06 Powershift Transmission

Chapter 6 POWERSHIFT TRANSMISSION
1. Structure .................................................................................................. 6-1

1.1 Transmission ........................................................................................................... 6-1
1.2 Power Transmission Path........................................................................................ 6-2
1.3 Torque Converter .................................................................................................... 6-4
1.4 Powershift Transmission Control............................................................................. 6-5
1.5 Control Valve ........................................................................................................... 6-6
1.6 Main Regulator Valve .............................................................................................. 6-6
1.7 Parking Brake Activation ......................................................................................... 6-7
1.8 Releasing parking brake with the release bolt......................................................... 6-8
1.9 Schematic Diagram of Powershift Transmission Hydraulic System ......................6-10
1.10 Powershift Transmission External View ................................................................ 6-11
2. Removal and Installation...................................................................... 6-12
2.1 Removal ................................................................................................................ 6-12
2.2 Installation ............................................................................................................. 6-13
3. Transmission Exterior Parts ................................................................ 6-14
3.1 Disassembly .......................................................................................................... 6-14
3.2 Reassembly........................................................................................................... 6-14
4. Torque Converter .................................................................................. 6-15
4.1 Disassembly .......................................................................................................... 6-15
6
4.2 Inspection and Repair............................................................................................ 6-16
4.3 Reassembly........................................................................................................... 6-16
5. Transmission......................................................................................... 6-17
5.1 Disassembly .......................................................................................................... 6-17
5.3 Reassembly........................................................................................................... 6-24
6. F2 Clutch Pack Assembly .................................................................... 6-31
6.1 Disassembly .......................................................................................................... 6-31
6.3 Reassembly........................................................................................................... 6-37
7. F1 Clutch Pack Assembly .................................................................... 6-41
7.1 Disassembly .......................................................................................................... 6-41
7.3 Reassembly........................................................................................................... 6-41
8. R1 Clutch Pack Assembly .................................................................... 6-42
8.1 Disassembly .......................................................................................................... 6-42
8.3 Reassembly........................................................................................................... 6-43
9. Parking Brake Assembly ...................................................................... 6-44
9.1 Disassembly .......................................................................................................... 6-44
9.3 Reassembly........................................................................................................... 6-49
10. Gear Pump Assembly ........................................................................... 6-50
10.1 Disassembly .......................................................................................................... 6-50
10.3 Reassembly........................................................................................................... 6-53
11. Control Valve ......................................................................................... 6-55
11.1 Disassembly ..........................................................................................................6-55
11.2 Inspection and Repair............................................................................................6-56
11.3 Reassembly ...........................................................................................................6-58
12. Main Regulator Valve ............................................................................ 6-60
12.1 Disassembly ..........................................................................................................6-60
12.2 Inspection and Repair............................................................................................6-61
12.3 Reassembly ...........................................................................................................6-61
13. Inspection and Adjustment .................................................................. 6-62
13.1 Oil Pressure Measurement ....................................................................................6-62
13.2 Brake Inching Pedal Adjustment ...........................................................................6-64
13.3 Inching Cable Adjustment......................................................................................6-66
14. Troubleshooting .................................................................................... 6-67
15. Service Data........................................................................................... 6-71
POWERSHIFT TRANSMISSION
Chapter 6 POWERSHIFT TRANSMISSION
1. Structure
1.1 Transmission
3 b(80)
2
4(No. 1 shaft)
1
Pd
a(67)
c(62)
8(No. 5 shaft)
10(No. 7 shaft) 9(No. 6 shaft)
6(No. 3 shaft)
d(89)
e(77)
f(66)
5(No. 2 shaft)
G(71)
No. 1 shaft
No. 2 shaft No. 7 shaft
No. 5 shaft
No. 3 shaft
No. 4 shaft
7(No. 4 shaft) No. 6 shaft
The figure in parentheses shows the number of gear teeth. 215293
1 Flexible plate 6 F2 (Forward 2nd gear) clutch shaft (3rd shaft)

2 Torque converter assembly 7 Output flange (4th shaft)
3 Control valve 8 PTO idler gear shift (5th shaft)
4 R1 (Reverse) clutch shaft (1st shaft) 9 PTO driven gear (6th shaft)
5 F1 (Forward 1st gear) clutch shaft (2nd shaft) 10 Parking brake (7th shaft)
(1) This transmission consists of two forward gears (4) The torque converter housing can be separated
and one reverse gear. The forward-reverse from the torque converter housing.
changeover is accomplished by a powershift
(5) The torque converter is made by welding steel
mechanism that uses hydraulically controlled mul-
plates together, therefore it needs to be replaced
tiple-disc clutches.
as an assembly when required.
(2) This transmission is equipped with a PTO (Power
Gear position Power transmission path
Take Off) that generates power to the hydraulic
pump and the parking brake. F1 (Forward 1st gear) a→ef→G
A wet disc parking brake is also built into this F2 (Forward 2nd gear) a→cd→G
transmission. R (Reverse) b→G
(3) An electronically controlled solenoid valve oper-
ates as a control valve for shifting.
6-1
1.2 Power Transmission Path
R1 clutch drum gear(67) R1 clutch drum gear(67)
From engine
F2 clutch drum gear(62)
F2 clutch gear(89)
F1 clutch gear(66)
F1 clutch drum gear(77)
Output gear(71)
Forward Forward
To transfer 1st gear 2nd gear
Output gear(71)
The figure in parentheses shows the number of gear teeth.
Transmission reduction ratio
77 71
F1 (Forward 1st gear) × = 1.236
67 66
62 71
F2 (Forward 2nd gear) × = 0.738
67 89
215902
6-2
R1 clutch gear(80) PTO
PTO drive gear(46)
Pd
PTO idler gear(68)
PTO driven gear(46)
Output gear(71) The figure in parentheses shows the number of gear teeth.
Reverse Transmission reduction ratio
71
R (Reverse) = 0.888
80
46 68
PTO × = 1.000
68 46
215903
6-3
1.3 Torque Converter
4
1
215294
1 Turbine runner 4 Pump impeller 7 Drive cover

2 Stator assembly 5 Pump boss 8 Turbine boss
3 Flexible plate 6 Clutch hub 9 Pilot boss
6-4
1.4 Powershift Transmission Control
F
3
N
R
215295
1 Forward/reverse shift lever 3 Inching cable

2 Inching pedal 4 Control valve assembly
6-5
1.5 Control Valve

Top
Main valve assembly Shift valve assembly

(Top of control valve) (Bottom of control valve)
‫ڏ‬
6 1 7
4
3
2 5
Bottom 215680
1 Filter 4 Directional valve 7 Inching lever

2 Inching valve 5 H-L shift valve
3 Accumulator valve 6 Cooler pipe
1.6 Main Regulator Valve
10 9 8
7 6 5 4 3 2 1
215546
1 Bolt 5 Spool 9 Main oil pressure port

2 Cover 6 Valve body 10 Torque converter inlet pressure
3 O-ring 7 Spring port
4 Slug 8 Drain port
6-6
1.7 Parking Brake Activation
Release disks Compress disks

Hydraulic oil flows from Hydraulic oil that flows from
the parking brake valve. the parking brake valve stops.
Parking brake gear
Piston Extend spring

Compress spring
Release F2 clutch gear Lock F2 clutch gear
Parking brake released state Parking brake applied state

215904
Parking brake released state Parking brake applied state
When the parking brake switch is released (shown on When the parking brake switch is actuated (pushed) or
the left in the illustration) when the engine is stopped (shown on the right in the
illustration)
Hydraulic oil flows into the parking brake through the
PKB port of the parking brake valve. Then the piston is Hydraulic oil that flows from the parking brake valve
forced to move to the right as shown in the illustration. stops.
This piston movement compresses the springs, The piston is clamped against the discs by the expan-
thereby releasing the discs (mating plate and friction sion force of the springs.
plate). The parking brake gear that has been disengaged is
This brings the parking brake gear into the disengaged now fixed and the F2 clutch is thereby fixed to gener-
position. ate a brake force.
6-7
1.8 Releasing parking brake with the release bolt
Disc released
Parking brake gear Emergency relief bolt

of the parking brake
Attaching portion of
the emergency relief bolt
of the parking brake
Piston
Spring compressed
F2 clutch gear
Emergency release
215818
Installing the PKB release tool kit mechanically disables the parking brake regardless of the parking brake switch
position and regardless of engine ON/OFF status.
If the engine is not running, the service brakes DO NOT have hydraulic pressure and will not operate.
Never disengage the parking brake with the lift truck on a slope or grade when the engine is OFF.
If the engine is OFF or hydraulic pressure is insufficient to disengage the parking brake, use the PKB release tool kit
to disengage the parking brake.
Parking brake emergency releasing method using the PKB release tool kit is as follows:
(1) Always block the wheels, with the lift truck on a

flat, level surface, prior to disengaging the parking
brake.
(2) Loosen the plug from the PKB release tool kit
mounting position of transmission case by using
the PKB release wrench.
6-8
(3) Remove the bolt that holds the ground wire and
the bolt that holds the hose clamp.
PKB release wrench
Bolt for the hose clamp
Bolt for the ground wire

506539
(4) Remove the plug and O-ring by hand.
Note: Transmission oil will leak out of the plug hole
when removed. Hold a rag over the plug hole to
prevent oil from spilling.
(5) Install the PKB release tool kit (bolt and gasket) in
place of the plug.
(6) Tighten the PKB release tool kit approximately
one turn after contact with the seat surface by
using the PKB release wrench.
Note: DO NOT overtighten the PKB release tool kit.
(7) The piston moves to compress the spring and free
the discs. As a result, the parking brake is
released.
(8) Install the ground wire and hose clamp and
tighten the bolts for the ground wire and the hose
clamp.
Note: Tighten the bolt securely. Spark may occur if
the bolt is not tightened securely.
When the above procedure is completed, drive the lift
truck to a safe area and block the wheels. Repeat the
Step (1) and (2) and remove the PKB release tool kit
and install the plug back in place.
Special tool Part number
PKB release wrench 91K67-14400
PKB release tool kit 91K67-10020
6-9
1.9 Schematic Diagram of Powershift Transmission Hydraulic System
T/C in(B)
T/C out(C)
Main regulator valve
Relief valve
Torque converter
Oil cooler Main orifice
Accumulator valve
Torque converter bypass M(A)
Lub(H)
Parking brake
T/M lubricating circuit

Inching valve
Pd(D)
Gear pump
logic capacity
Filter Strainer
Suction strainer with magnet
Solenoid valve
F R
Solenoid valve
SR (F, R switch)
PR(G) Directional valve

F1 F2 Reverse clutch
Solenoid valve
SH (F1, F2 switch)
H-L shift valve

Forward 2nd gear clutch
PF2(F)
Top view of transmission Main regulator valve PF1(E) Forward 1st gear clutch
T/C in(B) M(A)

Pd(D)
PF1(E)
T
Lub(H) M(A) : Main oil pressure
PF2(F) T/C in(B) : Torque converter inlet pressure
T/C out(C) : Torque converter outlet pressure

