Transmission Repair
REMOVE
1. Tilt the mast fully forward and lower the forks completely.
2. Turn the key to OFF position to shutdown the engine.
3. Apply the parking brake.
4. Tilt the operator compartment up to gain access to the transmission. See the section Operator's Cab 0100SRM1390.
5. Disconnect the cables from the battery. Disconnect the ground cable first and then the positive cable.
CAUTION
Drive shafts are balanced and configured at the time of manufacture. Prior to removal, make sure an alignment mark is present on the splined stub and the slip yoke, indicating their relative position. Always align slip yoke and splined stub correctly. Failure to assemble and install the drive shaft properly leads to excessive vibration levels and premature failure of components attached to the drive shaft.
6. Apply alignment marks on slip yoke and splined stub prior to drive shaft removal.
7. Disconnect the drive shaft at the transmission. See Figure 1.
Figure 1. Transmission Arrangement
8. Disconnect the Frame-Powertrain connector (CPP02) and the starter motor cable (TS13). See Figure 2.
1.FRAME-POWERTRAIN CONNECTOR
2.STARTER MOTOR TERMINAL
Figure 2. Powertrain Connections
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
9. Place a suitable container under the transmission sump, remove the transmission sump drain plug and drain the transmission oil [approximately 27 liter (28.5 qt)].
10. Disconnect the oil lines from the transmission to the thermostat valve. Drain the oil into a drain pan. Put plugs and caps on open lines and fittings.
11. Attach a lifting device to the hydraulic pumps
12. The hydraulic pumps are connected to the transmission with four capscrews. Attach a lifting device to hold the hydraulic pumps, remove the capscrews, and the hydraulic pumps. The drive shaft of the hydraulic pump is engaged in the splines of the drive gear. The drive shaft of the hydraulic pump will slide out of the drive gear when the hydraulic pump is removed.
13. Put a beam on the frame, that can carry the weight of the hydraulic pumps.
14. Turn the pumps away from the transmission (± 45°) towards the hydraulic tank, leaving the hoses connected, and attach the hydraulic pumps in that position to the beam. See Figure 3.
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1.HYDRAULIC PUMPS
15. Install blocks and a jack under the flywheel end of the engine as a support. If the support is under the engine oil sump, make sure that the support is across the width of the oil sump so the weight of the engine does not damage the oil sump.
16. Connect a lifting device, with a lifting capacity of at least 1200 kg (2650 lb), to the two lifting eyes located at the top of the transmission. See Figure 4.
Figure 3. Remove Transmission
1.LIFTING EYES
Figure 4. View of Transmission
17. Open the left cover to gain access to the engine area.
18. Remove the exhaust pipe to gain access to the convertor housing. See Figure 5.
1.ACCESS HOLE TO ROTATE FLYWHEEL
2.ACCESS PLUG
3.EXHAUST PIPE
4.ACCESS PLATE TO FLYWHEEL CAPSCREWS
23. Raise the lifting device to hold the weight of the transmission only. Remove the twelve capscrews that fasten the torque converter housing to the flywheel housing.
24. Remove the two M6 x 110 bolts that fasten the transmission mount to the frame.
CAUTION
Keep the transmission level when the transmission is separated from the engine to avoid damage to the drive plate.
25. Make sure that all connections have been removed and carefully lift the transmission assembly from the frame and engine.
DISASSEMBLE
Figure 6 shows a view of the ZF ERGOPOWER transmission mounted to the Holding Fixture Assembly.
19. Remove the access plug to gain access to the flywheel ring gear.
20. Remove the access plate to gain access to the capscrews that connect the flywheel to the drive plates.
21. Insert a flywheel rotation tool into the access plug hole and rotate the flywheel until one of the capscrews is visible through the access plate hole. See Figure 5.
22. Remove the capscrew. Rotate the flywheel and remove the remaining capscrews until all four capscrews have been removed.
1.HOLDING FIXTURE
2.CLAMPING DEVICE
Figure 6. ZF ERGOPOWER Transmission
Figure 5. Access Plug for Drive Plate Capscrews
Transmission Housing, Disassemble
STEP 1.
Remove electrical harness from the transmission. Put identification tags on the wires to be able to correctly reconnect.
