POWERSHIFT TRANSMISSION DESCRIPTION Hydraulic circuit Control... REMOVAL AND INSTALLATION DISASSEMBLY AND REASSEMBLY ...... Transmission assembly Disassembly Reassembly Pump assembly Input'shaft assembly Transmission assembly Control valve Disassembly Reassembly wecees INSPECTION AND ADJUSTMENT Testing hydraulic pressure Adjusting clutch (inching) pedal Testing clutch valve... Testing stall speed we 10-m (33-ft) starting acceleration test TA 72 73 13 14 14 14 7-10 7-10 Tell 714 TAT TAT 7-18 7-19 7-19 7-21 1-23 7-23 7-24POWERSHIFT TRANSMISSION DESCRIPTION ¢ (35) Figures shown in (__) indicate ‘the number of gear teeth. 31) a) ) (a) i 2octa ‘The transmission, integrally coupled to the torque converter, provides a choice of from one forward ratio and one reverse ratio, It has built-in multi-dise clutches, which are hydraulically actuated to control the flow of drive from the converter. The control lever - shift lever = is for operating a hydraulic control valve. Thus this transmission is of a "powershift” type. The transmission housing and torque converter housing ean be separated from each other. The pump, turbine and stator can be removed as one assembled unit from the stator shaft and from the input shaft. The torque converter is of one-piece construction fabricated by welding and is meant to be replaced as one assembled unit. The transmission parts, except for torque ‘converter, clutch valve, the output flange and universal joints, are common to all models. FG(D)IO thru 18 | FG(D)20 they 35A ‘Model 6687 66H8 ‘Type _| _Three-lement, single-stage, two-phase Range Powerflow FFORWARD) a-e de (REVERSE) b “Transmission reduction ratio F B10 (oRwARD) | “ap * “a R 70 (REVERSE) a Th 8POWERSHIFT TRANSMISSION Hydraulic Cireuit 98v02 tds 001 + 51 :Poeds out, sunssaid wo ogo | 0 amssoid yoni | 4 amnssad wey | @ 4 1 :Aypedeo pomioy duind 110 42009 110 0 9407 sunssoud yay Joyanuios enbsoy 7-2POWERSHIFT TRANSMISSION Control @ 3 2o6eus 1 FORWARD-REVERSE lever 4 Clutch (inching) pedal 2 Control valve 5 Bracket (inching) 3. Push rod 6 Clutch valve plunger REMOVAL AND INSTALLATION Removal this, place the torque converter in (1) Remove the engine and transmission as an assembly from the truck. (nore) For removal and installation of the engine and transmission, refer to POWER TRAIN. Drain oil from the transmission housing. (2) Unserew the bolts securing the flexible plate through the access hole in the torque converter housing. (3) Separate the torque converter and transmission from the engine. Installation (1) Couple the torque converter and transmission to the engine. To do the’ transmission housing so that the distance between the end face of the housing end the mating face of flexible plate is 50 to 52 mm [1.97 to 2,05 in] The clearance between the flywheel and flexible plate should be 1 to 5 mm[0.04 to 0.20 in.] when the torque converter is coupled to the engine. If the clearance is zero, it is an indication that the torque converter is improperly coupled to the engine; recouple the converter to the engine properly. (2) Tighten the bolts securing the flexible plate to the flywheel through the access hole in the converter housing. Tighten the bolts in a criss-cross pattern. 73POWERSHIFT TRANSMISSION DISASSEMBLY AND REASSEMBLY ‘Transmission Assembly Disassembly Mount bracket Start by: 1, remove two mount brackets from the transmission housing. 2. remove the brackets (inching) and springs TASequence 1 Troque converter assembly, flexible plate 2 Sender unit, drain plug, gasket 3 Oil level gauge, pipe 4 Air breather 5 Oil pipe, eye joint, gasket 6 Output flange 7 Filter case, magnet strainer 8 Control valve 9 Stator shaft, relief valve, spring, washer, snap ting, O-ring, steel ball 10 Pump body, internal gear, drive gear, oil seal, O-ring 11 Transmission housing, gasket, O-ring, steel ball, plug 12 Ball bearing, idler gear 13 Input shaft assembly (consisting of 14 thru 20) 1) Remove the pump as an assembly including 9 thru 10. 