Transmission REPAIR (ZF-WG161) : PART NO. 4034066 1300 SRM 1456

TRANSMISSION
REPAIR (ZF-WG161)
PART NO. 4034066 1300 SRM 1456

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER ® APPROVED parts when making repairs. Replacement parts must meet or
exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table...............................................................................................1
Special Tools List...................................................................................................................................................1
Transmission Repair............................................................................................................................................. 2
Remove.............................................................................................................................................................. 2
Disassemble...................................................................................................................................................... 6
Transmission Housing, Disassemble............................................................................................................ 7
Oil Pump, Disassemble................................................................................................................................14
Forward Clutch, Disassemble..................................................................................................................... 19
Reverse Clutch, Disassemble...................................................................................................................... 26
First Speed Clutch, Disassemble................................................................................................................ 32
Second Speed Clutch, Disassemble.............................................................................................................37
Third Speed Clutch, Disassemble............................................................................................................... 42
Input Shaft, Disassemble............................................................................................................................ 47
Clean and Inspect...........................................................................................................................................47
Housings.......................................................................................................................................................47
Oil Seals and Gaskets..................................................................................................................................48
Bearings........................................................................................................................................................48
Gears and Shafts..........................................................................................................................................48
Assemble......................................................................................................................................................... 49
Input Shaft, Assemble................................................................................................................................. 49
Third Speed Clutch, Assemble.................................................................................................................... 49
Second Speed Clutch, Assemble..................................................................................................................56
First Speed Clutch, Assemble..................................................................................................................... 64
Reverse Clutch, Assemble........................................................................................................................... 72
Forward Clutch, Assemble.......................................................................................................................... 80
Oil Pump, Assemble.....................................................................................................................................87
Transmission Housing, Assemble............................................................................................................... 89
Transmission Oil Filter Assembly Replacement.......................................................................................... 99
Remove......................................................................................................................................................... 99
Clean...........................................................................................................................................................101
Inspect........................................................................................................................................................ 101
Install..........................................................................................................................................................101
Install............................................................................................................................................................ 102
Control Valve Replacement...............................................................................................................................107
Remove.......................................................................................................................................................... 107
Install............................................................................................................................................................ 108
Control Valve Repair......................................................................................................................................... 109
Disassemble.................................................................................................................................................. 109
Clean............................................................................................................................................................. 113
Inspect...........................................................................................................................................................113
Assemble....................................................................................................................................................... 113
©2019 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1300 SRM 1456 Series Code / Model Designation Reference Table
Series Code / Model Designation Reference Table
This table consist of the following Series Codes used

in this manual.
Series European Model Americas Model

Code
H019 H13.00-16.0XM-6, H10.00-12.0XM-12EC H300-360HD2, H360HD2-EC
J007 H8.00-12.00XM-6 H190-280HD2
J019 H13.00-16.00XM-6, H10.00-12.00XM-12EC H300-360HD2, H360HD2-EC
K007 H8.00-12.00XM-6, H10.00XMS-6 H190-280HD2, H230HDS
K019 H13.00-16.00XM-6 H210-250-48HD2, H300-360HD2
K019EC H6.00-7.00XM-12EC H360HD2-EC
L007 H8.00-12.00XM-6 H190-280HD2, H250HD2
A238 H16.00XM-9, H18XM-7.5, H16XM-12, H18XM-9 H360-36HD, H360-48HD
B238 H16.00XM-9, H18XM-7.5, H16XM-12, H18XM-9 H360-36HD, H360-48HD
Special Tools List
The following list consists of the special tools

required to perform the assembly procedures
outlined in this manual.
Item Figure Nomenclature Part Number

Hyster® P/N 4612858
Clutch Pack Spring

1
Compression Tool
2 Holding Fixture Assembly
1
Transmission Repair 1300 SRM 1456
Item Figure Nomenclature Part Number

®
Hyster P/N 4612860
3 Shaft Seal Mounting Tool
4 Grip Handle
5 Pump Seal Mounting Tool
Transmission Repair
REMOVE CAUTION
1. Tilt the mast fully forward. The drive shaft for this truck is a two piece model,
consisting of a male splined drive shaft, a female
2. Turn the key to OFF position to shutdown the splined slip yoke and a universal joint on both
engine. ends where it connects to the drive axle and
transmission.
3. Apply the parking brake. Drive shafts are balanced and configured at the
time of manufacture. It is recommended that an
4. Tilt the operator compartment up to gain
alignment mark is made on the drive shaft
access to the transmission. See the section
indicating the position of the universal joint and
Operator's Cab 0100SRM1390.
drive shaft prior to removal.
5. Disconnect the cables at the battery. During removal, it may be possible for the drive
Disconnect the ground cable first and then the shaft to split apart into two pieces. Reassemble
positive cable. the drive shaft using the alignment mark made
prior to removal.
Failure to assemble and install the drive shaft
properly may lead to:
• Vibration of the drive shaft and/or truck
• Premature failure of the universal joints on
the drive shaft
2
1300 SRM 1456 Transmission Repair
• Excessive vibration levels in the 6. Disconnect the drive shaft at the transmission.
transmission See Figure 1.
• Excessive vibration levels in the drive axle
NOTE: Use a marker of some type to indicate

position and orientation of drive shaft prior to
removal.
1. FRAME (REFERENCE) 6. TRANSMISSION

2. DIPSTICK ASSEMBLY 7. TORQUE CONVERTER
3. DRIVE SHAFT 8. CAPSCREWS
4. OUTPUT YOKE 9. CAPSCREWS
5. TRANSMISSION MOUNT
Figure 1. Transmission Arrangement
7. Disconnect the wiring harnesses on the

transmission and wires for the sensors on the
transmission. Put identification tags on the
wires so they can be correctly connected again.
See Figure 2.
3
1. TRANSMISSION INTERNAL SPEED SENSOR 4. TRANSMISSION CONTROL VALVE CONNECTOR

2. TRANSMISSION TURBINE SPEED SENSOR 5. ENGINE SPEED SENSOR
3. DIFFERENTIAL PRESSURE SWITCH 6. TORQUE CONVERTER TEMPERATURE SENSOR
Figure 2. Transmission Wire Connectors and Sensors
4
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
8. Place a suitable container under the

transmission sump and remove the
transmission sump drain plug and drain the
transmission oil [approximately
20 liter (21 qt)].
9. Disconnect the oil lines from the transmission

to the thermostat valve. Drain the oil into a
drain pan. Put plugs and caps on open lines
and fittings.
10. Disconnect the oil hoses at the hydraulic

pumps. Install plugs and caps on open lines
and fittings.
11. The hydraulic pumps are connected to the

transmission with four capscrews. Attach a
lifting device to hold the hydraulic pumps,
remove the capscrews, and the hydraulic
pumps. The drive shaft of the hydraulic pump 1. LIFTING EYES
is engaged in the splines of the drive gear. The
drive shaft of the hydraulic pump will slide out Figure 3. View of Transmission
of the drive gear when the hydraulic pump is
removed. 14. Remove the access plug to gain access to the
flywheel ring gear. See Figure 4.
12. Install blocks and a jack under the flywheel
end of the engine as a support. If the support is
under the engine oil sump, ensure that the
support is across the width of the oil sump so
the weight of the engine does not damage the
oil sump.
13. Connect a lifting device, with a lifting capacity

of at least 1200 kg (2650 lb), to the two lifting
eyes located on the top of the transmission. See
Figure 3.
1. ACCESS HOLE TO ROTATE FLYWHEEL

