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120H Motor Grader 2AN00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP...

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Cerrar SIS

Pantalla anterior

Producto: MOTOR GRADER


Modelo: 120H MOTOR GRADER 2AN
Configuración: 120H Motor Grader 2AN00001-UP (MACHINE) POWERED BY
3116 Engine

Desarmado y Armado
120H & 135H MOTOR GRADERS POWER TRAIN
Número de medio -SENR8543-02 Fecha de publicación -01/09/2004 Fecha de actualización -31/08/2005

SENR85430018

Transmission
SMCS - 3400-011; 3400-012; 3400-015; 3400-016

Remove Transmission

Start By:

a. remove radiator*

*For information on the removal of the radiator, refer to the "3116 Engine Supplement for 120H and
135H Motor Graders."

b. remove batteries and battery boxes*

*For information on the removal of the batteries and battery boxes, refer to the "3116 Engine
Supplement for 120H and 135H Motor Graders."

c. Remove fuel tank **

**For information on the removal of the fuel tank, refer to "SENR8544 Machine Systems for 120H and
135H Motor Graders."

d. remove differential drive shaft

Be cautious of hot oil when draining the oil from the transmission and
when disconnecting and transmission oil lines.

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1. Drain the transmission fluid in a suitable container for storage or disposal. The capacity of the power
train system is 47 Liters (50 qt).

NOTICE
It is imperative that any oil ports on the transmission be covered when
any hydraulic lines or components are remove from the transmission.
This will prevent any damage to the transmission by preventing dirt
from entering the hydraulic system of the transmission controls.

2. Disconnect three wire terminals (2) from alternator (3).

3. Loosen bolts (4) that hold the alternator. Loosen V-belts (1).

4. Remove bolt (6) and the washer from the hose clip.

5. Attach lifting slings, or chains and a hoist to the fan and alternator assembly. Remove four mounting
bolts (5) and the washers that hold the fan assembly to the machine frame. Remove the fan assembly
from the machine. The weight of the fan assembly is 100 kg (220 lb).

Do not disconnect any air line from the machine until the air pressure in
the air tank is zero. Release air pressure from the air tank by loosening
the bleed valves. The valves are underneath the rear bumper on the
sides of the air tank.

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6. Relieve air pressure from air tank (7).

7. Put identification marks on four hoses (8) for installation purposes. Disconnect for hoses (8) from air
tank (7).

8. Remove four bolts (9), the washers and shims from mounting plates (10). Remove air tank (7) from
the machine frame. The weight of air tank (7) is 17 kg (37 lb).

View From Above And Right Side Of Transmission

9. Remove four bolts and washers (11) and flange (12) in order to disconnect filter hose assembly (13).
Plug the fittings to prevent the loss of oil, and to keep dirt of the hydraulic system.

View From Above And Left Side Of Transmission

10. Remove four bolts and washers (15) and flange (14) in order to disconnect two hose assemblies
(16). Plug the fittings to prevent the loss of oil, and to keep dirt out of the hydraulic system.

11. Disconnect two wire harness terminals (17) from the transmission control valve.

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12. Remove bolt (22) and the clip from transmission hose assembly (18).

13. Disconnect the fittings of hose assembly (20) from filter base (19). Plug the fittings to prevent the
loss of oil, and to keep dirt out of the hydraulic system.

14. Remove two bolts (21) and washers that hold filter base (19) to the machine frame. Move filter base
(19) out of the way.

15. Put identification marks on two hose assemblies (23) for installation purposes. Disconnect the
fittings of the hoses from the transmission. Plug the fittings to prevent the loss of oil, and to keep dirt
out of the hydraulic system.

16. Disconnect shift control cable (24) from the transmission hydraulic control valve.

17. Remove four bolts (26), the washers and the flange in order to disconnect hose assembly (25) from
the transmission. Plug the fittings to prevent the loss of oil, and to keep dirt out of the hydraulic system.

18. Disconnect the fittings on hose assembly (27) from the transmission.

19. Loosen clamp (29) and disconnect hose assembly (28) from hose connector (30).

20. Loosen clamp (32) and disconnect hose (31) from the differential.

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21. Install Tooling (A) to both sides of flywheel housing (33). Adjust both screws (34) in order to
contact the machine frame. This tooling will support the engine after the rear motor mounts are
removed.

22. Install Tooling (B) and a hoist to the transmission.

23. Remove twelve bolts (35) from the transmission flange.

24. Remove two bolts and washers (36) and mounting flange assemblies (37) from the machine frame
and motor mounts. Note the location of flange assembly (37) components for installation purposes.

NOTE: The transmission must be moved straight back approximately 50.8 mm (2.00 in) in order to
clear the torsion coupling with the splined shaft. The transmission can be lifted after the clearance is
attained.

25. Carefully remove the transmission from the machine frame and the flywheel housing. Check for
clearance of wire harnesses and hose assemblies when you remove the transmission. The weight of the
transmission is 817 kg (1800 lb).

26. Remove the fan drive pulley from the transmission.

Install Transmission

1. Clean the mounting faces of the transmission and the flywheel housing. Check the condition of all O-
ring seal used in the fittings of the hose assemblies that were disconnected. If any of the seals are
damaged, use new parts for replacement. Check the condition of mounting flange assemblies (33). If the
rubber components are misshapen, non-pliable or cracked, use new parts for replacement

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2. Install the fan drive pulley to the transmission. Install Tooling (B) and a hoist to the transmission.
Check the clearance if wire harnesses and hose assemblies when you install the transmission. Carefully
position the transmission to the machine frame and the flywheel housing.

