John Deere 18-Speed PST Repair Manual - PDF DOWNLOAD

DCT

18-Speed PST Repair Manual

TECHNICAL MANUAL 18-Speed PST Repair Manual

John Deere Coffeyville Works LITHO IN U.S.A.

CTM168

CTM168 10DEC07 (ENGLISH)

Introduction Foreword This manual is written for an experienced technician.

Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Use this component technical manual in conjunction with the machine technical manual. See the machine technical manual for information on component removal and installation, and gaining access to the components.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

This component technical manual covers the recommended repair procedure for the 18-speed PST

Some components from these transmission, may be serviced without removing the complete transmission assembly from the machine. You may have to determine this procedure yourself for a safe removal of such components. See information to remove and install the complete transmission assembly, found in your vehicle technical manual.

Clean transmission before servicing. Always work in a clean work area.

Binders, binder labels, and tab sets can be ordered by John Deere dealers direct from the John Deere Distribution Service Center.

This manual is part of a total product support program.

• FOS MANUALS—REFERENCE • TECHNICAL MANUALS—MACHINE SERVICE • COMPONENT MANUALS—COMPONENT SERVICE Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced technicians.

AG,OURX078,680 –19–28JUN00–1/1

Notice to the Dealer This Component Technical Manual should be used for the repair of 18-speed PST.

Transmission Identification Plate and see General—Group 10.)

IMPORTANT: Before beginning repair or making adjustments, become familiar with

AG,OURX078,679 –19–28JUN00–1/1

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Contents 01

SECTION 01—General Information Group 000—Safety Group 10—General Information SECTION 02—Repair and Adjustments Group 15—Transmission Group 20—Electrical Group 25—Hydraulics Group 30—Pump Drive Group 35—Housings, Geartrain and Clutch Shafts

02

03

SECTION 03—Theory of Operation Group 20—Theory of Operation SECTION 05—Tools and Other Materials Group 175—Special Tools Group 195—Dealer Fabricated Tools

05

SECTION 06—Specifications Group 205—Torque Value 06

INDX

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT  2001 - 2007 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual

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02

03

05

06

INDX

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Section 01

General Information Contents Page

Group 000—Safety . . . . . . . . . . . . . . . . . . . .01-000-1 Group 10—General Information Identification Plate . . . . . . . . . . . . . . . . . . . . . . .01-10-1 General Repair Procedures . . . . . . . . . . . . . . . .01-10-2 Sealants and Adhesives Cross-Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-10-3 Sealing Instructions . . . . . . . . . . . . . . . . . . . . . .01-10-4 Cold Weather Operation . . . . . . . . . . . . . . . . . .01-10-5 Oil Temperature Warning Signal . . . . . . . . . . . .01-10-6 Recommended Lubricants. . . . . . . . . . . . . . . . .01-10-6 Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . .01-10-7 Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . .01-10-7 Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-10-7 Alternative and Synthetic Lubricants . . . . . . . . .01-10-8 Check and Service Transmission Regularly . . .01-10-8 Intervals For Changing Transmission Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-10-9 Fill The Transmission With Oil (Wheel Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .01-10-10 Check Oil Lines and Fittings . . . . . . . . . . . . . .01-10-11 Hydraulic Connections. . . . . . . . . . . . . . . . . . .01-10-11 Transmission Storage . . . . . . . . . . . . . . . . . . .01-10-12 Transmission Removal From Storage . . . . . . .01-10-12 Towing The Vehicle. . . . . . . . . . . . . . . . . . . . .01-10-12

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Group 000

Safety 01 000 1

Recognize Safety Information

T81389

Follow recommended precautions and safe operating practices.

–UN–07DEC88

This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

DX,ALERT –19–29SEP98–1/1

Handle Fluids Safely—Avoid Fires

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

TS227

Do not store oily rags; they can ignite and burn spontaneously.

–UN–23AUG88

When you work around fuel, do not smoke or work near heaters or other fire hazards.

DX,FLAME –19–29SEP98–1/1

Prevent Battery Explosions

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

TS204

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

–UN–23AUG88

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

DX,SPARKS –19–03MAR93–1/1

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Safety

Prepare for Emergencies Be prepared if a fire starts.

TS291

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 –19–03MAR93–1/1

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.

2.

3.

4.

5.

Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

Avoiding spilling or dripping electrolyte.

Use proper jump start procedure.

If you spill acid on yourself:

–UN–23AUG88

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed: 1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3. Get medical attention immediately.

TS203

01 000 2

DX,POISON –19–21APR93–1/1

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Safety 01 000 3

Handle Chemical Products Safely

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

TS1132

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

–UN–26NOV90

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

DX,MSDS,NA –19–03MAR93–1/1

Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

DX,FLUID –19–03MAR93–1/1

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Safety

Park Machine Safely

Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

TS230

• • • •

–UN–24MAY89

Before working on the machine:

DX,PARK –19–04JUN90–1/1

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

Follow recommended procedures in this manual.

TS229

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

–UN–23AUG88

Support Machine Properly

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator’s manual.

DX,LOWER –19–24FEB00–1/1

Wear Protective Clothing

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

–UN–23AUG88

Wear close fitting clothing and safety equipment appropriate to the job.

TS206

01 000 4

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,WEAR –19–10SEP90–1/1

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Safety 01 000 5

Work in Clean Area

Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

T6642EJ

• • • •

–UN–18OCT88

Before starting a job:

DX,CLEAN –19–04JUN90–1/1

Service Machines Safely

TS228

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

–UN–23AUG88

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

DX,LOOSE –19–04JUN90–1/1

Work In Ventilated Area

TS220

If you do not have an exhaust pipe extension, open the doors and get outside air into the area

–UN–23AUG88

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

DX,AIR –19–17FEB99–1/1

TS223

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage.

The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

–UN–23AUG88

Illuminate Work Area Safely

DX,LIGHT –19–04JUN90–1/1

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Safety

Replace Safety Signs

TS201

–UN–23AUG88

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

DX,SIGNS1 –19–04JUN90–1/1

Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

TS226

–UN–23AUG88

Follow recommended procedure for removal and installation of components in the manual.

DX,LIFT –19–04JUN90–1/1

Avoid Harmful Asbestos Dust

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

–UN–23AUG88

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

TS220

01 000 6

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

DX,DUST –19–15MAR91–1/1

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Safety 01 000 7

TS953

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

–UN–15MAY90

Avoid Heating Near Pressurized Fluid Lines

DX,TORCH –19–10DEC04–1/1

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

TS220

Remove paint before heating:

–UN–23AUG88

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

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Safety

Use Proper Tools

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS779

Use power tools only to loosen threaded parts and fasteners.

–UN–08NOV89

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use only service parts meeting John Deere specifications.

DX,REPAIR –19–17FEB99–1/1

Construct Dealer-Made Tools Safely

Do not weld tools unless you have the proper equipment and experience to perform the job.

–UN–01JUL97

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

LX1016749

01 000 8

DX,SAFE,TOOLS –19–10OCT97–1/1

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Safety 01 000 9

Dispose of Waste Properly

Do not pour waste onto the ground, down a drain, or into any water source.

TS1133

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

–UN–26NOV90

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

DX,DRAIN –19–03MAR93–1/1

Live With Safety

TS231

–19–07OCT88

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

DX,LIVE –19–25SEP92–1/1

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Safety 01 000 10

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Group 10

General Information 01 10 1

Identification Plate

YZ5049

–UN–01JUL03

The identification plate is located in the upper left on the rear housing of the transmission. Should repair parts be required, please specify the model, specification, and serial number of your transmission.

YZ07927,000044C –19–23SEP05–1/1

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General Repair Procedures NOTE: Before beginning the repair, review the following guidelines. These are provided to emphasize the need for attention to detail and care when servicing the Transmission assembly.

Both the bearing cone and roller assembly should be replaced if either the cup or cone has excessive wear.

Thoroughly clean the outside before disassembly.

When installing bearing cups and cones, make sure they are fully seated.

Handle parts carefully to prevent nicking or burring machined surfaces.

Inspect tapered bearings and roller bearing surfaces for distortion, roughness, scoring, or wear.

Cups and cones are properly seated if a 0.05 mm (0.002 in.) feeler gauge will NOT pass for a 360° circular sweep between cone or cup mounting surface.

Inspection Before Disassembly.

Inspect the gears, shafts and bearing before removal as follows:

Shafts Inspect the shaft bearing surfaces for wear or damage.

1. Wipe the lubricant from the internal working parts and visually inspect the parts for excessive wear or damage.

Inspect shafts and replace if excessively worn or damaged.

2. Inspect the gears for roughness.

Gear Assemblies

3. Inspect the gear teeth for signs of scoring, abnormal wear, or nicks/chips.

Examine the gear teeth for excessive wear. Replace as necessary.

Heating Bearing

Fasteners and Tightening

IMPORTANT: Heat bearing in a bearing heater. Use a thermometer and DO NOT exceed 150°C (300°F).

Fasteners must be tightened to the specified torque.

Fasteners must be replaced with the same property class (grade).

Cleaning and Inspection Follow the specified tightening pattern when listed.

Clean all parts with clean solvent and use moisture-free air for drying.

Different models of transmission and Early Version Transmissions may have a different torque specification and fastener than Later Version Transmissions. Check the model number and/or the fastener removed and use the correct torque specification and fastener.

Bearings Never dry bearings with compressed air. Spinning a bearing without lubrication can damage the bearing.

Clean bearings with clean solvent, dry thoroughly, and oil before inspection. Inspect bearings for roughness of rotation and excessive wear of rollers.

Assembly Use the specified grease when installing seals.

Inspect bearing cups for excessive wear.

Continued on next page

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YZ,OURX078,687 –19–03JAN01–1/2

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General Information 01 10 3

During assembly, each part should be lubricated with clean hydraulic oil.

YZ,OURX078,687 –19–03JAN01–2/2

Sealants and Adhesives Cross-Reference Chart CANADIAN PART NUMBER

COLOR

SIZE

DESCRIPTION

LOCTITE NUMBER

SIMILAR LOCTITE PRODUCT

Bonding PM37391

-

CLEAR

3 gm (0.11 oz)

Instant Gel Adhesive

454

416, 409, or 495

Gasketing PM38656

PM38627

RED

568

PM38625

PURPLE

515

518

PM38657

PM38628

BLUE

PM37553

PM37553

BURGUNDY

PM37465

-

SILVER BLUE

Rigid Form-in-Place Gasket Flexible Form-in-Place Gasket High-Flex Form-in-Place Gasket High Tack Gasket Dressing Ultra Blue RTV Silicone Form-in-Place Gasket

277

PM38655

50 ml (1.69 oz) 50 ml (1.69 oz) 50 ml (1.69 oz) 0.47 L (16 oz) 88.7 ml (3 oz)

Priming PM37509

PM38611

GREEN

Retaining PM38651

PM38612

SILVER

PM37485

-

GREEN

PM38652

PM38626

GREEN

U.S. PART NUMBER

Threadlocking and Threadsealing PM37477 -

BLUE

PM37418

PM38621

BLUE

PM38654

PM38624

CLEAR

PM37421

PM38623

CLEAR

PM37397

PM38613

WHITE

—

Permatex #98

587

Permatex #77

Cure Primer

7649

—

50 ml (1.69 oz) 50 ml (1.69 oz) 50 ml (1.69 oz)

Quick Metal Press Fit

660

—

Maximum Strength

680

635

High-Temperature

620

50 ml (1.69 oz) 6 ml (0.02 oz) 50 ml (1.69 oz) 6 ml (0.20 oz) 50 ml (1.69 oz)

Medium Strength

242

241 or 243

Medium Strength

242

241 0r 243

High Strength

271

262 or 609

High Strength

271

262 or 609

Pipe Sealant w/TEFLON

592

565 or 567

133 ml (4.5 oz)

LOCTITE is a trademark of Loctite Corporation QUICK METAL is a trademark of Loctite Corporation TEFLON is a trademark of Du Pont Company

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General Information 01 10 4

Sealing Instructions Disassembly

IMPORTANT: Do not use an excessive amount of sealant.

On disassembly, the dowel pin holes provide a slip fit with a normal depth of 15 mm (0.6 in.).

Measure the length of protrusion to insure dowel pins will not prevent the housing from being drawn up tight.

If dowel pins protrude more than 15 mm (0.6 in.) from the components, remove the dowel pins, clean the holes, and reinstall the dowel pins to the specified depth.

Apply a THIN even layer of flexible gasket sealant to ONE surface of the joint. Sufficient amount should be applied so excess is seen around the outside edge of the flange. Narrow overlap areas must be covered with gasket material. Put a bead of sealant around all bolt holes.

IMPORTANT: Temperature of adjoining parts and gasket material must be 13°C (55°F) or above.

Cleaning IMPORTANT: DO NOT use clean and cure primer to clean the surfaces. The primer action will cause the new sealer to set up TOO fast to allow adequate assembly time.

Clean surfaces with a brass brush or scraper to remove old sealer material. Gel-type paint removers containing ethylene chloride or LOCTITE “Chisel” may be used.

Clean surfaces using rubbing alcohol to remove oil and grease residue.

Test for clean surface by applying a few drops of cool water to the surfaces. If water puddles or forms beads, repeat the cleaning procedure.

A file should be passed over burr on the joint faces to insure no nicks are present.

Apply flexible gasket sealant to the front housing machined surface.

Install rear housing onto front housing.

Tighten cap screws to the specified torque starting from center and working toward top and bottom.

Allow the assembly to cure overnight before filling with oil.

IMPORTANT: Apply TY162851 Cure Primer to sealing surfaces only if overnight curing is not possible.

Apply primer to the sealing surfaces.

Use the same sealing application and cap screw tightening procedures as previously instructed.

Prevent the gasket material from drying before assembly is completed (1 hour maximum).

Keep surfaces clean and oil free after cleaning.

Application and Assembly Front Housing-to-Rear Housing:

Allow 30 minutes minimum cure time at room temperature before filling with oil.

Pump Housing-to-Front Housing:

LOCTITE is a trademark of Loctite Corporation 1 See Cross-Reference Chart for Canadian and Loctite Product Numbers, this group.

Continued on next page

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General Information Apply a THIN even layer of flexible gasket sealant to one surface of the joint. Sufficient amount should be applied so excess is seen around the outside edge of the flange. Narrow overlap areas must be covered with gasket material. Put a bead of sealant around all bolt holes.

Tighten cap screws to specified torque beginning with the center two cap screws, across from each other, and alternately working toward top and bottom.

01 10 5

Apply primer to the sealing surfaces.

Use the same sealing application and cap screw tightening procedures as previously instructed.

Prevent the gasket material from drying before assembly is completed (1 hour maximum).

Allow 30 minutes minimum cure time at room temperature before filling with oil.

Allow the assembly to cure overnight before filling with oil.

IMPORTANT: Apply TY162851 Cure Primer to sealant surfaces only if overnight curing is not possible.

1 See Cross-Reference Chart for Canadian and Loctite Product Numbers, this group.

AG,OURX078,688 –19–28JUN00–2/2

Cold Weather Operation IMPORTANT: Preheat procedures are required when operating transmission below the oil’s MINIMUM critical temperature which is viscosity grade dependent and will effect shift performance.

ALTERNATE WARM-UP PROCEDURE: • Operate transmission in neutral for approximately 20 minutes or until oil is warmed to the MINIMUM temperature.

HOT WEATHER OPERATION

NOTE: Refer to Operators Manual for the MINIMUM transmission operating temperature recommended lubricants.

PREHEAT TRANSMISSION FLUID WITH AUXILIARY SOURCE • Preheat the transmission fluid to the MINIMUM temperature before operating.

Refer to AIR TEMPERATURE RANGE in the operators manual for: • Ambient temperatures consistently above 30°C (86°F).

• Frequent stop-and-go driving in hot weather.

• High grade climbing in hot weather.

DPSG,YZ07927,23 –19–12MAY99–1/1

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General Information

Oil Temperature Warning Signal

–UN–30JAN01

• The oil temperature gauge measures system oil temperature. If temperature rises to 115°C (230°F) or the transmission oil temperature warning light comes on, stop the vehicle immediately. Shift to neutral and run the engine at 1000—1200 rpm.

IMPORTANT: Do not stop the engine when the transmission is overheating if the cooling system is known to be in working order.

YZ3008A

01 10 6

• The transmission oil temperature should soon lower to the engine water temperature, or if an air-to-oil exchanger is used, the temperature should soon lower to ambient air temperature across the heat exchanger.

If the temperature does not lower, trouble is indicated.

• Correct overheating problem before the vehicle is operated again.

DPSG,YZ07927,28 –19–12MAY99–1/1

Recommended Lubricants Reference Operator’s Manuals for ambient air temperature charts and recommended transmission fluids.

Recommended lubricant for 18-Speed Transmission is:

Standard HY-GARDTransmission fluids are available through the John Deere dealer network worldwide.

IMPORTANT: Use JDM J20C anything else will effect shift quality.

• John Deere Standard JDM J20C

HY-GARD is a trademark of Deere & Company

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General Information 01 10 7

Lubricant Storage Equipment can operate at top efficiency only if clean lubricants are used.

Make certain all containers are correctly marked to identify contents.

Use clean containers to handle all lubricants.

Properly dispose of all old containers and any residual lubricant.

Store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers positioned to avoid water and dirt accumulation.

RX,4310,12C –19–07JAN98–1/1

Mixing of Lubricants In general, avoid mixing different brands or types of oil.

Oil manufacturers blend additives to their oils to meet certain specifications and performance requirements.

Refer to OM for lubricant specifications and to obtain specific information and recommendations.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

RX,4310,13C –19–07JAN98–1/1

Oil Analysis Oil analysis is best used by sampling at regular intervals to establish a baseline analysis for the oil and operation conditions present. Changes from this baseline may indicate unusual wear.

IMPORTANT: Change the oil and filter if an analysis of the used transmission oil indicates any of the following limits are exceeded.

• Glycol (Antifreeze), must not exceed 0% by volume.

• Water, must not exceed 0.05% by volume.

• Viscosity increase at 38°C (100°F), not more than 40% over new oil value.

• Total Acid Number (TAN) per ASTMD664, limit of 3.0 over new lubricant value.

DPSG,YZ07927,27 –19–12MAY99–1/1

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18-Speed PST Repair Manual 121007

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General Information 01 10 8

Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those in this manual.

The temperature limits and service intervals apply to both conventional and synthetic oils.

Refined base stock products may be used if the finished lubricant meets the performance requirements.

Synthetic lubricants may be used if meeting the performance requirements in this manual.

RX,4310,11C –19–07JAN98–1/1

Check and Service Transmission Regularly Routine checks will help prevent down time. The operator can aid in preventative maintenance by reporting signs of leaks or malfunctions.

the engine, or when the vehicle is parked and the engine is running.

CHECK THE OIL LEVEL DAILY

Because the transmission operates in and by oil, most of the maintenance is concerned with oil replenishment and oil cleanliness. The type of service and operating conditions shall determine the maintenance interval.

NOTE: Engage park brake before checking oil level.

• • • •

Set parking brake.

Put the gear selector lever in PARK position.

Operate the engine at idle speed.

Make sure the transmission oil temperature is above 38°C (100°F).

• Keep oil level at the “FULL” mark on the sight glass.

OIL LEVEL IMPORTANT: The 18-speed PST should always be in the PARK position before starting

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General Information 01 10 9

Intervals For Changing Transmission Oil Filters IMPORTANT: Change filter after the first 100 hours of transmission operation. The filter change intervals given here are for normal service conditions. If the transmission is to be operated in severe conditions contact the Funk Service Department for additional recommendations.

FIRST OIL AND FILTER CHANGE: • Change oil filter after first 100 hours of transmission operation.

oil is bypassing the filter. Change the oil filter if a “Filter Bypass Signal” is indicated and the transmission is at normal operating temperature.

• Change oil filter anytime the transmission is at normal operating temperature and a “Filter Bypass Signal” is indicated.

• Change oil and filter anytime there are signs of contamination in the oil or the oil has a burnt odor.

• Change filter at every 750 hours or if indicator light comes on. Change filter and oil every 1500 hours of transmission operation or if indicator light comes on.

ROUTINE OIL AND FILTER MAINTENANCE: IMPORTANT: Some vehicles are equipped with devices to alert the operator when

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General Information 01 10 10

Fill The Transmission With Oil (Wheel Tractors Only) AFTER INSTALLING TRANSMISSION IN VEHICLE: 1. Park machine on level surface.

2. Engage parking brake, block wheels.

3. Put transmission in PARK.

8. Start the engine, run at 2100 rpm, with transmission in park position, for at least 5 minutes to fill axles and return oil from the axles to the transmission.

CAUTION: While engine is running personal injury may occur, if steering wheel is turned while checking oil level on sight gauge.

IMPORTANT: Failure to prefill axles will shorten the life of the transmission.

9. Fill transmission with transmission-Hydraulic Oil at fill tube. Oil level should be between the top two marks on the site gauge.

4. Prefill axles with oil.

5. Remove oil filler cap from oil fill tube on transmission.

6. Begin filling operation: Specification System Capacities—HY-GARD JDM J20C Oil without PTO ........................................................ 129 L (34 gal) HY-GARD JDM J20C Oil with PTO............................................................................................. 131 L (35 gal)

IMPORTANT: The transmission will not hold enough oil to supply axles, oil lines and cooler on start-up. If transmission is operated outside the proper oil level damage will occur which will shorten the life of the transmission.

IMPORTANT: Do not overfill transmission. This will cause overheating. Damage to the transmission will result.

1. Stop engine and allow the oil level to stabilize in the sight gauge for at least 5 minutes. Recheck oil level and refill at fill tube as necessary.

2. The final oil level at the completion of this checking procedure, with engine off, should be between marks at the top of the sight gauge.

NOTE: During tractor operation, oil can appear foamy in sight gauge.

Oil level in the sight gauge may appear low while engine is running.

7. Check sight gauge.

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General Information 01 10 11

Check Oil Lines and Fittings CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately.

Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specified in torque chart.

When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.

DPSG,YZ07927,13 –19–30APR99–1/1

Hydraulic Connections There are several different combinations for hydraulic lines and fittings for brakes, differential housings, and lubrication lines.

Refer to the vehicle repair manual and/or parts information for the actual application of a particular axle configuration.

AG,OURX078,695 –19–28JUN00–1/1

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General Information 01 10 12

Transmission Storage This procedure applies to those transmissions and components that have been tested according to Funk Manufacturing test specifications and have had the oil drained from them prior to shipment.

The following actions will help protect the unit and component items from internal rust and corrosion damage for approximately one year, provided the transmissions are stored in a dry area:

• Seal all openings with moisture-proof covers or tape.

• Spray 113 mL (4 oz) of atomized NOX RUST1 VCI No. 10 oil or an equivalent into oil drain hole. This fluid is covered and approved per (MIL-P-46002 and MIL-I-23310).

• Dip, spray, or brush all exposed unpainted surfaces with NOX RUST X-110 or equivalent.

1

NOX RUST is a trademark of Daubert Chemical Company.

DPSG,YZ07927,30 –19–12MAY99–1/1

Transmission Removal From Storage • • • •

Wash off all external grease with a safety solvent.

Remove covers or tape from all openings.

Drain transmission completely.

Tag transmission to indicate it needs to be filled with oil after installing in vehicle.

DPSG,YZ07927,31 –19–12MAY99–1/1

Towing The Vehicle AVOID DAMAGE TO TRANSMISSION: • Run engine at idle speed to lubricate the clutches.

— Do not exceed normal vehicle speeds while towing.

• If the engine cannot be run: —Disconnect drive line from transmission.

• If drive line can not be disconnected:

spring applied park brake and must be manually pumped off before towing.

