUBE
TO EXTERNAL FILTER
ACCUMULATOR
REGULATING VALVE ASSEMBLY
CHECK VALVE
RETARDER VALVE BODY H00003
TO RETARDER CLUTCH
BREATHER
SPEEDOMETER PORT
OUTPUT FLANGE
FILL TUBE
OPENING
GOVERNOR COVER
H00004
CHECK
VALVE
TO RETARDER CLUTCH
ADAPTER HOUSING
RETARDER HOUSING
FROM CONVERTER
REAR SUPPORT
MOUNTING PAD
TO EXTERNAL FILTER
REGULATING
VALVE ASSEMBLY
ACCUMULATOR RETARDER VALVE BODY
H00009
PL
E
EM
ILE AEROSPAC
UAW
ENT
CORPORATION
WORKERS
933
INDIANAPOLIS an integral part of the transmission (Foldout 1 or 2).
OB
OM
OF
UT AM
DA ERI
UNITE CA
INDIANA
The overall transmission length, from the flywheel
SERIAL NO. PART NO. housing mounting face to the output flange face, re-
mains essentially the same with the addition of the
XXXXX XXXXXXX
output retarder.
MODEL
NO. XX XXXX X
V01251 1–5. OPERATING INSTRUCTIONS
Figure 1–9. Transmission Nameplate
Refer to Operator’s Manual OM1334EN for operating
c. Planetary Gearing, Clutches. The MT(B) 640, instructions.
643 have three planetary gear sets that produce four for-
ward speeds and one reverse speed. The planetaries are
controlled by five hydraulically-actuated clutches. The 1–6. SPECIFICATIONS AND DATA
MT(B) 650, 653 have four planetary gear sets that pro-
duce five forward speeds and one reverse speed. The The specifications and data shown in Table 1–1 are ap-
planetaries are controlled by six hydraulically-actuated plicable to MT(B) 640, 643, 650, and 653 transmis-
clutches. All gearing is in constant mesh. sions.
125 psi min. 125 psi min. 125 psi min. 125 psi min.
600
(861 kPa) (861 kPa) (861 kPa) (861 kPa)
Speedometer drive:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tone wheel or spiral gear
MT 640, 643 drive gear data . . . . . . . . . . . . . . . . 5 and 8 tooth lh helix angle or 16-tooth tone wheel
MT 650, 653 drive gear data . . . . . . . . . . . . . . . . 7, 8, and 11 tooth lh helix angle or 16-tooth tone wheel
MTB 643, 653 drive gear data . . . . . . . . . . . . . . . 17 tooth lh helix angle
Driven gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplied by customer
Power takeoff:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converter driven
Mounting flange . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 6-bolt, one opening
Gear data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 pitch, 64 teeth, 20 degree pressure angle
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right side (viewed from rear)
Parking brake provision:
Drum type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 x 3 or 12 x 4
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 lb (23 kg)
Output retarder models . . . . . . . . . . . . . . . . . . . . . None
Output flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplied by customer
** Overall torque multiplication ratio of transmission (output stalled) is the product of the converter torque multiplication ratio (see torque converter) and
the mechanical (gear) ratio.
NOTES
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LOCKUP FORWARD FOURTH THIRD SECOND FIRST LOW CLUTCH
CLUTCH ;; CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH (FIVE-SPEED MODELS ONLY)
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FRONT
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LOW GEAR SET
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(FIVE-SPEED MODELS ONLY)
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CENTER GEAR SET
FRONT
GEAR SET
V00752
b. Operation (Foldout 6). The engagement of the 3. The external tangs of clutch plates 22 engage
lockup clutch is controlled by the lockup relay valve the slots in the housing and shaft assembly.
which derives its lockup signal from the modulated The internal splines of clutch plates 23 engage
lockup valve. Clutch-apply pressure compresses the forward clutch hub 21, which is splined to
lockup clutch plate between the piston and backplate, main shaft assembly 33 (Foldout 9,A or 9,B).
locking all three together. The converter pump and tur- Clutch plates 23 are held in place by fourth
bine are locked together and provide a direct drive clutch driving hub 24, which is retained by
from the engine to the transmission gearing. As rota- snapring 25. PTO drive gear 13 is secured to
tional speed of the output shaft decreases, the relay forward clutch housing 6 by snapring 12.
valve automatically releases the lockup clutch. Refer
to Paragraph 2–24l for explanation of the hydraulic ac- 4. For transmissions after S/N 49489, housing 6
tion. contains centrifugal valve 11, valve spring 10,
and valve plug 9. Pin 8 retains these parts in
the housing.
2–8. OIL PUMP ASSEMBLY
b. Operation (Foldout 7,B)
a. Description (Foldout 7,A). Oil pump assembly 4
consists of three main elements: drive gear 9, driven 1. Housing 6 rotates when the converter turbine
gear 8, and pump body 7. The oil pump assembly is rotates. Fourth clutch driving hub 24 also ro-
bolted to front support assembly 22. tates. Fourth clutch internal-splined plates 4
(Foldout 8,A) are splined to the driving hub
b. Operation (Foldout 7,A). When the torque con- and rotate with it.
verter rotates, its rear hub drives pump drive gear 9.
Gear 9 is in mesh with driven gear 8. As the gears ro- 2. When hydraulic pressure is applied to the pis-
tate, they draw fluid into the oil pump and move the ton bore in forward clutch housing 6 (Foldout
fluid into the hydraulic system. 7,B), piston 16 compresses plates 22 and 23
against fourth clutch driving hub 24. This locks
2–9. OIL PUMP AND FRONT forward clutch hub 21 to forward clutch hous-
ing 6. Hub 21 is splined to main shaft assembly
SUPPORT ASSEMBLY 33 (Foldout 9,A or 9,B).
Oil pump and front support assembly 1 (Foldout 7,A)
is bolted to the transmission housing. The front sup- 3. The forward clutch is applied only in forward
port provides the ground sleeve for the torque con- range operation, and is always paired with an-
verter and supports the forward clutch and turbine other clutch (either first, second, third, fourth,
shaft. The rear side of the front support contains bores or low (MT 650, 653 only)). When the con-
for main-pressure regulator valve 13, converter-pres- verter turbine rotates and the forward clutch is
sure regulator valve 25, and lockup valve 17. applied, the main shaft assembly also rotates.
This drives components of the gear unit, which
drives the output shaft in any forward range.
2–10. FORWARD CLUTCH The specific forward range depends upon
AND TURBINE SHAFT which additional clutch is applied.
1. Internal-splined clutch plates 4 rotate when- 3. External-tanged plates 4 and 26 engage slots in
ever turbine shaft 5 (Foldout 7,B) and forward the transmission housing and are always sta-
clutch housing 6 rotate. tionary. Internal-splined plates 3 of the third
clutch engage splines in fourth clutch housing
2. When the fourth clutch is applied, piston 9 or 10 assembly 13 (Foldout 8,A). Internal-splined
(Foldout 8,A) compresses plates 4 and 5 against plates 27 of the second clutch engage splines in
backplate 3, locking plates 4 and 5 together and, front planetary carrier assembly 4 (Foldout 9,A
in turn, to clutch housing 13. Clutch housing 13 or 9,B).
rotates with the turbine shaft.
b. Operation of Third Clutch (Foldout 8,B)
3. The fourth clutch is engaged during fourth
range (MT 640, 643), fifth range (MT 650, 1. When the third clutch is applied, piston 9 com-
653), and reverse range operation. In fourth (or presses plates 3 and 4 against backplate 2. This
fifth) range, the fourth and forward clutches are locks plates 3 (which are splined to the fourth
engaged. Clutch housing 13 drives sun gear clutch housing) to plates 4 which are station-
and shaft assembly 23 (Foldout 9,A or 9,B) at ary. This holds the fourth clutch housing sta-
the same speed that forward clutch hub 21 tionary.
2. D, D3, D2, and D1 are forward ranges. The h. Governor Circuit (Green and White)
lowest range attainable is first range. In D1,
D2, D3, or D position, the transmission starts 1. Main pressure is directed to the governor
in first range (except on second range start). valve. The speed of the transmission output
Shifting within any range is automatic, de- controls the position of the governor valve. The
pending upon vehicle speed and throttle posi- position of the governor valve determines the
tion. amount of pressure in the governor circuit.
When the transmission output is not rotating,
3. The forward regulator circuit originates at the governor pressure is approximately 2 psi. Gov-
manual selector valve and terminates at the ernor pressure varies with the output rpm.
main-pressure regulator valve. The circuit is
pressurized in every forward range, reducing 2. In the MT 640 and 643, governor pressure is
main pressure. In reverse, forward-regulator directed to the 1–2, 2–3, and 3–4 shift signal
2. Although each trimmer valve is calibrated for 3. In its downward position, the modulated
the clutch it serves, all four trimmers function lockup valve directs main pressure to the top of
in the same manner. Each trimmer includes the lockup valve. Main pressure pushes the
(top to bottom) an orificed trimmer valve, trim- lockup valve downward. In its downward posi-
mer valve plug, one or two trimmer springs, tion, the valve directs main pressure to the
and a stop pin. lockup clutch. This engages the clutch.
3. When any clutch (except forward clutch) is ap- 4. The position of the lockup valve affects the
plied, clutch-apply pressure is sent to the top volume of fluid flowing to the torque converter.
end of the corresponding trimmer valve. Ini- When the valve is upward (lockup clutch re-
tially, the plug and valve are forced downward leased), there is maximum flow to the con-
against the spring until fluid escapes to ex- verter. When the valve is downward (clutch
haust. The escape of fluid, as long as it contin- engaged), an orifice restricts converter-in flow.
3. In any automatic upshift, the shift signal valve 2–25. RETARDER HYDRAULIC
acts first. This directs a shift signal pressure to CIRCUIT COMPONENTS
the relay valve. The relay valve moves down-
ward, exhausting the applied clutch and apply-
a. Circuit Schematic (Foldout 5). The schematic of
ing a clutch for the next higher range.
the retarder hydraulic circuit presented in the back of
q. Automatic Downshifts this manual shows the circuit in the retarder-off condi-
tion.
1. Automatic downshifts, like upshifts, are con-
trolled by rear governor and modulator pres- b. Priority Valve. Main pressure supplied by the
sures. Downshifts occur in sequence as rear transmission to the retarder passes through this valve.
f. Retarder Pressure Regulator Valve. The regula- b. Retarder Valve Partially Applied
tor valve is the most complex valve in the control sys-
tem. It provides regulated pressure for full clutch ap- 1. The position of the retarder valve in its bore is
ply. It provides clutch pressure priority by closing off controlled by the amount of air pressure ap-
the feed line from the retarder pressure regulator valve plied to the top of the valve. At partial apply,
to the charging valve during initial clutch fill. At low the initial air pressure application forces the re-
vehicle speeds, it reduces retarder clutch pressure by tarder and cutoff valves to the bottom of their
closing or regulating the feed line between the cutoff bores. Clutch pressure at maximum strength is
valve and the retarder pressure regulator valve. This released at the regulator valve and directed to
provides a smooth transition from retarder to vehicle the clutch-apply circuit. Fluid retained in the
service brakes. three accumulator cylinders is released to the
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TORQUE FOURTH THIRD SECOND
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FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
;; FORWARD CENTER
;
CLUTCH CLUTCH PLANETARY
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SHAFT
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TURBINE SHAFT; ; ; ; ;; ;;
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REAR PLANETARY
;;; CONNECTING DRUM
Clutch Applied
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00273.08
c. Neutral Operation (MT 640, 643) (Figure 2–2). gaged and torque is not transmitted beyond the fourth
Engine torque is transmitted through the torque con- clutch hub. Two clutches must be applied to produce
verter as described in Paragraph 2–27a. Although the output shaft rotation.
first clutch is applied, the forward clutch is not en-
;;;
TORQUE FOURTH THIRD SECOND
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FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH ;; FORWARD
CLUTCH
CENTER
PLANETARY
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SHAFT
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;; ;; ;;;
;
;;;;;
; ;;;
;
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;; ;
;
; ; ;;
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;;;;;;; ;;
;
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;; ;;; ;;
;;
;;;
; ;;;;
;;; ;;
;; ;
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;;
;;; ;;; ;;; ;;;;
; ;;
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;;
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;;;
; ;;;
;; ;;
;;
;;
;;;
;;;; ;
; ; ; ;; ;;
;; ;;
;;
;
;;
;
;;
;
;
TURBINE SHAFT ;
; REAR PLANETARY
;;; CONNECTING DRUM
Clutch Applied
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00273.09
d. First Range Operation (MT 640, 643) (Figure splined to the transmission main shaft and rotates with
2–3). Engine torque is transmitted through the torque it, rotating the planetary pinions. The pinions are part
converter as described in Paragraph 2–27a. The for- of the planetary carrier, which is splined to the output
ward clutch and the first clutch are applied. Forward shaft. With the rear planetary ring gear held stationary
clutch application locks the turbine shaft and the trans- by the applied first clutch and with the rear sun gear
mission main shaft together so that they rotate as a rotating the pinions, the rear planetary carrier rotates
unit. The first clutch application anchors the rear plan- within the ring gear and drives the output shaft at a
etary ring gear against rotation. The rear sun gear is speed reduction of 3.58:1.
;;;
TORQUE FOURTH THIRD SECOND
;;;
;;;;;
; ;;;;; ;
FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH ;; FORWARD
CLUTCH
CENTER
PLANETARY
;; ;;;;; ;
;; ;;
;;;
;
; ; OUTPUT
; ;;;
SHAFT
;;
;;;;;
;;
; ; ;;
;;
;;;;;;; ;;
; ;;;
;
;;
;;
;;
; ;;
;;; ;
;;;;
;
;;
; ;; ;
;; ;;
; ;
;
;; ;; ;;; ; ;; ;
;;;;;
; ;;;
;
;; ;;
;; ; ;
; ;
;;;;;;;;
;;;;;;; ;;
;
;;;;;;
;; ;;; ;;
;
;;
;
;;
; ;;;;
;;; ;;
;; ; ;;
;;;;
;;; ;;; ;;; ;;;;
; ;;
;;;;;;;;
;;
;; ;;;
;;;
; ;;;
;; ;;
;;
;;
;;;
;;; ; ;;
;
;;
;
TURBINE SHAFT ; ; ; ; ;; ;;
;;
;
;;
;
;
;;;
REAR PLANETARY
;;; CONNECTING DRUM
Clutch Applied
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00273.10
e. Second Range Operation (MT 640, 643) (Fig- the rotating center ring gear rotates the center sun gear.
ure 2–4). Engine torque is transmitted through the The center sun gear is splined to the sun gear shaft to
torque converter as described in Paragraph 2–27a. The which the front sun gear is splined. The rotating front
forward clutch and the second clutch are applied. For- sun gear rotates the front carrier pinions whose carrier
ward clutch application locks the turbine shaft to the is anchored. The front carrier pinions rotate the front
transmission main shaft so that they rotate together. ring gear which, along with the center carrier, is
The rear sun gear is splined to both the transmission splined to the rear planetary carrier through a connect-
main shaft and the center ring gear and all three parts ing drum. Rotation of the connecting drum drives the
rotate as a unit. With the front planetary carrier an- output shaft, through the splines of the rear planetary
chored against rotation (by second clutch application), carrier, at a speed reduction of 2.09:1.
;;;
TORQUE FOURTH THIRD SECOND
;;;
;;;;;
; ;;;;; ;
FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH ;; FORWARD
CLUTCH
CENTER
PLANETARY
;; ;;;;; ;
;; ;;
;;;
;
; ; OUTPUT
; ;;;
SHAFT
;;
;;;;;
;;
; ; ;;
;;
;;;;;;; ;;
; ;;;
;
;;
;;
;;
; ;;
;;; ; ;
;;;;
;
;;
;; ;
;; ;;
; ;
;
;; ;; ;;; ; ;; ;
;;;;;
; ;;;
;
;; ;;
;; ; ;
; ;
;;;;;;;;
;;;;;;; ;;
;
;;;;;;
;; ;;; ;;
;
;;
;;;
; ;;;;
;;; ;;
;; ; ;;
;;;;
;;; ;;; ;;; ;;;;
; ;;
;;;;;;;;
;;
;; ;;;
;;;
; ;;;
;; ;;
;;
;;
;;;
;;; ; ;;
;
;;
;
TURBINE SHAFT ; ; ; ; ;; ;;
;;
;
;;
;
;
;;;
REAR PLANETARY
;;; CONNECTING DRUM
Clutch Applied
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00273.11
f. Third Range Operation (MT 640, 643) (Figure center ring gear, and rotates at input speed. With the
2–5). Engine torque is transmitted through the lockup center sun gear held stationary and the center ring gear
clutch as described in Paragraph 2–27b. The forward rotating, the ring gear drives the center planetary pin-
and third clutches are applied. Third clutch application ions. This rotates the center planetary carrier at a speed
anchors the sun gear shaft against rotation, which pre- reduction of 1.39:1. This carrier and the rear planetary
vents the integral center sun gear from rotating. For- carrier are splined to the planetary connecting drum
ward clutch application locks the turbine shaft and the and rotate as a unit. The output shaft, being splined to
main shaft together so that they rotate as a unit. The the rear carrier, rotates at the same speed as the center
rear sun gear is splined to both the main shaft and the planetary carrier.
;;;
TORQUE FOURTH THIRD SECOND
;;;
;;;;;
; ;;;;; ;
FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
;; FORWARD CENTER
;
CLUTCH CLUTCH PLANETARY
;; ;;;;; ;
;;;;
;;;
;
; OUTPUT
; ;;;
SHAFT
;;
;;;;
;;
; ;
;;
;;;;;
;;;;; ;;;;
; ;;;
;
;;
;;
;; ;;
;;;;;; ;;
;;
; ;; ; ;;
; ; ;
; ; ; ;
;; ;; ;;;
;
;;
;;;
; ;;;
;
;;;;
;; ;; ; ; ;;
;;;;;;;;
;;;;;;; ;;
;
;;;;;;
;; ;;; ;;
;;
;
;;
; ;;;;
;;; ;;
;; ; ;;
;;;;
; ;; ; ;;
; ; ;;;;;
; ;;
;;;;;;;;
;;
;;
;;;
;
;;; ; ;;
;
;;
;;
;;
; ; ; ;;
;;;
;;
;
;;
;
TURBINE SHAFT; ; ; ; ;; ;;
;;
;
;;
;
;
;;;
REAR PLANETARY
;;; CONNECTING DRUM
Clutch Applied
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00273.12
g. Fourth Range Operation (MT 640, 643) (Fig- unit at input speed. With the center sun gear and rear
ure 2–6). Engine torque is transmitted through the sun gear rotating at the same speed (locked together)
lockup clutch as described in Paragraph 2–27b. The and their respective carriers splined to the planetary
forward and fourth clutches are applied. With these connecting drum, all components rotate at the same
clutches applied, the transmission main shaft and cen- speed. The transmission output shaft is splined to the
ter sun gear shaft are locked together and rotate as a rear carrier and produces an output ratio of 1.00:1.
;;;
TORQUE FOURTH THIRD SECOND
;;;
;;;;;
; ;;;;; ;
FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH ;; FORWARD
CLUTCH
CENTER
PLANETARY
;; ;;;;; ;
;; ;;
;;;
;
; ; OUTPUT
; ;;;
SHAFT
;;
;;;;;
;;
; ;
;;;;;;;;; ;; ;;
; ;;;
;
;;
;;
;; ;;
;;;; ; ;
;;;;
;;
;; ;;; ;;
; ;
;
;
;; ;; ;;; ; ;; ;
;;
;;;
; ;;;
;
;; ;;
;; ; ;
; ;
;;;;;;;;
;;;;;;; ;;
;
;;;;;;
;; ;;; ;;
;
;;
; ;;
; ;;;;
;;; ;;
;; ; ;;
;;;;
;;; ;;; ;;; ;;;;
; ;;
;;;;;;;;
;;
;; ;;;
;;;
; ;;;
;; ;;
;;
;;
;;;
;;; ; ;;
;
;;
;
;
TURBINE SHAFT
; ; ; ;; ;;
;;
;
;;
;
;
;;;
REAR PLANETARY
;;; CONNECTING DRUM
Clutch Applied
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00273.13
h. Reverse Range Operation (MT 640, 643) (Fig- which, in turn, rotate the center ring gear in the oppo-
ure 2–7). Engine torque is transmitted through the site direction. The center carrier is splined to the plan-
converter as described in Paragraph 2–27a. Reverse etary connecting drum, which is splined to the rear
range is the only range in which the forward clutch is carrier. The reverse direction of rotation of the center
not applied. In this range, the fourth clutch is applied ring gear rotates the rear sun gear. This causes the rear
and rotates the sun gear shaft (with the front sun gear planetary pinions to drive the rear carrier in a reverse
splined to it) at input speed. The first clutch is also ap- direction, within the stationary ring gear. The trans-
plied and anchors the rear ring gear against rotation. mission output shaft, splined to the rear carrier, rotates
The center sun gear rotates the center carrier pinions in a reverse direction at a speed reduction of 5.67:1.