PR(G) T/C out(C)
Pd(D) : Direction oil pressure
PF1(E) : F1 clutch oil pressure
PF2(F) : F2 clutch oil pressure
PR(G) : R clutch oil pressure
215296
6-10
1.10 Powershift Transmission External View
Control valve
Cooler out pipe Cooler in pipe
Oil level gage
Engine side
Output flange
Thermoswitch
Speed sensor Oil drain plug
215537
Viewed from the front side of lift truck
Serial number
Main regulator valve
Torque convertor
Dowel pin
Engine side
Hole for parking brake

emergency release bolt Dowel pin
215538
Viewed from the back side of lift truck
6-11
2. Removal and Installation

2.1 Removal
(1) Remove the engine and transmission as an
assembly from the lift truck.
Note: For removal and installation of the engine and
transmission assembly, refer to "Removal and
Installation" of POWER TRAIN. Drain the
transmission oil before removing the engine
and transmission assembly.
Unit: liter (cu.in.)
Transmission oil Approximately 17 (1037.4)
(2) Attach lift hooks to the transmission, and tie a wire

Lift hook Lift hook
rope to the hooks, and slightly lift the transmis-
mounting position mounting
sion. (M12×1.75) position
(M12×1.75)
Lift hook
(91A25-04100)
215547
(3) Remove the flexible plate bolts through the

access hole in the torque converter housing.
(4) Tie the torque converter housing to the torque
converter assembly with a wire rope to prevent
the torque converter assembly from slipping out.
(5) Lift the torque converter and transmission assem-
bly to separate it from the engine.
Unit: kg (lb)
Transmission weight Approximately 270 (595)
6-12
2.2 Installation
(1) Install the transmission onto the engine.
(a) Push the torque converter into the transmis- 42 to 43 mm (1.65 to 1.69 in.)
sion so that clearance between the end sur-
face of the torque converter housing and the
flywheel connecting surface of the flexible plate
falls within the range of 42 to 43 mm (1.65 to
1.69 in.).
Before installing the assembly onto the engine,
make sure that the pilot bearing has been
installed into the flywheel.
Replace the pilot bearing with a new one if
wear is found. 215548
Unit: mm (in.)
0
ø 20 -0.010
A 0
Pilot bearing inside diameter 1 (0.79 -0.0004)
ø 20.05
B
(0.81)
A:Standard value B:Repair or service limit
1
215901
(b) Install dowel pins into the torque converter

1 to 2 mm (0.04 to 0.08 in.)
housing mating face, and couple the torque Dowel pin
converter and transmission assembly to the (2 pcs.)
engine.
Check that the clearance between the flywheel
and the flexible plate is somewhere from 1 to 2
mm (0.04 to 0.08 in.).
If there is no clearance, disassemble and reas-
semble again. This is a result of an improper
spline engagement between the torque con-
verter and the PTO (Power Take Off) drive Pilot bearing
gear, or between the stator shaft and the R1 215906
clutch pack.
(2) Connect the flexible plate to the flywheel with the

33.3 ± 3.3 N·m
bolts mounted through the access hole in the
(3.40 ± 0.34 kgf·m)
torque converter housing. [24.56 ± 2.43 lbf·ft]
Insert a heavy-duty screwdriver through the
access hole in the side face of the torque con-
verter housing and turn the torque converter.
Note: Tighten the bolts evenly and progressively to
prevent strain to the flexible plate.
Unit: N·m (kgf·m) [lbf·ft]
33.3 ± 3.3
Tightening torque (3.40 ± 0.34) 215648
[24.56 ± 2.43]
6-13
3. Transmission Exterior Parts

3.1 Disassembly
39.2 ± 3.9 N·m 24.0 ± 2.4 N·m 19.6 ± 2.0 N·m (2.0 ± 0.2 kgf·m) [14.5 ± 1.5 lbf·ft]
(4.0 ± 0.4 kgf·m) (2.4 ± 0.2 kgf·m)
[28.9 ± 2.9 lbf·ft] [17.7 ± 1.8 lbf·ft]
10
53.9 ± 5.4 N·m 9

8
(5.5 ± 0.6 kgf·m)
[39.8 ± 4.0 lbf·ft]
7 1
53.9 ± 5.4 N·m
(5.5 ± 0.6 kgf·m) 2
[39.8 ± 4.0 lbf·ft] 1
1 Back view
19.6 ± 2.0 N·m

(2.0 ± 0.2 kgf·m)
[14.5 ± 1.5 lbf·ft]
6
24.0 ± 2.4 N·m

(2.4 ± 0.2 kgf·m)
[17.7 ± 1.8 lbf·ft]
11
5 29.4 ± 2.9 N·m

(3.0 ± 0.3 kgf·m)
[21.7 ± 2.1 lbf·ft]
3
4 31.4 to 47.1 N·m
88.3 ± 9.8 N·m (9.0 ± 1.0 kgf·m) [65.2 ± 7.2 lbf·ft] (3.2 to 4.8 kgf·m)
[23.2 to 34.8 lbf·ft]
215541
Disassembly sequence
1 Dowel pin 7 Cooler pipe, Eye bolt, Washer
2 Level gauge 8 Control valve assembly
3 Drain plug, Washer 9 Main regulator valve assembly
4 Thermo switch 10 Upper cover
5 Speed Sensor 11 Side cover
6 Magnetic strainer assembly
3.2 Reassembly
Observe the tightening torques shown in the illustra-
tion above when reassembling.
6-14
4. Torque Converter
4.1 Disassembly
1 58 to 75 N·m (5.9 to 7.6 kgf·m) [42.8 to 55.4 lbf·ft]

When assembling, clean bolts, degreasing,
2 and apply LOCTITE 242 or equivalent.
215298
1 Bolt, Plain washer
2 Flexible plate
3 Torque converter assembly
Suggestions for Disassembly

(1) Install two eye bolts to the torque converter hous-
ing.
(2) Tie a wire rope to the eye bolts, and lift the
assembly so that the torque converter side faces Eye bolt
upward.
(3) Install the stand to the transmission housing.
Part name Part number
91K67-01700
Stand
91K67-01800 216856
(4) Tie chain blocks to the access hole of the torque

converter housing. Support the assembly horizon-
tally at three points, and lower it down to the floor
while maintaining it in the horizontal position. Chain block
216857
6-15
(5) Install two eye bolts to the flexible plate.

(6) Remove the wire that was attached to the torque
Torque converter
convertor assembly to prevent it from slipping out. assembly
(7) Lift the torque converter assembly with a hoist.
Eye bolt
Unit: kg (lb) (hole diameter:
Torque converter Oil drain pan 11 mm (0.4 in.))
23 (55)
assembly weight
Note: a) The torque converter assembly cannot be dis-

assembled.
216858
b) Because the torque converter assembly has
no drain plug, oil remains trapped in the
torque converter assembly. A container
should be made available to catch oil. Drain
the oil by pulling out the torque converter as-
sembly and turning it over with its pump boss
side facing down.
4.2 Inspection and Repair

Pilot boss
Check the pilot bearing for wear or damage. 2
Unit: mm (in.)
Item All truck model
A -0.006 -0.0002
20 -0.041 (0.79 -0.0016) 1
Shank diameter 1
B 19.95 (0.7854)
31.85 ± 0.05
Pilot boss A
(1.2539 ± 0.0020)
height 2
B 31.5 (1.240)
A:Standard value B: Repair or service limit 215557
4.3 Reassembly
For reassembly, follow the disassembly sequence in
reverse.
Suggestions for Reassembly
Flexible plate
After installation of the flexible plate, measure face
runout of the plate with a dial gauge, and adjust it if the
measurement exceeds the service limit.
Unit: mm (in.)
Item All truck model
Flexible plate A 0.5 (0.020)
face runout B 0.5 (0.020)
A: Standard value B: Repair or service limit
Note: When installing the torque converter to the

transmission, use extreme care not to damage
the oil seal and the seal ring.
215558
6-16
5. Transmission
5.1 Disassembly
10
13
15 16
5
14
12
11
9
8
6
3 8 7
1
4
2
215559
1 Output flange, Oil seal 9 Snap ring, PTO bearing plate
2 Transmission housing 10 Torque converter housing, Oil seal
3 R1 clutch pack assembly 11 PTO idler shaft, Bearing
4 F2 clutch pack assembly 12 Stator shaft assembly
5 F1 clutch pack assembly 13 Gear pump assembly, Gasket
6 Output gear 14 PTO idler gear
7 Parking brake assembly, O-ring 15 Torque converter housing, Gasket
8 Baffle plate 16 Relief valve, Spring washer, Snap ring
6-17

Jack bolt holes
(1) Remove the twenty-four bolts that secure the
torque converter housing to the transmission
housing.
Part name Part number Qty
F1805-10035
20
(M10×35)
Bolt
F1805-10085
4
(M10×85)
F1805-10085
Note: Remove the oil level gauge before disassem- 215659
bly.
(2) Slightly lift the torque converter housing.
(3) Tap around the side shaft of the R1 clutch pack
assembly with a plastic hammer to loosen the
transmission housing and torque converter hous-
ing connection.
Note: If the housings are sticking to each other, tap
along the housing rims with a plastic hammer,
or use a jack bolt hole (M10×1.25 bolt) for easi-
er separation.
215561
(4) Lift the torque converter housing to separate it

from the transmission housing.
215562
(5) Since all gears are engaged, the R1 clutch pack

R1 clutch pack F1 clutch pack
assembly cannot be removed independently of assembly assembly
the F2 clutch pack assembly.
F2 clutch pack
assembly
215563
6-18
(6) Attach lift hooks and slings onto the gear rim of
the R1 clutch pack assembly. Slightly lift the R1 R1 clutch pack
clutch pack assembly, and tap along the side shaft assembly
of the F2 clutch pack assembly with a plastic ham-
mer to loosen the engagement.
F2 clutch pack
assembly
216859
(7) After the R1 clutch pack assembly is loosened,

detach the lift hooks and slings from the assembly
and attach them onto to the F2 clutch pack
assembly.
(8) Loosen the mating portion of the F2 clutch pack
assembly in the same way as the R1 clutch pack
assembly.
(9) After the F2 clutch pack assembly is loosened,
reattach the lifting hooks and slings to the R1
clutch pack assembly. F2 clutch pack
assembly
216860
(10)With the R1 clutch pack assembly being slightly

lifted, disengage the F2 clutch pack assembly R1 clutch pack
from the R1 clutch pack assembly by rocking or assembly
tapping the F2 clutch pack assembly with a plastic
hammer.
(11)Remove the R1 clutch pack assembly.
216861
(12)Remove the F2 clutch pack assembly.
F2 clutch pack
assembly
216862
6-19
(13)Attach the lifting hooks and slings to the F1 clutch

pack assembly. Slightly lift the assembly, and tap F1 clutch pack
assembly
along the side shaft of the assembly with a plastic
hammer to loosen the assembly.
(14)Remove the F1 clutch pack assembly.
216864
(15)Lift the torque converter housing and orient the

transmission housing mating surface upward.
(16)Securely, lay the torque converter housing on
wood blocks.
Wood block
215570
(17)Remove the output gear using the special tools

(Puller 91K67-01200 and Plate 91K67-01300).
Puller 91K67-01200
Plate 91K67-01300
Output gear
216863
(18)Remove the ten parking brake assembly mount-

ing bolts.
91K24-03900
Bolt
(M8×1.25 L=70)
Note: Do not remove the four black hexagon socket

head bolts, as they are used for the parking
brake assembly.
(19)Remove the parking brake assembly.
Parking brake assembly
215572
6-20
(20)Remove the two baffle plates.