2) Remove the input shaft as an assembly including 14 thru 20, and fisassemble it in the order shown. Suggestions 1. Removing torque converter assembly Remove the torque converter assembly complete with the flexible plate. Prepare @ container to catch the oil that flows out of the converter. POWERSHIFT TRANSMISSION 14 Seal ring, ball bearing, thrust washer 15 FORWARD gear, needle roller bearing, thrust washer 16 Seal ting, ball bearing, thrust washer 17 REVERSE gear, needle roller bearing, thrust washer 18 Snap ring, spring retainer, clutch spring 19 Snap ring, pressure plate,’ plates, friction plates, belleville ‘spring 20 Cluteh piston, ‘seal ring, input shaft 21 Idler shaft, ball bearing, snap ring 22 Output gear, ball bearing 23 Baffle plate 24 Torque converter housing, O-ring, steel ball 75POWERSHIFT TRANSMISSION 2. Removing pump assembly Unserew the pump mounting bolts, and Setew two bolts (special tool) into the M8 X 1.25 holes in the pump body to remove the pump assembly. Be sure to tighten the bolts equally, or the threads. will suffer damage. Use M8 x 1.25 bolts having an effective thread length of 55 mm [2.2 in). ‘Special tool needed Bolt (91268-05100 3. Removing transmission housing bolts After removing the pump assembly, unserew two transmission housing bolts (F1805-10025) from the torque converter housing side. 4. Removing transmission housing Lay the transmission and cluteh assembly with transmission housing down. Unscrew the transmission housing bolts. Fasten a hoist to the transmission housing with slings and eyebolts. Lift the housing, and take up slack in the slings. Under’ this condition, tap the transmission and clutch housing flanges somewhere near the dowel pins and a plastic hammer to separate the transmission housing from the cluteh housing. 5. Removing input shaft ball bearing Using a special tool, remove the ball bearing from the input shaft. Special tool needed Puller 91268-15810 Plate (91268-13820 Bolt F1035-10020 76 Bolt hole mare6. Disassembling input shaft Using a special tool or an arbor press, compress the clutch spring, and remove the snap ring. Special tool needed Piston tool | _ 65409-50010 (wore) 1) Do not attempt to remove steel balls and sealing caps from the transmission housing and torque converter housing. 2) Do not remove the oil seals from the pump body and transmission housing unless they are defective. Inspection after disassembly 1. Input shaft (1) Check the splines for wear or damage. (2) Check the width of each seal ring groove for wear; also check the groove for damage. (B) Check to be sure that oil grooves and passages are open and clean, free from sign of clogging. 2. Check the gears and splines for wear or defects. 3. Cluteh drums (1) Cheek the plate sliding surface for wear or damage. (2) Check the clutch piston sliding surface for wear or damage. POWERSHIFT TRANSMISSION zone Seal ring grooves, 017 rTPOWERSHIFT TRANSMISSION 4, Friction plates and plates (1) Cheek for sign of seizure, uneven contact, warpage or excessive wear. (2) Cheek the splines for wear or damage. Unit: mm fin] 2300.10 Thickarsof | {0.0806 + 0.0039), La B 2.0 (0.08) 365401 Thickness of [A] (0.1437 40.008) a B 3.210.131 5. Cluteh pistons (2) Shake each piston, making sure that the balls move freely in it. When piston {s overhauled and ‘cleaned, serew in the plug until its head gets flush with piston end face, and lock it there by punching. Do not disassemble the piston unless it is defective. (2) Cheek the seal rings and their grooves for wear or damage. 6. Transmission housing Check the seal ring contact surfaces for wear or damage. 7. Magnet stainer Cheek for clogging or breakage. 8. Idler shaft Check the splines for wear or damage. 9. Output flange Check the splines for wear or damage. Also, check the oil seal contact surface for defects. 200119]10. Oil pump (1) Cheek top clearance A between the drive gear and pump body with a feeler gauge. (2) Check side clearance B between the internal gear and drive gear and the pump body with a straight edge and a feeler gauge. (3) Cheek the backlash between the drive gear and internal gear with a feeler gauge. (4 Put the drive gear on the torque converter pump impeller, and check clearanee C between the gear and pump boss. aie mm fin Toy 0.30 to 0.33 A derance || (00118 0 0.0130) AT 0.080 w 0085 2 Ss (oe 2 oan anes 0.150 (0.00591) Gane cea a To © fesend”? |A| —ogo4 0 0.016) eed aL bab wore Gear backlash {0.0039 to 0.0071] Ell 0.30 [0.0118] POWERSHIFT TRANSMISSION 204891 7-9POWERSHIFT TRANSMISSION Reassembly Pump assembly zo1es2 Sequence 1 Stator shaft, relief valve, spring, washer, snap ring 2 Pump body, oil seal Suggestions 1, Installing oil seal Using installer (special tool), install oil seal to the pump body. Special tool needed Installer 91268-05300 the 3 Internal gear, drive gear, O-ring, bolt, washer2. Installing pump When installing the pump, coat the pump body interior, internal gear and drive gear with automatic transmission fluid. 