Cat TH336 TH337 TH40 TH407TH414 TH514 TH417 Telehandler PowerSynchro Transmission Parts Manual - PDF

PowerSynchro Transmission Parts Manual Models TH336, TH337, TH406, TH407, TH414, TH514, TH417 S/N TDE00100 & After S/N TDF00100 & After S/N TBX00100 & After S/N TBY00100 & After S/N TBZ00100 & After S/N TBW00100 & After S/N TBT00100 & After 31200493 Original June 25, 2008

Product and Dealer Information Delivery Date:

Product Information Model: Product Identification Number: Transmission Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:

Dealer Information Name:

Branch:

Address:

Dealer Contact Sales: Parts: Service:

Phone Number

Hours

GENERAL INFORMATION 1. MACHINE IDENTIFICATION

2. ORDERING PARTS

Caterpillar machines are identified by Product Identification Numbers (PIN). Some components included in a machine may be identified by Serial Numbers (S/N). Typical components that will be serialized include engines, transmissions, bulldozers, and rippers. The machine and engine are further identified by arrangement numbers and in some cases modification numbers. These numbers are shown on the product identification plate(s) and on the master plate in the operator’s compartment.

Caterpillar dealers need all of these numbers to determine accurate parts identification.

Effective First Quarter 2001 the Caterpillar Product Identification Number (PIN) will change from 8 to 17 characters. In an effort to provide uniform equipment identification, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard. Non-road machine PINs are defined by ISO 10261. The new PIN format will apply to all Caterpillar machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following:

Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Their parts inventories are up to date and include all parts normally required to protect your investment in Caterpillar machines. Dealers may offer repair kits or remanufactured parts to allow selection of the most effective repair alternative for a particular situation.

When ordering parts, your order should specify the quantity, part number, part name, and the serial number/product identification number of the machine for which the parts are needed.

3. PARTS MANUAL ORGANIZATION Product information in this manual is presented as "information elements" that represent all of the components for the specific model. Engine Arrangement and Seat Group are examples of information elements.

4. TABLE OF CONTENTS A table of contents (TOC) is found at the beginning of the manual. The TOC lists each section of the manual with a complete list of all information elements organized as they appear in the manual.

Where: 1. Caterpillar’s World Manufacturing Code (characters 1-3) 2. Machine Descriptor (characters 4-8) 3. Check Character (character 9) 4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number.

Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format.

Components such as engines, transmissions, axles, etc. and work tools will continue to use an 8 character Serial Number (S/N).

GENERAL INFORMATION 5. CAPTIONS

8. INDENTED PART NAMES

Captions located at the top of each page of an information element identify the part number and part name along with additional descriptive information.

PIN and S/N information found in each caption should be used to select correct information for a specific machine. Field replacement options, identification of optional attachment components, and where used ("part of") information is also provided.

When a part name is indented in a parts list, it is part of (included in) the group or assembly under which it is indented.

The first line of a caption is shown in larger type font to indicate the beginning of an information element.

Captions for additional pages that may be required to illustrate an information element will be shown in standard type font and will include the term (contd.).

6. NON-SERVICED PARTS In some instances it is necessary to display non-serviced parts that are a link to a lower level serviceable consist lists. These non-serviced part numbers are shown in italic type indicating that they are not available.

7. PARTS LIST REFERENCE NUMBERS Numbers shown in the Ref No column correspond to numbers used in the associated graphic(s). An alphabetic suffix may be added to a reference number to identify lower level consist items. Numbers shown in the Graphic Ref column refer to the graphic number identifier displayed in the lower left corner of each illustration. The Graphic Ref number may be used in combination with the item Ref No to determine the correct part number. There may be intentional omission of a Ref No in a consist list as information is updated to reflect the latest serviceable part numbers.

9. ILLUSTRATION REFERENCE LETTERS When necessary, illustrations contain reference letters (A, B, C etc.) that are intended to track lines and harnesses from one point to another. They are also used to show where to reconnect illustrations that have been separated.

10. ABBREVIATIONS AND SYMBOLS O.D. – Outside Diameter I.D. – Inside Diameter A – Not Part Of This Group B – Use As Required C – Change From Previous Type D – Order By The Meter E – Order By The Centimeter F – Not Shown G – Order By The Inch I – See Hose Fabrication Guide M – Metric Part R – Remfg Part May Be Available Y – Separate Illustration Z – Not Serviced Separately NOTE: Continuing improvement and advancement of product design may cause changes to your machine which may not be included in this publication. Whenever a question arises regarding your Caterpillar product or this publication, please consult your Caterpillar dealer for the latest available information.