2. ACCESS PLUG
3. CONVERTER HOUSING
4. ACCESS PLATE TO FLYWHEEL CAPSCREWS
Figure 4. Access Plug for Drive Plate Capscrews
15. Remove the access plate to gain access to the

capscrews that connect the flywheel to the
drive plates. See Figure 4.
5
16. Insert a flywheel rotation tool into the access

plug hole and rotate the flywheel until one of
the capscrews is visible through the access
plate hole. See Figure 4.
17. Remove the capscrew. Rotate the flywheel and

remove the remaining capscrews until all four
of the capscrews have been removed.
18. Raise the lifting device to hold the weight of the

transmission only. Remove the twelve
capscrews that fasten the torque converter
housing to the flywheel housing.
19. Remove the two 3/4 × 3-1/2 inch bolts that

fasten the transmission mount to the frame.
CAUTION
Keep the transmission level when the
transmission is separated from the engine so the
drive plate is not damaged.
Figure 5. ZF ERGOPOWER Transmission
20. Ensure that all connections have been removed
and carefully lift the transmission assembly
from the frame and engine.
DISASSEMBLE
Figure 5 shows a view of the ZF ERGOPOWER
transmission.
6
Transmission Housing, Disassemble

STEP 1.
Remove the oil filter assembly and control valve
assembly from the transmission. See
Transmission Oil Filter Assembly Replacement,
Remove and Control Valve Replacement,
Remove.
1. OIL FILTER ASSEMBLY

2. CONTROL VALVE ASSEMBLY
3. TRANSMISSION
STEP 2.
Remove the converter pressure back-up valve
and differential pressure switch from the
transmission housing. DO NOT remove the
pressure relief valve.
1. CONVERTER PRESSURE BACK-UP VALVE

2. DIFFERENTIAL PRESSURE SWITCH
3. PRESSURE RELIEF VALVE
7
STEP 3.
Remove the engine speed sensor, and oil fill
tube with dipstick from the transmission.
1. ENGINE SPEED SENSOR

2. OIL FILL TUBE WITH DIPSTICK
STEP 4.
Remove the internal speed sensor, turbine
speed sensor, and output speed sensor from the
transmission.
1. INTERNAL SPEED SENSOR

2. TURBINE SPEED SENSOR
3. OUTPUT SPEED SENSOR
8
STEP 5.
Remove the torque converter from the
transmission. Remove capscrews from torque
converter bell housing and transmission.
1. TORQUE CONVERTER
2. TORQUE CONVERTER BELL HOUSING
3. CAPSCREW
4. TRANSMISSION
STEP 6.
Remove the torque converter bell housing with
oil pump, and gasket from the transmission
housing. Remove the stator hollow shaft from
the input shaft.

2. GASKET
3. TRANSMISSION HOUSING
4. STATOR HOLLOW SHAFT
5. INPUT SHAFT
9
STEP 7.
Remove the oil pump from the torque converter
bell housing.
1. OIL PUMP
STEP 8.
Remove two capscrews, output flange, and
output shaft seal from the transmission
housing. Discard the seal.
1. CAPSCREW
2. OUTPUT FLANGE
3. OUTPUT SHAFT SEAL
STEP 9.
Remove the retaining ring and O-ring from the
transmission housing. Discard the O-ring.
1. RETAINING RING
2. O-RING
10
STEP 10.
Remove the PTO shaft from the housing.
Remove the retaining ring. Using a press,
remove the bearing from the PTO shaft.
1. PTO SHAFT
2. HOUSING
3. RETAINING RING
4. BEARING
WARNING
To prevent the possibility of injury to personnel, use a lifting device of sufficient lifting capacity while
performing the following step.
NOTE: Ensure that the guide pins have been removed before removing the rear transmission cover.
STEP 11.
Remove the capscrews, washers, and rear
transmission cover from the front transmission
cover.
1. CAPSCREW
2. WASHER
3. REAR TRANSMISSION COVER
4. FRONT TRANSMISSION COVER
5. GUIDE PIN
11
STEP 12.
Remove capscrews, suction tube, screen, and
tubes from the front transmission cover.
Remove and discard the O-rings from the tubes.
1. CAPSCREW
2. SUCTION TUBE
3. SCREEN
4. TUBE
5. GUIDE PIN
6. O-RING
WARNING
performing the following step.
STEP 13.
Remove the clutch packs and input shaft from
the front transmission cover in the order given
in the legend.
1. CLUTCH, 3RD SPEED/OUTPUT

2. CLUTCH, 2ND SPEED
3. CLUTCH, REVERSE
4. CLUTCH, FORWARD
5. INPUT SHAFT
6. CLUTCH, 1ST SPEED
12
STEP 14.
Remove capscrews and screen from front
transmission cover.
1. CAPSCREW
2. SCREEN
NOTE: Perform Step 15 only if any of the tubes are damaged.
STEP 15.
Remove the system pressure tubes from the
rear transmission cover in the order of the
legend. Prior to removal of the tubes remove
the holding segment from the tubes.

4. CLUTCH, REVERSE
5. CLUTCH, FORWARD
6. HOLDING SEGMENT
13
Oil Pump, Disassemble

STEP 1.
Remove the O-ring and capscrews from the oil
pump. Discard the O-ring.
1. O-RING
2. CAPSCREWS
3. OIL PUMP
STEP 2.
Remove the cover, inner rotor, and outer rotor
from the oil pump housing. Inspect the pump
housing, inner rotor outer rotor, and cover for
wear marks. If any wear is shown, replace the
oil pump.
1. COVER
2. INNER ROTOR
3. OUTER ROTOR
4. OIL PUMP HOUSING
14
STEP 3.
Remove and discard the shaft seal from the oil
pump housing.
1. SHAFT SEAL
2. OIL PUMP HOUSING
1. PISTON RING 12. FRICTION DISC

2. THREADED STUD 13. "L" RING
3. TAPERED ROLLER BEARING 14. GUIDE RING
4. CLUTCH SHAFT 15. COMPRESSION SPRING
5. BALL BEARING 16. OUTER O-RING
6. IDLER GEAR 17. INNER O-RING
7. NEEDLE BEARING 18. PISTON
8. RETAINING RING 19. CLUTCH PACK CARRIER
9. END SHIM 20. WASHER
10. OUTER FRICTION DISC 21. SNAP RING
11. INNER DISC
Figure 6. Forward Clutch Assembly
15
1. PISTON RING 12. INNER DISC

2. THREADED STUD 13. FRICTION DISC
3. TAPERED ROLLER BEARING 14. "L" RING
4. CLUTCH SHAFT 15. GUIDE RING
5. GEAR 16. COMPRESSION SPRING
6. NEEDLE BEARING 17. OUTER O-RING
8. BALL BEARING 19. PISTON
10. END SHIM 21. WASHER
11. OUTER FRICTION DISC 22. SNAP RING
Figure 7. Reverse Clutch Assembly
16

2. THREADED STUD 13. SNAP RING
5. AXIAL NEEDLE BEARING 16. PISTON
6. NEEDLE BEARINGS 17. INNER O-RING
7. IDLER GEAR 18. OUTER O-RING
9. END SHIM 20. SEALING CAP
10. OUTER FRICTION DISC 21. AXIAL WASHER
11. INNER DISC 22. RUNNING DISC
Figure 8. 1st Speed Clutch Assembly
17

2. THREADED STUD 13. SNAP RING
5. AXIAL NEEDLE BEARING 16. PISTON
7. NEEDLE BEARINGS 18. OUTER O-RING
9. END SHIM 20. AXIAL WASHER
10. OUTER FRICTION DISC 21. RUNNING DISC
11. INNER DISC
Figure 9. 2nd Speed Clutch Assembly
18
1. PISTON RING 14. COMPRESSION SPRING

2. PLUG 15. PISTON
3. TAPERED ROLLER BEARING 16. INNER O-RING
4. AXIAL NEEDLE BEARING 17. OUTER O-RING
5. IDLER GEAR 18. CLUTCH PACK CARRIER
6. NEEDLE BEARING 19. CLUTCH SHAFT
7. SNAP RING 20. PISTON RING
8. END SHIM 21. RUNNING DISC
9. OUTER FRICTION DISC 22. AXIAL WASHER
10. INNER DISC 23. THREADED STUD
11. FRICTION DISC 24. CAP
12. SNAP RING 25. PISTON RING
13. GUIDE RING 26. SEAL
Figure 10. 3rd Speed Clutch Assembly
Forward Clutch, Disassemble