Baffle plates
215573
(21)Remove the PTO bearing plate by removing the

snap ring from the PTO idler gear mounting por- Snap ring
tion. PTO bearing plate
215574
(22)Lay the torque converter housing with its torque

converter mounting side facing upward.
(23)Remove the mounting bolts from the torque con-
verter housing plate.
(24)Insert two bolts into the two jack bolt holes
(M10×1.25) of the torque converter housing, and
screw the bolts downward evenly to remove the
torque converter housing plate.
Note: The torque converter housing plate can be sep-
Jack bolt holes
arated from the bearing when it is raised at ap-
215575
proximately 19.5 mm (0.77 in.).
(25)Install the stand (special tool, 91K67-01600), and

raise the torque converter housing.
Stand 91K67-01600
Stand
216937
6-21
(26)Install a sliding hammer (thread tip diameter of

M20×1.5) to the PTO idler shaft.
(27)Remove the ball bearing and PTO idler shaft
assembly as a set with a sliding hammer.
Sliding hammer
216865
(28)Lay the torque converter housing with its torque

converter mounting side facing upward.
(29)Remove the twelve mounting bolts from the gear
pump assembly and remove the gear pump
assembly.
215579
(30)Remove the eight mounting bolts from the stator

shaft assembly. One of them is a black hexagon
socket head bolt, and another one is hidden Stator shaft assembly
behind the PTO idler gear. To remove the hidden
bolt, rotate the PTO idler gear until its through-
hole is aligned with the hidden bolt, and then
remove it.
215578
(31)Push the PTO idler gear against the gear pump to

disengage it from the stator shaft assembly gear. Stator shaft assembly PTO idler gear
(32)Remove the stator shaft assembly by rotating it to

an orientation for easy removal.
215580
6-22
(33)Remove the PTO idler gear from the same bore

as the stator shaft assembly was removed from.
PTO idler gear 215583

Check the relief valves and the springs for wear and
damage.
(1) If a relief valve is worn or damaged, replace it with
a new one.
(2) Measure the spring free length and the height of
spring under load.
Unit: mm (in.)
A 32 ± 1 (1.26 ± 0.04)
Free length
B 30 (1.18)
21.4 (0.84) /
48 ± 5N
A
Spring (4.9 ± 0.5kgf)
Height / [9.0 ± 1.1lbf]
under load 21.4 (0.84) /
40 N
B
(4.1 kgf)
[9.0 lbf]
6-23
5.3 Reassembly
1
1 16
13
15
7
14
4
2
8 Tightening torque:
88.3 ± 8.8 N·m
(9.0 ± 0.9 kgf·m)
[65.2 ± 6.5 lbf·ft]
12 9
11
10
215582
Reassembly sequence
1 Torque converter housing 9 Baffle plate
2 PTO idler gear 10 Output gear
3 Stator shaft assembly 11 Output flange
4 PTO bearing plate, Snap ring 12 F1 clutch pack assembly
5 PTO drive gear 13 R1 clutch pack assembly
6 Gear pump assembly 14 F2 clutch pack assembly
7 Torque converter housing plate 15 Transmission housing
8 Parking brake assembly 16 Relief valve, Spring
6-24

(1) Follow the instructions below when reassembling.
(a) Do not use liquid packing.
(b) Use LG2 grease.
(c) Unless otherwise specified, tighten bolts to the
specifications in the table below.
Part name Tightening torque
19.6 ± 2.0
M8×1.25 (2.0 ± 0.20)
[14.5 ± 1.48]
39.2 ± 3.8
M10×1.25 (4.0 ± 0.39)
[28.9 ± 2.80]
(d) Apply ATF Dexron-II to the gear pump assem-

bly, the clutch assembly, the bearings, and the
seal areas before installation.
(2) Install the PTO idler gear to the torque converter
housing through the mounting hole of the stator
shaft assembly.
PTO idler gear 216025
(3) Install the stator shaft assembly (with its ball bear-
ing pressed into place) to the torque converter Stator shaft assembly
67.7 ± 6.8 N·m
housing with mounting bolts. (6.9 ± 0.7 kgf·m)
Tighten one of the mounting bolts through the [50.0 ± 5.0 lbf·ft]
through-hole of the PTO idler gear.
Tighten from the

through-hole of the PTO idler gear. 215549
(4) Turn over the torque converter housing.

(5) After the PTO idler shaft is inserted into the PTO PTO idler gear
idler gear, hammer the ball bearing into the PTO
idler gear.
Ball bearing
Installer 91A68-02300
(6) Install the PTO bearing plate and secure it with

the snap ring.
216866
6-25
(7) Turn over the torque converter housing.

(8) Tap evenly around the ball bearing of PTO drive
Driving tool
gear using the remover (special tool, 91K67-
02800), and align the PTO drive gear and the
PTO idler gear.
Remover 91A68-02300
216867
(9) Check that the PTO drive gear turns smoothly

while turning the PTO idler gear. Stator shaft assembly PTO idler gear
Note: When the PTO drive gear is turned with the

torque converter housing laid flat, gear turning
may feel heavy. Raise the torque converter
housing to the installed position and check the
gear for smooth turn again.
(10)Install the gear pump assembly to the torque con-
verter housing.
215587
(11)Install the oil seal to the torque converter housing

plate using the installer (special tool, 91K67-
02900).
Guide bolt
216868
(12)Using the installer (91K67-02900), install the

guide bolt to align with the torque converter hous-
ing plate.
(13)Using the remover (special tool, 91A68-02800), Guide bolt
tap evenly around the torque converter housing
plate to install it into the torque converter housing.
Remover 91K67-02800
(14)Install and tighten the mounting bolts to the torque

converter housing. 216869
6-26
(15)Turn over the torque converter housing.

(16)Install the guide bolt to the torque converter hous- Guide bolt
ing for proper alignment to the parking brake
assembly.
215589
(17)Install the parking brake assembly, and evenly

tighten its bolts to the specified torque.
21.6 ± 2.2
Parking brake assembly
(2.20 ± 0.22)
mounting bolt tightening torque
[15.93 ± 1.62]
Note: When installing the parking brake assembly, be

sure to prevent the O-ring from protruding from
the mating surface and the piston seals from Parking brake assembly
being damaged.
215590
(18)Install the baffle plate.

Baffle plates
215550
(19)Install the output gear and each clutch pack by

referring to the following steps. Mesh upper gear
Each gear is meshed each other as shown in the
illustration on the right.
R1
F1
(a) Apply ATF Dexron-II to each bearing.
F2
Mesh lower gear
R1
F1 P
F2
OUT
215600
6-27
(b) Tentatively install the R1 clutch pack assembly

into place in the torque converter housing.
R1 clutch pack
(c) Suspend the R1 clutch pack assembly with a assembly
hoist.
Hook 91K67-01900
216870
(d) Tentatively install the F1 clutch pack assembly

into place in the torque converter housing. F1 clutch pack
assembly
Hook 91K67-01900
216871
(e) Tentatively install the F2 clutch pack assembly

into place. F2 clutch pack
assembly
Hook 91K67-01900
216872
(f) Tentatively install the output gear into place in

the torque converter housing.
Output gear
(g) Lower the R1 clutch pack assembly.
Hook 91K67-01900
R1 clutch pack
assembly
216873
6-28
(h) Adjust gear mesh between each gear by tap-

ping the top or side of each clutch assembly
with a hammer or wiggling them.
(i) Evenly tap each gear with a plastic hammer to
install them into the torque converter housing.
(j) Install the gasket to the transmission housing.
Note: Be sure to use a new gasket.
Gasket
215605
(k) When replacing the oil seal of transmission

output shaft, use the installer (special tool,
91268-05500) to install the oil seal to the trans- Oil seal
mission housing.
216874
(20)Install the guide bolt next to the dowel pin on the

torque converter housing for proper alignment to
the transmission housing.
(21)Lift the transmission housing while supporting it at
three points. Slowly lower it until it rests on the
torque converter housing.
Note: When installing the transmission housing, pay
attention to the seal rings in the each clutch
pack shaft, as seal ring protrusion from the
groove in the shaft may result in breakage of
the seal ring.
Apply a thin coat of grease to the seal ring be-
fore installing it in the groove to prevent seal
ring protrusion.
215606
(22)Align the mounting bolt holes of the transmission

housing to the mounting bolts holes of the torque
converter housing, tap the circumference of the
transmission housing with a plastic hammer to
complete fit.
215607
6-29
(23)Tighten the mounting bolts to the specified

torque.
Part number Qty Tightening torque
33.3 ± 3.3
F1805-10085 4 (3.40 ± 0.34)
[24.56 ± 2.43]
33.3 ± 3.3
F1805-10035 20 (3.40 ± 0.34)
[24.56 ± 2.43]
F1805-10085
215560
(24)After assembly, check the R1 clutch pack assem-

bly for proper gear engagement and smooth rota-
tion by turning the R1 clutch pack assembly by
hand.
Note: Clutch gears that are meshed with the output
gears will not turn unless the parking brake
switch is released. Activation of the parking
brake switch prevents the gears from turning.
215609
(25)Refilling transmission with oil

(a) After the transmission is installed in the truck
and the engine is ready to be started, be sure
to refill the transmission oil.
(b) Use a level gauge to check oil level.
(c) Run the engine at idling speed, then stop the
engine.
(d) Wait for 1 minute or more after stopping the
engine, and check the oil level.
(e) The checking procedure must be completed
within 3 minutes after the engine has stopped.
Note: Be sure to stop the engine before checking.
6-30
6. F2 Clutch Pack Assembly

6.1 Disassembly
1
2
7
7 3
4
10 5
12
8
11 9
12
215610
1 Ball bearing 7 Pressure plate, Mating plate, Friction plate
2 Spacer 8 Snap ring
3 Spacer 9 Spring retainer, Clutch return spring
4 Snap ring 10 Clutch piston, Piston seal
5 F2 clutch gear, Ball bearing, Snap ring 11 Clutch drum, Ball bearing
6 Snap ring 12 Seal ring

(1) Remove the seal ring from the shaft.
(2) Using the puller (special tool, 91K-01400, 91K67-
Ball bearing
01800), remove the ball bearing from the shaft.
(3) Remove the spacer from the shaft. Spacer
215611
6-31
(4) Pull the spacer off the shaft using two flathead
screwdrivers.
(5) Remove the snap ring.
Spacer
Snap ring
215612
(6) Using the puller (special tool, 91K-014700/91K67-

