INTRODUCTION GENERAL This section has the repair procedures for following parts of the transmission: the oil pump, clutch assemblies, control valve and the differential. The torque converter cannot be repaired. It must be replaced as a complete assembly.
the hydraulic lines for the main control valve and the return line. If necessary, disconnect the lines at the steering control unit. I. Disconnect the cables and fuel lines at the fuel injection pump or carburetor. Close the fuel valve at the tank and disconnect the fuel line.
Removal Of The Transmission Remove the engine and transmission as follows:
J. Remove the exhaust pipe that connects the exhaust manifold to the muffler.
A. Remove the overhead guard. On the S/H 2535XL units, remove the counterweight as described in the FRAME section.
K. Drain the oil from the differential housing.
B. Raise the hood and disconnect the gas spring from the frame. Close the hood and remove the capscrews that hold the hood assembly. Lift the hood assembly from the lift truck.
M. Connect a lifting device to the engine and transmission.
WARNING Always disconnect the cables at the battery before making any repairs. C. Disconnect the cables at the battery. Disconnect the negative cable first. On the S/H 25-35XL units, disconnect the wires at the battery holder. Remove the battery holder. D. Remove the floor plates. Disconnect the wire connectors between the engine and the frame. Disconnect the wires at the sending units on the engine and transmission. E. Drain the coolant from the radiator and engine. Disconnect the coolant hoses from the radiator at the engine. Loosen the fan shroud so that you have space to remove the bolts from the fan. Disconnect the lines to the oil cooler at the bottom of the radiator. Remove the hose for the auxiliary coolant reservoir at the radiator. F. Remove the fan from the water pump pulley. Remove the shroud and the fan. Carefully remove the radiator from the lift truck. G. Remove the air cleaner assembly from the frame. H. Put a drain pan under the hydraulic pump. Disconnect the supply lines at the pump. Disconnect
L. Disconnect the linkages at the transmission.
WARNING When lifting the engine and transmission, make sure that the lifting device has a capacity of 500 kg (1000 lb). N. Remove the capscrews that hold the differential housing to the transmission. These capscrews are metric. O. Remove the nuts and bolts for the engine mounts. Remove the clamps at the transmission for the parking brake cables. Remove all wires and hoses connected at the transmission. P. Remove the engine and transmission. Make sure all wires and hoses are disconnected during removal. Put the engine and transmission on a level surface. Q. Remove the capscrews that hold the torque converter housing to the engine. These capsrews are metric. Installation Of The Transmission A. Install the drive plate on the torque converter. Tighten the capscrews to 45 N. m (33 1bf ft). Lubricate the pilot hole in the flywheel and pilot hub on the torque converter with NEVER-SEEZ. Install the torque converter on the transmission. Make sure that the torque converter hub is engaged with the oil pump. Install the transmission to the engine. Tighten the capscrews that hold the torque converter housing to the engine to 38 N.m (28 lbf ft). 1