NOTE: As each clutch assembly is disassembled, ensure that all of the components of that assembly are
kept separate from any other clutch assemblies to prevent the possibility of parts being assembled to an
incorrect clutch assembly.
19
STEP 1.
Remove the threaded stud, and unsnap piston
ring. Using a bearing puller, remove the
tapered roller bearing from the clutch shaft.
1. THREADED STUD
2. PISTON RING
3. TAPERED ROLLER BEARING
4. CLUTCH SHAFT
STEP 2.
Remove the clutch pack carrier from the clutch
shaft.
1. CLUTCH PACK CARRIER

2. CLUTCH SHAFT
20
STEP 3.
Remove the snap ring. Using a press, remove
the clutch shaft from the idler gear.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
STEP 4.
Remove snap ring and roller bearing from the
idler gear.
1. SNAP RING
2. ROLLER BEARING
3. IDLER GEAR
21
STEP 5.
Remove the needle bearing from the clutch
shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
STEP 6.
Remove the piston ring. Using a bearing puller,
remove the tapered roller bearing from the
clutch shaft.
1. PISTON RING
3. CLUTCH SHAFT
22
STEP 7.
Remove the retaining ring from the clutch pack
carrier.
1. RETAINING RING
STEP 8.
Remove the end shim and disc set from the
clutch pack carrier.
1. END SHIM
2. DISC SET
WARNING
The spring has a force of 1700 ±147 N (382 ±33 lbf).
23
STEP 9.
Using a spring compression tool, Hyster® P/N
4612858 , compress the spring and remove the
"L" ring.
1. COMPRESSION TOOL
2. COMPRESSION SPRING
3. "L" RING
STEP 10.
Slowly release the compression spring and
remove the guide ring, compression spring, and
washer from the clutch pack carrier.
1. GUIDE RING
4. WASHER
NOTE: Use compressed air to aid in the removal of the piston.
24
STEP 11.
Remove piston from clutch pack carrier.
1. PISTON
STEP 12.
Remove and discard inner and outer O-rings
from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
25
Reverse Clutch, Disassemble

STEP 1.
Remove the threaded stud and piston ring.
Using a bearing puller, remove the tapered
roller bearing from the clutch shaft.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 2.
shaft.

2. CLUTCH SHAFT
26
STEP 3.
Remove the snap ring. Using a press, remove
the clutch shaft from the idler gear.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
STEP 4.
Remove snap ring and bearing from the idler
gear.
1. SNAP RING
2. BEARING
3. IDLER GEAR
27
STEP 5.
Remove the needle bearing and snap ring from
the clutch shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
3. SNAP RING
4. GEAR
STEP 6.
clutch shaft.
1. PISTON RING
3. CLUTCH SHAFT
28
STEP 7.
carrier.
1. RETAINING RING
STEP 8.
1. END SHIM
2. DISC SET
WARNING
29
STEP 9.
"L" ring.
1. COMPRESSION TOOL
3. "L" RING
STEP 10.
remove the guide ring, compression spring and
washer, from the clutch pack carrier.
1. GUIDE RING
4. WASHER
30
STEP 11.
1. PISTON
STEP 12.
from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
31
First Speed Clutch, Disassemble

STEP 1.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 2.
Remove the retaining ring and axial bearing
assembly from the clutch shaft.
1. RETAINING RING
2. AXIAL BEARING ASSEMBLY (3 PIECES)
3. CLUTCH SHAFT
32
STEP 3.
Remove the idler gear, two needle bearings,
and axial bearing assembly from the clutch
shaft.
1. IDLER GEAR
2. NEEDLE BEARING
4. CLUTCH SHAFT
STEP 4.
shaft.

2. CLUTCH SHAFT
33
STEP 5.
clutch shaft.
1. PISTON RING
3. CLUTCH SHAFT
STEP 6.
carrier.
1. RETAINING RING
34
STEP 7.
1. END SHIM
2. DISC SET
WARNING
STEP 8.
snap ring.
1. COMPRESSION TOOL
3. SNAP RING
35
STEP 9.
guide ring from the clutch pack carrier.
1. GUIDE RING
STEP 10.
1. PISTON
36
STEP 11.
from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
Second Speed Clutch, Disassemble

STEP 1.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
37
STEP 2.
Remove the retaining ring and axial bearing
assembly from the clutch shaft.
1. RETAINING RING
3. CLUTCH SHAFT
STEP 3.
Remove the idler gear, two needle bearings,
and axial bearing assembly from the clutch
shaft.
1. IDLER GEAR
2. NEEDLE BEARING
4. CLUTCH SHAFT
38
STEP 4.
shaft.

2. CLUTCH SHAFT
STEP 5.
clutch shaft.
1. PISTON RING
3. CLUTCH SHAFT
39
STEP 6.
carrier.
1. RETAINING RING
STEP 7.
1. END SHIM
2. DISC SET
WARNING
40
STEP 8.
snap ring.
1. COMPRESSION TOOL
3. SNAP RING
STEP 9.
1. GUIDE RING
41
STEP 10.
1. PISTON
STEP 11.
from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
Third Speed Clutch, Disassemble

STEP 1.
clutch shaft.
1. PISTON RING
3. CLUTCH SHAFT
42
STEP 2.
Remove the axial bearing assembly, idler gear,
and two needle bearings from the clutch shaft.

2. IDLER GEAR
3. NEEDLE BEARING
4. CLUTCH SHAFT
STEP 3.
shaft.

2. CLUTCH SHAFT
43
STEP 4.
Remove the piston rings. Using a bearing
puller, remove the tapered roller bearing from
the clutch shaft.
1. PISTON RING
3. CLUTCH SHAFT
STEP 5.
carrier.
1. RETAINING RING
STEP 6.
1. END SHIM
2. DISC SET
44
WARNING
STEP 7.
snap ring.
1. COMPRESSION TOOL
3. SNAP RING
STEP 8.
1. GUIDE RING
45
STEP 9.
1. PISTON
STEP 10.
Remove and discard the inner and outer O-
rings from the piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
46
Input Shaft, Disassemble

STEP 1.
Remove piston ring. Using a bearing puller,
remove two tapered roller bearings from the
input shaft.
1. PISTON RING
3. INPUT SHAFT
CLEAN AND INSPECT • Do not use gasoline or solvents that contain

gasoline. Gasoline can explode.
• Use hot solution tanks or alkaline solutions
WARNING correctly. Carefully follow manufacturer's
To prevent serious eye injury, always wear safe instructions.
eye protection when performing vehicle
Clean all parts thoroughly using solvent type
maintenance or service.
cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down
slowly until all old lubricant and foreign material is
WARNING dissolved and parts are thoroughly cleaned.
To avoid personal injury when cleaning parts, work
in a well-ventilated area, wear protective clothing The importance of careful and thorough inspection
(face shield or safety glasses and protective of all parts cannot be overstressed. Replacement of
gloves), and follow chemical manufacturer's all parts showing indication of wear or stress will
recommendations for safe usage. eliminate costly and avoidable failures at a later
date.
Solvent cleaners can be flammable, poisonous,
and cause burns. Examples of solvent cleaners are Housings
carbon tetrachloride, emulsion-type cleaners, and
petroleum-based cleaners. To avoid serious Clean interior and exterior of housings, bearing
personal injury when using solvent cleaners, caps, etc., thoroughly. Cast parts may be cleaned in
carefully follow manufacturer's instructions and hot solution tanks with mild alkali solution
these procedures: providing these parts do not have ground or
polished surfaces. Parts should remain in solution
• Wear safe eye protection. long enough to be thoroughly cleaned and heated.
• Wear clothing that protects skin. This will aid the evaporation of the cleaning
• Work in a well-ventilated area. solution and rinse water. Parts cleaned in solution
tanks must be thoroughly rinsed with clean water to
47
remove all traces of alkali. Cast parts may also be Bearings