3. Inspection after reassembly Turn the drive gear by hand to make sure the pump gears rotate smoothly. Input shaft assembly POWERSHIFT TRANSMISSION Sequence Input shaft, elutch piston, seal ring 2 Cluteh spring, spring retainer, snap ring 3 Belleville spring, plates, friction plates, pressure ‘plate, snap ring 4 Thrust washer, needle roller bearing, FORWARD gear 5 Thrust washer, ball bearing 6 Thrust washer, needle roller bearing, REVERSE gear 7 Thrust washer, ball bearing, seal ring 8 Seal ring Reassembly of the cluteh spring and plates on the REVERSE gear side is the same as that on the FORWARD gear side. mHPOWERSHIFT TRANSMISSION ‘Suggestions 1, Installing piston assembly When installing the piston assembly to the input shaft, coat the seal ring with automatic transmission fluid. 2. Reassembling input shaft To install the snap ring, compress the clutch spring with piston tool (special tool) or an arbor press. ‘Special tool needed Piston tool [65409-50010 3. Installing plate (1) Make sure that the combination and number of plates are correct. (2) Install the belleville spring with its inside (concave side) facing the piston, (3) Coat the plates and friction plates with automatie transmission fluid when installing them. (4) The frietion plates and the plates should be replaced at the same time. 7-12 200116! | Plate (6) Friction plate (5) Belleville spring (1) Pressure plate @ ald BONY ZA4. Installing FORWARD gear and REVERSE gear Make sure that the oil groove side of thrust washer faces the gear when installed, 5. Installing bearing To install the ball bearing to the input shaft, use installer (special tool). Special tool needed Installer 91268-04100 6. Testing clutch piston After reassembling the input shaft, apply pressure ait to the clutch piston through oil hole on the FORWARD gear side to make sure that the piston works properly. POWERSHIFT TRANSMISSION mooi 203400 FORWARD side REVERSE side FORWARD REVERSE 204837]POWERSHIFT TRANSMISSION Transmission assembly Sequence Torque converter housing, baffle plate Output gear, ball bearing Idler shaft, ball bearing, snap ring Input shaft assembly Idler gear, ball bearing Gasket, O-ring Transmission housing, oil seal Pump assembly, O-ring Gasket, control valve, O-ring Oil pipe, eyebolt, gasket Air breather, oil level gauge, pipe Output flange Magnet strainer, filter case Drain plug, gasket, sender unit Torque converter assemblySuggestions To reassemble, follow the reverse of disassembly sequence. 2. Lay the torque converter housing with its engine side down, 3. Apply grease to the lips of the oil seals of the pump assembly and transmission housing. 4, Coat the input shaft seal ring with automatic transmission fluid. 5. Fasten a hoist to the transmission housing with slings and _eyebolts. Lower the housing onto the torque converter housing by aligning the input shaft with the transmission. 6. Installing pump assembly (2) Ley the transmission housing in a normal position. (2) Drive the input shaft (which has not been inserted into the transmission yet) into position with a copper rod from the torque converter side. (3) Tighten two torque converter housing mounting bolts, (4) Put the O-ring on the pump assembly. Apply grease to the O-ring, and install the pump assembly to the torque converter assembly. Be sure to install the O-ring in the oil inlet port. POWERSHIFT TRANSMISSION 208820|POWERSHIFT TRANSMISSION 7. Installing torque converter (1) Install the torque converter in position by mating the splines of stator shaft and input and by positioning the groove of pump drive gear correctly. (2) Make sure that the distance between the end face of torque converter housing and the mating face of flexible plate is 50 to 52 mm [1.97 to 2.05 in}. (3) Fasten the flexible plate to the torque converter housing with a wire to prevent the torque converter from slipping out of position until the torque converter is coupled to the engine. 8, Filling torque converter with ATF Fill the torque converter after the transmission has been mounted on the truck and the engine is ready to be started. Run the engine at idle speed for a while. Stop the engine and, after having waited 1 minute, check the oil level in the transmission with the oil level gauge in less than 15 minutes. 