;;;
;;;
;;;;;
;;;;; ;
;;;;
;;
TORQUE FOURTH THIRD SECOND FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH
;;
;;
FORWARD
CLUTCH
CENTER
PLANETARY LOW CLUTCH
;;;;; ;;;;
;;
;;
;;
;
;;
;;;
;;;
; ;; ;;
;
;
OUTPUT
SHAFT
;;; ;;; ;;
;;;;
;;
;;;;;
;;;
; ;
;; ; ;
;;
;; ;;
; ;;
;;;;;;
;;;;;;;
; ;
;;;;; ;
; ;;;
;;;; ;;
;;
;;
;;;;
;;;;
;;; ;
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;; ; ;; ;
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;;
;;; ;;;
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;; ;; ; ;;;;;;;;;
; ;;
;;
; ;;;
;; ;;;; ;; ;;
;; ; ;
;;;;
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; ;;;;; ;;
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;;;;
; ;;
;; ;;
;;;
;
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;;;
;
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;;;;
;;;;
;; ; ;;;
;;; ;;
;;
; ; ;;
;
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; ;;
; ;;; ;;
;;; ;;;;;;;;;;
;;
;
; ; ;;;
;; ;;;
;;
;
;;
;;
;;; ;;;;;;;;;
; ;
;
;;
; ;;;
;;
LOW PLANETARY
;; ; ;; ; ;
;; ;
TURBINE SHAFT ; ;;;;
;; ; REAR PLANETARY
;;
Clutch Applied CONNECTING DRUM
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00272.10
i. Neutral Operation (MT 650, 653) (Figure 2–8). gaged and torque is not transmitted beyond the fourth
Engine torque is transmitted through the torque con- clutch hub. Two clutches must be applied to produce
verter as described in Paragraph 2–27a. Although the output shaft rotation.
first clutch is applied, the forward clutch is not en-
;;;
;;;
;;;;;
;;;;; ;
;;;;
;;
TORQUE FOURTH THIRD SECOND FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH
;;
;;
FORWARD
CLUTCH
CENTER
PLANETARY LOW CLUTCH
;;;;; ;;;;
;;
;;
;;
;
;;
;;;
;;;
; ;; ;;
;
;
OUTPUT
SHAFT
;;; ;;; ;;
;;;;
;;
;;;;;
;;;
; ;
;;;;;;;
; ;;
;;
;; ;;
; ;;
;;;;;;;; ; ;
;;;; ;
; ;;;
;;;; ;;
;;
;;
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;;;;
;;; ;
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;; ; ;; ;
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;;
;;;
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; ;;
; ;;;
;; ; ;
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;;;;
;;
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;; ;;
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;;;;
; ;;
;; ;;
;;;
;
;;
;;;
;
;;;;;
;;;;
;;;;
;; ; ;;;
;;; ;;
;;
; ; ;;
;
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;;;;;; ; ;;
;;;;;;;;
; ;;
; ;;; ;;
;;; ;;;;;;;;;;
;;
;
; ; ;;;
;; ;; ;;
;; ;;
;;
;;; ;;;;;;;;;
; ;
;
;;
; ;;;
;;
LOW PLANETARY
;; ; ;; ; ;
;; ;
TURBINE SHAFT ; ;;;;
;; ; REAR PLANETARY
;;
Clutch Applied CONNECTING DRUM
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00272.11
j. First Range Operation (MT 650, 653) (Figure resists rotation because it is restrained by the output
2–9). Engine torque is transmitted through the torque shaft to which it is splined. This causes the rear plane-
converter as described in Paragraph 2–27a. The for- tary carrier ring gear to rotate. The low planetary sun
ward clutch and the low clutch are applied. Forward gear is splined to the rear planetary ring gear and ro-
clutch application locks the turbine shaft and the trans-
tates with it. The low planetary sun gear rotates the
mission main shaft together so that they rotate as a
unit. Low clutch application anchors the low planetary pinions. Since the low planetary carrier is anchored
carrier against rotation. The rear planetary sun gear against rotation, the pinions rotate the low planetary
(splined to the transmission main shaft) rotates the rear ring gear which, in turn, rotates the output shaft to
planetary pinions; however, the rear planetary carrier which it is splined, at a speed reduction of 8.05:1.
;;;
;;;
;;;;;
;;;;; ;
;;;;
;;
TORQUE FOURTH THIRD SECOND FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP ;; FORWARD CENTER
CLUTCH ;; CLUTCH PLANETARY LOW CLUTCH
;;;;; ;;;;
;;
;;
;;
;
;;
;;
;;;
;
; ;; ;;
;
;
OUTPUT
SHAFT
;;; ;;; ;;
;;;;
;;
;;;;;
;;;
; ; ;;
;;
;; ;;
; ;;
; ; ;
; ;;;
;;;; ;;
;; ;;;;
;;;;
;
;;;;;;
;;
;;;;;;;
;;; ;
;; ; ;;
;;;;
;;;
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;;
;
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;;
;;;;;
;; ;; ;;;;;;;;;
; ;;
;;
; ;;;;;
;;
;;;;;; ;;; ; ;;
;; ; ;
;;;
;;;;;; ;;
;;;;;;;;
;;;;;;; ;;;;;
;;;;;
; ;;
;; ;;
;;;
;
;;
;;
;
;
;;;;;
;;;;
;;;;
;;
;;;;
; ;;;
;;; ;;
;;
; ; ;;
;
;;
;;;;;; ; ;;
;;;;;;;;
; ;;
; ;;; ;;
;;; ;;;;;;;;;
;;
;
; ; ;;;
;; ;; ;
;;
;
;;
;;
;;;
;
;;;;;;;;;;
;
;
;;
; ;;;
;;
LOW PLANETARY
;; ; ;; ; ;
;; ;
TURBINE SHAFT ; ;;;;
;; ; REAR PLANETARY
;;
Clutch Applied CONNECTING DRUM
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00272.12
k. Second Range Operation (MT 650, 653) (Fig- the main shaft and rotates with it, and rotates the plan-
ure 2–10). Engine torque is transmitted through the etary pinions. The pinions are part of the planetary car-
torque converter as described in Paragraph 2–27a. The rier which is splined to the output shaft. With the rear
forward clutch and the first clutch are applied. For- planetary ring gear held stationary by the applied first
ward clutch application locks the turbine shaft and the clutch, and with the rear sun gear rotating the pinions,
transmission main shaft together so that they rotate as the rear planetary carrier rotates within its ring gear
a unit. First clutch application anchors the rear ring and drives the output shaft at a speed reduction of
gear against rotation. The rear sun gear is splined to 3.58:1.
;;;
;;;
;;;;;
TORQUE
CONVERTER
LOCKUP
CLUTCH
;;;;;
;;
;;
;;
; ;;
;;
FOURTH
CLUTCH
FORWARD
CLUTCH
THIRD
CLUTCH
SECOND
CLUTCH
CENTER
PLANETARY
FIRST
CLUTCH
LOW CLUTCH
;;;;; ;;;;
;;
;;
;;
;
;;
;;
;;;
;
; ;; ;;
;
;
OUTPUT
SHAFT
;;; ;;
;;;;
;;
;;;;;
;;;
;
;;; ;
;
;;
;; ;;
; ;;
;;;;;;
;;;;;;;
; ; ;
;;;;
;;;
;
; ;;;
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;;
;;
;;;;
;;;;
;;; ;
;;; ; ;;;;;
;; ; ;; ;
;; ;;
;;
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;; ;; ;;;;;;;;;
; ;;
;;
;;;
;;; ;;;
;;
; ;;;
;;;; ; ;;
;;;;
;;
; ;; ;;
;;;;;;;;
;;;;;;; ;;;;;
;;;;;
; ;;
;; ;;
;;;
;
; ;;
;;
;
;
;;;;;
;;;;
;;;;;;
;;;;
; ;;;
;;; ;;
;;
; ; ;;
;;;;;
;
;;
; ; ;;
;;;;;;;;
; ;;;
;; ;;
;;; ;;;;;;;;;
;
;;
; ; ;;;
;;; ;;; ;
;; ;;
;;
;;; ;
;;;;;;;;;;;
;
;;
; ;;;
;;
LOW PLANETARY
;; ; ;; ; ;
;;;;
TURBINE SHAFT ; ;; ;
;; ; REAR PLANETARY
;;
Clutch Applied CONNECTING DRUM
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00272.13
l. Third Range Operation (MT 650, 653) (Figure tion by second clutch application, the rotating center
2–11). Engine torque is transmitted through the torque ring gear rotates the center sun gear. The center sun
converter as described in Paragraph 2–27a. The for- gear is integral with the sun gear shaft to which the
ward clutch and the second clutch are applied. For- front sun gear is splined. The rotating front sun gear
ward clutch application locks the turbine shaft and the rotates the front carrier pinions whose carrier is an-
transmission main shaft together so that they rotate as chored. The front carrier pinions rotate the front ring
a unit. Second clutch application anchors the front gear which, along with the center carrier, is splined to
planetary carrier against rotation. The rear sun gear is the rear planetary carrier through a connecting drum.
splined to both the transmission main shaft and the Rotation of the connecting drum drives the output
center planetary ring gear and all three rotate as a unit. shaft through the splines of the rear planetary carrier at
With the front planetary carrier anchored against rota- a speed reduction of 2.09:1
;;;
;;;
;;;;;
;;;;; ;
;;;;
;;
TORQUE FOURTH THIRD SECOND FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH
;;
;;
FORWARD
CLUTCH
CENTER
PLANETARY LOW CLUTCH
;;;;; ;;;;
;;
;;
;;
;
;;
;;;
;;;
; ;; ;;
;
;
OUTPUT
SHAFT
;;; ;;; ;;
;;;;
;;
;;;;;
;;;
; ;
;; ; ;
;;
;; ;;
; ;;
;;;;;;
;;;;;;;
; ;
;;;;; ;
; ;;;
;;;; ;;
;;
;;
;;;;
;;;;
;;; ;
;; ;;;
;; ; ;; ;
;; ;;
;;
;;; ;;;
;;;;;
;; ;; ; ;;;;;;;;;
; ;;
;;
; ;;;
;; ;;;; ;; ;;
;; ; ;
;;;;
;;;;;;
; ;;;;; ;;
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;;;;
; ;;
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;;;
;
;;
;;;
;
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;;;;
;;;;
;; ; ;;;
;;; ;;
;;
; ; ;;
;
;;
;;;;;; ; ;;
;;;;;;;;
; ;;
; ;;; ;;
;;; ;;;;;;;;;;
;;
;
; ; ;;;
;; ;;;
;;
;
;;
;;
;;; ;;;;;;;;;
; ;
;
;;
; ;;;
;;
LOW PLANETARY
;; ; ;; ; ;
;; ;
TURBINE SHAFT ; ;;;;
;; ; REAR PLANETARY
;;
Clutch Applied CONNECTING DRUM
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00272.14
m. Fourth Range Operation (MT 650, 653) (Fig- the center planetary ring gear and rotates at input
ure 2–12). Engine torque is transmitted through the speed. With the center sun gear held stationary, the
lockup clutch as described in Paragraph 2–27b. The center ring gear drives the center planetary carrier pin-
forward and third clutches are applied. Third clutch ions. This rotates the center planetary carrier at a speed
application anchors the sun gear shaft against rotation, reduction of 1.39:1. This carrier and the rear planetary
which prevents the integral center sun gear from rotat- carrier are splined to the planetary connecting drum
ing. Forward clutch application locks the turbine shaft and rotate as a unit. The output shaft, splined to the
and the main shaft together so that they rotate as a unit. rear carrier, rotates at the same speed as the center
The rear sun gear is splined to both the main shaft and planetary carrier.
;;;
;;;
;;;;;
;;;;; ;
;;;;
;;
TORQUE FOURTH THIRD SECOND FIRST
CONVERTER CLUTCH CLUTCH CLUTCH CLUTCH
LOCKUP
CLUTCH
;;
;;
FORWARD
CLUTCH
CENTER
PLANETARY LOW CLUTCH
;;;;; ;;;;
;;
;;
;;
;
;;
;;;
;;;
; ;; ;;
;
;
OUTPUT
SHAFT
;;; ;;; ;;
;;;;
;;
;;;;;
;;;
; ;
;; ; ;
;;
;; ;;
; ;;
;;;;;;
;;;;;;;
; ;
;;;;; ;
; ;;;
;;;; ;;
;;
;;
;;;;
;;;;
;;; ;
;; ;;;
;; ; ;; ;
;; ;;
;;
;;; ;;;
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;; ;; ; ;;;;;;;;;
; ;;
;;
; ;;;
;; ;;;; ;; ;;
;; ; ;
;;;;
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; ;;;;; ;;
;;;;;;;;
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;;;;
; ;;
;; ;;
;;;
;
;;
;;;
;
;;;;;
;;;;
;;;;
;; ; ;;;
;;; ;;
;;
; ; ;;
;
;;
;;;;;; ; ;;
;;;;;;;;
; ;;
; ;;; ;;
;;; ;;;;;;;;;;
;;
;
; ; ;;;
;; ;;;
;;
;
;;
;;
;;; ;;;;;;;;;
; ;
;
;;
; ;;;
;;
LOW PLANETARY
;; ; ;; ; ;
;; ;
TURBINE SHAFT ; ;;;;
;; ; REAR PLANETARY
;;
Clutch Applied CONNECTING DRUM
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY
V00272.15
n. Fifth Range Operation (MT 650, 653) (Figure speed. With the center sun gear and the rear sun gear
2–13). Engine torque is transmitted through the lockup rotating at the same speed (locked together) and their
clutch as described in Paragraph 2–27b. The forward respective carriers splined to the planetary connecting
and fourth clutches are applied. With the clutches ap- drum, all components rotate at the same speed. The
plied, the transmission main shaft and center sun gear output shaft is splined to the rear carrier and produces
shaft are locked together and rotate as a unit at input an output ratio of 1.00:1.
;;;
;;;
;;;;;
TORQUE
CONVERTER
LOCKUP
CLUTCH
;;;;;
;;
;;
;;
; ;;
;;
FOURTH
CLUTCH
FORWARD
CLUTCH
THIRD
CLUTCH
SECOND
CLUTCH
CENTER
PLANETARY
FIRST
CLUTCH
LOW CLUTCH
;;;;; ;;;;
;;
;;
;;
;
;;
;;
;;;
;
; ;; ;;
;
;
OUTPUT
SHAFT
;;; ;;
;;;;
;;
;;;;;
;;;
;
;;; ;
;
;;
;; ;;
; ;;
;;;;;;
;;;;;;;
; ; ;
;;;;
;;;
;
; ;;;
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;;
;;
;;;;
;;;;
;;; ;
;;; ; ;;;;;
;; ; ;; ;
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;;
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;; ;; ;;;;;;;;;
; ;;
;;
;;;
;;; ;;;
;;
; ;;;
;;;; ; ;; ;
;;;;
;;
;; ;;
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;;;;;;; ;;;;;
;;;;;
; ;;
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;;;
;
; ;;
;;
;
;
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;;;;
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;;;;
; ;;;
;;; ;;
;;
; ; ;;
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;
;;
; ; ;;
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; ;;;
;; ;;
;;; ;;;;;;;;;
;
;;
; ; ;;;
;;; ;;; ;
;; ;;
;;
;;; ;
;;;;;;;;;;
; ;
;;
; ;;;
;;
LOW PLANETARY
;; ; ;; ; ;
;;;;
TURBINE SHAFT ; ;; ;
;; ; REAR PLANETARY
;;
Clutch Applied CONNECTING DRUM
MAIN SHAFT SUN GEAR SHAFT
Torque Path FRONT PLANETARY V00272.16
o. Reverse Range Operation (MT 650, 653) (Fig- pinions, which rotate the center ring gear in the oppo-
ure 2–14). Engine torque is transmitted through the site direction. The center carrier is splined to the plan-
converter as described in Paragraph 2–27a. Reverse etary connecting drum, which is splined to the rear
range is the only range in which the forward clutch is carrier. The reverse direction of rotation of the center
ring gear rotates the rear sun gear. This causes the rear
not applied. In reverse range, the fourth clutch is ap-
planetary pinions to drive the rear carrier in a reverse
plied, rotating the sun gear shaft (with the front sun direction, within the stationary ring gear. The trans-
gear splined to it) at input speed. The first clutch is mission output shaft, splined to the rear planetary car-
also applied and anchors the rear ring gear against ro- rier, rotates in a reverse direction at a speed reduction
tation. The center sun gear rotates the center carrier of 5.67:1.
0.75" 0.75"
ture significantly affect the fluid level. An in- (19 mm) (19 mm)
crease in input speed lowers the fluid level; an
increase in fluid temperature raises the fluid 1.80"
(46 mm)
level. The fluid level must always be checked ADD
with the engine at idle (600–650 rpm) and the 1.50"
(38 mm)
transmission in N (Neutral).
b. Cold Check
COLD
RUN
NOTE:
• A Cold Check is performed with dipsticks similar
to those illustrated in Figures 3–2 and 3–4.
V00275
• The fluid level rises as sump temperature increases.
DO NOT FILL above the REF FILL (COLD
RUN) band if the transmission fluid is below nor- Figure 3–2. Dipstick Markings for 4.3 Inch
mal operating temperature. Pan — MT 640, 643, 650, 653
(Earlier and Later Models)
CHE
CHE
c. Hot Check
CK IN
CK IN
TRANSMISSION TRANSMISSION
OIL PAN OIL PAN
NEU
NEU
SPLITLINE SPLITLINE
TRA
TRA
NOTE:
L AT
L AT
0.75" 0.75"
(19.0 mm) (19.0 mm)
IDLE
IDLE
A Hot Check is performed with all dipstick designs 2.55"
1.50" (64.8 mm) 1.50"
(Figures 3–2 and 3–4). (38.0 mm) (38.0 mm)
HOT
HOT
RUN
RUN
2.22"
(57.1 mm)
1. Operate the transmission until normal operat-
ing temperature is reached (160–200°F (71–
REF
FILL
CAUTION:
Containers or fillers that have been used to han- b. Recommended Viscosity Grade. When choos-
dle antifreeze or engine coolant solution must ing the optimum viscosity grade of fluid to use, duty
never be used for transmission fluid. Antifreeze cycle, preheat capabilities, and/or geographical loca-
and coolant solutions contain ethylene glycol tion must be taken into consideration. Table 3–1 lists
which, if introduced into the transmission, can
cause the clutch plates to fail. the minimum fluid temperatures at which the transmis-
sion may be safely operated. Preheat with auxiliary
heating equipment or by running the vehicle with the
3–7. TRANSMISSION FLUID transmission in N (Neutral) for a minimum of 20 min-
RECOMMENDATIONS utes before attempting range operation.
1. Hydraulic fluids (oils) used in the transmission Viscosity Grade Fahrenheit Celsius
are important influences on transmission per- SAE 0W-20 –31 –35
formance, reliability, and durability. Use
DEXRON®-III fluids for standard duty, on- DEXRON®-III –22 –30
highway applications. Use C-4 fluids (Allison SAE 10W –4 –20
approved SAE 10W or SAE 30) for severe SAE 15W-40 5 –15
duty and off-highway applications. Also use
SAE 30 32 0
type C-4 SAE 30 in all applications where the
ambient temperature is consistently above SAE 40 50 10
95°F (35°C).
Table 3–3. Fluid Oxidation Measurement Limits b. Metal Particles. Metal particles in the fluid (ex-
cept for the minute particles normally trapped in the
Measurement Limit
filter) indicate damage has occurred in the transmis-
Viscosity +/- 25% change from new sion. When these particles are found in the sump or on
fluid the magnetic plate in the bottom of the pan, the trans-
Carbonyl absorbance +0.3 A*/0.1 mm change from mission must be disassembled and closely inspected to
new fluid find the source. Metal contamination requires com-
plete disassembly of the transmission and cleaning of
Total acid number +3.0 change from new fluid all internal and external circuits, cooler, and all other
Solids 2% by volume maximum areas where the particles could lodge. Refer to applica-
tion of the auxiliary filter, Paragraph 3–9d.
* A = Absorbance units
Refer to SIL 17-TR-83 for fluid analysis techniques and data interpretation.
Consult your local industrial yellow pages for fluid analysis firms. Use CAUTION:
one fluid analysis firm as results from various firms cannot be accurately
compared. Refer to the Technician's Guide for Automatic Transmission If excessive metal contamination has occurred,
Fluid (GN2055EN) for additional information. inspection of the cooler and all bearings within
the transmission is recommended.
RADIATOR
FROM COOLER
ENGINE
TO COOLER
TRANSMISSION
COOLANT
COOLANT
TRANSMISSION FLUID
FROM COOLER
NAMEPLATE
TYPICAL COOLER
AUXILIARY
FILTER
4. For transmissions equipped with paper element 6. Install filter tube 32 into a new paper filter ele-
filter 33, remove washer-head screw 35 that re- ment assembly 33 (if used). Install a new seal-
tains the filter. Remove the filter and discard. ring 31 or 39 onto filter tube 32 or sump screen
Filter tube 32 is not integral with the filter. Do filter assembly 40. Lubricate the sealring with
not discard the tube unless replacing the paper transmission fluid. Install the new filter, insert-
9. Install the remaining seventeen washer-head 3. Remove bolt 21 and nut 22. Remove strap 20,
screws 48 by hand, carefully threading each filter cover 19, spring 17, and retainer 16.
through the gasket and into the transmission.
Bottom all screws before tightening them. 4. Remove filter 14. Discard the filter retainer
10. Alternately tighten screws 180 degrees apart to sealring 15 and filter cover sealring 18.
5 lb ft (6.7 N·m). Repeat the process, tighten-
ing the screws to 15–20 lb ft (20–27 N·m). 5. Install a new sealring 15 on filter retainer 16.
Install filter 14 and retainer into external access
11. Install the fill tube at the side of the pan. canister 11.
12. Check Dimension A (Figure 3–6) to determine
what oil pan boss is present. If Dimension A is 6. Install a new filter cover sealring 18 onto the
0.570–0.580 inch (14.48–14.73 mm), tighten lip of the pan. Install spring 17 into cover 19
the tube fitting to 65–75 lb ft (88–102 N·m). If and place over the filter retainer.
Dimension A is 0.670–0.680 inch (17.02–
17.27 mm), tighten the tube fitting to 90–100 7. Install strap 20, 5⁄16-24 x 7⁄8 bolt 21, and nut 22
lb ft (122–136 N·m). onto pan. Torque the bolt to 11–14 lb ft (15–19
N·m).
13. Install drain plug 43 and gasket 44. Tighten the
plug to 15–20 lb ft (20–27 N·m). 8. Refill the transmission with transmission fluid.
14. Replace the external auxiliary filter element Use approximately 17 U.S. quarts (16 liters).
(cooler-out line), if present. Refer to Paragraph The quantity of fluid will vary depending on
3–9d. external circuits.
A
Dimension A Torque Specifications
0.570–0.580 in. (14.48–14.73 mm) 65 –75 lb ft (88–102 N·m)
0.670–0.680 in. (17.02–17.27 mm) 90 –100 lb ft (122–136 N·m)
NOTE: Except for Dimension A, the oil pan in Figure 3–6 does not represent all MT oil pan configurations.
V03277
Figure 3–6. Measuring the Length of Oil Pan Boss to Identify Torque Requirements
V02883
9. Check the fluid level using the procedure de- and reinstall it. If damaged, install a new filter.
scribed in Paragraph 3–5. Refer to Paragraph The open end must be installed first, into the
3–4 for dipstick calibration specifications. transmission rear cover. Install the pipe plug to
retain the filter. Tighten the plug to 4–5 lb ft
10. Refer to Table 3–2 and determine when the (5.5–6.7 N·m).
next fluid and filter changes will be required. If
labels are available (Figure 3–7), fill in the ap- 2. MT 643, 653 — Later Models. For MT 643
propriate dates and affix the labels in a con- (Foldout 12,A), remove hex plug 14, sealring
spicuous location in the vehicle. 13, and governor filter 12 from the rear cover
c. Governor Filter Change Procedures (Figure 3–9). For MT 653 (Foldout 12,B), re-
move hex plug 22, sealring 21, and governor
1. MT 643, 653 — Earlier Models. Remove the filter 20. Install a new filter, a new sealring, and
pipe plug that retains the governor oil screen the hex plug. Tighten the plug to 50–70 lb ft
(Figure 3–8). If the filter is undamaged, clean (68–95 N·m).