—Do not exceed 5 km/h (3 mph) —Tow no further than 2 km (1 mile)

IMPORTANT: If the vehicle is equipped with Internal Park Brake the unit has a

DPSG,YZ07927,29 –19–12MAY99–1/1

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PN=28

Section 02

Repair and Adjustments Contents

02

Page

Page

Group 15—Transmission Repair Stand Safety Precautions. . . . . . . . . . . .02-15-1 Engine Repair Stand . . . . . . . . . . . . . . . . . . . . .02-15-1 Install Adapter to Engine Rollover Stand . . . . . .02-15-2 Install Transmission Mounting Bracket . . . . . . .02-15-2 Install Transmission to Rollover Stand Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-15-3 Remove Transmission from Rollover Stand Bracket . . . . . . . . . . . . . . . . . . . . . . . .02-15-6 Remove and Install Yoke . . . . . . . . . . . . . . . . .02-15-6 Replace Input and Output Shaft Seals (In Tractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-15-8 Replace Bearing Retainer O-Ring Seals . . . . . .02-15-9

Remove, Repair and Install Oil Filter Head . . . .02-25-6 Remove, Repair and Install Main Regulator Valve . . . . . . . . . . . . . . . . . . . . . . .02-25-6 Remove and Install Lube Relief Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-7 Remove and Install Cooler Relief Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-10 Remove Oil Level Sight Glass (Wheel Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .02-25-12 Repair Oil Level Sight Glass (Wheel Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .02-25-12 Install Oil Level Sight Glass (Wheel Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .02-25-13

Group 20—Electrical Remove and Install Wiring Harness Bracket . . .02-20-1 Replacing the Transmission Wiring Harness . . .02-20-2 Front Housing Sensors and Ports . . . . . . . . . .02-20-14 Rear Housing Sensors and Ports . . . . . . . . . .02-20-16 Proportional Solenoid Identification - Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-18 Proportional Solenoid Identification - Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-20 Remove Proportional Solenoid . . . . . . . . . . . .02-20-22 Install Proportional Solenoid Valve . . . . . . . . .02-20-23 Remove and Install Input and Cylinder Speed Magnetic Pickup Sensors . . . . . . . . .02-20-25 Remove and Install Fifth Stage Magnetic Pickup Sensor (Speed) . . . . . . . . . . . . . . . .02-20-26 Remove and Install Output Magnetic Pickup Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-27 Remove and Install Oil Filter Head Pressure Switch. . . . . . . . . . . . . . . . . . . . . .02-20-28 Remove and Install System Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-29 Remove and Install Temperature Sensor . . . .02-20-30

Group 30—Pump Drive Remove and Install Oil Line to Input Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-1 Remove and Install Transmission Vent Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-2 Remove Pump Drive Cover. . . . . . . . . . . . . . . .02-30-2 Disassemble and Assemble Pump Drive Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-3 Install Pump Drive Cover. . . . . . . . . . . . . . . . . .02-30-3 Remove, Repair and Install Oil Pump Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-5 Remove Transmission Oil Pump . . . . . . . . . . . .02-30-8 Disassemble, Inspect and Assemble Transmission Oil Pump . . . . . . . . . . . . . . . . .02-30-9 Install Transmission Oil Pump . . . . . . . . . . . . .02-30-11 Remove and Install Pump Drive Input Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-13

Group 25—Hydraulics System Components . . . . . . . . . . . . . . . . . . . . .02-25-1 Remove and Install Suction Screen. . . . . . . . . .02-25-2 Remove and Install Oil Filter . . . . . . . . . . . . . . .02-25-3 Remove and Install Oil Filter Inlet Tube . . . . . .02-25-4 Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-4 Remove Oil Filter Switch . . . . . . . . . . . . . . . . . .02-25-5 Disassemble and Assemble Filter By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-5 CTM168 (10DEC07)

Group 35—Housings, Geartrain and Clutch Shafts Remove Rear Housing With Internal Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-1 Disassemble Rear Housing . . . . . . . . . . . . . .02-35-14 Remove Clutch Shaft Sealing Ring Sleeve Old Style Rear Housing Design . . . . . . . . . . . . . . . . . . . . .02-35-16 Install Bore Sleeves Old Style Rear Housing Design. . . . . . .02-35-18 Remove Clutch Assemblies. . . . . . . . . . . . . . .02-35-19 Exploded View— Output Shaft Without Internal Park Brake . . . . . . . . . . . . . . . . . . .02-35-22 Exploded View— Output Shaft With Internal Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . .02-35-23

02-1

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PN=1

Contents

Page

Page

Remove and Install Axle Pump Stand Pipe . . .02-35-24 Remove, Disassemble and Assemble Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-24 02 Remove Suction Tube Old Style Rear Housing . . . . . . . .02-35-27 Remove Suction Tube. . . . . . . . . . . . . . . . . . .02-35-28 Install Output Shaft Assembly . . . . . . . . . . . . .02-35-29 Install Suction Tube Old Style Rear Housing . . . . . . . . . .02-35-30 Install Suction Tube. . . . . . . . . . . . . . . . . . . . .02-35-30 Remove and Install Output Shaft Oil Dam. . . .02-35-31 Exploded View—First Stage Shaft Assembly (Input Shaft). . . . . . . . . . . . . . . . . . . . . . . . .02-35-31 Exploded View—Second Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-32 Cross-Sectional View—Second Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-33 9620 Series Exploded View—Second Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-34 9620 Series Cross-Sectional View— Second Stage Clutch Shaft Assembly . . . . .02-35-35 Exploded View—Third Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-36 Cross-Sectional View—Third Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-37 9620 Series Exploded View—Third Stage Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-38 9620 Series Cross-Sectional View—Third Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-39 Exploded View—Fourth Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-40 Cross-Sectional View—Fourth Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-41 9620 Series Exploded View—Fourth Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-42 9620 Series Cross-Sectional View— Fourth Stage Clutch Shaft Assembly . . . . . .02-35-43 Exploded View—Fifth Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-44 Cross-Sectional View—Fifth Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-45 9620 Series Exploded View—Fifth Stage Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-46 9620 Series Cross-Sectional View—Fifth Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-47 Exploded View—Sixth Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-48 Cross-Sectional View—Sixth Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-49 9620 Series Exploded View—Sixth Stage Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-50 9620 Series Cross-Sectional View—Sixth Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-51 Exploded View—Seventh Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-52

Cross-Sectional View—Seventh Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-53 9620 Series Exploded View—Seventh Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-54 9620 Series Cross-Sectional View— Seventh Stage Clutch Shaft Assembly. . . . .02-35-55 Disassembly and Assembly of Clutch Stage Shaft Assemblies . . . . . . . . . . . . . . . . . . . . .02-35-56 Disassemble and Assemble Second Stage Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-56 Disassemble and Assemble Fifth Stage Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-76 Disassemble and Assemble Seventh Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-82 Disassemble and Assemble Sixth Stage Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-83 Disassemble and Assemble Fourth Stage Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-86 Disassemble and Assemble Third Stage Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-93 Install Clutch Assemblies. . . . . . . . . . . . . . . . .02-35-96 Install Rear Housing . . . . . . . . . . . . . . . . . . . .02-35-97 Bearing Adjustment of Output Shaft Rear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-99 Internal Park Brake Assembly . . . . . . . . . . . .02-35-102 Bearing Adjustments to Clutch Stage Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-109 Install Clutch Rotation Tools . . . . . . . . . . . . .02-35-110 Bearing Adjustment Of Fifth and Sixth Clutch Stage Shaft Assemblies . . . . . . . . .02-35-112 Bearing Adjustment of Second, Third, Fourth and Seventh Clutch Stage Shaft Assemblies . . . . . . . . . . . . . . . . . . . . . . . .02-35-114 Bearing Adjustment of Output Shaft Front Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-120 Bearing Adjustment of Input Shaft . . . . . . . . .02-35-123

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Group 15

Transmission Repair Stand Safety Precautions To prevent possible personal injury due to transmission slippage, recheck to make sure transmission is solidly mounted before releasing support from transmission lifting device.

The engine repair stand should be used only by qualified service technicians familiar with this equipment.

To maintain shear strength specifications, alloy steel SAE Grade 8 or higher cap screws must be used to mount adapters or transmission.

02 15 1

Never permit any part of the body to be positioned under a load being lifted or suspended. Accidental slippage may result in personal injury.

For full thread engagement, be certain that tapped holes in adapters and transmission are clean and not damaged. A thread length engagement equal to 1-1/2 screw diameters minimum is required to maintain strength requirements.

To avoid structural or personal injury, do not exceed the maximum capacity rating of 2722 kg (6000 lb).

Maximum capacity is determined with the center of the transmission located not more than 330 mm (13 in.) from the mounting hub surface of the engine stand.

The lifting jack is to be used when it is necessary to lift the transmission for rotation. When working on the transmission, the jack should be at its lowest position to keep the center of gravity low and the possibility of tipping low.

To prevent possible personal injury due to sudden transmission movement, lower transmission by operating jack release valve slowly. Do not unscrew release valve knob more than two turns from its closed position.

To avoid an unsafe off-balance load condition, the center of balance of the transmission must be located within 51 mm (2 in.) of the engine stand rotating shaft.

DPSG,YZ07927,129 –19–15JUL99–1/1

Engine Repair Stand

Refer to TM1623 (W) or TM1782 (T) technical manual for steps to remove transmission from machine before installing it on rollover stand.

RG4929

A—Engine Rollover Stand

–UN–05DEC97

NOTE: Only the 2722 kg (6000 lb) heavy-duty engine rollover stand (A) No. DO5223ST manufactured

by Owatonna Tool Co., Owatonna, Minnesota is referenced in this manual. When any other repair stand is used, consult the manufacturer’s instructions for mounting the transmission.

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Transmission

Install Adapter to Engine Rollover Stand NOTE: The 205466 Engine Mounting Adapter if furnished with the D05223ST Engine Rollover Stand.

Attach the No. 205466 Engine Adapter (A) to mounting hub of D05223ST Engine Rollover Stand using SAE Grade 8 Socket-Head screws (B).

–UN–28FEB01

Tighten screws.

RXA0052046

Specification Socket-head Cap Screw-to-Repair Stand.—Torque ................................................. 135 N•m (100 lb-ft)

Remove end adapter (C) from engine mounting adapter (A) if adapter is fastened to engine mounting adapter.

A—205466 Engine Mounting Adapter B—Socket-Head Cap Screws (3 used) C—51400 End Adapter

DPSG,YZ07927,127 –19–15JUL99–1/1

Install Transmission Mounting Bracket Obtain JDG1476 Engine Rollover Stand Bracket.

IMPORTANT: Use the cap screws provided with the brackets and tighten to correct specification.

Install top bracket (A) to engine mounting adapter (D) and tighten cap screws (B) and (C).

Specification Bracket-to-Adapter Cap Screws (B)—Torque .................................................................................. 300 N•m (225 lb-ft) Adapter-to-Bracket Cap Screws (C)—Torque .................................................................................. 550 N•m (400 lb-ft)

–UN–26FEB01

A—Top Bracket B—Bracket-to-Adapter Cap Screws (2 used) C—Adapter-to-Bracket Cap Screws (2 used) D—Engine Mounting Adapter

RXA0051530

02 15 2

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CTM168 (10DEC07)

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PN=32

Transmission Install bottom bracket (A) to adapter (B) and tighten cap screws (C).

Specification Adapter-to-Bracket Cap Screws (C)—Torque .................................................................................. 550 N•m (400 lb-ft)

02 15 3

RXA0051529

–UN–26FEB01

A—Bottom Bracket B—Engine Mounting Adapter C—Adapter-to-Bracket Cap Screws

OURX078,0000008 –19–27JAN01–2/2

Install Transmission to Rollover Stand Bracket Install adapter to engine rollover stand. (See Install Adapter to Engine Rollover Stand, this group.)

Install transmission mounting bracket to engine mounting adapter. (See Install Transmission Mounting Bracket, this group.)

RXA0051531

–UN–26FEB01

Rotate the transmission mounting bracket to the vertical position.

Continued on next page

CTM168 (10DEC07)

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PN=33

Transmission Position transmission with right side in mounting bracket as shown.

Install bracket-to-transmission cap screws (A) and tighten.

Specification Bracket-to-Transmission Cap Screws—Torque ........................................................................... 475 N•m (350 lb-ft)

–UN–26FEB01

A—Bracket-to-Transmission Cap Screws

RXA0051526

02 15 4

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CTM168 (10DEC07)

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Transmission Install bottom bracket-to-transmission cap screws (A) and tighten.

Specification Bottom Bracket-to-Transmission Cap Screws (A)—Torque ............................................................. 240 N•m (175 lb-ft)

02 15 5

Install outer bracket (B) to top bracket (C) and install cap screws (D) and (E) and tighten.

Specification Outer Bracket-to-Top Bracket Cap Screws (D)—Torque ............................................................. 550 N•m (400 lb-ft) Outer Bracket-to-Transmission Cap Screws (E)—Torque ............................................................. 475 N•m (350 lb-ft)

RXA0051525

–UN–27FEB01

A—Bottom Bracket-to-Transmission Cap Screws B—Top/Outer Bracket C—Top Bracket D—Outer Bracket-to-Top Bracket Cap Screws E—Outer Bracket-to-Transmission Cap Screws F—Lift Chains G—Lifting Brackets

Old Style Transmission to Bracket

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18-Speed PST Repair Manual 121007

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Transmission

Remove Transmission from Rollover Stand Bracket Install JDG19 Lifting Brackets (G) and lift chains (F) and 02 attach to an overhead hoist.

Remove transmission assembly from mounting bracket in reverse order of installation.

RXA0051525

–UN–27FEB01

A—Bottom Bracket-to-Transmission Cap Screws B—Top/Outer Bracket C—Top Bracket D—Outer Bracket-to-Top Bracket Cap Screws E—Outer Bracket-to-Transmission Cap Screws F—Lift Chains G—JDG19 Lifting Brackets

Old StyleTransmission to Bracket

OURX078,000000A –19–27JAN01–1/1

Remove and Install Yoke

–UN–26FEB01

NOTE: All yokes are installed and removed in the same manner.

Install JDG924 Yoke Holding Tool (A) to yoke (B) using yoke cap screws (C).

Remove yoke retaining cap screw.

RXA0051503

15 6

A—Yoke Holding Tool B—Yoke C—Cap Screws

Remove Rear Output Yoke

Continued on next page

CTM168 (10DEC07)

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Transmission NOTE: Degrease cap screw threads and input shaft tapped hole threads using a non-petroleum based solvent.

–UN–05FEB01

Install yoke (A) to input shaft.

RXA0051502

Apply T43512 Thread Lock and Sealer to cap screw threads.

Install O-ring (B), washer (C) and cap screw (D).

A—Yoke B—O-Ring C—Washer D—Yoke Retaining Cap Screw

Install Rear Output Yoke

OURX078,0000006 –19–27JAN01–2/3

Install JDG924 Yoke Holding Tool to the yoke to prevent the yoke from rotating while tightening.

–UN–26FEB01

Tighten cap screw.

RXA0051524

Specification Input Yoke-to-Shaft Cap Screw— Torque .......................................................................................... 435 N•m (320 lb-ft)

Tighten Rear Output Yoke Cap Screw

OURX078,0000006 –19–27JAN01–3/3

CTM168 (10DEC07)

02-15-7

18-Speed PST Repair Manual 121007

PN=37

02 15 7

Transmission

Replace Input and Output Shaft Seals (In Tractor)

Disconnect driveline.

RXA0051500

Remove yoke. (See Remove and Install Yoke, this group.)

Remove and discard old oil seal.

Replace Input Shaft Oil Seal

Position new oil seal (A) in bearing retainer bore.

A—Oil Seal B—Seal Installer Plate C—Bearing Installer

Install JDG1487A Seal Installer Plate (B).

Position the JDG926A Bearing Installer (C) in the bore of the seal installer plate.

DPSG,YZ07927,328 –19–05DEC07–1/2

Force the seal into the bearing retainer until the seal bottoms on the bearing retainer oil seal flange.

–UN–05FEB01

Install yoke. (See Remove and Install Yoke, this group.)

Connect drive line.

A—Seal Installer Plate B—Bearing Installer

RXA0051501

15 8

–UN–05FEB01

NOTE: All shaft oil seals are removed and installed in the same manner.

02

Install Input Shaft Oil Seal

DPSG,YZ07927,328 –19–05DEC07–2/2

CTM168 (10DEC07)

02-15-8

18-Speed PST Repair Manual 121007

PN=38

Transmission

Replace Bearing Retainer O-Ring Seals Input Shaft –UN–02FEB01

Remove yoke. (See Remove and Install Yoke, this group.)

RXA0051493

Remove bearing retainer cap screws (A), bearing retainer (B) and shim pack (C).

Do not lose or misplace the shim pack.

A—Bearing Retainer Cap Screws (4 used) B—Bearing Retainer C—Shaft End Play Shim Pack

OURX078,000000B –19–03JUN05–1/10

Remove and discard O-ring oil seal (B).

–UN–05FEB01

Lubricate new O-ring with transmission fluid and install on bearing retainer.

RXA0051498

A—Bearing Retainer B—O-Ring Oil Seal C—Shim Pack

OURX078,000000B –19–03JUN05–2/10

Install the same shim pack (C) that was removed.

–UN–02FEB01

Install bearing retainer (B) and install and tighten cap screws (A).

RXA0051493

Specification Bearing Retainer-to-Front Housing Cap Screws—Torque ....................................................... 87 N•m (64 lb-ft)

Install yoke. (See Remove and Install Yoke, this group.)

A—Bearing Retainer Cap Screws (4 used) B—Bearing Retainer C—Shim Pack

Continued on next page

CTM168 (10DEC07)

02-15-9

OURX078,000000B –19–03JUN05–3/10

18-Speed PST Repair Manual 121007

PN=39

02 15 9

Transmission Old Style Output Shaft without Internal Park Brake Remove yoke. (See Remove and Install Yoke, this group.)

–UN–01MAR01

Remove bearing retainer cap screws (A), bearing retainer (B) and shim pack (C).

RXA0051494

Do not lose or misplace shim pack.

A—Bearing Retainer Cap Screws (4 used) B—Bearing Retainer C—Shaft End Play Shim Pack

OURX078,000000B –19–03JUN05–4/10

Remove and discard O-ring oil seal (B).

–UN–01MAR01

Lubricate new O-rings with transmission fluid and install on spacer and bearing retainer.

RXA0051499

A—Bearing Retainer B—Bearing Retainer O-Ring Oil Seal C—Shim Pack

OURX078,000000B –19–03JUN05–5/10

Install the same shim pack (C) that was removed.

Install bearing retainer (B).

–UN–01MAR01

Install and tighten bearing retainer cap screws (A).

Specification Bearing Retainer-to-Front Housing Cap Screws—Torque ....................................................... 87 N•m (64 lb-ft)

RXA0051494

02 15 10

Install yoke. (See Remove and Install Yoke, this group.)

A—Bearing Retainer Cap Screws (4 used) B—Bearing Retainer C—Shaft End Play Shim Pack

Continued on next page

CTM168 (10DEC07)

02-15-10

OURX078,000000B –19–03JUN05–6/10

18-Speed PST Repair Manual 121007

PN=40

Transmission Fifth and Sixth Clutch Stage Shafts

–UN–02FEB01

NOTE: Both the fifth and sixth stage clutch shaft O-ring seals are replaced in the same manner.

Remove bearing retainer cap screws (A), bearing retainer (B) and shim pack (C).

RXA0051495

Do not lose or misplace the shim pack.

A—Bearing Retainer Cap Screws (4 used) B—Bearing Retainer C—Shaft End Play Shim Pack

Sixth Stage Shaft Bearing Retainer

OURX078,000000B –19–03JUN05–7/10

Remove and discard O-ring oil seal (B).

–UN–02FEB01

Lubricate new O-ring with transmission fluid and install on bearing retainer.

RXA0051496

A—Bearing Retainer B—O-Ring Oil Seal C—Shim Pack

OURX078,000000B –19–03JUN05–8/10

Install the same shim pack (C) that was removed.

–UN–02FEB01

Install bearing retainer (B) and install and tighten cap screws (A).

RXA0051495

Specification Bearing Retainer-to-Front Housing Cap Screws—Torque ....................................................... 87 N•m (64 lb-ft)

Second, Third, Fourth and Seventh Clutch Stage Shafts Sixth Stage Bearing Retainer

Bearing retainers for the second, third, fourth and seventh clutch stage shafts are located behind the pump drive cover and DO NOT have O-ring seals.

A—Bearing Retainer Cap Screws (4 used) B—Bearing Retainer C—Shaft End Play Shim Pack

Continued on next page

CTM168 (10DEC07)

02-15-11

OURX078,000000B –19–03JUN05–9/10

18-Speed PST Repair Manual 121007

PN=41

02 15 11

Transmission 9620 Series

–UN–31MAY05

Earlier version of the 18-speed PST were not equiped with thrust washers on shaft stage assemblies. When repairing the 18-speed PST replace bearing retainers of 02 15 the old style with the new style bearing retainers, thrust 12 washers and screw.

YZ6213

A—Second Clutch Stage Shaft B—Third Clutch Stage Shaft C—Fourth Clutch Stage Shaft D—Seventh Clutch Stage Shaft

OURX078,000000B –19–03JUN05–10/10

CTM168 (10DEC07)

02-15-12

18-Speed PST Repair Manual 121007

PN=42

Group 20

Electrical Remove and Install Wiring Harness Bracket

YZ5047

–UN–14APR03

02 20 1

A—Wiring Harness

–19–23SEP05–1/1

CTM168 (10DEC07)

02-20-1

18-Speed PST Repair Manual 121007

PN=43

Electrical

Replacing the Transmission Wiring Harness

02 20 2

Should replacement of the entire transmission wiring harness become necessary, the following procedure should be used.

to prevent mislocation, but the references listed below should be used to correctly identify solenoids or sensors if there is any doubt.

IMPORTANT: Correct routing and connection of the harness is essential for proper transmission operation. It also vital that all connections are SECURELY made, with connector locking tabs engaged.

The following references in Group 25 may prove helpful.

It is important to match all harness connectors with their assigned solenoids or sensors. Identification of each branch of the harness can be done in two ways: • Each branch is individually labeled within two inches of the connector on the end of the branch, sometimes under the conduit, which can be carefully pushed back to locate the label.

• If the label is missing or obscured by paint, use the wire colors and circuit numbers to identify the branch.

• Transmission Wiring Harness • Transmission Wiring Harness Table (for wire colors and circuit numbers).

• Front Housing Sensors and Ports • Rear Housing Sensors and Ports • Proportional Solenoid Identification • Transmission Mating Connector • Transmission Harness Connector Tools needed: • • • •

Ratchet with 16mm socket 7mm open-end wrench Narrow flat-blade screwdriver 5/32” hex key / Allen wrench

Identifying labels are cast into the transmission housing, and the harness branch lengths are designed

Continued on next page

CTM168 (10DEC07)

02-20-2

YZ07927,0000031A –19–16JUN04–1/17

18-Speed PST Repair Manual 121007

PN=44

Electrical NOTE: You can use the new harness on the old transmission but the bracket must match the style of rear housing.

1. Begin removal of the existing wiring harness by using a 5/32” hex key to disconnect the tractor wiring harness from the transmission wiring harness at the 40-way J6 connector located on the lower left side of the transmission.

–UN–08APR03

02 20 3

YZ3935

NOTE: For this procedure, “left side” and “right side” designations are defined by standing at the output shaft side and facing the rear of the transmission.

YZ3473

–UN–09NOV01

J6 Connector Location New Style Rear Housing

YZ07927,0000031A –19–16JUN04–2/17

–UN–09NOV01

2. Disconnect the transmission harness connectors from the solenoid valves, speed sensors, filter switch, temperature sensor, and pressure sensor.

YZ3474

NOTE: When disconnecting the harness, it may be helpful to use a narrow, flat-blade screwdriver to pry gently up on the connector locking tab, especially for the cylinder and output speed sensors and the temperature sensor, which can be more difficult to disconnect.

Continued on next page

CTM168 (10DEC07)

02-20-3

YZ07927,0000031A –19–16JUN04–3/17

18-Speed PST Repair Manual 121007

PN=45

Electrical 3. Remove the two 16mm bolts securing the J6 connector mounting bracket.

YZ3475

Specification Wiring Harness Mounting Bracket-to-Rear Housing Cap Screw—Torque ........................................................................ 50 N˙m (37 lb-ft)

YZ3936

–UN–08APR03

A—Mounting Bracket Cap Srew

New Style Rear Housing

YZ07927,0000031A –19–16JUN04–4/17

–UN–08NOV01

4. Remove the four 7mm screws securing the J6 connector to the mounting bracket.

YZ3476

02 20 4

–UN–09NOV01

Install and tighten cap screws (A).

Continued on next page

CTM168 (10DEC07)

02-20-4

YZ07927,0000031A –19–16JUN04–5/17

18-Speed PST Repair Manual 121007

PN=46

Electrical

–UN–08APR03

5. Begin installation of the new harness by securing the J6 connector to the mounting bracket, using the orientation shown in the illustration.

YZ3937

NOTE: The connector is divided into two halves. Install the connector in the bracket so that the half with the most terminals missing is nearest the top of the transmission. This will simplify the harness routing.

6. Secure the mounting bracket to the transmission, and secure the yellow plastic terminal cover with tape until ready to reconnect the tractor wiring harness.

YZ07927,0000031A –19–16JUN04–6/17

YZ3938

–UN–08APR03

7. Make the connection to the clutch H solenoid, located just above the mounting bracket.

Continued on next page

CTM168 (10DEC07)

02-20-5

YZ07927,0000031A –19–16JUN04–7/17

18-Speed PST Repair Manual 121007

PN=47

02 20 5

Electrical NOTE: All wiring harness connectors have label tags that corresponds with the mating connector.

YZ3959

–UN–09APR03

02 20 6

YZ07927,0000031A –19–16JUN04–8/17

8. Position the major harness branch near the lower elbow of the metal tube as shown.

9. Identify the main branch carrying the input and cylinder speed sensors and the connections for solenoids 2, A, and M.

–UN–08APR03

10. Route this branch below the main regulator and up around the metal tube, as shown in the illustration.

YZ3939

A—Route Over Tube B—Main Regulator C—Major Harness Branch

Rear View of Transmission

Continued on next page

CTM168 (10DEC07)

02-20-6

YZ07927,0000031A –19–16JUN04–9/17

18-Speed PST Repair Manual 121007

PN=48

Electrical 11. Routing its harness to the outboard side of the metal tube, make the connection to solenoid 2, which is the topmost solenoid on the left side.

12. Routing its harness to the outboard side of the metal tube, make the connection to solenoid A, located just below solenoid 2.

02 20 7

IMPORTANT: Do not swap the connections for solenoids 2 and A. Identify using branch labels and circuit numbers; wire colors for 2 and A are the same.

13. Route the harness for solenoid M between the transmission housing and the branch which will be routed up to the input and cylinder speed sensors.

–UN–08APR03

IMPORTANT: Make certain that wires and conduit are not positioned against sharp metal edges in the area around the tube fitting.

YZ3940

A—Input and Cylinder Speed Sensor Branch B—Solenoid 2 Branch C—Clutch A Solenoid D—Solenoid M Branch Routed Inboard of Speed Sensors Branch

Continued on next page

CTM168 (10DEC07)

02-20-7

YZ07927,0000031A –19–16JUN04–10/17

18-Speed PST Repair Manual 121007

PN=49

Electrical 14. The final connections on the left side are for the input and cylinder speed sensors.

–UN–08APR03

IMPORTANT: Make especially certain that the locking tabs are securely engaged on these two 02 sensors, as these are the most difficult 20 to access for service when the 8 transmission is installed in the tractor.

YZ3941

The wiring harness branch must go over the top of the transmission behind the oil tube as shown in the artwork.

The harness will be damaged if installed wrong.

A—Input / Cylinder Speed Wiring Harness Branch B—Input Speed Sensor (Left Front of Transmission) C—Cylinder Speed Sensor

YZ07927,0000031A –19–16JUN04–11/17

–UN–08APR03

15. Route the remaining major harness branch parallel to the metal tube as shown, and make connections to the system pressure (A) and Oil Pressure sensors (B).

16. Make the filter pressure switch connection behind the main harness branch.

YZ3942

A—System Pressure Sensor B—Oil Pressure Sensor

Continued on next page

CTM168 (10DEC07)

02-20-8

YZ07927,0000031A –19–16JUN04–12/17

18-Speed PST Repair Manual 121007

PN=50

Electrical 17. Make connections to solenoids 1 and B. IMPORTANT: Do not swap the connections for solenoids 1 and B. Identify using branch labels and wire colors.

02 20 9

YZ3943

–UN–08APR03

A—Clutch 1 (Forward Directional Clutch), Third Stage Assembly B—Clutch B (Speed Clutch), Third Stage Assembly C—Clutch R (Reverse Directional Clutch), Fourth Stage Assembly D—Clutch C (Speed Clutch), Fourth Stage Assembly

Continued on next page

CTM168 (10DEC07)

02-20-9

YZ07927,0000031A –19–16JUN04–13/17

18-Speed PST Repair Manual 121007

PN=51

Electrical 18. Continuing down the right side of the transmission, make connections to solenoids R and C. IMPORTANT: Do not swap the connections for solenoids R and C. Identify using 02 branch labels and wire colors.

20 10

YZ3943

–UN–08APR03

A—Clutch 1 (Forward Directional Clutch), Third Stage Assembly B—Clutch B (Speed Clutch), Third Stage Assembly C—Clutch R (Reverse Directional Clutch), Fourth Stage Assembly D—Clutch C (Speed Clutch), Fourth Stage Assembly

Continued on next page

CTM168 (10DEC07)

02-20-10

YZ07927,0000031A –19–16JUN04–14/17

18-Speed PST Repair Manual 121007

PN=52

Electrical 19. Continuing down the right side of the transmission, make connections to solenoid L, fifth-stage speed sensor (branch is labeled “INT”) and the Temperature Sensor (A).

02 20 11

YZ3944

–UN–08APR03

A—Temperature Sensor B—Clutch L Solenoid C—Fifth-Stage Speed Sensor

YZ07927,0000031A –19–16JUN04–15/17

20. The final connections on the right side are for the output #1 and output #2 speed sensors.

IMPORTANT: Do not swap the connections for the output speed sensors. Identify using branch labels and wire colors.

YZ3945

–UN–08APR03

A—Output #1 Speed Sensor B—Output #2 Speed Sensor

Continued on next page

CTM168 (10DEC07)

02-20-11

YZ07927,0000031A –19–16JUN04–16/17

18-Speed PST Repair Manual 121007

PN=53

Electrical 21. Secure the harness to the metal tube with a cable tie at each of the two locations shown. The ties should be snug, but not so tight that they deform the conduit or draw it too tightly against the tube fitting.