01800), remove the F2 clutch gear from the clutch
drum.
91K67-01400 F2 clutch gear
Puller
91K67-01800
216875
(7) Using a round bar, hammer the ball bearing to

Round bar
remove.
Ball
(8) Remove the two snap rings. bearing Snap ring
Round bar
F2 clutch gear
217087
(9) Using a installer (special tool, 91A68-02300),

remove the ball bearing.
Ball bearing
F2 clutch gear
217088
6-32
(10)Remove the snap ring from the clutch drum using

two flathead screwdrivers.
Snap ring
215614
(11)Using a wire with a shaped hook at the end,

remove the pressure plate, mating plate and fric-
tion plate from the clutch drum.
215615
Note: Take note of the order in which the plates are

disassembled. Brake piston side
Pressure plate: 1 piece Pressure plate
Mating plate: 6 pieces
Friction plate: 5 pieces Mating plate
Friction plate
Brake cover side 215616
(12)Using a clutch pack stand kit (special tool) or a

press, compress the spring retainer and clutch
return spring together, and remove the snap ring.
Stand 91K67-00700
Ring 91K67-00800
Plate 91K67-00900
Board 91K67-01100
Note: Be sure to evenly tighten the clutch pack stand 216927

kit with bolts.
(13)Remove the clutch pack stand kit in order to
remove both the spring retainer and clutch return
spring.
6-33
(14)Blow compressed air into the oil hole of the clutch

drum shaft, and remove the clutch piston. Clutch piston
215618
(15)Remove the piston seal from the clutch piston.
Clutch piston
Piston seal
215619
6-34

(1) Clutch piston
(a) Inspect sliding area for wear and damage.
If any scratches are found, polish the
scratched surface using a fine grit sandpaper.
1 2
If significant scratches are found, replace the
clutch piston with a new one.
(b) Measure the width of both the clutch piston
seal groove and the piston seal, and if the
measured width exceeds the service limit,
replace it with a new one.
215620
Unit: mm (in.)
Clutch piston seal A 0 0

4 -0.1 (0.16 -0.004)
width 1
B 3.8 (0.150)
Clutch piston seal A +0.2 +0.008

4 +0.1 (0.16 +0.004)
groove width 2 B 4.3 (0.169)
A : Standard value B: Service limit
(2) Clutch shaft

Set screw
(a) Check both the spline and bearing mounting
portions for wear or damage.
(b) Measure the width of both the seal ring and
clutch shaft groove, and if the measured width
exceeds the service limit, replace it with a new
one.
1 2
Unit: mm (in.)
Clutch shaft seal ring A 2.5 ± 0.05 (0.098 ± 0.0020)
Oil passage
width 1 B 2.3 (0.091) 215621
A 2.5
+0.2
(0.098
+0.008
+0.004)
Clutch shaft groove +0.1
width 2
B 2.8 (0.110)
(c) Check oil passage for clogs.

If the passage is clogged, remove the set
screw, and blow out the passage with com-
pressed air.
Note: 1. After the set screw is removed, apply LOC-
TITE 242 to the set screw before reinstalling.
2. Be sure to use filtered compressed air.
(d) Check the fit between the clutch drum and
clutch shaft and check rivets for looseness.
(3) Gear
Check gears for wear or damage.
(4) Clutch drum
Check clutch piston sliding portion, mating plate
contact area and snap ring groove for wear or
damage.
6-35
(5) Friction plates and mating plates

(a) Check both plates for seizure, uneven contact,
distortion, or damage.
(b) Check mating plates for hot spots (scattered
black carbon deposits).
(c) Check both the inner and outer teeth of each
plate for wear or damage.
(d) Measure thickness of each plate.
Note: If any of the above defects is found, replace the
215641
entire plates with new ones.
Unit: mm (in.)
A 2.6 ± 0.1 (0.102 ± 0.004)
Friction plate
B 2.2 (0.087)
A 2.3 ± 0.07 (0.091 ± 0.0028)
Mating plate
B 2.1 (0.083)
(6) Measure the free length and the height under load
of the clutch return spring.
Unit: mm (in.)
A 68 ± 2 (2.68 ± 0.08)
Free length
B 64.5 (2.539)
33.5 (1.32) /
349 ± 135 N
Clutch return A
(35.6 ± 13.8 kgf)
spring [78.5 ± 30.3 lbf]
Height /
under load 33.5 (1.319) /
1147 N
B 215623
117.0 kgf
257.9 lbf
6-36
6.3 Reassembly
(1) Install the piston seal to the clutch piston.
(2) Apply ATF Dexron-II to both the piston seal and
sliding surface of the clutch piston.
(3) Using a wood bar, evenly push the clutch piston
into the clutch drum.
Note: Be sure to push the clutch boss when pushing
the clutch piston.
(4) Install both the clutch return spring and spring
retainer.
Note: Be sure to install a new snap ring. Do not reuse
snap rings once removed.
(5) Using a clutch pack stand kit (special tool) or a
press, compress the spring retainer and clutch
return spring together, and install the snap ring.
Stand 91K67-00700
Ring 91K67-00800
Plate 91K67-00900
Bolt 91K67-01100
Note: Be sure to evenly tighten the clutch pack stand

kit with bolts. 216927
(6) Assemble friction plates and mating plates in the

same order before they were removed.
(7) Install the pressure plate with the marked side fac-
ing upward.
(8) Install the snap ring into the clutch drum groove
using a flathead screwdriver. Snap ring
Note: Use a new snap ring. Do not reuse snap rings
once removed.
215624
6-37
(9) Measure clearance between the snap ring and the

pressure plate using a feeler gauge, and check 1
that the clearance is within the range of the stan-
dard value.
Unit: mm (in.)
Clearance 1 between F2 clutch
2.2 to 2.6
drum snap ring and pressure A
(0.087 to 0.102)
plate
A: Standard value
(10)If the clearance does not fall within the standard Thickness gauge
deviation range, select one of pressure plates 215625
listed in the table below for adjustment.
Unit: mm (in.)
Pressure Plate Selection
Thickness
Part number
91K24-05400 5.50 (0.217)
91K24-05500 5.75 (0.226)
91K24-05600 6.00 (0.236)
91K24-05700 6.25 (0.246)
91K24-05800 6.50 (0.256)
(11)Blow compressed air into the clutch drum shaft oil

hole and make sure that the clutch piston func-
tions properly.
Note: Be sure to use filtered compressed air.
(12)Align the inner teeth of friction plates using a wire.
215626
6-38
(13)Install the snap ring to the clutch gear, and using

the installer (special tool, 91A68-02300), hammer
the bearing until the bearing hits against the snap
ring. Ball
bearing
Snap ring
F2 clutch gear
217089
Ball
bearing
Snap ring
F2 clutch
gear
Ball
bearing
217090
(14)Install the F2 clutch gear to the clutch drum gear

while rotating the clutch gear carefully to engage
the clutch gear with the friction plate internal teeth.
Note: When a ball bearing is removed from the clutch
gear, reinstall the ball bearing by referring to the
following instructions.
(a) The bearing, located on the exterior of clutch
pack assembly, should be equipped with a
shield, and installed with that the shield side
facing outward.
(b) Be careful not to hammer the bearing exces-
sively, as it affects bearing positioning accu-
racy.
(15)Evenly tap the F2 clutch gear with a plastic ham-
mer while turning the gear, and then drive it into
the clutch drum until the ball bearing of the clutch
gear comes in contact with the shaft end surface.
(16)Install snap ring.

Note: Use a new snap ring. Do not reuse snap rings
once removed.
Snap ring
215628
6-39
(17)Install the spacer using the installer (special tool,

91K67-02100).
(18)Insert the spacer into the shaft.
Installer
Spacer
216877
(19)Evenly hammer the ball bearing into the shaft.
Installer
Ball bearing
216878
6-40
7. F1 Clutch Pack Assembly

7.1 Disassembly
5
1
2
3
6 6
11 7
8
10
11
215631
1 Ball bearing 7 Snap ring
4 F1 clutch gear, Ball bearing, Snap ring 10 Clutch drum, Ball bearing
6 Pressure plate, Mating plate, Friction plate

Refer to "Suggestions for Disassembly" of the F2
clutch pack assembly.

Refer to "Inspection and Repair" of the F2 clutch pack
assembly.
7.3 Reassembly
Refer to "Reassembly" of the F2 clutch pack assembly.
6-41
8. R1 Clutch Pack Assembly

8.1 Disassembly
1
6 6 2
3
4
9
11
7
8
10
11
215632
1 Ball bearing 7 Snap ring
4 R1 clutch gear, Ball bearing, Snap ring 10 Clutch drum, Ball bearing
6 Pressure plate, Mating plate, Friction plate

Refer to "Suggestions for Disassembly" of the F2
clutch pack assembly.

assembly.
6-42
8.3 Reassembly
assembly except for the following. 1
(1) Measure the clearance between the snap ring and
the pressure plate using a feeler gauge, and
check that the clearance is within the standard
value range.
Unit: mm (in.)
Clearance 1 between R1 clutch
3.5 to 3.9
drum snap ring and pressure A
(0.138 to 0.154)
plate Thickness gauge
A: Standard value 215625
(2) If the clearance does not fall within the range of

standard deviation, select one of pressure plates
listed in the table below for adjustment.
Unit: mm (in.)
Pressure Plate Selection
Thickness
Part number
91K24-05400 5.50 (0.217)
91K24-05500 5.75 (0.227)
91K24-05600 6.00 (0.236)
91K24-05700 6.25 (0.246)
91K24-05800 6.50 (0.256)
6-43
9. Parking Brake Assembly

9.1 Disassembly
9
1 Tightening torque:
31.4 ± 3.1 N·m
(3.2 ± 0.3 kgf·m)
[23.2 ± 2.3 lbf·ft]
10
7
8
2
5
3
3
Tightening torque:
245 ± 24.5 N·m 4
(25.0 ± 2.5 kgf·m)
[180.8 ± 18.1 lbf·ft] 5
215633
1 Hexagon socket head bolt 4 Main shaft nut 7 Housing
2 Pressure plate 5 Piston, Piston seal S, Piston seal L 8 Snap ring
3 Mating plate, Friction plate 6 Parking brake spring 9 Parking brake gear
10 Bearing retainer, Ball bearing
6-44

(1) Secure the parking brake assembly.
Note: If clamping the assembly in a vise, be careful
not to overtighten the vise.
(2) Loosen the hexagon socket head bolts using a
hexagon socket wrench.
Note: Only loosen the hexagon socket head bolts at
this point.
215634
(3) Unclamp the parking brake assembly from the

vise, and lay it on the workbench.
(4) Remove the hexagon socket head bolts.
Hexagon
Note: Loosen the bolts evenly and progressively for socket head bolt
removal.
215635
(5) Separate the bearing retainer from the housing.

