YMM130001

Powershift Transmission
Repair
GP/GLP/GDP15-20AK [C812];
GP/GLP/GDP20-35RK/TK [B871]

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 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 YALE 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), 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!

—1—
 GENERAL
This section has the repair procedures for the transmission.

CHARGE PUMP REPAIR

[1] Remove
NOTE: The charge pump is removed from the transmission after the transmission removal from the lift truck.

Remove five mounting capscrews, washers, transmission charge pump, from the torque
converter housing. See Figure 1.

[2] Inspect

Inspect the splines on the shaft of the transmission charge pump for damage or worn areas that
could affect the operation of the pump. If the splines are damaged, replace the transmission
charge pump.

[3] Install

Install new, transmission charge pump, five mounting capscrews, and washers in the torque
converter housing. Tighten capscrews to 21 N·m (211 kg·cm).

1. TORQUE CONVERTER ASSY

2. CHARGE PUMP
3. TORQUE CONVERTER HOUSING

NOTE: THE TRANSMISSION IS SHOWN REMOVED FROM THE LIFT TRUCK FOR CLARITY.

Figure 1. Transmission Charge Pump

—2—
 TORQUE CONVERTER REPLACE

[1] Remove

1. Remove the engine and transmission as a unit from the lift truck. See the section Frame.

WARNING
Make sure the engine and transmission are held in position so that they will not fall and
cause an injury and damage to the equipment.

CAUTION
Be careful that you do not damage parts of the torque converter or transmission when the
transmission is separated from the engine. Keep the transmission and engine in alignment
until they are completely separated so parts of the transmission are not damaged. Use a
crane or lifting device to separate the transmission from the engine.

CAUTION
Use care when disconnecting the wiring harness connectors from electrical connectors on
the transmission and control valve. The connectors on the transmission and control valve
are easily damaged.

NOTE: When disconnecting wiring harness connectors during disassembly, tag each connector to aid in
connecting the wiring harness during reassembly.

2. Put the engine and transmission on solid blocks on a work surface. Disconnect the
connectors of the transmission wiring harness from the control valve and transmission.
Remove the transmission wiring harness from the transmission. See Figure 2.

—3—
 1. WASHER
2. CPSCR

Figure 2. Engine-Transmission Combination

WARNING
Make sure that the engine/transmission assembly is stable before attempting to rotate the
engine.
Use a flashlight to see the bolts as they are rotated into view through the access hole. Do
not use your fingers to check for alignment of the bolts with the access hole.

3. Remove the access cover from the torque converter housing. Move each bolt into view
through the access hole of the torque converter housing by rotating the crankshaft. Remove
the four capscrews that attach the flywheel to the torque converter.
4. Remove the 10 capscrews that hold the torque converter housing to the flywheel housing on
the engine. Carefully separate the transmission from the engine.

NOTE: The torque converter cannot be repaired and must be replaced as a unit, if damaged.

5. Carefully remove the torque converter from the stator support of the charge pump. See
Figure 4.
6. Remove the plug, suction screen spring, and suction screen from the torque converter
housing, and drain the oil from the transmission.
7. Remove the transmission charge pump and transmission oil filter from the torque converter
housing.
8. Remove the dipstick from the dipstick tube and the inching bellcrank bracket from the
transmission control valve.
9. If damaged or clogged, replace the air breather from the torque converter housing.

NOTE: If the transmission clutch packs are in need of further repair, see Clutch Packs Repair.

—4—
 2. CLUTCH PACK 5 PLATE 38. SPRING REGULATOR
16. GEAR PUMP ASSY 39. SPRING REGULATOR
18. TORQUE CONVERTER ASSY 40. PLUG
19. WASHER 41. PISTON COLD RELIEF
20. CAPSCREW 42. SPRING COLD RELIEF
23. HEX HEAD BOLT 43. PLUG
24. CHOKE 50. PIN
37. PISTON REGULATOR

Figure 4. Torque Converter Removal

10. Remove 11 capscrews from the trans-

mission housing and one mounting
capscrew from the front of the torque
conver ter housing. Using a small pry
bar in the designated pry points, remove
the torque converter housing from the
transmission housing. Discard the gasket.
See Figure 5.