Table of Contents 4 Speed Transmission 323-8993-00 ............................. 2 5 Speed Transmission 323-8994-00 ............................. 22

POWERSYNCHRO TRANSMISSION 4 SPEED 323-8993

2

POWERSYNCHRO TRANSMISSION - 4 SPEED 323 - 8993 TRANSMISSION AR ENGINEERING MODEL: PT070 NOTE

REF NO

Y

Y Y - SEPARATE ILLUSTRATION

GRAPHIC NO

SERIAL NUMBER PREFIX: LKT PART NAME

PART NUMBER 311-4066 217-7217 230-7551 293-5003 312-3580

QTY 1 1 1 1 1

<END> 4

1

2

3

4

5

6 (PRODUCT LEVEL)

TRANSMISSION AR DRIVE GP - FLEX CONVERTER AS TC GP - BASIC XMSN GP - DIRECT DRIVE

SEE PAGE 5

6

POWERSYNCHRO TRANSMISSION - 4 SPEED 217 - 7217 DRIVE GP - FLEX PART OF 311-4066 TRANSMISSION AR NOTE

GRAPHIC # 1

REF NO 1 2 3

GRAPHIC NO 1 1 1

PART NAME PART NUMBER 6V-8455 117-9713 111-7906

QTY 6 1 1

<END> 5

1

2

3

BOLT PLATE PLATE

4

5

6 (PRODUCT LEVEL)

SEE PAGE

POWERSYNCHRO TRANSMISSION - 4 SPEED 312 - 3580 XMSN GP - DIRECT DRIVE PART OF 311-4066 TRANSMISSION AR NOTE

Y

REF NO 1

GRAPHIC NO 1

2

1

3 4 5 6 7 8 9 10 11 12

2 3,4 3 1 1 1 1 1 1 3,4

13

3,4

14

1

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

4 1,4 1 1 1 1 1,2 1,3 4 3,4 3 4 3,4 1 1

30 31 32 33 34 35 36 37 38

1,3,4 1 1 1,2,3 1 1 2 2 2

PART NAME PART NUMBER 206-4395 9W-0717 147-0268 178-8231 205-9244 221-6780 9W-0717 8T-7942 7T-3253 206-4397 316-1932 4F-4585 191-8304 178-8127 178-8229 216-2277 216-2278 147-0268 200-6210 200-2371 212-0061 121-7396 6V-4589 8L-2746 296-6617 252-9715 264-4297 206-4377 206-4382 6V-5215 6V-5217 8C-5748 6V-5220 6V-5221 6V-5842 8T-0276 8T-0100 6V-5815 237-5185 3J-1907 9S-8004 9S-4191 189-5746 117-1385 6V-5215 132-5789 085-8091 178-8159 178-8169 178-8166 195-7657

QTY 1 4 2 1 1 1 5 2 4 1 1 1 1 1 1 1 2 4 4 1 1 1 1 1 1 3 1 1 1 3 12 5 4 4 6 5 6 1 4 1 1 16 1 2 5 3 22 1 2 1 1

1

2

3

4

5

6 (PRODUCT LEVEL)

CASE AS - FRONT PLUG PLUG XMSN CASE PLUG CASE AS - REAR PLUG DOWEL DOWEL HOUSING PLATE - COVER PLUG - CORE SENSOR GP - SPEED FLANGE PLATE PLATE - COVER HOUSING AS PLUG VALVE GP - SOL SEAL KIT FLANGE VALVE GP - CONVERTER RELIEF SEAL - O-RING SEAL - O-RING HOUSING AS - VALVE VALVE GP - MDL SENSOR - TEMP PLATE - COVER HOUSING BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT PLUG 9/16" SEAL - O-RING PLUG - HEX SOCKET PLUG - STOR SENSOR GP - SPD - A SEAL - O-RING BOLT CLIP - LADDER BOLT REACTOR AS WASHER - THRUST GEAR AS SEAL - O-RING

