Remove And Install Transmission
Start By:
a. remove axle drive shaft assembly
b. remove ground drive hydraulic motor
1. Disconnect the brake cable (1) from the brake at the rear of the transmission.
2. Disconnect the shift lock hydraulic line (2) from the top of the transmission and cap or plug the openings.
3. Remove the mounting bolts for the shift lock solenoid valve mounting bracket (3) and move the bracket, with solenoid valve still attached, and lines out of the way.
4. Remove the bolt (4) and flatwasher holding the transmission shift bellcrank (5) to the shift lever (6).
5. Disconnect the shift cable at bellcrank (7) and, if used, the control rod at bellcrank (8).
6. Remove the two bolts from the shift bellcrank support bearing (9) on the left frame of the machine, and move transmission shift bellcrank out of the way.
7. Support transmission (10) with a transmission jack and remove the four bolts (11) that hold the transmission support plate (12) to the frame supports.
8. Lower the transmission and its support plate as a unit, and move it out from under the machine.
9. Remove the four transmission mounting bolts (13) and remove the support plate (12) from the transmission.
NOTE: The following steps are for installation of the transmission.
10. Bolt the transmission support plate back to the transmission.
11. Put the transmission and support plate on the transmission jack and move it into position under the machine.
12. Raise transmission (10) with the jack, align holes of support plate (12) with frame support holes and install the four mounting bolts (11).
13. Put the shift bellcrank support bearing (9) on the end of the transmission shift bellcrank, and position the bellcrank between the transmission shift lever shaft and the machine left frame.
14. Install the two bolts that hold the shift bellcrank support bearing (9) to the frame.
15. Connect the shift cable at bellcrank (7) and, if used, the control rod at bellcrank (8).
16. Install the bolt (4), nut and flatwasher holding the transmission shift bellcrank (5) to the shift lever (6), with the flatwasher installed between the lever and bellcrank.
17. Move the shift lock solenoid valve mounting bracket (3), with the solenoid valve and lines still attached, into position on the transmission and install the mounting bolts.
18. Remove the caps or plugs and connect the hydraulic shift lock line (2) back to the top of the transmission.
19. Connect the brake cable (1) back to the brake at the rear of the transmission.
End By:
a. install axle drive shaft assembly
b. install ground drive hydraulic motor
Remove And Install Parking Brake Assembly
Start By:
a. remove axle drive shaft assembly
1. Remove brake control cable pin (1) and remove control cable.
2. Remove the two jam nuts, lockwasher and guide bolt (7) from brake guide bracket (10).
3. Remove the two jam nuts, lockwasher, brake adjustment bolt (14) and the two springs (9).
4. Remove bolt (11) and spring (12) from brake band anchor (5).
5. Slide brake band assembly (15) off brake drum (13) and the brake band anchor.
6. Remove the four nuts and lockwashers and remove brake drum (13) from the shaft output flange.
7. Remove the two bolts and lockwashers and remove brake band anchor (5).
8. Remove the two bolts and lockwashers and remove brake guide bracket (10).
9. Remove brake adjustment pin (6) from the link brace (3) and cam levers (2), and remove the cam levers.
10. Remove clevis pin (8) and remove link brace (3).
11. Remove the bolt, lockwasher and nut, and remove brace link anchor bracket (4).
NOTE: The following steps are for assembly of the parking brake assembly.
12. Position brake band anchor (5) to the center holes at the left edge of the rear face of the transmission housing, and install the two bolts and lockwashers.
13. Position the brake guide bracket (10) to the center holes at the right edge of the rear face of the transmission housing, and install the bolts and lockwashers.
14. Mount the brace link anchor bracket (4) with a bolt, nut and lockwasher in the upper right corner on front of the rear face flange of the transmission housing. The brace link anchor bracket must be installed so that the tab points toward the input end of the transmission.
15. Position brake drum (13) on shaft output flange (16) and install the four nuts and lockwashers.
16. Slide brake band assembly (15) over brake drum (13) and anchor (5).
17. Insert anchor spring (12) between outboard side of brake band anchor (5) and brake band assembly. Install anchor bolt (11) but do not completely tighten.