3. Install twelve bolts (35) and the washers to the transmission flange.

4. Install mounting flange assemblies (37), two bolts and washers (36) to the machine frame and motor
mounts. Remember to install the rubber components in their original locations.

5. Loosen screws (34) and remove both halves of Tooling (A) from the flywheel housing.

6. Install hose connector (30) if it was removed. Hose connector (30) must be tightened to a torque of
470 ± 10 N·m (345 ± 7 lb ft).

7. Install hose assembly (28) to connector (30) and tighten clamp (29).

8. Install hose assembly (27) to the transmission.

9. Install hose assembly (31) to the differential and tighten clamp (32).

10. Install four bolts (26), the washers and the flange in order to connect hose assembly (25) to the
transmission.

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11. Install shift control cable (24) to the transmission control valve.

12. Install two hose assemblies (23) to the transmission.

13. Position filter base (19) to the machine frame. Install two bolts (21) and the washers that hold filter
base (19) to the machine frame.

14. Connect the fittings of hose assembly (20) to filter base (19).

15. Install bolt (22) to secure clip on transmission hose assembly (18) to the transmission.

16. Connect two wire harness terminals (17) to the transmission control valve.

17. Install four bolts and washers (15) and flange (14) to install two hose assemblies (16) to the
transmission.

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18. Install four bolts and washers (11) and flange (12) in order to install filter hose assembly (13) to the
transmission.

19. Position air tank (7) to its original location between the machine frames. Install four bolts (9), the
washers and original shims in two mounting plates (10) in order to secure the tank to the frame.

20. Install four hose assemblies (8) to their original locations on air tank (7).

21. Attach lifting slings, or chains and a hoist to the fan and alternator assembly. Position the fan and
alternator assembly to the machine. Install four mounting bolts and washers (5) that hold the fan and
alternator assembly to the machine frame.

22. Install bolt (6) and the washer to hold the hose and the clip to the fan assembly mount.

23. Install the V-belts to the fan and alternator assembly pulleys.

24. Adjust the belt tension and tighten bolts (4). Refer to the "Operation & Maintenance Manual" for the
proper procedure of adjusting belt tension.

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25. Connect three wire terminals (2) to alternator (3).

End By:

a. install differential drive

b. install batteries and battery boxes*

*For information on the installation of the batteries and battery boxes, refer to the "3116 Engine
Supplement for 120H and 135H Motor Graders."

c. install radiator*

*For information on the removal of the radiator, refer to the "3116 Engine Supplement for 120H and
135H Motor Graders."

d. install fuel tank**

**For information on the installation of the fuel tank, refer to "SENR8544 Machine Systems for 120H
and 135H Motor Graders."

Disassemble Transmission

Start By:

a. remove transmission hydraulic control valve.

b. remove parking brake

c. remove transmission speed sensor

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d. remove transmission oil pump

e. remove transmission magnetic filter screen base.

1. Place transmission level on floor as shown.

2. Remove twelve bolts (1). Remove four covers (2) and their O-ring seals from the transmission case.

3. Remove 43 bolts (3) from the transmission case flange.

4. Identify the location of seal carrier (4) in the transmission case for assembly purposes. Remove two
bolts (5) from seal carrier (4). Install an 8mm Eyebolt in seal carrier (4). Remove seal carrier (4) and its
O-ring seals from the transmission case bore.

5. Repeat Step (4) on the three remaining seal carriers.

6. Remove three seal rings (6) from seal carrier (4).

7. Remove three, or four O-ring seals (7) from seal carrier (4). Remove locating pin (8) from seal carrier
(4).

8. Repeat Steps (6) and (7) for the remaining three seal carriers.

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9. Install two 10 x 1.5 mm Forcing Bolts (9) in the transmission case flange. Tighten them evenly to
separate the transmission cases.

10. Install Tool (G), attach lifting chains and a hoist to the transmission case, as shown. Slowly raise the
upper portion of the transmission case from the lower portion of the transmission case. Be careful not to
bind the transmission case during separation.

11. Remove three bolts (10) from tube (11). Remove tube (11) from the transmission case.

12. Remove the O-ring seal from the elbow end of tube assembly (11).

NOTE: First/Third shaft assembly (12) and High/Low shaft assembly (13) must be removed together.

13. Install Tool (A) on First/Third shaft assembly (12) and High/Low shaft assembly (13). Use one 8 x
1.25 x 75 mm Bolt and one 8 x 1.25 x 50 mm Bolt, in order to hold Tool (A) on First/Third shaft
assembly (12) and High/Low shaft assembly (13) as shown. First/Third shaft assembly (12) and
High/Low shaft assembly (13) must be removed together.

14. Attach a suitable lifting device to Tool (A). Carefully remove First/Third shaft assembly (12) and
High/Low shaft assembly (13) from the transmission case. The weight of the two shaft assemblies is
177 kg (390 lb).

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15. Place First/Third shaft assembly (12) and High/Low shaft assembly (13) on Tooling (I) or on blocks
and remove Tool (A). Carefully separate First/Third shaft assembly (12) and High/Low shaft assembly
(13). The weight of each shaft assembly is 88.530 kg (195 lb)

NOTE: Place High/Low shaft assembly (13) in a modified work bench or on blocks. Modify a
substantial workbench by cutting a 116 ± 2 mm (4.6 ± .08 in) clearance hole in the top of the bench.

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NOTICE
Do not attach Tooling (E) to rotor (15). The rotor is cast iron, and will
be broken if pressure is applied to it with the puller. Attach the tooling
to gear assembly (16).