22. Reconnect the tractor wiring harness to the transmission at the 40-way J6 connector located on the lower left side of the transmission.

–UN–08APR03

23. Make a final check to verify that at the various branches in the harness, no exposed wires are drawn tight across fittings or the transmission housing. Verify that there are no harness pinch or rub points arising from interference with hydraulic hoses or the tractor frame, especially if this was the reason for replacing the harness.

YZ3946

02 20 12

A—Cable Ties

YZ07927,0000031A –19–16JUN04–17/17

CTM168 (10DEC07)

02-20-12

18-Speed PST Repair Manual 121007

PN=54

Electrical

02 20 13

CTM168 (10DEC07)

02-20-13

18-Speed PST Repair Manual 121007

PN=55

Electrical

Front Housing Sensors and Ports

YZ1910A

–UN–11OCT01

02 20 14

Front Housing Without Internal Park Brake A—Output Speed Sensors (Top)

B—Output Speed Sensors (Bottom)

C—Axle Lube Pump Air Suction Port (9/16-18 UNF-2B)

Continued on next page

CTM168 (10DEC07)

02-20-14

D—Front Axle Lube Return Port (1 1/16-12 UN-2B)

OURX078,0000001 –19–13AUG03–1/2

18-Speed PST Repair Manual 121007

PN=56

Electrical

YZ3933

–UN–08APR03

02 20 15

Front Housing With Internal Park Brake A—Output Speed Sensors (Top)

B—Output Speed Sensors (Bottom)

C—Axle Lube Pump Air Suction Port (9/16-18 UNF-2B)

D—Front Axle Lube Return Port (1 1/16-12 UN-2B)

OURX078,0000001 –19–13AUG03–2/2

CTM168 (10DEC07)

02-20-15

18-Speed PST Repair Manual 121007

PN=57

Electrical

Rear Housing Sensors and Ports

YZ1906B

–UN–21SEP01

02 20 16

Rear Housing Without Internal Park Brake A—Lube Pressure Test Port B—M Clutch Pressure Port C—PTO Lube Port D—Temperature Sensor E—Diff-Lock Supply Pressure Port

F—C Clutch Pressure Port G—R Clutch Pressure Port H—Transmission Oil Filter Switch I—Fifth Stage Magnetic Pickup Sensor (Speed)

J—PTO Pressure Supply Port K—PTO Oil Drain Back Port L—Vent to Axle Housing (T) M—System Pressure Sensor

Continued on next page

CTM168 (10DEC07)

02-20-16

N—System Pressure Check Port O—H Clutch Pressure Port

OURX078,0000003 –19–13AUG03–1/2

18-Speed PST Repair Manual 121007

PN=58

Electrical

YZ3947

–UN–02MAY03

02 20 17

Rear Housing With Internal Park Brake A—Lube Pressure Test Port B—M Clutch Pressure Port C—PTO Lube Port D—Temperature Sensor E—Diff-Lock Supply Pressure Port

F—C Clutch Pressure Port G—R Clutch Pressure Port H—Transmission Oil Filter Switch I—Fifth Stage Magnetic Pickup Sensor (Speed)

J—PTO Pressure Supply Port K—PTO Oil Drain Back Port L—Vent to Axle Housing (T) M—System Pressure Sensor N—System Pressure Check Port

O—H Clutch Pressure Port P—Internal Park Brake Check Valve Assembly Q—Internal Park Brake Release Port

OURX078,0000003 –19–13AUG03–2/2

CTM168 (10DEC07)

02-20-17

18-Speed PST Repair Manual 121007

PN=59

Electrical

Proportional Solenoid Identification - Left Side

YZ1888A

–UN–19SEP01

02 20 18

Left Side Rear Housing Without Internal Park Brake A—Clutch 2 (Forward Directional Clutch), Second Stage Assembly

B—Clutch A (Speed Clutch), Second Stage Assembly

C—Clutch M (Medium Range), Seventh Stage Assembly

Continued on next page

CTM168 (10DEC07)

02-20-18

D—Clutch H (High Range), Sixth Stage Assembly

OURX078,0000002 –19–14AUG03–1/2

18-Speed PST Repair Manual 121007

PN=60

Electrical

YZ3948

–UN–08APR03

02 20 19

Left Side Rear Housing With Internal Park Brake A—Clutch 2 (Forward Directional Clutch), Second Stage Assembly

B—Clutch A (Speed Clutch), Second Stage Assembly

C—Clutch M (Medium Range), Seventh Stage Assembly

D—Clutch H (High Range), Sixth Stage Assembly

OURX078,0000002 –19–14AUG03–2/2

CTM168 (10DEC07)

02-20-19

18-Speed PST Repair Manual 121007

PN=61

Electrical

Proportional Solenoid Identification - Right Side

YZ1889A

–UN–19SEP01

02 20 20

Right Side Rear Housing Without Internal Park Brake A—Clutch 1 (Forward Directional Clutch), Third Stage Assembly

B—Clutch B (Speed Clutch), Third Stage Assembly C—Clutch R (Reverse Directional Clutch), Fourth Stage Assembly

D—Clutch C (Speed Clutch), Fourth Stage Assembly

Continued on next page

CTM168 (10DEC07)

02-20-20

E—Clutch L (Low Range), Fifth Stage Assembly

OURX078,0000004 –19–14AUG03–1/2

18-Speed PST Repair Manual 121007

PN=62

Electrical

YZ3949

–UN–08APR03

02 20 21

Right Side Rear Housing With Internal Park Brake A—Clutch 1 (Forward Directional Clutch), Third Stage Assembly

B—Clutch B (Speed Clutch), Third Stage Assembly C—Clutch R (Reverse Directional Clutch), Fourth Stage Assembly

D—Clutch C (Speed Clutch), Fourth Stage Assembly

E—Clutch L (Low Range), Fifth Stage Assembly

OURX078,0000004 –19–14AUG03–2/2

CTM168 (10DEC07)

02-20-21

18-Speed PST Repair Manual 121007

PN=63

Electrical

Remove Proportional Solenoid Remove WEATHER PACK connector (A).

Remove nut (B).

Remove coil (C).

YZ3950

–UN–08APR03

A—Weather Pack Connector B—Valve Spool Nut C—Coil

WEATHER PACK is a trademark of Packard Electric

DPSG,YZ07927,306 –19–15APR03–1/3

NOTE: A deep-well socket is required to remove the valve stem.

Remove proportional valve stem.

YZ3951

–UN–08APR03

A—Proportional Cartridge Valve Stem

DPSG,YZ07927,306 –19–15APR03–2/3

Inspect components and replace as necessary.

–UN–04DEC00

A—O-Ring (3 used) B—Valve Stem C—Solenoid Coil D—Nut

YZ3019

02 20 22

DPSG,YZ07927,306 –19–15APR03–3/3

CTM168 (10DEC07)

02-20-22

18-Speed PST Repair Manual 121007

PN=64

Electrical

Install Proportional Solenoid Valve Install solenoid valve stem (A).

YZ3952

–UN–08APR03

02 20 23

DPSG,YZ07927,307 –19–15APR03–1/4

Tighten valve stem.

YZ3953

–UN–21APR03

Specification Proportional Cartridge Valve Stem-to-Rear Housing—Torque .............................................. 16—20 N•m (142—177 lb-in.)

Continued on next page

CTM168 (10DEC07)

02-20-23

DPSG,YZ07927,307 –19–15APR03–2/4

18-Speed PST Repair Manual 121007

PN=65

Electrical Install coil (A) and nut (B).

Install WEATHER PACK connector (C).

YZ3954

–UN–09APR03

A—Coil B—Solenoid Coil Retainer Nut C—Weather Pack Connector

WEATHER PACK is a trademark of Packard Electric

DPSG,YZ07927,307 –19–15APR03–3/4

Tighten solenoid coil retainer nut (A).

Specification Tighten Solenoid Coil Retainer Nut-to-Coil—Torque............................................................... 4.5—6.8 N•m (40—60 lb-in.)

–UN–09APR03

A—Solenoid Coil Retainer Nut

YZ3955

02 20 24

DPSG,YZ07927,307 –19–15APR03–4/4

CTM168 (10DEC07)

02-20-24

18-Speed PST Repair Manual 121007

PN=66

Electrical

Remove and Install Input and Cylinder Speed Magnetic Pickup Sensors Remove input speed magnetic pickup sensor (A).

02 20 25 –UN–09APR03

Remove cylinder speed magnetic pickup sensor (B).

YZ3956

A—Input Speed Magnetic Pickup Sensor B—Cylinder Speed Magnetic Pickup Sensor

DPSG,YZ07927,163 –19–15APR03–1/3

Check sensors for contamination.

–UN–09APR03

Remove and inspect O-ring (A) and discard.

Install new O-ring onto magnetic sensors.

YZ3957

A—Magnetic Pickup Sensor O-Ring

DPSG,YZ07927,163 –19–15APR03–2/3

NOTE: All wiring harness connectors have label tags that corresponds with the mating connector.

YZ3958

Specification Magnetic pickup sensor-to-front housing—Torque ..................................................................... 16—20 N•m (142—177 lb-in.)

–UN–09APR03

Install sensors (A) and (B) into housing and tighten.

A—Input Speed Magnetic Pickup Sensor B—Cylinder Speed Magnetic Pickup Sensor

DPSG,YZ07927,163 –19–15APR03–3/3

CTM168 (10DEC07)

02-20-25

18-Speed PST Repair Manual 121007

PN=67

Electrical

Remove and Install Fifth Stage Magnetic Pickup Sensor (Speed) NOTE: This sensor is used for calibration and shifting.

Remove fifth stage speed magnetic pickup sensor (A).

YZ3960

–UN–09APR03

A—Magnetic Pickup Sensor

DPSG,YZ07927,169 –19–10DEC07–1/3

Check for wear or damage and discard.

–UN–05DEC00

Install new O-ring A—O-Ring

YZ3010

02 20 26

Continued on next page

CTM168 (10DEC07)

02-20-26

DPSG,YZ07927,169 –19–10DEC07–2/3

18-Speed PST Repair Manual 121007

PN=68

Electrical Install sensor (A) into housing and tighten.

Specification Magnetic pickup sensor-to-housing—Torque ................................................... 16—20 N•m (142—177 lb-in.)

02 20 27

YZ3960

–UN–09APR03

A—Magnetic Pickup Sensor

DPSG,YZ07927,169 –19–10DEC07–3/3

Remove and Install Output Magnetic Pickup Sensors Remove output speed magnetic pickup sensors (A).

YZ3961

–UN–09APR03

A—Output Magnetic Pickup Sensors

Continued on next page

CTM168 (10DEC07)

02-20-27

DPSG,YZ07927,168 –19–15APR03–1/2

18-Speed PST Repair Manual 121007

PN=69

Electrical Check sensors for contamination.

Specification Magnetic pickup sensor-to-housing—Torque ..................................................... 16—20 N•m (12—15 lb-ft)

YZ3010

Install sensors into housing and tighten.

A—Magnetic Pickup Sensor O-Ring

DPSG,YZ07927,168 –19–15APR03–2/2

Remove and Install Oil Filter Head Pressure Switch Disconnect pressure switch WEATHER PACK connector (A).

Remove switch.

Install new pressure switch Tighten pressure switch.

–UN–09APR03

Connect pressure switch connector.

A—Pressure Switch Connector

YZ3962

02 20 28

–UN–05DEC00

Replace O-ring (A) on sensors.

WEATHER PACK is a trademark of Packard Electric

CTM168 (10DEC07)

DPSG,YZ07927,284 –19–15APR03–1/1

02-20-28

18-Speed PST Repair Manual 121007

PN=70

Electrical

Remove and Install System Pressure Sensor Disconnect WEATHER PACK connector (A).

Remove system pressure sensor.

02 20 29

YZ3963

–UN–09APR03

A—System Pressure Sensor Connector

WEATHER PACK is a trademark of Packard Electric

DPSG,YZ07927,296 –19–15APR03–1/2

Inspect and discard O-ring (A).

Reverse steps to install system pressure sensor.

YZ3003

Specification System Pressure Sensor-to-Rear Housing.—Torque........................................................................... 16 N•m (142 lb-in.)

–UN–30NOV00

Tighten system pressure sensor.

A—System Pressure Sensor O-Ring

DPSG,YZ07927,296 –19–15APR03–2/2

CTM168 (10DEC07)

02-20-29

18-Speed PST Repair Manual 121007

PN=71

Electrical

Remove and Install Temperature Sensor Disconnect connector and remove temperature sensor (A).

YZ3964

–UN–09APR03

A—Temperature Sensor

DPSG,YZ07927,297 –19–15APR03–1/3

Remove O-ring (A) from temperature sensor and discard.

Install new O-ring onto temperature sensor.

–UN–09APR03

Install and tighten temperature sensor.

YZ3965

Specification Temperature Sensor-to-Rear Housing—Torque........................................................................... 16 N•m (142 lb-in.)

DPSG,YZ07927,297 –19–15APR03–2/3

NOTE: Old Style Temperature Sensor are located in the center of the rear housing. The new style rear housing the Temperature Sensor is located on the right side of the rear housing.

Install and tighten temperature sensor.

–UN–30NOV00

Specification Temperature Sensor-to-Rear Housing—Torque........................................................................... 16 N•m (142 lb-in.)

YZ3005

02 20 30

Old Style Temperature Sensor Location

DPSG,YZ07927,297 –19–15APR03–3/3

CTM168 (10DEC07)

02-20-30

18-Speed PST Repair Manual 121007

PN=72

Group 25

Hydraulics System Components

YZ3966

–UN–09APR03

02 25 1

Internal Park Brake Rear Housing System Components A—Cooler Relief Bypass Valve B—Main Regulator Valve C—Oil Filter Head Inlet Tube

D—Filter Bypass Valve E—Oil Filter Head

F—Oil Filter G—Suction Screen Assembly

H—Oil Fill Tube (Wheel Tractor Only)

YZ07927,0000479 –19–23SEP05–1/1

CTM168 (10DEC07)

02-25-1

18-Speed PST Repair Manual 121007

PN=73

Hydraulics

Remove and Install Suction Screen Remove cap screws (A).

YZ3967

–UN–09APR03

A—Suction Screen Cover Cap Screws

YZ07927,000047A –19–23SEP05–1/5

Remove suction screen cover (A).

Remove and discard O-ring (B)

YZ3968

–UN–09APR03

A—Suction Screen Cover B—O-Ring

YZ07927,000047A –19–23SEP05–2/5

Remove suction screen (A).

Inspect for damage or contamination and clean or replace as necessary.

–UN–09APR03

A—Suction Screen

YZ3969

02 25 2

Continued on next page

CTM168 (10DEC07)

02-25-2

YZ07927,000047A –19–23SEP05–3/5

18-Speed PST Repair Manual 121007

PN=74

Hydraulics Install suction screen.

Lubricate new O-ring (B) with transmission fluid and install on suction screen cover (A).

YZ3968

–UN–09APR03

A—Suction Screen Cover B—O-Ring

YZ07927,000047A –19–23SEP05–4/5

Install suction screen cover assembly onto rear housing and tighten cap screws.

YZ3970

–UN–09APR03

Specification Suction Screen Cover-to-Rear Housing Cap Screw—Torque......................................................... 55 N•m (40 lb-ft)

YZ07927,000047A –19–23SEP05–5/5

Remove and Install Oil Filter Remove oil filter (A).

Install new oil filter onto oil filter head.

YZ3971

Turn new oil filter until filter makes contact with oil filter head and tighten 1/2 turn after contact.

–UN–09APR03

Lubricate rubber gasket on new oil filter.

A—Oil Filter

YZ07927,000047B –19–23SEP05–1/1

CTM168 (10DEC07)

02-25-3

18-Speed PST Repair Manual 121007

PN=75

02 25 3

Hydraulics

Remove and Install Oil Filter Inlet Tube Remove oil filter inlet tube (A).

IMPORTANT: Install oil filter inlet tube hand tight onto filter head before tightening bolts in filter head. Then tighten oil filter inlet tube.

–UN–09APR03

Install tube in reverse order.

YZ3972

A—Oil Filter Inlet Tube

YZ07927,000047C –19–23SEP05–1/1

–UN–09APR03

Oil Filter Head

YZ3973

02 25 4

A—System Pressure (Filtered) Oil

B—By-Pass Valve C—Transmission Oil Filter Switch

D—Oil from Oil Pump

E—By-Pass Oil (unfiltered) to Lube

YZ07927,000047D –19–23SEP05–1/1

CTM168 (10DEC07)

02-25-4

18-Speed PST Repair Manual 121007

PN=76

Hydraulics

Remove Oil Filter Switch NOTE: The filter head assembly is not a service item.

The following information is for cleaning only.

02 25 5

Remove oil filter switch.

Remove Filter By-Pass Valve Cap (A).

YZ3974

–UN–09APR03

A—Filter By-Pass Valve Cap

YZ07927,000047E –19–23SEP05–1/1

Disassemble and Assemble Filter By-Pass Valve

YZ3975

–UN–09APR03

A—O-Ring B—Spring C—Spool

YZ07927,000047F –19–23SEP05–1/1

CTM168 (10DEC07)

02-25-5

18-Speed PST Repair Manual 121007

PN=77

Hydraulics

Remove, Repair and Install Oil Filter Head

YZ3976

–UN–09APR03

02 25 6

YZ07927,0000480 –19–23SEP05–1/1

Remove, Repair and Install Main Regulator Valve

–UN–09APR03

Remove main regulator valve (A).

YZ3979

A—Regulator Valve

YZ07927,0000481 –19–23SEP05–1/3

NOTE: The only serviceable items are the O-rings (A).

–UN–09APR03

The Main Regulator Valve controls system pressure throughout the transmission and is preset to 1790—1930 kPa (265—275 psi) at a flow of 99—106L (26—28 gpm) in a temperature range of 130—150°C (105—115°F). If system pressure falls out-of-tolerance, the main regulator will need to be replaced.

YZ3980

Remove and replace O-rings (A).

Continued on next page

CTM168 (10DEC07)

02-25-6

YZ07927,0000481 –19–23SEP05–2/3

18-Speed PST Repair Manual 121007

PN=78

Hydraulics Install and tighten main regulator valve (A).

Specification Regulator Valve-to-Housing— Torque .......................................................................................... 142 N•m (105 lb-ft)

YZ3981

–UN–09APR03

02 25 7

YZ07927,0000481 –19–23SEP05–3/3

Remove and Install Lube Relief Bypass Valve Remove –UN–13DEC05

Remove plug (A) on rear of transmission housing.

YZ6307

A—Plug

Continued on next page

CTM168 (10DEC07)

02-25-7

YZ07927,0000482 –19–12SEP06–1/8

18-Speed PST Repair Manual 121007

PN=79

Hydraulics Install JDG1808A Relief Valve Tool (A) into opening and thread into the valve located in the internal bore.

A—JDG1808A

YZ6481

–UN–10APR06

YZ6480

–UN–10APR06

02 25 8

YZ07927,0000482 –19–12SEP06–2/8

Remove JDG1808A (A) with valve (B) attached.

–UN–10APR06

Remove valve from tool.

YZ6482

A—JDG1808AValve Removal Tool B—Lube Relief Bypass Valve

YZ07927,0000482 –19–12SEP06–3/8

YZ3985

–UN–10APR03

Inspect, clean or discard the valve as necessary.

Continued on next page

CTM168 (10DEC07)

02-25-8

YZ07927,0000482 –19–12SEP06–4/8

18-Speed PST Repair Manual 121007

PN=80

Hydraulics Install

–UN–10APR06

IMPORTANT: Install relief valve using JDG1808A relief valve tool. The relief valve is made of thin material and can be damaged.

Tap lightly until the valve is fully seated, or risk damaging the valve.

YZ6483

1. Install Relief Valve (A) onto JDG1808A Relief Valve Tool (B).

A—Relief Valve B—JDG1808A Relief Valve Removal Tool

YZ07927,0000482 –19–12SEP06–5/8

YZ6484

–UN–10APR06

2. Attach JDG1808A to rear housing.

YZ07927,0000482 –19–12SEP06–6/8

IMPORTANT: The lube relief valve is made of thin material and can be damaged. Tap lightly until the valve is fully seated, or risk damaging the valve.

YZ6485

–UN–10APR06

3. Install relief valve.

Continued on next page

CTM168 (10DEC07)

02-25-9

YZ07927,0000482 –19–12SEP06–7/8

18-Speed PST Repair Manual 121007

PN=81

02 25 9

Hydraulics 4. Install plug (A).

5. Tighten plug.

YZ6479

–UN–10APR06

02 25 10

YZ07927,0000482 –19–12SEP06–8/8

Remove and Install Cooler Relief Bypass Valve Remove

–UN–13DEC05

NOTE: The cooler relief bypass valve is located in the oil cooler line housing bore (B) behind the main regulator valve (A).

YZ6308

Remove main regulator valve (A).

A—Main Regulator Valve B—Oil Cooler Line Housing Bore

YZ07927,0000483 –19–12SEP06–1/5

Install JDG1808A Relief Valve Tool (A) into oil cooler bore opening.

–UN–24APR06

Remove the tool (A) with valve (B) attached.

YZ6486

A—JDG1808A Relief Valve Removal Tool B—Cooler Relief Valve

Continued on next page

CTM168 (10DEC07)

02-25-10

YZ07927,0000483 –19–12SEP06–2/5

18-Speed PST Repair Manual 121007

PN=82

Hydraulics Remove the valve from the tool.

IMPORTANT: Install relief valve using JDG1808A relief valve Tool. The relief valve can be easily damaged during installation.

YZ3985

1. Clean or discard valve as necessary.

–UN–10APR03

Install

YZ07927,0000483 –19–12SEP06–3/5

3. Push the slide into the valve bore located in the rear housing.

4. Install cooler relief valve.

YZ6487

IMPORTANT: The cooler relief valve is made of thin material and can be damaged. Tap lightly until the valve is fully seated, or risk damaging the valve. The JDG1808A is designed to provide a slide hammer action for removing relief valves and by reversing the slide it is a guide to aid in installing relief valves.

–UN–17APR06

2. Install cooler relief valve onto JDG1808A relief valve removal tool.

YZ07927,0000483 –19–12SEP06–4/5

5. Install main regulator valve (A).

6. Tighten main regulator valve (A).

–UN–13DEC05

Specification Regulator Valve-to-Rear Housing—Torque.......................................................................... 142 N•m (105 lb-ft)

YZ6310

A—Main Regulator Valve

YZ07927,0000483 –19–12SEP06–5/5

CTM168 (10DEC07)

02-25-11

18-Speed PST Repair Manual 121007

PN=83

02 25 11

Hydraulics

Remove Oil Level Sight Glass (Wheel Tractors Only) A—Sight Glass Cap Screws

YZ1993A

–UN–26JAN01

02 25 12

YZ07927,0000484 –19–23SEP05–1/1

Repair Oil Level Sight Glass (Wheel Tractors Only)

RXA0052610

–UN–16APR01

A—O-Ring

Sight Glass

YZ07927,0000485 –19–23SEP05–1/1

CTM168 (10DEC07)

02-25-12

18-Speed PST Repair Manual 121007

PN=84

Hydraulics

Install Oil Level Sight Glass (Wheel Tractors Only) Install and tighten cap screws.

02 25 13

YZ1995

–UN–30NOV00

Specification Sight Glass Cap Screw-to-Rear Housing—Torque........................................................................... 16 N•m (142 lb-in.)

Install Sight Glass YZ07927,0000486 –19–23SEP05–1/1

CTM168 (10DEC07)

02-25-13

18-Speed PST Repair Manual 121007

PN=85

Hydraulics

02 25 14

CTM168 (10DEC07)

02-25-14

18-Speed PST Repair Manual 121007

PN=86

Group 30

Pump Drive Remove and Install Oil Line to Input Bearing Remove lube oil line connector (A) from pump drive housing fitting.

02 30 1

Remove fitting and replace O-rings as necessary.

RXA0052190

–UN–06MAR01

A—Lube Oil Line Connector

DPSG,YZ07927,308 –19–05DEC00–1/2

Remove lube oil line connector (A) from rear housing fitting.

Remove oil line.

Remove fitting and replace O-ring as necessary.

Install fittings and line in reverse order.

RXA0052186

–UN–05MAR01

A—Lube Oil Line Connector

DPSG,YZ07927,308 –19–05DEC00–2/2

CTM168 (10DEC07)

02-30-1

18-Speed PST Repair Manual 121007

PN=87

Pump Drive

Remove and Install Transmission Vent Fitting

RXA0052188

A—Fitting

OURX078,0000001 –19–05MAR01–1/1

Remove Pump Drive Cover Remove transmission from vehicle. (See TM1623 (W) or TM1782 (T).)

–UN–27NOV00

Install transmission to rollover stand bracket. (See Install Transmission to Rollover Stand Bracket, Group 15.)

YZ1959

Remove input bearing lube oil line from front cover. (See Remove and Install Lube Oil Line to Input Bearing, this group.)

Remove yoke. (See Remove and Install Input Yoke, Group 15.)

A—Cap Screws B—Spacer and Retainer with Oil Seal C—Shims

Remove four cap screws (A).

Remove spacer and retainer with oil seal (B).

Remove shims (C).

OURX078,0000007 –19–15AUG03–1/3

Remove pump drive housing cap screws (A).

–UN–27NOV00

A—Pump Drive Housing Cap Screws (15 used)

YZ1960

02 30 2

–UN–05MAR01

Remove and replace fitting (A) as necessary.

Pump Drive Housing Continued on next page

CTM168 (10DEC07)

02-30-2

OURX078,0000007 –19–15AUG03–2/3

18-Speed PST Repair Manual 121007

PN=88

Pump Drive NOTE: Guide pins may be fabricated by removing the heads from M12 x 130 mm cap screws.

Install guide pins (A) into the housing across from each other.

02 30 3

Install JDG19 Lifting Brackets (B) and attach lift chains (C) to a lifting device.

–UN–01FEB01

Remove drive housing cover (D).

RXA0051492

A—Guide Pins (2 used) B—Lifting Brackets C—Lift Chains D—Pump Drive Housing Cover

OURX078,0000007 –19–15AUG03–3/3

Disassemble and Assemble Pump Drive Cover Inspect dowel pins (A) for wear or damage and replace as necessary.

–UN–09APR03

NOTE: Dowel pin holes provide a slip fit.

Install new dowel pins to protrude 15 mm (0.6 in.).

YZ3989

A—Dowel Pins (2 used)

DPSG,YZ07927,301 –19–15APR03–1/1

Install Pump Drive Cover Apply a thin film of TY16021 High-Flex Form-in-Place Gasket to housing surface (A).

YZ3175

–UN–22JAN01

A—Front Housing Gasket Surface

Continued on next page

CTM168 (10DEC07)

02-30-3

DPSG,YZ07927,399 –19–15AUG03–1/4

18-Speed PST Repair Manual 121007

PN=89

Pump Drive NOTE: Guide pins may be fabricated by removing the heads from M12 x 130 mm cap screws.

Install JDG19 Lifting Brackets (B) and attach lift chains (C) to a lifting device.

