TRANSMISSION TRAVELER CARD - H1 Refresh

265 / 275 / 415 / 475 / 575 FR/ Creeper/ SLIPTO SS/ CS

TRANSMISSION SERIAL NUMBER:- DATE :-

STATION SUCCESSOR CHECK POINTS AFTER CHECK POINTS Sign / Shift STATUS

Transcase की सफाई की जाँच करना Transmission पर सही नंबर पंच करना

Drain Plug Fitment चेक करना a) Rev idler gear and Shaft spacer and circlip fitment

Reverse idler NRB को चेक करना b) Counter shaft mounting CC

Expension Plug fitment को चेक करना 2/3/4/CM gear as per model

Check Low coupling position

1 Counter shaft mao ibayairMga va sari@lap kao caok krnaa .

CM model ko ilayao 2nd and 3rd/4th gear kao caok krnaa .

a) LH bull cage and Differential mounting

Bull cage sub assy ko sahI maa^Dla kao jaaÐcanaa .

iDf kosa ko daonaao hba ko nambar kao va irMga igayar ko laa^ikMga kao jaaÐcanaa
2
b) RH bull cage and Differential mounting

ip`laaoD kao jaaÐcanaa (2.27 kg-3.17 kg) SC

daonaao baula koja pr Ta^ik-Mga krnaa . Torque (88-94 N-m)

a) Spline shaft mounting

Set of Two ko sahI maOicaMga kao jaaÐcanaa . SC

Spline shaft ko Aa^yala groove kI position kao jaaÐcanaa, ga`Uva ]pr haonaa
caaihyao .
3 High coupling va 4th igayar kI position kao jaaÐcao .
CM model ko ilayao 1/R,2nd/3rdand 4th gear and spacer & bush kao caok
krnaa
b) Spline shaft tightening & Torquing

Spline shaft mounting nut torque ( 74-94) kao jaaÐcanaa . SC

Backlash setting

4 Set of Two ko sahI maOicaMga kao jaaÐcanaa . SC

Set of two ko baIca baOklaoSa ( 0.18mm to 0.28mm or 0.2mm to 0.3mm) saoT
SC
krnaa
a) Bull cage O ring fitment

Bull Cage LH/RH "O" ring fitment jaaÐcanaa .

Loctite 638 application & baula koja pr Ta^ik-Mga krnaa.Torque (88-94 N-m)
5 (Roll pin )
b) PTO lever mounting

PTO lever maa]nT krnaa . Torque (36 to 44 N-m)

Shifting of Transcase assembly from A conveyor to B

Set of two के सही मैचिंग को जांचना | SC

Spline shaft mounting nut torque jaaÐcanaa ( 74-94) kao jaaÐcanaa .

daonaao baula koja pr Ta^ik-Mga jaaÐcanaa . Torque (88-94 N-m)

QP -1 PTO lever maa]nT bolt torque jaaÐcanaa . Torque (36 to 44 N-m)

PTO Circlip fitment AaOr position kao jaaÐcanaa .

Diff. lock retainer "O" ring fitment jaaÐcanaa .

Set of two ko baIca baOklaoSa jaaÐcanaa ( 0.18mm to 0.28mm or 0.2mm to
SC
0.3mm) <SC>
Drive shaft and Counter front fitment

Counter front spacer kI ]pisqait va position jaaÐcanaa .

Lock plate locking bolt ko torque (20-27 N-m) kao jaaÐcanaa .

Shims & circlip fitment as for CRPTO model kao jaaÐcanaa .

6 Counter front mtg bolt Torque (36-44 Nm)

Drive shaft retainer mao kao[- crack na hao .

Drive shaft mao sari@lap va NRB kI ]pisqait kao jaaÐcao .

Drive shaft retainer oil grove kI position naIcao kI Aaor haonaI caaihyao .

Drive shaft retainer mtg. bolt torque jaaÐcanaa .(36N-m to 44N-m)

a) Rear Axle Assembly mounting

RAC mtg. bolts holes ko baIca, metlock 352 jaaÐcanaa |

7 RAC mtg. surface pr kao[- dent of damage nahI haonaa caaihyao .

RAC mtg. bolt को दो- तीन चूड़ी हाथ से प्रीटाईट तथा टाइट करे |

sahI maa^Dla ko RAC mounting kao jaaÐcanaa .

Fitment of OIB Brakes in Transmission as per model .