16. With High/Low shaft assembly (13) on the modified work bench or on blocks, use Tooling (E) in
order to remove bearing (14), rotor (15) and gear assembly (16) from shaft assembly (13). Bearing (14)
and rotor (15) are press fit on High/Low shaft assembly (13).

17. Remove bearing (14), rotor (15), thrust disc (15A) and gear assembly (16), as a unit, from
High/Low shaft assembly (13). Attach the tooling to gear assembly (16), not rotor (15).

18. Remove thrust disc and washer (17) from High/Low shaft assembly (13).

19. Install Tool (B) on High/Low shaft assembly (13) and clutch assembly (18). Use an 8 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten an 8 mm Nut on the threaded rod
in order to compress clutch assembly (18). Remove two half rings (19) and two lock rings (20) from the
shaft groove.

20. Carefully loosen the nut on Tool (B) in order to relieve pressure from clutch assembly (18). Remove
Tool (B) from High/Low shaft assembly (13) and clutch assembly (18). As you remove clutch assembly
(18) from the High/Low shaft assembly (13), identify the positions of the five clutch plates, six friction
disc and the hub assembly for assembly purposes.

21. Remove wave spring (21) from High/Low shaft assembly (13).

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22. Remove piston (22) from High/Low shaft assembly (13).

23. Remove two lip seals (23) from piston (22).

24. Turn High/Low shaft assembly (13) over in order to work on the other end. Place High/Low shaft
(13) in the modified work bench, or on blocks. The weight of the High/Low shaft assembly (13) is 49.9
kg (110 lb). Place High/Low shaft assembly (13) on the modified work bench or on blocks.

25. Install Tooling (F) and Tooling (H) on High/Low shaft assembly (13) and bearing (24). Remove
bearing (24) from High/Low shaft assembly (13). Remove two thrust disc (25) and gear assembly (26)
from High/Low shaft assembly (13).

26. Remove thrust disc and washer (27) from High/Low shaft assembly (13).

NOTE: If the 9U-7479 Tube, Tool (B), is the old style tool it will have to be modified. If it is the new
style tool, it will work without modification. Tool (B) may have to be modified so the hole in the top of
the tube will have clearance for a 12 mm Threaded Rod.

27. Install Tool (B) on High/Low shaft assembly (13) and clutch assembly (28). Use a 12 mm Threaded

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Rod that is approximately 508 mm (20 in) long. Tighten a 12 mm Nut on the threaded rod in order to
compress clutch assembly (28). Remove two half rings (29) and two lock rings (30) from the shaft
groove.

28. Carefully loosen the nut on Tool (B) in order to relieve pressure from clutch assembly (28). Remove
Tool (B) from High/Low shaft assembly (13) and clutch assembly (28). As you remove clutch assembly
(28) from the High/Low shaft assembly (13), identify the positions of the seven clutch plates, eight
friction disc and the hub assembly for assembly purposes.

NOTE: If the 9U-7479 Tube, Tool (B), is the old style tool it will have to be modified. If it is the new
style tool, it will work without modification. Tool (B) may have to be modified so the hole in the top of
the tube will have clearance for a 12 mm Threaded Rod.

29. Install Tool (B) on High/Low shaft assembly (13) and balance piston (31). Use a 12 mm Threaded
Rod that is approximately 508 mm (20 in) long. Tighten a 12 mm Nut on the threaded rod in order to
compress balance piston (31).

30. Use Tool (C) in order to remove retaining ring (32) from High/Low shaft assembly (13).

31. Carefully loosen the nut on Tool (B) in order to relieve pressure from the balance piston (31).
Remove Tool (B) from High/Low shaft assembly (13) and balance piston (31).

32. Remove balance piston (31) and lip seal (33) from High/Low shaft assembly (13).

33. Remove fifteen springs (34) from piston (35).

34. Remove piston (35) and two lip seals (not shown), from High/Low shaft assembly (13).

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35. Remove two lip seals (36) from piston (35).

First/Third Shaft assembly (12)

36. Place First/Third shaft assembly (12) on the modified work bench or on blocks. Use Tooling (E) in
order to remove bearing (37), thrust disc (not shown) and gear (38) from First/Third shaft assembly
(12).

37. Remove thrust disc (39) and gear assembly (40) from First/Third shaft assembly (12).

38. Remove thrust disc (41) and washer (42) from First/Third shaft assembly (12).

39. Install Tool (B) on First/Third shaft assembly (12) and clutch assembly (43). Use an 8 mm Threaded
Rod that is approximately 508 mm (20 in) long. Tighten a 8 mm Nut on the threaded rod in order to
compress clutch assembly (43). Remove two half rings (44) and two lock rings (45) from the shaft
groove.

40. Carefully loosen the nut on Tool (B) in order to relieve pressure from clutch assembly (43). Remove

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Tool (B) from First/Third shaft assembly (12) and clutch assembly (43). As you remove clutch
assembly (43) from First/Third shaft assembly (12), identify the positions of the five clutch plates, six
friction disc and the hub assembly for assembly purposes.

41. Remove wave spring (46) from First/Third shaft assembly (12).

42. Remove piston (47) from First/Third shaft assembly (12).

43. Remove two lip seals (48) from piston (47).

44. Turn First/Third shaft assembly (12) over in order to work on the other end. Place First/Third shaft
assembly (12) in the modified work bench, or on blocks. The weight of First/Third shaft assembly (12)
is 54.5 kg (120 lb). Place First/Third shaft assembly (12) on the modified work bench or on blocks.