1.TRANSMISSION TURBINE SPEED SENSOR
2.TRANSMISSION INTERNAL SPEED SENSOR
3.DIFFERENTIAL PRESSURE SWITCH
4.MAIN CONNECTOR
5.ENGINE SPEED SENSOR
6.TRANSMISSION CONTROL VALVE CONNECTOR
7.TORQUE CONVERTER TEMPERATURE SENSOR
8.TRANSMISSION OUTPUT SPEED SENSOR
STEP 2.
Remove the oil filter assembly and oil filler tube from the transmission. See Transmission Oil Filter Assembly and Oil Fill Tube Replacement, Remove.
STEP 3.
Remove the control valve assembly from the transmission. See Control Valve Replacement
STEP 4.
Remove the differential pressure switch for the ZF-Micro Filter from the duct plate.
1.COMPRESSION SPRING
2.PISTON
3.DIFFERENTIAL PRESSURE SWITCH
STEP 5.
Remove the torx screws and separate the duct plate and the gaskets from the housing front section.
1.DUCT PLATE
2.GASKET 3.SEAL
STEP 6.
Remove the converter safety valve from the housing bore.
1.COMPRESSION SPRING
2.PISTON
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STEP 7.
Remove the breather, internal speed input sensor and turbine sensor from the transmission.
1.BREATHER
2.INDUCTIVE TRANSMITTER - N INTERNAL SPEED INPUT
3.INDUCTIVE TRANSMITTER - N TURBINE
STEP 8.
Remove the inductive transmitter - n engine, speed sensor and temperature sensor from the transmission.
1.INDUCTIVE TRANSMITTER - N ENGINE
2.SPEED SENSOR - N OUTPUT (HALL SENSOR)
3.TEMPERATURE SENSOR
STEP 9.
Remove two screws and install the eye bolts. Use a lifting tackle to remove the torque converter from the transmission. Remove the diaphragm from the torque converter.
1.EYE BOLTS
2.SCREW 3.DIAPHRAGM
STEP 10.
Remove the capscrews from the bellhousing and remove bellhousing from transmission.
1.BELLHOUSING
2.TRANSMISSION
STEP 11.
Remove the O-ring from oil pump. Remove the capscrews from transmission housing plate and remove transmission housing plate.
1.O-RING
2.CAPSCREWS
3.TRANSMISSION HOUSING PLATE
STEP 12.
With a pulling device remove the stator hollow shaft/oil pump with a lifting tackle.
1.OIL PUMP
STEP 13.
Remove the screws and remove the cover.
1.SCREWS 2.COVER
STEP 14.
Remove the O-ring and retaining ring. Pull the pump shaft from the housing bore. Remove the retaining ring from the pump shaft.
1.O-RING
2.RETAINING RING
STEP 15.
Remove the retaing ring and remove the ball bearing from the pump shaft.
3.PUMP SHAFT
4.RETAINING RING
1.RETAINING RING
2.BALL BEARING
3.PUMP SHAFT
STEP 16.
Remove the screws and washer from the output flange. Remove and discard the O-ring.
1.SCREWS
2.OUTPUT FLANGE
STEP 17.
Remove the output flange and shaft seal. Drive out both pins and remove capscrews from front housing and rear housing sections.
1.OUTPUT FLANGE 2.SHAFT SEAL 3.PIN 4.CAPSCREWS
WARNING
To prevent the possibility of injury to personnel, use a lifting device of sufficient lifting capacity while performing the following step.
NOTE: Make sure that the cylindrical pins have been removed before removing the rear transmission cover.
STEP 18.
Use a lifting device to remove the rear transmission housing from the front transmission housing.
1.REAR TRANSMISSION HOUSING
2.FRONT TRANSMISSION HOUSING
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STEP 19.
Remove all piston rings from the clutches and input shaft. Remove two capscrews from clutch screen. Remove fluid tubes with O-rings, dicard Orings.
1.PISTON RING
2.FLUID TUBES
WARNING
To prevent the possibility of injury to personnel, use a lifting device of sufficient lifting capacity while performing the following step.
STEP 20.
Remove the clutch assemblies and input shaft from the front transmission cover in the order given in the legend.