8 Fitment of Brakes Rubber boot ( No damage and gap).

Metlock 352 application and Torquing of brakes Cover plates for integral
CC
model ( 88-101 N-m )
Rear Axle Torquing and Bull gear Torquing / Locking

Rear Axle mtg. bolt torque jaaÐcanaa .(88Nm to 115Nm ) SC

9
Metlock 352 application and Torquing of bull gear (265-292Nm) CC

Bull gear locking kao jaaÐcanaa .

PTO shaft mounting

PTO clutch fitment AaOr position kao jaaÐcanaa .(Small side should be towords
10
C/S)
PTO retainer mtg. bolt torque(20-27N-m) kao jaaÐcanaa .
STATION SUCCESSOR CHECK POINTS AFTER CHECK POINTS Sign / Shift STATUS

Clutch housing mounting / Dowel pins

Clutch hsg mao 515 Saelant /RTV sealant application check krnaa .
11
Clutch hsg Mtg holes mao Loctite 352 application check krnaa .

Regular model : Clutch hsg. mounting bolts Torquing (115-128Nm) SC

Check Brake Linkage Bolt tightening and Split pin fitment .

12 Linkage nut kao jaaÐcanaa .(Line Mark on Brake link nut).

CRPTO model :Clutch hsg. mounting bolts Torquing (129-155Nm) SC

Diff lock Pedal jaaÐcanaa (BP,NBP- Regular & NST white paint mark).

13 Metlock 352 application on Difflock pedal Pivot bolts |

Torquing of Pivot bolt (108-122 NM )

Gear shifter bolt tightening & torquing

Bull gear locking kao jaaÐcanaa .(Write OK mark on RAC housing)

Transcase ko Andr kao[- foreign material nahI haonaa caaihyao .

14
Torquing of gear shifter (36-44Nm)

jaÐaca lao ik Transcase pr sahI maa^Dla ka igayar iSaFTr mount hao .

sealant 5060 application on transcase at VTU mounting face |

a)VTU mounting

Transcase ko Andr kao[- foreign material nahI haonaa caaihyao .

Torquing of VTU mtg. bolts (36-44N-m)

15
Torquing of MALE STUD COUPLING (34-40 N-m)

Torquing of OIB pipe (34-40N-m)

VTU serial no. jaaÐcanaa va Traveller card mao ilaKnaa .

b)Tipping Trailer Pipe Fitment

jaÐaca lao ik sahI maa^Dla ka Tipping trailer Pipe mount hao .

16
jaaÐca laoM ik ilakoja joint ka fitment sahI p`kar hao .
Torquing of Banzo bolt (50-60 N-m)

Leakage testing

jaaÐca laoM ik ilakoja joint ka fitment sahI p`kar hao .

jaaÐca laoM ik ilakoja joint sahI p`kar lagao hao .
17
jaaÐca laoM ik RAC torquing sahI hooa
Leakage testing kI value 0-50 ml/min. haonaI caaihyaO SC

Transcase sao kao[- ilakoja nahI haonaa caaihyao .

a) Gear Shifter lever Fitment

Gear Shifter lever position kao jaaÐcanaa

Expension plug fitment kao jaaÐcanaa

18 b) Unloading of Transmission assembly and placing on new conveyor

jaaÐca laoM ik Transmission Skid pr sahI RrKa hooa

Regular Transmisison mao oil sahI Bara hao

jaaÐca laoM ik Transmission dip strick sahI lagaI hooa

a)Transmission testing

Transmission mao 23 Ltr. Transc lean oil haonaa caaihyao .

Torquing of VTU top breather (20-27 N-m)

Power steering model 7 minute running haonaa caaihyao .

inamna pr ilakoja kao jaaÐcaoM inamna kI Function testing kroM

1. RAC Retainer gasket & retainer oil seal 1. Both LH & RH brake.

2. PTO retainer oil seal & gasket 2. Engagement & disengagement of PTO shaft.
19
3. Diff. operation & diff. lock Functioning
3. PTO lever bkt. Oil sael & gasket.

4. Drive shaft retainer oil seal & gasket. 4. Smooth engagement & disengagement of all gears.

5. Counter shaft retainer gasket. inamnailaiKt NOISE kao jaaÐcaoM—

1.Neutral neutral gear position in both reverse & forward
6. Transmission expansion plug. direction.
2.High neutral gear position in both reverse & forward
7. Gear shifter gasket and oil seal. direction.
3.In all gears in high speed & low speed in both reverse &
8. Bull cage oil seal. forward direction.
4.Set of two gear in both reverse & forward direction.
9. Rear side of Transmission.
a) Oil draining Station

सुनिश्चित करें कि ब्रीथ कै प एसओपी के अनुसार टॉर्क किया गया है।

सुनिश्चित करें कि ट्रांसक्लीन तेल ट्रांसमिशन से पूरी तरह निकल जाए।
20
Transmission oil drain haonao ko baad Drain plug ka fitment krnaa

jaÐaca lao ik Transmission Drain plug pr Yellow Die sahI lagaI hao

Torquing of Drain plug (67-73 Nm)

Rewor
k
Details

Status
QP-2
FINAL OK

RDP/TRANS/001, Rev Date : 05.06.2022, Rev. No. : 25

 I Check, I do, I Check

I Check I Do
S. No.