45. Use Tool (E) in order to remove bearing (49), thrust disc (not show), gear (50) and thrust disc (not
shown).

46. Remove gear assembly (51), the thrust disc and washer (not shown) from First/Third shaft assembly
(12).

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47. Install Tool (B) on First/Third shaft assembly (12) and clutch assembly (52). Use an 8 mm Threaded
Rod that is approximately 508 mm (20 in) long. Tighten a 8 mm Nut on the threaded rod in order to
compress clutch assembly (52). Remove two half rings (53) and two lock rings (54) from the shaft
groove.

48. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (52). Remove Tool
(B) from First/Third shaft assembly (12) and clutch assembly (52). As you remove clutch assembly (52)
from First/Third shaft assembly (12), identify the positions of the three clutch plates, four friction disc
and the hub assembly for assembly purposes.

49. Remove wave spring (55) from First/Third shaft assembly (12).

50. Remove piston (56) from First/Third shaft assembly (12).

51. Remove two lip seals (57) from piston (56).

Input Shaft Assembly (58)

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52. Use Tooling (E) in order to remove bearing (59) and gear (60) from Input shaft assembly (58). This
is necessary at this time in order to remove the remaining two shaft assemblies.

53. Install an 8 mm Eyebolt and remove Reverse/Second shaft assembly (61) from the transmission
case. The weight of Reverse/Second shaft assembly (61) is 63.6 kg (140 lb).

54. Place Reverse/Second shaft assembly (61) on the modified work bench, or on blocks.

55. Use Tooling (E) in order to remove bearing (62), spacer (63) and gear (64) from Reverse/Second
shaft assembly (61).

56. Remove spacer (65) and thrust disc (not shown) from Reverse/Second shaft assembly (61).

57. Remove gear assembly (66), thrust disc and washer (not shown) from Reverse/Second shaft
assembly (61).

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58. Install Tool (B) on Reverse/Second shaft assembly (61) and clutch assembly (67). Use an 8 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten an 8 mm Nut on the threaded rod in
order to compress clutch assembly (67). Remove two half rings (68) and two lock rings (69) from the
shaft groove.

59. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (67). Remove Tool
(B) from Reverse/Second shaft assembly (61) and clutch assembly (67). As you remove clutch
assembly (67) from Reverse/Second shaft assembly (61), identify the positions of the three clutch
plates, four friction disc and the hub assembly for assembly purposes.

60. Remove wave spring (70) from Reverse/Second shaft assembly (61).

61. Remove piston (71) from Reverse/Second shaft assembly (61).

62. Remove two lip seals (72) from piston (71)

63. Turn Reverse/Second shaft assembly (61) over in order to work on the other end. Weight of
Reverse/Second shaft assembly (61) is 41 kg (90 lb).

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64. Place Reverse/Second shaft assembly (61) on the modified work bench, or on blocks.

65. Install Tooling (D) and (F) on gear assembly (74) and Reverse/Second shaft assembly (61).

66. Remove bearing (73), the thrust race (not shown), two thrust disc (not shown) and gear assembly
(74) from Reverse/Second shaft assembly (61).

67. Remove needle bearing (75) from Reverse/Second shaft assembly (61).

68. Remove thrust disc and washer (76) from Reverse/Second shaft assembly (61).

69. Use a second person in order to compress clutch assembly (77).

70. Remove two half rings (78) from the shaft groove. Release the pressure from clutch assembly (77),
slowly, until the spring underneath clutch assembly (77) is extended and relaxed.

71. Remove hub assembly (79) from Reverse/Second shaft assembly (61).

72. Remove spring (81) from Reverse/Second shaft assembly (61).

73. When removing the clutch plates and friction disc, identify their locations for installation purposes.
Remove six clutch plates and seven friction disc (80) from Reverse/Second shaft assembly (61).

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74. Remove valve assembly (82) from Reverse/Second shaft assembly (61).

75. Remove piston (83) from Reverse/Second shaft assembly (61).

76. Remove two lip seals (84) from piston (83).

77. Install an 8 mm Eyebolt in Forward shaft assembly (85). Remove Forward shaft assembly (85)
from the transmission case. The weight of Forward shaft assembly (85) is 63.6 kg (140 lb).

78. Place Forward shaft assembly (85) on the modified work bench, or on blocks. Install Tooling (D)
and Tooling (F) to Forward shaft assembly (85) and gear assembly (87).

79. Remove bearing (86), two thrust disc, (not shown), and gear assembly (87) from Forward shaft
assembly (85).

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80. Remove needle bearing (88) from Forward shaft assembly (85).

81. Remove thrust disc and washer (89) from Forward shaft assembly (85).

82. Use a second person in order to compress clutch assembly (90).

83. Remove two half rings (91) from the shaft groove. Release the pressure from clutch assembly (90),
slowly, until the spring underneath clutch assembly (90) is extended and relaxed.

84. Remove hub assembly (92) from the Forward shaft assembly (85).

85. Remove spring (94) from Forward shaft assembly (85).

86. Remove six clutch plates and seven friction discs (93) from Forward shaft assembly (85). Identify
the positions of the clutch plates and friction disc for assembly purposes.

87. Remove valve assembly (95) from Forward shaft assembly (85).

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88. Remove piston (96) from Forward shaft assembly (85).

89. Remove two lips seals (97) from piston (96).

90. Turn Forward shaft assembly (85) over in order to work on the other end. The weight of Forward
shaft assembly (85) is 43.1 kg (95 lb). Place Forward shaft assembly (85) in the modified work bench,
or on blocks.

91. Install Tooling (D) and (F) to Forward shaft assembly (85) and gear assembly (99).

92. Remove bearing (98), the thrust race (not shown), the two thrust disc (not shown) and gear assembly
(99) from Forward shaft assembly (85).

