Case L-Series Loader Backhoe Transmission Update Kits Installation Instructions Manual 7-54022 - PDF

1

INSTRUCTIONS FOR INSTALLING TRANSMISSION UPDATE KITS ON L-SERIES LOADER/BACKHOES PARTS LIST - Kit 256888A3 TRANSMISSION UPDATE/SHIFT IMPROVEMENT KIT REF

PART NO.

DESCRIPTION

QTY

1 2 3 4 5 6 7

181155A2 190427A1 181245A2 181174A2 244109A1 905794R1 278531A1

PISTON - forward and reverse .......

SYNCRO. - 3rd/4th ........................

RAIL - shift - 3rd/4th.......................

FORK - shift - 3rd/4th .....................

SPACER - synchronizers ...............

PIN - fork and rail ..........................

WASHER - thrust, 2nd shaft ..........

2 1 1 1 2 2 1

REF

PART NO.

DESCRIPTION

QTY

8 9 10 11 12 13 14

190428A3 279039A1 1967585C1 1967581C1 190436A1 278532A1 278533A1

LEVER - shift ................................

RING - snap, shift lever .................

PIN - shift lever .............................

BOOT - rubber, shift lever ..............

SPRING - modulator, small ...........

BUSHING .....................................

SPRING ........................................

1 1 2 1 1 1 1

PARTS LIST - Kit 278302A2 TRANSMISSION OVERHAUL KIT - 2WD REF

PART NO.

DESCRIPTION

QTY

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

100748A1 181141A1 181138A1 181144A1 181136A1 181137A1 279039A1 A48041 181111A1 181118A1 181114A1 181116A1 299324A1 1966993C1 190435A1 190441A1 181262A1 181261A1 181260A1 181166A1 181208A1 181256A1 181108A1

O-RING - oil filter sealing .............. 1 O-RING - housing ......................... 3 O-RING - shifter sealing ................ 1 O-RING - yoke, secondary shaft .... 1 O-RING - valve ............................. 4 O-RING - plug, valve, plunger ........ 3 RING - snap, shift lever ................. 1 RING - snap, primary/input shaft ... 3 RING - snap, clutch spring ............ 2 RING - snap, secondary shaft ....... 1 RING - snap, secondary shaft ....... 6 RING - snap, clutch backing plate . 2 RING - snap, valve ........................ 2 SPRING - detent, rail .................... 2 SPRING - inner, valve ................... 1 SPRING - outer, valve ................... 1 SPRING - spool, valve .................. 2 SPRING - check, valve .................. 1 SPRING - piston, valve ................. 1 GASKET - control valve to plate .... 1 GASKET - plate to trans. housing .. 1 GASKET - cover, valve .................. 2 PIN - roll, input/secondary shaft ... 7*

REF

PART NO.

DESCRIPTION

QTY

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

181132A1 864-10025 181123A1 181177A1 P3533055 181164A1 181253A1 181152A3 181157A3 181156A3 181154A1 181163A1 181193A1 934667R1 181105A1 1966835C1 181104A1 181165A1 181273A1 181107A1 B93654 N/A 905794R1

BEARING - roller, primary shaft ....

BOLT - socket, rail detent balls ......

SEAL - lip, secondary shaft ...........

CLAMP - rubber boot ....................

BOLT - output yoke ......................

SPACER - bearing, input shaft .......

SPACER - spring, valve .................

RING - seal, oil, input shaft ...........

RING - seal, piston, large ..............

RING - seal, piston, small ..............

WASHER - thrust, primary/input ....

WASHER - thrust, input shaft ........

WASHER - thrust, secondary shaft WASHER - copper, housing plug ...

WASHER - copper, oil lube tube ....

WASHER - rail detent spring .........

WASHER - copper, shift rails .........

WASHER - output yoke .................

WASHER - copper, valve ...............

WASHER - copper, valve ...............

LOCTITE - 518 or 529/539 ............

LOCTITE - 542 or super bond 321 PIN - roll, shift fork/rail ..................

2 2 1 1 1 1 2 4 2 2 4 2 1 8 4 3 4 1 1 1 1 1 4

* Two (2) extra roll pins are included in case of loss.

Bur 7-54022 Copyright © 1997 Case Corporation

Printed in U.S.A. Issued October, 1997

2 PARTS LIST - Kit 278836A2 TRANSMISSION OVERHAUL KIT - 4WD REF

PART NO.

DESCRIPTION

QTY

REF

PART NO.

DESCRIPTION

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92

100748A1 181141A1 181138A1 181144A1 181136A1 181137A1 279039A1 A48041 181111A1 181118A1 181114A1 181116A1 299324A1 1966993C1 190435A1 190441A1 181262A1 181261A1 181260A1 181166A1 181208A1 181256A1 181108A1 181132A1 864-10025 181123A1 181177A1 P3533055 181164A1 181253A1 181152A3 181157A3

O-RING - oil filter sealing ............... 1 O-RING - housing .......................... 3 O-RING - shifter sealing ................ 1 O-RING - yoke, secondary shaft .... 1 O-RING - valve .............................. 4 O-RING - plug, valve, plunger ......... 3 RING - snap, shift lever .................. 1 RING - snap, primary/input shaft .... 3 RING - snap, clutch spring ............. 2 RING - snap, secondary shaft ........ 1 RING - snap, secondary shaft ........ 6 RING - snap, clutch backing plate .. 2 RING - snap, valve ........................ 2 SPRING - detent, rail ..................... 2 SPRING - inner, valve .................... 1 SPRING - outer, valve ................... 1 SPRING - spool, valve ................... 2 SPRING - check, valve .................. 1 SPRING - piston, valve .................. 1 GASKET - control valve to plate ..... 1 GASKET - plate to trans. housing .. 1 GASKET - cover, valve .................. 2 PIN - roll, input/secondary shaft ... 7* BEARING - roller, primary shaft ..... 2 BOLT - socket, rail detent balls ...... 2 SEAL - lip, secondary shaft ........... 1 CLAMP - rubber boot ..................... 1 BOLT - output yoke ....................... 1 SPACER - bearing, input shaft ....... 1 SPACER - spring, valve ................. 2 RING - seal, oil, input shaft ............ 4 RING - seal, piston, large .............. 2

93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124

181156A3 181154A1 181163A1 181193A1 934667R1 181105A1 1966835C1 181104A1 181165A1 181273A1 181107A1 B93654 N/A 100753A1 181120A1 190430A1 181152A3 112517A1 100747A1 100748A1 238-8217 181141A1 190426A1 181154A1 181276A1 P2745466 934667R1 181274A1 P3533055 181122A1 181149A1 905794R1

RING - seal, piston, small .............

WASHER - thrust, primary/input ...

WASHER - thrust, input shaft ........

WASHER - thrust, secondary shaft WASHER - copper, housing plug ..

WASHER - copper, oil lube tube ...

WASHER - rail detent spring .........

WASHER - copper, shift rails ........

WASHER - output yoke .................

WASHER - copper, valve ..............

WASHER - copper, valve ..............

LOCTITE - 518 or 529/539 ............

LOCTITE - 542 or super bond 321 SPRING - MFD sleeve ..................

RING - snap, MFD shaft ...............

GASKET - MFD valve to housing ..

RING - seal, oil, MFD bushing ......

O-RING - cover, MFD shaft ...........

O-RING - MFD shaft, large ...........

O-RING - MFD shaft, small ...........

O-RING - output yoke, MFD ..........

O-RING - bypass valve .................

O-RING - bypass valve .................

WASHER - thrust, MFD shaft ........

WASHER - spring retaining, MFD .

WASHER - output yoke, MFD .......

WASHER - copper, MFD valve ......

VALVE KIT - 4WD only, oil filter .....

BOLT - output yoke .......................

SEAL - oil, MFD shaft ...................

SEAL KIT - solenoid, MFD valve ...

PIN- roll, shift fork/rail ...................

QTY 2 4 2 1 8 4 3 4 1 1 1 1 1 6 1 1 2 1 1 1 1 1 2 1 1 1 2 1 1 1 1 4

* Two (2) extra roll pins are included in case of loss.

Bur 7-54022

Issued 10-97

Printed in U.S.A

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TABLE OF CONTENTS Specifications ............................................................................................................................................................. 3 Special Torques .......................................................................................................................................................... 4 Special Tools .............................................................................................................................................................. 5 Disassembly of the Transmission Housing ....................................................................................................................... 6 Disassembly of the Input Shaft .................................................................................................................................... 25 Inspection of the Input Shaft ........................................................................................................................................ 36 Assembly of the Input Shaft ......................................................................................................................................... 37 Disassembly of the Secondary Shaft ............................................................................................................................. 47 Inspection of the Secondary Shaft ................................................................................................................................ 54 Assembly of the Secondary Shaft ................................................................................................................................. 55 Disassembly of the Primary Shaft ................................................................................................................................. 64 Inspection of the Primary Shaft .................................................................................................................................... 66 Assembly of the Primary Shaft ..................................................................................................................................... 67 Disassembly, Inspection, And Assembly of the Reverse Shaft .......................................................................................... 69 Disassembly ......................................................................................................................................................... 69 Inspection ............................................................................................................................................................. 69 Assembly .............................................................................................................................................................. 69 Shift Rods And Shift Forks .......................................................................................................................................... 71 Disassembly of the Oil Pump ....................................................................................................................................... 73 Inspection of the Oil Pump .......................................................................................................................................... 77 Assembly of the Oil Pump ........................................................................................................................................... 78 Disassembly of the Four-wheel Drive Shaft .................................................................................................................... 81 Inspection of the Four-wheel Drive Shaft ....................................................................................................................... 84 Assembly of the Four-wheel Drive Shaft ........................................................................................................................ 84 Disassembly of the Shifter Housing .............................................................................................................................. 86 Assembly of the Shifter Housing .................................................................................................................................. 89 Disassembly of the Four-wheel Drive Valve (If Equipped) ................................................................................................. 91 Assembly of the Four-wheel Drive Valve (If Equipped) ..................................................................................................... 93 Disassembly of the Transmission Control Valve .............................................................................................................. 95 Inspection of the Transmission Control Valve ................................................................................................................ 103 Assembly of the Transmission Control Valve ................................................................................................................. 104 Assembly of the Transmission Housing ........................................................................................................................ 111

SPECIFICATIONS Type of transmission oil ....................................................................................................................................... Case Hy-Tran Plus Capacities Two-wheel drive Total system ............................................................................................................................... 19.5 U.S. quarts (18.5 litres) Refill capacity with or without filter change .................................................................................. 16.9 U.S. quarts (16.0 litres) Four-wheel drive Total system .................................................................................................................................. 22 U.S. quarts (21.0 litres) Refill capacity with or without filter change .................................................................................. 19.5 U.S. quarts (18.5 litres) Clutch disc clearance (See step 188) ............................................................................................ 0.09 to 0.17 inch (2.3 to 4.3 mm)

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SPECIAL TORQUES Pipe plug in end of four-wheel drive shaft ................................................................................................ 266 pound-inches (30 Nm) Solenoid valve in four-wheel drive valve .................................................................................................. 195 pound-inches (22 Nm) Nut for solenoid coils on transmission control valve .............................................................................. 156 pound-inches (17.6 Nm) Fittings for four-wheel drive clutch tube ................................................................................................... 354 pound-inches (40 Nm) Allen head screws for valve plate on front housing .................................................................................. 204 pound-inches (23 Nm) Test port plugs ........................................................................................................................................ 204 pound-inches (23 Nm) Detent plugs ................................................................................................................................................. 59 pound-feet (80 Nm) Allen head screws for plate on rear housing .................................................................................................. 37 pound-feet (50 Nm) Cap screws for rear cover ............................................................................................................................. 37 pound-feet (50 Nm) Cap screw for output flange ....................................................................................................................... 103 pound-feet (139 Nm) Allen head screws for shifter assembly .................................................................................................... 204 pound-inches (23 Nm) Hollow cap screws for tube on front housing ........................................................................................... 354 pound-inches (40 Nm) Cap screws to fasten front and rear housings ................................................................................................ 37 pound-feet (50 Nm) Cap screws to fasten cover below four-wheel drive flange ....................................................................... 204 pound-inches (23 Nm) Cap screw for four-wheel drive flange ........................................................................................................ 103 pound-feet (139 Nm) Cap screws for oil pump .......................................................................................................................... 204 pound-inches (23 Nm) Fitting for oil filter .......................................................................................................................................... 37 pound-feet (50 Nm) Cap screws to fasten four-wheel drive valve to front housing ................................................................... 204 pound-inches (23 Nm) Cap screws to fasten cover for oil screen ................................................................................................ 204 pound-inches (23 Nm) Cap screws for transmission control valve ............................................................................................... 204 pound-inches (23 Nm) Drain plug ..................................................................................................................................................... 59 pound-feet (80 Nm) Allen head screws to fasten pump support to pump housing ..................................................................... 89 pound-inches (10 Nm) Nut for four-wheel drive solenoid coil ........................................................................................................... 71 pound-inches (8 Nm) Allen head screws for modulation cover .................................................................................................... 97 pound-inches (11 Nm) Solenoid plunger in transmission control valve ........................................................................................ 204 pound-inches (23 Nm)

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SPECIAL TOOLS

BP95F658 CAS-2379 Input Shaft Holder and Spring Compressor

BP95F659 CAS-2378 Transmission Leg Set. Maybe necessary to hold transmission dur ing repairs (depending on design of transmission stand). Not shown in use in these instructions.

BP95F661 CAS-2381 Seal Driver

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DISASSEMBLY OF THE TRANSMISSION HOUSING NOTE: Parts can be replaced individually for the transmission in which Kit 256888A3 has already been installed.

STEP 3

NOTE: If the transmission has already been updated (U3 stamped on the plate) and is to be overhauled for general service, the references to the update kit in the procedures should be ignored.

NOTE: There has been different revisions to these overhaul kits. Early revisions have only two O-rings (item 20 or 66), four copper washers (item 51 or 97), and no roll pins (item 60 or 124). If you have an early overhaul kit, reuse the existing parts as necessary.

BP95F007 Remove the drain plug and drain the oil from the transmission, if this was not done prior to removal.

STEP 1 Remove the transmission and torque converter from the tractor as a unit. Once the transmission has been removed from the tractor, carefully remove the torque converter from the transmission charge pump. Examine the drive hub of the torque converter. If any damage is apparent to the drive tangs or the diameter of the hub, the torque converter should be replaced and the charge pump should be disassembled and inspected carefully (see steps 311 through 344).

Examine the guide button on the crankshaft end of the torque converter. If the button shows any evidence of being bent, distorted, or worn on one side, the torque converter was not properly aligned with the crankshaft before being bolted to the flexplate-starter ring support (flywheel). Discard and replace the torque converter if any of these conditions are apparent. Also check the guide hole in the end of the crankshaft for damage from this condition. May be repaired with an abrasive cloth or a file if damage is miner. Replace if damage is excessive.

NOTE: The four-wheel drive transmission is shown. On two-wheel drive transmissions, the drain plug is at the rear of the transmission.

STEP 4 Examine the drain plug closely. If excessive iron and steel particles are present, it is possible the transmission charge pump is failing. If excessive bronze particles are apparent in the oil, the synchronizers my be worn. If the magnet is loose or missing, replace the drain plug.

STEP 5

STEP 2

BP95F013 Remove the cap screws which fasten the transmission control valve to the front housing.

BP95F004 Fasten the rear housing to acceptable support equipment. It is recommended that you use equipment that will let you rotate the transmission.

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STEP 6

STEP 10

BP95F369

BP95F014 Remove the transmission control valve.

Remove the valve plate from the front housing.

STEP 7

STEP 11

BP95F371

BP95F015 Remove the gasket.

Remove the gasket.

STEP 8

STEP 12

Remove the valve adaptor plate and gasket.

STEP 9

BP95F008 Remove the two cap screws which fasten the cover for the oil screen. Remove the cover.

BP95F370 Remove the three Allen head screws which fasten the valve plate to the front housing.

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STEP 13

STEP 16

BP95F009 Remove the oil screen and the O-ring. Discard the O-ring.

BP95F010 Use a prybar to remove the bolt along with the spool and the O-ring. Discard the O-ring.

STEP 14 STEP 17 Examine the oil screen and magnetic cover closely. If excessive iron and steel particles are present, it is possible that the transmission charge pump is failing. If excessive bronze particles are present, the synchronizers may be worn.

If the magnet is loose or missing from the screen cover, replace the cover.

NOTE: A new design suction screen (part no.

278534A1) is available from NAPO. The pleated construction of the new suction screen provides more surface area and less restriction during star t-up and cold weather operation. The new suction screen is not included in the update kit and replacement is optional (unless the original suction screen is damaged).

NOTE: Steps 15 through 21 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 22.

BP95F011 Install an M10 - 1.5 x 80 mm bolt in the sleeve in the same hole.

STEP 18

STEP 15

BP95F012 BP95F003 Install an M8 - 1.25 x 30 mm bolt in the end of the spool above the bore for the oil screen.

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Use a prybar to remove the bolt along with the sleeve and the two O-rings. Remove the O-rings and discard. New O-rings are provided in the overhaul kit for both sleeves.

Issued 10-97

Printed in U.S.A.

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STEP 19

STEP 22

BP95F016

BP95F019

Remove the three cap screws which fasten the four-wheel drive valve to the front housing. A copper washer is included in th eoverhaul kit and can be used if necessary.

Remove and discard the oil filter. The filter should never be reused dur ing a transmission rebuild. Be sure to use replacement filter 254686A1 (not included in the kits).

STEP 20

STEP 23

BP95F017 Remove the four-wheel drive valve and set aside. Rebuilding the four-wheel drive valve will be covered in later steps.

BP95F020 Remove the fitting for the oil filter.

