16M Motor Grader Power Train Transmission

Transmission - Disassemble

16M Motor Grader Power Train [KENR6019]

16M Motor Grader Power Train Transmission Oil Cooler - Install

16M Motor Grader Power Train Transmission - Assemble

POWER TRAIN

TRANSMISSION GP

16M Motor Grader Power Train Transmission - Remove

16M Motor Grader Power Train Transmission - Install

16M Motor Grader Power Train Transmission - Disassemble

16M Motor Grader Power Train Transmission - Assemble

1.1. Disassembly Procedure

Disassembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Bracket	4
B	1U-9202	Lever Puller Hoist	1
C	1P-2420	Transmission Repair Stand	1
D	4C-8156	Lifting Fixture	1
E	FT-2769	Table	1
F	1U-6410	Three Jaw Puller	1
G	9U-7480	Compressing Tube	1
	5P-7970	Nut	1
	8T-4224	Hard Washer	1
	-	Bolt M8 - 1.25 by 460 mm	1
H	1U-6415	Three Jaw Puller	1
J	9U-7480	Compressing Tube	1
	8T-4133	Nut	1
	8T-4121	Washer	1
	-	Bolt M10 - 1.5 by 460mm	1
K	189-0408	Shackle As	1
L	3E-3882	Eyebolt	1
M	9U-7480	Compressing Tube	1
	6V-8149	Nut	1
	5P-8245	Hard Washer	1
	-	Bolt M12- 1.75 by 460 mm	1

Start By:

Remove the transmission. Refer to Disassembly and Assembly, "Transmission - Remove".

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 1	g01390304

Position transmission (1) onto suitable cribbing. The weight of transmission (1) is approximately 1043 kg (2300 lb).
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Illustration 2 g01390307
Remove clip (2). Remove hose assembly (3). Remove tube assembly (4). Remove tube assembly (5). Remove tube assembly (6).
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Illustration 3 g01390308
Disconnect harness assembly (7). Remove bolts (8) to remove filter base (9).
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Illustration 4 g01390309
Remove yoke assembly (10).
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Illustration 5 g01390315
Remove retaining ring (11).
Remove cup (12). Remove O-ring seal (13).
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Illustration 6 g01390318
Remove bolts (14) to remove control module (15) and spacers (16).
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Illustration 7 g01390322

Use Tooling (A), Tooling (B), and a suitable lifting device to position transmission (1) with the output shaft upward.

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Illustration 8	g01390323

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Remove bolts (17) evenly to remove spring plate (18).
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Illustration 9 g01390327
Remove lip seal (19).
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Illustration 10 g01390329
Remove O-ring seal (20).
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Illustration 11 g01390331
Remove spring discs (21).
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Illustration 12 g01390334
Remove piston (22).
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Illustration 13 g01390338
Remove piston seal (23). Remove piston seal (24).
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Illustration 14 g01390339
Disconnect harness assembly (25) and harness assembly (26).
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Illustration 15 g01390342
Remove bolts (27). Use two people to remove housing (28). The weight of housing (28) is approximately 27 kg (60 lb).
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Illustration 16 g01390343
Remove pressure sensor (29) and the O-ring seal. Remove solenoid (30).
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Illustration 17 g01390345
Remove O-ring seal (31), O-ring seal (32), O-ring seal (33), O-ring seal (34), and O-ring seal (35).
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Illustration 18 g01390349
Remove seal (36).
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Illustration 19 g01390351
Remove discs (37) and plates (38).
Note: Note the quantity and the order of discs (37) and plates (38) for installation purposes.
Remove O-ring seals (39) and O-ring seal (40).
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Illustration 20 g01390352
Remove retaining ring (41). Remove hub (42).
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Illustration 21 g01390353
Use Tooling (A), Tooling (B), and a suitable lifting device to position transmission (1) onto Tooling (C) with the output shaft downward. The weight of transmission (1) is approximately 1043 kg (2300 lb).
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Illustration 22 g01390355
Remove bolt (43) to remove speed sensor (44).
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Illustration 23 g01390356
Remove bolts (45) to remove speed sensor (46) and speed sensor (47).
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Illustration 24 g01390359
Remove cover (48).
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Illustration 25 g01390360
Remove bolts (49) to remove speed sensor (50) and speed sensor (51).
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Illustration 26 g01390362
Remove bolts (52).
Use Tooling (A), Tooling (B), and a suitable lifting device to remove housing (53). The weight of housing (53) is approximately 261 kg (575 lb).
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Illustration 27 g01390365
Remove O-ring seal (54). Remove bolts (55). Remove tube assembly (56).
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Illustration 28 g01390366
Remove bolts (57) to remove seal carrier (58). Remove bolts (59) to remove seal carrier (60).
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Illustration 29 g01390367
Remove seal rings (61). Remove O-ring seals (62). Repeat this step for the remaining seal carrier.
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Illustration 30 g01390368