cleaned with steam cleaner.
Inspect housings, covers and bearing caps to ensure
that they are thoroughly clean and that mating WARNING
surfaces, bearing bores, etc., are free from nicks or Compressed air can move particles so that they
burrs. Check all parts carefully for evidence of cause injury to the user or to other personnel.
cracks or conditions which would cause subsequent Ensure that the path of the compressed air is away
oil leaks or failures. from all personnel. Wear protective goggles or a
face shield to prevent injury to the eyes.
Oil Seals and Gaskets
NOTE: Do not spin the bearings when drying.
Replacement of spring load oil seals, O-rings, metal
Remove bearings from cleaning fluid and strike flat
sealing rings, gaskets, and snap rings is more
against a block of wood to dislodge solidified
economical when the unit is disassembled than
particles of lubricant. Immerse again in cleaning
premature overhaul to replace these parts at a
fluid to flush out particles. Repeat above operation
future time. Further loss of lubricant through a
until bearings are thoroughly clean. Dry bearings
worn seal may result in failure of other more
using moisture-free compressed air. Be careful to
expensive parts of the assembly. Sealing members
direct air stream across bearing to avoid spinning.
should be handled carefully, particularly when
Bearings may be rotated slowly by hand to facilitate
being installed. Cutting, scratching, or curling
drying process.
under of lips of seals seriously impairs its efficiency.
When assembling new metal type piston rings, NOTE: Do not replace a bearing cone or cup
these should be lubricated with a coat of Vaseline to individually without replacing the mating cup or
stabilize rings in their grooves for ease of assembly cone at the same time.
of mating members. Lubricate all O-rings with Carefully inspect all rollers, cages and cups for
recommended type Automatic Transmission Fluid wear, chipping, or nicks to determine fitness of
before assembly. Prior to installation of rubber bearings for further use. After inspection, dip
seals, lightly coat the outer surface with mineral bearings in recommended Automatic Transmission
spirits, and coat the inner surface with Fluid and wrap in clean lint-free cloth or paper to
multipurpose grease. protect them until installed.
Gears and Shafts

If Magna-Flux process is available, use process to
check parts. Examine teeth on all gears carefully for
wear, pitting, chipping, nicks, cracks, or scores. If
gear teeth show spots where case hardening is worn
through or cracked, replace with new gear. Small
nicks may be removed with suitable hone. Inspect
shafts and quills to make certain they are not
48
sprung, bent, or spline-twisted, and that shafts are ASSEMBLE

true.
Input Shaft, Assemble
STEP 1.
Using a press, install two tapered roller
bearings on the input shaft until they bottom
out, and install the piston ring on the input
shaft.
1. PISTON RING
3. INPUT SHAFT
Third Speed Clutch, Assemble
CAUTION
Ensure that the O-rings are not deformed during installation, and DO NOT roll the O-rings onto the piston.
NOTE: Prior to installing O-rings, coat with transmission oil to make installation easier.
STEP 1.
Install new inner and outer O-rings on the
piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
49
NOTE: Check piston relief valve functionality prior to installation of the piston.
STEP 2.
Using the spring compression tool, Hyster® P/N
4612858 , install the piston into the clutch pack
carrier, as noted during disassembly, until it
bottoms out.
1. PISTON
STEP 3.
Install the guide ring, compression spring, and
guide ring into the clutch pack carrier.
1. GUIDE RING
50
STEP 4.
4612858 , depress the spring assembly and
install the snap ring into the annular groove.
Remove the spring compression tool from the
1. COMPRESSION TOOL
3. SNAP RING
STEP 5.
Install the friction disk, uncoated side down
toward the piston, into the clutch pack carrier.
See Figure 10.
NOTE: Prior to installation, the inner and friction

discs must be coated with clean automatic
transmission fluid.
STEP 6.
Install the inner discs and friction discs into the
clutch pack carrier as shown in Figure 10.
STEP 7.
Install the friction disc, uncoated side up, into
the clutch pack carrier. See Figure 10.
STEP 8.
Install the end shim and retaining ring into the
1. END SHIM
2. RETAINING RING
51
STEP 9.
Install a dial indicator as shown, and depress
the end shim with a force of 100 N (23 lbf), set
the dial indicator to zero.
1. DIAL INDICATOR
2. END SHIM
STEP 10.
Press the end shim against the retainer and
determine the clearance between the end shim
and the retainer. The disk clearance is to be
2.0 to 2.3 mm (0.079 to 0.090 in.). If the
clearance is not within the limits specified a
new retainer must be installed. See the Parts
Manual for the next size retainer.
1. DIAL INDICATOR
2. END SHIM
52
STEP 11.
Using a press, install the tapered roller bearing
on the clutch shaft until it bottoms out, and
install the two piston rings.
1. CLUTCH SHAFT
3. PISTON RINGS
STEP 12.
Turn the clutch pack carrier over so that the
bottom of the carrier is facing up, and using a
heat gun, heat the inner diameter to
120°C (248°F).

2. HEAT GUN
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns
53
STEP 13.
Install the clutch pack carrier on the clutch
shaft until it bottoms out.

2. CLUTCH SHAFT
STEP 14.
Install the running disc chamfer side up, axial
bearing, and axial washer on the clutch shaft.
1. AXIAL BEARING
2. RUNNING DISC
3. AXIAL WASHER
NOTE: Manually align the inner teeth of the disks prior to performing Step 15.
54
STEP 15.
Install the two needle bearings and idler gear
on the clutch shaft, rotating the idler gear left
and right small amounts to achieve final
alignment with the clutch pack.
1. AXIAL BEARING ASSEMBLY

2. NEEDLE BEARING
3. IDLER GEAR
4. CLUTCH SHAFT
STEP 16.
Install the axial washer, axial bearing, and
running disc chamfer side down on the clutch
shaft.
1. AXIAL WASHER
2. AXIAL BEARING
3. RUNNING DISC
55
STEP 17.
install the piston ring.
1. PISTON RING
3. CLUTCH SHAFT
STEP 18.
Check the opening of the clutch by applying
compressed air at the bore. See arrow in the
figure. The opening of the clutch must be
clearly audible.
Second Speed Clutch, Assemble
CAUTION
56
STEP 1.
piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
STEP 2.
bottoms out.
1. PISTON
57
STEP 3.
1. GUIDE RING
STEP 4.
4612858 and a press, depress the spring
assembly and install the snap ring into the
annular groove. Remove the spring compression
tool from the clutch pack carrier.
1. COMPRESSION TOOL
3. SNAP RING
STEP 5.
See Figure 9.
58
NOTE: Prior to installation, the inner and outer

friction discs must be coated with clean automatic
transmission fluid.
STEP 6.
STEP 7.
Install the friction disk, uncoated side up, into
STEP 8.
1. END SHIM
2. RETAINING RING
STEP 9.
the dial indicator to zero
1. DIAL INDICATOR
2. END SHIM
59
STEP 10.
2.0 to 2.3 mm (0.079 to 0.090 in.). If the
1. DIAL INDICATOR
2. END SHIM
STEP 11.
1. PISTON RING
3. CLUTCH SHAFT
60
STEP 12.
120°C (248°F).

2. HEAT GUN
WARNING
NOTE: Manually align the inner teeth of the disks prior to performing Step 13.
STEP 13.
Install the clutch pack carrier until it bottoms
out.