CAUTION:
• Failure to obtain proper detent in D (Drive), N
(Neutral), or R (Reverse) can cause metering of
the clutch-apply fluid to either forward or
fourth (reverse) clutch. The resulting low apply
pressure and clutch slippage will affect trans-
mission durability.
• Manual selector shafts that are center drilled at
GOVERNOR OIL SCREEN their outer ends require an M10 x 1.5-6G nut
H00005 (metric thread). Shafts that are undrilled re-
quire a 3⁄8-16 nut (standard inch series). Use of
Figure 3–8. MT 643, 653 Governor the wrong nut will damage both the shaft and
Filter — Earlier Models
nut. Torque for either nut is 15–20 lb ft (20–27
N·m). Excessive torque applied to the nut with-
out holding the lever can damage the internal le-
ver. Do not use an impact wrench.
RETARDER
H00007
Figure 3–9. MT 643, 653 Governor
Filter — Later Models Figure 3–10. MTB 643, 653 Governor Filter
b. Mechanical Actuator Adjustment. The mechan- 2. Special tool J 24314 is used to depress and ro-
ical linkage must be properly adjusted for efficient tate the adjusting rings. Clockwise rotation in-
performance. For installing and adjusting the mechani- creases spring force and raises the shift point;
cal modulator control, refer to MT 600 Series Me- counterclockwise rotation reduces spring force
chanic’s Tips, MT1357EN. and lowers the shift point.
Engine Governed Speed — rpm 2200 2400 2600 2800 3000 3200 3400 3600 4000
MT Parts Book Group S, AK** Q, AJ** J K G L N M H
Throttle
Position Range Shift Transmission Output Speed (rpm) at Start of Shift
D DR2 1–2 530–590 530–590 570–630 625–685 685–740 740–795 795–855 850–910 965–1020
R 2–3 875–1015 875–1015 970–1110 1110–1250 1240–1380 1255–1400 1420–1565 1445–1590 1640–1780
DR3
4 3C–3LU 1050–1400 1190–1600 1190–1600 1360–1615 1310–1600 1580–1870 1580–1870 1745–2155 2160–2450
Full or DR4 3–4 1475–1625 1580–1725 1725–1870 1870–2010 2085–2230 2160–2300 2300–2445 2445–2590 2735–2880
PREVENTIVE MAINTENANCE
DR3 4–3 1560 Min 1850 Min 1910 Min 2020 Min 2370 Min 2440 Min 2550 Min 2720 Min 3090 Min
DR2 3–2 945–1300 1190–1470 1280–1580 1340–1580 1450–1900 1530–1930 1620–2000 1730–2120 2080–2460
Copyright © 1996 General Motors Corp.
DR1 2–1 660–760 700–960 740–1080 775–1025 910–1100 930–1130 960–1200 1040–1280 1200–1590
4–3* 150–390 150–390 250–675 20–675 225–640 425–780 555–855 20–590 570–950
Closed DR4 3–2* 370–470 370–470 390–615 355–640 445–700 510–780 550–840 350–700 600–815
2–1 20–300 20–300 20–470 20–535 205–530 285–550 365–550 20–535 345–550
Full or DR4 3–4 1500–1580 1500–1580 1500–1580 1500–1580 1500–1580 1320–1400 — 1645–1725 1645–1725 1645–1725 1645–1725
Copyright © 1996 General Motors Corp.
DR3 4–3 1640–1955 1640–1955 1640–1955 1640–1955 1640–1955 1640–1955 — 1825–2145 1825–2145 1825–2145 1825–2145
DR2 3–2 1000–1310 1000–1310 1000–1310 1000–1310 1000–1310 1000–1310 1000–1310 1215–1495 1215–1495 1215–1495 1215–1495
DR1 2–1 640–730 640–730 640–730 640–730 640–730 640–730 640–730 715–810 715–810 715–810 715–810
4–3* 990–1360 740–1025 740–1025 740–1025 740–1025 805–1240 — 805–1240 645–805 805–1240 805–1240
3–2* 620–725 635–740 635–740 635–740 635–740 400–640 620–725 670–770 575–700 670–770 670–770
Closed DR4
LU–Conv 770–970 520–720 520–720 755–955 770–970 670–770 770–970 530–730 945–1145 530–730 475–675
2–1 20–320 20–320 + 20–320 20–320 20–225 20–320 20–380 20–225 + 20–225
PREVENTIVE MAINTENANCE
R 2–3 970–1050 970–1050 970–1050 1085–1165 1085–1165 970–1050 970–1050 970–1050 1135–1215
DR3
4 3C–3L 1230–1390 1230–1390 1230–1390 790–950 ++ 790–950 ++ 1230–1390 1230–1390 1230–1390 790–950 ++
Copyright © 1996 General Motors Corp.
o DR4 3–4 1645–1725 1645–1725 1645–1725 1645–1725 1645–1725 1645–1725 1645–1725 — 1715–1795
Full
r
DR3 4–3 1825–2145 1825–2145 1825–2145 1825–2145 1825–2145 1825–2145 1905–2225 — 1825–2145
DR2 3–2 1215–1495 1215–1495 1215–1495 1215–1495 1215–1495 1215–1495 1255–1530 1215–1495 1215–1495
DR1 2–1 715–810 715–810 715–810 715–810 715–810 715–810 730–830 715–810 715–810
4–3* 805–1240 805–1240 645–805 805–1240 645–805 805–1240 805–1240 — 690–900
3–2* 670–770 670–770 575–700 670–770 615–740 670–770 670–770 670–770 635–755
Closed DR4
LU–Conv 945–1175 945–1175 180–380 525–725 670–870 530–730 530–730 945–1175 670–870
2–1 20–380 300–410 20–225 20–380 20–225 300–410 300–410 20–380 20–305
4 3C–3L 1395–1555 1395–1555 1500–1660 1500–1660 1500–1660 1230–1390 1275–1435 790–950 ++ 1220–1380 1230–1390 1500–1660
Full or DR4 3–4 1725–1870 1725–1870 1760–1840 1760–1840 1760–1840 1760–1840 1760–1840 1510–1890 1505–1585 1645–1725 —
DR3 4–3 1905–2225 1905–2225 1905–2225 1905–2225 1905–2225 1905–2225 1905–2225 1905–2225 1905–2225 1905–2225 —
DR2 3–2 1255–1530 1255–1530 1255–1530 1255–1530 1225–1530 1225–1530 1255–1530 1290–1560 1255–1530 1255–1530 1225–1530
DR1 2–1 730–830 730–830 730–830 730–830 730–830 730–830 730–830 730–830 730–830 730–830 730–830
4–3* 675–1295 675–1295 970–1390 970–1390 970–1390 970–1390 1340–1645 1020–1430 995–1360 805–1240 —
3–2* 520–715 520–715 660–765 660–765 660–765 660–765 660–765 730–860 630–735 670–770 660–775
Closed DR4
LU–Conv 1180–1380 355–555 605–805 605–805 1275–1475 530–730 475–675 520–720 935–1135 945–1145 1275–1475
2–1 20–245 20–245 + 20–400 20–400 20–400 20–320 110–410 175–330 300–410 20–400
Engine Governed
Speed — rpm 2700 2800
Description Red Mod/
Red Mod/ Red Mod/ Fixed LU/ Red Mod/ Red Mod/
Red Mod/ Std Mod/ Std Mod/ Mod LU/ Red Mod/ Mod LU/ Red Mod/ LU 3–4/ Mod LU/ Std Mod/ Fixed LU/ Red Mod/
Mod LU/ Mod LU/ Fixed LU/ LU 3–4/ Mod LU/ LU 3–4 Mod LU/ 2GS LU 3–4/ Fixed LU/ LU 3–4/ Fixed LU/
LU 3–4 LU 3–4 LU 3–4 2GS LU 3–4 (Engessa) LU 2–4 (Trolley) (Gillig) LU 2–4 (Special) LU 3-4
MT Parts Book Group DG AE AM AW BF BN CT CK BF DH DZ EJ
Throttle
PREVENTIVE MAINTENANCE
Position Range Shift Transmission Output Speed (rpm) at Start of Shift
D DR2 1–2 620–660 690–750 690–750 + 700–740 680–720 700–740 + 700–740 700–740 500–545 700–740
Copyright © 1996 General Motors Corp.
R 2–3 1050–1130 1220–1300 1220–1300 1220–1300 1220–1300 1150–1250 1280–1360 1220–1300 1220–1300 1280–1360 1220– 1220–1300
4 DR3 1300
or 3C–3L 1360–1520 1395–1555 1395–1555 1500–1660 1500–1660 1560–1760 960–1120 1500–1660 1500–1660 960–1120 1500– 1500–1660
++ ++ 1660
DR4 3–4 1865–1940 1970–2050 1970–2050 1970–2050 1970–2050 1920–2000 1970–2050 1970–2050 1970–2050 1970–2050 1970– 1970–2050
Full
2050
DR3 4–3 1985–2305 2065–2390 2065–2390 2065–2390 2065–2390 2025–2445 2065–2390 2065–2390 2065–2390 2065–2390 2065– 2065–2390
2390
DR2 3–2 1335–1600 1390–1650 1390–1650 1390–1650 1390–1650 1250–1660 1390–1650 1375–1640 1390–1650 1390–1650 1390– 1390–1650
1650
DR1 2–1 755–915 745–975 745–975 745–975 745–975 790–980 745–975 745–975 745–975 745–975 745–975 745–975
4–3* 1105–1490 800–1340 800–1340 1285–1635 1285–1635 960–1320 1285–1635 800–1340 1285–1635 800–1340 1285– 1285–1635
1635
3–2* 675–780 600–810 600–810 735–890 735–890 730–940 775–1000 600–810 735–890 685–810 735–890 735–890
Closed DR4
LU–Conv 605–805 355–555 1150–1350 605–805 605–805 705–905 590–790 1290–1490 1010–1225 765–965 1310– 1150–1350
1475
2–1 265–490 270–540 270–540 + 425–595 310–505 425–595 + 425–595 270–540 300–410 425–595
Lockup signal pressure — 140 psi (965 kPa) minimum after C–L shift.
Table 3–5. MT 643 Shift Points with Modulated or Fixed Lockup (cont’d)
3–18
or
Full DR4 3–4 2085–2230 2085–2230 2120–2200 2120–2200 2085–2230 2160–2300 2160–2300 2160–2300
DR3 4–3 2360–2820 2360–2820 2360–2820 2360–2820 2360–2820 2375–2905 2375–2905 2375–2905
DR2 3–2 1365–1770 1365–1770 1365–1770 1365–1770 1365–1770 1400–1800 1400–1800 1400–1800
DR1 2–1 865–1055 865–1055 865–1055 865–1055 865–1055 900–1045 900–1045 900–1045
4–3* 595–1035 595–1035 955–1360 955–1360 595–1035 690–1115 690–1115 980–1540
3–2* 525–795 525–795 685–890 685–890 600–850 555–795 555–795 665–910
Closed DR4
LU–Conv 330–530 1260–1510 690–890 690–890 510–710 400–600 1340–1590 705–905
2–1 20–320 20–320 255–465 + 20–320 20–320 20–320 265–485
PREVENTIVE MAINTENANCE
R 2–3 1420–1565 1420–1565 1420–1565 1445–1590 1445–1590 1445–1590 1485–1625 1530–1670 1610–1720
DR3
4 3C–3L 1895–2095 1895–2095 1895–2095 2055–2255 2040–2240 2055–2255 1835–2040 2105–2305 1890–2090
Copyright © 1996 General Motors Corp.
Full or DR4 3–4 2300–2445 2300–2445 2300–2445 2445–2590 2445–2590 2445–2590 2575–2720 2590–2735 2720–2865
DR3 4–3 2525–3070 2525–3070 2525–3070 2675–3130 2675–3130 2675–3130 3055–3490 3055–3490 3055–3490
DR2 3–2 1525–1920 1525–1920 1525–1920 1575–2000 1575–2000 1575–2000 2010–2395 1960–2325 2010–2395
DR1 2–1 950–1145 950–1145 950–1145 980–1165 980–1165 980–1165 1155–1565 1135–1425 1155–1565
4–3* 830–1375 830–1375 1085–1735 415–980 1025–1580 415–980 1085–1735 870–1330 1245–1965
3–2* 635–920 635–920 705–1000 375–775 660–965 375–775 705–1000 460–895 810–1050
Closed DR4
LU–Conv 385–585 1635–1885 870–1045 375–575 740–940 1805–2005 1155–1435 410–610 1175–1375
2–1 20–320 20–320 305–615 20–320 215–570 20–320 305–615 20–370 315–630
Engine Governed Speed — rpm 2200 2400 2600 2800 3000 3200 3400 3600 4000
DR2 3–2 945–1300 1140–1450 1240–1540 1400–1700 1530–1990 1600–1860 1670–2030 1900–2200 1990–2370
DR2 2–1 660–760 700–960 740–1080 775–1025 910–1100 930–1130 960–1200 1040–1290 1200–1590
DR1 1–Low — 320–425 320–425 300–400 365–510 365–510 300–550 300–550 300–550
4–3* 150–390 150–390 250–675 20–675 225–640 425–780 555–855 20–590 570–950
DR4 3–2* 370–470 370–470 390–615 355–640 445–700 510–780 550–840 350–700 600–815
Closed
2–1 20–300 20–300 20–470 20–535 205–530 285–550 365–550 20–535 345–550
DR4–DR1 1–Low Check for Manual Shift Function Only
PREVENTIVE MAINTENANCE
DR1–DR2 1–2 Check for Manual Shift Function Only
2–3 530–570 460–500 530–570 530–570 550–590 550–590 550–590 550–590 550–590 550–590
D DR4
Copyright © 1996 General Motors Corp.
R 3–4 850–930 730–810 850–930 850–930 970–1050 970–1050 970–1050 970–1050 970–1050 970–1050
5 Conv–LU 1045–1205 1160–1320 1060–1220 1045–1205 1265–1425 1290–1450 1290–1450 1290–1450 1265–1425 1250–1410
Full or DR5
4–5 1540–1620 1360–1440 1540–1620 1540–1620 1645–1725 1645–1725 1645–1725 1645–1725 1645–1725 1645–1725
DR4 5–4 1610–1920 1610–1920 1620–1950 1610–1920 1780–2135 1780–2135 1780–2135 1930–2275 1780–2135 1740–2060
DR3 4–3 1045–1330 1030–1320 980–1320 1045–1330 1240–1495 1240–1495 1240–1495 1185–1465 1240–1495 1115–1415
DR2 3–2 295–340 190–355 340–400 295–340 325–390 325–390 325–390 370–430 325–390 340–390
5–4* 790–1180 665–890 750–1050 790–1180 970–1340 695–1010 695–1010 520–765 970–1340 795–1210
4–3* 540–700 450–640 610–730 540–700 630–775 525–685 525–685 440–610 630–775 650–755
DR5
Closed LU–Conv 810–1010 545–665 840–1040 425–625 580–780 1075–1275 325–525 325–525 1070–1270 545–745
3–2 200–410 100–335 30–330 240–410 300–430 160–360 160–360 160–360 300–430 20–370
DR5–DR1 2–1 Check for Manual Shift Function Only
PREVENTIVE MAINTENANCE
2–3 690–750 690–750 700–740 700–740 690–750 640–700 655–710 655–710
D DR4
R 3–4 1220–1300 1220–1300 1220–1300 1220–1300 1220–1300 1240–1380 1255–1400 1255–1400
Copyright © 1996 General Motors Corp.
Full or DR5
4–5 2300–2445 2300–2445 2445–2590 2445–2590 2590–2735 2575–2720 2720–2865
DR4 5–4 2540–3055 2540–3055 2815–3260 2815–3260 3055–3490 3055–3490 3055–3490
DR3 4–3 1525–1920 1525–1920 1710–2125 1710–2125 1960–2325 2010–2395 2010–2395
DR2 3–2 300–550 300–550 300–550 300–550 300–550 300–550 455–565
5–4* 830–1375 1085–1735 415–980 415–980 870–1330 1085–1735 1245–1965
4–3* 635–920 705–1000 375–775 375–775 460–895 705–1000 810–1050
DR5
Closed LU–Conv 385–585 840–1040 350–600 1805–2005 350–600 1155–1435 1175–1375
3–2 20–320 305–615 20–320 20–320 20–370 305–615 315–630
DR5–DR1 2–1 Check for Manual Shift Function Only
* Refer to the current Parts Catalog PC1316EN for the correct hold regulator spring for each assembly.
No adjustments are possible, but the internal valve may be removed and cleaned to ensure free operation. Refer to the current Parts Catalog PC1316EN
for kit part number with instructions.
3–14. OIL COOLER 2. Stall speed is the maximum engine rpm attain-
able when the engine is at full throttle and
Transmission operation at abnormally high tempera- when the torque converter turbine is not mov-
tures can cause clogging of the oil cooler as well as ing, or “stalled.”
transmission failure. Clean the oil cooler system thor-
oughly after each major or minor rebuild. Failure to 3. During a stall test, compare the actual engine
clean the cooler system may cause poor performance, speed at full throttle stall with established vehi-
overheating, and transmission damage. Recommenda- cle manufacturer's specifications.
tions for cleaning or flushing the oil cooler are in the
vehicle service manual.
NOTE:
Engine stall point data can be obtained from the ve-
3–15. TRANSMISSION STALL TEST hicle manufacturer or from the equipment dealer or
distributor.
a. Purpose
1. Stall testing is performed to determine whether 4. Stall tests are used as troubleshooting proce-
a power complaint is due to an engine problem dures only — do not perform them as general
or a transmission malfunction. checks or maintenance.
3. An extremely low stall speed, such as 33 per- 4. Coat all exposed, unpainted surfaces with pre-
cent of the specified engine stall rpm, during servative grease such as petrolatum (MIL-C-
which the engine does not smoke, could indi- 11796, Class 2).
cate a freewheeling torque converter stator. 5. If additional storage time is required, repeat
Steps (2) through (4) at yearly intervals.
4. If the engine stall speed conforms to specifica-
tion, but the transmission fluid overheats, refer
d. Storage, One Year — With Transmission Fluid
to the cool-down check. If the fluid does not
(Normally in a Vehicle Chassis)
cool during the two-minute cool-down check, a
stuck torque converter stator could be indi- 1. Drain the transmission fluid and replace the fil-
cated. ter element(s) if required.
OUTPUT SHAFT
NOTE: BEARING H00008.01
The dust shield is not used on models that have an
output retarder. Figure 3–11. Removing Output Shaft Rear
Bearing — in Vehicle
2. For MTB Series transmissions, install gover- g. Installation of Output Flange — MT 640, 643
nor and speedometer drive gear 25 (Foldout
18,A) and spacer 26 onto the output shaft. 1. Install the output flange on the output shaft.
3. A snapring was used on the front side of the 2. Retain the output flange with a new 1⁄2–20 x
output bearing in earlier rear covers to retain 11⁄2 inch Type BH bolt and washer. Do not use
the bearing in its proper location. Be sure the the earlier style bolt. Refer to the current Parts
snapring is firmly seated in its groove. Catalog PC1316EN and Figure 3–13.
1 ⁄2 in.
EARLIER BOLT
P/N 23014159
STANDARD (TYPE AA PATCH) SAE GRADE 8
3⁄4 in. HEXAGON HEAD
SIX (6) GRADE ID MARKINGS*
CONSTANT UNDERHEAD FILLET**
1 ⁄ 2 in.
LATER BOLT
P/N 29510838
NON-STANDARD (TYPE BH PATCH) SAE GRADE 8
OFFSET, 13⁄ 16 in. HEXAGON HEAD
FIVE (5) GRADE ID MARKINGS***
VARYING UNDERHEAD FILLET**
V01301
a. Inspect for transmission fluid leakage. Visually a. High Speed Mode Pressure Function Test
inspect all splitlines, connections, valve bodies, fluid
level indicator tube, and plugs and hoses at the trans- 1. Connect a high-pressure test hose, minimum
mission and cooler. Fluid leakage at splitlines may be 300 psi (2068 kPa), from the main pressure tap
caused by loose mounting bolts or defective gaskets. on the transmission main case (Figure 3–15) to
Tighten all bolts, plugs, and connections where leak- the governor pressure tap on the retarder valve
age is found. body (Figure 3–17).
b. Check to ensure the modulator control cable and 2. Connect a 0–150 psi (0–1000 kPa) pressure
linkage are free. Check the shift linkage for proper op- gauge to the retarder charging pressure tap
eration. (Figure 3–17).
4. Shift the transmission to N (Neutral). Set the c. Increasing Pump Volume. If after verifying and
engine speed at 1000 ± 20 rpm. observing minimum idle specifications, and utilizing
the troubleshooting charts, main pressure remains
5. Apply full retarder air pressure, 85 psi (586 low, consult SIL 5-TR-83 for additional procedures
kPa), at the retarder control air tap. required to increase pump volume.
NOTE
MT 650,653 external connections
and pressure taps are in identical
locations TO OIL CONVERTER DRIVEN
COOLER PTO LOCATION
REVERSE SIGNAL
PRESSURE TAP
OIL DRAIN
PLUG
NEUTRAL START
SWITCH LOCATION
GOVERNOR MODULATOR
PRESSURE TAP CONTROL OPENING
H00119
RETARDER CLUTCH
PRESSURE
TO FILTER
FROM FILTER
H00136
Figure 3–16. MTB Retarder Check Points — External Connections, Right-Front View
RETARDER CONTROL
AIR PRESSURE
RETARDER
CHARGING
PRESSURE
GOVERNOR PRESSURE
H00009.1
Figure 3–17. MTB Retarder Check Points — External Connections, Right-Rear View
* Clutch slippage may be recognized by alternate racing and loading of the engine, which is at times accompanied by a violent chatter.
NOTES
This section provides general information required for • Dial indicator set
overhaul, cleaning, and inspection, and general assem-
bly procedures for the transmission. It provides illus- • A three-leg lifting sling with 90 degree angle
trations and explanations for the fabrication of impro- attaching plates — 1⁄2 ton (500 kg) capacity
vised tooling. A listing and illustration of special tools • Hoist — 1⁄2 ton (500 kg) capacity
are included for your convenience.