–UN–01FEB01

Install pump housing cover (D).

RXA0051492

A—Guide Pins (2 used) B—Lifting Brackets C—Lift Chains D—Pump Drive Cover

DPSG,YZ07927,399 –19–15AUG03–2/4

Install cover-to-housing cap screws (15 used) and tighten.

–UN–17JAN01

Specification Pump Cover-to-Housing Cap Screws—Torque ............................................................................ 50 N•m (37 lb-ft)

YZ3172

02 30 4

Install guide pins (A) into the housing across from each other.

Continued on next page

CTM168 (10DEC07)

02-30-4

DPSG,YZ07927,399 –19–15AUG03–3/4

18-Speed PST Repair Manual 121007

PN=90

Pump Drive Install shims (C) and spacer and retainer (B).

Install and tighten cap screws (A).

YZ1959

–UN–27NOV00

Specification Input Shaft Spacer/Retainer-to-Cover Cap Screws—Torque ............................................................................. 87 N•m (64 lb-ft)

Install yoke. (See Remove and Install Input Yoke, Group 15.)

A—Cap Screws (4 used) B—Spacer and Retainer with Oil Seal C—Shims

Install input bearing lube oil line to housing. (See Remove and Install Lube Oil Line to Input Bearing, this group.)

Remove transmission from rollover stand bracket. (See Remove Transmission from Rollover Stand Bracket, Group 15.)

Install transmission to vehicle. (See TM1623 (W) or TM1782 (T).)

DPSG,YZ07927,399 –19–15AUG03–4/4

Remove, Repair and Install Oil Pump Gear Assembly Remove pump drive cover. (See Remove Pump Drive Cover, this group.)

–UN–27NOV00

NOTE: Oil pump gear assembly is a slip fit and will not require special tools to remove or install.

YZ1962

Remove oil pump gear assembly (A).

A—Oil Pump Gear Assembly

Continued on next page

CTM168 (10DEC07)

02-30-5

DPSG,YZ07927,177 –19–20SEP99–1/5

18-Speed PST Repair Manual 121007

PN=91

02 30 5

Pump Drive Inspect gear and bearings and replace parts as necessary.

RXA0051482

–UN–01FEB01

02 30 6

DPSG,YZ07927,177 –19–20SEP99–2/5

If necessary install tools and remove bearings (A) using a hydraulic press.

RXA0051483

–UN–01FEB01

A—Roller Bearings B—D01267AA Bearing Puller C—Spacer Disks

DPSG,YZ07927,177 –19–20SEP99–3/5

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

–UN–01FEB01

Install heated bearings (A) on gear shaft so bearings are tight against shoulder.

RXA0051484

A—Roller Bearings

Continued on next page

CTM168 (10DEC07)

02-30-6

DPSG,YZ07927,177 –19–20SEP99–4/5

18-Speed PST Repair Manual 121007

PN=92

Pump Drive NOTE: Oil pump gear assembly is a slip fit and does not require special tools to install.

Install oil pump gear assembly (A) into hydraulic oil pump.

02 30 7 –UN–27NOV00

Install pump drive cover. (See Install Pump Drive Cover, this group.)

YZ1963

A—Oil Pump Gear Assembly

DPSG,YZ07927,177 –19–20SEP99–5/5

CTM168 (10DEC07)

02-30-7

18-Speed PST Repair Manual 121007

PN=93

Pump Drive

Remove Transmission Oil Pump NOTE: The old style oil pump has (A) Pump Cover-to-Housing Cap Screw, (B) Pump Assembly-to-Front Housing Cap Screws 6 used, 02 (C) Oil Pump Assembly.

30 8

Remove oil pump gear assembly. (See Remove, Repair and Install Oil Pump Gear Assembly, this group.)

–UN–27FEB01

Remove cap screws (A) and remove pump assembly (B).

RXA0051497

A—Pump Cover-to-Housing Cap Screw B—Oil Pump Assembly

YZ3990

–UN–09APR03

Old Stryle Oil Pump

New Style Oil Pump

Continued on next page

CTM168 (10DEC07)

02-30-8

DPSG,YZ07927,322 –19–15APR03–1/2

18-Speed PST Repair Manual 121007

PN=94

Pump Drive Inspect, remove and discard O-rings (A) A—O-Rings

YZ3992

–UN–09APR03

02 30 9

DPSG,YZ07927,322 –19–15APR03–2/2

Disassemble, Inspect and Assemble Transmission Oil Pump Remove cap screw (A) and separate cover (B) from housing (C).

YZ3993

–UN–09APR03

A—Cover-to-Housing Cap Screw B—Cover C—Housing

Continued on next page

CTM168 (10DEC07)

02-30-9

OURX078,0000005 –19–15APR03–1/3

18-Speed PST Repair Manual 121007

PN=95

Pump Drive IMPORTANT: Mark gears with a marker. Gears must be re-installed exactly the same as before inspection.

Mark pump gears (C).

Inspect parts for wear or damage.

YZ3994

–UN–09APR03

A—Cover B—Housing C—Pump Gears D—Cover Pump Gear Bores

OURX078,0000005 –19–15APR03–2/3

Remove pump gears (A) from housing.

Inspect parts for wear or damage and replace as necessary.

Lubricate parts with transmission fluid.

–UN–09APR03

Align pump gears and assemble in reverse order.

Specification Pump Cover-to-Housing Cap Screw—Torque ............................................................................... 50 N•m (37 lb-ft)

YZ3995

02 30 10

A—Pump Gears B—Housing Pump Gear Bores C—Housing

OURX078,0000005 –19–15APR03–3/3

CTM168 (10DEC07)

02-30-10

18-Speed PST Repair Manual 121007

PN=96

Pump Drive

Install Transmission Oil Pump NOTE: For the old style front housings, guide pins may be fabricated by removing the heads from M10 x 100 mm cap screws to guide the oil pump onto the housing. The old style pump, oil sump suction tube will not protrude through front housing. The new style front housing has the oil sump tube that can be used as a guide for installing the oil pump.

–UN–09APR03

02 30 11

YZ3996

Clean oil pump-to-housing mating surface.

A—Oil Sump Tube

DPSG,YZ07927,323 –19–15APR03–1/3

Lubricate and install new O-rings (A) to oil pump assembly.

YZ3992

–UN–09APR03

A—O-Rings

Continued on next page

CTM168 (10DEC07)

02-30-11

DPSG,YZ07927,323 –19–15APR03–2/3

18-Speed PST Repair Manual 121007

PN=97

Pump Drive Install oil pump assembly (B).

Install and tighten cap screws (A).

Install oil pump gear assembly. (See Remove, Repair and Install Oil Pump Gear Assembly, this group.

A—Pump Cover-to-Housing Cap Screw B—Oil Pump Assembly

–UN–09APR03

Specification Oil Pump Assembly-to-Front Housing Cap Screws—Torque ....................................................... 50 N•m (37 lb-ft)

YZ3990

02 30 12

DPSG,YZ07927,323 –19–15APR03–3/3

CTM168 (10DEC07)

02-30-12

18-Speed PST Repair Manual 121007

PN=98

Pump Drive

Remove and Install Pump Drive Input Gear Remove pump drive cover and oil pump gear assembly.

(See Remove, Repair and Install Oil Pump Gear Assembly, this group.)

02 30 13

Install tools and remove bearing cone (A).

RXA0051481

–UN–01FEB01

A—Bearing Cone B—D01274AA Bearing Puller C—457 mm (18 in.) Puller Legs D—270 kN (30 Ton) Push Puller E—180 kN (20 Ton) Hydraulic Bottle Jack F—Spacer Disks

DPSG,YZ07927,405 –19–22FEB07–1/4

Install tools and remove pump drive input gear (A).

RXA0051434

–UN–30JAN01

A—Pump Drive Gear B—JDG1473 Pump Drive Gear Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller

Continued on next page

CTM168 (10DEC07)

02-30-13

DPSG,YZ07927,405 –19–22FEB07–2/4

18-Speed PST Repair Manual 121007

PN=99

Pump Drive Place input gear (A) onto input shaft.

Install forcing screw (C) into threaded input shaft.

Place the sleeve (B) over the forcing screw and install washer and nut (D).

Tighten forcing screw nut (C) to properly position input gear onto input shaft.

RXA0051435

–UN–30JAN01

A—Pump Drive Input Gear B—JDG1472AA Pump Drive Gear Installer Sleeve C—JDG1472A Pump Drive Gear Installer Forcing Screw D—JDG1472A Pump Drive Gear Installer Forcing Screw Nut and Washer

DPSG,YZ07927,405 –19–22FEB07–3/4

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

Install oil pump gear assembly and pump cover. (See Remove, Repair and Install Oil Pump Gear Assembly, this group.)

A—Bearing Cone

–UN–01FEB01

Install heated bearing (A) on shaft so bearing cone is tight against shoulder.

RXA0051487

02 30 14

DPSG,YZ07927,405 –19–22FEB07–4/4

CTM168 (10DEC07)

02-30-14

18-Speed PST Repair Manual 121007

PN=100

Group 35

Housings, Geartrain and Clutch Shafts Remove Rear Housing With Internal Park Brake Remove yoke assembly.

02 35 1

Remove oil filter.

YZ3997

–UN–10APR03

A—Yoke Assembly B—Oil Filter

Continued on next page

CTM168 (10DEC07)

02-35-1

DPSG,YZ07927,315 –19–12SEP06–1/25

18-Speed PST Repair Manual 121007

PN=101

Housings, Geartrain and Clutch Shafts

YZ3998

–UN–10APR03

02 35 2

SEQUENCE FOR REMOVING BRAKE COVER CAP SCREWS. IMPORTANT: The brake cover is under belleville spring pressure. All brake cover cap screws must be removed in sequence. Failure to remove in sequence will result in damage to Internal Park Brake Cover and cap screws.

Beside each cap screw is a number that has been cast into the Internal Park Brake Cover. The numbers one through seven and the numbered sequence must be followed whenever removing or installing the Internal Park Brake Cover. When removing or installing cap screws turn the cap screw no more than one complete turn then move to the next numbered cap screw. Keep all cap screws evenly engaged.

Remove cap screws following procedure below.

1. Loosen cap screw labeled number 1 one complete turn.

2. Loosen cap screw number 2 one complete turn.

3. Loosen cap screw number 3 one complete turn.

4. Loosen cap screw number 4 one complete turn.

5. Loosen cap screw number 5 one complete turn.

6. Loosen cap screw number 6 one complete turn.

7. Loosen cap screw number 7 one complete turn.

8. Continue loosening cap screws, one complete turn, in sequence until all tension is relaxed.

Continued on next page

CTM168 (10DEC07)

02-35-2

DPSG,YZ07927,315 –19–12SEP06–2/25

18-Speed PST Repair Manual 121007

PN=102

Housings, Geartrain and Clutch Shafts IMPORTANT: All belleville tension will be relaxed when you can measure 17.78 mm (.700 in.) gap between rear housing and brake cover housing.

02 35 3

YZ3999

–UN–10APR03

Failure to follow SEQUENCE FOR REMOVING BRAKE COVER CAP SCREWS, group 35 will result in damage to the transmission.

DPSG,YZ07927,315 –19–12SEP06–3/25

Remove cap screws 3 and 6 after tension is removed from all cap screws.

–UN–10APR03

Install guide pins (A) into cap screw bores 3 and 6.

YZ5000

A—Guide Pin

Continued on next page

CTM168 (10DEC07)

02-35-3

DPSG,YZ07927,315 –19–12SEP06–4/25

18-Speed PST Repair Manual 121007

PN=103

Housings, Geartrain and Clutch Shafts IMPORTANT: When removing Brake Cover with transmission in vertical position slowly remove brake cover be sure the belleville (B) doesn’t fall and damage output shaft bearing, spline or falls out 02 causing personel injury.

35 4

–UN–10APR03

Remove brake cover.

YZ5001

A—Wet Brake Cover B—Belleville Spring

DPSG,YZ07927,315 –19–12SEP06–5/25

Remove Belleville (A).

Remove Spacer (B).

Remove Belleville (C).

YZ5002

–UN–23APR03

A—Belleville B—Spacer C—Belleville

DPSG,YZ07927,315 –19–12SEP06–6/25

Remove lube tube.

Inspect for wear or damage.

–UN–10APR03

Discard O-ring.

YZ5003

A—Lube Tube

Continued on next page

CTM168 (10DEC07)

02-35-4

DPSG,YZ07927,315 –19–12SEP06–7/25

18-Speed PST Repair Manual 121007

PN=104

Housings, Geartrain and Clutch Shafts Rotate transmission to horizontal position.

Remove output bearing.

YZ5004

–UN–10APR03

02 35 5

DPSG,YZ07927,315 –19–12SEP06–8/25

Remove Piston with gear pullers.

NOTE: The Seal Ring (A) can be located on the piston or inside the rear housing internal park brake assembly bore.

Remove seal ring (A).

Inspect for wear and damage.

Discard seal ring (A).

YZ5005

–UN–10APR03

A—Seal Ring

Continued on next page

CTM168 (10DEC07)

02-35-5

DPSG,YZ07927,315 –19–12SEP06–9/25

18-Speed PST Repair Manual 121007

PN=105

Housings, Geartrain and Clutch Shafts IMPORTANT: Use caution not to damage the spacer.

Remove Brake Spacer (A).

YZ5006A

–UN–21JUN04

A—Brake Spacer

DPSG,YZ07927,315 –19–12SEP06–10/25

Remove Brake Spacer seals.

Inspect inner and outer seal for wear or damage.

Discard inner and outer seal ring.

–UN–21JUN04

A—Outer seal ring

YZ5184

02 35 6

Continued on next page

CTM168 (10DEC07)

02-35-6

DPSG,YZ07927,315 –19–12SEP06–11/25

18-Speed PST Repair Manual 121007

PN=106

Housings, Geartrain and Clutch Shafts Remove Separator and brake disks.

Remove oil sump filter assembly (A).

A—Oil Sump Filter Assembly

YZ5007

–UN–10APR03

02 35 7

DPSG,YZ07927,315 –19–12SEP06–12/25

I BRAKE VALVES AND SENSORS

YZ5008

–UN–10APR03

A—Brake 2 Valve Assembly B—Brake Pressure Sensor C—Brake 1 Valve Assembly

Continued on next page

CTM168 (10DEC07)

02-35-7

DPSG,YZ07927,315 –19–12SEP06–13/25

18-Speed PST Repair Manual 121007

PN=107

Housings, Geartrain and Clutch Shafts

–UN–10APR03 YZ5009

When diagnosing the park brake system, always attach a pressure gauge to the park brake pressure port before removing any park brake component.

A—Coil Nut B—Coil C—Washer

NOTE: The brake valve assemblies have washers behind the coils for clearance. These are the only two solenoid valves that will have washers behind the coils. Failure to install washers will cause damage to the coil.

Remove coil nut (A) coil (B) and washers (C).

DPSG,YZ07927,315 –19–12SEP06–14/25

IMPORTANT: While possible to install Park 2 into park 1. Doing so will prevent the brake from functioning correctly.

Remove Brake Valves.

Inspect for wear and damage.

Remove and discard O-rings.

–UN–10APR03

A—Brake 2 B—Brake 1

YZ5010

02 35 8

CAUTION: If working on transmission in the vehicle, personal injury can occur when removing park brake components which are under pressure. The park brake pressure system may be under pressure if one of the two park brake valves stick open, even with the engine off.

Continued on next page

CTM168 (10DEC07)

02-35-8

DPSG,YZ07927,315 –19–12SEP06–15/25

18-Speed PST Repair Manual 121007

PN=108

Housings, Geartrain and Clutch Shafts Remove Brake Pressure Sensor (A).

A—Brake Pressure Sensor

YZ5011A

–UN–24APR06

YZ6488

–UN–17APR06

02 35 9

DPSG,YZ07927,315 –19–12SEP06–16/25

YZ6489

–UN–17APR06

Remove Brake Pressure Relief Valve.

Continued on next page

CTM168 (10DEC07)

02-35-9

DPSG,YZ07927,315 –19–12SEP06–17/25

18-Speed PST Repair Manual 121007

PN=109

Housings, Geartrain and Clutch Shafts

–UN–10APR03 YZ3985

Inspect for wear and damage.

DPSG,YZ07927,315 –19–12SEP06–18/25

Install

YZ6489

–UN–17APR06

1. Place relief valve onto JDG1808A. 2. Place into Rear housing into brake pressure sensor bore.

DPSG,YZ07927,315 –19–12SEP06–19/25

3. Screw JDG1808A (A) into rear housing.

–UN–17APR06

IMPORTANT: The relief valve is made of thin material and can be damaged. Tap lightly until the valve is fully seated, or risk damaging the valve. Do not install without using JDG1808A tooling. Failure to use the JDG1808A could damage the relief valve.

4. Install relief valve.

YZ6490

02 35 10

IMPORTANT: The relief valve used behind the main regulator valve and used in the cooler port are not the same relief valve as used in the brake system. Do not mix and match relief valves.

A—JDG1808A Relief Valve Tool

Continued on next page

CTM168 (10DEC07)

02-35-10

DPSG,YZ07927,315 –19–12SEP06–20/25

18-Speed PST Repair Manual 121007

PN=110

Housings, Geartrain and Clutch Shafts 5. Install Brake Pressure Sensor (A).

A—Brake Pressure Sensor

YZ6491

–UN–17APR06

YZ6493

–UN–17APR06

02 35 11

DPSG,YZ07927,315 –19–12SEP06–21/25

6. Tighten Brake Pressure Sensor.

YZ6492

–UN–17APR06

Specification Brake Pressure Sensor-to-Rear Housing—Torque............................................................................ 18 N•m 13 (lb-ft)

Continued on next page

CTM168 (10DEC07)

02-35-11

DPSG,YZ07927,315 –19–12SEP06–22/25

18-Speed PST Repair Manual 121007

PN=111

Housings, Geartrain and Clutch Shafts Install transmission to rollover stand bracket. (See Install Transmission to Rollover Stand Bracket, Group 15.)

Drain oil from transmission assembly.

Remove all yokes. (See Remove and Install Yoke, Group 15.)

–UN–30JAN01

Remove hydraulic oil pump. (See Remove Hydraulic Oil Pump, Group 30.)

Remove pump drive input gear. (See Remove and Install Pump Drive Input Gear, Group 30.)

RXA0051433

02 35 12

Remove wiring harness bracket and wiring harness. (See Remove Wiring Harness Bracket and Wiring Harness, Group 20.)

A—Rear-to-Front Housing Cap Screws (24 used)

Remove all proportional solenoid valves. (See Remove Proportional Solenoid, Group 20.)

Remove all magnetic pickup sensors. (See Remove Output Magnetic Pickup Sensors, Remove and Install Input and Cylinder Speed Magnetic Pickup Sensors and Remove and Install Fifth Stage Magnetic Pickup Sensor (Speed), Group 20.)

Remove suction screen. (See Remove and Install Suction Screen, Group 25.)

Remove oil filter. (See Remove and Install Oil Filter, Group 25.)

Remove oil filter head. (See Remove, Repair and Install Oil Filter Head, Group 25.)

Remove rear-to-front housing cap screws (A).

NOTE: Guide pins may be fabricated by removing the heads from M16 x 200 mm cap screws.

Install four guide pins, one at each corner of rear cover.

Continued on next page

CTM168 (10DEC07)

02-35-12

DPSG,YZ07927,315 –19–12SEP06–23/25

18-Speed PST Repair Manual 121007

PN=112

Housings, Geartrain and Clutch Shafts Install JDG1489 Transmission Rear Cover Lifting Bracket (A) to suction screen cover threaded holes.

–UN–02FEB01

Install JDG19 Lifting Brackets (B) or Equivalent.

RXA0051599

A—Lift Bracket B—Lifting Brackets (3 used)

DPSG,YZ07927,315 –19–12SEP06–24/25

Attach lift chains (A) to brackets and overhead hoist.

NOTE: Housing joint is sealed with liquid gasket and may have to be pried apart.

Keep the rear housing parallel with the front housing, while lifting, to avoid binding the clutch shafts in the rear housing.

Carefully remove rear cover from transmission assembly.

YZ5014

–UN–10APR03

A—Lift Chains

DPSG,YZ07927,315 –19–12SEP06–25/25

CTM168 (10DEC07)

02-35-13

18-Speed PST Repair Manual 121007

PN=113

02 35 13

Housings, Geartrain and Clutch Shafts

Disassemble Rear Housing Remove plug with O-ring.

Inspect for contamination or damage.

Remove and discard O-ring (A).

Lubricate new O-ring with transmission fluid and install on plug.

–UN–10APR03

Install and tighten plug.

YZ5012

A—Diagnostic Receptacle B—Plug with O-ring

–UN–05JAN01

OURX078,000000C –19–15APR03–1/4

YZ3095

02 35 14

Continued on next page

CTM168 (10DEC07)

02-35-14

OURX078,000000C –19–15APR03–2/4

18-Speed PST Repair Manual 121007

PN=114

Housings, Geartrain and Clutch Shafts Turn rear housing (A) over.

A—Rear Housing

YZ5015

–UN–10APR03

02 35 15

OURX078,000000C –19–15APR03–3/4

NOTE: Bearing cups are a slip fit.

Remove bearing cups (A).

YZ5016

–UN–10APR03

A—Rear Housing Bearing Cups (7 used)

OURX078,000000C –19–15APR03–4/4

CTM168 (10DEC07)

02-35-15

18-Speed PST Repair Manual 121007

PN=115

Housings, Geartrain and Clutch Shafts

Remove Clutch Shaft Sealing Ring Sleeve

Old Style Rear Housing Design

YZ1896

–UN–03AUG99

02 35 16

Old Style Rear Housing Clutch Shaft Sealing Ring Sleeves A—Fourth Stage Bore Sleeve B—Third Stage Bore Sleeve

C—Second Stage Bore Sleeve D—Seventh Stage Bore Sleeve

E—Sixth Stage Bore Sleeve

Continued on next page

CTM168 (10DEC07)

02-35-16

F—Fifth Stage Bore Sleeve

DPSG,YZ07927,316 –19–16JUN04–1/4

18-Speed PST Repair Manual 121007

PN=116

Housings, Geartrain and Clutch Shafts NOTE: Old style rear housing are equipped with bore sleeves. New style rear housings design is without bore sleeves.

–UN–30JAN01

NOTE: For Blind Hole Puller (B), use JT01732 and for Forcing Screw and Nut, use JT01716 Forcing Screw and JT01717 Nut from D01061AA Blind Hole Puller Set

YZ3049A

Assemble the sleeve remover tool.

A—JDG1490 Sealing Ring Bore Sleeve Remover Sleeve B—JTO1732 Collet C—JTO1717 Forcing Screw and Nut

DPSG,YZ07927,316 –19–16JUN04–2/4

Insert the tool into the sleeve and expand the blind hole puller to firmly attach beneath the inner end of the sleeve in the bore.

Tighten the forcing screw nut (A) to remove the sleeve from the bore.

YZ3050

–UN–07DEC00

A—Nut

Continued on next page

CTM168 (10DEC07)

02-35-17

DPSG,YZ07927,316 –19–16JUN04–3/4

18-Speed PST Repair Manual 121007

PN=117

02 35 17

Housings, Geartrain and Clutch Shafts Inspect bore sleeve (A) for wear and damage.

A—Bore Sleeve

YZ3053

–UN–07DEC00

02 35 18

Bore Sleeve

DPSG,YZ07927,316 –19–16JUN04–4/4

Install Bore Sleeves

Old Style Rear Housing Design

–UN–30JAN01

IMPORTANT: Bore Sleeve (A) must be installed as shown. The inside chamfer (B) must be facing out.

YZ3054A

Position the sleeve (A) in the bore with the inside chamfer (B) facing out.

RXA0051485

–UN–01FEB01

A—Bore Sleeve B—Sleeve Inside Chamfer

Continued on next page

CTM168 (10DEC07)

02-35-18

DPSG,YZ07927,317 –19–15APR03–1/2

18-Speed PST Repair Manual 121007

PN=118

Housings, Geartrain and Clutch Shafts Install bore sleeve with JDG1479 Sealing Ring Sleeve Installer (A).

Install until installer tool bottoms on housing face.

02 35 19

YZ3055

–UN–07DEC00

A—Sealing Ring Sleeve Installer

DPSG,YZ07927,317 –19–15APR03–2/2

Remove Clutch Assemblies Remove rear housing. (See Remove Rear Housing, this group.)

IMPORTANT: DO NOT install used seal rings when assembling transmission.

YZ3106

–UN–06JAN01

Remove and discard seal rings from all clutch assemblies.

Continued on next page

CTM168 (10DEC07)

02-35-19

DPSG,YZ07927,363 –19–15APR03–1/5

18-Speed PST Repair Manual 121007

PN=119

Housings, Geartrain and Clutch Shafts Place JDG1471 Clutch Stack Lifting Fixture (A) onto clutch assemblies.

A—Clutch Stack Lifting Fixture

YZ5017

–UN–10APR03

02 35 20

DPSG,YZ07927,363 –19–15APR03–2/5

Secure the latches (A) and install the input shaft retaining cap (B).

NOTE: Keep the lifting fixture parallel with the housing surface to prevent the clutch shafts from binding in the housing.

Carefully remove the clutch nest from the front housing using an overhead hoist.

YZ5018

–UN–10APR03

A—Clutch Assembly-to-Lifting Fixture Latches B—First Stage (Input Shaft) Retaining Cap

Continued on next page

CTM168 (10DEC07)

02-35-20

DPSG,YZ07927,363 –19–15APR03–3/5

18-Speed PST Repair Manual 121007

PN=120

Housings, Geartrain and Clutch Shafts Place clutch stack nest into JDG1470 Clutch Stack Nest Fixture.

A—Clutch Stack Nest Fixture

RXA0051429

–UN–30JAN01

02 35 21

DPSG,YZ07927,363 –19–15APR03–4/5

NOTE: Keep the lifting fixture parallel with the housing surface to prevent the clutch shafts from binding in the housing.

RXA0051428

–UN–28FEB01

Disengage clutch assembly latches, remove input shaft retaining cap and remove clutch assembly lifting tool.

DPSG,YZ07927,363 –19–15APR03–5/5

CTM168 (10DEC07)

02-35-21

18-Speed PST Repair Manual 121007

PN=121

Housings, Geartrain and Clutch Shafts

Exploded View— Output Shaft Without Internal Park Brake

B 02 35 22

A

RXA0052137

–UN–01MAR01

C

A—Eighth Stage 36T L.H. Helical Shaft

B—Rear Bearing Cone

C—Front Bearing Cone

DPSG,YZ07927,154 –19–30JUL99–1/1

CTM168 (10DEC07)

02-35-22

18-Speed PST Repair Manual 121007

PN=122

Housings, Geartrain and Clutch Shafts

Exploded View— Output Shaft With Internal Park Brake

YZ5048

–UN–30APR03

02 35 23

Output Shaft Assembly With Internal Park Brake A—Front Bearing Cone

B—Eighth Stage 36T L.H. Helical Shaft

C—Rear Bearing Cone

YZ07927,00000B8 –19–30APR03–1/1

CTM168 (10DEC07)

02-35-23

18-Speed PST Repair Manual 121007

PN=123

Housings, Geartrain and Clutch Shafts

Remove and Install Axle Pump Stand Pipe Remove axle pump stand pipe cap screw (A).