93. Remove needle bearing (100) from Forward shaft assembly (85).

94. Remove thrust disc and washer (101) from Forward shaft assembly (85).

95. Use a second person in order to compress clutch assembly (102).

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96. Remove two half rings (103) from the shaft groove.

97. Release the pressure from clutch assembly (102), slowly, until the spring underneath clutch
assembly (102) is extended and relaxed.

98. Remove hub assembly (104) from Forward shaft assembly (85).

99. Remove spring (105) from Forward shaft assembly (85).

100. Remove six clutch plates and seven friction disc (106) from Forward shaft assembly (85). Identify
the positions of the clutch plates and friction disc (106) for assembly purposes.

101. Remove valve assembly (107) from Forward shaft assembly (85).

102. Remove piston (108) from Forward shaft assembly (85).

103. Remove two lip seals (109) from piston (108).

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104. Install an 8 mm Eyebolt in Input shaft assembly (58). Remove Input shaft assembly (58) from the
transmission case. The weight of Input shaft assembly (58) is 22.7 kg (50 lb).

105. Remove two seal rings (110) from Input shaft assembly (58).

106. Remove bearing (111) and gear (112) from Input shaft assembly (58).

107. Remove four bolts (113) from pump drive gear (114). Rotate pump drive gear (114) to locate the
two bolts not seen.

108. Remove drive pump gear (114) from the transmission case.

109. Turn pump drive gear (114) over. Use Tool (C) to remove retaining ring (117) from pump drive
gear (114).

110. Turn pump drive gear (114) over. Use a small driver through three small holes (not shown) in
order to drive bearing (115) off of gear (114).

111. Remove bearing (115) from retainer (116). This is a slip fit.

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112. Remove five bearing races (118) from the transmission case.

113. Repeat Step 112 on the other half of the transmission case.

Assemble Transmission

1. Lower the temperature of bearing races (118). Install bearing races (118) in their original locations in
both transmission case halves until they are seated.

2. Install retainer (116) on pump drive gear (114).

3. Heat bearing (115) to a maximum temperature of 135° C (275° F). Install bearing (115) to its original
location on pump drive gear (114).

4. Use Tool (C) in order to install retaining ring (117) to its original location on pump drive gear (114).

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5. Install pump drive gear (114) to its original location in the transmission case.

6. Install four bolts (113) in the pump drive gear (114). Tighten bolts (113) to a torque of 28 ± 7 N·m
(21 ± 5 lb ft).

7. Install gear (112) on Input shaft assembly (58).

8. Heat bearing (111) to a maximum of 135° C (275° F). Install bearing (111) on Input shaft assembly
(58) until it is seated. Gear (112) should be tight on Input shaft assembly (58).

9. Install two seal rings (110) to their original locations on Input shaft assembly (58).

10. Install an 8 mm Eyebolt to Input shaft assembly (58). Use a hoist to position Input shaft assembly
(58) to its original location in the transmission case. Install Input shaft assembly (58) in the transmission
case. Remove the eyebolt.

11. Install two lip seals (109) on piston (108). Install both seals (108) and (109) with the sealing lips
facing towards the small diameter of the piston.

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12. Place Forward shaft assembly (85) in the modified work bench or on blocks. Apply a light coat of
clean hydraulic oil on the lip seals. Install piston (108) to its original location on Forward shaft
assembly (85). Rotate the piston slightly during the seal entry. Make sure the lip seals are installed
properly.

13. Install valve assembly (107) to its original location on Forward shaft assembly (85).

14. Install six clutch plates and seven friction disc (106) in their original order on hub assembly (104).
The splines on hub (104) must align with the splines on the friction plates.

15. Install spring (105) to its original location on Forward shaft assembly (85).

16. As one unit, install hub assembly (104), six plates and seven friction disc (106) to their original
location on Forward shaft assembly (85).

17. Use a second person in order to manually compress clutch assembly (102) on spring (105). Install
two half rings (103) in the shaft groove.

18. Install washer and thrust disc (101) to their original locations on Forward shaft assembly (85).

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19. Install gear assembly (99) on Forward shaft assembly (85) and over clutch assembly (102). Align
the spline teeth on the outer diameter of the clutch plates with the splines on the inside of gear assembly
(99). Make sure the gear assembly (99) is down over the clutch assembly (102), completely.

20. Install needle bearing (100) to its original location on Forward shaft assembly (85).

21. Install two thrust disc and one thrust race (98A) on Forward shaft assembly (85). The metal thrust
should not spin the race.

22. Heat bearing (98) to a maximum of 132 °C (270° F). Install bearing (98) on Forward shaft assembly
(85) until it contacts the bearing race.

23. Turn the Forward shaft assembly (85) over in order to work on the other end. The weight of
Forward shaft assembly (85) is 43.1 kg (95 lb). Place Forward shaft assembly (85) in the modified work
bench, or on blocks.

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24. Install two lips seals (97) in piston (96). Install both seals (97) with the sealing lips facing towards
the small diameter of the piston.

25. Apply a light coat of clean hydraulic oil on the lip seals. Install piston (96) to its original location on
Forward shaft assembly (85). Rotate the piston slightly during the seal entry. Make sure the lip seals are
installed properly.

26. Install valve assembly (95) to its original location on Forward shaft assembly (85).

NOTE: Friction disc 1 and 7 are different than the rest of the disc. They must be assembled with the
grooved pattern facing towards the clutch pack center.

27. Install six clutch plates and seven friction disc (93) in their original order on hub (92). The splines
on hub (92) must align with the splines on the friction plates.