NOTE: Steps 24 through 27 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 28.

STEP 21

STEP 24

BP95F018 Remove and discard the gasket. A new gasket is provided in the overhaul kit.

BP95F021 Remove the spool.

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STEP 25

STEP 27 1 2 1

BP95F022 Remove the spring.

BP95F024 DO NOT remove the two plugs (1) unless the plugs (1) are leaking. The plugs (1) are sealed with Loctite 262 (red) and are difficult to remove. If removal is necessary, clean all oil from the threads and apply Loctite 262 (red) before installation. Some transmissions have an 6 mm diameter orifice plug installed in the hole (2) in the face of the filter base. This orifice plug is not needed. If your transmission has this orifice plug, remove and discard the orifice plug. To remove the plug, heat the area around the plug to release the Loctite and use a 7 mm hex wrench to remove.

STEP 26

STEP 28 BP95F023 Use a blind hole puller to remove the four-wheel drive priority valve. Discard both spools and the spring (steps 24, 25, and 26). A replacement kit containing these parts is provided in the overhaul kit.

NOTE: The replacement four-wheel drive priority valve was adjusted at the factory. DO NOT try to disassemble or adjust the bolt and lock nut on the end of the spool.

BP95F025 Remove the dipstick.

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STEP 29

STEP 31

BP95F026

BP95F031

Remove the dipstick tube only if damaged or if necessary to reposition on the transmission.

Install two cap screws in the four-wheel drive flange as shown.

STEP 30

STEP 32

BP95F027 If you remove the dipstick tube, replace the O-ring for the tube. The O-ring is not included in the overhaul kit.

NOTE: Steps 31 through 38 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 39.

BP95F030 Use a prybar between the two cap screws and against the front housing to hold the four-wheel drive flange while you remove the cap screw from the four-wheel drive shaft.

STEP 33

NOTE: It is NOT necessary to reposition the transmission (as shown) for steps 31 through 45. These steps can be done easily with the transmission positioned horizontally. This minimizes the number of times that you have to reposition the transmission on the stand.

BP95F032 Remove the washer.

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STEP 34

STEP 37

BP95F033 Remove the four-wheel drive flange and the O-ring. Discard the cap screw, washer, and O-ring.

BP95F351 Remove and discard the O-ring from the cover.

STEP 38 STEP 35

BP95F350 BP95F034 Remove the three cap screws which fasten the cover to the front housing.

Remove and discard the lip seal from the cover.

STEP 39

STEP 36

BP95F037 BP95F035 Remove the cover.

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Make a mark across the joint between the oil pump and the torque converter housing so that the oil pump can be aligned the same way during installation.

Issued 10-97

Printed in U.S.A.

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STEP 40

STEP 43 Examine the front cover of the oil pump. If it is the latest design, 181199A4, it will have triangular ribs supporting the center hub and an embossed round Carraro symbol between two of the ribs. Earlier pumps had flat ribs and no embossed symbol (see diagrams on page 22).

If the pump is not the latest design, it should be discarded and replaced with a new 181199A4 pump during reassembly of the transmission. If the pump is 181199A4, set it aside for disassembly and inspection later (see steps 311 through 330).

BP95F038

Remove the six cap screws which fasten the oil pump in position.

STEP 41

NOTE: If the oil pump failed and is the reason for the removal and rebuild of the transmission, it will be necessary to replace the oil cooler and torque conver ter also as they may be contaminated with metal particles that could damage a new oil pump and rebuilt transmission. These parts must be ordered separately from NAPO.

STEP 44

BP95F039 Use two prybars to lift the oil pump evenly until the oil pump can be removed.

BP95F041

STEP 42

Pull up the input shaft to get clearance as you release the snap ring.

STEP 45

BP95F040 Remove the oil pump.

BP95F042 Remove the snap ring and set aside. It will be reused later.

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STEP 46

STEP 49

BP95F048 Remove the three Allen head screws which fasten the shifter housing to the rear cover.

BP95F051 Use a prybar between the two cap screws and against the rear housing to hold the output flange while you remove the cap screw from the secondary shaft.

STEP 47 STEP 50

BP95F049 Remove the shifter assembly and the O-ring. Discard the Oring. Set the shifter assembly aside. The shifter assembly will be rebuilt with new parts in steps 362 through 377.

BP95F052 Remove the washer.

STEP 51 STEP 48

BP95F053 BP95F050

Remove the output flange.

Install two cap screws in the output flange as shown.

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STEP 52

STEP 55

BP95F054 Remove the O-ring from the output flange. Discard the cap screw, washer, and O-ring (steps 49, 50, and 52).

BP95F367 Remove and discard the seal from the rear cover.

STEP 56 STEP 53

BP95F057 BP95F055 Remove the seven cap screws which fasten the rear cover to the rear housing.

Use a punch to carefully remove the pins which fasten the shift collars to the shift rods. The shift collar and pins will be reused. New roll pins are included in the overhaul kits.

STEP 54

STEP 57

BP95F056 Use a prybar to loosen the rear cover from the rear housing.

Remove the rear cover. Place the prybar into the appropriate slots. DO NOT pry directly on machined seal surfaces.

Examine the dowel and hole at the top of the rear cover for damage. If damage is apparent, replace the dowel and cover as necessary.

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BP95F058 Remove the shift collars from the shift rods.

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STEP 58

STEP 61

BP95F059 Remove the two Allen head screws which hold the plate between the two shift rods. The Allen head screws will be replaced by new screws provided in the overhaul kit.

BP95F061 Remove one of the detent plugs from the right-hand side of the rear housing.

STEP 62 STEP 59

BP95F063 BP95F060

Remove the detent spring.

Remove the plate and set aside. it will be reused.

STEP 63 STEP 60

BP95G005 BP95F062 Remove the two detent balls from the groove between the two shift rods.

Remove the detent ball.

STEP 64 Repeat steps 61 through 63 to remove the other detent plug, spring, and ball. Set the balls aside. They will be reused.

Discard the springs. They will be replaced by new springs provided in the overhaul kit.

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STEP 65

STEP 67

BP95F064 Pull the secondary shaft to the rear so that there is clearance between the snap ring and the rear housing. Remove the snap ring carefully. This snap ring will be reused so do not expand excessively.

NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you remove the secondary shaft from the rear housing. To prevent this, you can install a hose clamp on the output end of the secondary shaft. This will keep the bearing in position during removal of the secondary shaft.

BP95F028 Remove all of the housing cap screws that are fastened from the rear housing to the front housing. There are 13 of these cap screws on the four-wheel drive and 14 on the two-wheel drive. On the two-wheel drive, two of the cap screws are longer than the others. Record the locations of these two.

STEP 68

STEP 66

BP95F029 Rotate the transmission so that the front housing is up. On four-wheel drive transmissions only, there are three cap screws fastened from the front housing to the rear housing.

Remove these cap screws.

BP95F065 Pull the primary shaft to the rear so that there is clearance between the snap ring and the rear housing. Remove the snap ring. This snap ring will also be reused.

NOTE: The large snap rings removed in steps 65 and 66 are not included in the overhaul kit. They will be reused when reassembling the transmission.

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STEP 69

STEP 71

BP95F043 Fasten acceptable lifting equipment to the front housing as shown. Use prybars at both ends of the housings to separate the front housing from the rear housing. Use the prybars at the provided slots. DO NOT pry against the machined sealing surfaces.

BP95F045 On machines with four-wheel drive, the collar can stay with either the four-wheel drive shaft or the front housing. Remove the collar.

STEP 72- 4WD only

STEP 70

BP95F354 BP95F044 As you lift the front housing, continue to use the prybar to make sure that the front housing comes up evenly. Also, it will probably be necessary to hit the end of the four-wheel drive shaft, if so equipped, and the end of the input shaft with a soft hammer so that the two shafts come down out of the front housing and stay with the rear housing.

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Remove and discard the two sealing rings from the collar.

New sealing rings are provided in the Overhaul Kit. Check the bore for the collar in the front cover. If grooves were worn by the sealing rings, replace the front cover.

NOTE: The bearings in steps 73 and 74 are a close slip fit. If a bearing is difficult to remove, the bearing is probably not straight in the bore or on the shaft. Push the bearing back into the installed position and try again.

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Printed in U.S.A.

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STEP 73

STEP 75

BP96J001

BP95F046 The bearing for the primary shaft and the bearing for the secondary shaft can stay with either the shafts or the front housing. Remove the two bearings. The inner races for these two roller bearings will remain on their respective shafts.

These bearings should be discarded. The bearings will be replaced, complete with new inner races, by new bearings provided in the overhaul kit.

Check for the bearing cavity drain hole in the upper rear corner of the bearing bore. The hole should be 20 mm long (centered @ 12 o’clock) and 7 mm high measured on the back wall of the cavity. Rework as necessary. Absence of this drain hole can result in recurrent oil leakage past the four wheel drive output flange seal.

STEP 76 STEP 74

BP95F373 BP95F047 On machines with four-wheel drive, remove the four-wheel drive shaft bearing from the front housing.

Remove the tube from the front housing. Discard the four copper washers. Examine the brazed welds at the bango fittings for oil and flaking paint. If apparent, replace the tube.

STEP 77

BP95F081 Remove and discard the three O-rings from the flange of the rear housing and install foam ear plugs in the holes.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

20

STEP 78

STEP 81

BP95F082 On machines with four-wheel drive, remove the four-wheel drive shaft. (See steps 345 through 361 for disassembly, inspection, and reassembly).

BP95F066 Connect acceptable lifting equipment to the top gear on the secondary shaft.

STEP 82 STEP 79 Mark the top end of the reverse idler shaft so it can be reassembled in the same orientation (the reverse idler shaft is symmetrical end for end).

STEP 80

BP95F067

BP95F083 Remove the input shaft and the reverse shaft together.

Bur 7-54022

Use the lifting equipment to begin lifting the secondary shaft while you use your hands to lift the primary shaft. At the same time, move the primary shaft back and forth to keep the primary shaft moving freely. It can be necessary to tap the ends of the shift rods (from below the rear housing) so that the shift rod and fork assemblies continue to move freely.

When the primary shaft is free of the rear housing and the secondary shaft, remove the primary shaft and set aside.

Issued 10-97

Printed in U.S.A.

21

STEP 83

Remove the shift rod and fork assembly for third and fourth gear from the rear housing. Remember that this assembly was installed in the bore nearer the top of the rear housing.

This assembly will be discarded and replaced by new parts in the update kit. If transmission has been updated, this assembly can be reused.

NOTE: Steps 86 through 88 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 89.

STEP 86 BP95F068 Continue to lift the secondary shaft until you can move the secondary shaft out of the shift forks. Then remove the secondary shaft and set aside.

STEP 84

BP95F071 Remove the four-wheel drive clutch gear. Examine the dog teeth on the face of the gear for chips, wear, and/or angularity. Replace the gear and four wheel drive shift collar if wear or damage is apparent.

STEP 87 BP95F069 Remove the shift rod and fork assembly for first and second gear from the rear housing. This will be reused unless worn or damaged. New roll pins are included in the overhaul kit.

STEP 85

BP95F072 Remove and discard the thrust washer. A new thrust washer is provided in the overhaul kit.

BP95F070

Bur 7-54022

Issued 10-97

Printed in U.S.A.

22

STEP 88

STEP 89 2

1

1

1

3

4 BP95F073

BP95F074

Remove the bearing. It will be reused (unless worn or damaged).

It should not be necessary to remove the test port plugs (1), the breather (2), and the temperature sender (3) from the rear housing.

Examine the input shaft bore (4) for grooves from the sealing rings. If these are apparent, the rear housing must be replaced.

Remove any sharp edges at the ends of the bore and at the oil distribution holes. New copper washers are included in the overhaul kit if replacements are necessary.

STEP 90

BP95F366 Remove the four-wheel drive clutch tube (four-wheel drive machines only) from the front housing only if the tube is leaking, damaged, or if the housing must be replaced.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

23

BT97F164

Early Design Oil Pump

CARRARO SYMBOL TRIANGULAR RIBS BT97F165

Latest Design Oil Pump (181199A4)

Bur 7-54022

Issued 10-97

Printed in U.S.A.

24

11

13

12

14 15 21 16

20

13

24

3

4 6 23

22 10 4

18 3 19

2

17 18

1 4

5 6 8

3 2

4

6

BT95G172

6 1. Tube 2. Hollow Cap Screw 3. Copper Washer 4. Cap Screw 5. Cover 6. O-Ring

7. Oil Screen 8. Spool 9. Sleeve 10. Front Housing 11. Oil Filter 12. Fitting

7

9

13. Plug 14. Spool 15. Spring 16. Four-Wheel Drive Priority Valve 17. Four-Wheel Drive Clutch Tube 18. Fitting

19. Rear Housing 20. Breather 21. Test Port Plug 22. Drain Plug 23. Rear Cover 24. Dowel Pin

Four-Wheel Drive Transmission Bur 7-54022

Issued 10-97

Printed in U.S.A.

25

13 9

16 12

3 4

10 6 15

14 4 3 4 11

8

2

1

2

4

4

5 6

3

7

BT95G173

BT95G173

1. Tube 2. Hollow Cap Screw 3. Copper Washer 4. Cap Screw

5. Cover 6. O-ring 7. Oil Screen 8. Front Housing

9. Oil Filter 10. Fitting 11. Rear Housing 12. Breather

13. Test Port Plug 14. Drain Plug 15. Rear Cover 16. Dowel Pin

Two-Wheel Drive Transmission

Bur 7-54022

Issued 10-97

Printed in U.S.A.

26

Bur 7-54022

Issued 10-97

Printed in U.S.A.

25

DISASSEMBLY OF THE INPUT SHAFT 6 4

5

3 2

7

2

REVERSE

1. Forward Clutch Passage 2. Reverse Clutch Passage

3. Forward Gear 4. Forward Clutch Pack

NOTE: When disassembling the input shaft assembly, be sure to place the removed parts together and identify their original orientation so that they can be reassembled in the same position, orientation, and with the same contact surfaces as when originally assembled.

NOTE: Perform the following tests prior to disassembly of the input shaft. These tests will be performed again after rebuilding the input shaft.

STEP 91 See the i llustration above. A pply compressed air of approximately 90 psi (620 kPa) to the forward clutch passage.

Listen to hear the forward piston moving to lock the forward clutch pack. Try to move the forward gear. The forward gear must not turn on the input shaft. Try to move the reverse gear.

The reverse gear must turn freely on the input shaft. If the clutches do not operate correctly, note the problem and examine the parts closely during disassembly so that you identify and correct the problem. The update and overhaul kits include new pistons and seals, but if the problem is the input shaft housing or the piston return springs, it will be necessary to order replacement parts from NAPO.

1

1

BT95G174

FORWARD

5. Reverse Clutch Pack 6. Reverse Gear

7. Input Shaft

STEP 92 See the illustrati on above. A pply compr essed air of approximately 90 psi (620 kPa) to the reverse clutch passage.

Listen to hear the reverse piston moving to lock the reverse clutch pack. Try to move the reverse gear. The reverse gear must not turn on the input shaft. Try to move the forward gear.

The forward gear must turn freely on the input shaft. If the clutches do not operate correctly, note the problem and examine the parts closely during disassembly so that you identify and correct the problem. The update and overhaul kits include new pistons and seals, but if the problem is the input shaft housing or the piston return springs, it will be necessary to order replacement parts from NAPO.

STEP 93

BP95F075 Use the bottom piece of CAS-2379 special tool as shown to fasten the input shaft in the vise so that the reverse clutch is up.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

26

STEP 94

STEP 97

BP95F076

BP95F079

Remove and discard the sealing ring.

Remove the bearing and set aside for examination later.

STEP 95

STEP 98

BP95F077

BP95F084

Remove and discard the snap ring above the bearing.

Remove the spacer. The spacer will be reused.

STEP 96

STEP 99

BP95F078 Install a bearing separator under the gear as shown. DO NOT install the bearing separator between the gear and the bearing. Install a puller on the bearing separator. Use a shaft protector between the puller and the end of the input shaft.

Use molydisulfide grease to lubricate the shaft protector and the end of the puller. Make sure that you pull only until the bearing is free. Pulling any farther can damage the parts.

Bur 7-54022

BP95F085 Remove and discard the thrust washer.

Issued 10-97

Printed in U.S.A.

27

STEP 100

STEP 103

BP95F086

BP95F089

Remove the gear and set aside for examination later.

Remove and discard the thrust washer.

STEP 101

STEP 104

BP95F087 Remove and discard the roll pin.

NOTE: The overhaul kit contains replacement roll pins.

Two extra roll pins are included in case any are lost.

BP95F090 Tap lightly on the end plate to move the end plate down so that there is clearance between the snap ring and the end plate.

STEP 105 STEP 102

BP95F091 BP95F088

Remove and discard the retaining ring.

Remove the two needle bearings and set aside for inspection later.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

28

STEP 106

STEP 109

BP95F093 Use prybars to lift the end plate evenly. Remove the end plate.

BP95F095 Tighten the nuts evenly (no more than 2 to 3 turns at a time) to compress the spring. Compress the spring just enough to get access to the snap ring.

STEP 107 STEP 110

BP95F092 BP95F096

Remove and discard the roll pin.

Remove and discard the snap ring.

STEP 108 STEP 111

BP95F094 Install the top piece of the CAS-2379 special tool as shown.

Use the three threaded rods and nuts to fasten the two pieces together.

Bur 7-54022

BP95F097 Loosen the nuts and the threaded rods evenly to release the tension from the spring. Remove the top piece of the CAS2379 special tool.

Issued 10-97

Printed in U.S.A.

29

STEP 112

STEP 115

BP95F098

BP95F101

Remove the retainer plate.

Remove and discard the piston.

STEP 113

STEP 116

BP95F099

BP95F102

Remove the spring.