Note: If they are sticking to each other, tap the as-
sembly around the housing rim assembly. Housing Bearing retainer
215636
(6) Remove the pressure plate, mating plates, and

Bearing retainer side
friction plates from the housing.
Pressure plate
Note: Note the order of the plates as they are disas-
Friction plate
sembled.
Pressure plate: 1 piece
Mating plate: 5 pieces
Friction plate: 3 pieces
Mating plate
Piston side 215637
6-45
(7) Remove the main shaft nut from the piston using
the socket (special tool, 91K67-00600).
Socket
Socket 91K67-00600
Main shaft nut
Holder 91K67-01500
(8) Remove the piston and spring.

Note: Note the orientation of spring (head and tail).
Holder
216879
(9) Remove the snap ring that secures the parking

brake gear.
(10)Fix the bearing retainer, and hammer out the
parking brake gear with the installer (special tool,
91K67-26000).
Snap ring
215639
(11)Remove the bearing from the bearing retainer

using the remover (special tool, 91K67-02500).
216930
6-46

(1) Piston
(a) Inspect sliding area for wear and damage.
If any scratches are found, polish the
scratched surface using a fine grit sandpaper.
If a significant scratches are found, replace the
clutch piston with a new one.
(b) Measure the width of the piston seal groove, 1
and if the measured width exceeds the service
limit, replace the piston with a new one.
Unit: mm (in.)
Width of piston seal A 40

+0.1
0 (1.57
+0.004
0 ) 215640
groove 1
B 0.165 (0.0065)
Note: Be sure to replace piston seals with new ones

whenever they are removed.
(2) Gear
Check gears for wear or damage.
(3) Housing
Check both the piston sliding portion and parking
brake spring contact area for wear or damage.
(4) Friction plates and mating plates
(a) Check both plates for seizure, uneven contact,
distortion, or damage.
(b) Check mating plates for hot spots (scattered
black carbon deposits).
(c) Check both the inner and outer teeth of each
plate for wear or damage.
(d) Measure thickness of each plate.
Note: If any of the above defects is found, replace the
entire plates with new ones.
215641
Unit: mm (in.)
A 2.55 ± 0.15 (0.1004 ± 0.0059)
Friction plate
B 2.37 (0.0933)
A 1.6 ± 0.1 (0.063 ± 0.004)
Mating plate
B 1.47 (0.0579)
6-47
(5) Parking brake spring

Measure the free length and the height of parking
brake spring under the load.
Unit: mm (in.)
1
7.5 (0.295)
Free length A
(reference)
5.6 (0.220) /
10360 ± 1040 N
A
Parking brake (1056.4 ± 106.1 kgf)
spring 1 Height / [2329.0 ± 233.8]
under load 5.6 (0.220) /
215642
9320 N
B
(950.4)
[2095.2]
Note: If it is impossible to measure height of the park-

ing brake spring under load, be sure to replace
it with a new one during overhaul in excess of
over 5000 total hours of operation.
6-48
9.3 Reassembly
For reassembly, follow the disassembly sequence in
reverse, while following the instructions below.
(1) After installing the piston and parking brake spring
in the housing, press the piston with a piston pin
press to compress the parking brake spring.
Note: When installing the spring, pay attention to the
orientation (head and tail).
(2) Tighten the main shaft nut to the specified torque

using a special tool.
Socket
Socket 91K67-00600
Main shaft nut
Holder 91K67-001500

245 ± 24.5
Tightening torque for main
(24.98 ± 2.50) Holder
shaft nut
[180.70 ± 18.07]
Note: Be sure to install a new main shaft nut. Do not 216879

reuse them after they have been removed.
(3) Assemble the friction plates and the mating plates

in the same order as they were.
(4) Hammer the bearing into the bearing retainer
using the installer (91K67-02500).
(5) After the parking brake assembly is reassembled,
insert the hexagon socket head bolts into the
parking brake assembly.
(6) Clamp the parking brake assembly, and tighten
the assembly evenly and progressively with hexa-
gon socket head bolts. Torque to specifications.
215634
31.4 ± 3.1
Tightening torque for
(3.20 ± 0.32)
hexagon socket head bolt
[23.16 ± 2.29]
Note: If clamping the assembly in a vise, be careful

not to overtighten the vise.
6-49
10.Gear Pump Assembly

10.1 Disassembly
1
215645
1 Bolt 5 Oil pump drive gear
2 Snap ring 6 Internal gear
3 PTO driven gear, Ball bearing, Seal ring 7 Gear pump case, O-ring, Gasket
4 Gear pump cover, Ball bearing, Pin
6-50

(1) Place wood blocks under the gear pump case so
that the PTO driven gear is raised off the ground.
Wood block
215646
(2) Remove the snap ring.

(3) From the gear pump cover side, hammer out the Snap ring
shaft end face indirectly through the remover Copper
bar
(special tool, 91K67-02800).
PTO driven gear

216880
(4) Remove the bolts that secure the gear pump

cover to the gear pump case.
(5) Insert two bolts into the jack bolt holes
(M10×1.25) of the gear pump cover, and screw
the bolts down evenly to remove the gear pump
cover.
Jack bolt holes

(M10 × 1.25) 215649
(6) Remove the pump drive gear, the internal gear,

Internal gear Pump drive gear O-ring
and O-ring.
215650
6-51

(1) Measure clearance between the internal gear and
the pump gear pump case.
Unit: mm (in.)
A 0.12 to 0.17
Clearance between internal (0.0047 to 0.0067)
gear and pump gear case
B 0.27 (0.0106)
215651
(2) Measure clearance between the internal gear and
the crescent-shaped part.
Unit: mm (in.)
A 0.21 to 0.27
Clearance between internal (0.0083 to 0.0106)
gear and crescent-shaped part
B 0.37 (0.0146)
(3) Measure clearance between the pump drive gear

and the crescent-shaped part.
Unit: mm (in.)
215652
Clearance between pump A 0.3 to 0.34
drive gear and crescent- (0.012 to 0.0134)
shaped part B 0.47 (0.0185)
(4) Measure clearance between the gear pump case

mounting surface and the gear.
Unit: mm (in.)
Clearance between gear pump A 0.05 to 0.08
case mounting surface and (0.0020 to 0.0031)
gear B 0.18 (0.0071)
215653
(5) Check both the gear and splines for wear or dam-
age.
(6) Measure the width of both the seal ring and shaft
groove of the PTO driven gear. Replace the seal
ring with a new one if the measured width
exceeds the standard value.
1
Unit: mm (in.)
A 2.5 ± 0.05
Seal ring width 1 (0.098 ± 0.0020)
B 2.3 (0.091)
2
A 2.5 +0.2 +0.008
+0.1 (0.098 +0.004)
PTO driven gear shaft seal
ring groove width 2 B 2.8 (0.110)
215654
6-52
10.3 Reassembly
Follow the disassembly sequence in reverse.

(1) Install the internal gear, pump drive gear and O- O-ring
Internal gear
ring to the gear pump case. Pump drive gear
Wood blocks
O-ring
Gear pump case

216948
(2) Install the gear pump cover, and tighten the

mounting bolts to the specified torque. Gear pump cover

39.2 ± 3.9
Tightening torque for gear pump
(4.00 ± 0.40)
cover mounting bolt
[28.93 ± 2.88]
216949
(3) Using the installer (special tool, 91K67-02300),

install the bearing (large) into the PTO driven Installer
gear.
Installer 91K67-02300 Bearing
PTO driven gear

216985
(4) Install the seal ring to the PTO driven gear.

Seal ring
PTO driven gear Seal ring
216950
6-53
(5) Lay the gear pump case with the gear pump cover
facing down.
(6) Hammer the PTO driven gear into the gear pump
case.
216952
(7) Lay the gear pump case with the gear pump cover
facing upward.
216954
(8) While taking care of the PTO driven gear so that it

does not fall out, install the bearing (small) to the
gear pump cover and the PTO driven gear using
Installer
the installer (special tool, 91K67-02600).
Installer 91K67-02600 Bearing
PTO
driven gear
216955
(9) Install the snap ring.
Snap ring
216956
6-54
11.Control Valve
11.1 Disassembly
Main valve assembly Shift valve assembly
(top of control valve) (bottom of control valve)
1
2
11 10
17
14
16 5
2
18 3 7
13 14 6
8
15
4
19 18
12
17 3
2
9
20
215655
1 Shift valve cover 13 Plug, O-ring, Main orifice
2 Solenoid valve, O-ring 14 Snap ring, Plug, O-ring, Accumulator piston,
3 Directional spring, Spring seat Inner spring, Outer spring
4 Directional spool 15 Snap ring, Accumulator seat, O-ring
5 H-L shift valve, Solenoid spring 16 Spring pin, Plate
6 Snap ring, Washer 17 Oil seal, Snap ring, Plug, O-ring
7 Plug, O-ring 18 Inching spring, Inching stopper, Inching rod,
8 Shift valve body, Gasket, Separator plate Inching valve, Spring pin, Return spring
9 Filter 19 Filter, O-ring
10 Cable bracket 20 Main valve body, Gasket
11 Retainer, Bushing, Inching lever
12 Eye bolt, Gasket, Cooler pipe

When removing the accumulator snap ring, slowly
remove the snap ring by pushing it against the accu-
mulator seat to prevent the accumulator spring from
popping out.
Note: Do not remove the harness from the main valve
body unless otherwise required.
215656
6-55

(1) Thoroughly wash the valve body using wash oil,
and blow it dry with compressed air.
(2) Check the valve body for clogged oil passages.
(3) Thoroughly wash the valves, the pistons, the
springs, and the main orifice, and blow them dry
with compressed air.
(4) When they are dried, check both the valve and
piston for abnormal wear or damage, and check
the springs for distortion or damage.
(5) Check both the accumulator piston and main ori-
fice for clogged holes.
(6) Do not reuse resin plugs and O-rings. Grease
should be applied in thin coats.
(7) Check the valves for wear, damage, and smooth-
ness of sliding movement.
(8) If a filter is clogged, replace the filter with a new
one.
6-56
(9) Measure the free length and the height under load 2
1
of each spring.
Unit: mm (in.)
Free A 154 ± 5 (6.1 ± 0.2)
length B 147 (5.8)
145 (5.7) /
Accumulator 61 ± 5 N
inner spring 1 A
Height / (6.5 ± 0.5 kgf)
under load [13.7 ± 1.1 lbf]
145 (5.7) / 4 3
B
54 N (5.5 kgf) [12.1 lbf] 5 5
Free A 109.5 ± 3.5 (4.3 ± 0.14)
length B 104 (4.1)
100 (3.9) /
Accumulator 61 ± 5 N
outer spring 2 A
Height / (6.5 ± 0.5 kgf)
6 215657
100 (3.9) /
B
54 N (5.5 kgf) [12.1 lbf]
Free A 87 ± 3 (3.4 ± 0.12)
length B 83.5 (3.3)
50.2 (2.0) /
Inching 51 ± 5 N
return spring 3 A
Height / (5.2 ± 0.5 kgf)
50.2 ( 2.0) /
B
43 N (4.4 kgf) [9.7 lbf]
Free A 18.4 (0.7)
length B 18.3 (0.7)
16.4 (0.6) /
Inching 49 ± 5 N
spring 4 A
Height / (5.0 ± 0.5 kgf)
16.4 (0.6) /
B
41 N (4.2 kgf) [9.2 lbf]
Free A 32.5 ± 1 (1.3 ± 0.04)
length B 30.5 (1.2)
23.4 (0.9) /
Directional 39 ± 3 N
spring 5 A
Height / (4.0 ± 0.3 kgf)
23.4 (0.9) /
B
34 N (3.5 kgf) [7.6 lbf]
Free A 87.5 ± 3 (3.4 ± 0.1)
length B 83.5 (3.3)
67 (2.6) /
Solenoid 80 ± 7 N
spring 6 A
Height / (8.2 ± 0.7 kgf)
67 (2.6) /
B
69 N (7.0 kgf) [15.5 lbf]
6-57
11.3 Reassembly
Shift valve assembly (bottom of control valve)
5 1 7 6 7 5
Section A-A
A A
3 2 4 5
Main valve assembly (top of control valve)
11 10 12 14 13 9 15 16
Section B-B
17
18 B
B
28
27
26 19 20 21 22 24 23 25
215658
Reassembly sequence
1 Shift valve body 15 Accumulator spring seat, O-ring
2 Plug, O-ring 16 Snap ring
3 Washer, Snap ring 17 Snap ring
4 Solenoid spring, H-L shift valve 18 Oil seal
5 Solenoid valve, O-ring 19 Inching rod
6 Directional spool 20 Inching valve
7 Spring seat, Directional spring 21 Inching spring
8 Filter 22 Inching stopper, Spring pin
9 Main valve body 23 Return spring
10 Plug, O-ring 24 Inching stopper
11 Snap ring 25 Plug, O-ring
12 Accumulator piston 26 Filter, O-ring
13 Outer spring 27 Plate, Spring pin
14 Inner spring 28 Main orifice
6-58