[2] Install

1. I n s t a l l n e w g a s k e t a n d u s i n g o n e
capscrew, install the torque converter
housing on the transmission case and
11 capscrews on the transmission case.
Tighten capscrews to 41–49 N·m (417–
500kg·cm). See Figure 5. 1. TRANSMISSION CASE
2. If removed, install the new air breather on 2. TORQUE CONVERTER HOUSING
3. CAPSCREW
the torque converter housing. See Figure
4. GASKET
6.
3. Install the dipstick into the dipstick tube
and the inching bellcrank bracket to the Figure 5. Transmission Housings

—5—
 transmission control valve.
4. Replace a transmission oil filter on the
transmission case if required.
5. Install the transmission charge pump on
the torque converter housing. Tighten
capscrews to 21 N·m (211 kg·cm).
6. Install the suction screen, suction screen
spring, and plug into the torque converter
housing.
7. Install the torque conver ter onto the
input shaft and stator suppor t of the
transmission. Make sure the splines are
aligned and the converter engages fully.
8. Lubricate the pilot hub on the torque
converter with antiseize compound. See
Figure 7.
9. Align the torque converter housing with 1. TRANSMISSION OIL FILTER
the flywheel housing. Make sure the pilot 2. DIPSTICK
hub on the torque converter engages the 3. TRANSMISSION CASE
flywheel. 4. TORQUE CONVERTER HOUSING
5. CAPSCREW
6. AIR BREATHER

CAUTION
Figure 6. Torque Converter Installation
Be careful that you do not damage parts
of the torque converter or transmission
when the transmission is joined to the
engine. Keep the transmission and engine in
alignment until they are completely joined so
parts of the transmission are not damaged.
Use a crane or lifting device to join the
transmission to the engine.

10. Install the transmission to the engine.

Install the capscrews that connect the
torque converter housing to the flywheel
housing. Tighten the capscrews to 41–49
N·m (417–500 kg·cm). See Figure 8.

1. GEAR PUMP ASSY

2. TORQUE CONVERTER ASSY
3. WASHER
4. CPSCR
5. WA HEX HEAD BOLT
6. PILOT HUB

Figure 7. Torque Converter Pilot Hub Lubrication

—6—
 CAUTION
Use care when connecting the wiring harness connectors to electrical connectors on the
transmission and control valve. The connectors on the transmission and control valve are
easily damaged.

11. Install the transmission wiring harness on the transmission. Connect the connectors of the
transmission wiring harness to the control valve and transmission. See Figure 8.
12. Rotate the engine crankshaft to position the flywheel mounting holes in line with the torque
converter mounting holes. Install the capscrews that hold the torque converter to the flywheel,
after coating the threads with LoctiteTM 242, through the access hole of the torque converter
housing. See Figure 9. Tighten the capscrews to 41–49 N·m (417–500 kg·cm). Install the
access cover on the torque converter housing.

WARNING
Make sure the engine and transmission are held in position so that they will not fall and
cause an injury and damage to the equipment.

13. Install the engine and transmission as a unit into the lift truck. See the section Frame.
14. Fill the transmission to the correct level using the correct transmission fluid and procedure
given in the section Periodic Maintenance.

1. WASHER
2. CPSCR

Figure 8. Engine-Transmission Combination

—7—
A

A. MAZDA ENGINE
B. YANMAR ENGINE

Figure 9. Torque Converter Bolt Access

—8—
 CLUTCH PACKS REPAIR

[1] Remove and Disassemble

(1) Transmission, Remove and Disassemble

1. Remove the engine and transmission as a unit from the lift truck. See the section Frame.

WARNING
Make sure the engine and transmission are held in position so that they will not fall and
cause an injury and damage to the equipment.

CAUTION
Be careful that you do not damage parts of the torque converter or transmission when the
transmission is separated from the engine. Keep the transmission and engine in alignment
until they are completely separated so parts of the transmission are not damaged. Use a
crane or lifting device to separate the transmission from the engine.

CAUTION
To prevent possible damage to the transmission assembly when placing the assembly on a
work surface, place blocks under the back side of the transmission housing for additional
support.

CAUTION
Use care when disconnecting the wiring harness connectors from electrical connectors on
the transmission and control valve. The connectors on the transmission and control valve
are easily damaged.