3.CAPSCREWS
1.CLUTCH, 3RD SPEED/OUTPUT
2.CLUTCH, 2ND SPEED
3.CLUTCH, 1ST SPEED
4.CLUTCH, 4TH SPEED
5.CLUTCH, FORWARD
6.CLUTCH, REVERSE
7.INPUT SHAFT
8.SCREEN
STEP 21.
Remove capscrews from suction pipe in the front transmission housing.
1.CAPSCREW 2.SUCTION PIPE
STEP 22.
Remove the bearing outer rings from the front transmission housing.
1.CLUTCH, 3RD SPEED/OUTPUT
2.CLUTCH, 2ND SPEED
3.CLUTCH, 1ST SPEED
4.CLUTCH, 4TH SPEED
5.CLUTCH, FORWARD
6.CLUTCH, REVERSE
7.INPUT SHAFT
STEP 23.
Remove the system pressure tubes from the rear transmission housing in the order of the legend.
NOTE: Perform STEP 23 only if any of the tubes are damaged.
1.CLUTCH, REVERSE
2.CLUTCH, 4TH SPEED
3.CLUTCH, 1ST SPEED
4.CLUTCH, 3RD SPEED/OUTPUT
5.CLUTCH, 2ND SPEED
STEP 24.
Remove the bearing outer rings from the rear transmission housing.
1.CLUTCH, 3RD SPEED/OUTPUT
2.CLUTCH, 2ND SPEED
3.CLUTCH, 1ST SPEED
4.CLUTCH, 4TH SPEED
5.CLUTCH, FORWARD
6.CLUTCH, REVERSE
7.INPUT SHAFT
Oil Pump, Disassemble
STEP 1.
Remove the O-ring and capscrews from the oil pump. Discard the O-ring.
1.O-RING
2.CAPSCREWS
STEP 2.
Remove the cover, inner rotor, and outer rotor from the oil pump housing. Inspect the pump housing, inner rotor outer rotor, and cover for wear marks. If any wear is shown, replace the oil pump.
3.OIL PUMP
1.COVER
2.INNER ROTOR
3.OUTER ROTOR
4.OIL PUMP HOUSING
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STEP 3.
Remove and discard the shaft seal from the oil pump housing.
1.SHAFT SEAL 2.OIL PUMP HOUSING
Figure 7. Forward Clutch Assembly
NOTE: See Parts Manual for breakdown.
NOTE: See Parts Manual for breakdown.
Figure 8. Reverse Clutch Assembly
NOTE: See Parts Manual for breakdown.
Figure 9. 1st Speed Clutch Assembly
NOTE: See Parts Manual for breakdown.
Figure 10. 2nd Speed Clutch Assembly
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NOTE: See Parts Manual for breakdown.
Figure 11. 3rd Speed Clutch Assembly
NOTE: See Parts Manual for breakdown.
Figure 12. 4th Speed Clutch Assembly
Forward Clutch, Disassemble
NOTE: As each clutch assembly is disassembled, ensure that all of the components of that assembly are kept separate from any other clutch assemblies to prevent the possibility of parts being assembled to an incorrect clutch assembly.
STEP 1. Remove the piston ring.
STEP 2.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.FORCING DEVICE
1.PISTON RING
2.GRAB SLEEVE
STEP 3. Remove the piston ring.
STEP 4.
Remove the clutch assembly and spur gear together with the two-arm puller.
1.TWO-ARM PULLER 2.CLUTCH ASSEMBLY
STEP 5. Remove the clutch assembly from the spur gear.
1.CLUTCH ASSEMBLY 2.SPUR GEAR
1.PISTON RING
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STEP 6.
Remove the snap ring from the clutch assembly.
1.SNAP RING
2.CLUTCH ASSEMBLY
STEP 7.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 1700 ±147 N (382 ±33 lbf).
STEP 8.
Using a spring compression tool, P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3."L" RING
STEP 9.
Slowly release the compression spring and remove the guide ring, compression spring, and washer from the disk carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.DISK CARRIER
4.WASHER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 10.
Remove piston from disk carrier.
1.PISTON 2.DISK CARRIER
STEP 11.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING 2.OUTER O-RING
STEP 12.
Remove the needle bearing from the shaft.
3.PISTON
1.NEEDLE BEARING 2.SHAFT
STEP 13.