SEE PAGE

19

(1 of 7) 6

POWERSYNCHRO TRANSMISSION - 4 SPEED 312 - 3580 XMSN GP - DIRECT DRIVE (contd) NOTE

Y Y Y Y

Y

REF NO 39

GRAPHIC NO 2

40 41 42 43 44 45

2 2 3 4 4 3

46 47 48 49 50 51 52

2 2 2 2 2 2 2

53 54 55 56 57 58 59 60 61 62 63 64 65 66

2 2 1 2 3 3 3 3 3 3 2 2,3 3 3

67 68 69 70 71 72 73

3 1 3 3 3 3,4 3,4

PART NAME PART NUMBER 178-8162 178-8164 221-6782 178-8201 178-8203 206-4379 178-8205 178-8138 178-8217 7T-2646 8T-1580 8T-1581 123-8907 123-8908 178-8139 178-8218 6T-9163 6T-9164 6T-9165 6T-9166 206-4396 206-4381 206-4375 206-4399 206-4400 238-7561 214-8970 151-9274 204-0728 9X-3401 8T-0328 238-7562 5P-4484 216-2280 178-8237 178-8236 216-2283 216-2282 216-2275 9P-9150 6V-8675 238-7563 7T-3195 122-6787 123-1377 6V-3668 237-5188 5P-8347 206-4403 206-4402 216-2264 221-6768

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 4 4 16 1 1 1 1 1 1 1 2 2 9 2 2 1 2 1 2 1 1 2 2

1

2

3

4

5

6 (PRODUCT LEVEL)

COVER GP SEAL - OIL COVER AS - SUB SHAFT AS - INPUT DRIVE AS - FAN SHAFT AS - PUMP DRIVE SHAFT AS - FORWARD / REVERSE GEAR - IDLER COUNTERSHAFT AS SPACER CUP - RLR BRG CONE - RLR BRG CONE - SPL TAPERED CUP - SPL TAPERED CONTERSHAFT SPACER SHIM SHIM SHIM SHIM TUBE AS TUBE AS TUBE AS FORK - SHIFT FORK - SHIFT SCREW - CAP SENSOR AS RECEPTACLE KIT SEAL - O-RING PIN - C0NNECTOR WASHER SCREW - CAP PLUG - MAGC O-RING GUARD AS PUMP GP - CHARGE PUMP GP - SCAVENGE INLET - SCAV PUMP BAFFLE SHAFT AS - OUTPUT WASHER BOLT SCREW - CAP WASHER YOKE AS GUARD BOLT PLUG - EXPANSION BOLT RAIL - SHIFT RAIL - SHIFT PISTON PISTON - INTO GEAR

SEE PAGE

13 14 15 16

18

(2 of 7) 7

POWERSYNCHRO TRANSMISSION - 4 SPEED 312 - 3580 XMSN GP - DIRECT DRIVE (contd) NOTE

Y

SERVICE REPAIR

REF NO 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 98 99 100 101 103 104 105 106 107

109 Y - SEPARATE ILLUSTRATION

PART NAME

GRAPHIC NO 3,4 3,4 4 4 4 3,4 3,4 3,4 2 1 1 2 2 4 4 3 2 2 2 1 1 1 1 1 3 4 4 4 4

PART NUMBER 221-6767 216-2265 014-5645 216-2271 6Y-1341 178-8209 178-8210 221-6769 138-1645 4P-7582 6V-8177 120-9762 238-6531 005-0469 7T-3034 302-8432 206-4392 206-4393 178-8171 278-0214 191-8303 178-8137 6V-4248 5F-7054 4P-7581 6T-9144 6T-9146 6T-9147 6T-9145

2

214-8970

QTY 2 2 6 1 2 4 2 2 2 1 1 20 2 2 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1

1

2

3

4

5

6 (PRODUCT LEVEL)

PISTON - NEUTRAL PISTON BALL PLUG SPRING PISTON SEAL PISTON SEAL PISTON SEAL PIN - SPRING CLIP - LADDER BOLT SEAL - O-RING SEAL - O-RING CUP - RLR BEARING SPACER SEAL - LIP TYPE PLATE - COVER PLUG QUAD RING VALVE GP - RLF SENSOR GP - SPD A WASHER BOLT SEAL - O-RING CLIP - LADDER SHIM SHIM SHIM SHIM

SEE PAGE

20

SENSOR AS

(3 of 7) 8

POWERSYNCHRO TRANSMISSION - 4 SPEED 312 - 3580 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 1

(4 of 7) 9

POWERSYNCHRO TRANSMISSION - 4 SPEED 312 - 3580 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 2

