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".
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Position transmission (1) onto suitable cribbing. The weight of transmission (1) is approximately
1043 kg (2300 lb) .Show/hide tableIllustration 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 Show/hide tablePersonal 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) .Show/hide tableIllustration 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) .Show/hide tableIllustration 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) .Show/hide tableIllustration 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 Show/hide tableIllustration 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 Show/hide tablePersonal 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.
Show/hide tableIllustration 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) .Show/hide tableIllustration 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 Show/hide tablePersonal 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.
Show/hide tableIllustration 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.
Show/hide tableIllustration 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) .Show/hide tableIllustration 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 Show/hide tablePersonal 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) .Show/hide tableIllustration 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 Show/hide tablePersonal 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.
Show/hide tableIllustration 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) .Show/hide tableIllustration 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 Show/hide tablePersonal 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.
Show/hide tableIllustration 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) .Show/hide tableIllustration 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 Show/hide tablePersonal 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.
Show/hide tableIllustration 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) .Show/hide tableIllustration 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 Show/hide tablePersonal 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.
Show/hide tableIllustration 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) .Show/hide tableIllustration 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).
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Illustration 1 | g01390304 |