(1) Replace the oil seals with new ones.
Note: Be sure to use a new snap ring. Do not reuse
them once they are removed.
(2) Apply ATF Dexron-II to the valves and spools
before assembling.
(3) If a filter is clogged, replace the filter with a new
one.
(4) Check that the projection of the inching rod does
not exceed the value indicated below when
A
assembled in the valve body.
Unit: mm (in.)
Projection A of inching rod
32.8 (1.29)
from valve body
215660
(5) Tighten each bolt and plug to the specified torque
as shown in the illustration below.
16.7 ± 1.7 N·m
Main valve assembly Shift valve assembly (1.7 ± 0.2 kgf·m)
[12.3 ± 1.3 lbf·ft]
(top of control valve) (bottom of control valve)
40 ± 4 N·m
7 ± 1 N·m 53.9 ± 5.4 N·m (5.5 ± 0.6 kgf·m) [40.0 ± 4.0 lbf·ft] (4.1 ± 0.4 kgf·m)
(0.7 ± 0.1 kgf·m) [29.5 ± 3.0 lbf·ft]
[5.2 ± 0.7 lbf·ft] 25 ± 2.5 N·m (2.5 ± 0.3 kgf·m) [18.5 ± 1.8 lbf·ft]
39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.9 lbf·ft] 2.2 ± 0.2 N·m
(0.22 ± 0.02 kgf·m)
40 ± 4 N·m (4.1 ± 0.4 kgf·m) [29.5 ± 3.0 lbf·ft] [1.62 ± 0.15 lbf·ft]
7 ± 1 N·m 16.7 ± 1.7 N·m 40 ± 4 N·m

44.1 ± 4.4 N·m 39.2 ± 3.9 N·m (0.7 ± 0.1 kgf·m) (1.7 ± 0.2 kgf·m) (4.1 ± 0.4 kgf·m)
(4.5 ± 0.4 kgf·m) (4.0 ± 0.4 kgf·m) [5.2 ± 0.7 lbf·ft] [12.3 ± 1.3 lbf·ft] [29.5 ± 3.0 lbf·ft]
[32.5 ± 3.2 lbf·ft] [28.9 ± 2.9 lbf·ft]
215661
6-59
12.Main Regulator Valve

12.1 Disassembly
Tightening torque:
19.6 ± 2.0 N·m
(2.0 ± 0.2 kgf·m)
[14.5 ± 1.5 lbf·ft]
5 1
6 4 3 2
215662
1 Cover, O-ring 3 Main relief valve 5 Cover, O-ring
2 Slug 4 Spring 6 Valve body

When removing the cover 1, slowly unscrew the bolts
from the cover to prevent the spring, inside, from pop-
ping out.
6-60

(1) Check the valve body for clogged oil passages.
(2) Check both the valve and slug for wear, damage,
and smoothness of sliding movement.
(3) Check the spring for damage or settling.
(4) Measure the free length and the height of the
main regulator spring under load.
Unit:mm (in.)
Free A 107 ± 3.5 (4.2 ± 0.14)
length B 102 (4)
74.9 (3) /
160 ± 13 N
Main regulator A
(16.3 ± 1.3kgf)
valve spring [36.0 ± 2.9lbf]
Height /
under load 74.9 (3) /
140 N
B
(14.3 kgf)
[31.5 lbf]
12.3 Reassembly
(1) For reassembly, follow the disassembly sequence
in reverse.
(2) Apply ATF Dexron-II to both the main relief valve
and slug before assembling.
6-61
13.Inspection and Adjustment

13.1 Oil Pressure Measurement
(1) Check transmission oil level.
(a) Check oil level using a level gauge.
(b) Run the engine at idling speed, then stop the
engine.
(c) Wait for 1 minute or more after the engine
stops, and check the oil level.
(d) The oil level checking must be completed
within 3 minutes after the engine stopped.
(2) Engine warm-up
(a) Warm up the engine, and raise the tempera-
ture of the transmission oil between the range
of 35 to 45°C (95 to 113°F).
(3) Engine speed measurement
(a) After the engine is warmed up, measure the
idling speed and maximum no-load speed
according to the engine service manual.
Make the necessary adjustments if either or
both of the speeds do not meet the specifica-
tions.
(4) Preparation for oil pressure measurement
(a) Stop the engine after checking and adjusting
the engine speeds.
(b) Raise the front wheels off the ground either by
jacking up the front axle housing or tilting the
mast forward after placing wood blocks under
the outer mast.
(c) Block the rear wheels.
Note: The front wheels spin during the clutch pres-
sure measurement. Stay away from the front
wheels and be careful not to get caught in the
spinning wheels.
(d) Connect oil pressure gauges to each of the oil
pressure taps shown in the illustration on the Top view of transmission Main regulator
c valve a(M)
right. b(D)
a: Main pressure (M)
b: Clutch pressure M
(D) Directional clutch pressure

b(F1)
(F1) Forward 1st gear clutch pressure T
(F2) Forward 2nd gear clutch pressure d

(R) Reverse clutch pressure
c: Torque converter inlet pressure b(F2)
d: Lubrication oil pressure
b(R)
Note: When loosening the plugs a through d, tap the
plugs on the head once or twice to loosen them.
215663
6-62
(e) Use the following tools for oil pressure measurement.

Oil pressure measurement tools
Special tool/part c: Torque converter d: Lubrication oil
Remark a: Main pressure b: Clutch pressure
number inlet pressure pressure
Connector
G1/8, Rc 1/8 ○ ○ - -
65628-00400
Connector (plug) Rc 1/8,
M16×1.5 - - ○ -
91K67-00500
Connector (eye bolt) Rc 1/8,
M16×1.5 - - - ○
91868-01600
*Gauge
64309-17714 0.6 MPa - - ○ ○
or 64309-17713 2 MPa
*Gauge
2 MPa ○ ○ - -
64309-17713
*Connector R(PT)1/8
thread ○ ○ ○ ○
64309-17733
*Hose
○ ○ ○ ○
64309-17722
*Connector For gauge
connection ○ ○ ○ ○
64309-17731
Note: The tool marked by * is included in the 64309-17701 gauge kit.

(5) Oil Pressure Measurement
(a) Start the engine and place the direction lever into the neutral position, and then measure the main oil pres-
sure, the torque converter inlet oil pressure, and the lubrication oil pressure.
(b) Place the direction lever into the forward position, and measure the clutch oil pressure. Repeat the proce-
dure with the lever shifted in reverse position.
Note: Oil temperature measurement should be within the range of 35 to 45°C (95 to 113°F).
Unit: MPa (kgf/cm2) [psi]

Pressure for measurement Engine speed Oil pressure
700 ± 25 min-1(rpm) 1.08 ± 0.03 (11.01 ± 0.30) [156.66 ± 4.35]
a Main pressure 1600 ± 25 min-1(rpm) Neutral 1.14 ± 0.02 (11.62 ± 0.20) [165.36 ± 2.90]
2450 ± 25 min-1(rpm) 1.18 ± 0.02 (12.03 ± 0.20) [171.16 ± 2.90]
Forward 1st gear 1.05 ± 0.05 (10.71 ± 0.51) [152.30 ± 7.25]
700 ± 25 min-1(rpm) Forward 2nd gear 1.05 ± 0.05 (10.71 ± 0.51) [152.30 ± 7.25]
Reverse 1.05 ± 0.05 (10.71 ± 0.51) [152.30 ± 7.25]
Forward 1st gear 1.15 ± 0.05 (11.73 ± 0.51) [166.81 ± 7.25]
b Clutch pressure 1600 ± 25 min-1(rpm) Forward 2nd gear 1.15 ± 0.05 (11.73 ± 0.51) [166.81 ± 7.25]
Reverse 1.15 ± 0.05 (11.73 ± 0.51) [166.81 ± 7.25]
Forward 1st gear 1.23 ± 0.05 (12.54 ± 0.51) [178.41 ± 7.25]
2450 ± 25 min-1(rpm) Forward 2nd gear 1.23 ± 0.05 (12.54 ± 0.51) [178.41 ± 7.25]
Reverse 1.23 ± 0.05 (12.54 ± 0.51) [178.41 ± 7.25]
600 ± 50 min-1(rpm) 0.12 ± 0.02 (1.22 ± 0.20) [17.41 ± 2.90]
Torque converter inlet
c 1600 ± 100 min-1(rpm) Neutral 0.40 ± 0.02 (4.08 ± 0.20) [58.02 ± 2.90]
pressure
2450 ± 25 min-1(rpm) 0.54 ± 0.02 (5.51 ± 0.20) [78.33 ± 2.90]
600 ± 50 min-1(rpm) 0.02 ± 0.01 (0.20 ± 0.10) [2.90 ± 1.45]
d Lubrication oil pressure 1600 ± 100 min-1(rpm) Neutral 0.03 ± 0.01 (0.30 ± 0.10) [4.35 ± 1.45]
2450 ± 25 min-1(rpm) 0.04 ± 0.01 (0.41 ± 0.10) [5.80 ± 1.45]
6-63
13.2 Brake Inching Pedal Adjustment
3 7
5
2
215664
1 Brake pedal 5 Inching stopper bolt