(5 of 7) 10

POWERSYNCHRO TRANSMISSION - 4 SPEED 312 - 3580 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 3

(6 of 7) 11

POWERSYNCHRO TRANSMISSION - 4 SPEED 312 - 3580 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 4

<END> 12

(7 of 7)

POWERSYNCHRO TRANSMISSION - 4 SPEED 178 - 8201 SHAFT AS - INPUT PART OF 312-3580 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4 5 6 7

GRAPHIC NO 1 1 1 1 1 1 1

PART NAME PART NUMBER 6Y-1192 178-8117 178-8118 178-8214 190-1570 190-1572 209-3766

QTY 1 1 1 1 1 1 1

<END> 13

1

2

3

4

5

6 (PRODUCT LEVEL)

RING - SEAL SHAFT - INPUT GEAR - 47 TEETH CIRCLIP BRG - SPL NEED THR RACE - THRUST BEARING - SPL AS

SEE PAGE

POWERSYNCHRO TRANSMISSION - 4 SPEED 178 - 8203 DRIVE AS - FAN PART OF 312-3580 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

GRAPHIC NO 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NAME PART NUMBER 095-0941 104-3288 121-2059 121-2060 121-2061 122-1878 122-1879 221-6795 178-8125 178-8129 178-8208 190-1576 206-4383 209-3764 221-6781 7T-3035 123-8905 123-8906

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

<END> 14

1

2

3

4

5

6 (PRODUCT LEVEL)

RING - RETAINING SHIM SHIM SHIM SHIM RING - SEAL SPACER - BRG GEAR - 38 TEETH GEAR - 38 TEETH WASHER - THRUST SEAL - OIL BRG AS - SPL TPR THRUST WASHER BEARING - SPL AS SHAFT AS PIN CONE - SPL TAPERED CUP SPL TAPERED

SEE PAGE

POWERSYNCHRO TRANSMISSION - 4 SPEED 206 - 4379 SHAFT AS - PUMP DRIVE PART OF 312-3580 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

GRAPHIC NO 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NAME PART NUMBER 6V-9097 7T-3195 061-7539 095-0942 178-8120 178-8122 178-8238 190-1574 206-4378 209-3768 221-6796 238-7568 7T-3035 5P-3132

QTY 1 1 1 1 1 1 1 2 1 1 1 2 1 1

<END> 15

1

2

3

4

5

6 (PRODUCT LEVEL)

BOLT - LOCKING WASHER SEAL - O-RING RING - RETAINING GEAR - 44 TEETH WASHER - THRUST SHAFT BRG - SPL CGD R AS WASHER - THRUST BEARING - SPL AS GEAR - 44 TEETH RING - RETAINING PIN BEARING - ROLLER

SEE PAGE

POWERSYNCHRO TRANSMISSION - 4 SPEED 178 - 8205 SHAFT AS - FORWARD / REVERSE PART OF 312-3580 XMSN GP - DIRECT DRIVE NOTE

REF NO 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

GRAPHIC NO 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NAME PART NUMBER 104-3288 121-0694 121-2059 121-2060 121-2061 121-2500 122-1879 122-1880 122-1881 122-1882 122-1886 122-3649 123-8913 172-5317 178-8189 178-8131 178-8132 178-8134 178-8135 178-8136 178-8151 178-8193 178-8200 178-8215 6V-8757 8T-1580 8T-1581 123-8905 123-8906

QTY 1 1 1 1 1 2 1 12 12 2 3 2 4 2 1 1 2 2 1 1 1 1 2 2 2 1 1 1 1

1

2

3

4

5

6 (PRODUCT LEVEL)

SEE PAGE

SHIM WASHER - THRUST SHIM SHIM SHIM WASHER - THRUST SPACER - BRG DISC - FRICTION PLATE - CLUTCH PLATE - END RING - SEAL RING - RET INT BEARING - CAGED BEARING - SPL SHAFT AS GEAR - 47 TEETH PISTON - SEAL SPRING GEAR - 31 TEETH GEAR - 34 TEETH SPACER SPACER SPRING - RETAINER SLEEVE RING - RETAINING CUP - RLR BRG CONE - RLR BRG CONE - SPL TAPERED CUP - SPL TAPERED

(1 of 2) 16

POWERSYNCHRO TRANSMISSION - 4 SPEED 178 - 8205 SHAFT AS - FORWARD / REVERSE (contd.)