28. Install spring (94) to its original location on Forward shaft assembly (85).

29. As one unit, install hub (92), six plates and seven friction disc (93) to their to their original location
on Forward shaft assembly (85).

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30. Use a second person in order to manually compress hub (90) on spring (94). Install two half rings
(91) in the shaft groove.

31. Install thrust disc and washer (89) on Forward shaft assembly (85). The metal thrust should not spin
the washer.

32. Install gear assembly (87) on Forward shaft assembly (85) and over clutch assembly (90). Align the
spline teeth on the outer diameter of the clutch plates with the splines on the inside of gear assembly
(87). Make sure the gear assembly (87) is down over the hub (90), completely.

33. Install needle bearing (88) to its original location on Forward shaft assembly (85).

34. Install thrust disc and washer (89) to Forward shaft assembly (85).

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35. Heat bearing (86) to a maximum of 132° C (270° F). Install bearing (86) on Forward shaft assembly
(85) until it contacts the bearing race.

36. Install an 8 mm Eyebolt and install Forward shaft assembly (85) to its original location in the
transmission case. The weight of Forward shaft assembly (85) is 63.6 kg (140 lb). Remove the eyebolt.

37. Install two lip seals (84) in piston (83). Install both seals (83) and (84) with the sealing lips facing
towards the small diameter of the piston.

38. Place Reverse/Second shaft assembly (61) in the modified work bench, or on blocks. Apply a light
coat of clean hydraulic oil on the lip seals. Install piston (83) to its original location on Reverse/Second
shaft assembly (61). Rotate the piston slightly during the seal entry. Make sure the lip seals are installed
properly.

39. Install valve assembly (82) to its original location on Reverse/Second shaft assembly (61).

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40. Install six clutch plates and seven friction disc (80) in their original order on hub (79). The splines
on the hub must align with the splines on the friction plates.

41. Install spring (81) in its original location on Reverse/Second shaft assembly (61).

42. As one unit, install hub (79), six plates and seven friction disc (80) to their original location on
Reverse/Second shaft assembly (61).

43. Use a second person in order to manually compress clutch plate (77) on spring (80). Install two half
rings (78) in the shaft groove.

44. Install the washer and the thrust disc that were under gear assembly (74) to their original locations
on Reverse/Second shaft assembly (61). The metal thrust should not spin the washer.

45. Install gear assembly (74) on Reverse/Second shaft assembly (61) and over clutch assembly (77).
Align the spline teeth on the outer diameter of the clutch plates with the splines on the inside of gear
assembly (74). Make sure the gear assembly (74) is down over the clutch assembly (77), completely.

46. Install needle bearing (75) to its original location on Reverse/Second shaft assembly (61).

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47. Install two thrust disc and one thrust race (73A) on Reverse/Second shaft assembly (61).

48. Heat bearing (73) to a maximum temperature of 132° C (270° F). Install bearing (73) on
Reverse/Second shaft assembly (61) until it contacts the bearing race. The metal thrust disc should not
spin.

49. Turn Reverse/Second shaft assembly (61) over in order to work on the other end. The weight of
Reverse/Second shaft assembly (61) is 40.9 kg (90 lb). Place Reverse/Second shaft assembly (61) in the
modified work bench, or on blocks.

50. Install two lip seals (72) in piston (71). Install both seals (71) and (72) with the sealing lips facing
toward the small diameter of the piston.

51. Apply a light coat of clean hydraulic oil on the lip seals. Install piston (71) to its original location on
Reverse/Second shaft assembly (61). Rotate the piston slightly during the seal entry. Make sure the lip
seals are install properly.

52. Install wave spring (70) on Reverse/Second shaft assembly (61).

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53. As you install clutch assembly (67) on Reverse/Second shaft assembly (61), position the three clutch
plates, four friction disc and the hub assembly to their original locations on Reverse/Second shaft
assembly (61).

54. Install Tool (B) using an 8 mm Threaded Rod that is approximately 508 mm (20 in) long. Tighten
an 8 mm Nut on the threaded rod in order to compress clutch assembly (67). Install two half rings (68)
and two lock rings (69) in the shaft groove.

55. Carefully loosen the nut on Tool (B) in order to relieve pressure from clutch assembly (67). Remove
Tool (B) from clutch (67).

56. Install thrust disc and the washer that were under gear assembly (66). Install gear assembly (66) on
Reverse/Second shaft assembly (61) and over clutch assembly (67). Align the spline teeth on the outer
diameter of the clutch plates with the splines on the inside of gear assembly (66). Make sure gear
assembly (66) is down over the clutch assembly (67), completely.

57. Install thrust disc (not shown) and spacer (65) to their original locations on Reverse/Second shaft
assembly (61).

58. Install gear (64) on Reverse/Second shaft assembly (61).

59. Install spacer (63) on Reverse/Second shaft assembly (61).

60. Heat bearing (62) to a maximum of 132° C (270° F). Install bearing (62) on Reverse/Second shaft
assembly (61) until it contacts spacer (63). Spacer (63) should not spin.

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61. Install an 8 mm Eyebolt and install Reverse/Second shaft assembly (61) to its original location in in
the transmission case. The weight of Reverse/Second shaft assembly (61) is 63.6 kg (140 lb). Remove
the eyebolt.

62. Install gear (60) to its original location on Input shaft assembly (58).

63. Heat bearing (59) to a maximum of 132° C (270° F). Install bearing (59) on Input shaft assembly
(58) until it contacts gear (60). Gear (60) should be tight on Input shaft assembly (58).

64. Install two lip seals (57) piston (56). Install both seals (56) and (57) with the sealing lips facing
towards the small diameter of the piston. Apply a light coat of clean hydraulic oil on the lip seals of
piston (56).