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Illustration 31 g01390372
Use Tooling (D) and a suitable lifting device to remove clutch assembly (63) and clutch assembly (64). The weight of clutch assembly (63) and clutch assembly (64) is approximately 204 kg (450 lb).
Position clutch assembly (63) and clutch assembly (64) onto Tooling (E). If necessary, support clutch assembly (63) with suitable blocking.
Remove Tooling (D) to separate clutch assembly (63) from clutch assembly (64).
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Illustration 32 g01390376
Use Tooling (F) to remove bearing (65) and rotor (66).
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Illustration 33 g01390377
Remove thrust washer (67). Remove gear (68).
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Illustration 34 g01390381
Remove bearing sleeves (69) from gear (68).
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Illustration 35 g01390383

Remove thrust washer (70).

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Illustration 36	g01390389

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Use Tooling (G) to compress spring (71). Remove retaining ring (72). Remove Tooling (G). Remove retainer (73). Remove spring (71).
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Illustration 37 g01390392
Remove slider (74).
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Illustration 38 g01390395
Remove retaining ring (75) to remove end plate (76).
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Illustration 39 g01390400
Remove discs (77) and plates (78).
Note: Note the quantity and the order of discs (77) and plates (78) for installation purposes.
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Illustration 40 g01390403
Remove piston (79).
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Illustration 41 g01390405
Remove seal ring (80).
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Illustration 42 g01390409
Remove seal ring (81) and O-ring seal (82).
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Illustration 43 g01390412
Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 104 kg (230 lb).
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Illustration 44 g01390413
Use Tooling (H) to remove bearing (83).
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Illustration 45 g01390414
Remove spacer (84) and thrust washer (85).
Remove gear (86).
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Illustration 46 g01390419
Remove bearing sleeves (87) from gear (86).
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Illustration 47 g01390420

Remove thrust washer (88).

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Illustration 48	g06210691

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Use Tooling (M) to compress spring (89). Remove retaining ring (90). Remove Tooling (M). Remove retainer (91). Remove spring (89).
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Illustration 49 g01390425
Remove retaining ring (92) to remove end plate (93).
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Illustration 50 g01390426
Remove discs (94) and plates (95).
Note: Note the quantity and the order of discs (94) and plates (95) for installation purposes.
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Illustration 51 g01390428
Remove piston (96).
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Illustration 52 g01390430
Remove seal ring (97).
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Illustration 53 g01390540
Remove seal ring (98) and O-ring seal (99).
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Illustration 54 g01390545
Use Tooling (H) to remove bearing (100) from clutch assembly (63).
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Illustration 55 g01390547
Remove thrust washer (101). Remove gear (102).
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Illustration 56 g01390549
Remove thrust washer (103). Remove gear (104).
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Illustration 57 g01390554
Remove bearing sleeve (105) from gear (104).
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Illustration 58 g01390555
Use Tooling (G) to compress spring (106). Remove retaining ring (107). Remove Tooling (G). Remove retainer (108). Remove spring (106).
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Illustration 59 g01390562
Remove retaining ring (109) to remove end plate (110).
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Illustration 60 g01390565
Remove hub (111).
Remove discs (112) and plates (113).
Note: Note the quantity and the order of discs (112) and plates (113) for installation purposes.
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Illustration 61 g01390572
Remove slider (114). Remove piston (115).
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Illustration 62 g06497026
Remove O-ring seal (250) and seal ring (251) from piston (115).
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Illustration 63 g01390578
Remove seal ring (118) and O-ring seal (119).
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Illustration 64 g01390580
Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 113 kg (250 lb).
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Illustration 65 g01390581
Use Tooling (F) to remove bearing (120).
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Illustration 66 g01390582
Remove spacer (121). Remove gear (122).
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Illustration 67 g01390583
Remove spacer (123). Remove thrust washer (124).
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Illustration 68 g01390584
Remove gear (125).
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Illustration 69 g01390586
Remove bearing sleeves (126) from gear (125).
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Illustration 70 g01390588