मैं कार्य शुरू करने से पहले, पहले स्टेशन का कार्य चेक करूँ गा मैं SOP के अनुसार दिए गए कार्य को पूरा करूँ गा

1. Model wise Transcase

1 2. Remove all masking Transcsae SPM

1. Model wise Suction strainer fitment

2 2. Torquing of all 4 bolts by applying yellow die Idler NRB Pressing

3 1. Check fitment of Idler shaft NRB Loading & Counter shaft fitment
2. Proper fitment of weltch Plug
1. Fitment of idler shaft circlip
4 2. Fitment of Counter shaft circlip Preload LH
3. Check correct model Counter shaft assembly
1. Check Model wise Diff case and BP shaft
5 2. Check Diff case Lock plate banding Preload RH

1. Check Preload value mentioned on Traveler card

6 2. Check no gap in High speed gear Spline shaft mtg
1. Check Set of 2 no match
7 2. Check Spline shaft mounting bolt washers and torquing Backlash Setting LH
3. Check correct model PTO lever and torquing
8 Backlash Setting RH

9 Transcsae Transfer A to B

10 1. Gears as per plan Counter Shaft SA

11 1. BP shaft as per plan Bull Cage SA

12 1. No Solvant on Parts Diff case SA 1

13 1. Proper banding of diff case mtg lock plates Diff case SA 2

14 Spline shaft SA 1

15 1. Proper banding of Spline shaft lock plate Spline shaft SA 2

16 Drive shaft SA

17 QP-1
 Drive shaft and counter front
18 1. Check Presence of counter front spacer fitment
1. Check metlock application in side RAC mounting holes
19 2. Check Bearing spacer and circlip fitment in RAC RAC mtg

20 1. Check the Axle LT/Non LT as per model RAC mtg Bolt Tightening

21 1. Check yellow die on all RAC mounting bolts RAC & Bull gear torquing

1. Check Bull cage mounting bolts torque

22 2. 585 Model Floayt setting chucknut locking Brake Fitment LH

1. Check Bull cage mounting bolts torque

23 2. 585 Model Floayt setting chucknut locking Brake Fitment RH

24 1. Check Brake cover plate mounting bolts Brake Link Fitment

1. Check Presence of PTO circlip in transcase

25 2. Check Yelloe die / torque on PTO lever mounting bolts. PTO Shaft Mtg

26 1. Yellow die on drive and counter front mounting bolts Clutch hsg mtg
2. Check circlip inside CRPTO model couplings

27 1. Spline shaft assembly circlip position TC Cover mtg

2. Check split pin banding and fitment of brake link

28 Diff lock Pedal fitment

29 1. LH side Brake cover plate Bolt yellow die VTU Mtg LH

30 1. RH side Brake cover plate Bolt yellow die VTU Mtg RH

2. Check the locking of bull gear mounting bolts

31 1. Check yellow die on VTU mounting bolts Aux / tipping pipe fitment

32 1. Check Tipping and aux lever mounting pipes torquing Leakage testing

33 1. Check the yellow die on Clutch housing mounting bolts Transmission unloading

1. Check Crpto link rod split pin fitment

34 Transmission testing 1
2. Check 2 nos. weltch plug inside gear change lever

35 1. Check Crpto link rod split pin fitment Transmission testing 2

2. Check 2 nos. weltch plug inside gear change lever

36 1. Check breather cap tightening Transmission oil draining

Group Leaders Name & Sign : Officers Name & Sign :

1 1

2 2
3 3

4 4
k, I do, I Check

I Check Stage Wise Operators Sign

मैं कार्य पूरा करने के बाद अपना कार्य चेक करूँ गा

1. Model wise Suction strainer fitment

2. Torquing of all 4 bolts by applying yellow die
1. Check fitment of Idler shaft NRB
2. Proper fitment of weltch Plug
1. Fitment of idler shaft circlip
2. Fitment of Counter shaft circlip
3. Check correct model Counter shaft assembly
1. Check Model wise Diff case and BP shaft
2. Check Diff case Lock plate banding