Remove pipe and O-ring (B).

Install axle pump stand pipe with New O-ring (B) into housing.

Install and tighten cap screw (A).

Specification Axle Pump Stand Pipe-to-Rear Housing Cap Screw—Torque....................................................... 122 N•m (90 lb-ft)

YZ5019

–UN–10APR03

A—Cap Screw B—Stand Pipe with O-Ring

DPSG,YZ07927,161 –19–15APR03–1/1

Remove, Disassemble and Assemble Output Shaft Assembly

–UN–10APR03

CAUTION: Output shaft assembly weight is approximately 32.18 Kg (71 lbs).

Remove clutch stack. (See Remove Clutch Assemblies, this group.)

YZ5021

02 35 24

Remove cap screws (A).

A—Oil Baffle Cap Screws (2 used) B—Oil Baffle Plate

Continued on next page

CTM168 (10DEC07)

02-35-24

DPSG,YZ07927,343 –19–15APR03–1/4

18-Speed PST Repair Manual 121007

PN=124

Housings, Geartrain and Clutch Shafts Install JDG1112 Eyebolt (A) and remove output shaft from transmission front housing using a lifting device.

A—Eyebolt B—Output Shaft

YZ5020

–UN–10APR03

02 35 25

DPSG,YZ07927,343 –19–15APR03–2/4

Place shaft between sturdy supports.

Install puller tools and remove rear bearing (A) from shaft.

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

Install heated bearing to shaft tight against shaft shoulder and allow to cool.

RXA0051566

–UN–26FEB01

A—Rear Bearing Cone B—D01267AA Bearing Puller C—457 mm (18 in.) Puller Legs D—Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller

Continued on next page

CTM168 (10DEC07)

02-35-25

DPSG,YZ07927,343 –19–15APR03–3/4

18-Speed PST Repair Manual 121007

PN=125

Housings, Geartrain and Clutch Shafts Turn shaft over and install puller tools.

Remove front bearing cone (A) from shaft.

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

Install heated bearing to shaft tight against shaft shoulder and allow to cool.

–UN–26FEB01

A—Front Bearing Cone B—D01267AA Bearing Puller C—457 mm (18 in.) Puller Legs D—Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller

RXA0051567

02 35 26

DPSG,YZ07927,343 –19–15APR03–4/4

CTM168 (10DEC07)

02-35-26

18-Speed PST Repair Manual 121007

PN=126

Housings, Geartrain and Clutch Shafts

Remove Suction Tube Old Style Rear Housing Remove cap screw (A) and remove tube.

RXA0051569

–UN–23MAR01

A—Cap Screw (2)

0ld Style Rear Housing

YZ07927,000009F –19–21APR03–1/2

Remove o-ring (A).

Inspect o-ring for wear and damage and discard.

YZ3068A

–UN–06MAR01

A—O-ring

YZ07927,000009F –19–21APR03–2/2

CTM168 (10DEC07)

02-35-27

18-Speed PST Repair Manual 121007

PN=127

02 35 27

Housings, Geartrain and Clutch Shafts

Remove Suction Tube Remove cap screw (A) and remove tube.

–UN–10APR03

A—Cap Screws (1 used)

YZ5022

02 35 28

DPSG,YZ07927,318 –19–15APR03–1/1

CTM168 (10DEC07)

02-35-28

18-Speed PST Repair Manual 121007

PN=128

Housings, Geartrain and Clutch Shafts

Install Output Shaft Assembly Place output shaft assembly (A) into front housing using JDG1112 Eyebolt (B) and a lifting device.

02 35 29

YZ5024

–UN–10APR03

A—Output Shaft Assembly B—Eyebolt

DPSG,YZ07927,365 –19–15APR03–1/2

Install oil baffle and tighten cap screws.

YZ5025

Install clutch stack. (See Install Clutch Assemblies, this group.)

–UN–10APR03

Specification Output Shaft Assembly Cap Screw-to-Front Housing—Torque................................................... 50 N•m (37 lb-ft)

DPSG,YZ07927,365 –19–15APR03–2/2

CTM168 (10DEC07)

02-35-29

18-Speed PST Repair Manual 121007

PN=129

Housings, Geartrain and Clutch Shafts

Install Suction Tube

Old Style Rear Housing

Lubricate new o-ring (A) with transmission fluid and install onto suction tube.

YZ3069A

–UN–06MAR01

A—Suction Tube O-ring

YZ07927,00000A0 –19–21APR03–1/1

Install Suction Tube Position suction tube into front housing.

–UN–10APR03

Install cap screw and tighten.

YZ5026

02 35 30

DPSG,YZ07927,319 –19–15APR03–1/1

CTM168 (10DEC07)

02-35-30

18-Speed PST Repair Manual 121007

PN=130

Housings, Geartrain and Clutch Shafts

Remove and Install Output Shaft Oil Dam Remove cap screws (A) and oil dam.

Inspect dam for wear or damage and replace as necessary.

02 35 31

Inspect Lubricating bore (B) for contamination.

–UN–10APR03

Install in reverse order, tightening cap screws top specification.

YZ5023

A—Oil Dam Cap Screws (2 used) B—Lubricating bore for output shaft bearing

DPSG,YZ07927,320 –19–15APR03–1/1

YZ501552A

–UN–02FEB01

Exploded View—First Stage Shaft Assembly (Input Shaft)

A—First Stage 32 T R.H. Helical Shaft

B—Rear Bearing Cone

DPSG,YZ07927,16 –19–05MAY99–1/1

CTM168 (10DEC07)

02-35-31

18-Speed PST Repair Manual 121007

PN=131

Housings, Geartrain and Clutch Shafts

Exploded View—Second Stage Clutch Shaft Assembly

YZ501577

–UN–23MAR01

02 35 32

1—Ring Seal 2—Bearing Cone 3—Bearing Cone 4—Bearing Cup 5—46T R.H. Helical Clutch Gear (Clutch A)

6—Tapered Bearing Set 7—Retaining Ring 8—Clutch Plate Retainer 9—Clutch Plate (20) 10—Clutch Separator Plate (20)

11—Retaining Ring 12—Snap Ring Retainer 13—Clutch Return Spring (12) 14—Lube Shutoff Washer 15—O-Ring 16—Outer Piston Seal

17—Clutch Piston 18—2nd and 4th Shaft Assembly 19—Ball Bearing (2) 20—52T R.H. Helical Clutch Gear (Clutch 2)

DPSG,YZ07927,152 –19–30JUL99–1/1

CTM168 (10DEC07)

02-35-32

18-Speed PST Repair Manual 121007

PN=132

Housings, Geartrain and Clutch Shafts

Cross-Sectional View—Second Stage Clutch Shaft Assembly

3

4

9

5

6

18

10

9

20

10

2

02 35 33

3

1

13 11

15 13

15

14

14

11

12

19

12

7

1—Ring Seal 2—Bearing Cone 3—Bearing Cone 4—Bearing Cup 5—46T R.H. Helical Clutch Gear (Clutch A)

8

6—Tapered Bearing Set 7—Retaining Ring 8—Clutch Plate Retainer 9—Clutch Plate (20) 10—Clutch Separator Plate (20)

16

16

8

11—Retaining Ring 12—Snap Ring Retainer 13—Clutch Return Spring (12) 14—Lube Shutoff Washer 15—O-Ring 16—Outer Piston Seal

RXA0052435

–UN–22MAR01

17

7

17—Clutch Piston 18—2nd and 4th Shaft Assembly 19—Ball Bearing (2) 20—52T R.H. Helical Clutch Gear (Clutch 2) OURX078,0000003 –19–14MAR01–1/1

CTM168 (10DEC07)

02-35-33

18-Speed PST Repair Manual 121007

PN=133

Housings, Geartrain and Clutch Shafts

9620 Series Exploded View—Second Stage Clutch Shaft Assembly

YZ6197

–UN–03MAY05

02 35 34

1—Seal Ring (3 used) 2—Bearing Cone Assembly 3—Bearing Cone 4—Bearing Cup 5—Retaining Ring (2 used) 6—Clutch Plate Retainer (2 used)

7—Clutch Plate (20 used) 8—Separator Plate (20 used) 9—Retaining Ring (2 used) 10—Snap Ring Retainer (2 used) 11—Belleville Spring (12 used) 12—Lube Shutoff Washer (2 used)

13—O-ring (2 used) 14—Outer Piston Seal (2 used) 15—Piston (2 used) 16—2nd and 4th Shaft Assembly 17—Ball Bearing (2 used)

18—52T Gear (Clutch 2) 19—Thrust Washer 20—Tapered Roller Bearing 21—46T Gear (Clutch A) 22—Screw

YZ07927,000043A –19–09MAY05–1/1

CTM168 (10DEC07)

02-35-34

18-Speed PST Repair Manual 121007

PN=134

Housings, Geartrain and Clutch Shafts

9620 Series Cross-Sectional View—Second Stage Clutch Shaft Assembly

YZ6196

–UN–02MAY05

02 35 35

1—Ring Seal (3 used) 2—Bearing Cone 3—Bearing Cone (2 used) 4—46T Gear (Clutch A) 5—Retaining Ring (2 used) 6—Snap Ring Retainer (2 used)

7—Belleville Spring (12 used) 8—Clutch Plate (20 used) 9—Lube Shutoff Washer (2 used) 10—O-Ring (2 used) 11—Retaining Ring (2 used) 12—Ball Bearing (2 used)

13—52T Gear (Clutch 2) 14—Screw 15—Thrust Washer 16—Clutch Plate Retainer (2 used) 17—Separator Plate (20 used)

18—Clutch Piston (2 used) 19—Outer Piston Seal (2 used) 20—Bearing Cone Assembly 21—Bearing Cone 22—2nd and 4th Shaft Assembly

YZ07927,0000439 –19–09MAY05–1/1

CTM168 (10DEC07)

02-35-35

18-Speed PST Repair Manual 121007

PN=135

Housings, Geartrain and Clutch Shafts

Exploded View—Third Stage Clutch Shaft Assembly

YZ501581

–UN–23MAR01

02 35 36

Continued on next page

CTM168 (10DEC07)

02-35-36

DPSG,YZ07927,151 –19–30JUL99–1/2

18-Speed PST Repair Manual 121007

PN=136

Housings, Geartrain and Clutch Shafts 1—Ring Seal (3) 2—Bearing Cone 3—Bearing Cone (2) 4—Bearing Cup 5—Clutch Gear Assembly (Clutch B)

6—Tapered Bearing Set 7—Retaining Ring (2) 8—Clutch Plate Retainer (2) 9—Clutch Separator Plate (20) 10—Clutch Plate (20) 11—Retaining Ring (2)

12—Snap Ring Retainer (2) 13—Clutch Return Spring (12) 14—Lube Shutoff Washer (2) 15—O-Ring (2) 16—Outer Piston Seal (2)

17—Clutch Piston (2) 18—Third Shaft Assembly 19—Ball Bearing (2) 20—64T L.H. Helical Clutch Gear (Clutch 1) 02 35 37

DPSG,YZ07927,151 –19–30JUL99–2/2

Cross-Sectional View—Third Stage Clutch Shaft Assembly 5

18 9 6

20 9 10

10

4 3

3

2 1

11 12

13

15

15

13 14

14

19 11 12

–UN–22MAR01

17

7 1—Ring Seal (3) 2—Bearing Cone 3—Bearing Cone (2) 4—Bearing Cup 5—Clutch Gear Assembly (Clutch B)

8

8

6—Tapered Bearing Set 7—Retaining Ring (2) 8—Clutch Plate Retainer (2) 9—Clutch Separator Plate (20) 10—Clutch Plate (20) 11—Retaining Ring (2)

RXA0052440

16

7

12—Snap Ring Retainer (2) 13—Clutch Return Spring (12) 14—Lube Shutoff Washer (2) 15—O-Ring (2) 16—Outer Piston Seal (2)

17—Clutch Piston (2) 18—Third Shaft Assembly 19—Ball Bearing (2) 20—64T L.H. Helical Clutch Gear (Clutch 1)

OURX078,0000004 –19–14MAR01–1/1

CTM168 (10DEC07)

02-35-37

18-Speed PST Repair Manual 121007

PN=137

Housings, Geartrain and Clutch Shafts

9620 Series Exploded View—Third Stage Clutch Shaft Assembly

YZ6199

–UN–04MAY05

02 35 38

1—Seal Ring (3 used) 2—Bearing Cone Assembly 3—Bearing Cone 4—Bearing Cup 5—Gear Assembly (Clutch B) 6—Tapered Roller Bearing 7—Retaining Ring (2 used)

8—Clutch Plate Retainer (2 used) 9—Clutch Plate (20 used) 10—Separator Plate (20 used) 11—Retaining Ring (2 used) 12—Snap Ring Retainer (2 used)

13—Belleville Spring (12 used) 14—Lube Shutoff Washer (2 used) 15—Outer Piston Seal (2 used) 16—O-Ring (2 used) 17—Clutch Piston (2 used)

18—3rd Stage Shaft Assembly 19—Ball Bearing (2 used) 20—64T Gear (Clutch I) 21—Thrust Washer 22—Screw

YZ07927,000043C –19–04MAY05–1/1

CTM168 (10DEC07)

02-35-38

18-Speed PST Repair Manual 121007

PN=138

Housings, Geartrain and Clutch Shafts

9620 Series Cross-Sectional View—Third Stage Clutch Shaft Assembly

YZ6198

–UN–03MAY05

02 35 39

1—Seal Ring (3 used) 2—Bearing Cone Assembly 3—Bearing Cone 4—Gear Assembly (Clutch B) 5—Retaining Ring (2 used) 6—Snap Ring Retainer (2 used)

7—Belleville Spring (12 used) 8—Clutch Plate (20 used) 9—Lube Shutoff Washer (2 used) 10—O-Ring (2 used) 11—64T Gear (Clutch I)

12—Screw 13—Thrust Washer 14—Ball Bearing (2 used) 15—Clutch Plate Retainer (2 used) 16—Retaining Ring (2 used)

17—Separator Plate (20 used) 18—Clutch Piston (2 used) 19—Outer Piston Seal (2 used) 20—Tapered Roller Bearing 21—Bearing Cup 22—3rd Stage Shaft Assembly

YZ07927,000043B –19–03MAY05–1/1

CTM168 (10DEC07)

02-35-39

18-Speed PST Repair Manual 121007

PN=139

Housings, Geartrain and Clutch Shafts

Exploded View—Fourth Stage Clutch Shaft Assembly

YZ501583

–UN–23MAR01

02 35 40

Continued on next page

CTM168 (10DEC07)

02-35-40

DPSG,YZ07927,150 –19–30JUL99–1/2

18-Speed PST Repair Manual 121007

PN=140

Housings, Geartrain and Clutch Shafts 1—Ring Seal (3) 2—Bearing Cone 3—Bearing Cone (2) 4—Bearing Cup 5—70T R.H. Helical Clutch Gear (Clutch C)

6—Tapered Bearing Set 7—Retaining Ring (2) 8—Clutch Plate Retainer (2) 9—Clutch Separator Plate (20) 10—Clutch Plate (20) 11—Retaining Ring (2)

12—Snap Ring Retainer (2) 13—Clutch Return Spring (12) 14—Lube Shutoff Washer (2) 15—O-Ring (2) 16—Outer Piston Seal (2)

17—Clutch Piston (2) 18—Third Shaft Assembly 19—Ball Bearing (2) 20—64T L.H. Helical Clutch Gear (Clutch R) 02 35 41

DPSG,YZ07927,150 –19–30JUL99–2/2

Cross-Sectional View—Fourth Stage Clutch Shaft Assembly 18

5

9

9 10

10

20

4 3 2

6

3

1

11 12

15

13

15

13 14

14

19 11 12

17

1—Ring Seal (3) 2—Bearing Cone 3—Bearing Cone (2) 4—Bearing Cup 5—70T R.H. Helical Clutch Gear (Clutch C)

8

8

6—Tapered Bearing Set 7—Retaining Ring (2) 8—Clutch Plate Retainer (2) 9—Clutch Separator Plate (20) 10—Clutch Plate (20) 11—Retaining Ring (2)

12—Snap Ring Retainer (2) 13—Clutch Return Spring (12) 14—Lube Shutoff Washer (2) 15—O-Ring (2) 16—Outer Piston Seal (2)

RXA0052438

7

–UN–22MAR01

16

7

17—Clutch Piston (2) 18—Third Shaft Assembly 19—Ball Bearing (2) 20—64T L.H. Helical Clutch Gear (Clutch R)

OURX078,0000005 –19–14MAR01–1/1

CTM168 (10DEC07)

02-35-41

18-Speed PST Repair Manual 121007

PN=141

Housings, Geartrain and Clutch Shafts

9620 Series Exploded View—Fourth Stage Clutch Shaft Assembly

YZ6201

–UN–05MAY05

02 35 42

1—Seal Ring (3 used) 2—Bearing Cone Assembly 3—Bearing Cone Assembly 4—Bearing Cup 5—70T Gear (Clutch C) 6—Tapered Roller Bearing 7—Retaining Ring (2 used)

8—Clutch Plate Retainer (2 used) 9—Clutch Plate (20 used) 10—Separator Plate (20 used) 11—Retaining Ring (2 used) 12—Snap Ring Retainer (2 used)

13—Belleville Spring (12 used) 14—Lube Shutoff Washer (2 used) 15—Outer Piston Seal (2 used) 16—Clutch Piston (2 used) 17—O-ring (2 used)

18—2nd and 4th Stage Shaft Assembly 19—Ball Bearing (2 used) 20—64T Gear (Clutch R) 21—Thrust Washer 22—Screw

YZ07927,000043E –19–05MAY05–1/1

CTM168 (10DEC07)

02-35-42

18-Speed PST Repair Manual 121007

PN=142

Housings, Geartrain and Clutch Shafts

9620 Series Cross-Sectional View—Fourth Stage Clutch Shaft Assembly

YZ6200

–UN–05MAY05

02 35 43

1—Seal Ring (3 used) 2—Bearing Cone Assembly 3—70T Gear (Clutch C) 4—Retaining Ring (2 used) 5—Snap Ring Retainer (2 used) 6—Belleville Spring (12 used)

7—Clutch Plate (20 used) 8—Lube Shutoff Washer (2 used) 9—O-ring (2 used) 10—64T Gear (Clutch R) 11—Bearing Cone Assembly 12—Screw

13—Thrust Washer 14—Ball Bearing (2 used) 15—Clutch Plate Retainer (2 used) 16—Retaining Ring (2 used) 17—Separator Plate (20 used)

18—Clutch Piston (2 used) 19—Outer Piston Seal (2 used) 20—Tapered Roller Bearing 21—Bearing Cup 22—2nd and 4th Stage Shaft Assembly

YZ07927,000043D –19–24MAY05–1/1

CTM168 (10DEC07)

02-35-43

18-Speed PST Repair Manual 121007

PN=143

Housings, Geartrain and Clutch Shafts

Exploded View—Fifth Stage Clutch Shaft Assembly

YZ501504

–UN–21MAR01

02 35 44

1—Ring Seal (2) 2—Bearing Cone (2) 3—Fifth Stage Shaft Assembly 4—Outer Piston Seal 5—Clutch Piston

6—O-Ring 7—Lube Shutoff Washer 8—Clutch Return Spring (8) 9—Snap Ring Retainer 10—Retaining Ring

11—Clutch Separator Plate (14) 12—Clutch Plate (14) 13—Clutch Plate Retainer 14— Retaining Ring

15— O-Ring 16—Ball Bearing 17—41T L.H. Helical Clutch Gear (Clutch L and M) 18—Ball Bearing

DPSG,YZ07927,149 –19–30JUL99–1/1

CTM168 (10DEC07)

02-35-44

18-Speed PST Repair Manual 121007

PN=144

Housings, Geartrain and Clutch Shafts

Cross-Sectional View—Fifth Stage Clutch Shaft Assembly

11 4

5

13

12

14 02 35 45

17

3 2

2

1

6

8

7

10

9

16

18

RXA0052260

–UN–23MAR01

15

1—Ring Seal (2) 2—Bearing Cone (2) 3—Fifth Stage Shaft Assembly 4—Outer Piston Seal 5—Clutch Piston

6—O-Ring 7—Lube Shutoff Washer 8—Clutch Return Spring (8) 9—Snap Ring Retainer 10—Retaining Ring

11—Clutch Separator Plate (14) 12—Clutch Plate (14) 13—Clutch Plate Retainer 14— Retaining Ring

15— O-Ring 16—Ball Bearing 17—41T L.H. Helical Clutch Gear (Clutch L and M) 18—Ball Bearing

OURX078,0000006 –19–14MAR01–1/1

CTM168 (10DEC07)

02-35-45

18-Speed PST Repair Manual 121007

PN=145

Housings, Geartrain and Clutch Shafts

9620 Series Exploded View—Fifth Stage Clutch Shaft Assembly

YZ6191

–UN–27APR05

02 35 46

1—Seal Ring (2 used) 2—Bearing Cone (2 used) 3—5th Stage Shaft Assembly 4—O-ring 5—Clutch Piston 6—Outer Piston Seal

7—Lube Shutoff Washer 8—Belleville Spring (8 used) 9—Snap Ring Retainer 10—Retaining Retainer 11—Separator Plate (14 used)

12—Clutch Plate (14 used) 13—Clutch Plate Retainer 14—Retaining Ring 15—O-ring 16—Ball Bearing

17— 41T Gear (Clutch L and M) 18—Ball Bearing 19—Thrust Washer 20—Screw

YZ07927,0000432 –19–27APR05–1/1

CTM168 (10DEC07)

02-35-46

18-Speed PST Repair Manual 121007

PN=146

Housings, Geartrain and Clutch Shafts

9620 Series Cross-Sectional View—Fifth Stage Clutch Shaft Assembly

YZ6190

–UN–27APR05

02 35 47

1—Ball Bearing 2—Ball Bearing 3—Retainer 4—Retainer 5—Belleville Spring (8 used)

6—Washer 7—Clutch Plate (14 used) 8—5th Stage Shaft Assembly 9—Outer Piston Seal 10—O-ring

11—Clutch Piston 12—Bearing Cone 13—Ring Gear (2 used) 14—Separator Plate (14 used) 15—O-ring

16—Retaining Ring 17—Retaining Ring 18—41T Gear (Clutch L and M) 19—Thrust Washer 20—Screw

YZ07927,0000431 –19–27APR05–1/1

CTM168 (10DEC07)

02-35-47

18-Speed PST Repair Manual 121007

PN=147

Housings, Geartrain and Clutch Shafts

Exploded View—Sixth Stage Clutch Shaft Assembly

YZ501508

–UN–21MAR01

02 35 48

1—Ring Seal (2) 2—Bearing Cone (2) 3—Ball Bearing 4—46T R.H. Helical Clutch Gear (Clutch H)

5—O-Ring 6—Ball Bearing 7—Retaining Ring 8—Clutch Plate Retainer 9—Clutch Separator Plate (14)

10—Clutch Plate (14) 11—Retaining Ring 12—Snap Ring Retainer 13—Clutch Return Spring (8) 14—Lube Shutoff Washer

15—O-Ring 16—Outer Piston Seal 17—Clutch Piston 18—Sixth Stage Shaft Assembly

DPSG,YZ07927,148 –19–30JUL99–1/1

CTM168 (10DEC07)

02-35-48

18-Speed PST Repair Manual 121007

PN=148

Housings, Geartrain and Clutch Shafts

Cross-Sectional View—Sixth Stage Clutch Shaft Assembly

YZ3452

–UN–24SEP01

02 35 49

1—Ring Seal (2) 2—Bearing Cone (2) 3—Ball Bearing 4—46T R.H. Helical Clutch Gear (Clutch H)

5—O-Ring 6—Ball Bearing 7—Retaining Ring 8—Clutch Plate Retainer 9—Clutch Separator Plate (14)

10—Clutch Plate (14) 11—Retaining Ring 12—Snap Ring Retainer 13—Clutch Return Spring (8) 14—Lube Shutoff Washer

15—O-Ring 16—Outer Piston Seal 17—Clutch Piston 18—Sixth Stage Shaft Assembly

OURX078,0000007 –19–14MAR01–1/1

CTM168 (10DEC07)

02-35-49

18-Speed PST Repair Manual 121007

PN=149

Housings, Geartrain and Clutch Shafts

9620 Series Exploded View—Sixth Stage Clutch Shaft Assembly

YZ6195

–UN–02MAY05

02 35 50

1—Seal Rings (2 used) 2—Bearing Cone 3—Ball Bearing 4—Gear 46T (Clutch H) 5—Ball Bearing 6—Snap Ring Retainer

7—Clutch Plate Retainer 8—Belleville Spring (8 used) 9—Lube Shutoff Washer 10—Clutch Plate (14 used) 11—Separator Plate (14 used)

12—O-Ring 13—6th Stage Shaft Assembly 14—Tapered Roller Bearing 15—Screw 16—Thrust Washer

17—Outer Piston Seal 18—Clutch Piston 19—Retaining Ring 20—Retaining Ring 21—O-Ring

YZ07927,0000438 –19–02MAY05–1/1

CTM168 (10DEC07)

02-35-50

18-Speed PST Repair Manual 121007

PN=150

Housings, Geartrain and Clutch Shafts

9620 Series Cross-Sectional View—Sixth Stage Clutch Shaft Assembly

YZ6194

–UN–29APR05

02 35 51

1—Seal Rings (2 used) 2—Bearing Cone 3—Ball Bearing 4—Gear 46T (Clutch H) 5—Ball Bearing 6—Snap Ring Retainer

7—Clutch Plate Retainer 8—Belleville Spring (8 used) 9—Lube Shutoff Washer 10—Clutch Plate (14 used) 11—Separator Plate (14 used)

12—O-Ring 13—6th Stage Shaft Assembly 14—Tapered Roller Bearing 15—Screw 16—Thrust Washer

17—Outer Piston Seal 18—Clutch Piston 19—Retaining Ring 20—Retaining Ring 21—O-Ring

YZ07927,0000437 –19–29APR05–1/1

CTM168 (10DEC07)

02-35-51

18-Speed PST Repair Manual 121007

PN=151

Housings, Geartrain and Clutch Shafts

Exploded View—Seventh Stage Clutch Shaft Assembly

YZ501512

–UN–21MAR01

02 35 52

1—Ring Seal (2) 2—Bearing Cone (2) 3—Seventh Stage Shaft Assembly 4—Clutch Piston 5—Outer Piston Seal

6—O-Ring 7—Lube Shutoff Washer 8—Clutch Return Spring (8) 9—Snap Ring Retainer 10—Retaining Ring

11—Clutch Separator Plate (14) 12—Clutch Plate (14) 13—Clutch Plate Retainer 14— Retaining Ring

15— O-Ring 16—Ball Bearing 17—41T L.H. Helical Clutch Gear (Clutch L and M) 18—Ball Bearing

DPSG,YZ07927,153 –19–30JUL99–1/1

CTM168 (10DEC07)

02-35-52

18-Speed PST Repair Manual 121007

PN=152

Housings, Geartrain and Clutch Shafts

Cross-Sectional View—Seventh Stage Clutch Shaft Assembly 11

12

13

5 3

14

17

4

2

02 35 53

2

15

1 9 8 10

6

16

18

RXA0052465

–UN–22MAR01

7

1—Ring Seal (2) 2—Bearing Cone (2) 3—Seventh Stage Shaft Assembly 4—Clutch Piston 5—Outer Piston Seal

6—O-Ring 7—Lube Shutoff Washer 8—Clutch Return Spring (8) 9—Snap Ring Retainer 10—Retaining Ring

11—Clutch Separator Plate (14) 12—Clutch Plate (14) 13—Clutch Plate Retainer 14— Retaining Ring

15— O-Ring 16—Ball Bearing 17—41T L.H. Helical Clutch Gear (Clutch L and M) 18—Ball Bearing

OURX078,0000008 –19–14MAR01–1/1

CTM168 (10DEC07)

02-35-53

18-Speed PST Repair Manual 121007

PN=153

Housings, Geartrain and Clutch Shafts

9620 Series Exploded View—Seventh Stage Clutch Shaft Assembly

YZ6193

–UN–28APR05

02 35 54

1—Seal Ring (2 used) 2—Bearing Cone (2 used) 3—Seventh Stage Shaft Assembly 4—O-ring 5—Clutch Piston

6—Outer Piston Seal 7—Lube Shutoff Washer 8—Belleville Spring (8 used) 9—Snap Ring Retainer 10—Snap Ring

11—Separator Plate (14 used) 12—Clutch Plate (14 used) 13—Clutch Plate Retainer 14—Retaining Ring 15—O-ring

16—Ball Bearing 17—41T Gear (Clutch L and M) 18—Ball Bearing 19—Thrust Washer 20—Screw

YZ07927,0000435 –19–28APR05–1/1

CTM168 (10DEC07)

02-35-54

18-Speed PST Repair Manual 121007

PN=154

Housings, Geartrain and Clutch Shafts

9620 Series Cross-Sectional View—Seventh Stage Clutch Shaft Assembly

YZ6192

–UN–02MAY05

02 35 55

1—Seal Ring (2 used) 2—Bearing Cone (2 used) 3—Clutch Piston 4—O-Ring 5—Separator Plate (14 used)

6—Shutoff Lube washer 7—Belleville Springs (8 used) 8—Clutch Plates (14 used) 9—Snap Ring Retainer 10—Ball Bearing

11—Screw 12—Thrust Washer 13—41T Gear (Clutch L and M) 14—O-Ring

15—Snap Ring 16—Outer Piston Seal 17—Seventh Stage Shaft Assembly

YZ07927,0000433 –19–27APR05–1/1

CTM168 (10DEC07)

02-35-55

18-Speed PST Repair Manual 121007

PN=155

Housings, Geartrain and Clutch Shafts

Disassembly and Assembly of Clutch Stage Shaft Assemblies Remove clutch stack. (See Remove Clutch Assemblies, 02 this group.)