CAUTION:
4–2. TOOLS AND EQUIPMENT
Caustic cleaning compounds will damage some
transmission parts. Use only mineral spirits.
a. Improvised Tools and Equipment
• A retarder piston spring compressor, consisting
• Container of mineral spirits for cleaning parts
of:
— Steel compressor bar (1) — 1 x 11⁄2 x 18 • A 100 inch pound (15 Newton meter) torque
inches (25 x 38 x 460 mm) wrench
— Threaded rods (2) — 1⁄2-13 x 10 inches • A 100 foot pound (150 Newton meter) torque
— Plain nuts (6) — 1⁄2-13 inch wrench
— Flat washers (4) — 1⁄2 inch
• A 1000 foot pound (1500 Newton meter)
— Compressor ring (1): 5 inches (127 mm) OD
torque wrench
x 4.5 inches (114 mm) ID x 1.5 inch (38
mm) wide. Make a cutout in the side to • Heating equipment (for heating bearings or
permit access with snapring pliers (refer to other interference-fit parts to aid assembly)
Figure 6–96)
• Output shaft lifting fixture (Figure 4–1). The • A press for disassembly and assembly of
materials and dimensions may be changed to spring-loaded clutches, valves, and interfer-
meet specified requirements. ence-fit parts
• Work table — 1500 pound (700 kg) capacity • Clean, lint-free shop cloths (do not use waste)
(Figure 4–2)
• Boxes, receptacles for parts
b. Special Tools. Special tools are listed in Table 4– • Supply of wood blocks
1 and are illustrated in Figures 4–3, 4–4, 4–5, 4–6, and
4–7. These special tools are available from: • Oil-soluble, non-fibrous grease (petrolatum)
* We believe these sources and their tools to be reliable. There may be additional manufacturers of such tools. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or tools from these firms, or for any such items which may be available from other sources.
48 in.
(120 cm)
78 in.
(200 cm) TRANSMISSION FLUID DRAIN
STEEL TOP
TROUGH
24 in. 16-GAUGE SHEET STEEL
(60 cm) 11⁄2 in. (35 mm) DEEP
11⁄2 in. (35 mm) WIDE
1 2 3 4
5 6 7 8
11
9 10 12
13 14 15 16
17 18 19 20
V00277
21 22
23
24
25 26 27
28
29 31 32
30
34
33
35
38
37
36
V03280
39
41
40
45
42 46
44
43
50
51
51
49
48
47
52
53
55
54
56 57
58 59 60
V03281
63
62 64
61
66
65 67
70
68
69
71
73
72
74
V03282
75
78
76
77
80 81 82
79
85
83
84 86
90
87
88
89
V03283
** NI — Not illustrated.
CAUTION:
CAUTION: Do not attempt to correct the governor driven
Distortions and imperfections in the hydraulic gear with the use of a soft stone. If the governor
circuit tracks will cause severe fluid leakage lead- driven gear is scuffed, nicked, burred, or has bro-
ing to transmission failure. ken teeth, replace the governor assembly.
GOVERNOR
MODULATOR
EXHAUST
EXHAUST
LOW CLUTCH
LOCKUP
FIRST SIGNAL
CLUTCH
MAIN
FIRST CLUTCH
TRIMMER DRIVE 3
GOVERNOR FORWARD
FEED CLUTCH
GOVERNOR DRIVE 2
MAIN
CHECK VALVE
EXHAUST DRIVE 3
DRIVE 2
FIRST CLUTCH
REVERSE
MODULATOR
SECOND TO
THIRD SIGNAL
MAIN MAIN FIRST TO FORWARD DRIVE 1
GOVERNOR SECOND SIGNAL
L00354
1. Inspect gears for scuffed, nicked, burred, or 2. If the turbine shaft is cracked or broken (indi-
broken teeth. If the defect cannot be removed cating the transmission was exposed to high
with a soft honing stone, replace the gear. torsional loads), magnaflux the main shaft and
closely inspect the lube oil holes.
2. Inspect gear teeth for wear that may have de-
stroyed the original tooth shape. If this condi- k. Inspecting Splined Parts. Inspect splined parts
tion is found, replace the gear. for stripped, twisted, chipped, or burred splines.
Remove burrs with a soft stone. Replace the part if
3. Inspect the thrust face of gears for scores,
other defects are found. Spline wear is not considered
scratches, and burrs. Remove such defects with
a soft honing stone. If the scratches and scores detrimental except where it affects tightness of fit of
cannot be removed with a soft stone, replace the splined parts.
the gear.
l. Inspecting Threaded Parts. Inspect parts for
j. Inspecting Shafts burred or damaged threads. Remove burrs with a soft
honing stone or fine file. Clean up damage on small
1. Inspect shafts closely for cracks. Cracks origi- threads by chasing threads with a used die. Clean up
nating at the lube oil holes may appear just be- damage on large threads with a fine file. Replace the
low the surface. part if damage cannot be cleaned up.
1. Check the snapring groove in the main housing 2. Install a retaining strap to hold the converter in
for debris, nicks, burrs, or shavings prior to in- place as soon as the transmission is clear of its
stalling the snapring. A burr or shaving can be mountings.
raised when the snapring is removed.
d. Clean Transmission. Clean the exterior of the
2. Install the snapring with the ends at the twelve transmission. If steam cleaning is used, disassemble
o’clock position to avoid scratches in the hy- and dry the transmission immediately because
draulic passages at the bottom of the main condensation from the steam could cause rust in the
housing bore. transmission.
NOTES
CAUTION:
The torque converter must be held into the trans-
mission by a retaining strap as shown in Figure
1–2. Be sure the retainer is in place before lifting
the transmission.
1. Remove the six bolts that retain the PTO cover. WASHER (6) J 3289-20 H00010.01
Remove the cover and gasket. Figure 5–1. Transmission Installed in Holding Fixture
NOTE:
For MT 650, 653 proceed to Paragraph 5–7.
COVER STRAP
PAN GASKET
TUBE
ADAPTER
H00092.01
H03285
Figure 5–6. Removing Oil Canister (Heavy-Duty
Configuration) and Modulated Lockup Valve Figure 5–7. Removing Tube Adapter — MT 640, 643
SHIFT
SELECTOR
VALVE
FIRST
TRIMMER DETENT
SPRING
DRIVE 1 CONTROL
VALVE
ASSEMBLY
SCREEN
LOW AND LOCATION
FIRST FEED
Figure 5–9. Removing External Tubes from Valve Figure 5–10. Removing Low Shift Valve Oil Transfer
Bodies — MT 650, 653 Plate — MT 650, 653
CAUTION:
J 24473
The pump and front support assembly is fitted to
the transmission housing with very little clear- OIL PUMP AND CONVERTER
FRONT SUPPORT GROUND
ance. It may bind in the housing if the housing is ASSEMBLY SLEEVE
cold. Heat the housing slightly, if necessary. DO TRANSMISSION
NOT USE a torch to heat the housing. A sun lamp HOUSING
or a current of warm air will be sufficient. If the
pump and support assembly starts upward and
then binds, tap it downward and lift again.
CENTER
FOURTH CLUTCH SUPPORT SNAPRING
ASSEMBLY ASSEMBLY
THRUST BEARING
RACE ASSEMBLY
H00126.01
FOURTH CLUTCH
PRESSURE PORT
J 24455
RETAINER
RING TANG (4)
H00127.01
H00097.01
TRANSMISSION
HOUSING
Figure 5–18. Removing Gear Unit Assembly
GOVERNOR ASSEMBLY
SECOND CLUTCH
SNAPRING
SPEEDOMETER DRIVEN FIRST CLUTCH
GEAR LOCATION SNAPRING
SECOND CLUTCH
PLATES
REAR PLANETARY
RING GEAR
REAR COVER
H00096
5–11. REMOVAL OF GEAR UNIT, Figure 5–19. Removing Second Clutch Snapring
1. Remove the rear planetary ring gear and hub RING GEAR
assembly from the transmission (Figure 5–21).
If parts replacement is necessary, remove
snapring 7 (Foldout 11,A) and separate ring BACKPLATE
gear 5 from ring gear hub 6.
NOTE:
MT 650 model transmissions S/N 49996 through
55402 may include a spacer between the output
flange and the output shaft rear bearing. If the let-
ter “F” is not stamped after the transmission serial H00098.01
number on the nameplate, spacer P/N 6883908 Figure 5–20. Removing Backplate, First Clutch Plates,
should be installed.This spacer should be used at re- and Rear Planetary Ring Gear — MT 640, 643
assembly, except when the output shaft is replaced.
tarder control valve assembly. Figure 5–23. Removing Governor Cover — MTB 643,
653
REAR
COVER
GOVERNOR
COVER
BOLT (4)
5/16-18 x 11/16 in.
REAR COVER
GASKET
ADAPTER
HOUSING
TRANSMISSION
HOUSING
H00134.01 H00112
Figure 5–22. Removing Governor Cover — MT 650, 653 Figure 5–24. Removing Rear Cover — MT 640, 643
SPEEDOMETER
DRIVE GEAR
LIFTING TOOL
GOVERNOR
DRIVE GEAR
OUTPUT SHAFT
REAR COVER
ASSEMBLY
OUTPUT SHAFT
PIN
REAR COVER
ASSEMBLY
H00114.01
GASKET
H00113.01 OUTPUT
SHAFT
Figure 5–25. Removing Rear Cover Assembly and RETARDER
HOUSING
Output Shaft — MT 650, 653
SEALRING (14)
ADAPTER
HOUSING
LOW PLANETARY
CARRIER
ASSEMBLY H00168.01
H00080.01
THRUST ADAPTER
WASHER HOUSING
LOW CLUTCH
LOW PLANETARY PLATES (11)
CARRIER
ASSEMBLY LOW
PLANETARY
SUN GEAR
THRUST
WASHER ADAPTER HOUSING
GASKET
TRANSMISSION
HOUSING H00081
H00116.01
Figure 5–30. Removing Low Planetary Carrier Figure 5–31. Removing Adapter
Assembly — MT 650, 653 Housing — MT 650, 653
NOTES
NOTE:
Before disassembling the converter assembly, check H00082.01
the amount of converter end play.
Figure 6–1. Installing Torque Converter End Play Gauge
LOCKUP
CLUTCH
PISTON
BEARING CONVERTER
RACE SEALRING STATOR
BEARING ASSEMBLY
TORQUE
CONVERTER LOCKUP
COVER CLUTCH
PLATE
LOCKUP
CLUTCH
BACKPLATE
Figure 6–3. Removing (or Installing) Torque Figure 6–4. Removing (or Installing) Torque
Converter Cover Assembly Converter Turbine Assembly
CAUTION:
NOTE: Apply the load only to the outer shell of the bear-
If it is necessary to rebuild stator assembly 24, re- ing during installation (Figure 6–7).
move needle bearing assembly 31 before starting
the rebuild procedure.
STATOR
ASSEMBLY J 8092
SEALRING
BEARING
J 23549
ROLLER
RACE BEARING
ASSEMBLY
LOCKSTRIP
BOLT (8), 1/4-20 x 5/8 in. H00118.01
STATOR
H00349.01
BEARING
A A
0.035 in. (0.89 mm) B
0.025 in. (0.64 mm) CAM
STATOR VIEW AT B -B
Assembly load to be DEEP POCKET
applied in this area
on outer shell only Assemble with
cam pockets in
position shown DIRECTION OF
FREEWHEEL
ENLARGED VIEW ROTATION
OF CROSS-SECTION
ENLARGED VIEW
SECTION A-A L00294.01
9. Inspect the stator and cam for cracks, and the BOLT, 5⁄8-11 x 31⁄4 in.
rivet holes for burrs or swelling. Deburr as re-
quired. If cam or stator is cracked or distorted, J 29521-2
TOP PLATE
replace the stator assembly.
11. Align the six rivet holes and insert six new 1⁄4 x Figure 6–9. Removing Stator Rivets
1.94 inch rivets into the stator assembly from
13. Place the stator assembly on fixture J 25587-1
the rear to the front of the stator (Figure 6–10).
(Figure 6–10). Install staking tool J 29121-1
into the fixture head and tighten the thumb
12. Place the stator assembly on base plate
screw finger tight.
J 29521-1 (Figure 6–10). Make sure the rivet
heads rest on the base plate, between the clear- 14. Apply approximately 8000 pounds (3629 kg)
ance holes. Install top plate J 29521-2 and the load to swage each rivet head. The amount of
5⁄8-11 x 31⁄4 retaining bolt. Strike the top plate force to apply will vary, depending on the con-
with a rubber mallet to seat the components. dition of the swaging tool and the press equip-
Tighten the retaining bolt to 60 lb ft (81 N·m). ment being used.
BOLT, CONVERTER
1⁄ 2-13 x 31⁄ 2 in. TURBINE
;;
;;;;
;;;;;
J 25587-1 GUIDE PLATE LOCKUP CLUTCH
J 29375-2 DRIVE HUB
RIVET PUNCH
J 29121-1
;;
;;; ;;
;;;
;; ;;
CONVERTER BOLT, 1⁄ 2-13 x 31⁄ 2 in.
TURBINE
LOCKUP CLUTCH GUIDE PLATE
DRIVE HUB J 29375-2
;; ;
;;
;; ;;
RIVET (8),
5⁄16 x 11⁄16 in.
;; ;;
;;;;;;
;;;;;
DRILL GUIDE
J 29375-5
GUIDE PLATE
J 29375-2
BASE PLATE
J 29375-1
V03290
;;
;;;
V03279
;;;;;
;; ;;
; ;;;;
;;;
; ;;
;
RIVET (8), STAKING TOOL
CONVERTER 5⁄16
x 11⁄16 in.
; ;
TURBINE HYDRAULIC J 29375-3
PRESS CONVERTER
LOCKUP CLUTCH TURBINE
DRIVE HUB
;;
;;;;;;
GUIDE PLATE
J 29375-2 PIN REMOVER
J 29375-4
V03291
13. Assemble the new and reusable turbine parts. 19. Swage the first rivet. Rotate 180 degrees from
Align the punch marks on the turbine and hub. the first rivet and swage the second rivet. Ro-
Use eight new rivets to ensure proper indexing. tate 90 degrees and swage the third rivet. Con-
tinue in an alternating pattern until all eight
14. Install the eight new rivets through the turbine rivets have been swaged.
and turbine hub (Figure 6–14).
20. Remove staking tool, retaining bolt, guide
15. Assemble base plate J 29375-1 with the solid plate, and base plate.
side of the plate against the rivet heads (Figure
21. Using a rotating type static balance, balance
6–14).
each rebuilt turbine assembly to within 0.50
16. Place guide plate J 29375-2 on top of the as- oz. in. (360 N·mm), with respect to the turbine
sembled components. Centrally locate the riv- shaft spline diameter, by welding weights to
ets in the holes of the guide plate. the shroud.
;;
bearing race 44 (lugged side first), and needle (Figure 6–4).
bearing 35 into converter pump hub 48. Install
sealring 49 into the groove of hub 48. ROLLER
;;
0.803 in. (20.39 mm)
0.08 in.
(2.03 mm)
0.04 in. (1.01 mm) R
MAX
25°– 50°
0.03 in. BEARING
(0.76 mm) AND RACE
ENLARGED VIEW STATOR AND
(4 x SIZE) V03292
CAM ASSEMBLY
H00348.01
Figure 6–16. Rework of Converter Pump Hub for
Wide Bearing Configuration Figure 6–17. Installing Freewheel Roller Race
THRUST WASHER
NOTE: RIVET This flap may point up
(as shown) or down
Install the same spacer 19 removed in Paragraph 6–
CURRENT SPRING
3b(9) only if the end play reading taken before dis- STATOR CAM
assembly was satisfactory, and if no parts affecting
end play are being replaced (refer to Paragraph 4–
11). Install the spacer (when used) into the hub of
converter turbine 20 before Step (11).
Roller to be installed in
small end of cam pocket
11. Install bearing race 18, outer lip upward, into
the hub of turbine assembly 20. Grease and in- CURRENT CONFIGURATION
stall bearing 17 onto the bearing race. THRUST WASHER
RIVET
12. Install sealring 13 onto lockup clutch backplate
14. Position the color identified edge of the STATOR CAM
seal outward, toward the converter pump stud
holes. Install the backplate onto torque con-
verter pump 42. Align the balance mark on the
backplate with the balance mark on the con-
verter pump.
ROLLER
13. Install lockup clutch plate 12 to backplate 14. SPRING
14. If converter cover bushing 7 in the converter FORMER CONFIGURATION V03293
hub was removed, use installer J 24648 to in-
16.
CAUTION:
The lockup clutch will not release if the piston is
not engaged with the piston guide pins.
H00100.01
19. Install six rubber spacers 4 (earlier models use 23. Using both hands as shown in Figure 6–2, lift
retainers 3 and spacers 4) onto each of the six the center screw as far as possible. Record the
drive studs on converter cover 6. dial indicator reading (Dimension B). Proper
end play is any reading between 0.001 and
0.025 inch (0.03 and 0.64 mm). Select the
NOTE: proper size spacer 19 from the following chart.
The end play check in Steps (20) through (23) veri-
Dimension B Use
fies that proper end play remains after rebuild. The Color
Inch / (mm) Part No.
check is necessary if spacer 19 was not installed at
buildup, and is recommended even if spacer 19 was Less than 0.014 (0.36) Use no spacer
installed. Omit Steps (24) through (26) if the end 0.014–0.016 (0.36–0.41) 6837429 Gold
play reading is satisfactory.
0.029–0.031 (0.74–0.79) 6837430 Silver
0.041–0.043 (1.04–1.09) 6837431 Plain
20. Support the converter assembly on the con- 0.059–0.061 (1.50–1.55) 6837432 Black
verter cover, pump hub upward. Place con-
verter end play gauge J 24470 into the 0.074–0.076 (1.88–1.93) 6837433 Copper
converter pump hub (Figure 6–1).
24. Remove only those items necessary to install
21. Hold the center screw of the gauge and tighten the spacer by following Paragraph 6–3b(2),
the nut until the gauge is securely retained in (3), and (9).
the converter turbine hub. Do not overtighten. 25. Install selected spacer 19 into the turbine hub.
26. Assemble the converter by following Paragraph
6–3f(11) through (18). The end play may be re-
PIN
PENCIL MARK ORIFICE checked as in Steps (20) through (23).
Figure 6–21. Compressing Modulator Valve Adjusting 1. Place valve assembly 1 on the work table,
Ring (Earlier Models) modulator valve body 47 upward.
6. Remove priority valve 4, spring 3, and stop 2. 13. Remove valve stop 79 and machined spacer 82.
Remove 1⁄4 inch (6.35 mm) check ball 49 (if
14. Remove relay valve springs 78 and 81. Re-
used). Note the location of the ball in the valve
move relay valves 77 and 80.
body before removal.
15. Mark adjusting ring 10 (models after S/N
66939) to indicate its position in relation to re-
NOTE:
tainer pin 12.
Refer to the current Parts Catalog PC1316EN for
servicing of check ball 49. 16. Compress adjusting ring 10 or spacer 8 (mod-
els prior to and including S/N 66939). Remove
pin 12, ring 10 or spacer 8, washer 9 (models
7. Place control valve body 50 on the work table,
after S/N 66939), valve stop 7, spring 6, and
flat side down.
valve 5.
17. Remove selector valve 11.
WARNING! 18. On models equipped with second range start
Trimmer valve cover 74 or 89 is spring-loaded (Foldout 13), remove retainer pin 18, washer
and must be restrained while the bolts are re- 88, valve stop 87, spring 86, valve 85, valve 84,
moved. and spring 83.
E E
A N
A
D D
SECTION E-E
M L
K J G SECTION B-B
I H
F F
B B
A
SECTION D-D
B O
C D E F SECTION F-F
SECTION A-A
L03318
18. Install valve stop 2, spring 3, and priority valve 4. Remove bolts 42 and 44, and washers 41 and
4 (open end first for later models), into Bore O 43. Separate regulating valve body 27, gasket
(Figure 6–23) in valve body 50. 26, and oil transfer plate 25.
5. Remove two bolts 40 and washers 39 that re-
19. Place separator plate 39 onto body 50 and align tain cover 38 to valve body 27. Remove cover
the bolt holes. The slot in the separator plate 38 and gasket 37. Do not remove orifice plug
must engage the flared end of pin 34. 32 unless part replacement is necessary.
20. Install the assembled modulator valve onto 6. Remove valve plug 36, springs 34 and 35, and
separator plate 39. Align the bolt holes. regulator valve 33.
6. Install spring 28, charging valve 29 (smaller 3. Remove oil pump sealring 2.
end first), sealring 30, and plug 31 into their 4. Remove roller bearing assembly 30 from the
bore in regulating valve body 27. Tighten the bore of converter ground sleeve 27 only if re-
plug to 50–70 lb ft (68–95 N·m). placement is necessary.
7. If governor orifice plug 32 was removed, in- 5. Remove twelve bolts 21 and two bolts 20 that
stall a new plug. Install the plug flush with or hold the oil pump and the front support to-
below the surface of the valve body. gether.
8. Install pressure regulator valve 33 (grooved 6. Separate front support assembly 22 from oil
end first), springs 34 and 35, and valve plug 36 pump body and gear assembly 4.
into their bore in regulating valve body 27.
7. If parts replacement is necessary, install valve
9. Align the slot in valve body cover 38 with the pin remover J 24412-2 onto the head of the
holes in the end of valve body 27. Install gas- converter pressure regulator valve guide pin
ket 37, cover 38, two 10 mm washers 39, and (Figure 6–25). Attach slide hammer J 6125-1
two M10 x 1.5 x 35 bolts 40. Tighten the bolts to the valve pin remover tool and remove guide
to 30–35 lb ft (39–48 N·m). pin 23, valve spring 24, and regulator valve 25.
Figure 6–24. Oil Pump and Front Support Assembly 11. If ground sleeve 27 is damaged and support 28
is serviceable, press the sleeve out of the sup-
port. Mark the position of the lube passage in
WARNING! the ground sleeve on the front support before
The main-pressure regulator valve spring is un- removal for correct installation of the new
der approximately 65 lbs (290 kN) compression. sleeve. If movement is detected, the parts must
be replaced as an assembly.
8. Attach the main-pressure regulator and lockup
spring compressor J 24459-A, and (for later 12. If replacement of plug 29 is necessary, remove
models) adapters J 24459-5, to front support the plug from the circumference of the support.
28 (Figures 6–26 and 6–27). For earlier models
(Figure 6–26), tighten the compressor screws 13. Remove oil pump gears 8 and 9 from oil pump
to remove all force from snaprings 10 and 14. body 7.
SPRING
J 6125-1
J 24412-2
GUIDE
CAUTION:
Do not attempt this rework procedure unless ad-
equate machining facilities are available.