18. Insert a brake adjustment spring (9) between each side of the brake guide bracket (10) and brake band (15), and install brake adjustment bolt (14) through brake band ends, springs and guide bracket. Install lockwasher and jam nuts, but do not tighten at this point.
19. Position link brace (3) to link brace anchor bracket (4) and install clevis pin (8).
20. Position a cam lever (2) on each side of the brake adjustment bolt (14) and install adjustment pin (6) through cam levers, adjustment bolt, and other end of the link brace.
21. Insert bolt (7) through brake band end and brake guide bracket (10). Install lockwasher and jam nuts, but do not tighten.
22. With the transmission in neutral, rotate the brake drum (13) while at the same time tightening anchor bolt (11) until a slight drag on brake drum is felt. Secure the bolt at this position by wiring through the bolt head and brake band.
23. Continue rotating the brake drum, and tighten nut of guide bolt (7) until a slight increase in drag is felt on the drum. Tighten the jam nut to lock the guide bolt at this position.
24. Continue rotating the brake drum while tightening nut of brake adjustment bolt (14) until a slight increase in drag is felt on the drum. Tighten the jam nut to lock the adjustment bolt at this position.
25. Put brake control cable (17) into position between the top holes of cam levers (2) and install brake control cable pin (1).
End By:
a. install axle drive shaft assembly
Disassemble And Assemble Shift Cap Group
Start By:
a. remove ground drive transmission
1. Remove the four bolts (2) that attach the shift cap group (1) to the gear and case group (3), and lift the shift cap group off the main case.
2. Remove the gasket.
3. Remove spring retainer cap (15).
4. Remove spring (28) and piston (27). O-rings (25 and 26) will come out with the piston.
5. Remove switch (23) and washer (22).
6. Remove the two roll pins (12) from shift rail (11).
7. Remove one of the expansion plugs (13) with a punch.
8. With a drift pin, drive against shift rail (11) to dislodge the other expansion plug (13).
 |
When removing the shift rail, opening (24) at the bottom of shift fork (10) must be shielded because detent spring (8) will propel detent ball (9) through the opening when end of rail moves past the ball. |
 |
9. Rotate shift rail (11) approximately 90° so that ball (9) will bypass the rail detents (14), and cover opening (24) with finger. Pull the shift rail out of shift cap (4).
10. The shift fork (10) is now free and can be removed from the shift cap. Be sure to retrieve the ball (9) and the spring (8).
11. Remove bushing reducer (18) and breather.
12. Remove cotter pin (7) and clevis pin (6).
13. Hit shift shaft (16) with a soft hammer at the serrated end to dislodge cup plug (21).
| NOTICE |
|---|
Remove shift shaft carefully so as not to damage seal (17) with the serrations on shaft. |
14. Remove the shift shaft (16) through cup plug end of the shift cap and out of shift lever (5) and the spring washer (19).
15. Remove the thrust washer, spacer (20) and retaining ring from the shift shaft.
16. If shaft oil seal (17) needs replacement, remove it from the shift cap.
NOTE: The following steps are for installation of the shift cap group.
17. If removed, install a new oil seal (17) in the shift cap (4).
18. Install retaining ring (30) in the groove on the end of shift shaft (16) opposite serrations.
19. Install thrust washer (29) onto serrated end of shift shaft until it is against the retaining ring.
20. Insert serrated end of shift shaft into its hole in shift cap (hole opposite oil seal) until it just begins to protrude on the inside of the cap.
| NOTICE |
|---|
Install shift shaft carefully so as not to damage the oil seal with the shaft serrations. |
21. Install spring washer (19) on the protruding shaft serrations, position shift lever (5) onto the same end of the shift shaft, and push the shaft through the lever and through the other side of cap with the oil seal.
22. Install spacer (20) on the shaft and install cup plug (21).
23. Align holes of shift lever (5) with hole in shift shaft and, using bushing hole at top of cap, insert pin (6) through lever and shaft and install cotter pin (7).