7-16 $0%052 | 1.97 0 2.05)Control Valve Disassembly POWERSHIFT TRANSMISSION Sequence Solenoid valve Plug, O-ring, strainer Cover, O-ring Accumulator piston, spring Main regulator valve, spring seat, O-ring, ‘main regulator spring, plug wawne Inspection after disassembly () Check oil ways and passages for clogging. (2) Cheek each spool for sign of wear, damage or seizure. (3) Cheek oil seals for damaged lips. (@ Cheek the orifice in the main regulator valve for cleanliness; also check the valve spring for weakness or damage. Clutch valve plunger, valve spring, clutch valve, return spring, slug, stopper pin, O-ring Oil seal Plug, bearing roller, O-ring Accumulator spring seat, pin, O-ring Drain plug, gasket Orifice screw 200220)POWERSHIFT TRANSMISSION Reassembly ‘Sequence Accumulator spring seat, O-ring, pin Plug, O-ring, bearing roller Oil seal ‘Clutch valve plunger, O-ring, stopper pin Clutch valve, valve spring, slug, return spring ‘Main regulator valve, slug, main regulator spring, O-ring, spring seat Start by: thoroughly clean the oil ways and passages in the valve by washing. 7 Accumulator piston, spring 8 Orifice screw 9 O-ring, cover 10 Drain plug, gasket 11 Strainer, O-ring, plug 12. Solenoid valve __JPOWERSHIFT TRANSMISSION INSPECTION AND ADJUSTMENT Testing Hydraulic Pressure 1. Run the engine at idle speed for a while. Stop the engine and, after having waited 1 minute, check’ the oil level in the transmission with the oil level gauge in less than 15 minutes. 2, Warm up until the transmission oil temperature rises (the torque converter oil temperature gauge needle moves into the white zone). 3. Cheek the no-load minimum and maximum speeds of the engine. If the speeds are not correct, make an adjustment by referring to SERVICE MANUAL for the engine. Uni ym Foidwhw 8] FOa0 ti 35a Ebiovtes i | @bs0 ase) Seid | 6s0 ‘so a 650) (650) Rete 600 2600 maximum) 500) 6300) 4. After checking the engine speeds, stop the engine. Raise the front wheels. To do this, jack the front axle housing, or place wood blocks under the outer mast and tilt the mast forward. The front wheels the cluteh pressure rotate when tested. 5. Connect a pressure gauge to a tap for the pressure to be tested. The pressure taps are located es shown, © Torque converter 4 Main pressure © Torgue come rel —_— NX © Lube oil b Clutch pressure d Torque converter outlet pressure saat 7-19POWERSHIFT TRANSMISSION 6. Use the following tools when testing the oil pressure: Tool name Pressure tap Remais Toate wT. [ae Consestor —[wiat3 | stzekono | tread ac “Connecor [ROT 1 64309-17733 | thread ~ i) ° Connestor | oie x 3 3 si26ea2%00 | ted | ~ | ~ ™ 6 kgffem? Gauge S8oSirns [O89 | - | 0 | 0 « 20 kgf/cm? Gauge SioSirris [Gabe | of - | - Tie 64309-17722, o1° ° Connecior Sew [Frm [ol o fo Remarks: The asterisked tools are included in the ‘gauge kit (64309-17701), 7. Start the engine. Move the FORWARD-REVERSE LEVER to the neutral position, and test the main Pressure, torque converter inlet Pressure, torque converter _ outlet Pressure end lube oil pressure. 8, Move the FORWARD-REVERSE LEVER to the FORWARD and REVERSE position, and test the clutch pressure. Unit: kPa Ckgtfem?) (psi) 883 10 1079 2 Main pressure A} @w19 (128 t0 156) 883 10 1079, b Clutch pressure A] @w10) [128 to 156] 196 10 490 @w5) (28 0 71) 147 10 294 5103) (Gi 43) 98 10 147 © Lube oll pressure al dois) [14 0 21) Torque converter inlet pressure S Torque converter In outlet pressure Engine speed: 1500 = 100 rpm 7-20Adjusting Clutch (Inching) Pedal POWERSHIFT TRANSMISSION 206474 The clutch (inching) pedal is interlocked with the brake pedal so that, when this Pedal is depressed, hydraulic pressure acting on the transmission is reduced to zero before the brake is applied to bring the transmission into neutral condition. If this linkage is out of adjustment, the transmission clutch will not disengage or grab, resulting in poor braking, abnormal temperature rise or clutch disk seizure. To adjust the cluteh pedal, proceed as follows: 1. Adjusting the brake (1) Adjust the released height A of the brake pedal to 220 + 3 mm [8.7 +0.1 in.]