NOTE: When mounted on DIA AS and NOTE: When mounted on DIA A features shall NOTE: Sleeve material specification: SAE 4100
SURFACE AZ features shall be within be within the total runout specified by B. series alloy tube, or 1141 and 1144, cold draw or
the total runout specified by BA. Must heat treated, RC20 min.
be clean and free from burrs.
L00303.01
H00087
Bushing joint
to be within Figure 6–30. Installing Oil Seal Into Oil Pump Body
this angle
60°
STRAIGHT EDGE OIL PUMP BODY
Bushing must
withstand
600 lbs in
direction
shown
DIA A Y REF
Press flush
to 0.010 in.
below surface
NOTE: When mounted on DIA B and SURFACE Y DIA B
REF DRIVE GEAR
the total runout of DIA A to be within 0.002 in. L00304.01 THICKNESS
GAUGE DRIVEN GEAR
H00088
NOTE: NOTE:
When ground sleeve 27 is replaced, the converter When replacing the main-pressure regulator valve
bearing assembly should also be replaced. For units or the front support assembly, refer to the current
prior to S/N 2410204975, refer to Paragraph 6–3e Parts Catalog PC1316EN for correct part selection.
and the current Parts Catalog PC1316EN for re- The current main-pressure regulator valves cannot
work of the converter pump hub to the “wide bear- be used with earlier front support assemblies, and
ing” configuration. earlier valves cannot be used with current front
support assemblies.
CAUTION:
10. Install main regulator valve 13 (smaller diame-
Do not use a full complement needle bearing in
transmissions which use calibrations of 3000 rpm ter first) and lockup valve 17 (longer land first)
and higher. into their proper bores in support assembly 22.
11. For earlier models (Figure 6–26), install com-
9. Place roller bearing 30 into ground sleeve 27, pressor tool J 24459-A. Place snaprings 10 and
with the numbered end of the bearing cup (the 14, plate side up, onto the compressor tool
outer bearing race) facing up. Using installer screws before compressing the springs. Com-
J 24457 and driver handle J 8092 for the caged press springs 12 and 16 and install the
needle bearing, or installer J 39362 and driver snaprings in their grooves. Remove the spring
handle J 8092 for the full complement needle compressor. Check that the plate sides of the
bearing, drive the bearing into the ground snaprings are facing upward in the grooves as
sleeve (Figure 6–34). If the special tools are installed. For later models, install springs 12
not available, drive the bearing (numbered end and 16, and valve stops 11 and 15, into their
of bearing cage up) into the ground sleeve until proper bores. Install main-pressure regulator
the bearing is 1.240–1.260 inch (31.50–32.00 and lockup valve spring compressor J 24459-A
mm) from the face of the hub (Figure 6–33). and adapters J 24459-5 on the front support
When installed, the bearing must withstand a (Figure 6–27). Compress the springs and stops
200 lb (91 kg) load without moving. to allow installation of cross pins 18 and 19.
12. If valve guide pin 23 was removed, replace it
with a new pin. Place the pin into valve guide
pin installer J 24458. Place spring 24 and con-
verter-pressure regulator valve 25 onto valve
guide pin 23. Install the valve guide pin and
components into the front support (Figure 6–
35). If valve pin installer J 24458 is not avail-
J 8092 able, install the guide pin and components to
extend 1.16–1.20 inches (29.5–30.5 mm)
above the finished surface (Figure 6–36).
OIL PUMP AND J 24457
FRONT SUPPORT OR J 39362
ASSEMBLY 13. Place oil pump body and gear assembly 4 on
the work table, front side down. Align the bolt
holes in front support assembly 22 with those
in assembly 4. Install two 5⁄16-18 x 13⁄4 inch
bolts 21 approximately 180 degrees apart.
Tighten the bolts one or two threads.
14. Install centering band J 24461 around the oil
H00071 pump body and front support assembly (Figure
Figure 6–34. Installing Needle Bearing 6–37). Install the remaining ten 5⁄16-18 x 13⁄4
Into Ground Sleeve inch bolts 21, and two 3⁄8-16 x 11⁄2 inch bolts 20.
;
3. Remove thrust bearing race assembly 20 (the as-
sembly may adhere to either forward clutch hub
21 or forward clutch housing 6). Remove five in-
; ;
ternal-splined plates 23 and five external-tanged
plates 22 from the forward clutch housing.
4. Place the housing and shaft assembly in a press
OIL PUMP AND FRONT
;;;;
SUPPORT ASSEMBLY (Figure 6–39). Using compressor J 6438-01,
H00072.01
compress spring retainer 18 and remove re-
Figure 6–35. Converter-Pressure Regulator tainer snapring 19. Remove retainer 18, piston
Valve Installation return spring 17, and piston 16. Remove seal-
ring 15 from the piston and sealring 14 from
the housing. For transmissions modified with a
;; ;;
spring apply piston, remove the twenty-four
springs from the piston bores.
;
;;;;
;; ;
SUPPORT ASSEMBLY
VALVE GUIDE
SPRING
;
J 24461
;
VALVE
Figure 6–36. Installing Converter-Pressure Figure 6–37. Installing Oil Pump and Front
Regulator Valve Components Support Assembly Bolts
PISTON
CAUTION:
SPRING
• Do not attempt this rework procedure unless
adequate machining facilities are available.
SPRING • Do not attempt to salvage the fourth clutch
SNAPRING RETAINER
housing using this rework procedure.
FORWARD
CLUTCH
HOUSING H00106.01
Figure 6–39. Removing (or Installing) Forward 1. Acceptable wear in the rotating sealring bore
Clutch Spring Retainer of the forward clutch housing consists of nor-
mal polishing of the sealing surfaces by the
5. Do not remove balls 7 from housing and shaft
seals, and step wear no greater than 0.0005
assembly 3 unless replacement is necessary. If
inch (0.0127 mm).
necessary, clear the bores of staked metal and
remove the balls.
2. If wear exceeds acceptable limits, rework the
6. On models after S/N 49489 remove retainer forward clutch rotating sealring bore. Refer to
pin 8, valve plug 9, valve spring 10, and valve Figure 6–40 for sleeve material information,
11 from the outer circumference of forward machining instructions, and installation direc-
clutch housing assembly 3. tions.
;;;
;;;
SURFACE
NOTE: When mounted on E
DIA C or DIA D, runout
of A must not exceed
;;;
0.005 in. (0.127 mm). Runout
of SURFACE E must not
exceed 0.004 in. (0.101 mm).
;; ;;;
Sleeve material specification: 3.049" (77.44 mm)
SAE 4100 series alloy steel REF.
tube, or 1141 and 1144, cold 0.030" (0.76 mm)
drawn or heat treated, RC20 Min. R
1.0625"
(26.987 mm)
D 0.005" (0.127 mm)
0.150"
0.651" (3.81 mm)
(16.54 mm)
;;;
15°
;;;
;;
OPPOSITE
SLEEVE – 3x SCALE
SURFACE
;;;
;;
prior to installation
30°
NOTE: No sleeve ID or OD dimension is
called out. Sleeve OD should be machined
so as to result in a 0.003 in. (0.076 mm) 2.9395" (74.663 mm)
press fit in housing bore A. Sleeve ID 2.9375" (74.613 mm) DIA DIA
must be machined after sleeve is installed (DIA B) C D
to dimension (DIA B).
;;;
0.16" (4.06 mm)
0.12" (3.05 mm)
ward clutch hub 21 (outer splines first) onto the Figure 6–42. Installing Bearing Into Forward Clutch
hub of forward clutch housing 6. Alternately Hub (Earlier Models)
J 6438-01
BACKPLATE
BEARING
RACE
SPRING RETAINER
BEARING
H00108.01
SNAPRING
H00157.01
Figure 6–43. Installing Bearing Onto Forward
Clutch Hub (Earlier Models) Figure 6–45. Removing (or Installing) Fourth Clutch
Spring Retainer Snapring
SEALRING
2. Using compressor J 6438-01 and compressor base
J 24204-2, compress spring retainer 7 sufficiently
to allow removal of snapring 6 (Figure 6–45). Re-
move the snapring. Remove the spring retainer
BEARING
RACE and piston return spring 8, which is directly be-
neath the retainer. Remove snapring 2 that retains
backplate 3, and remove the backplate.
SEALRING (2)
3. Remove four internal-splined plates 4 and four
external-tanged plates 5, and fourth clutch pis-
ton 9 or 10. Remove sealring 11 from the piston
and sealring 12 from fourth clutch housing 13.
4. Remove check balls 14 from fourth clutch
housing 13 only if replacement is necessary. If
necessary, clear the bores of staked metal and
remove the balls.
5. Inspect the clutch housing inner sealring
FORWARD CLUTCH
HOUSING AND groove to determine if a step is present in the
SHAFT ASSEMBLY
H00109.01 top side of the groove (refer to SIL 33-TR-96).
If a step is detected, replace the housing as-
Figure 6–44. Installing Bearing Race Onto Forward sembly. Refer to the current Parts Catalog
Clutch Housing (Earlier Models) PC1316EN for the correct housing part num-
ber for your transmission.
6–10. FOURTH CLUTCH b. Assembly (Foldout 8,A)
3. Position the fourth clutch housing, rear hub Check clearance here
FOURTH CLUTCH 0.064 in. – 0.125 in. (8 PLATES)
downward, on a work table. Lubricate and in- HOUSING (1.63 mm – 3.18 mm) BACKPLATE
stall piston sealrings 11 and 12 into their SNAPRING
grooves in the housing hub and piston. Make
sure the sealring lips face toward the fluid pres- PLATES (8)
PISTON
sure side of the piston (Figure 6–46).
4. Install piston 9 or 10 into the fourth clutch
housing (Figure 6–46). Alternately install four
external-tanged plates 5 and four internal-
splined plates 4, starting with an external-
tanged plate. Install backplate 3 and retain it
with snapring 2.
SEALRINGS
5. Using fourth clutch clearance gauge J 26917,
check the clearance between the backplate and 30 LB LOAD
(133 N) L00309
the first internal-splined plate. Correct fourth
clutch clearance is 0.064–0.125 inch (1.625–
3.175 mm). When clutch clearance is correct, Figure 6–46. Measuring Fourth Clutch Clearance
the first step of the gauge fits between the
backplate and the clutch plate, and the second
step does not.
6. If the clearance is excessive (the second step of
the gauge fits), replace the thinner clutch plates
with new plates. If the clearance is still exces- BEARING RACE
sive after all eight plates and the backplate
FOURTH CLUTCH
have been replaced, a thicker piston is re- HOUSING ASSEMBLY
quired. Refer to the current Parts Catalog
PC1316EN for selection of a thicker piston.
7. If the clearance is insufficient (the first step of
the gauge does not fit), a thinner piston is re-
quired. Refer to the current Parts Catalog
PC1316EN for selection of a thinner piston.
8. Install piston return spring 8 and spring re-
tainer 7. Using compressor J 6438-01 and H00158.01
compressor base J 24204-2, compress the
spring retainer (Figure 6–45). Install snapring Figure 6–47. Installing Bearing Race at Front of Fourth
6 to retain the spring retainer. Clutch (Earlier Models)
FOURTH CLUTCH
HOUSING ASSEMBLY
BEARING RACE SPRING RETAINER
EJECTOR
BOSS
SPRING (20)
CLUTCH PISTON PUSH-ON NUT
H00160.01
H00159.01
Figure 6–48. Installing Bearing Race at Rear of Fourth Figure 6–49. Removing Push-On Nuts
Clutch (Earlier Models) and Spring Retainer
2. For later models, remove oil filter 24 and seal- b. Rework Center Support Anchor Bolt Hole
ring 23 from center support 16. (Foldout 8,B)
5. If parts replacement is necessary, disassemble 1. Starting with S/N 2410260655, a longer (3⁄8-16
the two piston assemblies. Cut the push-on x 3 inch) patch lock anchor bolt 54 (Foldout
nuts to prevent damaging the piston projections 10,A) and a chamfered washer 55 are used.
(Figure 6–49). Remove four push-on nuts 6 or
2. Using a drill press, locate the center support
22, spring retainer ring 7 or 21, and twenty
against a square, flat surface.
springs 8 or 20 from each piston.
3. Turn a 3⁄8-16 tap into the existing hole by hand.
6. Remove two sealrings 12 from the hub of cen- Use a level and the shank of the tap to ensure
ter support assembly 13. that the center support is square and level.
7. If bushing 14 in center support 16 is worn or 4. Refer to Figure 6–50 for machining instruc-
damaged, collapse the bushing inward at the tions.
bushing splitline and remove.
5. Remove any burr from the top of the bore be-
8. Remove check ball 15 (freed by removing the fore checking depth reading (Figure 6–50).
bushing) from the hub of the support. Clean all chips out of the center support.
;;;;
Thrust Bearing Race Assembly (Foldout 8,B)
;;;;
rework to ensure correct fluid flow and proper
positioning of the bearing.
;;;;
3. Using a number 15 (1⁄4 x 1 inch) or number 91
(1⁄4 x 3⁄4 inch) woodruff key cutter wheel or
equivalent, undercut the area to the front of the
lube hole 0.090 inch (2.29 mm) deep and 0.250
inch (6.35 mm) wide (Figure 6–51). Do not cut
a groove around the entire circumference of the
1.380" MIN hub. Cut only the area the length of the hole di-
(35.0 mm) ameter. Clean all chips out of the center sup-
port.
TAP DRILL 1.610 in. (40.89 mm) MAX DEEP
COUNTERDRILL 0.469 in. DIA (11.91 mm) x 4. With the black oxide race facing upward, make
;;;;
0.66–0.70 in. (16.76–17.78 mm) DEEP 0.376–16
UNC 2B MIN FULL THREAD DEPTH TO DIMENSION sure there is clearance around the widest lip of
SHOWN V03296 the race for fluid flow to bearing 15 and the
third clutch.
Figure 6–50. Rework of Center Support
Anchor Bolt Hole d. Rework of Non-Eccentric Center Support to
Eccentric Support (Foldout 8,B)
;;;;
30°
NOTE:
0.250 in.
(6.35 mm)
0.090 in. Transmissions S/N 2410260655 and later have an
(2.29 mm) NOM.
eccentric center support in which the bushing bore
is slightly offset from center. This provides im-
0.090 in.
(2.29 mm) proved shaft alignment at normal transmission op-
erating temperature. The center support in
transmissions prior to S/N 2410260655 may be re-
worked to provide the offset by machining the cen-
CENTER SUPPORT ter support OD and installing shim 29 under the
0.156 in. (3.96 mm) DIA support.
LUBE HOLE
6. Machine a 10 degree chamfer on the front and If the pistons are not installed to the bottom of their
back edges of the OD (Figure 6–53). cavities during installation of push-on nuts 6 and 22,
;;
proper clutch clearance cannot be established.
7. Machine two grooves on the center support
OD. These grooves indicate that the support
;;
has been reworked for shim installation.
SEE VIEW A
8. Clean and remove all machining burrs and
;;
debris.
0.030–0.060"
(0.80–1.52 mm)
MEASUREMENT INSTRUCTIONS: 11.1145–11.1175"
(282.30–282.40 mm) 10°
DIM. B – Measured at bottom of
DIM. support (anchor bolt hole location) VIEW A
BOTH SIDES
A
;;
DIM. A – Measured directly
D
opposite DIM. B location
;
R
NON-ECCENTRIC SUPPORT:
DIM. B = DIM. A ± 0.002 in. (0.05 mm)
0.030"
0.030" (0.80 mm)
DIM. (0.080 mm)
B ECCENTRIC SUPPORT: VIEW B
2 IDENT. GROOVES
DIM. B – DIM. A = 0.015 ± 0.002 in. 0.75" (19.0 mm)
(0.38 ± 0.05 mm) BOTH SIDES
V03298
SEE VIEW B V03299
NOTE:
Notch must be • For MT 640, 643 proceed to Paragraph 6–13.
within this area
20° BALL
• For MTB 643, proceed to Paragraph 6–14.
10°
SECTION D-D
A CENTER THIRD CLUTCH
SUPPORT RETAINER PISTON
RING
J 24453
NOTCH
16°
D X-
D
BUSHING
A SECTION A-A
Press bushing flush
with, to 0.010 in. (0.25 mm)
below this surface
NOTE: After assembly, bushing must withstand EJECTOR BOSS CENTER SUPPORT
500 lb (2224 N) end load in direction of arrow X. L00319 H00073.01
Figure 6–54. Center Support Bushing Installation Figure 6–55. Installing Retainer Ring and Push-On Nuts
THRUST WASHER
SUN GEAR
SHAFT ASSEMBLY FRONT PLANETARY BUSHING
CARRIER ASSEMBLY
CENTER PLANETARY
CARRIER ASSEMBLY
H00162
H00163
Figure 6–57. Removing (or Installing) Front Figure 6–58. Removing (or Installing) Front Planetary
Planetary Sun Gear Carrier Assembly
NOTE:
Needle bearing assembly 39 or 49 may not easily
FRONT come out of the rear planetary carrier assembly. In
PLANETARY
RING GEAR most cases, it can be removed by careful manipula-
tion after rotating the planetary pinions to allow the
bearing race to tilt.
SNAPRING
MAIN SHAFT
PLANETARY
CONNECTING DRUM CENTER PLANETARY
CARRIER ASSEMBLY PLANETARY CENTER PLANETARY
H00165 CONNECTING DRUM RING GEAR
H00166
NOTE:
• Use a minimum of 600 lb (2.669 kN) assembly force
on bushing installer.
• Be careful not to damage the bushing ID coating
MAIN SHAFT
REAR SUN GEAR during installation.
CENTER RING GEAR
H00149
3. Using the short end of bushing installer tool
Figure 6–62. Removing (or Installing) Main Shaft J 41406 (Figure 6–65), press new front bushing
Spiral Snapring 26 into the small OD end of shaft 27 until it is
0.410 inch (10.41 mm) below the end surface
(Figure 6–64).
4. Using the long end of tool J 41406 (Figure 6–
66), press new rear bushing 26 into the large
OD end of shaft 27 until it is 0.660 inch (16.76
mm) below the end surface (Figure 6–64).
REAR PLANETARY
CARRIER ASSEMBLY 5. Using swaging tool J 28446-A, swage both
bushings into holes in the sun gear shaft (Fig-
SNAPRING
ure 6–67). Make sure to use the collar when
swaging the forward bushing to prevent dam-
age to the shaft.
6. Check the ID of bushings for runout. TIR must
PLANETARY
CONNECTING not exceed 0.002 inch (0.05 mm). Surface finish
DRUM should be 30 microinches (0.762 micrometer).
7. If spring pins 24 (Foldout 9,B) were removed
H00150
from shaft 27, install new pins. For each pin,
Figure 6–63. Removing (or Installing) Rear align the split so that it is approximately 90 de-
Planetary Snapring grees to the axis of the shaft. Press the pin into
b. Installing Replacement Sun Gear Shaft the shaft until it is flush to 0.010 inch (0.25
Bushings (Foldout 9,B) mm) below the top of the gear tooth.
DIA A
B.006 B.006
V03300
LONG
STEP
SHORT J 41406
STEP J 41406
SUN GEAR SHAFT
H00075.01
H00074.01
REAR PLANETARY
SUN GEAR
SUN GEAR
SHAFT ASSEMBLY
H00151
L00773
CUP PLUG
J 8092
OUTPUT SHAFT
H00076.01
H00077.01
Figure 6–69. Installing Orifice Plug Into Figure 6–70. Installing Bushing Into Output
Output Shaft — MT 650, 653 Shaft — MT 640, 643
13. Remove needle roller bearing assembly 47 10. Install center sun gear shaft assembly 23,
from the front of rear planetary carrier assem- larger diameter first (Figure 6–59). The shaft
bly 40. must seat on the needle bearing assembly in-
stalled in Step (8).
b. Assembly (Foldout 9,A)
11. Coat thrust washer 12 with oil-soluble grease
1. If lubrication orifice plug 34 was removed and install it onto the rear hub of front plane-
from main shaft 35, install a new one. Use in- tary carrier assembly 10 (Figure 6–58). Install
staller J 24369 and install the new orifice plug the carrier assembly.
into the main shaft. If the installer is not avail- 12. Coat thrust washer 3 with oil-soluble grease
able, press the plug into the shaft until it is re- and install it onto the rear of front sun gear 2
cessed 0.140–0.180 inch (3.56–4.57 mm) be- (Figure 6–57). Install the front sun gear, index-
low the front end of the shaft. ing the cutout splines with the spring pins in
the center sun gear shaft assembly.
2. Position planetary connecting drum 30, long
internal splines downward, and install rear 13. Coat front thrust washer 1 with oil-soluble
planetary carrier assembly 40. Install snapring grease and install it onto center sun gear shaft
48 that retains the rear planetary carrier assem- 27 (Figure 6–56).
bly (Figure 6–63).
3. Rotate the assembly so that the connecting NOTE:
drum is up. Coat needle roller bearing assem- For MTB 643, proceed to Paragraph 6–18.
bly 47 with oil-soluble grease. Install the bear-
ing assembly (inner lip downward) onto the
hub of rear planetary carrier assembly 40.
6–15. OUTPUT SHAFT (MT 650, 653)
4. Install rear planetary sun gear 37 into the rear
of center planetary ring gear 32. Retain the sun a. Disassembly (Foldout 12,B)
gear with snapring 31.
5. Install main shaft assembly 33 (rear first) into NOTE:
the front of rear planetary sun gear 37. Retain
• For models with a press-fit governor drive gear, use
the shaft assembly by installing spiral snapring
Steps (1) through (4) and Step (6).
38 (Figure 6–62).
• For earlier models with a loose-fit governor drive
6. Coat thrust washer 36 with oil-soluble grease gear use Steps (5) and (6).
and install it onto the rear of main shaft 35.
J 24171 J 24171
OIL SEAL
DUST SHIELD
REAR COVER
REAR COVER
H00153.01
H00152.01
Figure 6–73. Removing Oil Seal from
Figure 6–72. Removing Dust Shield from Rear Cover Rear Cover
REAR COVER
6. Remove spring retainer 21 and twenty-six pis-
ton return springs 22 (Figure 6–75). H00154.01
7. Remove low clutch piston 23 (Figure 6–76). Figure 6–74. Removing (or Installing) First
Remove inner and outer sealrings 25 and 24 Clutch (or Low Clutch) Spring
from the piston. Retainer Snapring
SPRING
2. If removed, install governor support pin 16 to
RETAINER the dimension shown in Figure 6–79 (earlier
models) or Figure 6–80 (later models). Use
special tool J 28684 to install the governor sup-
port pin. Accuracy of location and concentric-
ity with the governor bore are of the utmost
importance.