65. Place First/Third shaft assembly (12) in the modified work bench, or on blocks. Install piston (56) to
its original location on First/Third shaft assembly (12). Rotate the piston slightly during the seal entry.
Make sure the lip seals are installed properly.

66. Install wave spring (55) to its original location on First/Third shaft assembly (12).

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67. As you install clutch assembly (52) to First/Third shaft assembly (12), position the three clutch
plates, four friction disc and the hub assembly to their original locations on First/Third shaft assembly
(12).

68. Install Tool (B) using an 8 mm Threaded Rod that is approximately 508 mm (20 in) long. Tighten
an 8 mm Nut on the threaded rod in order to compress clutch assembly (52). Install two half rings (53)
and two lock rings (54) to the shaft groove.

69. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (52). Remove Tool
(B).

70. Install the washer and the thrust disc that was under gear assembly (51), to their original locations
on First/Third shaft assembly (12).

71. Install gear assembly (51) in its original location on First/Third shaft assembly (12) and over clutch
assembly (52). Align the spline teeth on the outer diameter of the clutch plates with the splines on the
inside of gear assembly (51). Make sure gear assembly (51) is down over the clutch assembly (52),
completely.

72. Install the thrust disc that was under gear (50) to its original location on First/Third shaft assembly
(12).

73. Install gear (50) to its original location on First/Third shaft assembly (12). Install the thrust disc that
was on top of gear (50).

74. Heat bearing (49) to a maximum of 132° C (270° F). Install bearing (49) on First/Third shaft
assembly (12) until the bearing contacts gear (50). Get thrust disc that is under bearing (49) should not
spin.

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75. Install two lip seals (48) on piston (47). Install both seals (47) and (48) with the sealing lips facing
towards the small diameter of the piston. Apply a light coat of hydraulic oil on the lip seals.

76. Turn First/Third shaft assembly (12) over in order to assemble the other end. The weight of
First/Third shaft assembly (12) is 54.5 kg (120 lb). Place the First/Third shaft assembly (12) on the
modified work bench, or on blocks. Install piston (47) to its original location on First/Third shaft
assembly (12). Rotate the piston slightly during the seal entry. Make sure the lip seals are installed
properly

77. Install wave spring (46) to its original location on First/Third shaft assembly (12).

78. As you install clutch assembly (43) to First/Third shaft assembly (12), position the five clutch
plates, six friction disc and the hub assembly to their original locations on First/Third shaft assembly
(12).

79. Install Tool (B) using an 8 mm Threaded Rod that is approximately 508 mm (20 in) long. Tighten
an 8 mm Nut on the threaded rod in order to compress clutch assembly (43). Install two half rings (44)
and two lock rings (45) to the shaft groove.

80. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (43). Remove Tool
(B).

81. Install washer (42) and thrust disc (41) to their original locations on First/Third shaft assembly (12).

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82. Install gear assembly (40) in its original location on First/Third shaft assembly (12). Install gear
assembly (40) on First/Third shaft assembly (12) and over clutch assembly (43). Align the spline teeth
on the outer diameter of the clutch plates with the splines on the inside of gear assembly (40). Make
sure the gear assembly (40) is down over the clutch assembly (43), completely.

83. Install thrust disc (39) on First/Third shaft assembly (12).

84. Install gear (38) First/Third shaft assembly (12).

85. Install the thrust disc that was under bearing (37) on First/Third shaft assembly (12). Heat bearing
(37) to a maximum of 132° C (270° F). Install bearing (37) on First/Third shaft assembly (12) until the
bearing (37) contracts gear (38). Thrust disc (38) should not spin.

86. Install an 8 mm Eyebolt in First/Third shaft assembly (12), and place it aside for now. The weight
of First/Third shaft assembly (12) is 88.5 kg (195 lb).

87. Install two lip seals (36) on piston (35). Install both seals (36) with the sealing lips facing towards
the small diameter of the piston (35).

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88. Place High/Low shaft (13) in the modified work bench, or on blocks. Apply a light coat of hydraulic
oil on the lip seals. Install piston (35) to its original location on High/Low shaft assembly (13). Make
sure the lip seals (36) are installed properly.

89. Install 15 springs (34) in recess pockets in piston (35).

90. Install one lip seal (33) on balance piston (31).

91. Install balance piston (31) on High/Low shaft assembly (13), and in piston (35). Make sure the
guides located on piston (31) are placed in the center of each spring.

92. Install Tool (B) on High/Low shaft assembly (13) and balance piston (31). Use an 8 mm Threaded
Rod that is approximately 508 mm (20 in) long. Tighten an 8 mm Nut on the threaded rod in order to
compress balance piston (31). Rotate the piston slightly during the seal entry.

93. Use Tool (C) to install retaining ring (32) to the shaft groove.

94. Carefully loosen the nut on Tool (B) to relieve pressure from balance piston (31). Remove Tool (B)
from balance piston (31) and High/Low shaft assembly (13).

95. Install seven friction disc, eight clutch plates and hub assembly (28) to their original locations on
High/Low shaft assembly (13).

96. Install Tool (B) on High/Low shaft assembly (13) and clutch assembly (28). Use an 8 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten an 8 mm Nut on the threaded rod
to compress clutch assembly (28). Install two lock rings (30) and two half rings (29) to the shaft groove.

97. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (28). Remove Tool
(B).

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98. Install thrust disc and washer (27) to their original locations on High/Low shaft assembly (13).