2 Inching pedal 6 Inching cable
3 Inching pedal stopper 7 Brake stopper
4 Stop lamp switch
The clutch (inching) mechanism is linked to the brake

pedal. Pressing the inching pedal cuts the pressure
acting on the transmission before the brakes take
effect, bringing the transmission to a neutral condition.
A faulty inching pedal adjustment may create such
problems as failure in clutch disengagement and par-
tial clutch engagement. This in turn may cause an
abnormal increase in the transmission oil temperature,
as well as braking malfunctions and clutch plate sei-
zures. Be sure to make all the following adjustments
carefully so that these problems can be avoided.
6-64
(1) Brake pedal adjustment

Free play
(a) Measure height A between the floor plate top
surface and the brake pedal top surface, and
adjust the height to the following standard
value by turning the stopper bolt 1 and then Brake A
lock it with the lock nut. pedal
Unit: mm (in.) Top of floor plate

187.6 to 191.6 Stopper bolt 1
Brake pedal height A
(7.386 to 7.543)
(b) Adjust the clearance to 1.0 mm (0.04 in.),

between the push rod and piston of the brake
valve 2. To do this, turn the push rod clockwise Stop lamp switch
until it contacts the piston, then turn it back
counterclockwise for approx. 0.8 turns, and
finally secure the clevis with nut. After this
adjustment, check the brake pedal play. Brake valve 2
215665
Unit: mm (in.)
Brake pedal free play Approx. 5 (0.2)
(2) Inching pedal adjustment

(a) Measure height A between the floor plate top Inching pedal
surface and the inching pedal top surface, and
A
adjust the height to the following standard
value by turning the stopper bolt 3 and then
lock it with the locknut. Top of floor plate
Stopper bolt 3
Unit: mm (in.)
187.6 to 191.6
Inching pedal height A
(7.386 to 7.543)
215666
(3) Stop lamp switch adjustment

(a) Adjust the stop lamp switch position so that the C
stop lamp glows when the brake pedal is
pressed, and then secure the switch to the
optimum position.
Unit: mm (in.)
Stop lamp switch installation 0.5 to 1.0
dimension C (0.020 to 0.039)
215667
6-65
13.3 Inching Cable Adjustment

(a) Make sure that the inching pedal stopper is in
3 to 6 mm
contact with the stopper bolt before installing (0.12 to 0.24 in.)
the inching cable.
(b) Make sure that the inching lever moves Stopper Inching pedal
smoothly before installing the inching cable.
B
Stopper bolt
(c) Install the inching cable onto the connecting
points of both the pedal and transmission.
(d) Tighten the cable adjusting nut so that clear-
ance between the inching pedal stopper and
stopper bolt meets within the range of specified
215669
value B. When the clearance is properly
adjusted, the free play of the inching pedal falls
within the range of 3 to 6 mm (0.12 to 0.24 in.). Transmission side mounting area
Note: The clearance is related to the motion between Inching lever

the inching pedal and the brake pedal. Cable adjust nut
Unit: mm (in.) Inching cable

Clearance B between inching
0.4 to 1.1
pedal stopper and stopper
(0.016 to 0.043)
bolt
If free play of the inching cable is not properly 215668

adjusted, the following failures may occur.
(a) When the clearance is less than 0.4 mm (0.016
in.):
Even if the inching pedal is lightly pressed or
not pressed at all, oil pressure in the clutch
system decreases, which causes the clutch to
slip. This results in premature wear or burnout
of the clutch plates.
(b) When the clearance is more than 1.1 mm (0.04
in.):
Even if the inching pedal is fully pressed, oil
pressure in the clutch system does not
decrease enough to disengage the clutch com-
pletely. This results in premature wear or burn-
out of the clutch plates.
6-66
14.Troubleshooting
Condition Possible cause Action

Engine lacks power. Tune up engine
Engine
Poor engine performance. Tune up engine
Seizure of stator freewheel. Replace torque converter assembly.
Torque converter
Impeller is damaged or rubbing. Replace torque converter assembly.
Spool action in main regulator valve is Repair or replace
faulty.
Fatigued spring in main regulator valve Replace the spring
Worn gears in oil pump, resulting in Disassemble for inspection. If defec-
reduced capacity tive, replace.
Magnet strainer is clogged. Replace
Power out-
put is low. Water is mixed with oil. Change oil
Transmission Oil level is too low. Refill
Clutch slips or brake drags due to Adjust
improper adjustment of pedal links.
Main pressure too low, resulting in slipping Adjust
clutches.
Seal rings or O-rings are worn. Inspect. If defective, replace.
Clutch piston is damaged. Replace
Friction plate is seized or dragging. Replace
High mechanical resistance in road Check and/or adjust brake system.
Road wheels
wheels.
Torque converter Flexible plate is broken. Replace
Oil pump drive is defective. Replace
Turbine shaft is broken. Replace
Main oil pressure is too low. Check pump gears for wear. If worn,
replace.
Oil level is too low. Refill
Improper adjustment of inching pedal link. Adjust
Clutch shaft seal ring is worn. Replace
Clutch shaft plug slips out, resulting in oil Repair
Transmission
leak.
No power
Clutch is seized. Replace
flow
Shafts are broken. Replace
Clutch drum is defective, particularly snap Replace
ring groove.
Snap ring for clutch drum is broken. Replace
Clutch piston oil passages are clogged. Clean or replace
Shaft splines are worn. Replace shafts
Faulty action of spools Repair or replace
Universal joint is broken. Replace
Power train
Either reduction differential parts or front Repair or replace
axle parts are broken.
6-67

Flexible plate is broken. Replace
Bearings are damaged. Replace
Torque converter Impeller is rubbing. Replace
Loose bolts. Retighten or replace
Splines are worn. Replace
Oil pump is worn. Disassemble for inspection. If defec-
tive, replace.
Clutch is seized, resulting in dragging Replace clutch plate.
noise.
Transmission Bearings are worn or seized. Replace
Gears are broken. Replace
Loose bolts. Retighten or replace bolts.
Splines are worn. Replace
Abnormal Oil strainer clogged Clean
noise
Main regulator valve is defective. Clean or replace
Restriction in oil pipe. Replace
Loud noise
High oil viscosity in cold weather. Change oil
Instruments are faulty. Replace
Improper oil is used. Change oil
Oil strainer is clogged. Clean or replace
Oil pump is defective. Replace
Excessive oil leaks
(1) Broken or settling of main regulator Replace
Low noise
valve spring
(2) Defective main regulator valve spool Repair or replace
Air being sucked in. Retighten or replace packing.
Leak from oil seals. Check lips and sliding surfaces for
wear. Replace seals.
Leak from case joint. Retighten or replace packing.
Leak from pipe connection or joint. Repair or replace pipes, gaskets and
O-rings.
Leak from drain plug. Retighten and replace gasket.
Oil leaks.
Leak from cracks or blowholes in case. Replace
Oil blowing out of transmission case. Check oil level.
(1) Water is mixed with oil. Change oil
(2) Oil leaks from air breather. Check oil level.
Oil level is too high. Drain oil
6-68

Oil level is too high or too low. Refill or drain
Oil strainer is clogged. Clean or replace
Torque converter
Impeller is rubbing. Repair or replace
Stator freewheel defective. Replace stator assembly.
Air being sucked in. Retighten or replace O-ring.
Water is mixed with oil. Change oil
Restriction in oil pipe (resulting in reduced Repair or replace
circulation flow).
Oil tempera- Transmission Bearings are worn or seized. Repair or replace
ture is too
Instruments are faulty. Replace
high.
Clutches are dragging. Replace clutch plate
Bearings are worn or seized. Repair or replace
Control linkage is defective. Repair or replace
Improper operation of lift truck. Urge user to operate properly.
Others
Others (1) Cooling fan belt is damaged. Replace
(2) Oil cooler is clogged. Clean or replace
(3) Brakes are dragging. Check and readjust
Main regulator valve is defective. Repair or replace valve assembly.
Oil viscosity is too high at low tempera- Change oil
Main oil pressure is too high.
ture.
Improper oil is used. Change oil
Magnet strainer is clogged. Clean or replace
Oil pump is defective. Replace
Coil spring in main regulator valve is Replace the spring.
defective.
Main oil pressure is too low. Spool action in main regulator valve is Repair or replace spool.
faulty.
Air being sucked in. Retighten or replace packing.
Torque converter relief valve is defective. Repair or replace
Magnet strainer is clogged. Clean or replace
Oil pump is worn or failed. Replace
Coil spring in main regulator valve is Replace the spring.
defective.
Spool action in main regulator valve is Repair or replace
faulty.
Clutch oil pressure is too low. Air being sucked in. Retighten or replace packing.
Control linkage is defective. Repair or replace
Clutch valve is defective. Repair or replace
Seal ring in servo case is broken. Replace
Clutch seal rings are broken. Replace
6-69

Lack of engine power when the speed is Tune up engine
slightly low in both forward and reverse
drive.
Stator and freewheel is damaged when Replace stator assembly.
Stall speed not within specifications
the speed is excessively low in both for-
ward and reverse drive.
Inching pedal linkage defective, or clutch Repair or replace
slipping when the speed is too high.
Parking brake assembly is damaged. Replace
Brake does Oil line is clogged. Disassemble the parking brake valve
not work for inspection after bleeding oil out of
the emergency relief port of the park-
ing brake valve.
Parking brake Oil line pressure is low. Measure and adjust oil pressure of
the main relief valve and the reducing
Brake can valve.
not be Solenoid valve spool is defective. Replace
released.
Parking brake assembly is damaged. Replace
Electrical wiring is damaged. Check wirings for continuity.
Note: For emergency parking brake release, refer to "3.7 Parking Brake Emergency Release" of "Chapter 9 Brake
System."
6-70
15.Service Data
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Main oil pressure, engine speed at
MPa (kgf/cm2) [psi] A 1.14 ± 0.02 (11.62 ± 0.20) [165.4 ± 2.9]
1600 ± 25 min-1
Clutch oil pressure, engine speed at
MPa (kgf/cm2) [psi] A 1.15 ± 0.05 (11.73 ± 0.51) [166.8 ± 7.3]
1600 ± 25 min-1
Torque converter inlet pressure,
MPa (kgf/cm2) [psi] A 0.40 ± 0.02 (4.08 ± 0.20) [58.0 ± 2.9]
engine speed at 1600 ± 100 min-1
Lubrication oil pressure, engine speed
MPa (kgf/cm2) [psi] A 0.03 ± 0.01 (0.31 ± 0.10) [4.4 ± 1.5]
at 1600 ± 100 min-1
Travel time for 10m starting acceleration (no load) Sec. A 3 to 5
Stall speed in theory A 1.900 min-1
Pump boss A 0 0
100 -0.035 (3.94 -0.0014)
Oil seal contact surface (outside diameter) 1
B 99.9 (3.9)
1 215671
6-71
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Pilot boss A -0.006 -0.0002
20 -0.041 (0.788 -0.0016)
Shank diameter 1
B 19.95 (0.7860)
A 31.85 ± 0.05 (1.255 ± 0.002)
Pilot boss height 2
B 31.5 (1.24)
215672
Flexible Face runout of flexible plate 1 A 0.5 (0.0197)