Remove thrust washer (127).

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Illustration 71	g06210695

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Use Tooling (G) to compress spring (128). Remove retaining ring (129). Remove Tooling (G). Remove retainer (130). Remove spring (128).
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Illustration 72 g01390592
Remove retaining ring (131) to remove end plate (132).
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Illustration 73 g01390593
Remove hub (133).
Remove discs (134) and plates (135).
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Illustration 74 g01390595
Remove slider (136). Remove piston (137).
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Illustration 75 g01390596
Remove seal ring (138).
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Illustration 76 g01390597
Remove seal ring (139) and O-ring seal (140).
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Illustration 77 g02521756
Remove seal ring (140A). Use Tooling (F) to remove bearing (140B) and spacer (140C). Remove gear (140D).
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Illustration 78 g01390601
Remove bolts (141). Remove seal carrier (142).
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Illustration 79 g01390603
Remove seal rings (143). Remove O-ring seals (144).
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Illustration 80 g01390604
Use Tooling (K), Tooling (L), and a suitable lifting device to remove clutch assembly (145). The weight of clutch assembly (145) is approximately 86 kg (190 lb).
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Illustration 81 g01390606
Position clutch assembly (145) onto Tooling (E).
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Illustration 82 g01390608
Use Tooling (H) to remove bearing (146).
Remove spacer (147). Remove thrust washer (148).
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Illustration 83 g01390612
Remove gear (149).
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Illustration 84 g01390614
Use a suitable press to remove bearing (150) from gear (149).
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Illustration 85 g01390620

Remove thrust washer (151).

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Illustration 86	g01390617

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Use Tooling (G) to compress spring (152). Remove retaining ring (153). Remove Tooling (G). Remove retainer (154). Remove spring (152).
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Illustration 87 g01390622
Remove retaining ring (155) to remove end plate (156).
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Illustration 88 g01390625
Remove slider (157).
Remove discs (158) and plates (159).
Note: Note the quantity and the order of discs (158) and plates (159) for installation purposes.
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Illustration 89 g01390627
Remove piston (160).
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Illustration 90 g01390629
Remove seal rings (161).
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Illustration 91 g02407538
Remove seal ring (161A) and O-ring seal (161B).
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Illustration 92 g01390632
Use a suitable lifting device to turn over clutch assembly (145). The weight of clutch assembly (145) is approximately 86 kg (190 lb).
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Illustration 93 g01390633
Use Tooling (H) to remove race (162). Remove thrust race (163). Remove thrust washer (164) and thrust washer (165).
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Illustration 94 g01390634
Remove gear (166).
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Illustration 95 g01390639
Use a suitable press to remove bearing (167) from gear (166).
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Illustration 96 g01390641

Remove thrust washer (168).