3. Install drain tube 23 into rear cover 15. For ear-
SPRING (26) lier models, press metal tube 23 into the rear
PISTON cover until it is 0.050–0.100 inch (1.27–2.54
REAR COVER mm) below the chamfer in the cover (Figure 6–
77). For later models, press rubber tube 23 into
H00155
rear cover 15 until it is 0.020–0.150 inch
Figure 6–75. Removing (or Installing) First Clutch (or (0.51–3.81 mm) below the surface in the cover
Low Clutch) Spring Retainer (Figure 6–78).
4. Lubricate sealrings 24 and 25 (Foldout 11,B)
with transmission fluid and install them into
the grooves of low clutch piston 23. The lip of
each sealring must face the rear of the piston
(toward the piston cavity in the rear cover).
;;;
;;
OUTER
SEALRING PISTON
OIL SHIELD
;;;
;;
1.05"
(26.7 mm)
DUST SHIELD
SNAPRING
BEVEL SNAPRING
INNER REAR COVER 0.050" (1.27 mm)
SEALRING 0.100" (2.54 mm)
H00156
DRAIN TUBE V03302
Figure 6–76. Removing (or Installing) First Clutch (or Figure 6–77. Oil Seal and Drain Tube
Low Clutch) Piston Location — Earlier Models
;;;;;
5. Align the lug on the piston with the recess in
1.05"
(26.67 mm) the housing and carefully install the piston into
0.020" (0.51 mm) the rear cover (Figure 6–76). Use extreme care
0.150" (3.81 mm)
BELOW SURFACE to prevent the lip of either seal from folding
back over itself. If installation is difficult, re-
;;;;;
OIL SEAL
move the piston and check the seal and the
DUST cover bore before again attempting installation.
SHIELD
NOTE: WARNING!
For MT 640, 643, proceed to Paragraph 6–21. Accumulator piston springs are highly com-
pressed. Use extreme caution during removal of
accumulator cover 27 (Foldout 17,A). Personal
injury can occur if the bolts are removed without
6–18. OUTPUT RETARDER HOUSING properly relieving the spring force.
(MTB 643, 653)
13. Using Figure 6–81 as a guide, remove four
bolts 32 (Foldout 17,A) and washers 31 that
a. Disassembly (Foldouts 17,A, 18,A, and 18,B)
permit installation of compressor J 33429.
1. Remove six (some models, 7) bolts 2 (Foldout 14. Install the four compressor bolts into the four
18,B) and washers 3 that retain stator 4 to the empty bolt holes. Tighten the four bolts finger
retarder housing. Remove the stator. tight.
2. Remove sealring 5 from the groove in the OD 15. Position the base of the compressor center
of stator 4. screw on the accumulator cover (Figure 6–81).
Tighten the center screw.
3. Remove clutch plate retaining snapring 1 from
stator 4. 16. Remove the remaining nine bolts 32 and wash-
ers 31 from the accumulator cover.
4. Remove four internal-splined plates 7 and four
17. Unscrew the center screw until piston spring
external-splined plates 6.
force is completely relieved (Figure 6–82). Re-
5. Remove retarder rotor hub 13 from the retarder move the spring compressor and accumulator
housing. Remove one sealring 12 from each cover 27.
end of the rotor hub. 18. Plugs 28 and 29 may be removed from cover
6. Remove rotor assembly 14. 27 if they obstruct proper cleaning, or if they
are damaged and require replacement.
7. Remove the three remaining clutch plates (two 19. Remove three pistons 24, three inner springs 21,
internal-splined plates 7 and one external- three outer springs 22, and three spring retainers
splined plate 6). 20. Remove two sealrings 23 and 25 from each
8. Remove backplate 15. piston. Do not remove spring retainer snaprings
19 unless they have been damaged.
9. Remove governor and speedometer drive gear
25 (Foldout 18,A). J 33429
ACCUMULATOR
10. Place the retarder housing on a work surface, COVER
front side down.
BOLT (13),
M10 x 1.5 x 50 mm
NOTE:
Perform Steps (11) and (12) only if replacement of
seal 29 (Foldout 18,A), snapring 28, or bearing 27 is
necessary.
12. Remove snapring 28. Using a suitable drift, re- Figure 6–81. Installing Accumulator
move bearing 27. Remove spacer 26. Remover (Installer) Tool
2. Install ball bearing 27 (Figure 6–84). Drive the Figure 6–83. Installing Governor Drive Gear Spacer
bearing to the bottom of its bore with installer
J 33820. Retain the bearing with snapring 28.
Make sure the snapring is properly seated in its
groove.
CENTER
SCREW
ACCUMULATOR
COVER BALL BEARING
BASE J 33429 SNAPRING
COMPRESSOR
ACCUMULATOR
PISTON (3)
PISTON
SPRING (6)
H00061 H00063
Figure 6–82. Removing (Installing) Accumulator Cover Figure 6–84. Installing Snapring
13. If accumulator cover plugs 28 and 29 were re- 15. Align and install a new gasket 26 and accumu-
moved during disassembly, install new plugs. lator cover assembly 27 on top of the three ac-
Tighten each plug to 4–5 lb ft (5–7 N·m). cumulator pistons 24. Using Figure 6–82 as a
guide, screw in the four bolts of spring com-
14. Check the retarder housing to determine if the
pressor J 33429. Make sure the base of the cen-
accumulator bores have been sleeved. If the
ter screw is not in contact with the cover. Then
bores have been sleeved, special flanged-head
tighten the four bolts finger tight.
bolts 34 and sealring washers 33 are required
at two locations when cover assembly 27 is in- 16. Make sure the gasket, cover, and pistons are in
stalled. proper alignment with the retarder housing.
NOTE:
Steps (23), (25), and (27) describe the three mea-
RETARDER surements that must be made during assembly to
HOUSING
ensure satisfactory running clearance.
H00066
H00067
H00068
Figure 6–88. Installing Governor and
Speedometer Drive Gear Figure 6–89. Installing Clutch Plates
DIM D
DIM A GASKET
DIM B
DIM E
DIM C
DIMENSION C
USE PISTON PISTON
INCHES MILLIMETERS PART NO. IDENT NO.
FROM TO FROM TO
H00051
11. If sleeve 11 (Foldout 19,A) is damaged, re-
place the entire adapter housing assembly.
Figure 6–93. Installing Retarder Stator
GUIDE BOLT (2),
1/2-13 x 10 in. NUT (6), 1/2-13 in.
INTERNAL-SPLINED EXTERNAL-SPLINED
PLATE PLATE PLAIN WASHER (4), 1/2 in.
COMPRESSOR
BAR
COMPRESSOR
SPRING RETAINER
PISTON
SNAPRING H00054.01
PLAIN WASHER (6), BOLT (6),
M10 M10 x 1.5 x 35 mm H00052.01 Figure 6–96. Removing (Installing) Piston
Figure 6–94. Installing Clutch Plates Retaining Snapring
SNAPRING
SPRING RETAINER
SPRING
PISTON
ADAPTER HOUSING
H00055
H00053
Figure 6–97. Removing (Installing) Clutch
Figure 6–95. Installing Snapring Spring and Retainer
14. For the MTB 653, tighten the two nuts evenly b. Assembly (Foldout 19,A or 19,B)
until spring retainer 32 (Foldout 19,B) is clear
of snapring 33 (Figure 6–96).
NOTE:
15. Using snapring pliers, release snapring 33 from • For MTB 643, follow Steps (1) through (9) and pro-
its groove in the hub. ceed to Step 20.
16. Carefully unscrew the two free-running nuts • For MTB 653, follow Steps (10) through (19).
evenly until the spring force is fully released.
Remove the removal tool. Remove the loose 1. For the MTB 643, install plugs 8 (Foldout
snapring. 19,A), 9, 15, and 16 and tighten the plugs to
8–10 lb ft (11–14 N·m).
17. Remove spring retainer 32, spring 31, and re-
tarder piston 28 from the adapter housing (Fig- 2. Install plug 17 and tighten to 4–5 lb ft (5–7
ure 6–97). Remove both inner and outer N·m).
sealrings 30 and 29 from the piston.
3. Install retainer and ball assembly 14. Press the
18. Turn the adapter housing over, front side up- new assembly into the housing until it bottoms
ward. against its shoulder. Stake the housing for posi-
tive retention.
19. Compress spring retainer 21 (Foldout 11,B)
and remove snapring 20 (Figure 6–98). Re- 4. Lubricate and install new inner and outer lip-
move the retainer and twenty-six springs 22. type sealrings 13 and 12 (Foldout 11,A) into the
grooves in first clutch piston 11 (Figure 6–99).
20. Remove the low clutch piston 23. Remove in- Make sure the lips of the sealrings point toward
ner and outer sealrings 25 and 24 from the pis- the bottom of the piston bore when the piston is
ton (Figure 6–99). installed.
21. If sleeve 20 (Foldout 19,B) is damaged, replace 5. Install first clutch piston 11 into its piston
the entire adapter housing. cavity (Figure 6–99).
ADAPTER
HOUSING
H00056 H00057.01
Figure 6–98. Removing (Installing) Snapring, Spring Figure 6–99. Removing (Installing) Low or
Retainer, and Springs First Clutch Piston
11. Install plug 23 and tighten to 4–5 lb ft (5–7 21. Tighten the two nuts evenly until the spring re-
N·m). tainer is compressed below the snapring
groove in the adapter housing hub. Install the
12. Install retainer and ball assembly 18. Press the snapring.
new assembly into the housing until it bottoms
against its shoulder. Stake the housing for posi- 22. Loosen the two free-running nuts evenly until
tive retention. the spring retainer is against the snapring. The
snapring should be recessed into the ID of the
13. Install bearing outer race 14, inner lip first, into retainer. If the snapring rides up on the surface
its bore in the front of the adapter housing. The of the retainer, it is not properly seated in the
outer edge of the race must be 0.200–0.207 snapring groove. Repeat Steps (21) and (22)
inch (5.08–5.26 mm) below the surface. Use until the snapring properly seats its groove.
installer J 33822 and handle J 8092 to install
the race. 23. Remove the compressor tool and components.
ADAPTER
2. To remove manual detent lever 49, remove
HOUSING shaft retainer pin 56 and nut 50. File the burred
detent lever side of the shaft. Hold the detent
lever in one hand and remove the shaft, care-
fully pulling it through the oil seal in the hous-
ing. Remove the detent lever.
3. If replacement of breather 2 is necessary, use
an open end wrench and rotate the breather
counterclockwise (Figure 6–102). Remove the
breather.
H00059.01
4. Remove 3⁄4-16 plug 62 and washer 63 (or neu-
Figure 6–101. Removing First Clutch tral switch) and two 1⁄8 inch plugs 57 only if
Piston — MT 650, 653 necessary for cleaning internal passages.
NOTE:
For accurate ordering of replacement parts, the in-
formation on a new nameplate must be identical to
the information that was stamped on the damaged
nameplate.
b. Assembly
8. Remove burrs from shaft 60 to protect oil seal
61. Guide the grooved end of the shaft through 1. Assemble the governor as outlined in the direc-
the seal. Position detent lever 49 so that the se- tions furnished with the governor service kit.
lector valve pin extends toward the inside of
2. Check the governor port openings as outlined
the housing, and engage the slot in the detent
in the kit instructions. Refer to Figure 6–105.
lever with the flats on the selector shaft. Install
nut 50 and retainer pin 56 to retain the shaft
and lever. Tighten the nut to 15–20 lb ft (20–27 6–23. CLUTCH STACK MEASUREMENT
N·m). Refer to Paragraph 3–12 for installation
of the external selector lever. a. Methods. When assembly line overhaul practices
are used, stack dimension computation may be more
9. If breather 2 was removed, install a new convenient than direct measurement. To obtain accu-
breather (Figure 6–102). Tighten the breather rate dimensions, the stack to be measured must have
sufficiently, using care not to distort or crush new clutch plates, and the applied load must be evenly
the breather stem. distributed over the entire clutch pack.
TRANSMISSION HOUSING
OIL SEAL
J 26282
GOVERNOR FEED
(Must open 0.020 in.
(0.51 mm) min)
GOVERNOR
PRESSURE
EXHAUST PORTS PORTS
(Must open 0.020 in.
(0.51 mm) min)
H00060.01 V02308
Figure 6–104. Installing Selector Shaft Oil Seal Figure 6–105. Governor Port Check
;;
2. Apply the specified load, and measure Dimen-
sion X. 2. Apply the specified load, and measure Dimen-
3. From the table in Figure 6–107, select the sion X.
;;
fourth clutch piston. Use the parts measured,
3. From the table in Figure 6–109, select the first
and the selected piston, in the fourth clutch as-
clutch backplate. Use the parts measured, and
;;
sembly.
the selected backplate, when the transmission
is assembled.
;;
980–1020 LB
(4359– 4537 N)
LOAD
;;
980–1020 LB
(4359– 4537 N)
LOAD X
EIGHT-PLATE CLUTCH
DIMENSION X USE PISTON MARKED PISTON THICKNESS
X
1.0140–1.0450 in. 6834668 B 1.020–1.030 in.
(25.756–26.543 mm) (25.91–26.16 mm)
TEN-PLATE CLUTCH
DIMENSION X USE PISTON MARKED PISTON THICKNESS DIMENSION X USE PISTON MARKED PISTON THICKNESS
1.2045–1.2305 in. 6834219 C 1.045–1.055 in. 1.2045–1.2299 in. 23017262 L 1.020–1.030 in.
(30.59–31.25 mm) (26.54–26.80 mm) (30.594–31.239 mm) (25.91–26.16 mm)
1.2305–1.2565 in. 6834668 B 1.020–1.030 in. 1.2300–1.2552 in. 23017261 K 0.995–1.005 in.
(31.25–31.91 mm) (25.91–26.16 mm) (31.242–31.882 mm) (25.27–25.53 mm)
1.2565–1.2820 in. 6834669 A 0.995–1.005 in. 1.2552–1.2804 in. 23017260 J 0.970–0.980 in.
(31.92–32.56 mm) (25.27–25.53 mm) (31.882–32.522 mm) (24.64–24.89 mm)
V03304 V03305
Figure 6–106. Forward Clutch Stack Dimensions Figure 6–107. Fourth Clutch Stack Dimensions
;;
980–1020 LB
(4359– 4537 N) 1. Stack the second clutch plates and piston (Fig-
LOAD
ure 6–110).
X
2. Apply the specified load, and measure Dimen-
sion X.
;;
NOTE:
If the measurement of Dimension X corresponds to
more than one backplate in Figure 6–110, use either
plate to obtain acceptable running clearance.
;;;
Figure 6–108. Low Clutch Stack
Dimensions — MT 650, 653 6–24. PLANETARY CARRIER
ASSEMBLIES
980–1020 LB
(4359– 4537 N) NOTE:
LOAD
• The disassembly and assembly procedures for all
;;;
the planetary carrier assemblies in the MT 600 Se-
ries transmissions differ only in the proper tool se-
lection for the specific carrier assembly. Refer to
the tool chart and Figure 6–111 for specific use and
the identity of the carrier (front, center, rear, low)
and tools involved. If the tool is common to all of
the planetary carrier assemblies, its number is
X
listed in the text. If the tool is not common, the text
refers to the chart. For planetary carrier detailed
information, refer to the exploded views at the
back of this manual.
• The hydraulic press used with J 25587-01 plane-
USE PLATE
tary rebuilding set (Figure 6–111) should have a
DIMENSION X PLATE THICKNESS
MARKED ten-ton (9072 kg) capacity, an adjustable press bed
2.286–2.317 in. 4 0.702–0.712 in. of 25 inches (64 cm) minimum opening, and a pres-
(58.06–58.85 mm) (17.83–18.08 mm) sure gauge to assist in determining proper installa-
2.317–2.348 in. 5 0.671–0.681 in. tion and staking of the pinion pins.
(58.85–59.64 mm) (17.04–17.30 mm)
980–1020 LB
will be drilled. Drill the front ends of the center
(4359– 4537 N) carrier assembly pins.
LOAD
;;
2. Place press fixture J 25587-01 in a hydraulic
press. Select the proper spacer and adapter, if
required, from the tool chart. Position these
parts (if used) to support the carrier assembly
solidly on the press fixture. The drilled ends of
X
the pinion pins should face upward.
DIMENSION X USE PLATE PLATE THICKNESS 4. Remove the pinion groups consisting of pin-
MARKED
ions, bearings, and thrust washers.
1.6984–1.7244 in. 7 0.476–0.486 in.
(43.139–43.799 mm) (12.09–12.34 mm)
-48
-49
-50
-01
-18
-20
-16
-22 -03
-04
-12
-25
-11
-23
-13
-06
-27 -08
-17 -02
H00045
Tools in the chart above are components of Planetary Rebuilding Kit J 25587-01. Refer to Paragraph 4–2.
;
Bushing to be 0.265 in. (6.73 mm) to
0.275 in. (6.99 mm) below this surface
C 0.002 in. (0.05 mm) TIR 2.5034 in. (63.586 mm)
Bushing installation load must be DIA A
2.5019 in. (63.548 mm)
525 LB (2335 N) in direction shown
BUSHING
0.275 in. (6.99 mm)
0.265 in. (6.73 mm)
SURFACE A
Diameter A must be perpendicular with surface B within 0.001 in. (0.02 mm) TIR.
With respect to surface B and the true position of the six (6) dummy pins,
diameter A shall be within the total runout specified by C.
;;
2.45 in. (62.2 mm)
0.025 in. (0.63 mm)
30°
0.5117 in. (12.997 mm)
0.5114 in. (12.990 mm)
;;;;
;;
DUMMY PIN
V03309
Bushing to be flush to
SURFACE A 0.010 in. below this surface
0.002 in.
(0.05 mm) E
3.2534 in. (82.636 mm)
3.2512 in. (82.580 mm) DIA B
NOTE: DIAMETER B must be perpendicular with SURFACE A within 0.001 in. (0.02 mm) TIR.
With respect to SURFACE A and the true position of the six (6) dummy pins, DIAMETER B shall
be within the total runout specified by E. V03310
NOTE:
NOTE:
• Non-rotating thrust washers may be used in any Lubricate needle rollers and thrust washers before
four-pinion center carrier assembly, if the center assembling the pinion groups.
carrier is machined at two locations to provide
clearance for the non-rotating thrust washers to lay
flat on the carrier thrust surface. 1. For MT 650, 653 rear carriers, if needle bear-
ing assembly 39 or 49 (Foldout 9,B) was not
• Do not attempt this rework unless adequate ma-
chining facilities are available. removed in Paragraph 6–12a(11), remove it
now. Make sure to install a new bearing assem-
bly (inner lip of race first) into the carrier be-
1. Disassemble the center carrier assembly. Refer
to Paragraph 6–24b. fore installing the pinions.
2. Machine the two points of interference (Figure 2. Assemble all the pinion groups for the carrier
6–114) flush to 0.020 inch (0.51 mm) below assembly. Assemble each group by inserting
the existing thrust surface. Maintain a 0.050 the proper loading pin into the pinion bore, in-
inch (1.27 mm) radius in the corners. Do not stalling the needle roller bearings around the
machine radially more than necessary to pro- loading pin, installing a steel thrust washer at
vide clearance for the thrust washers. each end of the pinion, and installing a bronze
3. Thoroughly clean the carrier to remove ma- thrust washer onto each steel thrust washer. If
chining debris. using non-rotating thrust washers, the bronze
surface must be next to the steel thrust washer.
4. Reassemble the carrier assembly. Refer to
Paragraph 6–24e.
3. Position the carrier assembly, rear upward
(center carrier, front upward). Install all the
CENTER
NON-ROTATING CARRIER pinion groups into the planetary carrier, align-
THRUST WASHERS ing the loading pins with the pin bores in the
carrier.
; ;
4. Install the proper pinion guide pins (refer to the
tool chart and Figure 6–111), larger diameters
first, into the pinion pin bores. Push the guide
pins through the carrier until the loading pins
INTERFERENCE drop out.
POINTS
5. Position the carrier assembly on the press fix-
ture, using the proper pin remover and installer
adapter (if required).
NOTE:
Pin installers are shaped to avoid interference with
NOTE: Remove interference points flush to 0.020 in. (0.51 mm)
below the existing thrust surface, with a 0.05 in. (1.27 mm) bosses on the carrier assemblies. They must be in-
radius in the corners. stalled in the ram so the cutaway portion of the in-
V03311
staller will clear the bosses when the pinion pin is
Figure 6–114. Rework of Center Carrier for pressed in.
Non-Rotating Thrust Washers
V02967
NOTE:
The clearances for low, first, second, and third
clutches are established by direct measurement in
this section (Paragraphs 7–3b, e, f, j, and o). Refer to CENTER
TAPPED HOLE SUPPORT
Paragraph 6–23 for stack dimension computation ASSEMBLY H00095.01
of clutch clearances.
Figure 7–1. Installing Center Support Assembly
J 23717-1
CENTER SUPPORT
BOLT HOLE J 24475-2
H03313
J 23717-1.
Measured Snapring
Clearance Thickness Snapring
in. (mm) in. (mm) Color
0.150–0.154 0.148–0.150
White
(3.81–3.91) (3.76–3.81)
0.154–0.157 0.152–0.154
Yellow J 24475-2
(3.91–3.99) (3.86–3.91)
0.157–0.160 0155–0.157
Green
(3.99–4.06) (3.94–3.99)
0.160–0.164 0.158–0.160 J 34127
Red
(4.06–4.17) (4.01–4.06)
1. Invert the transmission housing, output end up- Figure 7–4. Measuring for Selection of Center
ward. Support Snapring
2. Install rear cover assembly 6 (as assembled in 1. If bearing 4 (Foldout 19,A) was removed from
Paragraph 6–17) onto the transmission housing output shaft 11 (Foldout 18,B), install a new
(Figure 7–6). bearing. Press the new bearing to a firm seat
against the shaft shoulder. If bearing 9 and ori-
fice plug 10 were removed, install new ones. In-
J 26915 stall bearing 9 to 0.180–0.200 inch (4.57–5.08
mm) below end of shaft with installer J 34016.
BACKPLATE
Install orifice plug 10 (orifice end first) to just
below the chamfer of its bore in the shaft.