GRAPHIC # 1

<END> 17

(2 of 2)

POWERSYNCHRO TRANSMISSION - 4 SPEED 216 - 2275 SHAFT AS - OUTPUT PART OF 312-3580 XMSN GP - DIRECT DRIVE NOTE

REF NO

GRAPHIC NO

PART NAME PART NUMBER 7T-2646 7T-6655 8T-1580 8T-1581 123-8907 123-8908 178-8144 178-8145 178-8146 178-8147 178-8148 178-8149 178-8150 178-8152 178-8153 178-8220 190-1575 196-0187 206-4398 209-3765 238-7569 238-8539 6T-9163 6T-9164 6T-9165 6T-9166

QTY 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 2 1 1 1 1 1 1

NO GRAPHIC

<END> 18

1

2

3

4

5

6 (PRODUCT LEVEL)

SPACER BEARING - RLR AS CUP - RLR BRG CONE - RLR BRG CONE - SPL TAPERED CUP - SPL TAPERED DISC SPACER GEAR - 24 TEETH SYNCHRONIZER GEAR - 31 TEETH GEAR - 40 TEETH SYNCHRONIZER GEAR - 48 TEETH WASHER - THRUST SPACER BRG - SPL CGD R AS RING - RETAINING SHAFT - OUTPUT BEARING - SPL AS RING - RETAINING RING - RETAINING SHIM SHIM SHIM SHIM

SEE PAGE

POWERSYNCHRO TRANSMISSION - 4 SPEED 252 - 9715 VALVE GP - MODULATING PART OF 312-3580 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4

GRAPHIC NO 1 1 1 1

PART NAME PART NUMBER 164-2108 218-2373 226-9629 253-0247

QTY 1 1 1 1

108-2148

1

<END> 19

1

2

3

4

5

WASHER NUT COIL AS CARTRIDGE AS SEAL KIT

6 (PRODUCT LEVEL)

SEE PAGE

POWERSYNCHRO TRANSMISSION - 4 SPEED 278 - 0214 VALVE GP - RELIEF PART OF 312-3580 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3

GRAPHIC NO 1 1 1

PART NAME PART NUMBER 7X-4744 6V-9178 106-9586

QTY 1 1 1

<END> 20

1

2

SEAL SEAL SEAL

3

4

5

6 (PRODUCT LEVEL)

SEE PAGE

POWERSYNCHRO TRANSMISSION 5 SPEED 323-8994

22

POWERSYNCHRO TRANSMISSION - 5 SPEED 323 - 8994 TRANSMISSION AR ENGINEERING MODEL: PT070 NOTE

REF NO

Y

Y Y - SEPARATE ILLUSTRATION

GRAPHIC NO

SERIAL NUMBER PREFIX: LKT PART NAME

PART NUMBER 311-4067 217-7217 230-7551 293-5003 312-3581

QTY 1 1 1 1 1

<END> 24

1

2

3

4

5

6 (PRODUCT LEVEL)

TRANSMISSION AR DRIVE GP - FLEX CONVERTER AS TC GP - BASIC XMSN GP - DIRECT DRIVE

SEE PAGE 25

26

POWERSYNCHRO TRANSMISSION - 5 SPEED 217 - 7217 DRIVE GP - FLEX PART OF 311-4067 TRANSMISSION AR NOTE

GRAPHIC # 1

REF NO 1 2 3

GRAPHIC NO 1 1 1

PART NAME PART NUMBER 6V-8455 117-9713 111-7906

QTY 6 1 1

<END> 25

1

2

3

BOLT PLATE PLATE

4

5

6 (PRODUCT LEVEL)

SEE PAGE

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE PART OF 311-4067 TRANSMISSION AR NOTE

Y

Y

REF NO 1

GRAPHIC NO 1

2 3 4

5 5 1

5 6 7

5 4 4

8

4

9

4,5

10

3

11

4

12

3

13

3

14 15

3 3

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

5 4 4 3 4 4,5 4,5 4,5 5 4 3 3,4,5 1,4 4 4 5 4 4 3,4,5

PART NAME PART NUMBER 206-4395 9W-0717 147-0268 178-8231 205-9244 8T-7942 7T-3253 206-4394 9W-0717 206-4397 178-8127 206-4391 123-2920 178-8235 200-6210 200-2371 212-0061 216-2278 147-0268 200-6210 200-2371 212-0061 200-6210 200-2371 212-0061 200-6210 200-2371 212-0061 200-6210 200-2371 212-0061 278-0214 121-7396 6V-4589 8L-2746 296-6617 206-4377 206-4382 252-9715 239-7344 8C-5748 6V-5220 6V-5221 6V-5842 6V-5815 237-5185 9S-4191 6V-5217 9S-4182 189-5746 191-8304 191-8303 117-1385 6V-5215