24. Install bushing reducer (18) and breather in the top of the cap.
25. With shift lever (5) in a vertical position, position shift fork (10) so that pin (31) of the shift lever is in slot of the fork, and install shift rail (11) through cap and half way into shift fork.
26. Insert spring (8) and detent ball (9) through opening (24).
27. Rotate the shift rail (11) so that detents of rail are approximately 90° to detent ball (9) and, while pressing the ball inside cavity in fork to compress spring (8), push the rail on through the fork into the hole at other side of cap.
NOTE: Before installing the roll pins in shift rail, make sure the rail detents are rotated back in alignment with the detent ball.
28. Align holes in shift rail with the holes in the cap and install the roll pins (12).
29. Install the expansion plugs (13) in the shift cap at each end of the shift rail.
30. Install washer (22) and neutral switch (23).
31. Install new O-rings (25 and 26) on piston (27), and insert the piston into its cavity in the shift cap.
32. Install spring (28) and retainer cap (15).
33. Put a new gasket (32) on top of transmission case, position shift cap (4) with shift fork (10) straddling the main shaft shift gear, and install the four bolts (2).
End By:
a. install ground drive transmission
Disassemble And Assemble Input Adapter Group
Start By:
a. remove ground drive transmission
1. Drain the transmission oil from bottom of the main case.
2. Remove the four mounting bolts (2) that attach the input adapter group (1) to the gear and case group (3).
3. Separate the input adapter group from the gear and case group.
4. Slide pilot bearing (7) out of input shaft (6).
5. Drive input shaft (6) and bearing (5) outward from inside the adapter housing (9).
6. Remove retaining ring (4) from the input shaft and pull main shaft front support bearing (5) from the input shaft.
7. If bearing (5) needs replacement, remove retaining ring (8) from the bearing groove.
NOTE: The following steps are for assembly of the input adapter group.
8. Clean the mating surfaces of input adapter (9) and gear and case group (3) to remove any gasket material.
9. Install retaining ring (8) in outer groove of main shaft front support bearing (5).
NOTE: Make sure bearing (5) is installed with retaining ring (8) next to spline of the input shaft.
10. Install bearing (5) on input shaft (6) and install retaining ring (4) in groove of input shaft.
11. Carefully drive the input shaft and bearing back into the housing of input adapter (9) until retaining ring (8) is against housing counterbore.
12. Install pilot bearing (7) into the end of input shaft (6).
13. Apply a thin bead of RTV 732 Silicon Sealant to the mating surface of main gear and case group (3).
14. Position the pilot bearing of the input shaft over the end of the main shaft, push input adapter group against housing of gear and case group and install mounting bolts (2).
15. Install the drain plug in bottom of main case and fill with the correct transmission oil.
End By:
a. install ground drive transmission
Disassemble And Assemble Gear And Case Group
Start By:
a. remove ground drive transmission
b. remove parking brake assembly
1. Remove drain plug at bottom of the main case and drain the transmission oil.
2. Remove the four mounting bolts (4) that attach the input adapter group (1) to the gear and case group.
3. Separate the input adapter group from the gear and case group.
4. Remove the four bolts (2) that attach the shift cap group (3) to the gear and case group, and lift the shift cap group off the main case.
5. Remove the gasket.
6. Remove the cotter pin and remove nut (13), washer, gasket, O-ring and output flange (14).
7. Remove bolts (17) that attach rear cover (16) to the main case (5).
8. Remove rear cover (16) and the rear cover gasket.
9. Drive oil seal (15) from the rear cover.
| NOTICE |
|---|
Drive out main shaft carefully so as not to damage the threads of output end. |
10. Drive the main shaft (6), from the output (threaded) end, through the main shaft rear support bearing (12).
NOTE: The needle rollers (8) between the shaft and output gear will fall to bottom of case when shaft is removed from gear.
11. Remove the main shaft by passing it through the thrust washer (10), output gear (9), shift gear (7), and through the input side of the main case (5).
12. The shift gear (7) and output gear (9) are now free to be removed from the main housing. Care must be taken to retrieve all thirty-nine needle rollers (8) and the thrust washer (10).