Unsnap the retaining ring from the idler gear and remove the ball bearing.
1.IDLER GEAR
2.BALL BEARING
STEP 14.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
STEP 15.
Remove the piston ring.
3.RETAINING RING
1.FORCING DEVICE
2.GRAB SLEEVE
1.PISTON RING
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Reverse Clutch, Disassemble
STEP 1.
Remove the piston ring.
STEP 2.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.PISTON RING
2.CLUTCH SHAFT
1.FORCING DEVICE
2.GRAB SLEEVE
STEP 3.
Remove the piston ring.
1.SNAP RING
2.CLUTCH SHAFT
3.IDLER GEAR
STEP 4.
Remove the clutch assembly and spur gear together with the two-arm puller.
1.TWO-ARM PULLER 2.CLUTCH ASSEMBLY
STEP 5.
Remove the snap ring from the clutch assembly.
1.SNAP RING
2.CLUTCH ASSEMBLY
STEP 6.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 1700 ±147 N (382 ±33 lbf).
STEP 7.
Using a spring compression tool, P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3."L" RING
STEP 8.
Slowly release the compression spring and remove the guide ring, compression spring and washer, from the disk carrier.
1.GUIDE RING
2.COMPRESSION SPRING
3.DISK CARRIER
4.WASHER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 9.
Remove piston from disc carrier.
1.PISTON 2.DISC CARRIER
STEP 10.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING 2.OUTER O-RING
STEP 11.
With a cut-off device and pulling device remove the idler gear from the shaft.
3.PISTON
1.CUT-OFF DEVICE
2.PULLING DEVICE
3.SPUR GEAR
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STEP 12.
Unsnap the retaining ring from the idler gear and remove the ball bearing.
1.RETAINING RING 2.BALL BEARING 3.IDLER GEAR
STEP 13.
Remove the needle bearing from the shaft.
1.NEEDLE BEARING 2.SHAFT
STEP 14.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
STEP 15.
Remove the piston ring.
1.FORCING DEVICE 2.GRAB SLEEVE
1.PISTON RING
First Speed Clutch, Disassemble
STEP 1. Remove the piston ring.
STEP 2. Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.PISTON RING
1.FORCING DEVICE
2.GRAB SLEEVE
STEP 3. Remove the retaining ring.
1.RETAINING RING
STEP 4.
Remove the axial bearing and idler gear.
1.AXIAL BEARING 2.IDLER GEAR
STEP 5. Remove the needle bearing and the axial bearing.
1.NEEDLE BEARING 2.AXIAL BEARING
STEP 6.
Remove the clutch assembly with the two-arm puller.
1.TWO-ARM PULLER 2.CLUTCH ASSEMBLY
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STEP 7.
Remove the snap ring from the clutch assembly.
1.SNAP RING
2.CLUTCH ASSEMBLY
STEP 8.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 580 ±72 N (130 ±16 lbf).
STEP 9.
Using a spring compression tool, P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING
3."L" RING
STEP 10.
Slowly release the compression spring and remove the guide ring, compression spring from the clutch pack carrier.
1.GUIDE RING
2.CUP SPRING SET
3.DISC CARRIER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 11. Remove piston from disc carrier.
1.PISTON
2.DISC CARRIER
STEP 12.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING 2.OUTER O-RING
STEP 13. Remove the piston ring.
3.PISTON
1.PISTON RING
2.TAPERED ROLLER BEARING 3.SHAFT
STEP 14.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.FORCING DEVICE
2.GRAB SLEEVE
Second Speed Clutch, Disassemble
STEP 1.
Remove the piston ring.
STEP 2.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.PISTON RING
1.FORCING DEVICE
2.GRAB SLEEVE
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STEP 3.
Remove the retaining ring.
1.RETAINING RING
STEP 4. Remove the axial bearing and idler gear.
1.AXIAL BEARING 2.IDLER GEAR
STEP 5.
Remove the needle bearing and the axial bearing.
1.NEEDLE BEARING 2.AXIAL BEARING
STEP 6.
Remove the clutch assembly with the two-arm puller.
1.TWO-ARM PULLER 2.CLUTCH ASSEMBLY
STEP 7.