1. Check Preload value mentioned on Traveler card

1. Check Set of 2 no match
2. Check Spline shaft mounting bolt washers and
torquing
Check Torquing of all 3 bolts after Backlash setting

Mention Backlash value on traveler card

Bar code pasting on each SA

Bar code pasting on each SA

1. Proper banding of diff case mtg lock plates

1. Proper banding of Ring Gear mtg lock plates

1. Proper banding of Spline shaft lock plate

1. Model wise gears

2. Complete pressing of High speed gear

1. Presence of circlip
1. Check lock plate banding
2. Check NRB in Drve shaft

1. Check the Axle LT/Non LT as per model

1. Check yellow die on all RAC mounting bolts

1. Check Lock plate banding

1. Torque on all bolts

2. Check complete pressing of Rubber boot
1. Torque on all bolts
2. Check complete pressing of Rubber boot

1. Check fitment of split pin and torquing of link nuts

1. Check PTO retaing mounting bolts

1. Check Yellow die on all Clutch housing mounting bolts

1. Check yellow die on TC cover mounting bolts

1. Check yellow die on LH side mounting bolts

1. Check yellow die on RH side mounting bolts

1. Check torque on all pipe fitments

1. Check correct model suction pipe fitment

Check the 2 nos weltch plug fitment

1. Check Crpto link rod split pin fitment

2. Check breather cap tightening
1. Check Crpto link rod split pin fitment
2. Check breather cap tightening

1. Check the draing plug torquing

Approvar Name & Sign :

 TRANSMISSION TRAVELER CARD - BP/NBP/NST Model
255 / 265 / 275 / 415 / 475 / 575 BP/ NBP/ NST Yellow
SERIES:-
DATE-:
TRANSMISSION SERIAL NUMBER:-

STATION CHECK POINTS STATUS REMARKS / IDENTIFICATION

Transcase kI safa[- kao jaaÐca krnaa Transcase kao knavaoyaor pr rKnaa . Shift of Loading

Drain Plug kao caok krnaa .

Transmission pr sahI nambar pMicaga krnaa CC
Chamfer
a) Reverse idler gear mounting
Idler shaft Identification;
Reverse idler NRB kao caok krnaa . BP Model : NRB area width short
CM South : Doubble ring/groove
1 Reverse gear kI chamfer position Transcase ko Aagao kI trf haonaa caaihyao . SC 415model : 3 cuts on gear teeth
BX / NST : 2 Cuts on gear teeth

b) Counter shaft mounting C.M.Gear

3rd/4th Gear

Counter Shaft mao saBaI igayar va Low coupling kI position kao caok krnaa 2nd Gear

Counter shaft mao ibayairMga va sari@lap kao caok krnaa . REGULAR

Counter Shaft
with 1st Gear[18]
a) LH bull cage and Differential mounting Low Coupling

For 3DI models common LH & RH BP shaft.

Bull cage sub assy ko sahI maa^Dla kao jaaÐcanaa . For 4DI models RH BP shaft with notch /
Common LH & RH shaft for 475 NST
iDf kosa ko daonaao hba ko nambar kao va irMga igayar ko laa^ikMga kao jaaÐcanaa
2
b) RH bull cage and Differential mounting Notch on
RH Bull
13
ip`laaoD kao jaaÐcanaa (2.27 kg-3.17 kg) SC pinion

LH RH
daonaao baula koja pr Ta^ik-Mga krnaa . Torque (88-94 N-m)
a) Spline shaft mounting
1st Gear
Set of Two ko sahI maOicaMga kao jaaÐcanaa . SC 4th Gear
09
Spline shaft ko Aa^yala groove kI position kao jaaÐcanaa, ga`Uva ]pr haonaa caaihyao .
3 High coupling va 4th igayar kI position kao jaaÐcao .
2nd gear
3rd Gear
[44]