2. CLUTCH SHAFT
61
STEP 14.
Install the running disk chamfer side up, axial
1. AXIAL BEARING
2. RUNNING DISK
3. AXIAL WASHER
STEP 15.
Install two needle bearings and the idler gear
on the clutch shaft, rotate the idler gear left
and right small amounts to achieve final
alignment with the clutch pack.
1. IDLER GEAR
2. NEEDLE BEARINGS
3. AXIAL BEARING ASSEMBLY
4. CLUTCH SHAFT
62
STEP 16.
Install the axial washer, axial bearing and
running disc, chamfer side down on the clutch
shaft.
1. AXIAL WASHER
2. AXIAL BEARING
3. RUNNING DISK
STEP 17.
Install the retaining ring on the clutch shaft.
1. RETAINING RING
2. CLUTCH SHAFT
63
STEP 18.
on the clutch shaft until it bottoms out, piston
ring, and threaded stud.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 19.
clearly audible.
First Speed Clutch, Assemble
CAUTION
64
STEP 1.
piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
STEP 2.
bottoms out.
1. PISTON
65
STEP 3.
1. GUIDE RING
STEP 4.
4612858 , depress the spring assembly and
install the snap ring into the annular groove.
Remove the spring compression tool from the
1. COMPRESSION TOOL
3. SNAP RING
STEP 5.
See Figure 8.
66

transmission fluid.
STEP 6.
STEP 7.
STEP 8.
1. END SHIM
2. RETAINING RING
STEP 9.
1. DIAL INDICATOR
2. END SHIM
67
STEP 10.
2.45 to 2.75 mm (0.096 to 0.108 in.). If the
1. DIAL INDICATOR
2. END SHIM
STEP 11.
1. PISTON RING
3. CLUTCH SHAFT
STEP 12.
120°C (248°F).

2. HEAT GUN
68
WARNING
NOTE: Manually align the inner teeth of the disks prior to performing the step below.
STEP 13.
Install the clutch pack carrier on the clutch
shaft until it bottoms out.

2. CLUTCH SHAFT
STEP 14.
Install the running disc chamfer side up, axial
1. RUNNING DISK
2. AXIAL BEARING
3. AXIAL WASHER
69
STEP 15.
Install the axial bearing assembly, two needle
bearings, and idler gear on the clutch shaft,
rotating the idler gear left and right small
amounts to achieve final alignment with the
clutch pack.
1. IDLER GEAR
2. NEEDLE BEARING
4. CLUTCH SHAFT
STEP 16.
Install the axial washer, axial bearing, and
running disc, chamfer side down on the clutch
shaft.
1. AXIAL WASHER
2. AXIAL BEARING
3. RUNNING DISC
70
STEP 17.
Install the retaining ring on the clutch shaft.
1. RETAINING RING
2. CLUTCH SHAFT
STEP 18.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
71
STEP 19.
clearly audible.
Reverse Clutch, Assemble
CAUTION
STEP 1.
piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
NOTE: Check piston relief valve functionality prior to installation.
72
STEP 2.
bottoms out.
1. PISTON
NOTE: Installation tool, Hyster® P/N 4612859 , consists of two parts: an inner installer and pressure piece.
STEP 3.
Install the inner installer on the clutch pack
carrier.
Install the washer, compression spring, guide
ring, and new "L" ring into the clutch pack
carrier.
1. WASHER
3. GUIDE RING
4. "L" RING
73
STEP 4.
4612858 , and pressure piece, depress the
spring assembly until the "L" ring has engaged
the annular groove. Remove the spring
compression tool, pressure piece, and inner
installer from the clutch pack carrier.
1. COMPRESSION TOOL
2. INSTALLATION TOOL
STEP 5.
See Figure 7.

transmission fluid.
STEP 6.
STEP 7.
STEP 8.
1. END SHIM
2. RETAINING RING
74
STEP 9.
the end shim with a force of 100 N (23 lbf). Set
1. DIAL INDICATOR
2. END SHIM
STEP 10.
2.45 to 2.75 mm (0.096 to 0.108 in.). If the
1. DIAL INDICATOR
2. END SHIM
75
STEP 11.
1. PISTON RING
3. CLUTCH SHAFT
STEP 12.
Using a heat gun, heat the inner diameter of
the gear to 120°C (248°F).
1. GEAR
2. HEAT GUN
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns.
WARNING
Cold parts. Wear protective clothing and gloves.
76
STEP 13.
Cool the clutch shaft to -60°C (-76°F) and
install the gear on the clutch shaft making sure
that the chamfered side is facing up and the
gear is bottomed out. Install the snap ring and
needle bearing on the clutch shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
3. SNAP RING
4. GEAR
STEP 14.
Install the bearing and snap ring into the idler
gear.
1. SNAP RING
2. BEARING
3. IDLER GEAR
77
STEP 15.
Using a press, install the idler gear onto the
clutch shaft until it bottoms out. Install the
snap ring on the clutch shaft.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
STEP 16.
120°C (248°F).

2. HEAT GUN
WARNING
NOTE: Manually align the inner teeth on the discs prior to performing Step 17.
78
STEP 17.
Install the clutch pack carrier, rotating the
clutch pack left and right small amounts to
achieve final alignment on the clutch shaft
until it bottoms out.

2. CLUTCH SHAFT
STEP 18.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
79
STEP 19.
clearly audible.
Forward Clutch, Assemble
CAUTION
STEP 1.
piston.
1. INNER O-RING
2. OUTER O-RING
3. PISTON
80
STEP 2.
bottoms out.
1. PISTON
NOTE: Installation tool, Hyster® P/N 4612859 , consists of two parts; an inner installer and pressure piece.
STEP 3.
Install the inner installer on the clutch pack
carrier.
Install the washer, compression spring, guide
ring, and new "L" ring into the clutch pack
carrier.
1. WASHER
3. GUIDE RING
4. "L" RING
81
STEP 4.
4612858 , and pressure piece, depress the
spring assembly until the "L" ring has engaged
the annular groove. Remove the spring
compression tool, pressure piece, and inner
installer from the clutch pack carrier.
1. COMPRESSION TOOL
2. INSTALLATION TOOL
STEP 5.
See Figure 6.
STEP 6.
STEP 7.
STEP 8.
1. END SHIM
2. RETAINING RING
82
STEP 9.
the end shim with a force of 100 N (23 lbf). Set
1. DIAL INDICATOR
2. END SHIM
STEP 10.
2.45 to 2.75 mm (0.090 to 0.108 in.). If the
1. DIAL INDICATOR
2. END SHIM
83
STEP 11.
1. PISTON RING
3. CLUTCH SHAFT
STEP 12.
Install the needle bearing on the clutch shaft.
1. NEEDLE BEARING
2. CLUTCH SHAFT
84
STEP 13.
Install the bearing and snap ring into the idler
gear.
1. SNAP RING
2. BEARING
3. IDLER GEAR
STEP 14.
Using a press, install the idler gear onto the
clutch shaft until it bottoms out. Install the
snap ring on the clutch shaft.
1. SNAP RING
2. CLUTCH SHAFT
3. IDLER GEAR
85
STEP 15.
120°C (248°F).

2. HEAT GUN
WARNING
NOTE: Manually align the inner teeth on the discs prior to performing Step 16.
STEP 16.
Install the clutch pack carrier, rotating the
clutch pack left and right small amounts to
achieve final alignment on the clutch shaft
until it bottoms out.