NOTE: When disconnecting wiring harness connectors during disassembly, tag each connector to aid in
connecting the wiring harness during reassembly.

2. Put the engine and transmission on solid blocks on a work surface. Disconnect the two
connectors of the chassis wiring harness from the transmission wiring harness. Disconnect
the connectors of the transmission wiring harness from the control valve and transmission.
Remove the transmission wiring harness from the transmission.

WARNING
Make sure that the engine/transmission assembly is stable before attempting to rotate the
engine.
Use a flashlight to see the bolts as they are rotated into view through the access hole. Do
not use your fingers to check for alignment of the bolts with the access hole.

3. Remove the access cover from the torque converter housing. Move each bolt into view
through the access hole of the torque converter housing by rotating the crankshaft. Remove

—9—
A

A. MAZDA ENGINE
B. YANMAR ENGINE

Figure 20. Torque Converter Bolt Access

— 10 —
 the four capscrews that attach the flywheel to the torque converter. See Figure 20.
4. Remove the 10 capscrews that hold the torque converter housing to the flywheel housing.
Carefully separate the transmission from the engine.
5. Carefully remove the torque converter startor support of the charge pump. See torque
converter replace, Step 6 through Step 11.
6. Remove the bolt and washer, from the back of the transmission. See Figure 21.
7. Remove the bearing from the output shaft.
8. Remove the output gear from the back of the transmission.
9. Remove the output shaft, the bearing, and the oil seal from the transmission.
10. Disassembly of the clutch pack assemblies as follows.

2. CLUTCH PACK 5 PLATE, FORWARD

3. CLUTCH PACK 5 PLATE, REVERSE
4. GEAR OUTPUT
5. SHAFT OUTPUT
6. BRG, RADIAL BALL
7. BRG, RADIAL BALL
8. WASHER
9. CPSCR
10. OIL SEAL
18. GEAR PUMP ASSY
60. TORQUE CONVERTER ASSY

Figure 21. Output Gear Removal

— 11 —
(2) Clutch Assemblies, Remove and Disassemble

NOTE: The forward clutch assembly is shown in

the illustrations for the disassembly procedures.

STEP 1.
Pull the forward clutch assembly straight from
the transmission case.

1. FORWARD CLUTCH

STEP 2.
Remove the shaft seal and bearing from the
input shaft. Discard the shaft seal.

1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 3.
Remove the snap ring from the output gear.
Remove the output gear from the input shaft.

1. SNAP RING
2. BEARING
3. OUTPUT GEAR

— 12 —
NOTE: Before removing the seal bearing, note the
position of the seal on the bearing.

STEP 4.
Remove seal from the output gear. Remove
seal bearing, snap ring, spacer, snap ring,
and bearing from the output gear.

1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING

STEP 5.
Remove the snap ring and pressure plate
from the gear assembly drum.

1. SNAP RING
2. BACK PLATE
3. GEAR ASSEMBLY DRUM

STEP 6.
Remove the friction disks and separator plates
alternately until all have been removed from
the gear assembly drum.

1. FRICTION DISK
2. SEPARATOR PLATE
3. GEAR ASSEMBLY DRUM

— 13 —
 STEP 7.
Remove the conical plate from the gear
assembly drum.

1. CONICAL PLATE
2. GEAR ASSEMBLY DRUM

WARNING
The spring for the piston is compressed. Make sure the spring and spring retainer cannot
cause injury when the snap ring is removed.

NOTE: Remove the piston only if there is a problem with the piston or piston seals.

STEP 8.
Using the spring compression tool Yale P/N
150121831 and a press, place the spring
compression tool on the spring guide with
the opening of the tool above the opening of
the snap ring, and compress the spring just
enough to allow removal of the snap ring from
the spring guide. Slowly release the press to
decompress the spring.

1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

— 14 —
STEP 9.
Remove the snap ring, spring guide, and
return spring from the input shaft.

1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT

STEP 10.
Remove the piston from the gear assembly
drum and the piston seal from the piston.
Discard the piston seal.

1. PISTON
2. PISTON SEAL
3. GEAR ASSEMBLY DRUM
4. SHAFT SEAL

STEP 11.
Remove the shaft seals and bearing from the
input shaft. Discard shaft seals.