b) Spline shaft tightening & Torquing Common Spline gear for BX and
NST Refresh Model
Spline shaft mounting nut torque ( 74-94) kao jaaÐcanaa . SC
Backlash setting
4 Set of Two ko sahI maOicaMga kao jaaÐcanaa . SC
Set of two ko baIca baOklaoSa ( 0.18mm to 0.28mm or 0.2mm to 0.3mm) saoT krnaa SC
a) Bull cage O ring fitment
Bull Cage LH/RH "O" ring fitment jaaÐcanaa .
Loctite 638 application & baula koja pr Ta^ik-Mga krnaa.Torque (88-94 N-m) (Roll pin )
5
b) PTO lever mounting Short Band : BP
long band: NBP, NST
PTO lever maa]nT krnaa . Torque (36 to 44 N-m)
Shifting of Transcase assembly from A conveyor to B
Set of two के सही मैचिंग को जांचना | SC
Spline shaft mounting nut torque jaaÐcanaa ( 74-94) kao jaaÐcanaa .
daonaao baula koja pr Ta^ik-Mga jaaÐcanaa . Torque (88-94 N-m)
QP -1 PTO lever maa]nT bolt torque jaaÐcanaa . Torque (36 to 44 N-m)
PTO Circlip fitment AaOr position kao jaaÐcanaa .
Diff. lock retainer "O" ring fitment jaaÐcanaa .
Set of two ko baIca baOklaoSa jaaÐcanaa ( 0.18mm to 0.28mm or 0.2mm to 0.3mm) <SC> SC
Drive shaft and Counter front fitment
Counter front spacer kI ]pisqait va position jaaÐcanaa .
Lock plate locking bolt ko torque (20-27 N-m) kao jaaÐcanaa .
Shims & circlip fitment as for CRPTO model kao jaaÐcanaa . Drive Shaft
Retainer
oil groove
6 Counter front mtg bolt Torque (36-44 Nm) position

Drive shaft retainer mao kao[- crack na hao .

Drive shaft mao sari@lap va NRB kI ]pisqait kao jaaÐcao .
Drive shaft retainer oil grove kI position naIcao kI Aaor haonaI caaihyao . NST Model Drive shaft length
shorter than BP and NBP
Drive shaft retainer mtg. bolt torque jaaÐcanaa .(36N-m to 44N-m)
a) Rear Axle Assembly mounting
RAC mtg. bolts holes ko baIca, metlock 351 jaaÐcanaa |
Axle shaft identification
7 RAC mtg. surface pr kao[- dent of damage nahI haonaa caaihyao . Big Flange- All LT models& NST Models
Small flange- Non LT models.
RAC mtg. bolt को दो- तीन चूड़ी हाथ से प्रीटाईट तथा टाइट करे |

sahI maa^Dla ko RAC mounting kao jaaÐcanaa .

Fitment of OIB Brakes in Transmission as per model .
8 Fitment of Brakes Rubber boot (No damage and gap).
Metlock 351 application and Torquing of brakes Cover plates for integral model ( 88-101 N-m ) CC
Rear Axle Torquing and Bull gear Torquing / Locking

Rear Axle mtg. bolt torque jaaÐcanaa .(88Nm to 115Nm ) SC

9
Metlock 351 application and Torquing of bull gear (265-292Nm) CC
Bull gear locking kao jaaÐcanaa .
PTO shaft mounting
10 PTO clutch fitment AaOr position kao jaaÐcanaa .(Small side should be towords C/S)
PTO retainer mtg. bolt torque(20-27N-m) kao jaaÐcanaa .
STATION CHECK POINTS STATUS REMARKS / IDENTIFICATION
Clutch housing mounting / Dowel pins
Grease Nipple
Clutch hsg mao 515 Saelant /RTV sealant application check krnaa .
11 BP, NBP MAHINDRA

Clutch hsg Mtg holes mao Loctite 351 application check krnaa .
Regular model : Clutch hsg. mounting bolts Torquing (115-128Nm) SC
Breather
Check Brake Linkage Bolt tightening and Split pin fitment . Grease Nipple
12 Linkage nut kao jaaÐcanaa .(Line Mark on Brake link nut). MAHINDRA

NST
CRPTO model :Clutch hsg. mounting bolts Torquing (129-155Nm) SC
Diff lock Pedal jaaÐcanaa (BP,NBP- Regular & NST white paint mark).
13 Metlock 351 application on Difflock pedal Pivot bolts |
Torquing of Pivot bolt (108-122 NM )
Gear shifter bolt tightening & torquing
Bull gear locking kao jaaÐcanaa .(Write OK mark on RAC housing)
Transcase ko Andr kao[- foreign material nahI haonaa caaihyao .
14
Torquing of gear shifter (36-44Nm)
jaÐaca lao ik Transcase pr sahI maa^Dla ka igayar iSaFTr mount hao .
sealant 5060 application on transcase at VTU mounting face |
a)VTU mounting
Transcase ko Andr kao[- foreign material nahI haonaa caaihyao .
Torquing of VTU mtg. bolts (36-44N-m)
15
Torquing of MALE STUD COUPLING (34-40 N-m)
Torquing of OIB pipe (34-40N-m)
VTU serial no. jaaÐcanaa va Traveller card mao ilaKnaa .
b)Tipping Trailer Pipe Fitment
jaÐaca lao ik sahI maa^Dla ka Tipping trailer Pipe mount hao .
16
jaaÐca laoM ik ilakoja joint ka fitment sahI p`kar hao .
Torquing of Banzo bolt (50-60 N-m)
Leakage testing
jaaÐca laoM ik ilakoja joint ka fitment sahI p`kar hao .
jaaÐca laoM ik ilakoja joint sahI p`kar lagao hao .
17
jaaÐca laoM ik RAC torquing sahI hooa
Leakage testing kI value 0-50 ml/min. haonaI caaihyaO SC