Remove the snap ring from the clutch assembly.
1.RETAINING RING 2.CLUTCH ASSEMBLY
STEP 8.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM 2.DISC SET 3.CLUTCH PACK CARRIER
WARNING
The spring has a force of 430 ±25 N (97 ±6 lbf).
STEP 9.
Using a spring compression tool, P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING 3."L" RING
STEP 10.
Slowly release the compression spring and remove the guide ring, compression spring from the clutch pack carrier.
1.GUIDE RING
2.COMPRESSION SPRING 3.DISC CARRIER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 11.
Remove piston from disc carrier.
1.PISTON 2.DISC CARRIER
STEP 12.
Remove and discard inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
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STEP 13.
Remove the piston ring.
STEP 14.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.SHAFT
1.FORCING DEVICE
2.GRAB SLEEVE
Third Speed Clutch, Disassemble
STEP 1.
Remove the piston ring.
STEP 2.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.PISTON RING
1.FORCING DEVICE 2.GRAB SLEEVE
STEP 3.
Remove the axial bearing and idler gear.
1.AXIAL BEARING 2.IDLER GEAR
STEP 4. Remove the needle bearing and the axial bearing.
1.NEEDLE BEARING 2.AXIAL BEARING
STEP 5. Remove the clutch assembly with the two-arm puller.
1.TWO-ARM PULLER 2.CLUTCH ASSEMBLY
STEP 6.
Remove the snap ring from the clutch assembly.
1.RETAINING RING
2.CLUTCH PACK CARRIER
STEP 7.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET
3.CLUTCH PACK CARRIER
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WARNING
The spring has a force of 430 ±25 N (97 ±6 lbf).
STEP 8.
Using a spring compression tool, P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING 3."L" RING
STEP 9.
Slowly release the compression spring and remove the guide ring, compression spring from the clutch pack carrier.
1.GUIDE RING
2.CUP SPRING SET
3.DISC CARRIER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 10.
Remove piston from disc carrier.
1.PISTON 2.DISC CARRIER
STEP 11.
Remove and discard the inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
STEP 12.
Remove the piston rings.
1.PISTON RING
2.TAPERED ROLLER BEARING
3.SHAFT
STEP 13.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.FORCING DEVICE
2.GRAB SLEEVE
Fourth Speed Clutch, Disassemble
STEP 1.
Remove the piston ring.
STEP 2.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.PISTON RING
1.FORCING DEVICE
2.GRAB SLEEVE
STEP 3.
Remove the piston ring.
STEP 4.
Remove the clutch assembly and spur gear together with the two-arm puller.
1.TWO-ARM PULLER 2.CLUTCH ASSEMBLY
STEP 5.
Remove the axial bearing and idler gear.
NOTE: Input gear can NOT be dissasembled (shrink fit).
1.AXIAL BEARING 2.IDLER GEAR
1.PISTON RING
STEP 6.
Remove the needle bearing and the axial bearing.
1.NEEDLE BEARING 2.AXIAL BEARING 3.INPUT GEAR
STEP 7.
Remove the snap ring from the clutch assembly.
1.SNAP RING 2.CLUTCH ASSEMBLY
STEP 8.
Remove the end shim and disc set from the clutch pack carrier.
1.END SHIM
2.DISC SET 3.CLUTCH PACK CARRIER
STEP 9.
Using a spring compression tool, P/N 4612858, compress the spring and remove the "L" ring.
1.COMPRESSION TOOL
2.COMPRESSION SPRING 3."L" RING
STEP 10.
Slowly release the compression spring and remove the guide ring, compression spring from the clutch pack carrier.
1.GUIDE RING
2.CUP SPRING SET
3.DISC CARRIER
NOTE: Use compressed air to aid in the removal of the piston.
STEP 11.
Use compressed air to aid in the removal of the piston.
1.PISTON 2.DISC CARRIER
STEP 12.
Remove and discard the inner and outer O-rings from the piston.
1.INNER O-RING
2.OUTER O-RING
3.PISTON
STEP 13.
Remove the piston ring.
STEP 14.
Remove the tappered roller bearing from the shaft with the use of a forcing device and grab sleeve.
1.PISTON RING
1.FORCING DEVICE
2.GRAB SLEEVE
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