1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT

— 15 —
[2] Clean

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When
using cleaning solvents, always follow the solvent manufacturer’s recommended safety
procedures.

Clean all metal parts with cleaning solvent and place on a lint-free cloth to dry. Ensure that the
cleaning and assembly environment is free of dust, dirt, and any other foreign matter that would
affect the performance of the parts.

[3] Inspect

1. Inspect the gear teeth on clutch assemblies and all other gears for wear or damage. If the
gear teeth are worn or damaged, replace the damaged component.
2. Check all parts that have splines for damage to the splines. Check for notches worn in the
splines. Replace the clutch pack or gears that have spline damage.
3. Inspect the friction discs for burned lining or bent surfaces. Check for small holes in the lining.
Replace the friction discs if one-half the depth of the oil grooves is worn away or the discs
are damaged. Discard a friction disc that has a thickness less than 2.2 mm (0.087 in.).
4. The conical plate and separator plates
must not be bent, have damaged surfaces,
or have large blue areas from too much
heat. If any of the above conditions exist,
replace the damaged component.
5. Check the “H” dimension of the conical
plate as shown in Figure 25. If the
dimension is less than 3.2 mm (0.126 in.),
replace the conical plate.
6. Check the “t” dimension of the conical
plate as shown in Figure 25. If the
dimension is less than 2.4 mm (0.094 in.),
Figure 25. Conical Plate Inspection
replace the conical plate.
7. Inspect the bearings for wear or damage.
If the bearings are damaged, replace them.
8. Inspect the piston for damage. Make sure that the sealing surfaces are good. Make sure the
orifice is clean.
9. Check for grooves or other damage on the machined surfaces of the clutch pack shafts and
transmission housing. Check the mounting and sealing surfaces in the housing for damage. If
there is evidence of any damage, replace the housing or transmission. If the clutch pack shaft
is damaged, replace the clutch pack assembly.
10. Inspect all hardware and mounting surfaces for the presence of rust, sealing compounds,
and usable condition. If the hardware is to be reused, clean all rust and sealing compounds
from the threaded areas. If the hardware is not in usable condition, replace the hardware.

CAUTION
The dowel pins are used to properly align the housings for proper mating to each other. If
the alignment is not correct, damage to the transmission assembly could occur.

— 16 —
 11. Inspect dowel pins and dowel pin holes. If any dowel pin is damaged at all, replace the dowel
pin. If a dowel pin hole is damaged, replace the housing.
12. Check the fit of bearings in the transmission housings. If the bearings fit too loosely into the
housings, this could mean that the bores are oversized. Replace housings as necessary.

[4] Assemble and Install

(1) Clutch Assemblies, Assemble and Install

NOTE: The forward clutch assembly is shown in

the illustrations for the assembly procedures.

STEP 1.
Install the bearing and new shaft seals on the
input shaft.

1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT

NOTE: Perform STEP 2 through STEP 5 only if the

piston was removed.

STEP 2.
Lubricate all parts with clean transmission
oil. Install the shaft seal on the shaft and the
piston seal on the piston.

1. PISTON SEAL
2. PISTON

STEP 3.
Install the piston into the gear assembly drum.

1. PISTON
2. PISTON SEAL
3. GEAR ASSEMBLY DRUM
4. SHAFT SEAL

— 17 —
STEP 4.
Install the piston return spring, spring guide,
and snap ring on the input shaft.

1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT

STEP 5.
Using the spring compression tool Yale P/N
150121831 and a press, place the spring
compression tool on the spring guide with
the opening of the tool above the opening of
the snap ring, and compress the spring just
enough to allow installation of the snap ring in
the spring guide. Slowly release the press.

1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

— 18 —
NOTE: The conical plate is properly installed when
the inner diameter is touching the piston, and the
outer diameter of the conical plate is touching the
outer diameter of the friction disk.

STEP 6.
Install the conical plate into the gear assembly
drum.

1. CONICAL PLATE
2. GEAR ASSEMBLY DRUM

STEP 7.
Install the separator plates and friction disks
alternately until all have been installed in the
gear assembly drum.