2. CLUTCH SHAFT
86
STEP 17.
ring and threaded stud.
1. THREADED STUD
2. PISTON RING
4. CLUTCH SHAFT
STEP 18.
clearly audible.
Oil Pump, Assemble

NOTE: Lubricate the shaft seal with mineral spirits on the outside and multipurpose grease on the inside of
the seal.
87
STEP 1.
Using pump seal mounting tool Hyster® P/N
4612862 with handle Hyster® P/N 4612861 ,
install the new shaft seal, lip facing down, into
the oil pump housing.
1. SHAFT SEAL
2. OIL PUMP HOUSING
STEP 2.
Install the outer rotor with the chamfer facing
down, inner rotor with the threads facing up,
and cover on the oil pump housing.
1. COVER
2. INNER ROTOR
3. OUTER ROTOR
4. OIL PUMP HOUSING
CAUTION
88
STEP 3.
Install new O-ring and capscrews on the oil
pump. Tighten the capscrews until contact is
made, then loosen 180 degrees.
1. O-RING
2. CAPSCREWS
3. OIL PUMP
Transmission Housing, Assemble

NOTE: Perform Step 1 only if tubes have been removed.
STEP 1.
Install the system pressure tubes into the rear
transmission cover in the order of the legend.
Tighten the locking nuts to 42 N•m (31 lbf ft).
After installation of the tubes, install the
holding segment on the tubes. Tighten screw to
23 N•m (17 lbf ft).
1. CLUTCH, FORWARD
2. CLUTCH, REVERSE
6. HOLDING SEGMENT
89
STEP 2.
Install screen and capscrews into the front
transmission cover. Tighten capscrews to
23 N•m (17 lbf ft).
1. CAPSCREW
2. SCREEN
WARNING
performing Step 3.
CAUTION
During installation of the clutch packs, ensure that the piston rings are properly aligned. If they are not
properly aligned, serious damage to the transmission will occur.
STEP 3.
To help insure proper installation, ensure the
piston rings are aligned, and use Vaseline to
keep them in place.
Install the clutch packs in the order given in
the legend.

2. INPUT SHAFT
3. CLUTCH, FORWARD
4. CLUTCH, REVERSE
90
STEP 4.
Install new O-rings on the tubes. Install tubes,
capscrews, and suction tube into the front
23 N•m (17 lbf ft).
Install screen and capscrews into the front
9.5 N•m (84 lbf in).
1. CAPSCREW
2. SUCTION TUBE
3. SCREEN
4. TUBE
5. GUIDE PIN
6. O-RING
WARNING
performing Step 5.
CAUTION
During installation of the rear transmission cover, ensure that the piston rings are properly aligned. If they
are not properly aligned, serious damage to the transmission will occur.
91
STEP 5.
Coat the mounting flange of the front cover
with Loctite® 574, Install the rear transmission
cover, and position the rear cover over the
clutch packs. Install guide pins, washers, and
capscrews on the front transmission cover.
Tighten capscrews to 46 N•m (34 lbf ft).
1. CAPSCREW
2. WASHER
4. FRONT TRANSMISSION COVER
5. GUIDE PIN
STEP 6.
Coat the outer surface of the shaft seal with a
light coat of mineral spirits; fill the shaft seal
between the dust lip and sealing lip with
multipurpose grease. Install the shaft seal,
using shaft seal mounting tool Hyster® P/N
4612860 , with the lip facing inward.
1. SHAFT SEAL
2. SHAFT SEAL MOUNTING TOOL
92
STEP 7.
Install output flange, washer, and two new
capscrews on transmission housing. Tighten
capscrews to 34 N•m (25 lbf ft).
1. CAPSCREW
2. OUTPUT FLANGE
3. OUTPUT SHAFT SEAL
STEP 8.
Using a press, install the bearing on the PTO
shaft, and install the retaining ring. Install the
PTO shaft in the housing.
1. PTO SHAFT
2. HOUSING
3. RETAINING RING
4. BEARING
STEP 9.
Install the power take-off retaining ring and
new O-ring on transmission housing.
1. RETAINING RING
2. O-RING
93
STEP 10.
Install two alignment pins and the stator
hollow shaft.
1. ALIGNMENT PINS
2. STATOR HOLLOW SHAFT
STEP 11.
Install the converter safety valve into the
transmission cover until it bottoms out.
1. CONVERTER SAFETY VALVE

2. TRANSMISSION COVER
94
STEP 12.
Install two additional alignment pins and
install a new gasket on the transmission cover.
1. ALIGNMENT PINS
2. GASKET
3. TRANSMISSION COVER
STEP 13.
Install the torque converter bell housing on the
transmission housing.

2. GASKET
4. INPUT SHAFT
95
STEP 14.
Install the oil pump into the torque converter
bell housing.
1. OIL PUMP
NOTE: Capscrews used for the oil pump have an O-ring instead of a washer and the O-ring must coated
with clean transmission oil.
STEP 15.
Install capscrews on the torque converter bell
housing and transmission housing. The bell
housing will align the oil pump. Install the oil
pump capscrews. Tighten all capscrews to
46 N•m (34 lbf ft). Install the torque converter
into the torque converter bell housing.
1. TORQUE CONVERTER
3. CAPSCREW
96
STEP 16.
Install the oil fill tube with dipstick, oil drain
plug 80 N•m (59 lbf ft), engine speed sensor
30 N•m (22 lbf ft), torque converter
temperature sensor 25 N•m (18 lbf ft), and
breather 12 N•m (106 lbf in).
1. BREATHER
2. ENGINE SPEED SENSOR
3. TORQUE CONVERTER TEMPERATURE
SENSOR
4. OIL DRAIN PLUG
5. OIL FILL TUBE WITH DIPSTICK
STEP 17.
Install the converter pressure backup valve and
differential pressure switch in the transmission
housing. Tighten the plug for the converter
pressure backup valve to 100 N•m (74 lbf ft),
differential pressure switch 30 N•m (22 lbf ft).
The pressure relief valve should not have been
removed.
1. CONVERTER PRESSURE BACKUP VALVE

2. DIFFERENTIAL PRESSURE SWITCH
3. PRESSURE RELIEF VALVE
97
STEP 18.
Install the output speed sensor
23 N•m (17 lbf ft), turbine speed sensor
30 N•m (22 lbf ft), and internal speed sensor
30 N•m (22 lbf ft).
1. INTERNAL SPEED SENSOR

2. TURBINE SPEED SENSOR
3. OUTPUT SPEED SENSOR
98
STEP 19.
Install the control valve assembly and oil filter
assembly. See Transmission Oil Filter
Assembly Replacement, Install and Control
Valve Replacement, Install.
1. OIL FILTER ASSEMBLY

3. TRANSMISSION
TRANSMISSION OIL FILTER ASSEMBLY

REPLACEMENT
Remove
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
99
STEP 1.
Remove the drain plug from the transmission,
and drain the transmission oil into a suitable
container with a capacity of 20 liter (21 qt).
1. DRAIN PLUG
2. TRANSMISSION
STEP 2.
Using a strap wrench, remove the transmission
oil filter from the transmission oil filter head,
and dispose of the oil into the container used in
the previous step.
1. TRANSMISSION OIL FILTER

2. TRANSMISSION OIL FILTER HEAD
100
STEP 3.
Remove two capscrews and the transmission oil
filter head from the transmission. Remove and
discard two O-rings from the transmission oil
filter head.
1. CAPSCREW
3. O-RING
Clean Inspect
Clean the transmission oil filter head with cleaning Inspect the mating surfaces for scratches, gouges,
solvent. abrasions or cracks. Replace the filter head if
damaged.
Install
STEP 1.
Coat two new O-rings with clean transmission
oil and install into the transmission oil filter
head. Using two capscrews mount the
transmission oil filter head on the
transmission. Tighten capscrews to
23 N•m (21 lbf ft).
1. CAPSCREW
3. O-RING
101
STEP 2.
Coat the gasket located on the top of the
transmission oil filter with a light coat of
transmission oil. Install transmission oil filter
on the transmission oil filter head, by hand,
until the gasket fully contacts the transmission
oil filter head and tighten 1/3 to 1/2 turn more.
1. TRANSMISSION OIL FILTER

INSTALL
1. Connect a lifting device, with a lifting capacity
CAUTION
of at least 1200 kg (2650 lb), to the two lifting Keep the transmission level when the
eyes located on the top of the transmission. See transmission is separated from the engine so the
Figure 11. drive plate is not damaged.
2. Carefully lower the transmission into position

on the frame and engine.
3. Install two 3/4 × 31/2-inch bolts that fasten the

transmission mount to the frame.
4. Still supporting the weight of the transmission

with the lifting device, install twelve capscrews
that fasten the torque converter housing to the
flywheel housing. Torque to 46 N•m (34 lbf ft).
5. Insert a flywheel rotational tool into the access

plug hole and rotate the flywheel until one of
the capscrew mounting holes is visible through
the access plate hole. See Figure 12.
1. LIFTING EYES
Figure 11. Left Side View of Transmission
102
10. Remove the blocks and jack that are supporting

the flywheel end of the engine.
11. Attach a lifting device to the hydraulic pumps.