REAR COVER
GASKET
CENTER SUPPORT
TRANSMISSION
HOUSING
H00141.01 H00112
Figure 7–5. Checking Second Clutch Clearance Figure 7–6. Installing Rear Cover — MT 640, 643
SEALRING
GASKET
REAR
ADAPTER
HOUSING
GASKET
H00047
ADAPTER H00115.01
Figure 7–7. Installing Retarder Adapter Housing HOUSING
Assembly — MTB 653 Figure 7–8. Installing Retarder Housing Assembly
DEPTH MICROMETER
B PISTON
SNAPRING
BACKPLATE
GASKET
REAR
SECOND CLUTCH J 26914
COVER
PLATES
A – B = CLEARANCE L00342
H00048.01
Figure 7–12. Establishing Low Clutch
Figure 7–11. Checking First Clutch Clearance Clearance — MT(B) 650, 653
LOW PLANETARY
J 1927-1 J 1927-1 ASSEMBLY
ADAPTER
HOUSING
GASKET
H00143.01
H00050.01
Figure 7–13. Installing Adapter
Housing — MT(B) 650, 653 Figure 7–15. Installing Low Planetary Carrier
Assembly — MT(B) 650, 653
LOW
THRUST PLANETARY
WASHER ASSEMBLY
THRUST
WASHER
H00049 H00031.01
Figure 7–14. Installing Low Planetary Sun Figure 7–16. Installing Low Planetary Ring
Gear — MT(B) 650, 653 Gear — MT(B) 650, 653
NOTE:
Do not mix zinc plated and non-zinc plated rear
cover bolts in the same transmission. Do not use
washers with zinc plated flanged hex head bolts.
OUTPUT REAR
SHAFT COVER
ASSEMBLY ASSEMBLY
BEARING
LOW RING SPEEDOMETER
GEAR DRIVE GEAR
GOVERNOR
DRIVE GEAR
J 1927-1 J 1927-1
H00033.01
OUTPUT SHAFT
REAR COVER
SPACER
BEARING RACE
BOLT (14), 1/2-13 x 51/4 in. AND ROLLERS
OUTPUT SHAFT
WASHER (14)
ADAPTER
HOUSING
H00035
H00144.01
Figure 7–20. Tightening Rear Cover Bolts — MT 650, Figure 7–22. Installing Output Shaft
653 Assembly — MTB 653
GASKET
REAR
ADAPTER
HOUSING
GASKET
H00047
ADAPTER H00115.01
HOUSING
Figure 7–23. Installing Retarder Adapter Housing
Assembly— MTB 653 Figure 7–24. Installing Retarder Housing Assembly
4. Install ring gear hub 6 into ring gear 5 and re- NOTE:
tain it with snapring 7. For MT(B) 650, 653 proceed to Paragraph 7–3l.
NOTE:
For MT(B) 640, 643 proceed to Paragraph 7–3m.
RING GEAR
AND HUB SNAPRING
ASSEMBLY
BACKPLATE
FIRST
CLUTCH
PISTON
FIRST CLUTCH
PLATES (12)
THRUST WASHER
H00036.01 H00037.01
Figure 7–25. Installing Rear Planetary Ring Gear and Figure 7–26. Installing First Clutch
Hub Assembly— MT 650, 653 Snapring — MT 650, 653
NOTE:
Before installing the second clutch, be sure the
clutch pack meets the required clearance. Refer to
Paragraph 7–3b.
plates 26.
Figure 7–28. Installing Second Clutch Plates
J 24454
MAIN SHAFT
GEAR UNIT
THRUST
WASHER
H00097.01
H00039
Figure 7–27. Installing Gear Unit Figure 7–29. Installing Second Clutch Snapring
(Figure 7–30) with the anchor bolt hole in the Figure 7–30. Installing Center Support Assembly
transmission housing (Figure 7–31). Install the
center support (as assembled in Paragraph 6–
11) and shim 29 (if required). Seat the support
firmly against the second clutch snapring.
6. Check the support and shim alignment by
viewing from the valve body mounting surface.
The support and shim should align with all
fluid passages in the transmission housing.
7. Remove the lifter from the center support. Start
a new 3⁄8-16 x 3 inch special self-locking bolt
54 (Foldout 10,A) and chamfered washer 55
into the center support assembly. Earlier mod-
els use a 3⁄8-16 x 21⁄4 inch bolt and plain
washer. Refer to Paragraph 6–11b for rework CENTER SUPPORT
to the later configuration. BOLT
H03314
8. Install snapring 5 (Foldout 8,B) selected in
Figure 7–31. Tightening Center Support Bolt
Paragraph 7–3a, to retain the center support.
Place the ends of the snapring at the top of the
main case. Tighten the center support anchor NOTE:
bolt to 39–46 lb ft (53–62 N·m) (Figure 7–31). For earlier models, install the needle roller bearing
assembly (rollers upward) onto the center support
CAUTION: hub.
Improper installation of butt-joint sealrings may
cause transmission failure. Refer to Paragraph o. Third Clutch Clearance (Foldout 8,B)
4–6f for proper installation procedure. 1. Starting with external-tanged plate, as shown
in Figure 7–32, alternately install three exter-
9. Install needle roller thrust bearing race assem- nal-tanged plates 4 and three internal-splined
bly 15 (Foldout 8,A), lube relief scallops and plates 3. Note the location of the three sets of
black oxide race up, onto the center support double tangs. If the tangs are not positioned as
hub. Install two butt-joint sealrings 12 (Foldout shown, movement of the stationary plates will
8,B) onto the hub. occur.
FOURTH SNAPRING
Figure 7–32. Installing Third Clutch Plates CLUTCH GAP
ASSEMBLY
J 26916
SNAPRING
BACKPLATE
THIRD
CLUTCH
PISTON
H00146.01
RETAINER RING
TANG
H00022
Figure 7–33. Checking Third Clutch Clearance Figure 7–34. Installing Fourth Clutch Assembly
BEARING
RACE
H00024
CAUTION:
Improper installation of butt-joint sealrings may
cause transmission failure. Refer to Paragraph
AIR SUPPLY 4–6f for proper installation procedure.
H00023.01
RUBBER-COVERED
WASHER (12)
CONTROL ACTUATOR PIN
VALVE
H00025.01
ASSEMBLY
H03286
Simultaneously insert the first clutch feed tube BOLT (16), 1/4-20 x 21/4 in.
into its bore in the tube adapter and valve body.
2. On earlier models, insert the first clutch feed FIRST CLUTCH GOVERNOR PRESSURE
tube and the two governor feed and pressure FEED
GOVERNOR FEED
tubes into tube adapter 20 (Figure 7–41). Place
the tube adapter in position on the transmission
housing and insert the three tubes into their re- TUBE ADAPTER
spective bores in the valve body. H00026.01
6. If the external tubes illustrated in Figure 7–44 Figure 7–43. Tightening Control Valve Bolts
are used, tighten the eighteen control valve
bolts, working from the center outward, to 8–
12 lb ft (11–16 N·m). Use preset torque wrench
J 29612 for this operation. Then proceed to
Paragraph 7–5d. If the external tubes illus-
trated in Figure 7–45 are used, do not tighten
the bolts and proceed with Paragraph 7–5d. FORWARD REGULATOR TUBE
CONTROL DRIVE 1
VALVE
ASSEMBLY
GOVERNOR
OIL SCREEN
TUBES
OIL
TRANSFER
PLATE
H00027
Figure 7–44. Installing External Tubes into Valve
Figure 7–42. Installing Oil Transfer Plate — MT 650, 653 Bodies — MT 650, 653 (Earlier Models)
BOLT (7),
1⁄4-20x 2 3⁄4 in. SEPARATOR
PLATE
DRIVE 1
LOW AND
FIRST FEED
LOW SHIFT
VALVE ASSEMBLY
H03287 H03316
Figure 7–45. Installing External Tubes into Valve Figure 7–46. Tightening Low Shift Valve
Bodies — MT 650, 653 (Later Models) Bolts — MT 650, 653
CAUTION:
When installing the oil filter, filter tube, and seal-
ring, avoid twisting the tube or filter in any way
that might pinch, cut, or deform the sealring. An
airtight seal must be maintained to enable the oil
pump to draw fluid from the sump free of en-
trained air.
GASKET
BOLT (3)
No bolt required
MODULATED OIL PAN
LOCKUP VALVE
ASSEMBLY
H00011.01
H03317
Figure 7–49. Installing Oil Pan — Standard
Figure 7–47. Tightening Modulated Lockup Valve Bolts Configuration
d. Oil Pan and Filter (Heavy-Duty 4. When the converter assembly is seated, mea-
Configuration) (Foldout 10,B) sure the distance from the transmission mount-
ing flange to the converter cover (Figure 7–52).
1. Install two 5⁄16-18 x 3 inch headless guide bolts This distance should be approximately 9⁄16
J 3387-2 into the transmission housing. Install inch (14.3 mm). If the measurement is signifi-
gasket 28 (Figure 7–50). Install oil pan 25 and cantly greater than 9⁄16 inch (14.3 mm), raise
retain it with twenty-one washer-head screws the converter assembly slightly, rotate it to
24. Tighten the screws to 15–20 lb ft (20–27 align the pump hub flats, and reseat it.
N·m).
2. Install sealrings on filter retainer 16 and filter J 6795-01
access lip of pan. Install filter 14 and retainer 16.
3. Install spring 17 in cover 19 and place over the ASSEMBLED
filter retainer. Install 5⁄16-24 x 7⁄8 inch bolt 21 TORQUE
CONVERTER
and nut 22 to attach strap 20 to pan. Tighten
the bolt to 12–15 lb ft (16–20 N·m). FLAT AREA
4. Refer to Paragraph 3–4 for dipstick calibration
specifications.
e. Torque Converter (Foldout 6) H00012.01
1. For transmissions after S/N 49489, check that Figure 7–51. Installing Torque Converter Assembly
sealring 49 is lubricated with oil-soluble grease
and installed into its groove in pump hub 48 be-
SCALE
fore installing the torque converter assembly.
BAR STOCK
HEX HEAD SCREWS (23) J 6795-01
SEALRING
FILTER
RETAINER
H00130 H00013.01
RETARDER
VALVE BODY
Figure 7–53. Converter Retaining Strap Figure 7–55. Installing Retarder Valve Body
NOTE: NOTE:
Hose clamp bracket 12 is retained to the adapter • Check valve 17 must be installed with the flow ar-
housing by one of the retarder housing bolts (Figure row (on side of valve) pointing upward.
7–56). If bracket 12 was not previously installed, in- • Do not mix current clutch feed hose 15 and fitting
stall it now. 16 with the earlier hose and fitting. Refer to the
current Parts Catalog PC1316EN.
3. Install one 5⁄16-18 x 1⁄2 inch bolt 5 through 8. Attach check valve 17 onto elbow 18 and
hose clamp 4 and hose clamp bracket 12. Re- tighten the valve to 12–15 lb ft (16–21 N·m).
tain the bolt, clamp, and bracket together with Install fitting 16 into check valve 17 and
one 5⁄16 inch lockwasher 11 and one 5⁄16-18 tighten the fitting to 12–15 lb ft (16–21 N·m).
hex nut 10. Tighten the nut to 120–144 lb in. Attach clutch feed hose assembly 15 to fitting
(14–16 N·m). 16 and elbow 23 (Foldout 18,A). Tighten the
4. Install sealrings 6 and 9 onto flared tube con- hose coupling nuts to 16–20 lb ft (22–27 N·m).
nectors 7 and 8.
5. Install connector 8 into the center port in the 7–8. INSTALLING GOVERNOR AND
front of the retarder valve (Figure 7–56). Tighten GOVERNOR COVER
the connector to 25–35 lb ft (34–47 N·m).
a. Install the governor assembly by pushing it in-
RETARDER HOSE CLAMP ward with a slight rotation, counter-clockwise (Figure
CONTROL AND BRACKET
TO RETARDER
VALVE 7–57 or 7–58).
CLUTCH CONVERTER-OUT
HOSE ASSEMBLY
OUTPUT SHAFT
REAR COVER
GOVERNOR
ADAPTER
HOUSING
CHECK
VALVE COOLER OIL TO TRANSMISSION
LUBE CONNECTORS HOUSING H00145
H00136.2
ADAPTER
HOUSING
GOVERNOR
ASSEMBLY
H00133
I
GASKET
c. For MTB 643 and 653, install the governor cover COVER
gasket and cover (Figure 7–60). Retain the cover with
four M8 x 1.25 x 25 bolts and M8 lockwashers.
Tighten the bolts to 13–16 lb ft (18–22 N·m).
NOTE:
For MTB 643, 653, proceed to Paragraph 7–10.
7–9. INSTALLATION OF
OUTPUT COMPONENTS
(MT 640, 643, 650, 653)
J 24447
J 24202-4
REAR COVER
ASSEMBLY
OUTPUT SHAFT
GEAR
PIN SLOT
H00016.01
H00015
J 24202-4
J 24202-4
OIL SEAL
REAR COVER
ASSEMBLY
REAR COVER
ASSEMBLY
H00019.01
H00017.01
Figure 7–65. Installing Output Shaft Oil Seal Figure 7–66. Installing Dust Shield
J 24462-1 CAUTION:
The transmission and PTO can be damaged if the
PTO is installed with its drive gear to the front of
the PTO drive gear.
1. Be sure the mounting pad is clean and free of 3. Install the PTO as described in Paragraph
burrs, debris, and shims. Position tool J 34814 7–12a.
(Figure 7–68) onto the pad so that the gauge
4. If a lubrication source is required, the return
pin is between two drive-gear teeth.
line from cooler-to-transmission may be
tapped. Provide a 0.032 inch (0.81 mm) restric-
2. Tighten the two hold-down bolts.
tion in the lubrication circuit (usually already
3. Measure the height between the gauge pin and provided in the PTO assembly).
base plate (Figure 7–68) with a feeler gauge.
Refer to the chart for the quantity of shims or CAUTION:
gaskets required to establish gear backlash of
0.006–0.029 inch (0.15–0.73 mm). Do not remove lubrication regulator valve
adapter 9 (Foldout 10,A). Remove only the fluid
4. Place the shim(s) onto the mounting pad and line or fitting that connects to the adapter. Drill
install two headless guide bolts, one into the and tap the fitting or hose end to provide PTO lu-
top and one into the bottom of the PTO mount- brication.
MEASUREMENT
PTO PAD
HOLD-DOWN
BOLT
J 34814 PTO DRIVE
GEAR
MEASUREMENT CORRECTION
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31 30 29 28 27 26 25 24 23 22 21
Foldout 1. Model MT(B) 640, 643 Automatic Transmission — Cross Section View
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 2
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V00280.01
36 35 34 33 32 31 30 29 28 27 26 25 24
Foldout 2. Model MT(B) 650, 653 Automatic Transmission — Cross Section View
F OLDOUT 3
THIRD CLUTCH PRESSURE
Converter
Pressure
Regulator
Open
Lubrication
Throttle
Pressure
(Optional)
Regulator
ORIFICE
Oil Pump
ORIFICE
ORIFICE Main
FILTER Pressure
SUMP Tap
Lockup CONVERTER–OUT
Relay CONVERTER–IN
Valve Modulator
MAIN PRESSURE
Valve
Main Pressure FORWARD CLUTCH PRESSURE
Regulator FOURTH CLUTCH PRESSURE
MAIN PRESSURE
SECOND CLUTCH PRESSURE Mechanical
OIL SCREEN Control
GOVERNOR PRESSURE MODULATOR PRESSURE
Regulator NEUTRAL
D1
ORIFICE
MAIN PRESSURE D2
ORIFICE
D3
Priority
LOCKUP ORIFICE 1 – 2 SIGNAL Valve Hold Regulator
REDUCED MODULATION ORIFICE
SIGNAL FILTER Valve
SUMP
Lockup Manual
Relay Selector Valve
Valve MAIN ORIFICE
ORIFICE
LOCKUP Main Pressure ORIFICE ORIFICE ORIFICE
Regulator ORIFICE Earlier Models
Governor Pressure
ORIFICE Tap
Lockup Signal MAIN PRESSURE REVERSE
Pressure Tap MODULATOR GOVERNOR PRESSURE
ORIFICE
Trimmer 2–3 1–2 FILTER
1st Clutch 3rd Clutch Relay Valve Relay Valve 0.090 in.
Regulator Valve 2nd Clutch 4th Clutch (2.29 mm)
Trimmer Valve Trimmer Valve 0.250 in. MAIN PRESSURE GOVERNOR FEED
Trimmer Valve Trimmer Valve (6.35 mm) ORIFICE
BALL
Reverse Bypass
Priority Check Ball
Trim Boost
(Earlier Models)
Accumulator
ORIFICE FIRST TRIMMER
Governor Valve
FIRST TRIMMER FORWARD REGULATOR PRESSURE
GOVERNOR PRESSURE GOVERNOR PRESSURE
Modulated ORIFICE
Lockup Valve Trimmer 1 – 2 Shift
Regulator Valve Signal Valve
FORWARD
GOVERNOR REGULATOR MAIN PRESSURE
PRESSURE ORIFICE REVERSE CONVERTER–IN
ORIFICE ORIFICE ORIFICE
SIGNAL
MODULATED LOCKUP PRESSURE CONVERTER–OUT
ORIFICE FORWARD LUBRICATION
REGULATOR
DRIVE – 1
EXHAUST OR SUMP
MAIN
GOVERNOR PRESSURE
1st Clutch 3rd Clutch 2nd Clutch 4th Clutch
Modulated
Lockup Valve
ORIFICE Trimmer Valve Trimmer Valve Trimmer Valve Trimmer Valve 1–2 MODULATOR PRESSURE
SIGNAL FORWARD REGULATOR
ADJUSTABLE LOCKUP GOVERNOR
FIRST CLUTCH PRESSURE
Trim Boost
Accumulator
SECOND GEAR START TRIMMER REGULATOR PRESSURE
STANDARD MODULATION
V03319
;;
Clutch Clutch Clutch Clutch Clutch Clutch GOVERNOR PRESSURE
Lube Press. MODULATOR PRESSURE
ORIFICE Regulator FORWARD REGULATOR
LOW CLUTCH PRESSURE
LOW AND FIRST CLUTCH FEED
Main FIRST CLUTCH PRESSURE
Oil Pressure TRIMMER REGULATOR PRESSURE
Pump Tap
FILTER
SUMP
ORIFICE
ORIFICE
; ORIFICE
CONVERTER – OUT
Modulator
Lockup DRIVE–3 PRESSURE Valve
Relay CONVERTER – Main Pressure FOURTH CLUTCH FORWARD REGULATOR PRESSURE
Valve IN Regulator Valve PRESSURE FORWARD CLUTCH PRESSURE
4th CL. OIL SCREEN MAIN PRESSURE
LOCKUP
SIGNAL Lockup Signal MAIN PRESSURE
Pressure Tap MODULATOR PRESSURE
DRIVE–2 PRESSURE
Neutral D1 1
Start D2 2–3
Switch D3 2–4
D 2–5
N
R
ORIFICE
FORWARD HOLD FEED
Modulated CLUTCH
Lockup Valve 1–2
Trimmer 4–5 Shift Valve
Regulator Relay Valve
Valve 4 – 5 Shift Manual
Signal Valve Hold
3 – 4 Shift 2 – 3 Shift Selector Regulator
REVERSE Signal Valve Signal Valve Valve Valve
ORIFICE
REVERSE
Reverse
Signal Switch
DRIVE–1 PRESSURE
Priority
Valve
MAIN PRESSURE
ORIFICE
REVERSE
2–3
Relay Valve
Air Retarder
Supply Control
CONVERTER – OUT
Retarder
Priority Valve
Retarder
Valve
Priority
Valve
MAIN PRESSURE
LUBRICATION
Pressure
Regulator REGULATED
Plug Valve PRESSURE Cutoff
Lube Pressure Valve
Regulator Valve
ORIFICE
ORIFICE RETARDER – IN
CONVERTER – IN Pressure
Regulator
Oil Valve ORIFICE
Pump
MAIN PRESSURE ORIFICE
FORWARD
REGULATOR
TO PRESSURE
ORIFICE
SUMP Charging REGULATOR
RETARDER ORIFICE
CHARGING
Valve VALVE
FROM RETARDER – IN PRESSURE
PRESSURE
TO RETARDER
Lockup
Relay ACCUMULATOR
Valve Main Pressure
LOCKUP Regulator Valve
MAIN PRESSURE
ACCUMULATOR PISTON
LOCKUP SIGNAL MAIN PRESSURE ACCUMULATOR PISTON SPRINGS
FROM RETARDER
CONVERTER–IN
CONVERTER–OUT
LUBRICATION
LUBRICATION FEED
GOVERNOR PRESSURE
SUMP
RETARDER CLUTCH Governor
AIR SUPPLY Valve
V00283
Foldout 5. Model MTB 643, 653 Output Retarder Hydraulic Schematic (Retarder Off)
F OLDOUT 6
Foldout 7,A. Oil Pump and Front Support Assembly Foldout 7,B. Forward Clutch and Turbine Shaft Assembly
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 8
8,A 8,B
1 — Fourth clutch assembly 1 — Snapring
2 — Snapring 2 — Third clutch backplate (selective):
3 — Clutch backplate ID No. 7: 0.476–0.486 inch (12.09–12.34 mm)
ID No. 8: 0.450–0.460 inch (11.43–11.68 mm)
4 — Internal-splined plate (4) (some models, 5)
ID No. 9: 0.463–0.473 inch (11.76–12.01 mm)
5 — External-tanged plate (4) (some models, 5) 3 — Internal-splined clutch plate (3)
6 — Snapring 4 — External-tanged clutch plate (3)
7 — Piston spring retainer 5 — Snapring (selective):
8 — Piston return spring Color code: White 0.148– 0.150 inch
9 — Fourth clutch piston (selective)* (3.76– 3.81 mm)
Color code: Yellow 0.152– 0.154 inch
Piston A 0.995–1.005 inch (25.27–25.53 mm)
(3.86– 3.91 mm)
Piston B 1.020–1.030 inch (25.91–26.26 mm) Color code: Green 0.155– 0.157 inch
10 — Fourth clutch piston (selective)** (3.94– 3.99 mm)
Piston J 0.970–0.980 inch (24.64–24.89 mm) Color code: Red 0.158– 0.160 inch
Piston K 0.995–1.005 inch (25.27–25.53 mm) (4.01– 4.06 mm)
Piston L 1.020–1.030 inch (25.91–26.16 mm) 6 — Push-on nut (4)
11 — Piston outer sealring 7 — Spring retainer ring
12 — Piston inner sealring 8 — Piston return spring (20)
13 — Fourth clutch housing assembly 9 — Third clutch piston
14 — Check ball (4) 10 — Piston inner sealring
11 — Piston outer sealring
15 — Thrust bearing assembly
12 — Butt-joint sealring (2)
* Use with four-plate clutch. 13 — Center support housing assembly
** Use with five-plate clutch. 14 — Bushing
15 — Check ball
16 — Center support
17 — Piston outer sealring
18 — Piston inner sealring
19 — Second clutch piston
20 — Piston return spring (20)
21 — Spring retainer ring
22 — Push-on nut (4)
23 — Sealring (after S/N 100431)
24 — Oil filter (after S/N 100431)
25 — Snapring
26 — External-tanged plate (3)
27 — Internal-splined plate (3)
28 — Second clutch backplate (selective):
ID No. 7: 0.476– 0.486 inch (12.09–12.34 mm)
ID No. 8: 0.450– 0.460 inch (11.43–11.68 mm)
ID No. 9: 0.463–0.473 inch (11.76–12.01 mm)
29 — Shim (use with grooved center support only)
Foldout 8,A. Fourth Clutch Assembly Foldout 8,B. Third Clutch, Center Support, and Second Clutch
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 9
9,A 9,B
1 — Thrust washer 1 — Thrust washer
2 — Front sun gear 2 — Front sun gear
3 — Thrust washer 3 — Thrust washer
4 — Front planetary carrier assembly 4 — Front planetary carrier assembly
5 — Pinion pin (6) 5 — Pinion pin (6)
6 — Bronze thrust washer (12) 6 — Bronze thrust washer (12)
7 — Steel thrust washer (12) 7 — Steel thrust washer (12)
8 — Front planetary pinion (6) 8 — Front planetary pinion (6)
9 — Roller (120) 9 — Roller (120)
10 — Front planetary carrier assembly 10 — Flange and carrier assembly
11 — Bushing 11 — Bushing
12 — Thrust washer 12 — Thrust washer
13 — Snapring 13 — Snapring
14 — Front planetary ring gear 14 — Front planetary ring gear
15 — Center planetary carrier assembly 15 — Center planetary carrier assembly
16 — Pinion pin (4) 16 — Pinion pin (4)
17 — Center planetary carrier 17 — Center planetary carrier
18 — Bronze thrust washer (8) 18 — Bronze thrust washer (8)
19 — Steel thrust washer (8) 19 — Steel thrust washer (8)
20 — Center planetary pinion (4) 20 — Center planetary pinion (4)
21 — Roller (72) 21 — Roller (72)
22 — Bronze thrust washer, two-pinion (4) 22 — Bronze thrust washer, two-pinion (4)
23 — Sun gear shaft assembly 23 — Center sun gear shaft assembly
24 — Spring pin (2) 24 — Spring pin (2)
25 — Shaft and bushing assembly 25 — Shaft and bushing assembly
26 — Bushing (2) 26 — Bushing (2)
27 — Sun gear shaft 27 — Center sun gear shaft
28 — Needle roller bearing 28 — Needle roller bearing assembly
29 — Bearing race 29 — Roller bearing race
30 — Planetary connecting drum 30 — Planetary connecting drum
31 — Snapring 31 — Snapring
32 — Center planetary ring gear 32 — Center planetary ring gear
33 — Main shaft assembly 33 — Main shaft assembly
34 — Lubrication orifice plug 34 — Lubrication orifice plug
35 — Main shaft 35 — Main shaft
36 — Thrust washer 36 — Rear planetary sun gear
37 — Rear planetary sun gear 37 — Snapring
38 — Snapring 38 — Rear planetary carrier assembly, four-pinion
39 — Snapring 39 — Needle roller bearing assembly
40 — Rear planetary carrier assembly 40 — Pinion pin (4)
41 — Pinion pin (4) 41 — Bronze thrust washer, two-pinion (4)
42 — Bronze thrust washer, two-pinion (8) 42 — Steel thrust washer (8)
43 — Steel thrust washer (8) 43 — Roller (72)
44 — Roller (72) 44 — Rear planetary pinion (4)
45 — Pinion (4) 45 — Rear planetary carrier
46 — Rear planetary carrier 46 — Snapring
47 — Needle roller bearing assembly* 47 — Thrust washer
48 — Snapring 48 — Rear planetary carrier assembly, five-pinion
49 — Ball bearing** 49 — Needle roller bearing assembly
50 — Output shaft assembly** 50 — Pinion pin (5)
51 — Bushing** 51 — Bronze thrust washer, two-pinion (2)
52 — Cup plug** 52 — Steel thrust washer (10)
53 — Spring pin** 53 — Roller (90)
54 — Output shaft** 54 — Pinion (5)
55 — Rear planetary carrier
* Used on MTB Series only. 56 — Bronze thrust washer, three-pinion (2)