Remove and discard the sealing ring.

STEP 114

STEP 117

BP95F100 Remove the clutch pack. Set aside and identify which end of the assembly it was removed from. These will be examined in steps 144 and 145.

Bur 7-54022

BP95F103 Put the input shaft in the bottom piece of the CAS-2379 special tool as shown so that the forward clutch is up.

Issued 10-97

Printed in U.S.A.

30

STEP 118

STEP 120 2

2 1 1 1

BP95F104 Remove and discard the three sealing rings (1). DO NOT remove the two plugs (2) unless the plugs (2) are leaking.

The plugs (2) are sealed with Loctite 262 (red) and are difficult to remove. If removal is necessary, clean all oil from the threads and apply Loctite 262 (red) before installation.

STEP 119

BP95F106 Install a bearing separator under the gear as shown. DO NOT install the bearing separator between the gear and the bearing. Install an acceptable puller on the bearing separator.

Use a shaft protector between the puller and the end of the input shaft. Use molydisulfide grease to lubricate the shaft protector and the end of the puller. Make sure that you pull only until the bearing is free. Pulling any farther can damage the parts.

STEP 121

BP95F105 Remove and discard the snap ring. A new snap ring is provided in the overhaul kit.

BP95F107 Remove the bearing and put aside for examination later.

STEP 122

BP95F108 Remove and discard the thrust washer.

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Issued 10-97

Printed in U.S.A.

31

STEP 123

STEP 126

BP95F109

BP95F111

Remove and discard the roll pin.

Remove and discard the spacer.

NOTE: It is possible that the gear moved partially out of the clutch pack when the bearing was removed. If this occurs, it can be difficult to remove the roll pin. Move the gear as necessary until the gear goes back down into the clutch pack and there is clearance to remove the roll pin.

STEP 127

STEP 124

BP95F112 Remove the bottom needle bear ing and set aside for examination later.

STEP 128 BP95F110 Remove the gear and set aside for examination later.

STEP 125

BP95F113 Remove and discard the thrust washer.

BP95G004 Remove the top needle bearing and set aside for examination later.

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Issued 10-97

Printed in U.S.A.

32

STEP 129

STEP 132

BP95F115 Tap lightly on the end plate to move the end plate down so that there is clearance between the snap ring and the end plate.

BP95F117 Remove and discard the roll pin.

STEP 133

STEP 130

BP95F118

Remove and discard the retaining ring.

Install the top piece of the CAS-2379 special tool as shown.

Use the three threaded rods and nuts to fasten the two pieces together.

STEP 131

STEP 134

BP95F114

BP95F116 Use prybars to lift the end plate evenly. Remove the end plate.

Bur 7-54022

BP95F119 Tighten the nuts evenly to compress the spring. Compress the spring just enough to get access to the snap ring.

Issued 10-97

Printed in U.S.A.

33

STEP 135

STEP 138

BP95F120

BP95F123

Remove and discard the snap ring.

Remove the spring.

STEP 136

STEP 139

BP95F121 Loosen the nuts and the threaded rods to release the tension from the spring. Remove the top piece of the CAS-2379 special tool.

BP95F124 Remove the clutch pack and set aside to be examined in steps 145 and 146.

STEP 140 STEP 137

BP95F125 BP95F122

Remove and discard the piston.

Remove the retainer plate.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

34

STEP 141

BP95F126 Remove and discard the sealing ring.

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Issued 10-97

Printed in U.S.A.

35

9 10 9 2

5

10

8 7 9

6

10

5 3

4

11

2

13

2

12

1

1 1

16

15

1 1

1

13 12

6

11

14

2 2

14 5

3

4 10

7 5

9 2

8

9 9 BT95G175

10 1. Sealing Ring 2. Snap Ring 3. Bearing 4. Spacer Bur 7-54022

BT95G175

5. Thrust Washer 6. Needle Bearing 7. Gear 8. End Plate

9. Steel Disc 10. Friction Disc 11. Retainer Plate 12. Spring

13. Piston 14. Roll Pin 15. Input Shaft Housing 16. Plug Issued 10-97

Printed in U.S.A.

36

INSPECTION OF THE INPUT SHAFT STEP 142

STEP 146

Check the piston return springs for broken or cracking coils.

Compare the height of both springs. If they are not the same height, or show evidence of damage, replace both springs.

The springs should be approximately 63 mm (2.48 inches) long.

1

STEP 143 Check the teeth on the gears for wear and damage. If a tooth is badly damaged, be sure to inspect the gear or spline that is in mesh with the damaged gear.

STEP 144 Check the splines on the input shaft for wear and damage.

Check the passages in the input shaft to be sure that the passages are open and free of foreign material. Inspect the input shaft housing piston bores for evidence of irregular wear patterns, rough finish, grooving, or scratches that might cause leakage or cause the piston to bind in the bore when reassembled. Also check the slots in the side of the housing for grooves or notching from the tangs on the OD of the separator plates. If any of these conditions are apparent, replace the input shaft housing.

BP95F130

2

STEP 145

BP95F131

BP95F129 If the clutch discs are to be used again, keep the clutch packs separate and record which clutch pack goes with each clutch.

See photo above for correct number and arrangement of clutch discs.

Use a straight edge to check each steel disc (1) and each friction disc (2) to be sure each part is flat. If a steel disc (1) or a friction disc (2) is not flat, a new part must be installed during assembly. If the friction discs (2) are smooth or almost s m o o t h ( s o m e o r a l l o f t h e g r o ov e s a r e n o l o n g e r distingushable) or the friction material is chipped, flaking or appears burned, use new parts during assembly. Inspect the steel discs (1) for pitting, scoring, or other damage. If there is any damage, use new parts during assembly. Also, check the splines for wear. Inspect the bore and the shaft in the clutch housing for damage that will cause leakage when the clutch is assembled. Use new parts as required during assembly. If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil before assembly.

STEP 147 Check the ball bearings and the needle bearings for flat areas, pitting, and other damage. Replace as necessary.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

37

ASSEMBLY OF THE INPUT SHAFT STEP 148

STEP 151

BP95F127 Use clean transmission oil to lubricate the sealing rings.

Install a sealing ring in each piston. New pistons are provided in the update kit. New seals are provided in the overhaul kit.

BP95F207 Install the spring.

STEP 152

STEP 149

BP95F208 BP95F126 Install the sealing ring on the input shaft in the forward clutch housing. This seal ring is provided in the overhaul kit.

Lubricate the input shaft and inside of housing with clean transmission oil.

Install the retainer plate. The side which has a raised area around the bore goes down. The side which has the groove around the bore goes up. The outer edge of the snap ring must fit in this groove after the parts are assembled.

STEP 150

BP95F206 Use clean transmission oil to lubricate the edge and the bore of the piston. Install the piston.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

38

STEP 153

STEP 155

BP95F209 Install the top piece of the CAS-2379 special tool. Use the three threaded rods and nuts to fasten the two pieces together. Tighten the nuts evenly to compress the spring just enough to get access to the snap ring groove in the input shaft. Install a new snap ring from the overhaul kit. Loosen the nuts to relieve the spring tension and remove the CAS2379 special tool. Make sure that the outer edge of the snap ring is seated in the groove in the retainer plate.

BP95F211 Use clean transmission oil to lubricate a new thrust washer from the overhaul kit. Install the thrust washer so that the notch in the inner edge fits over the pin. Make sure that the side with the oil grooves is up.

STEP 156

STEP 154

BP95F213 Use clean transmission oil to lubricate the needle bearings.

Install the first needle bearing.

BP95F210

STEP 157

Install a new pin from the Overhaul Kit.

BP95F214 Install a new spacer from the overhaul kit.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

39

STEP 158

STEP 161

BP95F215

BP95F234

Install the second needle bearing.

Install one friction disc.

STEP 159

NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil before assembly.

STEP 162

BP95F232 To assemble the clutch pack, star t with the gear on the bench. Install the end cover so that the flat side is up.

STEP 160 BP95G003 Install one steel disc.

STEP 163 Repeat steps 160 and 161 until all the clutch discs are installed. The clutch pack will finish with one steel disc instead of two as are at the other end. The assembled clutch pack should contain eight steel discs and six friction discs.

BP95F233 Install TWO steel discs.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

40

STEP 164

STEP 166

BP95F226 Make sure that the tabs on all the steel discs are aligned with each other. Hold the clutch pack together so that the parts do not move and rotate the clutch pack so that the clutch discs are down. Put the clutch pack on the clutch housing as shown so that the tabs on the steel discs are almost ready to start into the slots in the clutch housing.

BP95F228 When all the clutch discs are down, and the gear is down as far as the end cover will permit, remove the screwdrivers. Use a punch and a hammer to move the end cover down evenly just far enough to get access to the snap ring groove in the clutch housing.

STEP 167 STEP 165

BP95F229 BP95F227 Use two screwdrivers in opposite slots in the clutch housing to support the clutch pack as you start the clutch pack into the clutch housing. Move the clutch pack down slowly and evenly, making sure that all the tabs are going into the slots.

Also make sure that the gear moves down with the clutch pack.

Install a new retaining ring from the overhaul kit.

STEP 168

BP95F230 Use two screwdrivers to move the end cover up until the end cover is against the snap ring. There is a recess in the outer edge of the end cover. When the end cover is up all the way, the inner edge of the snap ring will fit in this recess.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

41

STEP 169

STEP 172

BP95F109

BP95F105

Install a new pin from the overhaul kit.

Install a new snap ring from the overhaul kit.

STEP 170

STEP 173

BP95F108 Use clean transmission oil to lubricate the thrust washer.

Install the thrust washer so that the notch in the inner edge fits over the pin. Make sure that the side with the oil grooves is down.

STEP 171

BP95F104 Use clean transmission oil to lubricate three new sealing rings from the overhaul kit. Install the three sealing rings on the input shaft. Turn the sealing rings on the input shaft so that the connecting ends of each sealing ring are 120 degrees from the connecting ends of the other two sealing rings.

NOTE: The connecting ends of the sealing rings in the photo above are shown aligned so that the sealing rings can be seen clearly.

NOTE: New sealing rings provided in the overhaul kit may be “unplated” or maybe plated with a material that does not exhibit the flaking problem experienced with earlier sealing rings. Whether plated or unplated, lubricate the sealing rings and their mating bores generously with clean transmission fluid during assembly.

BP95F231 Use an acceptable driver or press to force the bearing onto the input shaft until the bearing makes contact with the thrust washer.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

42

STEP 174

STEP 177

BP95F102 Put the input shaft in the bottom piece of the CAS-2379 special tool so that the reverse clutch housing is up. Lubricate the shaft and inside the clutch housing with clean transmission oil. Install a new sealing ring from the overhaul kit on the input shaft in the reverse clutch housing.

BP95F656 Install the retainer plate. The side which has a raised area around the bore goes down. The side which has the groove around the bore goes up. The outer edge of the snap ring must fit in this groove after the parts are assembled.

STEP 178 STEP 175

BP95F237 BP95F235 Use clean transmission oil to lubricate the edge and the bore of the new piston and seal. Install the piston.

STEP 176

Install the top piece of the CAS-2379 special tool. Use the three threaded rods and nuts to fasten the two pieces together. Tighten the nuts evenly to compress the spring just enough to get access to the snap ring groove in the input shaft. Install a new snap ring from the overhaul kit. Loosen the nuts to relieve the spring tension and remove the CAS2379 special tool. Make sure that the outer edge of the snap ring is seated in the groove in the retainer plate.

BP95F236 Install the spring.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

43

STEP 179

STEP 182

BP95F239

BP95F232

Install a new pin from the overhaul kit. Push the pin until it bottoms out in the hole.

To assemble the clutch pack, star t with the gear on the bench. Install the end cover so that the flat side is up.

STEP 180

STEP 183

BP95F240 Use clean transmission oil to lubricate a new thrust washer from the overhaul kit. Install the thrust washer so that the notch in the inner edge fits over the pin. Make sure that the side with the oil grooves is up.

BP95F233 Install TWO steel discs.

STEP 184

STEP 181

BP95F234 Install one friction disc.

BP95F241 Use clean transmission oil to lubricate the needle bearings.

Install the needle bearings.

Bur 7-54022

NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil before assembly.

Issued 10-97

Printed in U.S.A.

44

STEP 185

STEP 188

BP95G003 Install one steel disc.

STEP 186 Repeat steps 183 and 184 until all the clutch discs are installed. The clutch pack will finish with one steel disc instead of two as are at the other end. The assembled clutch pack should contain eight steel discs and six friction discs.

BP95F243 Use two screwdrivers in opposite slots in the clutch housing to support the clutch pack as you start the clutch pack into the clutch housing. Move the clutch pack down slowly and evenly, making sure that all the tabs are going into the slots.

Also make sure that the gear moves down with the clutch pack.

STEP 189

STEP 187

BP95F244 BP95F242 Make sure that the tabs on all the steel discs are aligned with each other. Hold the clutch pack together so that the parts do not move and rotate the clutch pack so that the clutch discs are down. Put the clutch pack on the clutch housing as shown so that the tabs on the steel discs are almost ready to start into the slots in the clutch housing.

When all the clutch discs are down, and the gear is down as far as the end cover will permit, remove the screwdrivers. Use a punch and a hammer to move the end cover down evenly just far enough to get access to the snap ring groove in the clutch housing.

STEP 190

BP95F245 Bur 7-54022

Issued 10-97

Printed in U.S.A.

45

STEP 193

Install a new snap ring from the overhaul kit.

STEP 191

3 2 1 BP95F248 BP95F246 Use two screwdrivers to move the end cover up until the end cover is against the snap ring. There is a recess in the outer edge of the end cover. When the end cover is up all the way, the inner edge of the snap ring will fit in this recess.

STEP 192

Use clean transmission oil to lubricate a new thrust washer (1) from the overhaul kit. Install the thrust washer (1) so that the notch in the inner edge fits over the pin. Make sure that the side with the oil grooves is down. Install the spacer (2).

Put the bearing (3) into position so that the snap ring groove on the outside of the bearing (3) is up. Use an acceptable driver or press to force the bearing (3) onto the input shaft until the bearing (3) makes contact with the spacer (2).

STEP 194

BP95F247 Install a new pin from the overhaul kit.

BP95F077 Install a new snap ring from the overhaul kit.

STEP 195

BP95F076 Use clean transmission oil to lubricate the sealing ring. Install a new sealing ring from the overhaul kit on the input shaft.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

46

STEP 196

Measure the clutch disc clearance for each clutch assembly.

The end cover must be all the way up against the snap ring.

Use a feeler gauge to measure the distance between the end cover and the first metal disc. The distance must be 0.09 to 0.17 inch (2.3 to 4.3 mm). If the distance is not within specification, the clutch is probably assembled wrong. Clutch plate wear will not cause the distance to be outside the specification.

BP95F249

6 4

5

3 2

7

2

REVERSE

1. Forward Clutch Passage 2. Reverse Clutch Passage

3. Forward Gear 4. Forward Clutch Pack

1

1

BT95G174

FORWARD

5. Reverse Clutch Pack 6. Reverse Gear

7. Input Shaft

STEP 197

STEP 198

See the i llustration above. A pply compressed air of approximately 90 psi (620 kPa) to the forward clutch passage.

Listen to hear the forward piston moving to lock the forward clutch pack. Try to move the forward gear. The forward gear must not turn on the input shaft. Try to move the reverse gear.

The reverse gear must turn freely on the input shaft. If the clutches do not operate correctly, disassemble the clutches to find and correct the problem.

See the illustration above. A pply compr essed air of approximately 90 psi (620 kPa) to the reverse clutch passage.

Listen to hear the reverse piston moving to lock the reverse clutch pack. Try to move the reverse gear. The reverse gear must not turn on the input shaft. Try to move the forward gear.

The forward gear must turn freely on the input shaft. If the clutches do not operate correctly, Disassemble the clutches to find and correct the problem.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

47

DISASSEMBLY OF THE SECONDARY SHAFT NOTE: When disassembling the secondary shaft, be sure to place the removed parts together and identify their orientation and position so that the parts can be reassembled in the same position, orientation, and with the same contact surfaces as when originally assembled.

STEP 201

STEP 199

BP95F136 Remove the bearing and set aside for examination later.

STEP 202 BP95F134 Suppor t the secondary shaft on blocks on the bench as shown or with soft jaws in a bench vise.

STEP 200

BP95F135 Remove and discard the thrust washer. All thrust washers on the secondary shaft will be replaced with new parts included in the overhaul and update kits.

STEP 203 BP95F133 Install a bearing separator under the gear as shown. DO NOT install the bearing separator between the gear and the bearing. If the bearing separator has a beveled edge, the beveled edge must be down. Do not tighten the bearing separator so much that the bearing separator pushes the synchronizer down. Install an acceptable puller on the bearing separator. Use a shaft protector between the puller and the end of the secondary shaft. Use molydisulfide grease to lubricate the shaft protector and the end of the puller. Make sure that you pull only until the bearing is free. Pulling any farther can damage the parts.

BP95F137 Remove third gear.

Bur 7-54022

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Printed in U.S.A.

48

STEP 204

STEP 207

BP95F138 Re move t he s ync hr oni zer r in g f r om t he th ird - fo ur th synchronizer assembly in order to get access to the snap ring.

BP95F141 Remove and discard the snap ring.

STEP 208

STEP 205

BP95F142 BP95F139 Remove and discard the snap ring. All snap rings on the secondary shaft will be replaced with new parts included in the overhaul kit.

Remove fourth gear.

STEP 209

STEP 206

BP95F143 Remove and discard the snap ring.

BP95F140 Remove and discard the third-fourth synchronizer assembly.

A new synchronizer assembly is included in the update kit.