While lifting the hydraulic pumps into position,
carefully slide the drive shaft of the hydraulic
pump into the drive gear, making sure to
properly align the splines of the drive shaft into
the drive gear.
12. Install the hydraulic pumps to the

transmission with four capscrews. Tighten
capscrews to 25 N•m (18 lbf ft).
1. ACCESS HOLE TO ROTATE FLYWHEEL
2. ACCESS PLUG 13. Remove plugs and caps from hydraulic oil hoses
3. CONVERTER HOUSING and fittings. Connect hydraulic oil hoses to the
4. ACCESS PLATE TO FLYWHEEL CAPSCREWS hydraulic pumps.
Figure 12. Access Plug for Drive Plate Capscrews 14. Remove plugs and caps from transmission oil
hoses and fittings. Connect oil hoses from the
6. Install a capscrew. Rotate flywheel and install
thermostat valve to the transmission.
the remaining capscrews until all four
capscrews have been installed. Torque to 15. Insert a funnel into the transmission dipstick
115 N•m (85 lbf ft). tube. Fill the transmission with 20 liter (21 qt)
of ZF TE-ML03 fluid.
7. Install access plate to converter housing. See
Figure 12. 16. Connect the transmission wiring harness and
connectors for the transmission sensors as
8. Install flywheel ring gear access plug. See
marked during removal. See Figure 13.
Figure 12.
9. Remove the lifting device from the two lifting

eyes of the transmission.
103
1. TRANSMISSION INTERNAL SPEED SENSOR 4. TRANSMISSION CONTROL VALVE CONNECTOR

2. TRANSMISSION TURBINE SPEED SENSOR 5. ENGINE SPEED SENSOR
3. DIFFERENTIAL PRESSURE SWITCH 6. TORQUE CONVERTER TEMPERATURE SENSOR
Figure 13. Transmission Wire Connectors and Sensors
104
Failure to assemble and install the drive shaft

CAUTION properly may lead to:
The drive shaft for this truck is a two piece model, • Vibration of the drive shaft and/or truck
consisting of a male splined drive shaft, a female Premature failure of the universal joints on
•
splined slip yoke and a universal joint on both the drive shaft
ends where it connects to the drive axle and
• Excessive vibration levels in the
transmission.
transmission
Drive shafts are balanced and configured at the • Excessive vibration levels in the drive axle
time of manufacture. It is recommended that an
alignment mark is made on the drive shaft NOTE: Use marks created during removal to aid in
indicating the position of the universal joint and installing drive shaft in proper position and
drive shaft prior to removal. orientation.
During removal, it may be possible for the drive 17. Connect the drive shaft to the transmission.
shaft to split apart into two pieces. Reassemble See Figure 14.
the drive shaft using the alignment mark made
prior to removal.
105
1. FRAME (REFERENCE) 6. TRANSMISSION

2. DIPSTICK ASSEMBLY 7. TORQUE CONVERTER
3. DRIVE SHAFT 8. CAPSCREWS
4. OUTPUT YOKE 9. CAPSCREWS
5. TRANSMISSION MOUNT
Figure 14. Transmission Arrangement
18. Connect the battery cables. First the ground 22. Check transmission fluid levels on the dipstick.
cable, then the positive cable. At operating temperature
80 to 90°C (176 to 194°F), the fluid level should
19. Tilt the Operator's compartment down. See the measure in the HOT zone on the dipstick. Add
section Operator's Cab 0100SRM1390. transmission fluid as needed to bring fluid level
to the proper level on the dipstick.
20. Apply the parking brake.
21. Turn the key to ON position and start truck

with the transmission in neutral, allow engine
to idle for 2-3 minutes.
106
1300 SRM 1456 Control Valve Replacement
Control Valve Replacement

REMOVE
STEP 1.
Disconnect the vehicle negative battery
terminal.
STEP 2.
Disconnect the electrical connector from the
transmission control valve.
STEP 3.
Remove two screws, one at each end at the top
of the control valve, and install two alignment
screws in their place.
1. TORX SCREWS
NOTE: During removal of the sealing plates and gasket; note the position of the sealing plates as they are
very different from each other.
NOTE: The intermediate plate can be reused if it is not damaged.
STEP 4.
Remove the remaining mounting screws,
control valve assembly, front sealing plate,
intermediate plate and rear sealing plate from
the transmission. Discard sealing plates.

2. FRONT SEALING PLATE
3. INTERMEDIATE PLATE
4. REAR SEALING PLATE
107
Control Valve Repair 1300 SRM 1456
INSTALL
NOTE: The intermediate plate can be reused if it is not damaged.
STEP 1.
Install the new rear sealing plate, intermediate
plate, and new front sealing plate, as noted
during removal, onto the alignment pins.
Install the control valve assembly, and torx
mounting screws onto the transmission.
Tighten the torx mounting screws in a opposite
pattern to 9.5 N•m (84 lbf in).

2. FRONT SEALING PLATE
3. INTERMEDIATE PLATE
4. REAR SEALING PLATE
STEP 2.
Remove the two alignment screws. Install two
torx screws, one at each end at the top of the
control valve in their place. Tighten to
9.5 N•m (84 lbf in).
1. TORX SCREWS
STEP 3.
Connect the electrical connector from the
transmission control valve.
STEP 4.
Connect the vehicle negative battery terminal.
108
1300 SRM 1456 Control Valve Repair
Control Valve Repair

DISASSEMBLE
STEP 1.
Remove the control valve assembly from the
transmission. See Remove.
STEP 2.
Place a match mark on the cover and the valve
block on both ends of the control valve to assist
in proper assembly of these components.
1. COVER
2. VALVE BLOCK
STEP 3.
Remove the torx screws from the duct plate.
1. TORX SCREWS
2. DUCT PLATE
3. CONTROL VALVE BODY
109
STEP 4.
Remove the duct plate and sealing plate from
the control valve body. Discard the sealing
plate.
1. DUCT PLATE
2. SEALING PLATE
STEP 5.
Remove the retaining clamp, capscrews, cover,
and gasket from the housing. Discard gasket.
Remove capscrews, cover, and gasket from the
opposite end of the control valve. Discard the
gasket.
1. RETAINING CLAMP
2. CAPSCREW
3. COVER
4. GASKET
STEP 6.
Remove the wiring harness from the housing.
1. WIRING HARNESS
2. CAP SCREW
3. FIXING PLATE
4. PRESSURE REGULATOR
110
STEP 7.
Remove three capscrews, three fixing plates,
and three pressure regulators from the housing.
1. CAPSCREW
2. FIXING PLATES
4. HOUSING
WARNING
The housing is under spring pressure, use care during removal of the housing.
STEP 8.
Remove two capscrews and install two
alignment screws in their place in the housing.
Remove the remaining capscrews from the
housing.
1. CAPSCREW
2. ALIGNMENT SCREW
3. HOUSING
4. GASKET
111
STEP 9.
Remove the pressure reducing valve with
spring, three vibration dampers with springs,
and three follow-on slides with springs.
1. PRESSURE REDUCING VALVE WITH SPRING