QTY 1 4 2 1 1 2 4 1 5 1 1 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 5 4 4 6 1 4 18 9 1 1 1 1 2 7

1

2

3

4

5

6 (PRODUCT LEVEL)

CASE AS - FRONT PLUG PLUG XMSN CASE PLUG DOWEL DOWEL CASE AS - REAR PLUG HOUSING FLANGE ACTUATOR AS PLUG ACTUATOR VALVE GP - SOL SEAL KIT FLANGE HOUSING AS PLUG VALVE GP - SOL SEAL KIT FLANGE VALVE GP - SOL SEAL KIT FLANGE VALVE GP - SOL SEAL KIT FLANGE VALVE GP - SOL SEAL KIT FLANGE VALVE GP - RLF VALVE GP - CONVERTER RELIEF SEAL - O-RING SEAL - O-RING HOUSING AS - VALVE PLATE - COVER HOUSING VALVE GP - MDL SCREW - CAP BOLT BOLT BOLT BOLT BOLT PLUG - 9/16" PLUG - STOR BOLT PLUG - O-RING SENSOR GP - SPD - A SENSOR GP - SPEED SENSOR GP - SPD A SEAL - O-RING BOLT

SEE PAGE

41

40

(1 of 8) 26

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE (contd) NOTE

Y Y Y Y

Y

REF NO 35 36 37 38 39

GRAPHIC NO 3 4 1 1 1

40

1

41 42 43 44 45 46

1 1 1 1 2 1

47 48 49 50 51 52

5 5 5 1 1 3,4

53 54 55 56 57 58 59 60 61 62 63 64 65 66

2 3,4 3,4,5 4 4 5 5 5 5 1 5 4 1,3 4

PART NAME PART NUMBER 132-5789 085-8091 178-8159 178-8169 178-8166 195-7657 178-8162 178-8164 221-6782 178-8201 178-8203 206-4379 178-8205 178-8138 178-8206 7T-2646 8T-1580 8T-1581 123-8907 123-8908 123-8913 178-8139 178-8140 178-8141 178-8218 6T-9163 6T-9164 6T-9165 6T-9166 206-4396 206-4381 206-4375 206-4399 206-4400 214-8970 151-9274 204-0728 9X-3401 206-4401 8T-0328 238-7562 5P-4484 216-2280 178-8237 178-8236 216-2283 216-2282 216-2276 9P-9150 6V-8675 238-7563 238-7564

QTY 3 22 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 4 1 6 18 1 1 1 1 1 1 1 2 2 9 1

1

2

3

4

5

6 (PRODUCT LEVEL)

CLIP - LADDER BOLT REACTOR AS WASHER - THRUST GEAR AS SEAL - O-RING COVER GP SEAL - OIL COVER AS - SUB SHAFT AS - INPUT DRIVE AS - FAN SHAFT AS - PUMP DRIVE SHAFT AS - FORWARD / REVERSE GEAR - IDLER COUNTERSHAFT AS SPACER CUP - RLR BRG CONE - RLR BRG CONE - SPL TAPERED CUP - SPL TAPERED BEARING - CAGED CONTERSHAFT GEAR - 46 TEETH SYNCHRONIZER SPACER SHIM SHIM SHIM SHIM TUBE AS TUBE AS TUBE AS FORK - SHIFT FORK - SHIFT SENSOR AS RECEPTACLE KIT SEAL - O-RING PIN - C0NNECTOR FORK - SHIFT WASHER SCREW - CAP PLUG - MAGC O-RING GUARD AS PUMP GP - CHARGE PUMP GP - SCAVENGE INLET - SCAV PUMP BAFFLE SHAFT AS - OUTPUT WASHER BOLT SCREW - CAP SCREW - CAP