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49

STEP 210

STEP 213

BP95F144 Remove the four-wheel drive gear, if equipped. On two-wheel drive transmissions, there is a spacer here instead of the gear. If the transmission is a two-wheel drive, remove the spacer.

STEP 211

BP95F147 Install a bearing separator under the gear as shown. DO NOT install the bearing separator between the gear and the bearing race. If the bearing separator has a beveled edge, the beveled edge must be down. Do not tighten the bearing separator so much that the bearing separator pushes the synchronizer down. Install an acceptable puller on the bearing separator. Use a shaft protector between the puller and the end of the secondary shaft. Use molydisulfide grease to lubricate the shaft protector and the end of the puller. Make sure that you pull only until the bearing race is free. Pulling any farther can damage the parts.

STEP 214

BP95F145 Turn the secondary shaft over so that second gear is at the top. You can use the output flange as a stand to hold the secondary shaft in position or hold it with soft jaws in a vise.

STEP 212

BP95F148 Remove and discard the bearing race. This bearing set will be replaced with parts included in the overhaul kit.

STEP 215

BP95F146 Remove and discard the snap ring.

BP95F150 Remove and discard the thrust washer.

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50

STEP 216

STEP 219

BP95F151 Remove and discard the pin.

BP95F154 Remove the synchronizer r ing fr om the first-second synchronizer assembly in order to get access to the snap ring.

STEP 217

STEP 220

BP95F152 Remove second gear.

BP95F155

STEP 218

Remove and discard the snap ring.

STEP 221

BP95F153 The spacer can stay with either the synchronizer ring or second gear. Remove the spacer.

BP95F156 Remove the synchronizer assembly.

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51

STEP 222

STEP 225

Re-install the top synchronizer ring on top of the synchronizer. Use a feeler gauge to measure the clearance between the bottom of the teeth on the top ring and the edge of the large sleeve on the outside of the synchronizer assembly. This clearance should be approximately 1.0 mm with used parts in good condition. If the clearance is 0.5 mm or less, the synchronizer rings are worn out and the assembly should be replaced. A new synchronizer assembly that has not been used will have approximately 1.5 mm clearance and a new synchronizer that has had sufficient operating time to “break-in” will have approximately 1.0 to 1.2 mm clearance.

Repeat the measurement for the opposite side of the synchronizer assembly before disassembling. Replace the f ir s t - s e c o nd s y n ch r on i ze r a s s e m bl y i f e i th e r o f th e measurements are marginal or if damage or unusual wear patterns are apparent during disassembly.

BP95F163 Tur n the synchronizer assembly over and remove the synchronizer ring from the other side.

STEP 226

STEP 223 1 1 2 2

BP95F164 BP95F164 Remove the steel ring (1) and the bronze ring (2) together.

Remove the steel ring (1) and the bronze ring (2) together.

STEP 227

STEP 224

BP95F165 BP95F165 Remove the tapered friction ring.

Bur 7-54022

Remove the tapered friction ring.

NOTE: The parts will fly out of the hub when you do the following step. Putting the synchronizer assembly in a cardboard box during this step can prevent loss of parts.

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52

STEP 228

STEP 231

BP95F167 Support the sleeve on blocks. Push down on the hub while you use a punch to push the detent assemblies out of the sleeve and hub. Remove the sleeve from the hub.

BP95F158 Remove and discard the snap ring.

STEP 232

STEP 229 1 3

2 4

2

3

1

3

2 1 BP95F168

This photo shows the relationship of the balls (1), the blocks (2), the springs (3), and the hub (4). Replace any damaged or broken parts.

BP95F159 Remove first gear.

STEP 233

STEP 230

BP95F160 Remove and discard the last snap ring.

BP95F157 Remove the spacer.

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53

1

4 2

17

15

3

1

1 1 5

6

14

7 12

13

21

16

8

11

20

9

10

8

1

16

5

6

7 6

7 16

5

12

8

19

11 9 8

10

16 7

13

6

24

5 22

25

26

27

23

3

1 18 1. Snap Ring 2. Bearing 3. Thrust Washer 4. Second Gear 5. Spacer 6. Synchronizer Ring 7. Steel Ring

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8. Tapered Friction Ring 9. Hub 10. Spring 11. Block 12. Ball 13. Sleeve 14. First Gear

15. Spacer (Two-Wheel Drive Only) 16. Bronze Ring 17. Four-Wheel Drive Gear 18. Fourth Gear 19. Pin 20. Secondary Shaft

21. Third Gear 22. Bearing and Snap Ring 23. Seal 24. Output Flange 25. O-Ring 26. Washer 27. Cap Screw

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INSPECTION OF THE SECONDARY SHAFT NOTE: Clean bearings and gears with clean transmission oil, compressed air, and lint free shop towels.

STEP 236

STEP 234

STEP 237

Check the teeth on the gears for wear and damage. If a tooth is badly damaged, be sure to inspect the gear or spline that is in mesh with the damaged gear.

Check the teeth in the first-second synchronizer assembly for wear and damage. Replace as necessary.

Check the bearings for flat areas, pitting, and other damage.

Replace as necessary.

STEP 238 STEP 235 Check the splines on the secondary shaft for wear and damage. Check the passages in the secondary shaft to be sure that the passages are open and free of foreign material.

Bur 7-54022

Check the steel friction ring and tapered bronze ring from the first-second synchronizer for wear or damage. Replace as necessary. Check the springs in the synchronizer assemblies for wear, cracks, heat distortion, and other damage. Replace as necessary.

Issued 10-97

Printed in U.S.A.

55

ASSEMBLY OF THE SECONDARY SHAFT NOTE: Before each gear is installed on the secondary shaft, make sure that the bore of the gear and the outside diameter of the secondary shaft are completely lubricated with clean transmission oil.

STEP 240

NOTE: When you install snap rings on the secondary shaft, make sure that the ends of each snap ring are seated in the snap ring groove. Do not install a snap ring so that the ends extend into an axial slot on the secondary shaft.

NOTE: Before starting to assemble the secondary shaft, make the following measurement with a vernier caliper.

BP95F159 Install first gear.

DIM A

STEP 241

1 & 2 GEARS END

3 & 4 GEARS END

MEASUREMENT ___________________ Record this measurement as it will be used to determine the correct thrust washer to install at step 279.

BP95F162

STEP 239

Install a new snap ring from the overhaul kit. Position the ends of the snap ring as previously noted.

STEP 242

BP95F161 Put the secondary shaft on the bench so that the first-second gear end is up. You can use the output flange as a stand to hold the secondary shaft in position. Install a new snap ring from the overhaul kit as shown.

BP95F157 Install the spacer.

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56

STEP 243

STEP 245 1 3

3 2 2

2

1 3

1 BP95F169

This photo shows the correct relationship between the hub and the sleeve for assembly of the first-second synchronizer.

The tabs (1) in the inside diameter of the sleeve fit into the small recesses (2) in the outside diameter of the hub. The large recesses (3) in the hub are for the detent assemblies, which are not yet installed.

BP95F173 Use a punch or screwdriver to push the balls into the blocks and to push the blocks down so that the balls are on the flat faces of the teeth, but not into the detent grooves. When all the balls are in position, push the hub and the blocks down until the balls move into the detent groove.

STEP 246 STEP 244

BP95F165 BP95F172 This photo is for reference only. It shows the correct positions of the hub, the sleeve, the springs, the blocks, and the balls prior to final assembly.The springs are installed in the hub, and the blocks are on the springs. The blocks are not yet pushed down into the sleeve and are holding the hub up out of sleeve. The balls are loose in the recesses of the blocks.

Install the tapered friction ring on the synchronizer assembly.

STEP 247 2

1

NOTE: Position each ball, block, and spring in the assembly one-at-a-time and complete the installation of the parts as shown in step 245 before positioning the next set of parts. Otherwise you risk loosing some of the parts.

BP95F164 Lubricate both rings liberally with clean transmission oil and install the bronze ring (1) and the steel ring (2) as shown.

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57

STEP 248

STEP 251

Install the synchronizer ring as shown. The flat sides of the teeth must be up and the tapered side of the teeth must be towards the large sliding sleeve.

Position the top synchronizer ring on top of the assembly.

Pick the assembly up and align the teeth on the top ring with the teeth on the inside of the sliding sleeve. Press the sliding sleeve up until it engages the teeth on the top ring. This will require enough effort to overcome the force of the detent spr ings and balls. When the r ing and sleeve are fully engaged, the detent should hold the sleeve in this position.

Press the sleeve back down to the neutral position, turn the synchronizer over, and repeat the above check with the bottom synchronizer ring. If the sleeve does not engage the teeth readily or does stay in place when moved to any of the three positions, it is an indication that the synchronizer was not assembled correctly or that damaged par ts were reassembled into the synchronizer. First check that the top and bottom rings are positioned correctly (note step 248). If this is not the problem, disassemble and determine the cause.

STEP 249

STEP 252

BP95F163

Remove the top synchronizer ring.

STEP 253

BP95F165 Turn the synchronizer assembly over and install the tapered friction ring on the other side.

BP95F156

STEP 250

I n s t a l l t h e s y n c h r o n i z e r a s s e m bl y w i t h o u t t h e t o p synchronizer ring.

2 1

NOTE: There is a groove in the bore at one end of the synchronizer hub. The synchronizer assembly must be installed so that the groove is down.

BP95F164 Lubricate both rings liberally with clean transmission oil and install the bronze ring (1) and the steel ring (2) as shown.

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Printed in U.S.A.

58

STEP 254

STEP 257

BP95F174

BP95F151

Install a new snap ring from the overhaul kit.

Install a new pin from the overhaul kit.

STEP 255

STEP 258

BP95F154 Install the top synchronizer ring so that the flat sides of the teeth are up and the tapered side of the teeth face down toward the sliding sleeve.

BP95F150 Use clean transmission oil to lubricate a new thrust washer from the overhaul kit. Install the thrust washer so that the notch in the inner edge fits over the pin. Make sure that the side with the oil grooves is down.

STEP 256 STEP 259

BP95F153 Install the spacer and second gear. The teeth in the inside diameter of the spacer must engage the teeth on the bottom of second gear before second gear is installed.

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BP95F176 Use an acceptable driver or press to force the bearing race from one of the new roller bearing sets in the overhaul kit onto the secondary shaft until the bearing race makes contact with the thrust washer.

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Printed in U.S.A.

59

STEP 260

STEP 262

BP95F146 Install a new snap ring from the overhaul kit.

BP95F179 Install a new snap ring from the overhaul kit. The snap ring must be in the lowest groove. There is a lubrication groove just above the snap ring groove. If you install the snap ring in the lubrication groove, you will not be able to assemble the other parts correctly.

STEP 261

STEP 263

BP95F144 Turn the secondary shaft over so that second gear is at the bottom. Use blocks or a soft jawed vise to suppor t the secondar y shaft. Install the four-wheel dr ive gear, if equipped. On two-wheel drive transmissions, there is a spacer here instead of the gear. If the transmission is a twowheel drive, install the spacer.

BP95F142 Install fourth gear.

STEP 264

BP95F180 Install a new snap ring from the overhaul kit.

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STEP 265

STEP 267

BP95F157 Install the spacer.

NOTE: If the new third-fourth synchronizer in the update kit is pre-assembled, remove the rings (reference steps 219, 223 through 227) leaving only the hub, shift sleeve, and detent parts intact.. Verify that the blocks and balls are in the correct positions and fully engaged into the detent groove according to step 268.

Reassemble according to steps 269 through 274.

STEP 266 1 3

BP95F172 This photo is for reference only. It shows the correct positions of the hub, the sleeve, the springs, the blocks, and the balls prior to final assembly.The springs are installed in the hub, and the blocks are on the springs. The blocks are not yet pushed down into the sleeve and are holding the hub up out of sleeve. The balls are loose in the recesses of the blocks.

NOTE: Position each ball, block, and spring in the assembly one-at-a-time and complete the installation of the par ts as shown in step 245 before positioning the next set of parts. Otherwise you risk loosing some of the parts.

STEP 268

3 2 2

2

1 3

1 BP95F169

This photo shows the correct relationship between the hub and the sleeve for assembly of the third-fourth synchronizer.

The tabs (1) in the inside diameter of the sleeve fit into the small recesses (2) in the outside diameter of the hub. The large recesses (3) in the hub are for the detent assemblies, which are not yet installed.

BP95F173 Use a punch or screwdriver to push the ball into the block and to push the block down so that the ball is on the flat faces of the teeth, but not into the detent grooves. Repeat this for the other two sets of detent parts. When all the balls are in position, push the hub and the blocks down until the balls move into the detent groove.

NOTE: To avoid loosing some of the parts, put the parts in a small box while performing this assembly work.

Bur 7-54022

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Printed in U.S.A.

61

STEP 269

STEP 272

BP95F165 Install the tapered friction ring on the synchronizer assembly.

BP95F165 Turn the synchronizer assembly over and install the tapered friction ring on the other side.

STEP 270 STEP 273 2 2 1

1

BP95F164 Lubricate both rings liberally with clean transmission oil and install the bronze ring (1) and the steel ring (2) as shown.

BP95F164 Lubricate both rings liberally with clean transmission oil and install the bronze ring (1) and the steel ring (2) as shown.

STEP 271 STEP 274

BP95F163 Install the synchronizer ring as shown. The flat sides of the teeth must be up and the tapered side of the teeth must be towards the large sliding sleeve.

Position the top synchronizer ring on top of the assembly.

Pick the assembly up and align the teeth on the top ring with the teeth on the inside of the sliding sleeve. Press the sliding sleeve up until it engages the teeth on the top ring. This will require enough effort to overcome the force of the detent spr ings and balls. When the r ing and sleeve are fully engaged, the detent should hold the sleeve in this position.

Press the sleeve back down to the neutral position, turn the synchronizer over, and repeat the above check with the bottom synchronizer ring. If the sleeve does not engage the teeth readily or does stay in place when moved to any of the three positions, it is an indication that the synchronizer was not assembled correctly or that damaged par ts were reassembled into the synchronizer. First check that the top and bottom rings are positioned correctly (note step 248). If this is not the problem, disassemble and determine the cause.

STEP 275 Remove the top synchronizer ring.

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Issued 10-97

Printed in U.S.A.

62

STEP 276

STEP 279

BP95F156 I n s t a l l t h e s y n c h r o n i z e r a s s e m bl y w i t h o u t t h e t o p synchronizer ring.

NOTE: There is a groove in the bore at one end of the synchronizer hub. The synchronizer assembly must be installed so that the groove is down.

STEP 277

BP95F153 Install the spacer and third gear. The teeth in the inside diameter of the spacer must engage the teeth on the bottom of third gear before third gear is installed.

NOTE: Refer to the measurement (DIM A) that was made on the secondary shaft prior to starting to assemble. If the measurement was 28.75 to 29.25 mm, use one thrust washer (part no. 181154A1, 4.0 mm thick) from the overhaul kit, between the third gear and the bearing on the end of the shaft. If the measurement was 29.26 to 29.45, use one thrust washer (par t no.

278531A1, 3.8 mm thick) from the update kit.

STEP 280

BP95F174 Install a new snap ring from the overhaul kit.

STEP 278 BP95F135 Use clean transmission oil to lubricate the selected thrust washer. Install the thrust washer so that the side with the oil grooves is down.

BP95F154 Install the top synchronizer ring so that the flat sides of the teeth are up and the tapered side of the teeth face down toward the sliding sleeve.

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Printed in U.S.A.

63

STEP 281

STEP 283 Check for proper movement of both synchronizer assemblies. if they do not shift readily, with teeth on the synchronizer ring aligned with the splines on the hub, the synchronizers were probably not assembled correctly. Identify the problem, disassemble, and correct as necessary.

BP95F136 Put the bearing in position on the secondary shaft. Make sure that the snap ring groove is at the top.

STEP 282

BP95F193 Use an acceptable driver or press to force the bearing onto the secondary shaft until the bearing makes contact with the thrust washer.

NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you install the secondary shaft in the rear housing. To prevent this, you can install a hose clamp on the output end of the secondary shaft. This will keep the bearing in position during installation of the secondary shaft.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

64

DISASSEMBLY OF THE PRIMARY SHAFT STEP 284

STEP 286

BP95F194 Put the primary shaft on the bench so that the end with the bearing attached is up. Remove and discard the snap ring. A replacement snap ring is provided in the overhaul kit.

BP95F196 Remove the bearing and set aside to be examined later.

STEP 287

STEP 285

BP95F197 BP95F195 Install a bearing separator under the gear as shown. DO NOT install the bearing separator between the gear and the bearing. Install an acceptable puller on the bearing separator.

Use a shaft protector between the puller and the end of the primary shaft. Use molydisulfide grease to lubricate the shaft protector and the end of the puller. Pull the bearing from the primary shaft.

Remove and discard the thrust washer. A replacement thrust washer is provided in the overhaul kit.

STEP 288

BP95F198 Remove the small gear.

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STEP 289

STEP 290

BP95F199 Turn the primary shaft over so that the large gear is down.

Tap the gear with a soft hammer or use a press to remove the gear from the primary shaft.

Bur 7-54022

BP95F200 Install a bearing separator under the lip of the bearing race as shown. Install an acceptable puller on the bearing separator.

Use a shaft protector between the puller and the end of the primary shaft. Use molydisulfide grease to lubricate the shaft protector and the end of the puller. Pull the bearing race from the primary shaft and discard. This bearing set will be replaced by parts in the overhaul kit.

Issued 10-97

Printed in U.S.A.

66

INSPECTION OF THE PRIMARY SHAFT STEP 291

STEP 293

Check the teeth on the gears for wear and damage. If a tooth is badly damaged, be sure to inspect the gear or spline that is in mesh with the damaged gear.

Check the ball bearing for flat areas, pitting, and other damage. Replace as necessary.