1. FRICTION DISK
2. SEPARATOR PLATE
3. GEAR ASSEMBLY DRUM

STEP 8.
Install the pressure plate and snap ring in the
gear assembly drum. Using a dial indicator or
feeler gauge, check the clearance between
the snap ring and pressure plate. There must
be 1.8 ± 0.2 mm of clearance. If the clearance
is not correct, see the Parts Manual for the
correct pressure plate.

1. SNAP RING
2. BACK PLATE
3. GEAR ASSEMBLY DRUM

— 19 —
NOTE: Make sure the seal on seal bearing is in
correct position as noted during removal.

STEP 9.
Install seal onto output gear. Install the
bearing, snap ring, spacer, snap ring, and
seal bearing into output gear.

1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING

STEP 10.
Install the output gear on the input shaft.
Install bearing and snap ring in the output
gear.

1. SNAP RING
2. BEARING
3. OUTPUT GEAR

STEP 11.
Install the bearing and shaft seal on the input
shaft.

1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

— 20 —
 STEP 12.
Install the reverse clutch assembly in the
transmission housing. Do not damage the seal
rings on the end of the clutch shaft.

STEP 13.
Install the forward clutch assembly in the
transmission housing. Do not damage the seal
rings on the end of the clutch shaft.

2. CLUTCH PACK 5 PLATE, FORWARD

3. CLUTCH PACK 5 PLATE, REVERSE
4. GEAR OUTPUT
5. SHAFT OUTPUT
6. BRG, RADIAL BALL
7. BRG, RADIAL BALL
8. WASHER
9. CPSCR
10. OIL SEAL
18. GEAR PUMP ASSY
60. TORQUE CONVERTER ASSY

(2) Transmission, Assemble and Install

1. Install the bearing, on the transmission. See Figure 26.

2. Install the oil seal into the back of the transmission carefully after applying adhesive agent to
the outside diameter.
3. Apply grease on the inside lip of the oil seal. Install the output shaft into the transmission
carefully not to damage the oil seal.
4. Install the output gear, bearing, washer and capscrew in the back of the transmission. Apply
Loctite™ 242 on the capscrew. Tighten capscrew to 157 N·m (1600 kg·cm). See Figure 26.
5. Install the torque converter housing on the transmission. See Torque Converter Replace,
Install, Step 1 through Step 15.

CAUTION
Use care when connecting the wiring harness connectors to electrical connectors on the
transmission and control valve. The connectors on the transmission and control valve are

— 21 —
easily damaged.
6. Install the transmission wiring harness on the transmission. Connect the connectors of
the transmission wiring harness to the control valve and transmission. Connect the two
connectors of the chassis wiring harness to the transmission wiring harness.
7. Rotate the engine crankshaft to position the flywheel mounting holes in line with the torque
converter mounting holes. Install the capscrews that hold the torque converter to the
flywheel through the access hole of the torque onverter housing. See Figure 28. Tighten the
capscrews to 41–49 N·m (417–500 kg·cm). Install the access cover on the torque converter
housing.
8. Install the engine and transmission as a unit into the lift truck. See the section Frame.
9. Fill the transmission to the correct level using the correct transmission fluid and procedure
given in Periodic Maintenance.

2. CLUTCH PACK 5 PLATE, FORWARD

3. CLUTCH PACK 5 PLATE, REVERSE
4. GEAR OUTPUT
5. SHAFT OUTPUT
6. BRG, RADIAL BALL
7. BRG, RADIAL BALL
8. WASHER
9. CPSCR
10. OIL SEAL
18. GEAR PUMP ASSY
60. TORQUE CONVERTER ASSY

Figure 26. Output Gear Installation

— 22 —
A

A. MAZDA ENGINE
B. YANMAR ENGINE

Figure 28. Torque Converter Bolt Access

— 23 —
 CONTROL VALVE REPAIR

[1] Remove and Disassemble

CAUTION
Use care when disconnecting the wiring
h a r n e s s e s f ro m t h e c o n n e c t o r s . T h e
connectors are easily damaged.

NOTE: That two regulator valves are in the

transmission housing, not in the control valve
assembly.