SEE PAGE

34 35 36 37

39

(2 of 8) 27

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE (contd) NOTE

SERVICE REPAIR

REF NO 67 68 69

GRAPHIC NO 5 1 1

70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101

104 105 106 107

PART NAME

1 1 1 1 3 5 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1,2 2,5 5 2 2 1 3 5 4 4 5

PART NUMBER 8T-0100 7T-3195 122-6787 123-1377 6V-3668 5F-7054 178-8137 6V-4248 237-5188 5P-8347 206-4403 206-4402 206-4404 178-8128 216-2264 221-6768 221-6767 216-2265 178-8171 014-5645 216-2271 6Y-1341 178-8209 178-8210 221-6769 138-1645 120-9762 238-6531 005-0469 7T-3034 302-8432 4F-4585 4P-7581 316-1932 6V-8177 8T-0276

QTY 6 2 2 1 2 1 1 1 1 2 1 1 1 1 3 2 2 2 1 7 1 3 4 3 2 3 22 2 2 1 2 1 3 1 1 5

2 2 2 2

6T-9144 6T-9145 6T-9146 6T-9147

1 1 1 1

1

2

3

4

5

6 (PRODUCT LEVEL)

SEE PAGE

BOLT WASHER YOKE AS GUARD BOLT SEAL - O-RING WASHER BOLT PLUG - EXPANSION BOLT RAIL - SHIFT RAIL - SHIFT RAIL - SHIFT ROD PISTON PISTON - INTO GEAR PISTON - NEUTRAL PISTON QUAD RING BALL PLUG SPRING PISTON SEAL PISTON SEAL PISTON SEAL PIN - SPRING SEAL - O-RING SEAL - O-RING CUP - RLR BEARING SPACER SEAL - LIP TYPE PLUG - CORE CLIP - LADDER PLATE - COVER BOLT BOLT

SHIM SHIM SHIM SHIM

Y - SEPARATE ILLUSTRATION

(3 of 8) 28

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 1

(4 of 8) 29

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 2

(5 of 8) 30

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 3

(6 of 8) 31

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 4

(7 of 8) 32

POWERSYNCHRO TRANSMISSION - 5 SPEED 312 - 3581 XMSN GP - DIRECT DRIVE (contd)

GRAPHIC # 5

<END> 33

(8 of 8)

POWERSYNCHRO TRANSMISSION - 5 SPEED 178 - 8201 SHAFT AS - INPUT PART OF 312-3581 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4 5 6 7

GRAPHIC NO 1 1 1 1 1 1 1

PART NAME PART NUMBER 6Y-1192 178-8117 178-8118 178-8214 190-1570 190-1572 209-3766

QTY 1 1 1 1 1 1 1

<END> 34

1

2

3

4

5

6 (PRODUCT LEVEL)

RING - SEAL SHAFT - INPUT GEAR - 47 TEETH CIRCLIP BRG - SPL NEED THR RACE - THRUST BEARING - SPL AS

SEE PAGE

POWERSYNCHRO TRANSMISSION - 5 SPEED 178 - 8203 DRIVE AS - FAN PART OF 312-3581 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

GRAPHIC NO 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NAME PART NUMBER 095-0941 104-3288 121-2059 121-2060 121-2061 122-1878 122-1879 221-6795 178-8125 178-8129 178-8208 190-1576 206-4383 209-3764 221-6781 7T-3035 123-8905 123-8906

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

<END> 35

1

2

3

4

5

6 (PRODUCT LEVEL)

RING - RETAINING SHIM SHIM SHIM SHIM RING - SEAL SPACER - BRG GEAR - 38 TEETH GEAR - 38 TEETH WASHER - THRUST SEAL - OIL BRG AS - SPL TPR THRUST WASHER BEARING - SPL AS SHAFT AS PIN CONE - SPL TAPERED CUP SPL TAPERED

SEE PAGE

POWERSYNCHRO TRANSMISSION - 5 SPEED 206 - 4379 SHAFT AS - PUMP DRIVE PART OF 312-3581 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

GRAPHIC NO 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NAME PART NUMBER 6V-9097 7T-3195 061-7539 095-0942 178-8120 178-8122 178-8238 190-1574 206-4378 209-3768 221-6796 238-7568 7T-3035 5P-3132

QTY 1 1 1 1 1 1 1 2 1 1 1 2 1 1

<END> 36

1

2

3

4

5

6 (PRODUCT LEVEL)