STEP 292 Check the splines on the primary shaft for wear and damage.

NOTE: Clean bearings and gears with clean transmission oil, compressed air, and lint free shop towels. If inspection reveals problems with any of the primary shaft assembly parts, replace as necessary. Be sure to check for evidence of similar problems with the mating par ts.

1 2 4

3

5

6

7

BT95G177

1. Snap Ring 2. Bearing and Snap Ring

Bur 7-54022

3. Thrust Washer 4. Small Gear

5. Large Gear 6. Primary Shaft

7. Bearing

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67

ASSEMBLY OF THE PRIMARY SHAFT STEP 294

STEP 297

BP95F201 Use an acceptable driver or press to force the bearing race for the new bearing in the overhaul kit all the way onto the primary shaft.

STEP 295

BP95F197 Use clean transmission oil to lubricate a new thrust washer from the overhaul kit. Install the thrust washer so that the side with the oil grooves is down.

STEP 298

BP95F202 Turn the primary shaft over. Lubricate the splines of the shaft and gear with clean transmission oil. Use a soft hammer or press to move the large gear into position. Install with the long side of the gear’s hub positioned up.

BP95F196 Put the bearing into position so that the snap ring groove on the outside diameter of the bearing is at the top.

STEP 299

STEP 296

BP95F203 BP95F198 Lubricate the splines of the small gear with clean transmission oil. Install the small gear with the long end of the gear’s hub facing down.

Bur 7-54022

Use an acceptable driver or press to force the bearing onto the primary shaft until the bearing makes contact with the thrust washer.

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68

STEP 300

BP95F194 Install a new snap ring from the overhaul kit.

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69

DISASSEMBLY, INSPECTION, AND ASSEMBLY OF THE REVERSE SHAFT Disassembly

Inspection

NOTE: It is not necessary to disassemble the reverse shaft unless inspection reveals evidence of damage or irregular wear patterns on the gears, shaft splines, and bearings. No replacement parts are provided for the reverse idler shaft assembly in either overhaul or update kits.

STEP 304 Check the teeth on the gears for wear and damage. If a tooth is badly damaged, be sure to inspect the gear or spline that is in mesh with the damaged gear.

STEP 305 Check the splines on the reverse shaft for wear and damage.

STEP 301 STEP 306 Check the bearings for flat areas, pitting, and other damage.

Replace as necessary.

Assembly STEP 307 Install a gear and a spacer on one end of the reverse shaft.

STEP 308

BP95F204 Install a bearing separator under the gear as shown. DO NOT install the bearing separator between the gear and the bearing. Install an acceptable puller on the bearing separator.

Use a shaft protector between the puller and the end of the reverse shaft. Use molydisulfide grease to lubricate the shaft protector and the end of the puller. Pull the bearing from the reverse shaft.

STEP 302 Remove the spacer and the gear from the reverse shaft.

BP95F205

STEP 303

Use an acceptable driver or press to force the bearing onto the reverse shaft until the bearing makes contact with the spacer.

Repeat steps 301 and 302 to disassemble the other end of the reverse shaft.

STEP 309

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Repeat steps 307 and 308 to assemble the other end of the reverse shaft.

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1 3

2

4 3

2 1

BT95G178

1. Bearing 2. Spacer

3. Gear 4. Reverse Shaft

L

Bur 7-54022

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71

SHIFT RODS AND SHIFT FORKS The original third-fourth rod assembly will not be re-used. It will be replaced by new parts from the update kit. The new fork will appear the same as the original third-fourth except for the machining on the legs that engage the synchronizer collar. Using the original third-fourth shift rod assembly as a pattern, assemble the new rod, fork, and roll pin from the update kit. Note the new rod may have different machining on the ungrooved end and may have two cross drilled holes for the fork roll pin. Use the hole closest to the detent grooves. The hole closest to the ungrooved end corresponds to the location for the first-second shift fork.

These parts may be common in future production.

STEP 310

Inspect the first-second shift rod assembly for abnormal wear patterns on the shift rod diameter and detent grooves. The fork should be tight on the rod. Check the fingers on the firstsecond shift fork for abnormal or excessive wear. Replace as necessary. It is not necessary to disassemble the first-second shift rod assembly if it is in good condition for re-use. Roll pins are included in the uoverhaul kit if replacements are necessary.

1st/2nd

Bur 7-54022

3rd/4th

BP95F132

If disassembly is required, remove the roll pins and separate the shift forks from the shift rods. Make sure that you remember how the parts are assembled and which parts go together. Except for the roll pins, none of the par ts are interchangeable. Inspect all parts for burrs and excessive wear. Assembly is the reverse of disassembly.

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72

1 2 3 4

4 6 5

7 4

8

16

9 10

14 15 17

21

17

18

13

19

5

13

18

11

12

22 21 20 BT95G179

23 1. Boot 2. Band 3. Shift Lever 4. Pin 5. Allen Head Screw 6. Shifter Housing

Bur 7-54022

7. O-Ring 8. Spring 9. Bushing 10. Snap Ring 11. Shift Collar 12. Plate

13. Detent Ball 14. Detent Plug 15. Washer 16. Detent Spring 17. Cap Screw 18. Copper Washer

BT97D125

19. Shift Rod for Third and Four th Gear 20. Shift Rod for First and Second Gear 21. Roll Pin 22. Shift Fork for Third and Fourth Gear 23. Shift Fork for First and Second Gear

Issued 10-97

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73

DISASSEMBLY OF THE OIL PUMP NOTE: If the transmission already has an “A4” pump, (refer to STEP 43 regarding proper identification of the pump) disassemble to determine its condition.

Reassemble or replace as appropriate.

NOTE: If the pump is not identifiable as part no.

181199A4 as described in STEP 43, replace it with a new pump from NAPO. It will not be necessary (and is not recommended) to disassemble a new pump; however, before proceeding with the transmision rebuild, it is advisable to disassemble the original (used) pump even if it is not going to be re-used. Check for scoring of the housing and suppor t by the gears. Check for excessive wear on the gear teeth. Check for looseness and excessive wear of the small gear bearing and supporting shaft. If any of the conditions are extreme, the charge pump was in the process of failing and has contaminated the transmission system with metal par ticles. If this has happened, also replace the torque converter and oil cooler. These must be ordered separately from NAPO.

STEP 312

BP95F252 Remove the two Allen head screws which fasten the pump support to the pump housing.

STEP 313

STEP 311

BP95F253 Separate the pump support from the pump housing.

BP95F251

STEP 314

Remove the O-ring carefully. This part is NOT included in the overhaul or update kits. If necessary, replace with a new Oring from NAPO.

BP95F254 Remove the large gear from the pump housing.

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STEP 315

STEP 320

BP95F255 Remove the small gear from the pump housing.

BP95F261 Check the shaft for the small gear for looseness and deep wear marks from the needle bearing.

STEP 316 STEP 321 Check the bushing in the end of the pump support for wear, damage, and heat discoloration.

STEP 322

BP95F256 Examine the seal in the pump housing for wear, cracks, and damage. Replace with a new seal (from NAPO) if necessary.

Remove the seal from the pump housing as shown if replacement is necessary.

BP95F267

STEP 317

Remove the roll pin for the torque converter relief valve.

Turn the pump housing over and examine the bushing for wear, damage, and heat discoloration.

STEP 323

STEP 318 Examine the bushing in the large gear for wear, damage, and heat discoloration.

STEP 319 Examine the needle bearing in the small gear for damage, missing or broken needles, and pitting.

BP95F268 Remove the plug, the spring, and the ball for the torque converter relief valve.

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STEP 324

STEP 325

BP95F269 Remove the roll pin for the oil pump relief valve. Be very careful because the large amount of spring tension will force the parts out when the roll pin is removed.

Bur 7-54022

BP95F599 Remove the plug, the spring, the pin, and the plunger for the oil pump relief valve.

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76

16 10 11

17

15

18

19

14

9

8 7 13 12

4

14

2 2 16 6

15

5 2

BT95G180

1 1. Seal 2. Bushing 3. Pump Housing 4. Cap Screw 5. O-Ring

Bur 7-54022

6. Large Gear 7. Needle Bearing 8. Small Gear 9. Shaft 10. Pump Suppor t

3 BT95G180

11. Allen Head Screw 12. Torque Converter Relief Valve 13. Ball 14. Spring 15. Plug

16. Roll Pin 17. Oil Pump Relief Valve 18. Pin 19. Plunger

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77

INSPECTION OF THE OIL PUMP STEP 326 Inspect the large gear and the small gear for wear and damage. If the teeth have scoring, excessive wear, or sharp points or edges, replace the pump. Examine the lugs on the large gear for damage. If found, examine the hub on the torque converter for similar damage. Replace pump and torque converter as necessary.

Inspect the splines on the shaft for wear and damage. If you find damage, replace the pump and torque converter.

STEP 329 Inspect all passages to be sure that the passages are open and free of foreign material.

STEP 330 STEP 327 Inspect the gear pockets in the pump housing for wear or damage. If the gear pockets have scoring or excessive wear, use a new oil pump.

STEP 328

Bur 7-54022

Inspect the parts of the torque converter relief valve and the oil pump relief valve for wear and damage.

NOTE: If any problems are detected in steps 317 through 330, replace the pump with a new pump part no.

181199A4 from NAPO.

Issued 10-97

Printed in U.S.A.

78

ASSEMBLY OF THE OIL PUMP NOTE: Other than reassembling an “A4” pump found in good condition, DO NOT attempt to rebuild the pump as part of the transmission update rebuild. Any pump found in questionable condition should be replaced with a new 181199A4 pump from NAPO (must be ordered separately).

STEP 333

STEP 331

BP95F601 Install the spring.

STEP 334

BP95F603 Install the plunger for the oil pump relief valve.

STEP 332

BP95F600 Install the plug.

STEP 335

BP95F602 Install the pin for the oil pump relief valve. The machined end of the pin must be toward the plunger. Make sure that the pin goes into the bore of the plunger.

BP95F269 This step will be difficult because the spring will be under heavy tension. Push the plug in until the plug is to the inside of the hole for the roll pin. Install the roll pin. It helps to use an appropriate size punch, inserted from the bottom to hold the plug in place, while the roll pin is driven in from the top.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

79

STEP 336

STEP 339

BP95F268

BP95F255

Install the ball, the spring, and the plug for the torque converter relief valve. Make sure that the hole in the plug is aligned with the hole for the roll pin.

Use clean transmission oil to lubricate the small bore in the housing, the small gear, and the needle bearing. Install the small gear on the shaft in the pump housing.

STEP 337

STEP 340

BP95F271 Install the roll pin through the holes in the pump support and the hole in the plug.

BP95F254 Use clean transmission oil to lubricate the large gear, the bushing in the large gear, and the bore in the pump housing.

Install the large gear so that the side with the lugs is down.

STEP 338 STEP 341

BP95F259 If the seal was damaged or worn but the rest of the pump was found to be in acceptable condition, replace the seal with a new seal from NAPO on 181199A4 pumps only. Use an acceptable driver or a press to install a new seal in the end of the pump housing.

Bur 7-54022

BP95F253 Install the pump support on the pump housing. Make sure that all the bolt holes are aligned.

Issued 10-97

Printed in U.S.A.

80

STEP 342

STEP 344

BP95F252 Install the two Allen head screws to fasten the pump support to the pump housing. Tighten the Allen head screws snug.

BP95F251 Reinstall the O-ring, if still in usable condition. Install a new O-ring if available.

STEP 343 Install a large worm gear clamp (radiator hose clamp) around the outside of the pump housing and support. Position the clamp so that it covers the seam between the two parts and contacts both. Tighten the clamp.

Tap the housing with a soft hammer. Retighten the clamp.

Tap the housing again with a soft hammer. Retighten the clamp.

Tighten the Allen head screws to 10 mm (89 pound-inches).

Remove the clamp and set the pump on a clean work surface with the housing facing up. Insert a small screw driver or punch through the torque converter hub hole and rotate the large gear by pushing against one of the drive tangs. The gear should rotate freely. If it does not, loosen the Allen head screws and repeat the above steps.

If the large gear rotates freely, fill the pump full of clean transmission oil and rotate the large gear three revolutions before installing the pump on the transmission.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

81

DISASSEMBLY OF THE FOUR-WHEEL DRIVE SHAFT STEP 345

STEP 347

BP95F279 There is a pipe plug at the bottom of the hole in the end of the shaft (see arrow). DO NOT remove the pipe plug unless the pipe plug is damaged.

BP95F274 Remove and discard the snap ring from the shaft.A new snap ring is included in the overhaul kit.

STEP 348 STEP 346

BP95F276 BP95F273 Use an acceptable tool to press the spring retainer down until you have access to the snap ring (see arrow). Remove the snap ring from the groove. Release the tension and remove the tool.

Remove and discard the spring retainer. A new spring retainer is included in the overhaul kit.

STEP 349

NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out.

BP95F275 Remove and discard the springs. New springs are included in the overhaul kit.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

82

STEP 350

BP95F277 Remove the sleeve.

STEP 351

BP95F278 Remove and discard the two O-rings from the shaft. New O-rings are included in the overhaul kit.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

83

8 9 7

8

6 3 5 4

2

1

3

1

17

3

7

16

15 14 3 12 13 BT95G181

10

11

BT95G181

1. Cap Screw 2. Washer 3. O-Ring 4. Four-Wheel Drive Flange 5. Cover

Bur 7-54022

6. Seal 7. Bearing 8. Sealing Ring 9. Collar

10. Snap Ring 11. Spring Retainer 12. Spring 13. Sleeve

14. Pipe Plug 15. Shaft 16. Four-Wheel Drive Clutch Gear 17. Thrust Washer

Issued 10-97

Printed in U.S.A.

84

INSPECTION OF THE FOUR-WHEEL DRIVE SHAFT STEP 352

STEP 353

Inspect the lugs on the sleeve for peening, chipping, or other damage. If you find damage to the lugs, also inspect the fourwheel drive clutch gear (see step 86). Replace the sleeve and clutch gear (as a pair) if necessary.

Check the splines on the shaft and inside the sleeve for wear and damage.

NOTE: Loss of charge pump pressure due to a failing transmission oil pump can cause inadvertent engagement and disengagement of the four-wheel drive even through the selector switch is in the “OFF” position.

This can lead to damage of the teeth on the sleeve and clutch gear.

STEP 354 Check the passages in the shaft to be sure that the passages are open and free of foreign material.

ASSEMBLY OF THE FOUR-WHEEL DRIVE SHAFT STEP 355

STEP 357

BP95F278 Install new O-rings from the overhaul kit on the shaft. Use clean transmission oil to lubricate the O-rings.

BP95F275 Install the new springs from the overhaul kit.

STEP 358 STEP 356

BP95F276 BP95F277 Install the sleeve on the shaft.

Bur 7-54022

Install the new spring retainer from the overhaul kit. Make sure that the side with the recess in the bore is on top. The recess is for the snap ring.

Issued 10-97

Printed in U.S.A.

85

STEP 359

STEP 361

BP95F274 Put a new snap ring from the overhaul kit on the shaft.

STEP 360

BP95F279 If the pipe plug at the bottom of the hole in the end of the shaft (see arrow) was removed, apply Loctite 242 (blue) to the threads of the new pipe plug before installation. Tighten the pipe plug to a torque of 266 pound-inches (30 Nm).

BP95F273 Use an acceptable tool to press the spring retainer down until you have access to the snap ring groove (see arrow). Install the snap ring in the groove. Release the tension and remove the tool. Make sure that the snap ring is seated in the recess in the spring retainer.

NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

86

DISASSEMBLY OF THE SHIFTER HOUSING STEP 362

STEP 365

BP95F341 Use side cutters as shown to release the catch on the band which fastens the boot to the shifter housing. Remove and discard the band. A new band is included in the overhaul kit.

BP95F345 Remove and discard the snap ring from the shift lever. A new snap ring is included in the update kit.

STEP 366 STEP 363

BP95F349 BP95F342 Remove and discard the boot from the shifter housing. A new boot is included in the update kit.

Remove and discard the bushing from the shift lever. A new bushing is included in the update kit.

STEP 367 STEP 364

BP95F347 BP95F343 Remove and discard the two pins (one on either side of the shifter housing). Use a screwdriver to lift each pin as shown until you can reach the pin with your fingers. Then pull the pin out. New pins are included in the update kit.

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Remove and discard the spring. A new spring is included in the update kit.

Issued 10-97

Printed in U.S.A.

87

STEP 368

BP95F346 Remove and discard the shift lever from the shifter housing. A new shift lever is included in the update kit.

STEP 369 Before starting to reassemble the shifter housing, make the following measurements on the shifter housing.

101 mm 109 mm

10 mm

NOTE: If any of the measurements are more than 0.5 mm less than those shown, the shifter housing has been modified and should be discarded. Assemble the new shifter par ts into a new shifter housing purchased separately from NAPO.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

88

1 2 3 4

4 6 5

7 14

9 15

17

17

18

8

4

10

16

13

19

5 21

13

18

12

11

22 21 20

BT95G179

23 1. Boot 2. Band 3. Shift Lever 4. Pin 5. Allen Head Screw 6. Shifter Housing

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7. O-Ring 8. Spring 9. Bushing 10. Snap Ring 11. Shift Collar 12. Plate

13. Detent Ball 14. Detent Plug 15. Washer 16. Detent Spring 17. Cap Screw 18. Copper Washer

BT97D125

19. Shift Rod for Third and Fourth Gear 20. Shift Rod for First and Second Gear 21. Roll Pin 22. Shift Fork for Third and Four th Gear 23. Shift Fork for First and Second Gear

Issued 10-97

Printed in U.S.A.

89

ASSEMBLY OF THE SHIFTER HOUSING STEP 370

STEP 373

BP95F346 Apply lithium grease to the ball of the new shift lever. Install the shift lever in the shifter housing.