NOTE: All clutch stage shaft assemblies in the 18-speed PST assemble and disassemble in the same or similar manner.

OURX078,000000D –19–18MAY05–1/1

Disassemble and Assemble Second Stage Shaft Assembly CAUTION: Second stage shaft assembly weight is approximately 78 Kg (170 lbs).

Remove second stage shaft assembly from next fixture using JDG1106 Lifting Hook (A).

–UN–20FEB01

A—Lifting Hook

YZ3104A

35 56

Continued on next page

CTM168 (10DEC07)

02-35-56

DPSG,YZ07927,364 –19–06DEC07–1/36

18-Speed PST Repair Manual 121007

PN=156

Housings, Geartrain and Clutch Shafts Place second stage shaft assembly on sturdy supports.

RXA0051532

–UN–26FEB01

02 35 57

DPSG,YZ07927,364 –19–06DEC07–2/36

Disassemble Second Stage Clutch A Clutch Assembly Place JDG1482 Shaft Protector (A) on end of shaft and install puller tools.

Remove rear bearing cone (G).

RXA0051533

–UN–26FEB01

A—Shaft Protector B—D01267AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Rear Bearing Cone

Continued on next page

CTM168 (10DEC07)

02-35-57

DPSG,YZ07927,364 –19–06DEC07–3/36

18-Speed PST Repair Manual 121007

PN=157

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch gear (G).

Inspect parts for wear and damage and replace as necessary.

RXA0051534

–UN–26FEB01

A—JDG1482 Shaft Protector B—JDG1480 Gear Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Clutch A Gear

DPSG,YZ07927,364 –19–06DEC07–4/36

Remove clutch gear bearing (A).

Remove both rear and front bearing cups from clutch gear Inspect parts and remove and replace as necessary.

–UN–08JAN01

A—Clutch A Gear Rear Bearing Cone

YZ3111

02 35 58

IMPORTANT: Fifth, sixth, and seventh stage assembly clutch gears will have an O-ring. The O-ring is for lubrication to the clutches.

Continued on next page

CTM168 (10DEC07)

02-35-58

DPSG,YZ07927,364 –19–06DEC07–5/36

18-Speed PST Repair Manual 121007

PN=158

Housings, Geartrain and Clutch Shafts

CAUTION: Wear eye protection when removing retaining ring.

Remove retaining ring (A).

02 35 59

YZ3112

–UN–08JAN01

A—Retaining Ring

DPSG,YZ07927,364 –19–06DEC07–6/36

Remove clutch plate retainer (A).

Inspect for wear and damage and replace as necessary.

YZ3114

–UN–08JAN01

A—Clutch Plate Retainer

Continued on next page

CTM168 (10DEC07)

02-35-59

DPSG,YZ07927,364 –19–06DEC07–7/36

18-Speed PST Repair Manual 121007

PN=159

Housings, Geartrain and Clutch Shafts Remove clutch disks and separator plates (A).

A—Clutch Disks (10 used) and Plates (10 used)

RXA0051535

–UN–26FEB01

02 35 60

DPSG,YZ07927,364 –19–06DEC07–8/36

Install puller tools and remove bearing (D).

RXA0051536

–UN–26FEB01

A—JDG1482 Shaft Protector B—JDG1477 Puller Legs C—JDG542 Gear and Pulley Puller D—Clutch Gear Front Bearing

Continued on next page

CTM168 (10DEC07)

02-35-60

DPSG,YZ07927,364 –19–06DEC07–9/36

18-Speed PST Repair Manual 121007

PN=160

Housings, Geartrain and Clutch Shafts Use a press and JDG1485 Spring Compressor Tool (A) and compress clutch return springs (B).

Remove snap ring (C) and retaining ring (D).

02 35 61

RXA0051537

–UN–26FEB01

A—Clutch Piston Return Spring Compressor B—Clutch Return Springs (6 used) C—Snap Ring Retainer D—Snap Ring

DPSG,YZ07927,364 –19–06DEC07–10/36

IMPORTANT: Pay attention to the assembly of the clutch return springs. They must be reassembled correctly.

Remove clutch return springs (A) and lube shut off washer (B).

YZ3086

–UN–20DEC00

A—Piston Return Springs (6 used) B—Lube Shut Off Washer

Continued on next page

CTM168 (10DEC07)

02-35-61

DPSG,YZ07927,364 –19–06DEC07–11/36

18-Speed PST Repair Manual 121007

PN=161

Housings, Geartrain and Clutch Shafts

–UN–02FEB01 YZ3088A

Using a rubber-tipped air nozzle, apply air pressure to the oil passage.

Remove clutch piston (A).

A—Clutch Piston

DPSG,YZ07927,364 –19–06DEC07–12/36

Disassemble Clutch Piston Remove outer piston seal (A) from clutch piston (B) and discard.

–UN–31AUG99

Inspect piston for wear and damage and replace as necessary.

YZ1921

A—Piston Seal B—Clutch Piston

DPSG,YZ07927,364 –19–06DEC07–13/36

Remove O-ring (A) from shaft.

–UN–02FEB01

A—O-Ring

YZ3089A

02 35 62

CAUTION: Wear eye protection when removing piston from cylinder. If cylinder is damaged DO NOT place hand on top of piston. If cylinder is turned upside down the piston will blow all the way out of the cylinder. Air pressure must be applied to the system pressure port to remove piston.

Continued on next page

CTM168 (10DEC07)

02-35-62

DPSG,YZ07927,364 –19–06DEC07–14/36

18-Speed PST Repair Manual 121007

PN=162

Housings, Geartrain and Clutch Shafts Assemble and Install Clutch Piston Lubricate new O-ring (A) with transmission fluid and install on shaft.

02 35 63

YZ3121A

–UN–02FEB01

A—O-Ring

DPSG,YZ07927,364 –19–06DEC07–15/36

Lubricate new outer piston seal (A) with transmission fluid and install onto piston.

Position piston in piston bore and install into place.

YZ3122A

–UN–02FEB01

A—Outer Piston Seal

Continued on next page

CTM168 (10DEC07)

02-35-63

DPSG,YZ07927,364 –19–06DEC07–16/36

18-Speed PST Repair Manual 121007

PN=163

Housings, Geartrain and Clutch Shafts Assemble Clutch Install lube shut off washer (B).

IMPORTANT: Clutch return springs must be installed stacked as shown.

–UN–20DEC00

Install clutch piston return springs (A).

YZ853A

–UN–02FEB01

YZ3086

A—Piston Return Springs (6 used) B—Lube Shut Off Washer

DPSG,YZ07927,364 –19–06DEC07–17/36

Position the spring compressor (A) on top of return springs (B).

Position snap ring retainer (C).

Place snap ring (D) on shaft.

Using a press, compress the return springs enough to allow snap ring (D) to be installed in the shaft snap ring groove inside the snap ring retainer (C).

Install snap ring.

Release pressure on clutch return springs slowly making sure the snap ring and snap ring retainer are correctly positioned.

–UN–26FEB01

A—JDG1485 Clutch Piston Return Spring Compressor B—Return Springs C—Snap Ring Retainer D—Snap Ring

RXA0051537

02 35 64

Continued on next page

CTM168 (10DEC07)

02-35-64

DPSG,YZ07927,364 –19–06DEC07–18/36

18-Speed PST Repair Manual 121007

PN=164

Housings, Geartrain and Clutch Shafts

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

Install heated front bearing cone (A) onto shaft tight against the shoulder.

02 35 65

Position JDG1475A Clutch Disk Alignment Guide (B) on clutch shaft.

Alternately install disks (C) and separator plates (D), starting with a plate against the piston.

–UN–26FEB01

Front Bearing Cone Disk Alignment Guide Disks (10 used) Separator Plates (10 used)

RXA0051538

A—Clutch B—Clutch C—Clutch D—Clutch

Continued on next page

CTM168 (10DEC07)

02-35-65

DPSG,YZ07927,364 –19–06DEC07–19/36

18-Speed PST Repair Manual 121007

PN=165

Housings, Geartrain and Clutch Shafts

Install clutch plate retainer (A) and retaining ring (B).

Remove alignment tool (C).

YZ5062

–UN–16JUL03

A—Clutch Plate Retainer B—Retaining Ring C—Alignment Tool

–UN–30JUL03

B—Retaining Ring

YZ5082

02 35 66

IMPORTANT: The retaining ring (B) is designed with a die break edge on one side. The die break edge must be installed with the die break edge up or facing away from the clutch plate retainer.

Continued on next page

CTM168 (10DEC07)

02-35-66

DPSG,YZ07927,364 –19–06DEC07–20/36

18-Speed PST Repair Manual 121007

PN=166

Housings, Geartrain and Clutch Shafts Verify that there is clearance in the clutch pack.

B

A

• Speed and Directions Clutches Assemblies will have 10 clutch disks per side and measure 3.81 mm — 4.57 mm (.150—.180 in.)

• Range Clutch Assemblies will have 14 clutch disks and measure 5.20 mm—6.35 mm (.205—.250 in.)

–UN–23FEB01

C

RXA0052103

Check free clearance on Speed and Directions Clutches Assemblies, 10 clutch disks per side, and measure 3.81mm — 4.57mm (.150—.180 in.) or Range Clutch Assemblies, 14 clutch disks, and measure 5.20 mm—6.35 mm (.205—.250 in.) clearance (C) between retainer (A) and first disk (B) or clutch piston.

IMPORTANT: If minimum clearance is not present, disassemble and determine the cause.

Transmission will not calibrate in tractor if clutch assembly free clearance is not between minimum and maximum free clearance tolerances.

This can be checked using a couple of methods: • Using indicator placed on first disk.

• Using indicator placed on piston.

–UN–24APR06

• Using feeler gauge between retainer and snap ring.

YZ6494

A—Retainer B—Clutch Disk C—Clearance

Continued on next page

CTM168 (10DEC07)

02-35-67

DPSG,YZ07927,364 –19–06DEC07–21/36

18-Speed PST Repair Manual 121007

PN=167

02 35 67

Housings, Geartrain and Clutch Shafts NOTE: Whichever method used to check free clearance be sure to check more than once. The piston, retainer, or clutch disks can stick.

IMPORTANT: Make sure clutch disk teeth are aligned to allow clutch gear installation.

–UN–31JAN01

Install clutch gear (A).

RXA0051540

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

Install clutch gear rear bearing cone (B) into gear tight against shoulder.

A—Clutch Gear B—Clutch Gear Rear Bearing

DPSG,YZ07927,364 –19–06DEC07–22/36

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

Install shaft rear bearing cone (A) onto shaft tight against shoulder.

–UN–31JAN01

A—Shaft Rear Bearing Cone

RXA0051541

02 35 68

Continued on next page

CTM168 (10DEC07)

02-35-68

DPSG,YZ07927,364 –19–06DEC07–23/36

18-Speed PST Repair Manual 121007

PN=168

Housings, Geartrain and Clutch Shafts Disassemble Second Stage Clutch 2 Clutch Assembly 9620 Series Remove Screw (A) and Thrust Washer (B).

02 35 69

YZ6206

–UN–31MAY05

YZ6207

–UN–31MAY05

A—Screw B—Thrust Washer

Continued on next page

CTM168 (10DEC07)

02-35-69

DPSG,YZ07927,364 –19–06DEC07–24/36

18-Speed PST Repair Manual 121007

PN=169

Housings, Geartrain and Clutch Shafts IMPORTANT: All 9620 series tractors will have thrust washers on all shaft assemblies. All other 9020 series tractors equipped with the 18-Speed Power Shift Transmissions will need to have thrust 02 washers installed at time of repair.

35 70

Using JDG1484 Eyebolt (A) place on sturdy supports.

RXA0051542

–UN–31JAN01

A—Eyebolt

DPSG,YZ07927,364 –19–06DEC07–25/36

NOTE: Spacer disks (A) must have a minimum thickness of 38 mm (1.50 in.) and 67 mm (2.625 in.) diameter to allow bearing removal.

Place spacer disks (A) on end of shaft.

Install puller tools and remove shaft front bearing cone (G).

RXA0051543

–UN–31JAN01

A—Spacer Disks B—D01267AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Shaft Front Bearing

Continued on next page

CTM168 (10DEC07)

02-35-70

DPSG,YZ07927,364 –19–06DEC07–26/36

18-Speed PST Repair Manual 121007

PN=170

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch gear (G).

A—Spacer Disks B—D01267AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Clutch Gear

RXA0051544

–UN–31JAN01

02 35 71

DPSG,YZ07927,364 –19–06DEC07–27/36

Remove roller ball bearing (A) from clutch gear.

Inspect parts for wear and damage and replace as necessary.

RXA0051545

–UN–31JAN01

A—Clutch Rear Roller Ball Bearing

Continued on next page

CTM168 (10DEC07)

02-35-71

DPSG,YZ07927,364 –19–06DEC07–28/36

18-Speed PST Repair Manual 121007

PN=171

Housings, Geartrain and Clutch Shafts

CAUTION: Wear eye protection when removing retaining ring.

Remove retaining ring (A) and clutch plate retainer (B).

Inspect parts for wear and damage and replace as necessary.

RXA0051550

–UN–31JAN01

A—Retaining Ring B—Clutch Plate Retainer

DPSG,YZ07927,364 –19–06DEC07–29/36

Remove clutch disks and separator plates (A).

Inspect parts for wear and damage and replace as necessary.

–UN–31JAN01

A—Clutch Disks (10 used) and Separator Plates (10 used)

RXA0051551

02 35 72

Continued on next page

CTM168 (10DEC07)

02-35-72

DPSG,YZ07927,364 –19–06DEC07–30/36

18-Speed PST Repair Manual 121007

PN=172

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch rear roller ball bearing (A) from shaft.

A—Clutch Rear Roller Ball Bearing B—Spacer Disks C—JDG1477 Puller Legs D—JDG542 Gear and Pulley Puller

RXA0051552

–UN–31JAN01

02 35 73

Continued on next page

CTM168 (10DEC07)

02-35-73

DPSG,YZ07927,364 –19–06DEC07–31/36

18-Speed PST Repair Manual 121007

PN=173

Housings, Geartrain and Clutch Shafts Disassemble remaining Clutch 2 components from gear clutch using the same procedures and tools as used for Clutch A.

YZ1932A

–UN–02FEB01

Assemble Clutch 2 components into gear clutch using the same procedures and tools as used for Clutch A, up to the rear roller ball bearing installation.

DPSG,YZ07927,364 –19–06DEC07–32/36

Position roller ball bearing (A) onto shaft and place JDG1474 Installer Plate (B) on top of bearing.

–UN–31JAN01

A—Clutch Rear Roller Ball Bearing B—Roller Ball Bearing Installer Plate

RXA0051553

02 35 74

Continued on next page

CTM168 (10DEC07)

02-35-74

DPSG,YZ07927,364 –19–06DEC07–33/36

18-Speed PST Repair Manual 121007

PN=174

Housings, Geartrain and Clutch Shafts NOTE: Bearing will drop freely between the two shaft diameters (D) and (E).

Place JDG1485 Spring Compressor (A) on top of bearing installer plate (B) and using a press, force the bearing (C) past the first shaft diameter (D) and onto shaft diameter (E) tight against shoulder.

02 35 75

RXA0051554

–UN–31JAN01

A—Clutch Piston Return Spring Compressor B—Roller Ball bearing Installer Plate C—Clutch Rear Roller Ball Bearing D—Shaft Diameter For Clutch Front Roller Ball Bearing E—Shaft Diameter For Clutch Rear Roller Ball Bearing

DPSG,YZ07927,364 –19–06DEC07–34/36

IMPORTANT: Make sure clutch disk teeth are aligned to allow clutch gear installation.

Install clutch gear (A).

Install clutch gear front bearing (B) using JDG1474 Bearing Installer Plate (C) and JDG1485 Spring Compressor (D).

Use a press and install bearing (B) tight to bottom bore of clutch gear.

RXA0051555

–UN–31JAN01

A—Clutch Gear B—Clutch Gear Front Roller Bearing C—Roller Ball Bearing Installer Plate D—Clutch Piston Return Spring Compressor

Continued on next page

CTM168 (10DEC07)

02-35-75

DPSG,YZ07927,364 –19–06DEC07–35/36

18-Speed PST Repair Manual 121007

PN=175

Housings, Geartrain and Clutch Shafts

CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F).

Plan a safe handling procedure to avoid burns.

–UN–31JAN01

Install heated front bearing cone (A) to shaft tight against shoulder.

RXA0051556

Remove clutch shaft assembly from supports using JDG1484 Eyebolt and turn over.

Install second stage shaft assembly into nest fixture using JDG1106 Lifting Hook.

A—Shaft Front Bearing Cone

DPSG,YZ07927,364 –19–06DEC07–36/36

Disassemble and Assemble Fifth Stage Shaft Assembly CAUTION: Fifth stage shaft assembly weight is approximately 47 kg (103 lb) Remove fifth stage shaft assembly from nest fixture using JDG1106 Lifting Hook (A).

–UN–26FEB01

A—Lifting Hook

RXA0051557

02 35 76

Continued on next page

CTM168 (10DEC07)

02-35-76

OURX078,000000F –19–24MAY05–1/8

18-Speed PST Repair Manual 121007

PN=176

Housings, Geartrain and Clutch Shafts Place fifth stage shaft assembly on sturdy supports

RXA0051558

–UN–26FEB01

02 35 77

OURX078,000000F –19–24MAY05–2/8

Disassemble Fifth Stage Shaft Assembly Place JDG1482 Shaft Protector (B) on end of shaft and install puller tools.

Remove rear bearing cone (A).

RXA0051559

–UN–26FEB01

A—Rear Bearing Cone B—Shaft Protector C—D01267AA Bearing Puller D—458 mm (18 in.) Puller Legs E—180 kN (20 Ton) Hydraulic Bottle Jack F—Spacer Disks G—270 kN (30 Ton) Push Puller

Continued on next page

CTM168 (10DEC07)

02-35-77

OURX078,000000F –19–24MAY05–3/8

18-Speed PST Repair Manual 121007

PN=177

Housings, Geartrain and Clutch Shafts 9620 Series A—Hex Head Cap Screw B—Thrust washer

YZ6202

–UN–31MAY05

YZ6204

–UN–31MAY05

02 35 78

Continued on next page

CTM168 (10DEC07)

02-35-78

OURX078,000000F –19–24MAY05–4/8

18-Speed PST Repair Manual 121007

PN=178

Housings, Geartrain and Clutch Shafts IMPORTANT: All 9620 series tractors will have thrust washers on all shaft assemblies. All other 9020 series tractors equipped with the 18-Speed Power Shift Transmissions will need to have thrust washers installed at time of repair.

02 35 79

Turn fifth stage shaft assembly (A) over using JDG1484 Eyebolt (B) and a lifting device.

Place shaft assembly on sturdy supports.

RXA0051560

–UN–26FEB01

A—Fifth Stage Shaft Assembly B—Eyebolt

OURX078,000000F –19–24MAY05–5/8

NOTE: Spacer disks (A) must have a minimum thickness of 38 mm (1.50 in.) and 67 mm (2.625 in.) diameter to allow bearing removal.

Place spacer disks (A) on end of shaft.

Install puller tools and remove shaft front bearing Cone (B).

RXA0051561

–UN–26FEB01

A—Spacer Disks B—Shaft Front Bearing Cone C—D01067AA Bearing Puller D—45 mm (18 in.) Puller Legs E—180 kN (20 Ton) Hydraulic Bottle Jack F—Spacer Disks G—270 kN (30 Ton) Push Puller

Continued on next page

CTM168 (10DEC07)

02-35-79

OURX078,000000F –19–24MAY05–6/8

18-Speed PST Repair Manual 121007

PN=179

Housings, Geartrain and Clutch Shafts Disassemble and Assemble Fifth Stage Clutch L Install puller tools and remove clutch gear (A).

–UN–26FEB01

A—Clutch Gear L B—Spacer Disk C—D01067AA Bearing Puller D—45 mm (18 in.) Puller Legs E—180 kN (20 Ton) Hydraulic Bottle Jack F—Spacer Disks G—270 kN (30 Ton) Push Puller

RXA0051562

02 35 80

Continued on next page

CTM168 (10DEC07)

02-35-80

OURX078,000000F –19–24MAY05–7/8

18-Speed PST Repair Manual 121007

PN=180

Housings, Geartrain and Clutch Shafts NOTE: All single stage clutch shaft clutch assemblies will have an O-ring (B).

Remove bearing (A), inspect for wear and damage and replace as necessary.

02 35 81

Remove and discard O-ring (B).

–UN–20DEC00

Lubricate new O-ring (B) with transmission fluid and install on gear.

Assemble clutch L components and fifth stage shaft assembly following the same procedures as for clutch 2 and second stage shaft assembly.

YZ3077

Disassemble remaining clutch L components following the same procedures as for clutch 2 of the second stage shaft assembly.

A—Clutch L Gear Front Roller Ball Bearing B—O-Ring

Remove clutch shaft assembly from supports and turn over using JDG1484 Eyebolt.

Install fifth stage shaft assembly into nest fixture using JDG1106 Lifting Hook.

OURX078,000000F –19–24MAY05–8/8

CTM168 (10DEC07)

02-35-81

18-Speed PST Repair Manual 121007

PN=181

Housings, Geartrain and Clutch Shafts

Disassemble and Assemble Seventh Stage Clutch Shaft Assembly Remove seventh stage shaft assembly (A) from nest 02 fixture using JDG1106 Lifting Hook (B. CAUTION: Seventh stage shaft assembly weight is approximately 52 Kg (115 lb).

–UN–26FEB01

Disassemble seventh stage shaft assembly clutch M components following the same procedures as for clutch L of the fifth stage shaft assembly.

Assemble clutch M components and seventh stage shaft assembly following the same procedures as for clutch L and fifth stage shaft assembly.

RXA0051563

35 82

Remove clutch shaft assembly from supports.

9620 series tractors IMPORTANT: All 9620 series tractors will have thrust washers on all shaft assemblies. All other 9020 series tractors equipped with the 18-Speed Power Shift Transmissions will need to have thrust washers installed at time of repair.

A—Seventh Stage Shaft Assembly B—Lifting Hook

Remove thrust washer and turn over using JDG1484 Eyebolt.

Install seventh stage shaft assembly into nest fixture using JDG1106 Lifting Hook.

OURX078,0000011 –19–24MAY05–1/1

CTM168 (10DEC07)

02-35-82

18-Speed PST Repair Manual 121007

PN=182

Housings, Geartrain and Clutch Shafts

Disassemble and Assemble Sixth Stage Clutch Shaft Assembly CAUTION: Sixth stage shaft assembly weight is approximately 63 Kg (139 lb).

02 35 83

Remove sixth stage shaft assembly from nest fixture using JDG1106 Lifting Hook (A).

RXA0051600

–UN–26FEB01

A—Lifting Hook

Continued on next page

CTM168 (10DEC07)

02-35-83

OURX078,0000013 –19–24MAY05–1/3

18-Speed PST Repair Manual 121007

PN=183

Housings, Geartrain and Clutch Shafts Place sixth stage shaft assembly on sturdy supports.

Place JDG1482 Shaft Protector (A) on end of shaft and install puller tools.

Remove rear bearing cone (G).

–UN–26FEB01

A—Shaft Protector B—D01267AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Rear Bearing Cone

RXA0051602

02 35 84

Continued on next page

CTM168 (10DEC07)

02-35-84

OURX078,0000013 –19–24MAY05–2/3

18-Speed PST Repair Manual 121007

PN=184

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch gear (G).

Disassemble sixth stage shaft assembly clutch H components following the same procedures as for clutch L of the fifth stage shaft assembly.

02 35 85

Assemble clutch H components and sixth stage shaft assembly following the same procedures as for clutch L and fifth stage shaft assembly.

Remove and install sixth stage shaft assembly front bearing cone following the same procedures as for fifth stage shaft assembly.

Remove clutch shaft assembly from supports.

9620 series tractors

Install sixth stage shaft assembly into nest fixture using JDG1106 Lifting Hook.

A—JDG1482 Shaft Protector B—JDG1480 Gear Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disk F—270 kN (30 Ton) Push Puller G—Clutch H Gear

RXA0051603

Remove thrust washer and turn over using JDG1484 Eyebolt .