Transcase sao kao[- ilakoja nahI haonaa caaihyao .

a) Gear Shifter lever Fitment
Gear Shifter lever position kao jaaÐcanaa
Expension plug fitment kao jaaÐcanaa
18 b) Unloading of Transmission assembly and placing on new conveyor
jaaÐca laoM ik Transmission Skid pr sahI RrKa hooa
Regular Transmisison mao oil sahI Bara hao
jaaÐca laoM ik Transmission dip strick sahI lagaI hooa
a)Transmission testing

Transmission mao 23 Ltr. Transc lean oil haonaa caaihyao .

Torquing of VTU top breather (20-27 N-m)

Power steering model 7 minute running haonaa caaihyao .

inamna pr ilakoja kao jaaÐcaoM
1. RAC Retainer gasket & retainer oil seal
2. PTO retainer oil seal & gasket
19
3. PTO lever bkt. Oil sael & gasket.
inamna kI Function testing kroM
1. Both LH & RH brake. I Bolt Identification
Short Length : BP & NBP
2. Engagement & disengagement of PTO shaft. long I Bolts : NST Models
3. Diff. operation & diff. lock Functioning

4. Drive shaft retainer oil seal & gasket.
5. Counter shaft retainer gasket.
6. Transmission expansion plug.
7. Gear shifter gasket and oil seal.
4. Smooth engagement & disengagement of all gears.
inamnailaiKt NOISE kao jaaÐcaoM—
1.Neutral neutral gear position in both reverse & forward direction.
2.High neutral gear position in both reverse & forward direction.

8. Bull cage oil seal. 3.In all gears in high speed & low speed in both reverse & forward direction.

9. Rear side of Transmission. 4.Set of two gear in both reverse & forward direction.

a) Oil draining Station

jaÐaca lao ik Transclean oil Transcase sao pUrI trh Suck hao caUkI hao .
20 Transmission oil drain haonao ko baad Drain plug ka fitment krnaa (70~78NM)
jaÐaca lao ik Transmission Drain plug pr Yellow Die sahI lagaI hao
Torquing of Drain plug (67-73 Nm)

Rework
Details

Status
QP-2 FINAL OK

RDP/TRANS/001, Rev Date : 05.06.2022, Rev. No. : 25

 TRANSMISSION TRAVELER CARD - H1 Refresh Model
Yellow
SERIES:-
DATE-:
TRANSMISSION SERIAL NUMBER:-

STATION CHECK POINTS STATUS REMARKS / IDENTIFICATION

Transcase kI safa[- kao jaaÐca krnaa Transcase kao knavaoyaor pr rKnaa . Shift of Loading

Drain Plug kao caok krnaa.(2Nos - 70 NM)

Transmission pr sahI nambar pMicaga krnaa CC
Chamfer
a) 2Wheel Driving
Press the Bush for Idler Gear
Press the NRB for Idler Gear
b) 4Wheel Driving
Expension Plug fitment को चेक करना

a) Reverse idler gear mounting

Idler shaft Identification;
Reverse idler NRB kao caok krnaa . BP Model : NRB area width short
CM South : Doubble ring/groove
Expansion plug kao caok krnaa . SC 415model : 3 cuts on gear teeth
BX / NST : 2 Cuts on gear teeth
Reverse gear kI chamfer position Transcase ko Aagao kI trf haonaa caaihyao .
b) Counter shaft mounting C.M.Gear
3rd/4th Gear

Counter Shaft mao saBaI igayar va Low coupling kI position kao caok krnaa 2nd Gear

Counter shaft mao ibayairMga va sari@lap kao caok krnaa . REGULAR

Counter Shaft
with 1st Gear[18]
a) LH bull cage and Differential mounting Low Coupling

For 3DI models common LH & RH BP shaft.