BP95F349 Install the new bushing from the update kit.

STEP 374 STEP 371 2 4 3

1

BP95F344 BP95F352

The correct alignment of the shift lever and the shifter housing is shown above. The slot (1) in the shift lever must be toward the flat side (2) of the flange on the shifter housing.

The slots (3) on each side of the shift lever must be aligned with the holes (4) in each side of the shifter housing.

Put a new snap ring from the update kit on the shift lever. Use a 5/8 inch deep socket to push the snap ring into the snap ring groove.

STEP 375

STEP 372

BP95F343

BP95F347

Install the new pins from the update kit through the holes in the shifter housing so that the pins engage the slots in the shift lever.

Install the new spring from the update kit.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

90

STEP 376

STEP 377

BP95F342 Install the boot so that the end of the boot fits over the ends of the pins. Be careful so that the pins do not fall out during this step. A new boot is provided in the update kit.

Bur 7-54022

BP95F341 Install the band from the overhaul kit on the boot as shown.

Use the side cutters to engage the catch on the band.

Issued 10-97

Printed in U.S.A.

91

DISASSEMBLY OF THE FOUR-WHEEL DRIVE VALVE (IF EQUIPPED) STEP 378

STEP 381

BP95F356

BP95F358

Remove the nut.

Remove the solenoid valve.

STEP 379

STEP 382

BP95F355 Remove the solenoid coil.

BP95F362 Remove the check valve from the solenoid valve body. DO NOT tr y to disassemble the check valve. There are no serviceable parts. If there is a problem, use a new check valve.

STEP 380

STEP 383

BP95F357 Remove and discard the O-ring. Replacement O-rings for the solenoid valve are included in a kit contained in the overhaul kit.

BP95F359 Remove and discard the three O-rings from the solenoid valve.

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Printed in U.S.A.

92

STEP 384

BP95F361 Remove and discard the O-ring from the nut.

10 7 9 7 2

8

1 3

7

4

5 6 BT95G182

BT97D124

1. Cap Screw 2. Plug

Bur 7-54022

3. Copper Washer 4. Solenoid Valve Body

5. Check Valve 6. Gasket

7. O-Ring 8. Solenoid Valve

9. Solenoid Coil 10. Nut

Issued 10-97

Printed in U.S.A.

93

ASSEMBLY OF THE FOUR-WHEEL DRIVE VALVE (IF EQUIPPED) STEP 385

STEP 388

BP95F361 Install a new O-ring on the nut. Use clean transmission oil to lubricate the O-ring. New O-rings for the nut and solenoid are provided in the overhaul kit.

BP95F358 Install the solenoid valve in the solenoid valve body. Tighten the solenoid valve to a torque of 195 pound-inches (22 Nm).

STEP 389 STEP 386

BP95F357 BP95F359 Install the three new O-rings on the solenoid valve. Use clean transmission oil to lubricate the O-rings.

Install a new O-ring on the solenoid valve. Use clean transmission oil to lubricate the O-ring.

STEP 390 STEP 387

BP95F355 BP95F362

Install the solenoid coil on the solenoid valve.

Install the check valve in the valve body as shown.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

94

STEP 391

BP95F356 Install the nut. Tighten the nut to a torque of 71 pound-inches (8 Nm).

Bur 7-54022

Issued 10-97

Printed in U.S.A.

95

DISASSEMBLY OF THE TRANSMISSION CONTROL VALVE STEP 392

STEP 395

BP95F284 Mark the solenoids so that they can be reassembled in the same position and orientation. Remove the nut.

BP95F287 Remove and discard the O-ring from the first solenoid coil.

Replacement O-rings for the solenoids are included in the overhaul kit.

STEP 393 STEP 396

BP95F285 Remove and discard the copper washer. A replacement is included in the overhaul kit.

BP95F288 The second O-ring can stay with either the solenoid coil or the solenoid plunger. Remove and discard the second O-ring.

STEP 394 STEP 397

BP95F286 BP95F290

Remove the first solenoid coil.

Remove the second solenoid coil.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

96

STEP 398

STEP 400

BP95F291 Remove and discard the O-ring from the second solenoid coil.

BP95F293 Remove the retainer from the rear of the connector for the solenoid coils.

NOTE: Before removing any wires from the connector, you may want to record the locations of the wires for reference during assembly.

STEP 399

STEP 401

BP95F292 The remaining O-ring can stay with either the solenoid coil or the solenoid plunger. Remove and discard the remaining Oring.

NOTE: It is not necessary to separate the solenoids to complete the transmission update overhaul; therefore, steps 400 through 403 are not required unless it is necessary to replace one of the solenoids due to damage or malfunction.

BP95F295 Use a small punch to release the locking tab on the terminal.

STEP 402

BP95F296 Pull the wire and the terminal from the connector.

STEP 403 Repeat steps 401 and 402 for the remaining wires and terminals.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

97

STEP 404

STEP 407 1 2 3 4

BP95F297 Loosen the solenoid plunger.

BP95F333 Separate the solenoid plunger (1), the spring (2), the spring spacer (3), and the forward/reverse spool (4). Discard the spring (2) and spring spacer (3). They will be replaced with new parts included in the overhaul kit.

STEP 405

STEP 408

BP95F299 Remove the solenoid plunger with the forward/reverse spool attached.

STEP 406

BP95F334 Remove the O-ring from the solenoid plunger unless it is damaged. A replacement is included in the overhaul kit.

STEP 409

BP95F335 Use a small screwdriver to push down the spring as shown so that you can disengage the notched end of the forward/ reverse spool from the post on the end of the solenoid plunger.

Bur 7-54022

BP95F300 Remove the four Allen head screws which fasten the modulation cover to the control valve body.

Issued 10-97

Printed in U.S.A.

98

STEP 410

STEP 413

BP95F301

BP95F305

Remove the modulation cover.

Remove and discard the first gasket.

STEP 411

STEP 414

BP95F302 Remove the outer modulation piston from the modulation cover. Set the piston and cover aside for inspection later.

STEP 412

BP95F306 Remove the plate. The ball will probably come out of the small bore when you remove the plate. Be careful so that you do not lose the ball.

NOTE: Examine the hole for the check ball. There is a very small orifice hole connecting to one side of the hole for the check ball. Make sure this hole is not plugged.

This condition will result in very slow shuttle shift modulation. Set the ball on the top of the hole in the plate with the ball in contact with the edge that has a radius.

Hold the plate and ball up to bright light and look at the bottom side of the plate and ball. The light should not be visible except at the adjoining orifice hole. If light is visible around the ball, replace the plate (order separately from NAPO).

4 3 2 1

BP95F304 Remove the large spring (1), the small spring (2), the medium spring (3), and the pin (4). Discard the small spring (2). It will be replaced by a new spring included in the update kit.

NOTE: The small spring may be found with broken coils.

This condition can cause abrupt shuttle shifts.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

99

STEP 415

STEP 417

BP95F307 Remove the ball and the spring from the small bore. Discard the spring. A replacement is included in the update kit.

BP95F310 Remove the inner modulation piston.

STEP 418 STEP 416

BP95F309 BP95F308 Remove and discard the remaining gasket. Replacement gaskets are included in the update kit.

Remove the snap ring from the bore. The force of the spring below will probably push up the flow divider shaft. Discard the snap ring. A replacement is included in the overhaul kit.

STEP 419

BP95F311 Remove the flow divider shaft.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

100

STEP 420

STEP 423

BP95F314

BP95F316

Remove and discard the spring. A replacement is included in the overhaul kit.

Remove the snap ring. A replacement is included in the overhaul kit.

STEP 421

STEP 424

BP95F313

BP95F317

Remove the flow divider piston.

Remove the plug from the bore for the forward/reverse spool.

STEP 422

STEP 425

BP95F315 Remove the plug from the opposite end of the bore. Discard the O-ring. New O-rings for both plugs are included in the overhaul kit.

Bur 7-54022

BP95F319 Remove and discard the spring.

Issued 10-97

Printed in U.S.A.

101

STEP 426

STEP 427 1

1

1 1 2

BP95F318 Remove and discard the spring spacer.

Bur 7-54022

BP95F320 Remove the four hex head plugs (1) and the Allen head plug (2). There are copper washers under the plugs. Discard the copper washers. Replacement washers are provided in the overhaul kit.

Issued 10-97

Printed in U.S.A.

102

2

3

5

1 7 8

4 5 3 22 21

6

27 19 25

26

10

11

18

19

20 19

9

3

23

12 14

3

9

13

15 16

26

17

3 24 23

9 29

7

19 28 25

3

17 30

9

1. Nut 2. Copper Washer 3. O-Ring 4. Connector 5. Solenoid Coil 6. Solenoid Plunger 7. Allen Head Screw 8. Modulation Cover

Bur 7-54022

9. Gasket 10. Plate 11. Outer Modulation Piston 12. Small Spring 13. Medium Spring 14. Large Spring 15. Pin 16. Inner Modulation Piston

BT97D123

17. Snap Ring 18. Ball 19. Spring 20. Control Valve Body 21. Cap Screw 22. Hex Head Plug 23. Copper Washer

24. Allen Head Plug 25. Plug 26. Spring Spacer 27. Forward/Reverse Spool 28. Flow Divider Piston 29. Flow Divider Shaft 30. Valve Plate

Issued 10-97

Printed in U.S.A.

103

INSPECTION OF THE TRANSMISSION CONTROL VALVE STEP 428

STEP 430

Use cleaning solvent to clean all metal parts.

Inspect the control valve body for cracks, corrosion, and wear.

Inspect the bores for wear or scoring. If the control valve body is bad, you must use a new transmission control valve.

STEP 429 Inspect the spool and the pistons for damage, wear, or scoring. Use new parts as necessary. Check that the orifice in the outer modulation piston is open. If this is plugged, modulation will be abrupt.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

104

ASSEMBLY OF THE TRANSMISSION CONTROL VALVE STEP 431

Use clean transmission oil to lubricate the flow divider piston.

Install the flow divider piston in the opposite end of the bore.

The closed end of the flow divider piston must be toward the plug in the end of the bore so that the spring will fit inside the open end of the piston..

1 1

1 1

STEP 434 2

BP95F320 Install the four hex head plugs (1) and the Allen head plug (2) using the new copper washers provided in the overhaul kit.

Lubricate the bores of the valve body with clean transmission oil.

STEP 432

BP95F314 Install the new spring from the overhaul kit in the bore.

STEP 435

BP95F316 Install a new snap ring from the overhaul kit in the bore as shown.

BP95F311

STEP 433 Install the flow divider shaft in the bore.

STEP 436

BP95F313

BP95F312

Bur 7-54022

Issued 10-97

Printed in U.S.A.

105 Put a new snap ring into the bore. Use a small screwdriver or punch to push the snap ring and the flow divider shaft down against the spring tension until the snap ring is seated in the snap ring groove.

STEP 440

STEP 437

BP95F324 Install the ball on top of the spring.

STEP 441 BP95F310 Use clean transmission oil to lubricate the inner modulation piston. Install the inner modulation piston so that the end with the deeper bore is toward the outside of the control valve body.

STEP 438

BP95F325 Put the plate into position so that the small hole is over the ball. Position the plate so that the the radius on the edges of the holes and plate are next to the valve casting and the check ball.

STEP 442 BP95F322 Install the new spring from the overhaul kit in the small bore.

STEP 439

BP95F330 Put the remaining new gasket into position on top of the plate.

BP95F323 Install a new gasket from the overhaul kit.

Bur 7-54022

Issued 10-97

Printed in U.S.A.

106

STEP 443

Use clean transmission oil to lubricate the outer modulation piston and bore of the cover. Install outer modulation piston in the modulation cover so that the closed end of the outer modulation piston is toward the modulation cover. Install the modulation cover on the control valve body so that the outer modulation piston fits over the spring and pin assembly.

STEP 446

4

1

2 3

BP95F329

Put the pin (1) and the new small spring (2) from the update kit inside the medium spring (3). Then put the medium spring (3) inside the large spring (4).

STEP 444 BP95F300 Install the four Allen head screws to fasten the modulation cover to the control valve body. Tighten the Allen head screws to a torque of 97 pound-inches (11 Nm).

STEP 447

1 BP95F331 Install the spring and pin assembly into the bore so that the end which has the pin (1) is toward the inside of the control valve body.

STEP 445 BP95F334 Install a new O-ring from the overhaul kit on the solenoid plunger. Use clean transmission oil to lubricate the O-ring.

BP95F332

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Issued 10-97

Printed in U.S.A.

107

STEP 448

STEP 450

1 2 3 4 BP95F333 Assemble the solenoid plunger (1), a new spring (2), a new spring spacer (3), and the forward/reverse spool (4) as shown above. One side of the spring spacer (3) has a chamfer in the bore. Install the spring spacer (3) so that the chamfer is toward the forward/reverse spool (4). The new spring and spacer are included in the overhaul kit.

BP95F299 Install the solenoid plunger and the forward/reverse spool in the control valve body. Make sure that the end of the forward/ reverse spool goes into the spring spacer which was installed in the opposite end of the bore in step 433.

STEP 451

STEP 449

BP95F297 BP95F335 Use a small screwdriver to push down the spring as shown so that you can engage the notched end of the forward/reverse spool with the post on the end of the solenoid plunger. When the notched end and the post are fully engaged, release the spring to hold the forward/reverse spool in position.

Tighten the solenoid plunger to a torque of 204 pound-inches (23 Nm).

STEP 452

BP95F318

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Issued 10-97

Printed in U.S.A.

108 Install the new spring spacer provided in the overhaul kit in the bore as shown. One side of the spring spacer has a very small chamfer on the edge of the inside diameter. Install the spring spacer so that the chamfer is toward the inside of the control valve body. Visually check that the end of the spool protrudes through the hole in the spring spacer.

STEP 455

NOTE: It may be easier to position the spring spacer (step 452) and to install the spring (step 453) if the valve is positioned vertically with the bore facing up.

STEP 453 BP95F315 Install a new O-ring on the plug. Use clean transmission oil to lubricate the O-ring. Install the plug in the bore.

NOTE: Steps 456 through 458 are necessary only if the two solenoids were separated (or one or both are being replaced) at the time of disassembly.

STEP 456 BP95F319 Install the new spring provided in the overhaul kit in the bore.

STEP 454

BP95F298 Before inserting a terminal in the connector, use a small screwdriver to push the locking tab out slightly so that the locking tab will engage the plastic tab in the connector when you insert the terminal.

BP95F317 Install a new O-ring from the overhaul kit on the plug. Use clean transmission oil to lubricate the O-ring. Install the plug in the bore.

Bur 7-54022

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Printed in U.S.A.

109

STEP 457

STEP 459

BP95F296

BP95F294

Push each terminal into the connector until the locking tab and the plastic tab engage, locking the terminal into the connector.

STEP 458

BP95F291 Install new O-rings from the overhaul kit at each end of the solenoid coil which goes next to the control valve body. Use clean transmission oil to lubricate the O-rings.

BP95F293

STEP 460

After all the terminals are in the connector, install the retainer on the rear of the connector.

BP95F290 Install the solenoid coil on the solenoid plunger.

Bur 7-54022

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Printed in U.S.A.

110

STEP 461

Install the remaining solenoid coil on the solenoid plunger.

Recheck that the solenoids are in the same position and orientation as when they were removed.

STEP 463

BP95F289

BP95F285 Install a new copper washer from the overhaul kit.

STEP 464

BP95F287 Install new O-rings at each end of the remaining solenoid coil.

Use clean transmission oil to lubricate the O-rings.

STEP 462 BP95F284 Install the nut. Tighten the nut to a torque of 156 poundinches (17.6 Nm).

BP95F286

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Issued 10-97

Printed in U.S.A.

111

ASSEMBLY OF THE TRANSMISSION HOUSING STEP 465

STEP 467

BP95F366 If the four-wheel drive clutch tube (four-wheel drive machine only) was removed from the front housing, install the fourwheel drive clutch tube.Tighten the fittings to a torque of 354 pound-inches (40 Nm).

STEP 466

BP95F366 If you did not previously install plugs (foam ear plugs work well) in the three oil passages in the edge of the front housing, do so now. (The plugs have not been installed in the picture above.) Scrape all sealing material from the sealing surface of the front housing. Prepare the sealing surface by rubbing with a 3M Scotch-Brite fiber pad or equivalent. DO NOT use steel wool or anything that can leave material on the sealing surface. Flush the front housing with solvent.

STEP 468

BP95F374 If you did not previously install plugs (foam ear plugs work well) in the three oil passages in the edge of the rear housing, do so now. Scrape all sealing material from the sealing surface of the rear housing. Prepare the sealing surface by rubbing with a 3M Scotch-Brite fiber pad or equivalent. DO NOT use steel wool or anything that can leave material on the sealing surface. Flush the rear housing with solvent.

Bur 7-54022

BP95F371 Install the new gasket from the overhaul kit for the valve plate on the front housing.

Issued 10-97

Printed in U.S.A.

112

STEP 469

NOTE: Steps 471 through 473 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 474.

STEP 472

BP95F369 Put the valve plate into position.

STEP 470

BP95F073 Put the bearing for the four-wheel drive shaft into position in the rear housing.

STEP 473

BP95F370 Install the three Allen head screws to fasten the valve plate to the front housing. Tighten the Allen head screws to a torque of 204 pound-inches (23 Nm).

BP95F072

STEP 471 1

1

Use clean transmission oil to lubricate the new thrust washer from the overhaul kit. Install the thrust washer so that the side with the oil grooves is up.

2

STEP 474 1

3

BP95F074 If th e t es t p o r t p lu gs ( 1 ) , th e b r e at he r ( 2 ) , an d t he temperature sender (3) were removed from the rear housing, install these parts. Tighten the test port plugs (1) to a torque of 204 pound-inches (23 Nm). New washers are included in the overhaul kit if replacements are necessary.