–UN–27FEB01

IMPORTANT: All 9620 series tractors will have thrust washers on all shaft assemblies. All other 9020 series tractors equipped with the 18-Speed Power Shift Transmissions will need to have thrust washers installed at time of repair.

OURX078,0000013 –19–24MAY05–3/3

CTM168 (10DEC07)

02-35-85

18-Speed PST Repair Manual 121007

PN=185

Housings, Geartrain and Clutch Shafts

Disassemble and Assemble Fourth Stage Shaft Assembly CAUTION: Fourth stage clutch shaft assembly weight is approximately 93 Kg (206 lb).

Remove fourth stage shaft assembly from nest fixture using JDG1106 Lifting Hook (A).

–UN–26FEB01

A—Lifting Hook

RXA0051606

02 35 86

Continued on next page

CTM168 (10DEC07)

02-35-86

OURX078,0000015 –19–03JUN05–1/8

18-Speed PST Repair Manual 121007

PN=186

Housings, Geartrain and Clutch Shafts Place fourth stage clutch shaft assembly on sturdy supports.

RXA0051607

–UN–26FEB01

02 35 87

Continued on next page

CTM168 (10DEC07)

02-35-87

OURX078,0000015 –19–03JUN05–2/8

18-Speed PST Repair Manual 121007

PN=187

Housings, Geartrain and Clutch Shafts Install puller tools and remove rear bearing cone (G).

–UN–28FEB01 RXA0051609

02 35 88

A—JDG1482 Shaft Protector B—D01067AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Rear Bearing Cone

Continued on next page

CTM168 (10DEC07)

02-35-88

OURX078,0000015 –19–03JUN05–3/8

18-Speed PST Repair Manual 121007

PN=188

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch C gear (G).

Disassemble and assemble clutch C components following the same procedures as for clutch A of the second stage clutch shaft assembly.

02 35 89

Install the rear bearing cone following the same procedures as for second stage clutch shaft assembly.

RXA0051610

–UN–26FEB01

A—JDG1482 Shaft Protector B—D01398AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disk F—270 kN (30 Ton) Push Puller G—Clutch C Gear

OURX078,0000015 –19–03JUN05–4/8

9620 Series

YZ6214

–UN–31MAY05

A—Thrust Washer B—Cap Screw

Continued on next page

CTM168 (10DEC07)

02-35-89

OURX078,0000015 –19–03JUN05–5/8

18-Speed PST Repair Manual 121007

PN=189

Housings, Geartrain and Clutch Shafts IMPORTANT: All 9620 series tractors will have thrust washers on all shaft assemblies. All other 9020 series tractors equipped with the 18-Speed Power Shift Transmissions will need to have thrust 02 washers installed at time of repair.

35 90

Turn shaft assembly over.

Remove thrust washer and place on sturdy supports using JDG1484 Eyebolt (A).

RXA0051611

–UN–26FEB01

A—Eyebolt

Continued on next page

CTM168 (10DEC07)

02-35-90

OURX078,0000015 –19–03JUN05–6/8

18-Speed PST Repair Manual 121007

PN=190

Housings, Geartrain and Clutch Shafts NOTE: Spacer disks (A) must have a minimum thickness of 38 mm (1.50 in.) and 67 mm (2.625 in.) diameter to allow bearing removal.

Install puller tools and remove front bearing cone (G).

02 35 91

RXA0051613

–UN–26FEB01

A—Spacer Disks B—D01067AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Front Bearing Cone

Continued on next page

CTM168 (10DEC07)

02-35-91

OURX078,0000015 –19–03JUN05–7/8

18-Speed PST Repair Manual 121007

PN=191

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch gear R.

Install the rear bearing cone following the same procedures as for second stage clutch shaft assembly.

Remove clutch shaft assembly from supports and turn over using JDG1484 Eyebolt .

Install fourth stage shaft assembly into nest fixture using JDG1106 Lifting Hook.

–UN–26FEB01

A—Clutch Gear R B—D01398AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller

RXA0051614

02 35 92

Disassemble and assemble clutch R components following the same procedures as for clutch A of the second stage clutch shaft assembly.

OURX078,0000015 –19–03JUN05–8/8

CTM168 (10DEC07)

02-35-92

18-Speed PST Repair Manual 121007

PN=192

Housings, Geartrain and Clutch Shafts

Disassemble and Assemble Third Stage Shaft Assembly CAUTION: Third stage clutch shaft assembly weight is approximately 97 Kg (213 lb).

02 35 93

Remove third stage shaft assembly from nest fixture using JDG1106 Lifting Hook (A).

RXA0051615

–UN–26FEB01

A—Lifting Hook

OURX078,0000017 –19–24MAY05–1/5

Place third stage clutch shaft assembly on sturdy supports.

Install puller tools and remove rear bearing cone (G).

RXA0051617

–UN–26FEB01

A—JDG1482 Shaft Protector B—D01067AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Rear Bearing Cone

Continued on next page

CTM168 (10DEC07)

02-35-93

OURX078,0000017 –19–24MAY05–2/5

18-Speed PST Repair Manual 121007

PN=193

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch B gear (G) and 70 tooth gear (H).

Disassemble and assemble clutch B components following the same procedures as for clutch A of the second stage 02 35 clutch shaft assembly.

94

Install the rear bearing cone following the same procedures as for second stage clutch shaft assembly.

RXA0051618

–UN–26FEB01

A—JDG1482 Shaft Protector B—D01398AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disk F—270 kN (30 Ton) Push Puller G—Clutch B Gear H—70 Tooth Gear

OURX078,0000017 –19–24MAY05–3/5

NOTE: Spacer disks (A) must have a minimum thickness of 38 mm (1.50 in.) and 67 mm (2.625 in.) diameter to allow bearing removal.

Turn shaft assembly over and place on sturdy supports using JDG1484 Eyebolt.

Install puller tools and remove front bearing cone (G).

RXA0051622

–UN–26FEB01

A—Spacer Disks B—D01067AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller G—Front Bearing Cone

Continued on next page

CTM168 (10DEC07)

02-35-94

OURX078,0000017 –19–24MAY05–4/5

18-Speed PST Repair Manual 121007

PN=194

Housings, Geartrain and Clutch Shafts Install puller tools and remove clutch gear 1.

Disassemble and assemble clutch 1 components following the same procedures as for clutch A of the second stage clutch shaft assembly.

02 35 95

Install the rear bearing cone following the same procedures as for second stage clutch shaft assembly.

9620 series tractors IMPORTANT: All 9620 series tractors will have thrust washers on all shaft assemblies. All other 9020 series tractors equipped with the 18-Speed Power Shift Transmissions will need to have thrust washers installed at time of repair.

Install third stage shaft assembly into nest fixture using JDG1106 Lifting Hook.

RXA0051623

Remove thrust washer and turn over using JDG1484 Eyebolt.

–UN–26FEB01

Remove clutch shaft assembly from supports.

A—Clutch Gear 1 B—D01398AA Bearing Puller C—457 mm (18 in.) Puller Legs D—180 kN (20 Ton) Hydraulic Bottle Jack E—Spacer Disks F—270 kN (30 Ton) Push Puller

OURX078,0000017 –19–24MAY05–5/5

CTM168 (10DEC07)

02-35-95

18-Speed PST Repair Manual 121007

PN=195

Housings, Geartrain and Clutch Shafts

Install Clutch Assemblies Position the clutch shaft assemblies in the clutch stack nest fixture.

–UN–21APR03

IMPORTANT: Keep the lifting fixture level during installation to the clutch shaft assemblies to prevent damage to the shaft sealing ring grooves.

Install lifting fixture (A) onto clutch nest.

Secure the latches (B) and install input shaft retaining cap (C).

YZ5027

02 35 96

Carefully remove the clutch nest from the nest fixture.

A—JDG1471 Clutch Stack Lifting Fixture B—First Stage (Input Shaft) Retaining Cap

NOTE: Keep the lifting fixture parallel with the housing surface to prevent the clutch shafts from binding in the housing.

Carefully install the clutch nest into the front housing.

Disengage clutch assembly latches, remove input shaft retaining cap and remove clutch lifting fixture.

Continued on next page

CTM168 (10DEC07)

02-35-96

OURX078,0000018 –19–15APR03–1/2

18-Speed PST Repair Manual 121007

PN=196

Housings, Geartrain and Clutch Shafts IMPORTANT: DO NOT install used seal rings.

Compress the sealing rings past the meeting point.

–UN–03MAR94

Install the sealing rings onto the shaft starting with the bottom sealing ring groove.

YZ5028

–UN–10APR03

RW35217

Check the installed sealing rings and make sure there is not a large gap and that the sealing ring joints are staggered.

OURX078,0000018 –19–15APR03–2/2

Install Rear Housing

–UN–02FEB01

Install JDG1489 Transmission Rear Cover Lifting Bracket (A) to suction screen cover threaded holes.

Install JDG19 Lifting Brackets (B).

RXA0051599

NOTE: Adjust lift chain lengths so that the mating surfaces of the front and rear housings will be parallel.

Attach lift chains to the lifting brackets and overhead hoist.

Old Style Rear Housing

YZ5013

–UN–10APR03

A—Rear Cover Lift Bracket B—Lifting Brackets (3 used)

Continued on next page

CTM168 (10DEC07)

02-35-97

OURX078,0000019 –19–15APR03–1/3

18-Speed PST Repair Manual 121007

PN=197

02 35 97

Housings, Geartrain and Clutch Shafts Apply a thin film of TY16021 High-Flex Form-in-Place Gasket to front-to rear housing mating surface.

Install four guide pins, one at each corner of rear cover.

IMPORTANT: Keep the rear housing parallel with the front housing, while installing, to avoid binding the clutch shafts in the rear housing.

Carefully install rear cover to transmission assembly.

RXA0051432

–UN–30JAN01

A—Lift Chains

OURX078,0000019 –19–15APR03–2/3

NOTE: Tighten cap screws in a criss-cross pattern starting from the middle of the transmission case.

Install and tighten cap screws (A).

Specification Rear-to-Front Transmission Housing Cap Screws—Torque ..................................................... 216 N•m (159 lb-ft) –UN–30JAN01

DO NOT install additional parts, proceed to bearing adjustment procedures.

A—Rear-to-Front Housing Cap Screws (24 used)

RXA0051433

02 35 98

NOTE: Guide pins may be fabricated by removing the heads from M16 x 200 mm cap screws.

OURX078,0000019 –19–15APR03–3/3

CTM168 (10DEC07)

02-35-98

18-Speed PST Repair Manual 121007

PN=198

Housings, Geartrain and Clutch Shafts

Bearing Adjustment of Output Shaft

Rear Housing

–UN–10APR03

1. Install guide pins.

YZ5029

A—Guide Pin B—Internal Park Brake Cover

YZ07927,00000A2 –19–30JUN05–1/6

2. Install Yoke washer and cap screw (A).

–UN–10APR03

IMPORTANT: Tighten seven internal park brake-to-rear housing cap screws evenly to the torque specification listed below.

YZ5030

Install seven cap screws (B).

Tighten seven cap screw (B).

Specification Internal Park Brake-to-Rear Housing Cap Screw—Torque......................................... 2.8 N•m (25 lb-in)

A—Washer and Cap Screw B—Cap Screw

YZ07927,00000A2 –19–30JUN05–2/6

3. Rotate output shaft 2 turns clockwise.

Check cap screw torque

YZ5031

–UN–10APR03

Specification Internal Park Brake Housing-to-Rear Housing Cap Screw—Torque ............................................................... 2.8 N•m (25 lb-in)

.

A—Output shaft

Continued on next page

CTM168 (10DEC07)

02-35-99

YZ07927,00000A2 –19–30JUN05–3/6

18-Speed PST Repair Manual 121007

PN=199

02 35 99

Housings, Geartrain and Clutch Shafts IMPORTANT: A gap measurement in more than one location must be taken to obtain an average reading.

–UN–10APR03

4. Measure and record gap adjacent to four cap screws 90° apart using a feeler gage.

Add the four measurements and divide by four to determine the average measurement.

YZ5032

02 35 ,100

Remove cap screws and remove internal park brake cover.

IMPORTANT: To obtain shim thickness for shimming add 0.064 mm (0.003 in.) to the average gap measurement.

5. Install determined shim pack.

6. Install internal park brake housing.

IMPORTANT: Tighten cap screws using a criss-cross pattern in two separate steps.

7. Install and tighten cap screws in a cross-cross pattern.

Specification Internal Park Brake Housing-to-Rear Housing Cap Screw — Initial Torque—Torque .................................................... 40•N•m (30 lb-ft) Specification Internal Park Brake Housing-to-Rear Housing Cap Screw — Final Torque—Torque .................................................... 80 N•m (60 lb-ft)

8. Rotate output shaft two turns clockwise.

Continued on next page

CTM168 (10DEC07)

02-35-100

YZ07927,00000A2 –19–30JUN05–4/6

18-Speed PST Repair Manual 121007

PN=200

Housings, Geartrain and Clutch Shafts 9. Using a push pull torque wrench check end play.

Specification Push Pull Torque Wrench—Push Pull Output Shaft .......................................................................... 400 N•m (300 ft-lbs)

02 35 ,101 –UN–14APR03

Adjust if necessary by adding or subtracting shims to meet specifications

YZ5033

Specification Output Shaft—End Play .................................................... 0.02—0.12 mm (0.001 — 0.005 in.)

NOTE: After bearing adjustment of output shaft (rear housing) remove internal park brake cover and install internal park brake components.

IMPORTANT: When installing the internal brake cover onto the guide pins the internal brake cover will not set flush witht he main case rear housing. There will be a 17.78 mm (.700 in.) gap between the main case rear housing and the internal park brake cover.

If you do not have the 17.78 mm (.700 in.) gap between the main case rear housing and the internal park brake cover double check to be sure that the belleville springs are installed correctly.

Slowly tighten the cap screws following the tightening sequence. DO NOT USE torque gun to tighten cap screws.

Failure to follow the tightening sequence will damage the seals. Seals must move slowly across rear housing and brake cover housing chanfers to prevent damage to seals.

Install brake cover-to-rear housing cap screw.

1. Tighten cap screw labeled number 1, one complete turn.

2. Tighten cap screw labeled number 2, one complete turn.

Continued on next page

CTM168 (10DEC07)

02-35-101

YZ07927,00000A2 –19–30JUN05–5/6

18-Speed PST Repair Manual 121007

PN=201

Housings, Geartrain and Clutch Shafts 3. Tighten cap screw labeled number 3, one complete turn.

4. Tighten cap screw labeled number 4, one complete turn.

5. Tighten cap screw labeled number 5, one complete 02 turn.

35 6.

Tighten cap screw labeled number 6, one complete ,102 turn.

7. Tighten cap screw labeled number 7, one complete turn.

8. Continue tightening cap screws, one complete turn, in sequence until final torque.

YZ07927,00000A2 –19–30JUN05–6/6

Internal Park Brake Assembly IMPORTANT: When removing internal brake housing retain shims installed under the internal park brake cover.

YZ5034

–UN–14APR03

1. Alternately install brake disks and separator plates, starting with a separator plate (A) against the rear housing bore, then install brake disk (B). Continue this process until all clutch (B) and separator (A) plates are installed.

A—Separator Plate B—brake disk

Continued on next page

CTM168 (10DEC07)

02-35-102

YZ07927,00000A1 –19–22APR05–1/15

18-Speed PST Repair Manual 121007

PN=202

Housings, Geartrain and Clutch Shafts 2. Install new seal ring (A) onto rear housing .

A—Internal seal ring

YZ5185

–UN–21JUN04

02 35 ,103

YZ07927,00000A1 –19–22APR05–2/15

3. Install new seal ring (A) into brake spacer.

YZ5184

–UN–21JUN04

4. Install brake spacer (A).

Continued on next page

CTM168 (10DEC07)

02-35-103

YZ07927,00000A1 –19–22APR05–3/15

18-Speed PST Repair Manual 121007

PN=203

Housings, Geartrain and Clutch Shafts 5. Install new seal rings onto brake piston (A).

A—Brake Piston

YZ5036

–UN–14APR03

02 35 ,104

YZ07927,00000A1 –19–22APR05–4/15

Install brake piston (A).

YZ5037

–UN–14APR03

A—Brake Piston

Continued on next page

CTM168 (10DEC07)

02-35-104

YZ07927,00000A1 –19–22APR05–5/15

18-Speed PST Repair Manual 121007

PN=204

Housings, Geartrain and Clutch Shafts

YZ5050

–UN–13MAY03

IMPORTANT: The Belleville Springs can be installed wrong. Be sure and install springs properly. The illustration with key callouts 1, 2 and 3 shows proper installation. Belleville (1) is concave toward the spring spacer (2) and Bellville (3) is concave toward the spring spacer (2).

6.

1—Belleville Spring 2—Spring Spacer 3—Belleville Spring

YZ07927,00000A1 –19–22APR05–6/15

Install belleville spring (A) and spring spacer (B).

YZ5038

–UN–14APR03

A—Belleville Spring B—Spring Spacer

YZ07927,00000A1 –19–22APR05–7/15

7. Install second belleville spring (A).

YZ5039

–UN–14APR03

A—Belleville Spring

Continued on next page

CTM168 (10DEC07)

02-35-105

YZ07927,00000A1 –19–22APR05–8/15

18-Speed PST Repair Manual 121007

PN=205

02 35 ,105

Housings, Geartrain and Clutch Shafts 8. Install new o-rings onto oil tube.

Install oil tube assembly.

YZ5040

–UN–14APR03

A—Oil Tube

YZ07927,00000A1 –19–22APR05–9/15

9. Install guide pins (A) and shims (B).

NOTE: Refer to Bearing Adjustment of Output Shaft Housing in this group for determined shims.

Rear

NOTE: Check Oil Tube (B) and Brake housing (A) align.

–UN–14APR03

10. Lubricate new o-ring with transmission fluid and install onto brake housing.

YZ5041

A—Guide Pin B—Shim

YZ07927,00000A1 –19–22APR05–10/15

Install brake housing (A) onto guide pins.

–UN–14APR03

A—Brake Housing B—Oil Tube

YZ5042

02 35 ,106

Continued on next page

CTM168 (10DEC07)

02-35-106

YZ07927,00000A1 –19–22APR05–11/15

18-Speed PST Repair Manual 121007

PN=206

Housings, Geartrain and Clutch Shafts

–UN–14APR03

IMPORTANT: When installing the internal brake cover onto the guide pins the internal brake cover will not set flush with the main case rear housing. There will be a 17.78 mm (.700 in.) gap between the main case rear housing and the internal park brake cover.

YZ5043

If you do not have the 17.78 mm (.700 in.) gap between the main case rear housing and the internal park brake cover double check to be sure that the belleville springs are installed correctly.

Slowly tighten the cap screws following the tightening sequence. DO NOT USE torque gun to tighten cap screws.

Failure to follow the tightening sequence will damage the seals. Seals must move slowly across rear housing and brake cover housing chamfers to prevent damage to seals.

11. Follow numbered tightening sequence to tighten cap screws.

12.Install brake cover-to-rear housing cap screw.

1. Tighten cap screw labeled number 1, one complete turn.

2. Tighten cap screw labeled number 2, one complete turn.

3. Tighten cap screw labeled number 3, one complete turn.

4. Tighten cap screw labeled number 4, one complete turn.

5. Tighten cap screw labeled number 5, one complete turn.

6. Tighten cap screw labeled number 6, one complete turn.

7. Tighten cap screw labeled number 7, one complete turn.

8. Continue tightening cap screws, one complete turn, in sequence until final torque.

Continued on next page

CTM168 (10DEC07)

02-35-107

YZ07927,00000A1 –19–22APR05–12/15

18-Speed PST Repair Manual 121007

PN=207

02 35 ,107

Housings, Geartrain and Clutch Shafts Tighten cap screw.

–UN–14APR03 YZ5044

Specification Brake Housing-to-Rear Housing Cap Screw — Final Torque— Torque ............................................................................................ 80 N•m (60 lb-ft)

YZ07927,00000A1 –19–22APR05–13/15

13. Install yoke (A).

–UN–14APR03

14. Install O-ring (B).

15. Install washer (C).

16. Install cap screw (D).

YZ5045

02 35 ,108

Specification Brake Housing-to-Rear Housing Cap Screw — Initial Torque— Torque ............................................................................................ 40 N•m (30 lb-ft)

A—Yoke B—O-ring C—Washer D—Cap screw

Continued on next page

CTM168 (10DEC07)

02-35-108

YZ07927,00000A1 –19–22APR05–14/15

18-Speed PST Repair Manual 121007

PN=208

Housings, Geartrain and Clutch Shafts 17. Tighten cap screw.

YZ5046

–UN–14APR03

Specification Output Yoke-to-Shaft Cap Screw—Torque ............................................................................. 435 N•m (320 lb-ft)

YZ07927,00000A1 –19–22APR05–15/15

Bearing Adjustments to Clutch Stage Shafts

–UN–30APR01

NOTE: To make bearing adjustments install JDG1486 Clutch Rotation Tools and attach to air supply to engage two clutch assemblies using air. When seating bearings the input or output shaft must be rotated. The forward sixth gear (F6) can be engaged by applying air pressure to clutch “2” and “B”.

RXA0052927

A—JDG1486-1 Hose Assembly B—JDG1486-2 Input Fitting Assembly C—Quick Coupler Fitting (Dealer Furnished)

OURX078,000000B –19–11APR01–1/1

CTM168 (10DEC07)

02-35-109

18-Speed PST Repair Manual 121007

PN=209

02 35 ,109

Housings, Geartrain and Clutch Shafts

Install Clutch Rotation Tools Install input fitting assembly (A) into clutch port “2” opening (B).

YZ3179A

–UN–25APR01

A—JDG1486-2 Input Fitting Assembly1 B—Clutch Port “2” Opening

1 JDG1486-2 Input Fitting Assembly is part of JDG1486 Clutch Rotation Tool Set

DPSG,YZ07927,406 –19–03JUN05–1/5

Install one end of hose assembly to special plug.

–UN–22JAN01

A—JDG1486-1 Hose Assembly1

YZ3180

02 35 ,110

1 JDG1486-1 Hose Assembly is part of JDG1486 Clutch Rotation Tool Set

Continued on next page

CTM168 (10DEC07)

02-35-110

DPSG,YZ07927,406 –19–03JUN05–2/5

18-Speed PST Repair Manual 121007

PN=210

Housings, Geartrain and Clutch Shafts Install special plug (A) into clutch port “B” opening (B).

1 JDG1486-2 Input Fitting Assembly is part of JDG1486 Clutch Rotation Tool Set

RXA0052607

–UN–29MAR01

A—JDG1486-2 Input Fitting Assembly1 B—Clutch Port “B” Opening

DPSG,YZ07927,406 –19–03JUN05–3/5

Attach end of hose assembly (A) to input fitting assembly (B).

–UN–29MAR01

Attach tool to air supply.

RXA0052608

A—JDG1486-1 Hose Assembly1 B—JDG1486-2 Input Fitting Assembly2

1 JDG1486-1 Hose Assembly is part of JDG1486 Clutch Rotation Tool Set

2 JDG1486-2 Input Fitting Assembly is part of JDG1486 Clutch Rotation Tool Set

DPSG,YZ07927,406 –19–03JUN05–4/5

IMPORTANT: To properly rotate shaft assemblies during bearing adjustment procedures, the input shaft alignment fixture MUST be installed.

Temporarily install yokes to input and/or output shafts.

YZ6215

A—Input Shaft Alignment Fixture

–UN–31MAY05

Install JDG1481 Input Shaft Alignment Fixture (A) to the transmission.

DPSG,YZ07927,406 –19–03JUN05–5/5

CTM168 (10DEC07)

02-35-111

18-Speed PST Repair Manual 121007

PN=211

02 35 ,111

Housings, Geartrain and Clutch Shafts

Bearing Adjustment Of Fifth and Sixth Clutch Stage Shaft Assemblies

Item

Measurement

Specification

Clutch Stage Shaft Assemblies

End Play

0.02—0.12 mm (0.001—0.005 in.)

DPSG,YZ07927,407 –19–23JAN01–1/7

Position the transmission in the rollover stand so that the clutch shafts are in a vertical position.

Remove bearing retainer cap screws (A).

YZ3184A

–UN–06MAR01

A—Bearing Retainer Cap Screws (4 used)

DPSG,YZ07927,407 –19–23JAN01–2/7

Remove bearing retainer with O-ring.

–UN–24JAN01

Remove shims.

YZ3185

02 35 ,112

IMPORTANT: All clutch stage shaft assemblies MUST have the bearings set with the correct end play.

Continued on next page

CTM168 (10DEC07)

02-35-112

DPSG,YZ07927,407 –19–23JAN01–3/7

18-Speed PST Repair Manual 121007

PN=212

Housings, Geartrain and Clutch Shafts Install bearing retainer without O-rings or shims.

Install and tighten four cap screws.

Specification Bearing Retainer-to-Front Housing Cap Screw—Torque........................................................ 2.8 N•m (25 lb-in)

02 35 ,113

–UN–24JAN01

Install clutch rotation tools. (See Install Clutch Rotation Tools, this group.)

Apply air pressure to engage clutches “2” and “B”.

YZ3186

Rotate shaft two complete turns clockwise; then rotate two complete turns counterclockwise.

Release air pressure.

Retighten cap screws.

Specification Bearing Retainer-to-Front Housing Cap Screw—Torque........................................................ 2.8 N•m (25 lb-in)

DPSG,YZ07927,407 –19–23JAN01–4/7

IMPORTANT: A gap measurement in more than one location must be taken to obtain an average reading.

–UN–24JAN01

Measure and record gap adjacent to each cap screw between front housing and bearing retainer using a feeler gage.

YZ3187

Add the four measurements and divide by four to determine the average measurement.

Remove cap screws and remove bearing retainer.

Continued on next page

CTM168 (10DEC07)

02-35-113

DPSG,YZ07927,407 –19–23JAN01–5/7

18-Speed PST Repair Manual 121007

PN=213

Housings, Geartrain and Clutch Shafts IMPORTANT: To obtain shim thickness for shimming add 0.064 mm (0.003 in.) to the average gap measurement.

–UN–24JAN01

Install determined shim pack.

YZ3185

Lubricate new O-ring with transmission fluid and install to bearing retainer.

Install bearing retainer.

DPSG,YZ07927,407 –19–23JAN01–6/7

IMPORTANT: Tighten cap screws using a criss-cross pattern in two separate steps.

–UN–24JAN01

Install and tighten cap screws in a criss-cross pattern.

Specification Bearing Retainer-to-Front Housing Cap Screw—Initial Torque ............................................................................................ 40 N•m (30 lb-ft)

YZ3189

02 35 ,114

Specification Bearing Retainer-to-Front Housing Cap Screw—Final Torque ............................................................................................ 80 N•m (60 lb-ft)

DPSG,YZ07927,407 –19–23JAN01–7/7

Bearing Adjustment of Second, Third, Fourth and Seventh Clutch Stage Shaft Assemblies IMPORTANT: All clutch stage shaft assemblies MUST have the bearings set with the correct end play.

Item

Measurement

Specification

Clutch Stage Shaft Assemblies

End Play

0.02—0.12 mm (0.001—0.005 in.)