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Illustration 97	g06210699

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Use Tooling (J) to compress spring (169). Remove retaining ring (170). Remove Tooling (J). Remove retainer (171). Remove spring (169).
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Illustration 98 g01390646
Remove retaining ring (172) to remove end plate (173).
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Illustration 99 g01390647
Remove slider (174).
Remove discs (175) and plates (176).
Note: Note the quantity and the order of discs (175) and plates (176) for installation purposes.
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Illustration 100 g01390651
Remove piston (177).
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Illustration 101 g01390652
Remove seal rings (178).
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Illustration 102 g01391047
Remove seal ring (179) and O-ring seal (180).
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Illustration 103 g01390655
Remove bolts (181) to remove seal carrier (182).
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Illustration 104 g01390657
Remove seal rings (183). Remove O-ring seals (184).
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Illustration 105 g01390658
Use Tooling (K), Tooling (L), and a suitable lifting device to remove clutch assembly (185). The weight of clutch assembly (185) is approximately 68 kg (150 lb).
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Illustration 106 g01390662
Position clutch assembly (185) onto Tooling (E).
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Illustration 107 g01390666
Use Tooling (F) to remove bearing (186).
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Illustration 108 g01390668
Remove spacer (187). Remove gear (188).
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Illustration 109 g01390671
Remove spacer (189). Remove slugs (190). Remove spacer (191).
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Illustration 110 g01390672
Remove thrust washer (192). Remove gear (193).
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Illustration 111 g01390676
Remove bearing sleeves (194) from gear (193).
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Illustration 112 g01390680

Remove thrust washer (195).

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Illustration 113	g01390682

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Use Tooling (G) to compress spring (196). Remove retaining ring (197). Remove Tooling (G). Remove retainer (198). Remove spring (196).
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Illustration 114 g01390949
Remove retaining ring (199) to remove end plate (200).
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Illustration 115 g01390685
Remove slider (201).
Remove discs (202) and plates (203).
Note: Note the quantity and the order of discs (202) and plates (203) for installation purposes.
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Illustration 116 g01390686
Remove piston (204).
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Illustration 117 g01390688
Remove seal ring (205).
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Illustration 118 g01390689
Remove seal ring (206) and O-ring seal (207).
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Illustration 119 g01390946
Use a suitable lifting device to turn over clutch assembly (185). The weight of clutch assembly (185) is approximately 68 kg (150 lb).
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Illustration 120 g01390863
Use Tooling (H) to remove race (208). Remove thrust race (209). Remove thrust washer (210). Remove thrust washer (211).
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Illustration 121 g01390871
Remove gear (212).
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Illustration 122 g01390872
Use a suitable press to remove bearing (213) from gear (212).
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Illustration 123 g01390877

Remove thrust washer (214).

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Illustration 124	g06210706

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Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Use Tooling (J) to compress spring (215). Remove retaining ring (216). Remove Tooling (J). Remove retainer (217). Remove spring (215).
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Illustration 125 g01390880
Remove retaining ring (218) to remove end plate (219).
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Illustration 126 g01390883
Remove slider (220).
Remove discs (221) and plates (222).
Note: Note the quantity and the order of discs (221) and plates (222) for installation purposes.
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Illustration 127 g01390885
Remove piston (223).
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Illustration 128 g01390887
Remove seal rings (224).
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Illustration 129 g01390889
Remove seal ring (225) and O-ring seal (226).
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Illustration 130 g02517216

Input Shaft
Use a suitable lifting device to remove shaft assembly (227). The weight of shaft assembly (227) is approximately 36 kg (80 lb).
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Illustration 131 g02517356
Use a suitable lifting device to position shaft assembly (227) onto Tooling (E).
Use suitable blocking to support shaft assembly (227). Use Tooling (H) to remove race (228).
Remove gear (229).
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Illustration 132 g02517358
Remove bolts (230). Use bolts (230) to remove gear (231).
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Illustration 133 g02517359
Remove retaining ring (232). Remove bearing (233). Remove retainer (234).
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Illustration 134 g02517360
Remove retaining ring (235).
Remove gear (236).
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Illustration 135 g02517362
Remove retaining ring (237). Remove bearing (238).
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Illustration 136 g02517376
Remove O-ring seal (239).
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Illustration 137 g02517378
Remove races (240) and races (241) from housing (54).
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Illustration 138 g02517380
Remove covers (242) and covers (243) from housing (54).
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Illustration 139 g02517381
Remove bearings (244), race (245), and race (246) from housing (247).