plate (in free state) B 0.5 (0.0197)
Distance between end face of transmission
A 42 to 43 (1.655 to 1.694)
case and mating face of flexible plate 2
215674
6-72
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Clutch A 2.3 ± 0.07 (0.0906 ± 0.0028)
Thickness of mating plate 1
B 2.1 (0.0827)
A 2.6 ± 0.1 (0.1024 ± 0.0039)
Thickness of friction plate 2
B 2.2 (0.0867)
A 0.1 to 0.3 (0.0039 to 0.0118)
Backlash of friction plate and gear 3
B 0.4 (0.0158)
A 4
0
-0.1
0
(0.1576 -0.0118)
Width of piston seal 4
B 3.8 (0.1497)
A 4
+0.2
+0.1
+0.0079
(0.1576 +0.0039)
Width of piston seal ring groove 5
B 4.3 (1.694)
A 68 ± 2 (2.6792 ± 0.0788)
Free length
B 64.5 (2.5413)
Return spring 6 33.5 (1.3199) /
Height / under A
1349 ± 135 N (137.6 ± 13.8 kgf) [303.3 ± 30.3 lbf]
load
B 33.5 (1.3199) / 1147N (117.0 kgf) [257.9 lbf]
R1 A 3.5 to 3.9 (0.1379 to 0.1537)
Clearance 7 between clutch drum snap
F1
ring and pressure plate A 2.2 to 2.6 (0.0867 to 0.1024)
F2
1·3 2
7
215593
6-73
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
R1 clutch A 2.5 ± 0.05 (0.0985 ± 0.0029)
shaft, Seal ring width 1
B 2.3 (0.0906)
F1 clutch
shaft, A 2.5
+0.2
+0.1
+0.0079
(0.0985 +0.0039)
F2 clutch Seal ring groove width 2
shaft B 2.8 (0.1103)
Seal ring contact surface of stator shaft (inside A 35

+0.025
0 (1.379
+0.0010
0 )
diameter) 3 B 35.2 (1.3869)
Seal ring contact surface of transmission hous- A

+0.025 +0.0010
35 0 (1.379 0 )
ing (inner diameter) 4 B 35.2 (1.3869)
2
215476
6-74
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Stator shaft A 2.5 ± 0.05 (0.0985 ± 0.0020)
Seal ring width 1
B 2.3 (0.0906)
A 2.5
+0.2
+0.1
+0.0079
(0.0985 +0.0039)
Seal ring groove width 2
B 2.8 (0.1103)
Seal ring contact surface of pump boss (inside A 70

+0.03
0 (2.758
+0.0012
0 )
diameter) 3 B 70.1 (2.7619)
215677
6-75
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Gear Between R1 clutch drum gear and F1 clutch
A 0.13 to 0.29 (0.0051 to 0.0114)
backlash drum gear 1
Between R1 clutch gear and output gear 2 A 0.13 to 0.29 (0.0051 to 0.0114)
Between F1 clutch gear and output gear 3 A 0.13 to 0.29 (0.0051 to 0.0114)
Between F2 clutch gear and output gear 4 A 0.12 to 0.28 (0.0047 to 0.0110)
Between R1 clutch drum gear and F2 clutch
A 0.12 to 0.26 (0.0047 to 0.0102)
drum gear 5
Between F2 clutch gear and parking brake
A 0.13 to 0.31 (0.0051 to 0.0122)
gear 6
Between PTO drive gear and PTO idler gear 7 A 0.13 to 0.31 (0.0051 to 0.0122)
Between PTO idler gear and PTO driven gear
A 0.13 to 0.31 (0.0051 to 0.0122)
8
1·5
2
5
1 4
3
2·4
215678
6-76
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Parking A 1.6 ± 0.1 (0.0630 ± 0.0039)
brake Thickness of mating plate 1
B 1.47 (0.0579)
A 2.55 ± 0.15 (0.1005 ± 0.0059)
Thickness of friction plate 2
B 2.37 (0.0934)
A 0.1 to 0.3 (0.0039 to 0.0118)
Backlash of friction plate and gear 3
B 0.4 (0.0158)
A 3.1 ± 0.1 (0.1221 ± 0.0039)
Width of piston seal 4
B 2.9 (0.1143)
A 5.7 ± 0.1 (0.2246 ± 0.0039)
Piston seal height 5
B 5.5 (0.2167)
A 4.0
+0.1
0 (0.1576
+0.0039
0 )
Piston groove width 6
B 4.2 (0.1655)
Free length A 7.5 (0.295) [reference]
5.6 (0.2206) /
Parking brake 10360 ± 1040 N
Height / under A
spring 7 (1056.4 ± 106.1kgf)
load [2329.0 ± 233.8 lbf]
B 5.6 (0.2206) / 9320 N (950.4 kgf) [2095.2 lbf]
7
1
4
2
5
3
215905
6-77
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Gear pump Clearance between internal gear and gear A 0.12 to 0.17 (0.0047 to 0.0067)
pump case 1 B 0.27 (0.0106)
Clearance between internal gear and A 0.21 to 0.27 (0.0083 to 0.0106)
crescent-shaped part 2 B 0.37 (0.0146)
Clearance between pump drive gear and A 0.3 to 0.34 (0.0118 to 0.0134)
crescent-shaped part 3 B 0.47 (0.0185)
Clearance between gear pump case mounting A 0.05 to 0.08 (0.0020 to 0.0032)
face and gear 4 B 0.18 (0.0071)
A 2.5 ± 0.05 (0.0985 ± 0.0020)
Seal ring width 5
B 2.3 (0.0906)
A 2.5
+0.2
+0.1
+0.0079
(0.0985 +0.0039)
PTO driven gear shaft seal ring groove width 6
B 2.8 (0.1103)
1 3
215673
6-78
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Control A 154 ± 5 (6.07 ± 0.2)
valve Free length
B 147 (5.8)
Accumulator inner spring 1
A 145 (5.7) / 61 ± 5 N (6.5 ± 0.5 kgf) [13.7 ± 1.1 lbf]
Height / under load
B 45 (5.7) / 54 N (5.5 kgf) [12.1 lbf]
A 109.5 ± 3.5 (4.3 ± 0.1)
Free length
B 104 (4.1)
Accumulator outer spring 2
A 100 (3.9) / 61 ± 5 N (6.5 ± 0.5 kgf) [13.7 ± 1.1 lbf]
Height / under load
B 100 (3.9) / 54 N (5.5 kgf) [12.1 lbf]
A 87 ± 3 (3.4 ± 0.1)
Free length
B 83.5 (3.3)
Inching return spring 3
A 50.2 (2.0) / 51 ± 5 N (5.2 ± 0.5 kgf) [11.5 ± 1.1 lbf]
Height / under load
B 50.2 ( 2.0) / 43 N (4.4 kgf) [9.7 lbf]
A 18.4 (0.7)
Free length
B 18.3 (0.7)
Inching spring 4
A 16.4 (0.6) / 49 ± 5 N (5.0 ± 0.5 kgf) [11.0 ± 1.1 lbf]
Height / under load
B 16.4 (0.6) / 41 N (4.2 kgf) [9.2 lbf]
A 32.5 ± 1 (1.28 ± 0.04)
Free length
B 30.5 (1.2)
Directional spring 5
A 23.4 (0.9) / 39 ± 3 N (4.0 ± 0.3 kgf) [8.8 ± 0.7 lbf]
Height / under load
B 23.4 (0.9) / 34 N (3.5 kgf) [7.6 lbf]
A 87.5 ± 3 (3.45 ± 0.1)
Free length
B 83.5 (3.3)
Solenoid spring 6
A 67 (2.6) / 80 ± 7 N (8.2 ± 0.7 kgf) [18.0 ± 1.6 lbf]
Height / under load
B 67 (2.6) / 69 N (7.0 kgf) [15.5 lbf]
2 6
1 6
5
4 3
215679
6-79
Unit: mm (in.)
Truck model
Item P8000 P9000 P10000 P11000 P12000
PD8000 PD9000 PD10000 PD11000 PD12000
Main regu- A 107 ± 3.5 (4.22 ± 0.14)
lator valve Free length
B 102 (4.02)
Valve spring 1 74.9 (2.95) /
A
Height/under load 160 ± 13N (16.3 ± 1.3 kgf) [36.0 ± 2.9 lbf]
B 74.9 (2.95) / 140N (14.3 kgf) [31.5 lbf]
1
215592
6-80

06 Powershift Transmission

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06 Powershift Transmission

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Chapter 6 POWERSHIFT TRANSMISSION

1. Structure .................................................................................................. 6-1

Chapter 6 POWERSHIFT TRANSMISSION

The figure in parentheses shows the number of gear teeth. 215293

1 Flexible plate 6 F2 (Forward 2nd gear) clutch shaft (3rd shaft)

1.2 Power Transmission Path

R1 clutch drum gear(67) R1 clutch drum gear(67)

F2 clutch drum gear(62)

F1 clutch drum gear(77)

Transmission reduction ratio

R1 clutch gear(80) PTO

PTO drive gear(46)

PTO idler gear(68)

PTO driven gear(46)

Reverse Transmission reduction ratio

1.3 Torque Converter

1 Turbine runner 4 Pump impeller 7 Drive cover

1.4 Powershift Transmission Control

1 Forward/reverse shift lever 3 Inching cable

1.5 Control Valve

Main valve assembly Shift valve assembly

1 Filter 4 Directional valve 7 Inching lever

1.6 Main Regulator Valve

1 Bolt 5 Spool 9 Main oil pressure port

1.7 Parking Brake Activation

Release disks Compress disks

Piston Extend spring

Parking brake released state Parking brake applied state

Parking brake released state Parking brake applied state

1.8 Releasing parking brake with the release bolt

Parking brake gear Emergency relief bolt

(1) Always block the wheels, with the lift truck on a

PKB release wrench

Bolt for the hose clamp

Bolt for the ground wire

1.9 Schematic Diagram of Powershift Transmission Hydraulic System

Main regulator valve

Oil cooler Main orifice

Torque converter bypass M(A)

T/M lubricating circuit

Suction strainer with magnet

PR(G) Directional valve

H-L shift valve

T/C in(B) M(A)

Lub(H) M(A) : Main oil pressure

PF2(F) T/C in(B) : Torque converter inlet pressure

T/C out(C) : Torque converter outlet pressure

1.10 Powershift Transmission External View

Cooler out pipe Cooler in pipe

Oil level gage

Hole for parking brake

2. Removal and Installation

(2) Attach lift hooks to the transmission, and tie a wire

(3) Remove the flexible plate bolts through the

(b) Install dowel pins into the torque converter

(2) Connect the flexible plate to the flywheel with the

3. Transmission Exterior Parts

53.9 ± 5.4 N·m 9

19.6 ± 2.0 N·m

24.0 ± 2.4 N·m

5 29.4 ± 2.9 N·m

1 58 to 75 N·m (5.9 to 7.6 kgf·m) [42.8 to 55.4 lbf·ft]

Suggestions for Disassembly