. (2) Set the master cylinder pushrod length E to 106.6 mm [4.20 in}. Unit: mm fin. FG(D)I0 thra 354, 106.6 {420} E _Pushrod length (3) Adjust and confirm the brake drum to-lining clearance. Do not adjust the Clearance by. setting the pushrod fength. Unit: mm {in} FEO | FED tw 5A Berto | asi 10 02007 lining | coozw009 | oor wos) Stoke forbitke| 35 1061 531089 applica 11.4024] (2.1035) & 7-21POWERSHIFT TRANSMISSION 2. Adjusting the inching pedal Start by: warm up the transmission oil, raise the front wheels, and block the rear wheels (1) Connect a pressure gauge to the clutch pressure tap. @) Adjust the released height A of the inching pedal to 220 mm (8.7 in.) by means of the stopper bolt. Set the clearance B between the inching pedal and brake pedal connecting parts to 9 to 9.5 mm [0.354 to 0.374 in,] for the 1-ton models or 0.1 to 0.5 mm [0.004 to 0.020 in.] for the 2- to 3-ton models. @) Start the engine, and release the brake pedal. Depress the clutch (inching) pedal until the brake starts to be applied (the pedal encounters resistance). Under this condition, make an adjustment by means of the push rod so that the clutch valve plunger stroke (D) is 16.5 mm [0.65 in.] at 0 kgf/cm? hydraulic pressure. (4) Release the clutch (inching) pedal, and ‘make sure that clutch valve plunger stroke (Os 9 t0 9.5 mm [0.354 to 0.374 in.] for the 1-ton models or 6 to 9.5 mm [0.236 to 0.374 in] for the 2- to 3-ton models at 883 to 1079 kPa (9 to 11 kgf/cm?) [128 to 156 psi] read on the pressure gauge. Make an adjustment by means of the inching cable. If the plunger stroke is out of specification, readjust the brake and brake pedal, and repeat the adjustment. + If the plunger stroke is more than 9.6 mm (0.378 in.], the drum-to-lining clearance is too small. If the plunger stroke is less than 8.9 mm {0.350 in.] for the 1-ton models or 5.9 mm {0.232 in] for the 2- to 3-ton models, the drum-to-lining clearance is too large. 7-22 2048194 wa 8k | 838 oo, Cinch ave phnger sete in} agate Unit: mn in] Relesed Regi peal BOTT Clearance between] Fon 31095 Sieh (acting) pan | models | (0384000374 end brake pedal 2-3 0105 comecing pars | fod" (abet 0.020) Ton 31095 uch vave 1035406374) ger Soke ro (0236 6374) Stover aceon aoe at 165 (0.65)Testing Cluteh Valve 1. Connect a pressure gauge to the cluteh pressure tap. 2, Start the engine, FORWARD-REVERSE FORWARD position. and move the lever to the Depress the clutch (inching) pedal. Gradually pull out the clutch valve plunger from its fully pushed position, fand plot the hydraulic pressure curve relative to the clutch valve plunger stroke. Make sure that the plotted pressure curve coincides with the curve shown. Testing Stall Speed 1. Check to make sure that the transmission oil level is correct. See the topic, 1. Testing hydraulie pressure.) 2. Warm up until the transmission oil temperature reaches 40°C to 60°C (104°F to 140°F] (the torque converter oil temperature gauge needle moves into the green zone). 3. Block the front and rear wheels, and apply the parking brake. 4. Cheek the no-load maximum speed of the engine. 5. Run the engine at le speed. 6. Move the FORWARD-REVERSE lever to the FORWARD position. Gradually depress the accelerator pedal all the way by the right foot. Under this condition, read the stall speed with an electric or stroboscopic tachometer. (nore) Do not depress the clutch (inching) pedal. Also, do not allow the engine to keep on running at the highest speed attained or the torque converter may suffer damage. Stall- speed running of the engine should be limited to 30 seconds. POWERSHIFT TRANSMISSION ——_—_—_—_—<_<_< $$ on (io, tay sat & Pathan Gch 3) to 02 | oa (Cuch valve planger sok, Fin] 2ocsss 7-23POWERSHIFT TRANSMISSION 7. Similarly read the stall speed for reverse drive. FGIO thru 18 |FG20 and 25] FG30 and 354] (FD10 thru 18) |“ (FD20 thru 35a) Sallspeed Sul speed | 1370 v1 | ism Gegamee:| asa (20095) (nore) The stall speed is determined on the basis of a combination of the engine and torque converter. It will vary if the engine or torque converter is changed. 10-m [33-ft] Starting Acceleration Test 1, Stand ready to start with the engine idling and the FORWARD-REVERSE lever in the neutral position. 2. At the signal, shift into forward and, at the ‘same time, depress the accelerator pedal all the way. 3. Measure the amount of time that the truck elapses to travel 10 meters (33 feet) by using a watch. 4. Measure for reverse, too. “Time required for 10 m (33 ft] | 5 seconds, travel (n0 load) maximum 7-24