BP95F071 Install the four-wheel drive clutch gear so that the side with the lugs is up.

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STEP 475

STEP 477

BP95F375 Connect acceptable lifting equipment to the top gear on the secondary shaft. Lift the secondar y shaft over the rear housing. Engage the shift forks with the synchronizers as shown. Begin to lower the assembly into the rear housing.

BP95F065 Push the primary shaft toward the rear of the rear housing so that there is clearance between the snap ring groove and the rear housing. Install the snap ring.

STEP 478 STEP 476

BP95F064 BP95F067 As you lower the assembly into the rear housing, also begin to install the primary shaft so that the gears on the primary shaft go into mesh with the gears on the secondary shaft.

Continue to lower the parts, making sure that each part goes into the correct bore in the rear housing. (Remember that the shift rod and fork assembly for third and fourth gear goes into the bore nearer the top of the rear housing). When all of the parts are in position, disconnect the lifting equipment.

Push the secondary shaft toward the rear of the rear housing so that there is clearance between the snap ring groove and the rear housing. Install the snap ring. These two snap rings are reused from the original assembly.

NOTE: In order to minimize the number of times that the transmission must be repositioned in the stand, steps 499 through 506, may be completed prior to steps 479 through 498.

NOTE: In steps 479 through 481, the photos show the upper detent parts already installed. It is necessary for you to install both the upper and lower detent parts according to the instructions in the procedure. Make sure you start with both shift rods in the NEUTRAL position.

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STEP 479

STEP 483

BP95G005 Install the lower detent ball.

BP95F062 Install the two detent balls in the groove between the two shift rods.

STEP 480 STEP 484

BP95F063 BP95F060

Install a new lower detent spring.

Install the plate over the two detent balls.

STEP 481 STEP 485

BP95F061 Install a new washer from the overhaul kit on the plug. Install the lower detent plug. Tighten the lower detent plug to a torque of 59 pound-feet (80 Nm).

STEP 482

BP95F059 Apply Loctite 542 or super bond 321 to the threads on the new Allen head bolts included in the overhaul kit. Install the Allen head bolts to fasten the plate in position. Tighten the two bolts to a torque of 37 pound-feet (50 Nm)..

Repeat steps 4767through 479 to install the upper detent ball, spring, and plug.

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STEP 486

STEP 489

BP95F058 Install the shift collars on the shift rods.

BP95F377 Scrape all sealing material from the sealing surface of the rear cover. Prepare the sealing surface by rubbing with a 3M Scotch-Brite fiber pad or equivalent. DO NOT use steel wool or anything that can leave material on the sealing surface.

Wipe the sealing surface with Loctite Safety Solvent or equivalent. Apply a layer of Loctite 518 or Super bond 539 to the sealing surface, including the circle (see arrow) which seals the end of the input shaft.

STEP 487

STEP 490

BP95F376 Install new pins to fasten the shift collars to the shift rods.

1

STEP 488

BP95F055 Put the rear cover in position and install the seven cap screws to fasten the rear cover to the rear housing. Tighten the seven cap screws to a torque of 37 pound-feet (50 Nm). Make sure the dowel (1) is installed in the rear housing and through the hole in the rear cover. It may be necessary to tap the rear cover (near the dowel and bearing embossments) with a soft faced hammer to close the gap between the housing and cover before tightening the bolts.

BP95F368 Use the CAS-2381 special tool to install the new seal from the overhaul kit in the rear cover. Push the seal just until the seal makes contact with the lip in the bore.

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STEP 491

STEP 494 2 2

1 BP95F054 Install a new O-ring from the overhaul kit in the output flange.

Use clean oil to lubricate the O-ring.

BP95F050 Install the new cap screw (1) from the overhaul kit to fasten the output flange to the secondary shaft. Install two cap screws (2) in the output flange as shown.

STEP 492 STEP 495

BP95F053 BP95F051

Install the output flange on the secondary shaft.

Use a prybar between the two cap screws to hold the output flange while you tighten the cap screw in the secondary shaft to a torque of 103 pound-feet (139 Nm).

STEP 493

STEP 496

BP95F052 Install the new washer from the overhaul kit.

BP95F049 Install a new O-ring from the overhaul kit on the shifter assembly. Use clean oil to lubricate the O-ring. Make sure both shift rod assemblies are in the NEUTRAL position. Put the shifter assembly into position on the rear cover.

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STEP 497

STEP 500

BP95F048 Install the three Allen head screws to fasten the shifter assembly to the rear cover. Tighten the three Allen head screws to a torque of 204 pound-inches (23 Nm).

STEP 498

BP95F082 On machines with four-wheel drive, install the four-wheel drive shaft. Use clean transmission oil to lubricate the bearing surfaces on the four-wheel drive shaft. Make sure that the four-wheel drive shaft goes through the four-wheel drive clutch gear, the thrust washer, and the bearing.

STEP 501

BP95F373 Use the four new copper sealing washers from the overhaul kit to install the oil tube to the front housing. Tighten the hollow cap screws to a torque of 354 pound-inches (40 Nm).

STEP 499

BP95F378 Wipe the sealing surface of the rear housing and the front housing with Loctite Safety Solvent or equivalent. Apply a layer of Loctite 518 or Super bond 529 to the sealing surface of the rear housing.

BP95F083 Install the input shaft and the reverse shaft together as shown. Make sure that the reverse shaft is installed with the same end up as when it was removed.

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STEP 502

STEP 505

BP95F081 Remove the three plugs from the oil passages in the rear housing (see arrows). Install three new O-rings from the overhaul kit for the oil passages. Remove the three plugs from the oil passages in the front housing.

STEP 503

BP95F385 Install all of the housing cap screws that fasten from the rear housing to the front housing. There are 13 of these cap screws on four-wheel drive transmissions and 14 on twowheel drive transmissions. Tighten the cap screws to a torque of 37 pound-feet (50 Nm).

NOTE: Steps 506 through 517 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 518.

STEP 506

BP95F046 Use clean transmission oil to lubricate the new bearing for the primary shaft and the new bearing for the secondary shaft.

Install the bearings.

BP95F382

STEP 504

Install the three cap screws that fasten from the front housing to the rear housing. Tighten the cap screws to a torque of 37 pound-feet (50 Nm).

BP95F379 Install the front housing on the rear housing. Make sure that the bearings on the shafts go straight into the bores in the front housing. Push the front housing all the way down on the rear housing.

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STEP 507

STEP 509

BP95F354 Install the two new sealing rings from the overhaul kit on the collar for the four-wheel drive shaft. Turn the sealing rings on the collar so that the connecting end of each sealing ring is 180 degrees from the connecting end of the other sealing ring.

BP95F383 Use clean transmission oil to lubricate the bearing for the four-wheel drive shaft. Install the bearing on the four-wheel drive shaft.

STEP 510

NOTE: The connecting ends of the sealing rings in the photo above are shown aligned so that the sealing rings can be seen clearly.

STEP 508

BP95F353

BP95F384 Use clean transmission oil to lubricate the collar and the fourwheel drive shaft. Install the collar on the four-wheel drive shaft.

Use the CAS-2381 special tool to install the new seal from the overhaul kit in the cover. Use of a press, rather than a hammer, assures that the seal is installed straight. Push just until the seal stops moving. DO NOT use excessive force. Fill the cavity under the lip of the seal with high temperature wheel bearing grease.

STEP 511

BP95F351 Install a new O-ring from the overhaul kit on the cover. Use clean transmission oil to lubricate the O-ring.

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STEP 512

STEP 515

BP95F035 Install the cover in the front housing.

BP95F032 Install a new washer. This washer and the new cap screw being installed in step 516 are provided in the overhaul kit.

STEP 513 STEP 516 2

2

1 BP95F034 Install the three cap screws which fasten the cover to the front housing. Tighten the cap screws to a torque of 204 poundinches (23 Nm).

BP95F031 Install the cap screw (1) to fasten the four-wheel drive flange to the four-wheel drive shaft. Install two cap screws (2) in the four-wheel drive flange as shown.

STEP 514 STEP 517

BP95F033 Install a new O-ring from the overhaul kit in the four-wheel drive flange. Use clean transmission oil to lubricate the Oring. Install the four-wheel drive flange on the four-wheel drive shaft.

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BP95F030 Use a prybar between the two cap screws to hold the fourwheel drive flange while you tighten the cap screw in the fourwheel drive shaft to a torque of 103 pound-feet (139 Nm).

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STEP 518

STEP 521

BP95F380 Pull the input shaft toward the front of the transmission to get clearance for the snap ring.

BP95F386 Use clean transmission oil to lubricate the O-ring on the oil pump. Install the oil pump. Make sure that the alignment marks which you made during disassembly are aligned.

STEP 519 STEP 522

BP95F381 BP95F038

Install the snap ring on the bearing. This snap ring must be reused from the original assembly (unless a new bearing has b e e n i n s t a l l e d - t h e s n a p r i n g i s p r ov i d e d w i t h t h e replacement bearing).

If you used a guide stud, remove the guide stud. Install the six cap screws which fasten the oil pump in position. Tighten the cap screws to a torque of 204 pound-inches (23 Nm).

STEP 520

STEP 523

BP95F387 It will be easier to install the oil pump if you use a guide stud as shown above. You can make a guide stud by cutting the head from an M8 cap screw.

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BP95F027 If you removed the dipstick tube, install a new O-ring (not provided in the overhaul kit). Use clean transmission oil to lubricate the O-ring.

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STEP 524

STEP 526

BP95F026 Install the dipstick tube.

BP95F024 If the two plugs were removed, make sure that the threads are clean and apply Loctite 262 (red) to the threads before installation. Tighten the plugs to a torque of 354 poundinches (40 Nm).

STEP 525

NOTE: The parts being installed in steps 527 through 529 are contained in a priority valve kit that is included in the overhaul kit.

STEP 527

BP95F025 Install the dipstick.

NOTE: Steps 526 through 529 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 530.

BP95F389 Install the new four-wheel drive priority valve in the oil filter bore. The end with the screw and lock nut is inserted first.

STEP 528

BP95F022 Install the new spring.

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STEP 529

STEP 532

BP95F021 Install the new spool.

BP95F018 Install the new gasket for the four-wheel drive valve. The gasket is included in the overhaul kit.

STEP 530 STEP 533

BP95F020 BP95F017

Install the fitting for the oil filter. Tighten the fitting to a torque of 37 pound-feet (50 Nm).

Put the four-wheel drive valve in position on the gasket.

STEP 531

STEP 534

BP95F019 Use clean transmission oil to lubricate the gasket on the oil filter. Install the oil filter. Use only part no. 254686A1.

NOTE: Steps 531 through 535 are for four-wheel drive transmissions only. If you are working on a two-wheel drive transmission, go to step 536.

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BP95F016 Install the three cap screws which fasten the four-wheel drive valve to the front housing. Tighten the cap screws to a torque of 204 pound-inches (23 Nm). A new washer is included in the overhaul kit if replacement is necessary.

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STEP 535

STEP 538

BP95F390 Install new O-rings from the overhaul kit on the sleeve. Use clean transmission oil to lubricate the O-rings. Install the sleeve in the bore above the bore for the oil screen.

BP95F393 Make sure the magnet is firmly attached to the plate before installing the cover. Install the cover for the oil screen.

STEP 539 STEP 536

BP95F008 BP95F391 Install a new O-ring from the overhaul kit on the spool. Use clean transmission oil to lubricate the O-ring. Install the spool.

Install the two cap screws which fasten the cover for the oil screen. Tighten the cap screws to a torque of 204 poundinches (23 Nm).

STEP 540 STEP 537

BP95F388 BP95F009 Install a new O-ring from the overhaul kit on the oil screen.

Use clean transmission oil to lubricate the O-ring. Install the oil screen and O-ring.

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STEP 541

STEP 544 After completing the transmission update/rebuild, stamp the transmission serial number tag with “U3” so that it can be identified as “updated” if necessary, in the future.

BP95F014 Put the transmission control valve in position on the gasket.

NOTE: Install the torque converter into the transmission oil pump before the transmission is reinstalled in the tractor. Bolt the transmission securely to the engine flywheel housing before sliding the torque converter against the flywheel housing. Make sure the disc on the flywheel end of the torque converter slides freely into the bore in the end of the crankshaft. Torque the bolts securing the torque converter gradually-all snug at first, followed by all at approximately 50% of required torque, then all at full specified torque. See page 4.

NOTE: When installing the rebuilt transmission into the tractor, tighten the bolts attaching the rear mounting brackets to the transmission to a torque of 90 to 107 Nm (66 to 79 pound-feet). Use the new lock nuts (part no.

832-10416) on the bolts through rear isolation mounts for the engine-transmission assembly. Tighten to a torque of 174 to 220 Nm (132 to 161 pound-feet). Remember to use Loctite 707 Activator (part no. 345-153) and 324 Sealant (part no. 345-152) and new bolts (par t no. 60812025) when attaching the drive shafts to the transmission output flanges. Tighten the bolts to a torque of 128 to 142 Nm (95 to 105 pound-feet). Reference Case Service Bulletin NLB SB00595.

STEP 542

BP95F013 Install the cap screws which fasten the transmission control valve to the front housing. Tighten the cap screws in a pattern alternating from front to back and side to side until all the cap screws are at a torque of 204 pound-inches (23 Nm).

STEP 543

NOTE: After installation in the tractor, fill the transmission with the specified amount of Case HyTranPlus transmission oil. See page 4. It is recommended that the oil and filter are replaced at approximately 100 hours of operation after the rebuild.

Clean the suction screen at the same time. This will purge any initial assembly debris and provide an acceptable baseline for future oil analysis. After the initial service at 100 hours, 1000 hour intervals are acceptable.

BP95F007 Install the drain plug. Tighten the drain plug to a torque of 59 pound-feet (80 Nm).

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11

12 13 14 15 21

16 13

3

24 4

20 6

23

22 4

10 18 17 3 19

2 1

2

18

4

3 4

6 5 8

6 6

9 6 7 1. Tube 2. Hollow Cap Screw 3. Copper Washer 4. Cap Screw 5. Cover 6. O-Ring

7. Oil Screen 8. Spool 9. Sleeve 10. Front Housing 11. Oil Filter 12. Fitting

BT95G172

13. Plug 14. Spool 15. Spring 16. Four-Wheel Drive Priority Valve 17. Four-Wheel Drive Clutch Tube 18. Fitting

19. Rear Housing 20. Breather 21. Test Port Plug 22. Drain Plug 23. Rear Cover 24. Dowel Pin

Four-Wheel Drive Transmission

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13

3

9

16 12

4

10 6

15 14

8 4

3

4 11

2 1

4

2 3

4

5 6 7

BT95G173

BT95G173

1. Tube 2. Hollow Cap Screw 3. Copper Washer 4. Cap Screw

5. Cover 6. O-Ring 7. Oil Screen 8. Front Housing

9. Oil Filter 10. Fitting 11. Rear Housing 12. Breather

13. Test Por t Plug 14. Drain Plug 15. Rear Cover 16. Dowel Pin

Two-Wheel Drive Transmission

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ALPHABETICAL INDEX DESCRIPTION

PAGE

Transmission Dipstick................................................................................................................................................... 131 Filter - Oil................................................................................................................................................ 133 Housing ........................................................................................................................................... 135,137 Idler and Primary Shaft .......................................................................................................................... 143 Input Shaft .............................................................................................................................................. 145 Mounting................................................................................................................................................. 131 Output Shaft ........................................................................................................................................... 149 Pump - Oil .............................................................................................................................................. 139 Secondary Shaft..................................................................................................................................... 147 Shift Lever .............................................................................................................................................. 131 Shifter Mechanism.................................................................................................................................. 141 Valve - Control ........................................................................................................................................ 151 Valve - Solenoid ..................................................................................................................................... 153

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B9501064S

131

TRANSMISSION MOUNTING, DRIVE SHAFT, DIPSTICK AND GEAR SHIFT LEVER REF. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO. 187714A1 187715A1 484-6316 459-11014 493-41020 179689A1 190618A1 280-16516 828-12055 492-11050 829-1412 126-116 143370A1 123842A1

15

123843A1

16 17 18 19 20 21 22 23 24 25 26 27* 28 29 30 31 32 33 34 35 36 37

614-10035 895-11010 222-3006 121659A1 121658A1 1995137C1 428-510 A15672 A178706 895-11010 626-10016 614-12040 896-15012 184791A1 185338A1 814-16110 D35009 117846A1 832-10416 119045A1 608-12025 183175A1

DESCRIPTION REQ’D. KNOB - upper, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KNOB - lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SCREW - set, hex socket, 5/16 NF x 3/8 inch, half dog point . . . . . . . . . . . . . . . .1 SCREW - machine, pan head slotted, No. 10 NF x 7/8 inch . . . . . . . . . . . . . . . . .2 WASHER - external tooth lock, 3/16 inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 LEVER - transmission gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOOT - transmission gear shift lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SCREW - self-tapping, hex washer head, No. 10 - 16 x 1 inch . . . . . . . . . . . . . . .4 BOLT - hex, 12 - 1.75 x 55 mm, class 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - lock, 1/2 inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 NUT - hex, 12 mm - 1.75, class 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KEY - Woodruff, 3/16 x 3/4 inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - return, shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, full threads, 10 - 1.5 x 35 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 WASHER - flat, 11 x 21 x 2 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 ADAPTER - compression, 1 tube OD x 3/4 inch PT . . . . . . . . . . . . . . . . . . . . . . .1 TUBE - transmission dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 DIPSTICK - oil level, transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 CONVERTER - torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, 5/16 NF x 5/8 inch, grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 WASHER - flat, hardened, special. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 PLATE - adapter, torque converter to engine flywheel . . . . . . . . . . . . . . . . . . . . .1 WASHER - flat, 11 x 21 x 2 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 BOLT - hex, full threads, 10 - 1.5 x 16 mm, class 10.9 . . . . . . . . . . . . . . . . . . . . .6 BOLT - hex, full threads, 12 - 1.75 x 40 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 WASHER - flat, 13.5 x 28 x 4 mm, hardened . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 BRACKET - mounting, transmission, right-hand . . . . . . . . . . . . . . . . . . . . . . . . . .1 BRACKET - mounting, transmission, left-hand . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, 16 - 2.0 x 110 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 WASHER - flat, special, 5/8 inch, hardened . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 INSULATOR - engine mount, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 NUT - hex, self-locking, 16 mm - 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SHAFT - drive, transmission to rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, self-locking, 12 - 1.75 x 25 mm, class 10.9 . . . . . . . . . . . . . . . . . . . .4 SEAL - foam, transmission control lever, installed between firewall and flange on four speed shift lever boot, cab models only . . . . . . . . . . . . . . . . . . . . .1

* Some early 580SL units had 50 mm long bolts (part no. 614-12040) on the left side. These units had a spacer bolted to the transmission case. Later transmissions had the “spacer” cast onto the transaxle.