13. Remove the rear main shaft support bearing (12) by driving it outward from inside the main case.
14. Remove retaining ring (11) from the groove on the outside of the bearing.
15. Remove retaining ring (21) on the input side of center gear (19) on counter shaft (23).
16. Carefully drive counter shaft (23) and rear support bearing (26) from the input side of the main case toward the output side until the shaft comes free of front support bearing (25).
NOTE: If front support bearing (25) becomes dislodged from its bore in the housing, the front support bearing will have to be removed from the shaft before shaft can be removed from the main case.
17. Slide counter shaft drive gear (18) and center gear (19) off counter shaft (23) as the counter shaft and rear support bearing (26) are withdrawn from the main case.
18. Remove rear support bearing (26) and center gear output side retaining ring (22) from the counter shaft.
19. The counter shaft drive gear (18), center gear (19) and front support bearing (25) can now be removed from the main case.
NOTE: The following steps are for assembly of the gear and case group.
20. If a new front support bearing (25) or new rear support bearing (26) is used, retaining rings (20 and 24) must be installed on the new bearings.
21. Install front support bearing (25) in the main case. Retaining ring (20) must be positioned against the inside of the case.
22. Install rear support bearing (26) onto the counter shaft against the shoulder of the gear. Bearing must be positioned with retaining ring (24) at end of shaft, away from gear shoulder.
23. Install center gear output side retaining ring (22) on counter shaft (23) if it was removed.
24. Insert the small end of the counter shaft into output end of the case, and then slide center gear (19) onto the counter shaft splines against retaining ring (22). Install center gear input side retaining ring (21).
25. Install counter shaft drive gear (18) over the shaft onto the splines with longer shoulder of the drive gear hub facing the center gear.
26. Position small end of counter shaft in front support bearing (25) and outer race of rear support bearing in case, and install the counter shaft assembly into the case. Check to make sure that bearings are fully installed in case with the retaining ring of each bearing against the case surface.
27. Install retaining ring (11) in groove of rear support bearing (12) and install bearing from output end of main case (5).
28. Install oil seal (15) into rear cover (16) until seal is flush with outside edge of cover.
29. Position the rear cover gasket and rear cover on the main case, and install bolts (17).
30. Hold shift gear (7) in position inside the case and insert the threaded end of main shaft (6) through the rear of the case and through the shift gear until the internal teeth of shift gear are meshed with the gear teeth on main shaft.
31. Position output gear (9) over the end of the main shaft with gear teeth of hub facing the gear teeth on the shaft, and install gear against shaft shoulder.
NOTE: To aid installation of the needle rollers, raise output gear until it touches bottom of shaft, install half of the rollers at top of shaft and then slowly lower gear until the rollers can roll around the gear hub to the bottom of the shaft. Slide the shift gear toward output gear to mesh teeth of the gears, then install the remaining rollers while output gear is centered by the shift gear.
32. Install the thirty-nine needle rollers (8) between output gear and shaft, and install thrust washer (10).
33. Align teeth of main shaft gears with the teeth of counter shaft gears, and install main shaft (6) into rear support bearing (12).
34. Apply a thin coat of oil to the oil seal contact surface of output flange (14), and install flange over the main shaft splines and through oil seal until shoulder of flange is against bearing (12).
35. Cover shaft threads with tape and install O-ring and gasket over the covered threads.
36. Remove the tape from the threads and install and tighten nut (13). Install the cotter pin.
37. Thoroughly clean the front surface of main case (5), and apply a thin bead of RTV 732 Silicon Sealant to this surface.
38. Make sure pilot bearing (28) is still Installed inside the end of adapter input shaft (27), and position the pilot bearing and input shaft over the end of main shaft (6).
39. Start main shaft front support bearing (29) into the main case and push input adapter group (1) inward until it is against the RTV gasket material. Install and tighten the four mounting bolts (4).
40. Put a new gasket on top of the transmission case and position shift cap (3) with the shift fork straddling the teeth of shift gear (7). Install the four mounting bolts (2).
41. Install the drain plug at bottom of the main case and fill with the correct transmission oil.
End By:
a. install parking brake assembly
b. install ground drive transmission