99. Install gear assembly (26) in its original location on High/Low shaft assembly (13). Install gear
assembly (26) on High/Low shaft assembly (13) and over clutch assembly (28). Align the spline teeth
on the outer diameter of the clutch plates with the splines on the inside of gear assembly (26). Make
sure gear assembly (26) is down over clutch assembly (28), completely.

100. Install two thrust disc (25) on High/Low shaft assembly (13).

101. Heat bearing (24) to a maximum of 132° C (270° F). Install bearing (24) on the High/Low shaft
assembly (13) until the bearing (24) contacts the thrust disc. The metal thrust disc should not spin.

102. Install two lip seals (23) on piston (22). Install both lip seals (23) with the sealing lips facing
towards the small diameter of the piston. Apply a light coat of hydraulic oil on the lip seals (23).

103. Turn High/Low shaft assembly (13) over to work on the other end. The weight of High/Low shaft
assembly (13) is 49.9 kg (110 lb). Place High/Low shaft assembly (13) on the modified work bench, or
on blocks. Install piston (22) to its original location on High/Low shaft assembly (13). Rotate the piston

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slightly during the seal entry. Make sure lip seals (23) are installed properly.

104. Install wave spring (21) to its original location on High/Low shaft assembly (13).

105. As you install clutch assembly (18) to High/Low shaft assembly (13), position the five clutch
plates, six friction disc and the hub assembly to their original locations on High/Low shaft assembly
(13).

106. Install Tool (B) on High/Low shaft assembly (13) and clutch assembly (18). Use an 8 mm
Threaded Rod that is approximately 508 mm (20 in) long. Tighten an 8 mm Nut on the threaded rod
to compress clutch assembly (18). Install two half rings (19) and two lock rings (20) to the shaft groove.

107. Carefully loosen the nut on Tool (B) to relieve pressure from clutch assembly (18). Remove Tool
(B).

108. Install thrust disc and washer (17) to their original locations on High/Low shaft assembly (13).

109. Install gear assembly (16) in its original location on High/Low shaft assembly (13). Install gear
assembly (16) on High/Low shaft assembly (13) and over clutch assembly (18). Align the spline teeth
on the outer diameter of the clutch plates with the splines on the inside of gear assembly (16). Make
sure gear assembly (16) is down over clutch assembly (18), completely.

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110. Install thrust disc (15A) that was under rotor (15) to High/Low shaft assembly (13). Heat rotor (15)
to a maximum of 135° C (275° F). Install rotor (15) to High/Low shaft assembly (13) until it makes
contact with gear assembly (16). The metal thrust disc should not spin.

111. Heat bearing (14) to a maximum of 135° C (275° F). Install bearing (14) to High/Low shaft
assembly (13) until bearing (14) makes contact with rotor (15).

112. Install an 8 mm Eyebolt in High/Low shaft assembly (13) and place it next to First/Third shaft
assembly (12) and in Tooling (E). The weight of High/Low shaft assembly (13) is 88.5 kg (195 lb). The
use of Tooling (E) will hold First/Third shaft assembly (12) and High/Low shaft assembly (13) to the
proper gear mesh height and will allow Tool (A) to be installed properly. Slide the two shafts together
until the gear mesh is obtained.

113. Install Tool (A), using two 8 x 1.25 x 75 mm bolts, on First/Third shaft assembly (12) and
High/Low shaft assembly (13). First/Third shaft assembly (12) and High/Low shaft assembly (13) must
be installed in the transmission case together.

114. Attach a suitable lifting device to Tool (A). Carefully install First/Third shaft assembly (12) and
High/Low shaft assembly (13) to their original locations in the transmission case. The weight of the two

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shaft assemblies is 177 kg (390 lb).

115. Position tube assembly (11) and the O-ring (not shown) to their original positions in the
transmission case. Install three bolts (10) to secure tube assembly (11) to the transmission case. Three
bolts (10) must be tightened to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

116. Clean the flanges of both halves of the transmission case. Apply a 3.0 mm (.12 in) bead of 6V-
5765 Sealer to the joint between the transmission case flanges.

NOTE: Remove the pusher bolts that were used to break the seal on the transmission case.

117. Attach Tool (D) and a suitable lifting device to the upper portion of the transmission case.
Carefully install the upper half of the transmission case. Be careful not to bind on the locating pins
during the installation.

118. Install locating pin (8) in seal carrier (4).

119. Install three seal rings (6) on seal carrier (4).

120. Install three or four O-rings (7) in seal carriers (4).

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121. Install an 8 mm Eyebolt in seal carrier (4). Carefully install seal carrier (4) in its original
transmission case bore. Make sure that pin (8) is installed in the proper location in the shaft assembly.

122. Install two bolts (5) to secure seal carrier (4) to the shaft assembly. Tighten bolts (5) to a torque of
55 ± 10 N·m (40 ± 7 lb ft)

123. Repeat Steps 121 and 122 to install the remaining three carriers to their original locations in the
transmission case.

124. Install 43 bolts (3) around the transmission case flange. Tighten bolts (3) to a torque of 55 ± 10
N·m (40 ± 7 lb ft).

125. Install four covers (2) and their O-ring seals to the transmission case.

126. Install twelve bolts (1) in the four covers. Tighten bolts (1) to a torque of 28 ± 7 N·m (21 ± 5 lb ft)

End By:

a. install parking brake

b. install transmission hydraulic control valve

c. install transmission speed sensor

d. install transmission oil pump

e. install transmission magnetic filter screen base

Copyright 1993 - 2008 Caterpillar Inc. Sat Mar 29 14:20:36 EST 2008
Todos los derechos reservados.
Red privada para licenciados del SIS.

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