REMOVING OUTPUT FLANGE OR YOKE

3–3. UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE

W ARNING: Chock wheels prevent vehicle from moving when driveline is disconnected. This is not necessary if vehicle is a lift jackstands.

Disconnect the vehicle drive shaft from the transmission output flange yoke. Position the disconnected shaft avoid interference when removing the transmission.

PT O equipped, disconnect PT O connections such as:

PT O hydraulic hoses

PT Opowered equipment drive shaft transmission mountings support the rear the engine, place a jack other support under the engine. Securely support the transmission with a hoist, jack, other suitable removal equipment.

NOTE: may necessary remove engine flywheel housing access cover remove flexplate flexplate adapter bolts. This is the engine transmission connection.

Remove all bolts, nuts, washers, spacers, and supports that attach the transmission the vehicle and the engine.

3–4. REMOVING THE TRANSMISSION

CAUTION: not pull the transmission away from the torque converter assembly . The torque converter drive cover must entirely free any restraint the flexplate drive crankshaft pilot when the transmission separates from the engine.

W ARNING: Be sure the torque converter is moving rearward with the transmission it is removed. not allow the torque converter become disengaged from the oil pump fall completely out the transmission causing damage and/or personal injury .

Move the transmission away from the engine, approximately 34.6 (1.36 inch) for a number 2 flywheel housing 44.2 (1.74 inch) for a number 3 flywheel housing, until it is completely clear the engine. used, remove the adapter ring and/or gasket.

Raise lower the transmission necessary remove it from the vehicle.

3–5. REMOVING THE FLEXPLA ADAPTER

Remove the flexplate adapter , if present, from the front the torque converter . This part will needed for transfer if a replacement transmission is being installed.

W ARNING: Handle the transmission carefully whenever the torque converter retaining bracket is not present. NEVER tilt the converter end down the torque converter can slide forward, disengaging the oil pump, can fall completely out the transmission causing damage and/or personal injury .

Attach a torque converter retaining bracket the earliest opportunity . The bracket keeps the torque converter from sliding out engagement with the oil pump from falling f completely and being damaged causing personal injury .

3–6. REMOVING OUTPUT FLANGE YOKE

replacing the transmission, you may need transfer the output flange yoke the replacement transmission. The output flange yoke is retained one 1/2 20 x 23/4 inch flangedhead bolt.

TRANSMISSION PREP ARA TION Section

4–1. CHECKING INPUT COMPONENTS

Bolt Holes. Check all bolt holes the front the transmission and rear the engine that are used in connecting the transmission the engine. The threads must undamaged and the holes free chips foreign material.

Pilot Boss. Check the pilot boss (at the center the flywheel) for damage raised metal that prevents free entry into the crankshaft hub (or adapter).

Starter Ring Gear . Check the starter ring gear for excessive wear damage.

T ransmission Mounting Flange. Check the transmission mounting flange for raised metal, dirt, if used, pieces gasket material.

T ransmissiontoEngine Mounting. Inspect the transmissiontoengine mounting flange for raised metal, burrs, pieces gasket material (if used). Remove any these defects. Inspect the threaded holes for damaged threads.

4–2. INST ALLING OUTPUT FLANGE YOKE

Output Oil Seal. Check the output oil seal for leaks damage. Refer

GN4008EN, InChassis Maintenance, for replacement instructions. not replacing the oil seal, lubricate it with hightemperature grease transmission fluid.

CAUTION: NOT attempt polish the oil seal contact surface the flange yoke. Scratches machinetype lead can cause the seal leak.

Check Flange Y oke. Check each flange yoke for damage wear . The oil seal contact surface must smooth and regular prevent oil leaking past the seal. Rotate the flange after installation check for binding.

Install Output Flange Y oke.

CAUTION: Be sure that the flange, output shaft and retaining hardware are clean. Care must exercised avoid transmission output seal journal damage. Check verify that the seal is free tears and cuts. Nicks and scratches must not exist the leadin chamfer seal journal section the output flange yoke.

Lubricate the splines the output shaft and the oil seal assembly with transmission fluid oilsoluble grease.

CAUTION: not use a hammer other similar tool force the flange/yoke onto the shaft. Forcing the flange/yoke onto the shaft may result in transmission damage.

Start the yoke/flange assembly onto the output shaft, ensuring that the splines are properly engaged and slide freely . Push the yoke/flange assembly into the rear cover module. Install a new output shaft sealing washer and the output shaft bolt.

CAUTION: Use impact wrench requires the retention the yoke/flange prevent internal transmission damage.

Tighten the output shaft bolt 108–136

N∙m (80–100 lb ft). Rotate the yoke/flange assembly hand check for binding, interference, and runout.

4–3. INST ALLING PT O

Access the PT O mounting pads and the space available maneuver the transmission determine whether the PT O should installed before after the transmission is installed.

CAUTION: NOT use cork other soft gaskets install the PT Use only the shims/gaskets listed in the Sales T ech Data Book the Allison Extranet.

NOTE: NOT use sealing compounds—they are usually incompatible with automatic transmission fluid.

Install Guide Pins. Guide pins are included in the PT O manufacturers installation kit. Determine the required position the guide pins in relation the mounted position the PT Install two headless guide pins into the main housing PT O pad. Tighten the pins.

Install Gasket. Install the special gasket over the guide pins—ribbed surface away from the transmission.

Mount the PT

CAUTION: M10 bolts must used attach the PT O the transmission. Inch series threads (0.37516 UNC) will damage the transmission main housing.

Mount the PT O the guide pins studs provided in the PT O kit. Mesh the PT Odriven gear with the transmission PT O drive gear . Retain the PT O installing a bolt in the top bolt hole. Install the remaining bolts and nuts, if used. When nuts are not used, two bolts replace the guide pins. Tighten all bolts 57–68 N∙m (42–50 lb ft). Tighten nuts manufacturers specifications. Be sure that the PT O backlash meets manufacturers requirements.

Connect PT O Lube, required.

Some PT require pressure lubrication. When needed, tap into the cooler return fitting line the transmission converter housing (refer Figure 4–1

NOTE: is not acceptable use the transmission main pressure for PT O lubrication. There is only one acceptable use transmission main pressure for accessories—that being control engagement the PT O clutch. This practice is permitted for this function only because there is flow (the fluid is deadheaded).

An orifice 0.81 (0.032 inch) must present in the line control the amount fluid diverted from the transmission. Some PT O assemblies contain internal restrictions equivalent the required orifice (check with the PT O manufacturer for lubrication needs and the orifice installation). This connection can made later if the lube line will interfere with transmission installation. Refer Figure 4–2 which shows this connection schematically .