1. Clean the area around the control valve.

Put identification tags on the wire harness
connectors and the connectors on the
transmission and control valve. Disconnect
the wiring har ness connectors from
transmission and control valve connectors,
and remove the cable connector from the
standoff located on the torque converter 1. SOLENOID VALVE
housing. See Figure 29. 2. CPSCR

Figure 29. Transmission Assembly

2. Remove the capscrews that attach

the control valve to the transmission.
Remove the control valve assembly and
discard the gasket. Put a cover on top of
the transmission to keep dirt out of the
transmission. See Figure 30.

NOTE: Disassemble the control valve only to the

extent to complete any repairs that are required.
NOTE: Disassemble the control valve in a clean,
contamination-free area.

1. CONTROL VALVE ASSEMBLY

2. CAPSCREW
3. BRACKET BELLCRANK
4. GASKET

Figure 30. Control Valve Removal

— 24 —
 1. CONTROL VALVE ASSEMBLY 37. PISTON REGULATOR
2. CAPSCREW 38. SPRING REGULATOR
3. BRACKET BELLCRANK 39. SPRING REGULATOR
4. GASKET 40. PLUG
41. PISTON COLD RELIEF
42. SPRING COLD RELIEF
43. PLUG
50. PIN

Figure 31. Control Valve Arrangement

3. Remove the inching bellcrank, four capscrews, solenoid valve assembly and clip from the
control valve body.

WARNING
There are compressed springs under the cover in the control valve. Carefully remove the
cover so that the compressed springs do not cause injury.

4. Remove the cover from the valve body. Discard the gasket. Remove the spring and spools
from the control valve body

WARNING
There are compressed springs under the plug in the regulator valve. Carefully remove the
plug so that the compressed springs do not cause injury.

5. Remove the plug for the main regulator and torque converter regulator valves. Discard the
O-rings. Remove the spring and regulator spools from the transmission case. See Figure 31.

— 25 —
[2] Clean

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When
using cleaning solvents, always follow the solvent manufacturer’s recommended safety
procedures.
Compressed air can move particles so they cause injury to the user or to other personnel.
Make sure the path of the compressed air is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the eyes.

CAUTION
Do not allow cleaning solvent to come in contact with rubber or plastic components as it
can damage those components.

Clean all metal components in solvent and dry with compressed air.

[3] Inspect

1. Make sure there are no scratches or damage on the spools or in the bores of the control
valve body and transmission housing. If the valve bores are damaged, replace the control
valve or transmission housing.
2. Inspect the valve bore for the presence of burrs. Burrs may be removed using a fine file,
emery cloth, or crocus cloth.
3. Check that the springs are not bent or damaged. Make sure the spools move freely in their
bores.
4. Inspect the connectors on the solenoid valve and, if they are damaged, replace the damaged
solenoid valve.

[4] Assemble and Install

NOTE: Lubricate the parts of the control valve with clean transmission oil during assembly.

1. Install the solenoid valve and socket head screws into the control valve body. Tighten socket
head screws to 6 to 7 N·m (60 to 70 kg·cm). See Figure 29.
2. Install the spools and springs into the control valve body. Install the cover with new gasket.
3. Install the main and torque converter regulator spools and springs into the transmission
housing. Install the plugs and new O-rings.
4. Install the clip, capscrews, and into the control valve body.
5. Install a new control valve gasket on the transmission. Install the control valve on the
transmission. Install the capscrews that hold the control valve on the transmission. Do not
tighten at this time.
6. Tighten capscrews to 14.7 N·m (148 kg·cm) in the sequence shown in Figure 32. Retighten
capscrews to 21–25 N·m (211–253 kg·cm) in the sequence shown in Figure 32.

CAUTION
Use care when connecting the wiring harnesses to the connectors. The connectors are

— 26 —
easily damaged.

7. Install the cable connector in the standoff and connect the wiring harness connectors to the
transmission and control valve as tagged during removal. See Figure 29.

Figure 32. Control Valve Mounting Screw Tightening Sequence

— 27 —
 FOOT DIRECTIONAL CONTROL PEDAL REPAIR

[1] Remove and Disassemble

1. Remove screws, dash panel, and kick plate from the lift truck. Disconnect cable assembly
from the pedal assembly. See Figure 34.

CAUTION
Use care when removing the connector from its holder as the connector can be easily
damaged.

NOTE: Remove only those components necessary to complete the repair of the Foot Directional Control
pedal.