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1 2

3 13 12

4

11

5 6 7 6

10 9 8

B9505102T

B9505102T

133

TRANSMISSION ASSEMBLY OIL FILTERS TWO WHEEL AND FOUR WHEEL DRIVE REF.

PART NO. 123842A1 123843A1

1 2 3 4 5 6

254686A1 181101A1 181274A1 181141A1 181196A1 190426A1

7 8 8 9 10 11 12 13

190433A1 181168A1 278534A1 100748A1 181219A1 614-8018 181102A1 181202A1

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DESCRIPTION TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILTER - oil, cartridge, transmission, 15 micron rating . . . . . . . . . . . .

PLUG - oil, 14 - 1.5 mm, used on four wheel drive models only . . . . .

KIT - valve, used on four wheel drive models only. . . . . . . . . . . . . . . .

O-RING - small, used on four wheel drive models only . . . . . . . . . . . .

PLUG - bypass valve, used on four wheel drive models only . . . . . . .

O-RING - bypass valve, cylinder, one (1) used at each end of item 7, cylinder bypass valve, used on four wheel drive models only . . . . . . .

CYLINDER - bypass valve, used on four wheel drive models only . . .

FILTER - oil, cylindrical mesh. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILTER - oil, pleated mesh O-RING - sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COVER - access, oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOLT - hex, full threads, 8 - 1.25 x 18 mm . . . . . . . . . . . . . . . . . . . . .

PLUG - oil, used on four wheel drive models only, external to filter. . .

CONNECTOR - straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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REQ’D. . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .2 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .2 . . . . . .1 . . . . . .1

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B9503038T

4 5

3

7 2 14

6 8

12 9

7 13 10

11

1

12 7

B9503038T

B9503038T

135

TRANSMISSION ASSEMBLY TRANSMISSION HOUSING - TWO WHEEL DRIVE REF.

PART NO. 123842A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14

181267A1 1530028C1 934667R1 181100A1 K260177 181197A1 614-10030 100557A1 814-10150 181268A1 181179A1 181105A1 181232A1 181141A1

Bur 7-54022

DESCRIPTION REQ’D. TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 HOUSING - front half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BREATHER - housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - flat, copper, special, 10 x 14 x 1.5 mm . . . . . . . . . . . . . . . . . . . . .2 PLUG - housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 PIN - dowel, special, 10 x 25 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 COVER - housing, rear half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, full threads, 10 - 1.5 x 30 mm . . . . . . . . . . . . . . . . . . . . . . . . . .23 PLUG - drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, 10 - 1.5 x 150 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 HOUSING - rear half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 WASHER - flat, copper, special, 14 x 20 x 1.5 mm . . . . . . . . . . . . . . . . . . . . .4 TUBE - oil lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 O-RING - housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Issued 10-97

Printed in U.S.A.

136

B9503037T

4 3

6

7

5

2 15

8

10

9

7

12

14 13 9

11

12

1 7

B9503037T

B9503037T

137

TRANSMISSION ASSEMBLY TRANSMISSION HOUSING - FOUR WHEEL DRIVE REF.

PART NO. 123843A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

181200A1 1530028C1 934667R1 181100A1 K260177 181197A1 614-10030 100557A1 218-1023 181201A1 181179A1 181105A1 181232A1 181176A1 181141A1

Bur 7-54022

DESCRIPTION REQ’D. TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 HOUSING - front half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BREATHER - housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - flat, copper, special, 10 x 14 x 1.5 mm . . . . . . . . . . . . . . . . . . . . .2 PLUG - housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 PIN - dowel, special, 10 x 25 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 COVER - housing, rear half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, full threads, 10 - 1.5 x 30 mm . . . . . . . . . . . . . . . . . . . . . . . . . .23 PLUG - drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 ADAPTER - straight, 1/2-20 flare x 1/4 inch PT . . . . . . . . . . . . . . . . . . . . . . . .2 HOUSING - rear half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 WASHER - flat, copper, special, 14 x 20 x 1.5 mm . . . . . . . . . . . . . . . . . . . . .4 TUBE - oil lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TUBE - oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 O-RING - housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Issued 10-97

Printed in U.S.A.

138

B9503040T

1

5

8 7

3

4

3A

6

2 21 20

9 16

10 12 5

13 18 19

17 14 15 B9503040T

B9503040T

11

139

TRANSMISSION ASSEMBLY OIL PUMP TWO WHEEL OR FOUR WHEEL DRIVE REF.

PART NO. 123842A1 123843A1

1 2 3 3A 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Bur 7-54022

181199A4 181143A1 181270A1 192803A1 198713A1 181109A1 192802A1 864-6025 NSS 181145A1 181214A1 198712A1 181215A1 181217A1 181216A1 181205A1 814-8060 NSS 247748A1 181142A1 246767A1 NSS

DESCRIPTION REQ’D. TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PUMP ASSEMBLY - oil, transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SHAFT - small. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PIN - valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - flat, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PIN - roll, 5 x 22 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 VALVE - piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex socket, 6 - 1.0 x 25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SUPPORT - pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BALL - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GUIDE - spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BUSHING - pump support, small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BUSHING - pump support, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BUSHING - pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SEAL - oil, pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, 8 - 1.25 x 60 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 HOUSING - oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GEAR - large, 23 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 O-RING - pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BEARING - needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GEAR - small, 12 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Issued 10-97

Printed in U.S.A.

140

10

11 B9501063T

8 9

7 6 12 13 14

24

25

23

2

15

3

20

4

1

5 23

5 16 17

20 18 20 19

B9501063T B9501063T

22 21

B9501063T

141

TRANSMISSION ASSEMBLY TRANSMISSION SHIFTER MECHANISM TWO WHEEL OR FOUR WHEEL DRIVE REF.

PART NO. 123842A1 123843A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Bur 7-54022

181206A2 614-12016 1966835C1 1966993C1 181139A1 864-8025 181171A1 190428A3 1967585C1 1967581C1 181177A1 181138A1 278533A1 278532A1 279039A1 181173A1 864-10025 181175A1 181245A1 905794R1 181203A1 181174A2 181104A1 181275A1 614-8016

DESCRIPTION REQ’D. TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 RAIL - shifter fork, third and fourth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, full threads, 12 - 1.75 x 16 mm . . . . . . . . . . . . . . . . . . . . . . . . . .3 WASHER - flat, special, 12 x 16 x 1.5 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SPRING - detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 BALL - detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 BOLT - hex socket, 8 - 1.25 x 25 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 COVER - shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 LEVER - shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PIN - shift lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 BOOT - rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 CLAMP - adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 O-RING - sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BUSHING - shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 RING - snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SHIFTER - rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 BOLT - hex socket, 10 - 1.5 x 25 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 PLATE - retainer, detent ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 RAIL - shifter fork, first and second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PIN - roll, 6 x 30 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 FORK - gear shift, first and second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 FORK - gear shift, third and fourth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - sealing, copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 BOLT - hex, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, full threads, 8 - 1.25 x 16 mm . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Issued 10-97

Printed in U.S.A.

142

1 2 5

4

3 2 1 6 7 8 9 10

11

12

B9407070T

143

TRANSMISSION ASSEMBLY IDLER AND PRIMARY SHAFT TWO WHEEL OR FOUR WHEEL DRIVE REF.

PART NO. 123842A1 123843A1

1 2 3 4 5 6 7 8 9 10 11 12

Bur 7-54022

ST205A 181151A1 181186A1 181181A1 181186A1 A48041 181128A1 181154A1 181188A1 181187A1 181184A1 181132A1

DESCRIPTION TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIM - bearing, 52 x 35.1 x 4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - idler, 27 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHAFT - idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - idler, 27 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER - thrust, 65 x 45 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - drive, third, 28 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - drive, fourth, 39 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHAFT - primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 10-97

REQ’D. . . . . . .1 . . . . . .1 . . . . . .2 . . . . . .2 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1

Printed in U.S.A.

144

11 12 11

JOHN

9

10 12

8 7 6 4

5 14

3

13

15 2

16

1

17 18 21

20

1 18 17 16

19

15

6

14

2

19

13

24 5 23 22 12

10 8

11 9

BT97D126

11

12 BP97d126

145

TRANSMISSION ASSEMBLY INPUT SHAFT TWO WHEEL OR FOUR WHEEL DRIVE REF.

PART NO. 123842A1 123843A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Bur 7-54022

181152A1 A48041 181128A1 181153A1 181154A1 181135A1 181228A1 181162A1 181116A1 181163A1 181159A1 181158A1 181111A1 181161A1 181160A1 181155A2 181157A1 181156A1 181108A1 181185A1 D142898 181227A1 181164A1 181126A1

DESCRIPTION TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAL - oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPACER - bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER - thrust, 65 x 45 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - input shaft, 35 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLATE - thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER - thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLATE - disc, intermediate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLATE - disc, clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLATE - pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPRING - clutch piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTON - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - seal, small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PIN - roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHAFT - input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLUG - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - shaft, 29 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPACER - bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 10-97

REQ’D. . . . . . .1 . . . . . .1 . . . . . .4 . . . . . .2 . . . . . .1 . . . . . .1 . . . . . .2 . . . . . .4 . . . . . .1 . . . . . .2 . . . . . .2 . . . . . .2 . . . . .16 . . . . .12 . . . . . .2 . . . . . .2 . . . . . .2 . . . . . .2 . . . . . .2 . . . . . .2 . . . . . .4 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1

Printed in U.S.A.

146

5 5

4

17

3 2 1

5 18 6 16

7

14 8

15

13

28

9 12 10 11

27

10 5

9 8 7 6

26 6 7

14 15

13

8

9 12 10 11 35

10 9 8

34

7 6

33 32

5 31

19 30 29

B9501064S

147

TRANSMISSION ASSEMBLY SECONDARY SHAFT TWO WHEEL OR FOUR WHEEL DRIVE REF.

PART NO. 123842A1 123843A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 26 27 28 29 29 30 31 32 33 34 35

Bur 7-54022

181118A1 181132A1 181193A1 181190A1 181114A1 294109A1 190427A1 NSS NSS NSS NSS NSS NSS NSS NSS NSS 181189A1 181226A1 181224A1 181220A1 181192A1 181108A1 181183A1 181191A1 181154A1 278531A1 181130A1 181123A1 181231A1 181144A1 181165A1 P3533055

DESCRIPTION REQ’D. TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 RING - lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - thrust, 64 x 40 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GEAR - driven, second, 43 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 RING - snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 SPACER - gear to synchronizer ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 KIT - synchronizing service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 RING - synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 RING - synchronizer, flanged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SPACER - hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 RETAINER - spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 HUB - synchronizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SPRING - hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 BALL - hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 PLATE - spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 SLEEVE - hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 GEAR - driven, first, 49 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPACER - gear, two-wheel drive models. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GEAR - drive, MFD, 44 teeth, backhoe models . . . . . . . . . . . . . . . . . . . . . . . .1 GEAR - drive, 43 teeth, 570LXT only . . . . . .1 GEAR - driven, fourth, 23 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PIN - roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SHAFT - secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GEAR - driven, third, 33 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - thrust, 65 x 45 mm, 4 mm thick . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - thrust, 65 x 45 mm, 3.8 mm thick . . . . . .1 BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SEAL - oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 FLANGE - shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 O-RING - flange sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - flat, special, 52 x 12.5 x 5 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SCREW - locking, special, 12 - 1.25 x 25 mm . . . . . . . . . . . . . . . . . . . . . . . . .1

Issued 10-97

Printed in U.S.A.

148

7 6

8

5 4 3 1

2

22 21 20

9 10 11 12 13

16 14 15 17 18 19

B9407072T

B9407072T

149

TRANSMISSION ASSEMBLY FOUR WHEEL DRIVE OUTPUT SHAFT REF.

PART NO. 123843A1

1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22

181230A1 614-8022 181198A1 112517A1 181122A1 ST205A 181152A1 181194A1 181126A1 181154A1 181221A1 181223A1 100747A1 181182A1 100748A1 181248A1 D142898 100753A1 181276A1 181120A1 P3533055 P2745466 238-8217

Bur 7-54022

DESCRIPTION TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLANGE - shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOLT - hex, full threads, 8 - 1.25 x 22 mm . . . . . . . . . . . . . . . . . . . . .

COVER - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O-RING - cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAL - oil, 60 x 75 x 8 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BUSHING - grooved. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING - ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER - thrust, 65 x 45 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - driven, MFD, 37 teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR - driven, MFD, 36 teeth, backhoe models O-RING - shaft, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHAFT - output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O-RING - shaft, small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SLEEVE - shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLUG - shaft, 10 x 1 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPRING - sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER - flat, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING - snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCREW - locking, special, 12 - 1.25 x 25 mm . . . . . . . . . . . . . . . . . . .

WASHER - flat, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O-RING - 1-3/16 ID x 1/8 inch wide . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 10-97

REQ’D. . . . . . .1 . . . . . .1 . . . . . .3 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .2 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .2 . . . . . .1 . . . . . .1 . . . . . .6 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1

Printed in U.S.A.

150

7

6

9

8

5 4

3

3 5 2

35 34 1

5

10

36

11 12

18

30

14

31 31 30

15 32

16

28

17

29 20 22

19

25 26 27

28 29

16

B9411168T

B9411168T

21 23 24

38

13

37

10

151

TRANSMISSION ASSEMBLY TRANSMISSION CONTROL VALVE TWO WHEEL OR FOUR WHEEL DRIVE REF.

PART NO. 123842A1 123843A1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38

Bur 7-54022

190434A1 NSS 190442A1 190443A1 190437A1 181136A1 181273A1 181272A1 864-6020 181251A1 181256A1 190439A1 190438A1 190435A1 190441A1 181234A1 112504A1 181261A1 181146A1 181107A1 181103A1 864-8020 181166A1 181207A1 181208A1 181254A1 181260A1 181255A1 181137A1 181258A1 181262A1 181253A1 190444A1 814-8080 181100A1 934667R1 190436A1 190440A1

DESCRIPTION REQ’D. TRANSMISSION ASSEMBLY - two wheel drive, parts list pages 133, 135, 139 - 147 and 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 VALVE ASSEMBLY - transmission control . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BODY - transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PLUNGER - solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 COIL - solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 CONNECTOR - solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 O-RING - sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 WASHER - sealing, copper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PLUG - hex, cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex socket, 6 - 1.0 x 20 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 COVER - modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GASKET - cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SPACER - gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PISTON - modulation, outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - outer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PISTON - modulation, inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 RING - snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BALL - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 WASHER - sealing, copper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PLUG - oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex socket, 8 - 1.25 x 20 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 GASKET - body to valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PLATE - valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 GASKET - valve plate to transmission housing . . . . . . . . . . . . . . . . . . . . .1 SHAFT - flow divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SPRING - piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PISTON - flow divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 O-RING - plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 PLUG - valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SPRING - spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SPACER - spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SPOOL - forward/reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 BOLT - hex, 8 - 1.25 x 80 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 PLUG - valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 WASHER - flat, copper, special, 10 x 14 x 1.5 mm . . . . . . . . . . . . . . . . . .2 SPRING - piston, outer modulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PIN - piston, inner modulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Issued 10-97

Printed in U.S.A.

152

1 2 3

2

5 7 6

4

8

10

9

BT97d124

153

TRANSMISSION ASSEMBLY SOLENOID VALVE - FOUR WHEEL DRIVE REF.

1 2 3 4 5 6 7 8 9 10

Bur 7-54022

PART NO. 123843A1 190432A1 NSS NSS NSS 181149A1 181100A1 934667R1 814-8060 190429A1 190430A1 190431A1

DESCRIPTION TRANSMISSION ASSEMBLY - four wheel drive, parts list pages 133 and 137 - 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE ASSEMBLY - solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NUT - cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COIL - solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE - solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KIT - seal, solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLUG - valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER - flat, copper, special, 10 x 14 x 1.5 mm . . . . . . . . . . . . . . .

BOLT - hex, 8 - 1.25 x 60 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BODY - solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKET - body to transmission housing . . . . . . . . . . . . . . . . . . . . . . .

VALVE - solenoid, installed between item 8 and item 9. . . . . . . . . . . .

Issued 10-97

REQ’D. . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .1 . . . . . .2 . . . . . .2 . . . . . .3 . . . . . .1 . . . . . .1 . . . . . .1

Printed in U.S.A.

154