Bull cage sub assy ko sahI maa^Dla kao jaaÐcanaa .
For 4DI models RH BP shaft with notch /
Common LH & RH shaft for 475 NST
iDf kosa ko daonaao hba ko nambar kao va irMga igayar ko laa^ikMga kao jaaÐcanaa
2
b) RH bull cage and Differential mounting Notch on
RH Bull
13
ip`laaoD kao jaaÐcanaa (2.27 kg-3.17 kg) SC pinion

LH RH
daonaao baula koja pr Ta^ik-Mga krnaa . Torque (88-94 N-m)
a) Spline shaft mounting
1st Gear
SC 4th Gear
09
Set of Two ko sahI maOicaMga kao jaaÐcanaa .
3 Spline shaft ko Aa^yala groove kI position kao jaaÐcanaa, ga`Uva ]pr haonaa caaihyao .
2nd gear
3rd Gear
High coupling va 4th igayar kI position kao jaaÐcao . [44]

b) Spline shaft tightening & Torquing Common Spline gear for BX and
NST Refresh Model
Spline shaft mounting nut torque ( 74-94) kao jaaÐcanaa . SC
Backlash setting
4 Set of Two ko sahI maOicaMga kao jaaÐcanaa . SC
Set of two ko baIca baOklaoSa ( 0.18mm to 0.28mm or 0.2mm to 0.3mm) saoT krnaa SC
a) Bull cage O ring fitment
Bull Cage LH/RH "O" ring fitment jaaÐcanaa .
Loctite 638 application & baula koja pr Ta^ik-Mga krnaa.Torque (88-94 N-m) (Roll pin )
5
b) PTO lever mounting Short Band : BP
long band: NBP, NST
PTO lever maa]nT krnaa . Torque (36 to 44 N-m)
Shifting of Transcase assembly from A conveyor to B
Set of two के सही मैचिंग को जांचना | SC
Spline shaft mounting nut torque jaaÐcanaa ( 74-94) kao jaaÐcanaa .
daonaao baula koja pr Ta^ik-Mga jaaÐcanaa . Torque (88-94 N-m)
QP -1 PTO lever maa]nT bolt torque jaaÐcanaa . Torque (36 to 44 N-m)
PTO Circlip fitment AaOr position kao jaaÐcanaa .
Diff. lock retainer "O" ring fitment jaaÐcanaa .
Set of two ko baIca baOklaoSa jaaÐcanaa ( 0.18mm to 0.28mm or 0.2mm to 0.3mm) <SC> SC
Drive shaft and Counter front fitment
Counter front spacer kI ]pisqait va position jaaÐcanaa .
Lock plate locking bolt ko torque (20-27 N-m) kao jaaÐcanaa .
Shims & circlip fitment as for CRPTO model kao jaaÐcanaa . Drive Shaft
Retainer
oil groove
6 Counter front mtg bolt Torque (36-44 Nm) position

Drive shaft retainer mao kao[- crack na hao .

Drive shaft mao sari@lap va NRB kI ]pisqait kao jaaÐcao .
Drive shaft retainer oil grove kI position naIcao kI Aaor haonaI caaihyao . NST Model Drive shaft length
shorter than BP and NBP
Drive shaft retainer mtg. bolt torque jaaÐcanaa .(36N-m to 44N-m)
a) Rear Axle Assembly mounting
RAC mtg. bolts holes ko baIca, metlock 351 jaaÐcanaa |
Axle shaft identification
7 RAC mtg. surface pr kao[- dent of damage nahI haonaa caaihyao . Big Flange- All LT models& NST Models
Small flange- Non LT models.
RAC mtg. bolt को दो- तीन चूड़ी हाथ से प्रीटाईट तथा टाइट करे |

sahI maa^Dla ko RAC mounting kao jaaÐcanaa .

Fitment of OIB Brakes in Transmission as per model .
8 Fitment of Brakes Rubber boot (No damage and gap).
Metlock 351 application and Torquing of brakes Cover plates for integral model ( 88-101 N-m ) CC
Rear Axle Torquing and Bull gear Torquing / Locking

9
STATION CHECK POINTS STATUS REMARKS / IDENTIFICATION

Rear Axle mtg. bolt torque jaaÐcanaa .(88Nm to 115Nm ) SC

9
Metlock 351 application and Torquing of bull gear (265-292Nm) CC
Bull gear locking kao jaaÐcanaa .
PTO shaft mounting
10 PTO clutch fitment AaOr position kao jaaÐcanaa .(Small side should be towords C/S)
PTO retainer mtg. bolt torque(20-27N-m) kao jaaÐcanaa .
STATION CHECK POINTS STATUS REMARKS / IDENTIFICATION
Clutch housing mounting / Dowel pins
Grease Nipple
Clutch hsg mao 515 Saelant /RTV sealant application check krnaa .
11 BP, NBP MAHINDRA