** Used on MT Series only.
17 5
16 10
1 6
2 7
8 9 18
3 7
5 6 11
10 4
1 6 18
2 7 19
8 9 18 22 20
3 7 12 13 21
6 11 19
4 18
15
19 14 22
22 20
12 21
13 23
19
15 24
14
22
31 25
32 26
23
27
24
33
25 34 26
31 32 26 28
27 29 30
35
33
34 26
28 36
29 30
35 37
36
37 46
49
38
39
50 47
48
47 48
38
41
49
50 51 55
52 39 45
40 51
52 53
53 54 40
56 52
42 46 54
43 51
44
45
43
56
42
41
42
43
44
42 41
E01331.01 E01330.01
Foldout 9,A. Gear Unit Assembly — MT(B) 640, 643 Foldout 9,B. Gear Unit Assembly — MT(B) 650, 653
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 10
Foldout 10,A. Transmission Housing, Standard Oil Filter and Oil Pan Configuration Foldout 10,B. Heavy-Duty Oil Filter and Oil Pan Configuration
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 11
11,A 11,B
1 — Snapring 1 — Adapter housing gasket
2 — First clutch backplate (selective): 2 — Thrust washer
ID No. 4: 0.702–0.712 inch (17.83–18.08 mm) 3 — Adapter housing
ID No. 5: 0.671–0.681 inch (17.04–17.30 mm) 4 — Hex head pipe plug, 1⁄4 inch A
ID No. 6: 0.640–0.650 inch (16.26–16.51 mm) 5 — Thrust washer
3 — Internal-splined plate (6) 6 — Low sun gear
4 — External-tanged plate (6) 7 — Thrust washer
5 — Rear planetary ring gear (MT(B) 650, 653) 8 — Low planetary carrier assembly
6 — Rear planetary ring gear hub 9 — Pinion pin (6)
(MT(B) 650, 653) 10 — Bronze thrust washer (12)
7 — Snapring (MT(B) 650, 653) 11 — Steel thrust washer (12)
8 — Snapring 12 — Pinion (6)
9 — Spring retainer 13 — Roller (114)
10 — Piston return spring (26) 14 — Carrier and bushing assembly
11 — First clutch piston 15 — Bushing
12 — Piston outer sealring 16 — Thrust washer
13 — Piston inner sealring 17 — External-tanged plate (6)
14 — Rear planetary ring gear (MT(B) 640, 643) 18 — Internal-splined plate (5)
19 — Low planetary ring gear
20 — Snapring
21 — Piston spring retainer
22 — Piston return spring (26)
23 — Low clutch piston (selective)
Piston C 0.858–0.868 inch (21.79–22.05 mm)
Piston B 0.829–0.839 inch (21.06–21.31 mm)
Piston A 0.800–0.810 inch (20.32–20.57 mm)
24 — Piston outer sealring
25 — Piston inner sealring
Torque lb ft N·m
A 8–10 11–14
3
4
8
9 11
10
12
14
13
V03323
Foldout 11,A. First Clutch and Rear Planetary Ring Gears Foldout 11,B. Low Clutch, Planetary, and Adapter Housing — MT(B) 650, 653
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 12
12,A 12,B
1 — Governor drive gear 1 — Shaft and plug assembly
2 — Speedometer drive gear 2 — Output shaft bushing
3 — Cup plug
3 — Speed sensor wheel 4 — Output shaft
4 — Sleeve spacer 5 — Spring pin
5 — Rear cover gasket 6 — Ball bearing assembly (earlier models)
7 — Roller bearing (later models)
6 — Rear cover assembly
8 — Governor drive gear
7 — Rear cover 9 — Speedometer drive gear (used with sleeve
8 — Governor support pin spacer 11, earlier models)
9 — Plug, 1⁄8 C 10 — Speed sensor wheel
11 — Sleeve spacer (earlier models)
10 — Plug, 1⁄8 C 12 — Rear cover gasket
11 — Governor filter kit 13 — Rear cover assembly
12 — Governor filter 14 — Roller bearing outer race (later models)
15 — Rear cover
13 — Sealring 16 — Governor support pin
14 — Filter plug,7⁄8-14 E 17 — Plug, 1⁄8 D
15 — Drain tube 18 — Plug, 1⁄8 D
19 — Governor filter kit
16 — Plug, 3⁄8 D 20 — Governor filter
17 — Flat washer, 1⁄2 (14) (used with non-flanged 21 — Sealring
bolt) 22 — Filter plug, 7⁄8-14 F
18 — Bolt, 1⁄2-13 x 11⁄2 (14) A* or F** 23 — Drain tube
24 — Plug, 3⁄8 E
19 — Flanged bolt, 1⁄2-13 x 11⁄2 (14) F
25 — Flat washer, 1⁄2 (14) (used with non-flanged
20 — Snapring (earlier models) bolt)
21 — Ball bearing 26 — Bolt, 1⁄2-13 x 51⁄4 (14) A* or G**
22 — Beveled snapring 27 — Flanged bolt, 1⁄2-13 x 51⁄4 (14) G
28 — Snapring (earlier models)
23 — Oil seal 29 — Ball bearing
24 — Dust shield 30 — Beveled snapring
25 — Output flange washer 31 — Oil seal
32 — Dust shield
26 — Bolt, 1⁄2-20 x 11⁄2 33 — Spacer (if used)
27 — Governor assembly 34 — Self-locking nut B
28 — Governor service kit 35 — Governor assembly
36 — Governor service kit
29 — Governor weight pin (2) 37 — Governor weight pin (2)
30 — Governor cover gasket 38 — Governor cover gasket
31 — Governor cover 39 — Governor cover
32 — Bolt, 5⁄16-18 x 11⁄16 (4) B 40 — Bolt, 5⁄16-18 x 11⁄16 (4) C
Torque lb ft N·m
Torque lb ft N·m A 67–80
A 67–80 91–108
91–108 B 600–800
B 15–20 814–1085
20–27 C 15–20
C 4–8 20–27
5–11 D 4–8
D 18–22 5–11
24–30 E 18–22
E 50–70 24–30
68–95 F 50–70
F 61–73 68–95
83–99 G 61–73 83–99
* Non-plated bolts * Non-plated bolts
** Zinc plated bolts ** Zinc plated bolts
5
3
6 17
7
18
19
16
20
21
9 15 22
12
28 13 23
11 14
10 24
29 27
30
31
32 25
26
E03335.01
Foldout 12,A. Rear Cover Components — MT 640, 643 Foldout 12,B. Output Shaft and Rear Cover Components — MT 650, 653
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 13
39
46
45
44
43
42
40 41 46
43
42 97 96
37 1
41
36 47
29 33 98
28 35 48
27 32
23 38
22 26 31
49
21 25 34
17
16 20 76 51
88
87 15 30 52
19 50
86 14 53
85 24
13 56 54
84 57 55
18
11 83 58
61
10 12 59
62
9
60
66 63
7
4 67 64
6
69 68 65 74
5 3
8 70
77 71
2
78 72 89
80 73 75
79
81
90
82 91
92
93
94
95
V03338
39
46
45
44
43
42
40 41 46
43
83
42 1
41
47 84
37
48 88
36
29 33
28 35
27 32 85
23 38
22 26 31
49 86
21 25 34 87
17
16 20 76 51
15 30 52
19 50
14 53
24
13 56 54
57 55
11 18
58
61
10 12 59
62
9
60
66 63
7
4 67 64
6
69 68 65
5 3
8 70
77 71
2 74
78 72
80 73
79
81
82
75
V03339
15,A
1 — Modulated lockup valve body assembly
2 — Modulated lockup valve body
3 — Retainer pin
4 — Modulated lockup valve
5 — Modulated lockup valve spring
6 — Modulated lockup valve stop
7 — Adjusting ring
15,B
1 — Oil transfer plate
2 — Separator plate
3 — Low shift valve assembly
4 — Valve body
5 — Retainer pin
6 — Retainer pin
7 — 1–2 relay valve
8 — 1–2 relay valve spring
9 — Valve stop
10 — 1–2 shift valve
11 — 1–2 shift valve spring
12 — Valve stop
13 — Washer
14 — Adjusting ring
6
7
V01919
Foldout 15,A. Modulated Lockup Valve Body Assembly Foldout 15,B. Low Shift Valve Body Assembly — MT(B) 650, 653
F OLDOUT 16
Torque lb ft N·m
A 117–140 159–190
17,A 17,B
1 — Sealring 1 — Retarder valve gasket (2)
2 — Flared tube 90˚ elbow B 2 — Separator plate
3 — Converter-out hose assembly C 3 — Flat washer, 10 mm (2)
4 — Hose clamp 4 — Bolt, hex, M10 x 1.5 x 45 (2) A
5 — Hex head bolt, 5⁄16-18 x 11⁄16 D 5 — Flat washer, 10 mm (10)
6 — Sealring 6 — Bolt, hex, M10 x 1.5 x 100 (10) A
7 — Flared tube connector B* 7 — Retarder control valve assembly
8 — Flared tube connector B* 8 — Bolt, hex, M6 x 1 x 80 (4) B
9 — Sealring 9 — Lockwasher, 6 mm (4)
10 — Nut, 5⁄16-18 hex H 10 — Retarder valve body top cover
11 — Lockwasher, 5⁄16 11 — Retarder valve body top cover gasket
12 — Hose clamp bracket 12 — Sealring
13 — Sealring 13 — Sealring
14 — Flared tube 90˚ elbow B 14 — Piston
15 — Clutch feed hose assembly A 15 — Retarder valve
16 — Flared tube 90˚ fitting G 16 — Retarder valve spring
17 — Check valve 17 — Retarder valve body
18 — Flared tube 90˚ elbow G 18 — Pipe plug, 1⁄2 NPTF D
19 — Internal snapring (3) 19 — Pipe plug, 1⁄4 NPTF E
20 — Pipe plug, 1⁄16 NPTF F
20 — Accumulator spring retainer (3) 21 — Retarder cutoff valve
21 — Accumulator inner spring (3) 22 — Retarder cutoff valve spring
22 — Accumulator outer spring (3) 23 — Gasket
23 — Accumulator piston sealring (3) 24 — Regulating valve assembly
24 — Accumulator piston (3) 25 — Oil transfer plate
25 — Accumulator piston sealring (3) 26 — Gasket
26 — Accumulator cover gasket 27 — Regulating valve body
27 — Accumulator cover assembly 28 — Charging valve spring
28 — Hex head pipe plug, 1⁄8 NPTF E 29 — Charging valve
29 — Hex head pipe plug, 1⁄8 NPTF E 30 — Sealring
30 — Accumulator cover 31 — Plug, hex socket, 7⁄8-14 UNF G
31 — Flat washer, 10 mm (13) 32 — Charging pressure orifice plug
32 — Bolt, M10 x 1.5 x 50 mm (13) F 33 — Retarder-pressure regulator valve
33 — Flat washer, sealring (2) 34 — Retarder-pressure regulator valve spring, inner
34 — Flanged bolt, M10 x 1.5 x 50 (2) F 35 — Retarder-pressure regulator valve spring, outer
35 — Governor assembly 36 — Valve plug
36 — Governor service kit 37 — Cover gasket
37 — Governor weight pin (2) 38 — Valve body cover
38 — Governor cover gasket 39 — Flat washer, 10 mm (2)
39 — Governor cover 40 — Bolt, hex, M10 x 1.5 x 35 (2) A
40 — Flat washer, 8 mm (4) 41 — Flat washer, 8 mm (2)
41 — Bolt, M8 x 1.25 x 25 mm (4) D 42 — Bolt, hex, M8 x 1.25 x 50 (2) C
43 — Flat washer, 8 mm (4)
Torque lb ft N·m 44 — Bolt, hex, M8 x 1.25 x 60 (4) C
A 16–20 22–27 45 — Flat washer, 8 mm (2)
B 25–35 34–47 46 — Bolt, hex, M8 x 1.25 x 80 (2) C
C 55–65 75–88 47 — Flat washer, 8 mm (2)
D 13–16 18–22 48 — Bolt, hex, M8 x 1.25 x 90 (2) C
E 4–5 5–7
F 30–35 39–48 Torque lb ft N·m
G 12–16 16–22 A 30–35 39–48
H 10–12 14–16 B 4–7 6–9
C 13–16 18–22
D 16–20 22–27
* OEM supplied filter assembly is located between connectors 7 and 8. E 8–10 11–14
F 3–4 4–6
G 50–70 68–95
Foldout 17,A. Retarder Accumulators and Governor Foldout 17,B. Retarder Control Valve
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS
Legend For Foldout 18
18,A 18,B
1 — Retarder housing gasket 1 — Internal snapring
2 — Retarder housing assembly 2 — Bolt, M10 x 1.5 x 35 mm
3 — Housing assembly (6, some models, 7) A
4 — Governor bushing 3 — Flat washer, 10 mm (6, some models, 7)
5 — Retarder housing and bushing assembly 4 — Retarder stator
6 — Retarder housing 5 — Stator sealring
7 — Dowel pin 6 — Retarder external-splined clutch plate (5)
8 — Sleeve 7 — Retarder internal-splined clutch plate (6)
9 — Retainer and ball assembly 8 — Output shaft assembly (MTB 643 only)
10 — Speedometer bushing 9 — Roller bearing assembly (MTB 643 only)
11 — Hex head pipe plug, 1⁄8 NPTF B 10 — Lube orifice plug (MTB 643 only)
12 — Governor filter kit 11 — Output shaft (MTB 643 only)
13 — Governor filter 12 — Sealring (2)
14 — Sealring 13 — Retarder rotor hub
15 — Hex socket plug, 7⁄8-14 UNF C 14 — Retarder rotor assembly
16 — Hex head pipe plug, 1⁄4 NPTF D 15 — Retarder clutch backplate
17 — Retarder priority valve
Torque lb ft N·m
18 — Retarder priority valve spring A 29–35 39–48
19 — Valve stop
20 — Pipe plug, 1⁄2 NPTF E
21 — Pipe plug, 1⁄2 NPTF E
22 — Valve stop pin
23 — Elbow, flared tube, 45˚ D
24 — Hex head pipe plug, 1⁄8 NPTF B
25 — Governor and speedometer drive gear
26 — Output shaft spacer
27 — Ball bearing
28 — Internal snapring
29 — Output shaft oil seal
30 — Nut, hex, self-locking F
31 — Flat washer, 12 mm (3)
32 — Bolt, hex, M12 x 1.75 x 130 (3) A
33 — Plug, speedo, 0.8125-20 UNEF-2A G
Torque lb ft N·m
A 53–63 72–85
B 4–5 5–7
C 50–70 68–95
D 8–10 11–14
E 16–20 22–27
F 600–800 814–1085
G 20–30 27–40
9 8
10
11
12
14
12
13
15
V03321
19,A 19,B
1 — Adapter housing gasket 1 — Roller bearing assembly
2 — Bolt, hex, M12 x 1.75 x 60 (11) A 2 — Output shaft assembly
3 — Flat washer, 12 mm (11) 3 — Bushing
4 — Ball bearing 4 — Cup plug
5 — Bolt, M12 x 1.75 x 45 (6) A 5 — Output shaft
6 — Flat washer, 12 mm (6) 6 — Bearing inner race and rollers
7 — Retarder adapter housing assembly 7 — Adapter housing gasket
8 — Hex head pipe plug,1⁄4 NPTF B 8 — Bolt, hex, M12 x 1.75 x 90 (12) (11, earlier
9 — Hex head pipe plug,1⁄4 NPTF B models) A
10 — Adapter housing and sleeve assembly 9 — Flat washer, 12 mm (12) (11, earlier models)
11 — Sleeve 10 — Output shaft spacer
12 — Pin 11 — Bolt, hex, M12 x 1.75 x 45 (5) A
13 — Adapter housing 12 — Flat washer, 12 mm (5)
14 — Retainer and ball assembly 13 — Retarder adapter housing assembly
15 — Hex head pipe plug,1⁄4 NPTF B 14 — Bearing outer race
16 — Hex head pipe plug,1⁄4 NPTF B 15 — Hex head pipe plug,1⁄4 NPTF B
17 — Hex head pipe plug,1⁄8 NPTF (2) C 16 — Hex head pipe plug,1⁄4 NPTF B
18 — Sealring (14) 17 — Adapter housing and sleeve assembly
19 — Flat washer, 1⁄2 (14) 18 — Retainer and ball assembly
20 — Bolt, hex head, 1⁄2-13 x 2 (14) D 19 — Adapter housing
21 — Adapter housing sealring 20 — Sleeve
22 — Retarder piston (selective) 21 — Pin
ID No. 5 0.736–0.740 inch (18.7–18.8 mm) 22 — Hex head pipe plug,1⁄4 NPTF B
ID No. 6 0.768–0.772 inch (19.5–19.6 mm) 23 — Hex head pipe plug,1⁄8 NPTF (2) C
ID No. 7 0.799–0.803 inch (20.3–20.4 mm) 24 — Sealring (14)
23 — Piston outer sealring 25 — Flat washer, 1⁄2 (14)
24 — Piston inner sealring 26 — Bolt, hex head, 1⁄2-13 x 51⁄2 (14) D
25 — Piston return spring 27 — Adapter housing sealring
26 — Piston return spring retainer 28 — Retarder piston (selective)
27 — External snapring ID No. 5 0.736–0.740 inch (18.7–18.8 mm)
ID No. 6 0.768–0.772 inch (19.5–19.6 mm)
Torque lb ft N·m
A 53–63 72–85 ID No. 7 0.799–0.803 inch (20.3–20.4 mm)
B 8–10 11–14 29 — Piston outer sealring
C 4–5 5–7 30 — Piston inner sealring
D 81–97 110–132 31 — Piston return spring
E 8 11
32 — Piston return spring retainer
33 — External snapring
Torque lb ft N·m
A 53–63 72–85
B 8–10 11–14
C 4–5 5–7
D 81–97 110–132
E 8 11
5
19
9
20
13
14 18 21
11
1 6
7
12
8
2 16 9 22
3 23
7 15 10 17
17 13
10
4
18
19 24
20 25
26
27
21
22 28
5
6
23 29
11
12
24
30
25
31
26
32
27
33
E03337.01
E03336.01
Foldout 19,A. MTB 643 Retarder Adapter Foldout 19,B. MTB 653 Retarder Adapter