2. VIBRATION DAMPER WITH SPRING
3. FOLLOW-ON SLIDE WITH SPRING
STEP 10.
Remove three capscrews three fixing plates,
and three pressure regulators from the housing.
1. CAPSCREW
2. FIXING PLATE
4. HOUSING
WARNING
The housing is under spring pressure, use care during removal of the housing.
112
STEP 11.
Remove two capscrews and install two
alignment screws in their place in the housing.
Remove the remaining capscrews from the
housing.
1. CAPSCREW
2. ALIGNMENT SCREW
3. HOUSING
4. GASKET
STEP 12.
Remove the main pressure valve with spring,
three vibration dampers with springs, and
three follow-on slides with springs from the
control valve body.
1. MAIN PRESSURE VALVE WITH SPRING

CLEAN INSPECT
Clean all metal components, except as noted below, Inspect the control valve components for any signs
with cleaning solvent and dry with compressed air. of wear. If components show signs of wear replace
those components. If the valve body shows signs of
The main pressure valve, vibration damper, and
wear, replace the entire control valve assembly.
follow-on-slides are specially coated aluminum
parts. If cleaning is required; these components are
to be cleaned using transmission oil only.
ASSEMBLE
NOTE: Perform Step 1 only if a new valve body is being used.
113
STEP 1.
Place the control valve body on a clean, flat
surface. Install the orifices concave side up
until contact as shown.

2. ORIFICES
NOTE: Coat all parts with clean transmission oil prior to installation.
STEP 2.
Install the three follow-on slides with springs,
three vibration dampers with springs, and
main pressure valve with spring, into the
control valve body.
1. MAIN PRESSURE VALVE WITH SPRING

114
STEP 3.
Install two adjusting screws on either end of
the control valve body. Compress the follow-on
slides and springs and lock them in position
using an M5 capscrew.
1. M5 CAPSCREW
2. ADJUSTING SCREW
STEP 4.
Install a new gasket and the housing on the two
adjusting screws. Install the capscrews into the
housing. Remove the adjusting screws and
insert two cap screws. Tighten all capscrews to
5.5 N•m (48.7 lbf in), and remove the M5
capscrews from the control valve body.
1. CAPSCREW
2. ADJUSTING SCREW
3. HOUSING
4. GASKET
NOTE: Install the fixing plates with the neck facing downward.
115
STEP 5.
Install three pressure regulators, three fixing
plates, and three capscrews into the housing.
Tighten the capscrews to 5.5 N•m (48.7 lbf in).
1. CAPSCREW
2. FIXING PLATE
4. HOUSING
STEP 6.
Install three follow-on slides with springs, three
vibration dampers with springs, and pressure
reducing valve with spring.
1. PRESSURE REDUCING VALVE WITH SPRING

116
STEP 7.
Install two adjusting screws on either end of
the control valve body. Compress the follow-on
slides and springs and lock them in position
using an M5 capscrew.
1. M5 CAPSCREW
2. ADJUSTING SCREW
STEP 8.
Install a new gasket and the housing on the two
adjusting screws. Install the capscrews into the
housing. Remove the adjusting screws and
insert two cap screws. Tighten all capscrews to
5.5 N•m (48.7 lbf in), and remove the M5
capscrews from the control valve body.
1. CAPSCREW
2. ADJUSTING SCREW
3. HOUSING
4. GASKET
STEP 9.
Install three pressure regulators, three fixing
plates, three capscrews, and the wiring harness
in the housing. Tighten the capscrews to
5.5 N•m (48.7 lbf in).
1. WIRING HARNESS
2. CAPSCREW
3. FIXING PLATE
117
STEP 10.
Using the match marks applied before removal,
see Step 2, install a new gasket, cover,
capscrews and the retaining clamp on the
housing. Tighten the capscrews to
5.5 N•m (48.7 lbf in).
1. RETAINING CLAMP
2. CAPSCREW
3. COVER
4. GASKET
STEP 11.
Install two adjusting screws on the control
valve body.
1. ADJUSTING SCREW
STEP 12.
Install the screens, facing up, in the new
sealing plate as shown.
1. SEALING PLATE
2. SCREEN
118
STEP 13.
Install the new sealing plate and the duct plate
on the control valve body.
1. DUCT PLATE
2. SEALING PLATE
STEP 14.
Install the 23 torx screws into the duct plate.
Tighten the torx screws to 10.5 N•m (93 lbf in)
1. TORX SCREWS
2. DUCT PLATE
STEP 15.
Install the control valve assembly on the
transmission. See Control Valve Replacement,
Install.
119
TECHNICAL PUBLICATIONS
1300 SRM 1456 7/19 (12/15)(8/15)(4/14)(11/13)(8/12)

Transmission REPAIR (ZF-WG161) : PART NO. 4034066 1300 SRM 1456

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Transmission REPAIR (ZF-WG161) : PART NO. 4034066 1300 SRM 1456

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TRANSMISSION

PART NO. 4034066 1300 SRM 1456

©2019 HYSTER COMPANY i

Series Code / Model Designation Reference Table

This table consist of the following Series Codes used

Series European Model Americas Model

Special Tools List

The following list consists of the special tools

Item Figure Nomenclature Part Number

Clutch Pack Spring

Hyster® P/N 4612859

2 Holding Fixture Assembly

Item Figure Nomenclature Part Number

3 Shaft Seal Mounting Tool

Hyster® P/N 4612861

Hyster® P/N 4612862

5 Pump Seal Mounting Tool

NOTE: Use a marker of some type to indicate

1. FRAME (REFERENCE) 6. TRANSMISSION

Figure 1. Transmission Arrangement

7. Disconnect the wiring harnesses on the

1. TRANSMISSION INTERNAL SPEED SENSOR 4. TRANSMISSION CONTROL VALVE CONNECTOR

Figure 2. Transmission Wire Connectors and Sensors

8. Place a suitable container under the

9. Disconnect the oil lines from the transmission

10. Disconnect the oil hoses at the hydraulic

11. The hydraulic pumps are connected to the

13. Connect a lifting device, with a lifting capacity

1. ACCESS HOLE TO ROTATE FLYWHEEL

Figure 4. Access Plug for Drive Plate Capscrews

15. Remove the access plate to gain access to the

16. Insert a flywheel rotation tool into the access

17. Remove the capscrew. Rotate the flywheel and

18. Raise the lifting device to hold the weight of the

19. Remove the two 3/4 × 3-1/2 inch bolts that

Transmission Housing, Disassemble

1. OIL FILTER ASSEMBLY

1. CONVERTER PRESSURE BACK-UP VALVE

1. ENGINE SPEED SENSOR

1. INTERNAL SPEED SENSOR

1. TORQUE CONVERTER BELL HOUSING

1. CLUTCH, 3RD SPEED/OUTPUT

NOTE: Perform Step 15 only if any of the tubes are damaged.

1. CLUTCH, 3RD SPEED/OUTPUT

Oil Pump, Disassemble

1. PISTON RING 12. FRICTION DISC

Figure 6. Forward Clutch Assembly

1. PISTON RING 12. INNER DISC

Figure 7. Reverse Clutch Assembly

1. PISTON RING 12. FRICTION DISC

Figure 8. 1st Speed Clutch Assembly

1. PISTON RING 12. FRICTION DISC

Figure 9. 2nd Speed Clutch Assembly

1. PISTON RING 14. COMPRESSION SPRING

Figure 10. 3rd Speed Clutch Assembly

Forward Clutch, Disassemble

1. CLUTCH PACK CARRIER

NOTE: Use compressed air to aid in the removal of the piston.

Reverse Clutch, Disassemble

1. CLUTCH PACK CARRIER

NOTE: Use compressed air to aid in the removal of the piston.

First Speed Clutch, Disassemble

1. CLUTCH PACK CARRIER