BOLT - LOCKING WASHER SEAL - O-RING RING - RETAINING GEAR - 44 TEETH WASHER - THRUST SHAFT BRG - SPL CGD R AS WASHER - THRUST BEARING - SPL AS GEAR - 44 TEETH RING - RETAINING PIN BEARING - ROLLER

SEE PAGE

POWERSYNCHRO TRANSMISSION - 5 SPEED 178 - 8205 SHAFT AS - FORWARD / REVERSE PART OF 312-3581 XMSN GP - DIRECT DRIVE NOTE

REF NO 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

GRAPHIC NO 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NAME PART NUMBER 104-3288 121-0694 121-2059 121-2060 121-2061 121-2500 122-1879 122-1880 122-1881 122-1882 122-1886 122-3649 123-8913 172-5317 178-8189 178-8131 178-8132 178-8134 178-8135 178-8136 178-8151 178-8193 178-8200 178-8215 6V-8757 8T-1580 8T-1581 123-8905 123-8906

QTY 1 1 1 1 1 2 1 12 12 2 3 2 4 2 1 1 2 2 1 1 1 1 2 2 2 1 1 1 1

1

2

3

4

5

6 (PRODUCT LEVEL)

SEE PAGE

SHIM WASHER - THRUST SHIM SHIM SHIM WASHER - THRUST SPACER - BRG DISC - FRICTION PLATE - CLUTCH PLATE - END RING - SEAL RING - RET INT BEARING - CAGED BEARING - SPL SHAFT AS GEAR - 47 TEETH PISTON - SEAL SPRING GEAR - 31 TEETH GEAR - 34 TEETH SPACER SPACER SPRING - RETAINER SLEEVE RING - RETAINING CUP - RLR BRG CONE - RLR BRG CONE - SPL TAPERED CUP - SPL TAPERED

(1 of 2) 37

POWERSYNCHRO TRANSMISSION - 5 SPEED 178 - 8205 SHAFT AS - FORWARD / REVERSE (contd.)

GRAPHIC # 1

<END> 38

(2 of 2)

POWERSYNCHRO TRANSMISSION - 5 SPEED 216 - 2275 SHAFT AS - OUTPUT PART OF 312-3581 XMSN GP - DIRECT DRIVE NOTE

REF NO

GRAPHIC NO

PART NAME PART NUMBER 7T-2646 7T-6655 8T-1580 8T-1581 123-8907 123-8908 178-8143 178-8144 178-8145 178-8146 178-8147 178-8148 178-8149 178-8150 178-8152 178-8153 190-1575 196-0187 206-4398 209-3765 238-7569 238-8539 6T-9163 6T-9164 6T-9165 6T-9166

QTY 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 2 1 1 1 1 1 1

NO GRAPHIC

<END> 39

1

2

3

4

5

6 (PRODUCT LEVEL)

SPACER BEARING - RLR AS CUP - RLR BRG CONE - RLR BRG CONE - SPL TAPERED CUP - SPL TAPERED GEAR - 20 TEETH DISC SPACER GEAR - 24 TEETH SYNCHRONIZER GEAR - 31 TEETH GEAR - 40 TEETH SYNCHRONIZER GEAR - 48 TEETH WASHER - THRUST BRG - SPL CGD R AS RING - RETAINING SHAFT - OUTPUT BEARING - SPL AS RING - RETAINING RING - RETAINING SHIM SHIM SHIM SHIM

SEE PAGE

POWERSYNCHRO TRANSMISSION - 5 SPEED 252 - 9715 VALVE GP - MODULATING PART OF 312-3581 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3 4

GRAPHIC NO 1 1 1 1

PART NAME PART NUMBER 164-2108 218-2373 226-9629 253-0247

QTY 1 1 1 1

108-2148

1

<END> 40

1

2

3

4

5

WASHER NUT COIL AS CARTRIDGE AS SEAL KIT

6 (PRODUCT LEVEL)

SEE PAGE

POWERSYNCHRO TRANSMISSION - 5 SPEED 278 - 0214 VALVE GP - RELIEF PART OF 312-3581 XMSN GP - DIRECT DRIVE NOTE

GRAPHIC # 1

REF NO 1 2 3

GRAPHIC NO 1 1 1

PART NAME PART NUMBER 7X-4744 6V-9178 106-9586

QTY 1 1 1

<END> 41

1

2

SEAL SEAL SEAL

3

4

5

6 (PRODUCT LEVEL)

SEE PAGE