Clutch hsg Mtg holes mao Loctite 351 application check krnaa .
Regular model : Clutch hsg. mounting bolts Torquing (115-128Nm) SC
Breather
Check Brake Linkage Bolt tightening and Split pin fitment . Grease Nipple
12 Linkage nut kao jaaÐcanaa .(Line Mark on Brake link nut). MAHINDRA

NST
CRPTO model :Clutch hsg. mounting bolts Torquing (129-155Nm) SC
Diff lock Pedal jaaÐcanaa (BP,NBP- Regular & NST white paint mark).
13 Metlock 351 application on Difflock pedal Pivot bolts |
Torquing of Pivot bolt (108-122 NM )
Gear shifter bolt tightening & torquing
Bull gear locking kao jaaÐcanaa .(Write OK mark on RAC housing)
Transcase ko Andr kao[- foreign material nahI haonaa caaihyao .
14
Torquing of gear shifter (36-44Nm)
jaÐaca lao ik Transcase pr sahI maa^Dla ka igayar iSaFTr mount hao .
sealant 5060 application on transcase at VTU mounting face |
a)VTU mounting
Transcase ko Andr kao[- foreign material nahI haonaa caaihyao .
Torquing of VTU mtg. bolts (36-44N-m)
15
Torquing of MALE STUD COUPLING (34-40 N-m)
Torquing of OIB pipe (34-40N-m)
VTU serial no. jaaÐcanaa va Traveller card mao ilaKnaa .
b)Tipping Trailer Pipe Fitment
jaÐaca lao ik sahI maa^Dla ka Tipping trailer Pipe mount hao .
16
jaaÐca laoM ik ilakoja joint ka fitment sahI p`kar hao .
Torquing of Banzo bolt (50-60 N-m)
Leakage testing
jaaÐca laoM ik ilakoja joint ka fitment sahI p`kar hao .
jaaÐca laoM ik ilakoja joint sahI p`kar lagao hao .
17
jaaÐca laoM ik RAC torquing sahI hooa
Leakage testing kI value 0-50 ml/min. haonaI caaihyaO SC

Transcase sao kao[- ilakoja nahI haonaa caaihyao .

a) Gear Shifter lever Fitment
Gear Shifter lever position kao jaaÐcanaa
Expension plug fitment kao jaaÐcanaa
18 b) Unloading of Transmission assembly and placing on new conveyor
jaaÐca laoM ik Transmission Skid pr sahI RrKa hooa
Regular Transmisison mao oil sahI Bara hao
jaaÐca laoM ik Transmission dip strick sahI lagaI hooa
a)Transmission testing

Transmission mao 23 Ltr. Transc lean oil haonaa caaihyao .

Torquing of VTU top breather (20-27 N-m)

Power steering model 7 minute running haonaa caaihyao .

inamna pr ilakoja kao jaaÐcaoM
1. RAC Retainer gasket & retainer oil seal
2. PTO retainer oil seal & gasket
19
3. PTO lever bkt. Oil sael & gasket.
inamna kI Function testing kroM
1. Both LH & RH brake. I Bolt Identification
Short Length : BP & NBP
2. Engagement & disengagement of PTO shaft. long I Bolts : NST Models
3. Diff. operation & diff. lock Functioning

4. Drive shaft retainer oil seal & gasket.
5. Counter shaft retainer gasket.
6. Transmission expansion plug.
7. Gear shifter gasket and oil seal.
4. Smooth engagement & disengagement of all gears.
inamnailaiKt NOISE kao jaaÐcaoM—
1.Neutral neutral gear position in both reverse & forward direction.
2.High neutral gear position in both reverse & forward direction.

8. Bull cage oil seal. 3.In all gears in high speed & low speed in both reverse & forward direction.

9. Rear side of Transmission. 4.Set of two gear in both reverse & forward direction.

a) Oil draining Station

jaÐaca lao ik Transclean oil Transcase sao pUrI trh Suck hao caUkI hao .
20 Transmission oil drain haonao ko baad Drain plug ka fitment krnaa (70~78NM)
jaÐaca lao ik Transmission Drain plug pr Yellow Die sahI lagaI hao
Torquing of Drain plug (67-73 Nm)

Rework
Details

Status
QP-2 FINAL OK

RDP/TRANS/001, Rev Date : 05.06.2022, Rev. No. : 25