2. Remove the spring from the lever bracket and pedal assembly.
3. Remove the nut and joint boll from the pedal assembly.

1. BRACKET
2. SPRING
3. NUT
4. JOINT BOLL
5. PEDAL ASSEMBLY
6. BOLTS

Figure 34. Foot Directional Control Pedal Removal

— 28 —
4. Remove two bolts that hold bracket to the
cowl, and remove the pedal assembly
from the lift truck.
5. Remove the roll pin and the throttle pedal
shaft from the pedal assembly. Discard the
roll pin.
6. Remove u-clip, foam lock seal, and wiring
harness from the pedal frame. Remove
four pan head screws, lockwashers,
washers, pedal pad, and springs from
the pedal frame. If any metal inserts in
the pedal pad are damaged, replace as
necessary. See Figure 36.
7. Remove two hex head screws, lock-
washers, nuts, and microswitch from
the pedal pad. Repeat for remaining 1. PEDAL ASSEMBLY
microswitch and remove the wir ing 2. ROLL PIN
3. SHAFT
harness from the pedal frame.
4. BUSHINGS
8. If damaged, remove the stop screw and 5. BRACKET
nut from the pedal frame.

Figure 35. Foot Directional Control

Pedal Bracket Disassembly

1. WIRING HARNESS
2. FOAM LOCK SEAL
3. U-CLIP
4. PAN HEAD SCREW
5. LOCKWASHER
6. WASHER
7. STOP SCREW
8. NUT
9. METAL INSERT
10. NUT
11. LOCKWASHER
12. MICROSWITCH
13. HEX HEAD SCREW
14. SPRING
15. PEDAL PAD
16. PEDAL FRAME

Figure 36. Foot Directional Control Pedal Disassembly

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[2] Assemble and Install

1. If removed, install the stop screw and nut

on the pedal frame. See Figure 36.
2. Install the microswitch and two hex head
screws in the pedal pad. Coat the exposed
threads of the hex head screws with
Loctite™ 222. Install the two lockwashers
and nuts on the hex head screws. Do not
tighten the nuts at this time. Repeat for the
other microswitch.
3. Put the wires through the hole in the
pedal frame. The mark “R” banded wire
is for the reverse microswitch, and the
mark “F” banded wire is for the forward
microswitch. Adjust each microswitch
in its mount so that the measurement
between the edge of the mount and the
base of the microswitch equals 0.0 to 0.5
mm (0.0 to 0.02 in.). Tighten the mounting
nuts of each microswitch as adjustment is
completed. See Figure 37.
4. Install the wiring harness in the pedal
frame. Install the foam lock seal and u-clip. 1. MICROSWITCH MOUNT
2. MICROSWITCH BASE
Install pedal pad and springs in the pedal
frame. Coat the threads of four pan head
screws with Loctite 222. Install pan head Figure 37. Microswitch Adjustment
screws, lockwashers, and washers in the
pedal pad. Tighten pan head screws to
2.25 to 2.50 N·m (19 to 32 lbf in).
5. Using an ohmmeter, check for continuity
b e t w e e n p i n s 2 a n d 3 o f t h e Fo o t
Directional Control wiring harness
connector with the Foot Directional Control
pedal in the reverse position, and between
pins 1 and 2 with the pedal in the forward
position. See Figure 38.
6. Install the throttle pedal shaft, bushings
and new roll pin in the Foot Directional
Control pedal assembly. See Figure 35.
7. Apply adhesive compound to the two
mounting bolts. Using the two bolts that
hold the bracket to the cowl, install the
pedal assembly on the lift truck. Tighten
the bolts to 19 to 25 N·m (168 to 221 lbf 1. WIRING HARNESS CONNECTOR
in). See Figure 34.
8. Install the spring on the lever bracket and Figure 38. Microswitch Continuity Check
Foot Directional Control pedal assembly.
9. Install nut and joint boll on the pedal
assembly.
10. Connect the cable assembly to the pedal assembly. See Figure 34. Install the dashboard on
the lift truck.
11. Depress the Foot Directional Control pedal until it stops. Unscrew stop screw until it contacts
the accel bracket. Tighten the nut to 10 N·m (89 lbf in).

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