Item

Measurement

Specification

All Clutch Stage Shaft Assemblies

Push Pull Torque Wrench Setting

340 N•m (250 lb-ft)

Continued on next page

CTM168 (10DEC07)

02-35-114

OURX078,0000002 –19–07JUN05–1/13

18-Speed PST Repair Manual 121007

PN=214

Housings, Geartrain and Clutch Shafts NOTE: Second, third and fourth clutch stage shafts are located behind the pump drive cover.

–UN–22JAN01

Remove pump drive input gear (A). (See Remove and Install Pump Drive Input Gear, Group 30.)

YZ3175

A—Pump Drive Input Gear

OURX078,0000002 –19–07JUN05–2/13

Second, Third and Fourth Clutch Stage Shafts NOTE: Shaft alignment tool is used to position the input shaft for proper gear teeth alignment when shafts are rotated.

–UN–31MAY05

Install JDG1481 Input Shaft Alignment Fixture (E) to the transmission.

NOTE: There is no O-ring seal on the bearing retainers.

YZ6208

Follow the same procedures used for fifth and sixth stage shaft assemblies. (See Bearing Adjustment of Fifth and Sixth Clutch Stage Shaft Assemblies, this group.)

NOTE: 9620 Series shows new style of bearing retainer the old style bearing retainers should be replaced with new style at time of repair.

A—Second Stage Clutch Shaft Bearing Retainer B—Third Stage Clutch Shaft Bearing Retainer C—Fourth Stage Clutch Shaft Bearing Retainer D—Seventh Stage Clutch Shaft Bearing Retainer E—Input Shaft Alignment Fixture

Continued on next page

CTM168 (10DEC07)

02-35-115

OURX078,0000002 –19–07JUN05–3/13

18-Speed PST Repair Manual 121007

PN=215

02 35 ,115

Housings, Geartrain and Clutch Shafts Seventh Stage Clutch Shaft Assembly Remove transmission oil pump. (See Remove Transmission Oil Pump, Group 30.)

–UN–03JUN05

Remove bearing retainer cap screws (A).

YZ6209

A—Bearing Retainer Cap Screws (4 used) B—Plugs

OURX078,0000002 –19–07JUN05–4/13

Remove bearing retainer (A) and shim pack (B).

–UN–31MAY05

A—Bearing Retainer B—Shim Pack

YZ6210

02 35 ,116

Continued on next page

CTM168 (10DEC07)

02-35-116

OURX078,0000002 –19–07JUN05–5/13

18-Speed PST Repair Manual 121007

PN=216

Housings, Geartrain and Clutch Shafts NOTE: End play must be present to properly set end play. If end play is not present add .010 thousands shim to shims.

Install bearing retainer without shims.

02 35 ,117 –UN–03JUN05

Install and tighten four cap screws.

YZ6209

Specification Bearing Retainer-to-Front Housing Cap Screw—Torque........................................................ 2.8 N•m (25 lb-in)

Install clutch rotation tools. (See Install Clutch Rotation Tools, this group.)

Apply air pressure to engage clutches “2” and “B”.

Rotate shaft two complete turns clockwise; then rotate two complete turns counterclockwise.

Release air pressure.

Retighten cap screws.

Specification Bearing Retainer-to-Front Housing Cap Screw—Torque........................................................ 2.8 N•m (25 lb-in)

OURX078,0000002 –19–07JUN05–6/13

Install JDG1795 Seventh Stage End Play Adjustment Tool (A) and dial indicator tools (B).

YZ6211

–UN–31MAY05

A—JDG1795 Seventh Stage End Play Adjustment Tool B—Dial Indicator Tools

Continued on next page

CTM168 (10DEC07)

02-35-117

OURX078,0000002 –19–07JUN05–7/13

18-Speed PST Repair Manual 121007

PN=217

Housings, Geartrain and Clutch Shafts Install JDG1797 seventh stage pivot block and pry bar.

–UN–31MAY05 YZ6212

OURX078,0000002 –19–07JUN05–8/13

Install a standard socket under JDG1797 seventh stage pivot block as shown.

Move shaft assembly up using prybar and note the end play reading.

Remove tools, cap screws and bearing retainer.

–UN–03JUN05

C—Socket

YZ6216

02 35 ,118

A—JDG1797 Seventh Stage Pivot Block B—JDG1795 Seventh Stage End Play Adjustment Tool

Continued on next page

CTM168 (10DEC07)

02-35-118

OURX078,0000002 –19–07JUN05–9/13

18-Speed PST Repair Manual 121007

PN=218

Housings, Geartrain and Clutch Shafts

–UN–31MAY05

IMPORTANT: To obtain shim thickness for shimming add 0.064 mm (0.003 in.) to the average gap measurement. Refer back to Bearing Adjustment of Fifth and Sixth Clutch Stage Shaft Assemblies for how to obtain the average gap measurement.

Install determined shim pack (B).

YZ6210

Install bearing retainer (A).

A—Bearing Retainer B—Shim Pack

OURX078,0000002 –19–07JUN05–10/13

IMPORTANT: Tighten cap screws using a criss-cross pattern in two separate steps.

Install and tighten cap screws (A) in a criss-cross pattern.

–UN–03JUN05

Specification Bearing Retainer-to-Front Housing Cap Screw—Initial Torque ............................................................................................ 40 N•m (30 lb-ft)

YZ6209

Specification Bearing Retainer-to-Front Housing Cap Screw—Final Torque ............................................................................................ 80 N•m (60 lb-ft)

A—Bearing Retainer Cap Screws (4 used)

Continued on next page

CTM168 (10DEC07)

02-35-119

OURX078,0000002 –19–07JUN05–11/13

18-Speed PST Repair Manual 121007

PN=219

02 35 ,119

Housings, Geartrain and Clutch Shafts NOTE: Second, Third, Fourth and Seventh shaft stage assemblies will have thrust washers.

Install Thrust Washer (A).

Apply TY9370 High Strength Threadlock and Sealer to screw.

–UN–03JUN05

Install Screw (B).

YZ6217

A—Thrust Washer B—Screw

OURX078,0000002 –19–07JUN05–12/13

Tighten Screw.

–UN–03JUN05

Specification Screw-to-Shaft Assembly— Torque ..................................................................................... 54—80 N•m 40—59 (lb-ft)

YZ6218

02 35 ,120

OURX078,0000002 –19–07JUN05–13/13

Bearing Adjustment of Output Shaft

Front Housing

IMPORTANT: The output shaft MUST have the bearings set with the correct end play.

Item

Measurement

Specification

Output Shaft

End Play

0.02—0.12 mm (0.001—0.005 in.)

Continued on next page

CTM168 (10DEC07)

02-35-120

OURX078,000001A –19–02FEB01–1/7

18-Speed PST Repair Manual 121007

PN=220

Housings, Geartrain and Clutch Shafts Position the transmission in the rollover stand so that the shaft is in a vertical position.

–UN–27FEB01

Remove bearing retainer cap screws (A).

RXA0051643

A—Bearing Retainer Cap Screws (4 used)

OURX078,000001A –19–02FEB01–2/7

Remove bearing retainer (A) with O-ring (B).

Remove and discard O-ring.

–UN–01MAR01

Remove shims (C).

RXA0051499

A—Bearing Retainer B—Bearing Retainer O-Ring Oil Seal C—Shim Pack

Continued on next page

CTM168 (10DEC07)

02-35-121

OURX078,000001A –19–02FEB01–3/7

18-Speed PST Repair Manual 121007

PN=221

02 35 ,121

Housings, Geartrain and Clutch Shafts Install bearing retainer without oil seal, O-ring or shims.

RXA0051644

Specification Bearing Retainer-to-Front Housing Cap Screws—Torque ...................................................... 2.8 N•m (25 lb-in)

Install yoke to output shaft without installing the retaining components.

Rotate output shaft two complete turns clockwise; then rotate two complete turns counterclockwise.

Remove yoke and retighten cap screws.

RXA0051647

–UN–27FEB01

Specification Bearing Retainer-to-Front Housing Cap Screw—Torque........................................................ 2.8 N•m (25 lb-in)

OURX078,000001A –19–02FEB01–4/7

IMPORTANT: A gap measurement in more than one location must be taken to obtain an average reading.

–UN–27FEB01

Measure and record gap adjacent to each cap screw between front housing and bearing retainer using a feeler gage.

Add the four measurements and divide by four to determine the average measurement.

RXA0051645

02 35 ,122

–UN–27FEB01

Install and tighten four cap screws.

Remove cap screws and remove spacer and bearing retainer.

Continued on next page

CTM168 (10DEC07)

02-35-122

OURX078,000001A –19–02FEB01–5/7

18-Speed PST Repair Manual 121007

PN=222

Housings, Geartrain and Clutch Shafts IMPORTANT: To obtain shim thickness for shimming add 0.064 mm (0.003 in.) to the average gap measurement.

–UN–01MAR01

Install determined shim pack (C).

Install new oil seal (B) in bearing retainer (A).

RXA0051499

Install bearing retainer with O-ring.

A—Bearing Retainer B—Bearing Retainer O-Ring Oil Seal C—Shim Pack

OURX078,000001A –19–02FEB01–6/7

IMPORTANT: Tighten cap screws using a criss-cross pattern in two separate steps.

–UN–27FEB01

Install and tighten cap screws in a criss-cross pattern.

RXA0051644

Specification Bearing Retainer-to-Front Housing Cap Screw—Initial Torque ............................................................................................ 40 N•m (30 lb-ft) Specification Bearing Retainer-to-Front Housing Cap Screw—Final Torque ............................................................................................ 80 N•m (60 lb-ft)

OURX078,000001A –19–02FEB01–7/7

Bearing Adjustment of Input Shaft IMPORTANT: All clutch stage shaft assemblies MUST have the bearings set with the correct end play.

Item

Measurement

Specification

Clutch Stage Shaft Assemblies

End Play

0.02—0.12 mm (0.001—0.005 in.)

Continued on next page

CTM168 (10DEC07)

02-35-123

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PN=223

02 35 ,123

Housings, Geartrain and Clutch Shafts Position the transmission in the rollover stand so the shaft is in a vertical position

–UN–27FEB01

Remove bearing retainer cap screws (A).

RXA0051650

A—Bearing Retainer Cap Screws (4 used)

DPSG,YZ07927,167 –19–19AUG99–2/7

Remove bearing retainer (A) with O-ring (B).

–UN–05FEB01

Remove oil seal from inner diameter of retainer and discard.

Remove O-ring (B) from retainer and discard.

Remove shims (C).

RXA0051498

02 35 ,124

Install pump drive cover. (See Install Pump Drive Cover, Group 30.)

A—Bearing Retainer B—O-Ring Oil Seal C—Shim Pack

Continued on next page

CTM168 (10DEC07)

02-35-124

DPSG,YZ07927,167 –19–19AUG99–3/7

18-Speed PST Repair Manual 121007

PN=224

Housings, Geartrain and Clutch Shafts Install bearing retainer without oil seal, O-rings or shims.

Install and tighten four cap screws.

–UN–27FEB01

Specification Bearing Retainer-to-Front Housing Cap Screw—Torque........................................................ 2.8 N•m (25 lb-in)

RXA0051651

Install yoke to input shaft without installing the retaining components.

Rotate input shaft two complete turns clockwise; then rotate two complete turns counterclockwise.

Remove the yoke.

–UN–27FEB01

Retighten cap screws.

RXA0051649

Specification Bearing Retainer-to-Front Housing Cap Screw—Torque........................................................ 2.8 N•m (25 lb-in)

DPSG,YZ07927,167 –19–19AUG99–4/7

IMPORTANT: A gap measurement in more than one location must be taken to obtain an average reading.

–UN–27FEB01

Measure and record gap adjacent to each cap screw between front housing and bearing retainer using a feeler gage.

RXA0051652

Add the four measurements and divide by four to determine the average measurement.

Remove cap screws and remove bearing retainer.

Continued on next page

CTM168 (10DEC07)

02-35-125

DPSG,YZ07927,167 –19–19AUG99–5/7

18-Speed PST Repair Manual 121007

PN=225

02 35 ,125

Housings, Geartrain and Clutch Shafts

Install determined shim pack (C).

RXA0051498

Lubricate new O-ring (B) with transmission fluid and install to bearing retainer (A).

Install bearing retainer.

A—Bearing Retainer B—O-Ring Oil Seal C—Shim Pack

DPSG,YZ07927,167 –19–19AUG99–6/7

IMPORTANT: Tighten cap screws using a criss-cross pattern in two separate steps.

Specification Bearing Retainer-to-Front Housing Cap Screw—Initial Torque ............................................................................................ 40 N•m (30 lb-ft) Specification Bearing Retainer-to-Front Housing Cap Screw—Final Torque ............................................................................................ 80 N•m (60 lb-ft)

–UN–27FEB01

Install and tighten cap screws in a criss-cross pattern.

RXA0051651

02 35 ,126

–UN–05FEB01

IMPORTANT: To obtain shim thickness for shimming add 0.064 mm (0.003 in.) to the average gap measurement.

DPSG,YZ07927,167 –19–19AUG99–7/7

CTM168 (10DEC07)

02-35-126

18-Speed PST Repair Manual 121007

PN=226

Section 03

Theory of Operation Contents Page

Group 20—Theory of Operation Transmission Operation . . . . . . . . . . . . . . . . . .03-20-1 Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . .03-20-2 Clutch Actuation . . . . . . . . . . . . . . . . . . . . . . . .03-20-3 Gear Train Operation . . . . . . . . . . . . . . . . . . . .03-20-4 Directional and Speed Clutch Operation . . . . . .03-20-6 Range Clutch Operation . . . . . . . . . . . . . . . . . .03-20-8 Internal Park Brake Operation . . . . . . . . . . . . .03-20-10 Transmission Hydraulic Diagram . . . . . . . . . . .03-20-12 Transmission Hydraulic Diagram - Internal Park Brake Model . . . . . . . . . . . . . . . . . . . .03-20-14 Transmission Pump Operation . . . . . . . . . . . .03-20-16 Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . . .03-20-17 Main Regulator Valve . . . . . . . . . . . . . . . . . . .03-20-18 Main Regulator Valve Operation . . . . . . . . . . .03-20-20 Proportional Solenoid Valve Operation . . . . . .03-20-22 Powershift Control Unit . . . . . . . . . . . . . . . . . .03-20-24

CTM168 (10DEC07)

03-1

03

18-Speed PST Repair Manual 121007

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Contents

03

CTM168 (10DEC07)

03-2

18-Speed PST Repair Manual 121007

PN=2

Group 20

Theory of Operation Transmission Operation The engine is connected to the input shaft of the transmission. The Powershift transmission (PST) has 18 speeds forward and 6 reverse speeds. When the transmission is in gear, the engine power is connected to the output shaft of the transmission at different speed ratios depending on which directional, speed and range clutches are engaged. Each clutch is engaged hydraulically and controlled by an individual

proportional valve. The rate of pressure rise behind each clutch piston is determined by the Powershift Control Unit (PCU) providing the current to each valve.

The engine power may be disconnected from the transmission output shaft by depressing the clutch pedal or by shifting the transmission to the neutral or park position.

YZ07927,0000022 –19–01FEB01–1/1

CTM168 (10DEC07)

03-20-1

18-Speed PST Repair Manual 121007

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03 20 1

Theory of Operation

Gear Selection Three clutches—one directional, one speed and one range—must be engaged in order to transmit torque from the transmission input to the transmission output shaft. In neutral all clutches are disengaged.

The following table shows which clutches are engaged in each gear.

03 20 2

18-SPEED PST GEAR TABLE Gear

Clutches Engaged

Gear Ratio

1F

1AL

4.648

2F

2AL

3.776

3F

1AM

3.410

4F

1BL

3.054

5F

2AM

2.771

6F

2BL

2.481

7F

1BM

2.241

8F

1CL

2.007

9F

2BM

1.821

10F

2CL

1.631

11F

1CM

1.473

12F

1AH

1.333

13F

2CM

1.197

14F

2AH

1.083

15F

1BH

0.876

16F

2BH

0.712

17F

1CH

0.576

18F

2CH

0.468

N

-

-

1R

RAL

4.648

2R

RAM

3.410

3R

RBL

3.054

4R

RBM

2.241

5R

RCL

2.007

6R

RCM

1.473

YZ07927,000002F –19–01FEB01–1/1

CTM168 (10DEC07)

03-20-2

18-Speed PST Repair Manual 121007

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Theory of Operation

Clutch Actuation Hydraulic oil pressure is directed from the proportional valve, through passages in the rear housing, to the seal rings on the end of the clutch shaft. The oil pressure is transferred from the stationary housing to the rotating shaft in the area between the shaft seal rings. The oil then travels down a hole in the shaft until it enters the area enclosed by clutch shaft weldment, the clutch apply piston and the piston seals. Here it acts on the piston area, causing it to move toward the

clutch pack, compressing the clutch return springs, and removing the free clearance in the clutch. The piston also moves the lube shut-off washer, trapped between the piston and the clutch return springs, causing it to uncover the lube holes that provide increased cooling oil flow to the clutch. Once the free clearance in the clutch is eliminated, the piston applies pressure to the clutch plates, causing the clutch to transmit torque in 03 proportion to the oil pressure applied.

20 3

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03-20-3

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Theory of Operation

Gear Train Operation

YZ5051

–UN–24JUN03

03 20 4

A—First Stage (Input) Shaft Assembly B—Second Stage Shaft Assembly (A, 2)

C—Third Stage Shaft Assembly (B, 1) D—Fourth Stage Shaft Assembly (C, R)

E—Fifth Stage Shaft Assembly (L) F—Sixth Stage Shaft Assembly (H)

The clutches labeled “1”, “2” and “R” are referred to as directional clutches. Clutches “1” and “2” will engage forward gears and clutch “R” will engage reverse gears. The directional clutches connect the input shaft of the transmission through various ratios to the cylinder gears located in the upper part of the transmission. Directional clutches are located opposite the seal ring side of the double clutch stage assemblies. These clutches have two passages through the shaft in order to supply the “lube flow” to cool the clutches.

Clutches “A”, “B” and “C” are referred to as speed clutches. The speed clutches connect the cylinder gear

G—Seventh Stage Shaft Assembly (M) H—Output Shaft Assembly

train to the range clutches of the transmission.

Working in conjunction with the directional clutches up to 18 speed ranges in forward and 6 speed ranges in reverse are possible. The speed clutches are located on the seal ring side of the double clutch stage assemblies in the upper part of the transmission.

Clutches “L”, “M” and ”H” are referred to as range clutches. They are single clutches located in the lower portion of the transmission and have three lube passages for cooling. These clutches are used for modulation during the shift and when using the clutch pedal.

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03-20-4

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Theory of Operation

03 20 5

CTM168 (10DEC07)

03-20-5

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Theory of Operation

Directional and Speed Clutch Operation

YZ3321

–UN–08MAR01

03 20 6

A—Lube Passage B—Seal Rings C—System Pressure Passage

D—Lube Shutoff Washer E—Clutch and Separator Plates

F—Directional Clutch G—Piston

Continued on next page

CTM168 (10DEC07)

03-20-6

H—Speed Clutch

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PN=234

Theory of Operation Directional and speed clutches are located in the upper part of the transmission. Directional and speed clutches make up the double clutch shaft assemblies.

The directional clutches are located opposite the seal ring end. The speed clutches are located on the seal ring end of the shaft assembly.

Directional Clutches Directional clutches (F) are designated 1, 2 and R. Clutches 1 and 2 engage forward gears, clutch R engages reverse gears. Directional clutches are modulated along with the range clutches when using the clutch pedal.

The clutch pressure oil passage (C) is used to engage the clutch piston. The clutch pressure oil for each clutch is kept separated by the clutch shaft seal rings (B). The piston applies pressure to the clutch and separator plates (E) using clutch pressure oil against the piston (G). Once the free clearance between the clutch and separator plates is eliminated the clutch transmits applied torque in proportion to the oil pressure.

The lubrication oil enters the shaft through an axially drilled hole. Lubrication oil comes from the cooler through oil passages in the rear housing into lube passages (A) in the shaft assembly.

When the clutch is disengaged, system pressure oil becomes pressure-free oil and remains in the passages, ready to be pressurized again.

Speed Clutches Speed clutches (H) are designated A, B, and C. System pressure oil passage (C) is used to engage the clutches. The oil pressure for each clutch is kept separated by the clutch shaft seal rings (B). The piston applies pressure to the clutch and separator plates once the free clearance between the clutch and separator plates is eliminated and the clutch transmit torque in proportion to the oil pressure applied. When the clutch piston is engaged, the lube shut-off washer (D) moves to uncover the oil passage allowing more lubrication to the clutch.

Lubrication oil comes from the cooler through oil passages in the main case rear housing. The lubrication oil enters the shaft through an axially drilled hole. All clutches have a lubrication shut-off washer (D) that restricts lubrication oil flow to the clutch when it is not engaged. The extra oil flow provides additional lubrication and cooling.

When the clutch is disengaged, clutch pressure oil becomes pressure free-oil and remains in the passages ready to be pressurized again.

Range Clutches Range clutches L, M, and H are located in the lower part of the transmission, on the single-clutch shafts.

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CTM168 (10DEC07)

03-20-7

18-Speed PST Repair Manual 121007

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03 20 7

Theory of Operation

Range Clutch Operation

YZ3320

–UN–07MAR01

03 20 8

A—Sealing Ring B—Passage to Lubricate Clutch and Separator Plates

C—Clutch and Separator Plates D—Cross Section of Shaft Assembly

E—Oil to Sump F—Seal Ring End of Shaft G—Clutch Piston H—Shutoff Washer

Continued on next page

CTM168 (10DEC07)

03-20-8

I—Seal Rings J—Clutch Pressure Passage K—Lube Passage

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Theory of Operation Range clutches have a third lube passage in the shaft to provide additional flow for cooling. They also have more clutch and separator plates (C) than in the directional and speed clutches. The extra plates provide more friction area and higher thermal capacity.

These clutches are modulated along with directional clutches during shifting and inching pedal operations.

Range clutches have a sealing ring (A) that helps contain oil in the clutch. This causes the lubrication oil (K) to flow mainly through the holes in the clutch gear hub (B) to the clutch and separator plates (C) and out the holes in the clutch cylinder (E) back to sump. All clutches have a lubrication shut-off washer (H) that restricts lubrication oil flow to the clutch when it is not engaged.

When the clutch is engaged, the piston (G) moves to apply pressure to the clutch plates and at the same

time moving the lubrication shut-off washer and uncovering the oil passage, allowing more lubrication to the clutch pack. The extra oil flow provides additional lubrication and cooling.

Clutch pressure oil (J) is used to engage the clutches.

Lubrication oil (K) comes from the cooler through oil passages in the rear housing. The oil pressures for each clutch are kept separated by the clutch shaft seal rings (I). The lubrication oil enters the shaft through an axially drilled hole. Once the free clearance between the clutch and separator plates is eliminated, the piston applies pressure to the clutch and separator plates, causing the clutch to transmit torque in proportion to the oil pressure applied. When the clutch is disengaged, clutch pressure oil becomes pressure free-oil and remains in the passages ready to be pressurized again.

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CTM168 (10DEC07)

03-20-9

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03 20 9

Theory of Operation

Internal Park Brake Operation

YZ5061

–UN–10JUL03

03 20 10

A—Transmission Rear Housing B—Transmission Output Shaft

C—Brake Disk D—Oil Passage E—Piston

F—Springs G—Disks and Plates H—Separator Plates

I—Internal Park Brake Assembly

The internal park brake assembly (I) is located on the rear end of the transmission output shaft (B). The brake disks (C) are splined to a hub on the output shaft and the separator plates (H) are tabbed to the transmission rear housing (A).

The park brake is OFF when system pressure oil moves from the parking brake valve through the oil passage (D). The system pressure oil moves the piston against the springs and releases the brake disks (C) and plates.

The park brake is ON when there is no hydraulic pressure applied to the piston (E). The spring (F) applies pressure to the piston forcing the brake disks and plates (G) together. This locks the transmission output shaft to the rear housing.

Park brake components are cooled and lubricated by transmission oil moving through passages in the transmission housings.

Continued on next page

CTM168 (10DEC07)

03-20-10

YZ07927,00000D7 –19–09JUL03–1/2

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PN=238

Theory of Operation The park brake is spring applied and hydraulically released. This multi-plate brake is immersed in an oil filled chamber located on the transmission. It is

connected to and holds the transmission output shaft stationary to prevent drive train rotation when applied.

YZ07927,00000D7 –19–09JUL03–2/2

03 20 11

CTM168 (10DEC07)

03-20-11

18-Speed PST Repair Manual 121007

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Theory of Operation

Transmission Hydraulic Diagram

YZ3322

–UN–26SEP01

03 20 12

A—Park Brake Release B—To PTO Lube C—Transmission Lube D—Lube Bypass E—Cooler Bypass F—Main Regulator G—Filter Element

H—Pressure Sensor I—Switch J—Transmission Pump K—Suction Screen L—Stand Pipe M—From Steering Return (LTV Only)

N—To Axle Lube Pump O—From Axle Lube (4WD Only) P—Filter Assembly Q—Filter Bypass R—To Cooler

Continued on next page

CTM168 (10DEC07)

03-20-12

S—From Cooler T—Sump U—To Supplement Steering Charge V—Diff. Lock W—To PTO Control

YZ07927,00000C0 –19–13MAR01–1/2

18-Speed PST Repair Manual 121007

PN=240

Theory of Operation

YZ3323

–UN–26SEP01

03 20 13

T—Sump

X—Proportional Solenoid

Y—Clutches YZ07927,00000C0 –19–13MAR01–2/2

CTM168 (10DEC07)

03-20-13

18-Speed PST Repair Manual 121007

PN=241

Theory of Operation

Transmission Hydraulic Diagram - Internal Park Brake Model

YZ5084

–UN–07AUG03

03 20 14

Continued on next page

CTM168 (10DEC07)

03-20-14

YZ07927,00000F0 –19–07AUG03–1/2

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PN=242

Theory of Operation 1—To PTO Control 2—To DIFF Lock 3—To Supplement Steering Charge Pump (Track only) 4—Transmission Lube 5—From Cooler 6—To Cooler 7—Filter Bypass 4.0 Bar

8—From Axle Lube (4WD Only) 9—To Axle Lube Pump 10—From Steering Pump (Track Only) 11—Rear Housing 78.6 cc/rev 12—Filter Head 13—Elment

14—Bypass Indicator 3.4 Bar 15—Regulator 19.3 Bar 16—Cooler Bypass 6.2 Bar 17—Lube Bypass 6.2 Bar 18—Inlet Check Valve 19—S2 Solenoid 20—S1 Solenoid 21—To Cab Connection Point

22—Port Orifice 23—Pressure Transducer 24—Park Brake Clutch 25—Park Brake Relief 22.4 Bar 26—Pressure Transducer 27—Clutches 28—Sump

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03-20-15

18-Speed PST Repair Manual 121007

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03 20 15

Theory of Operation

Transmission Pump Operation

–UN–01FEB01

A—Cover-to-Housing Cap Screw B—Cover C—Housing

RXA0051489

03 20 16

Older Style Transmission Oil Pump

YZ07927,000002D –19–15AUG03–1/2

YZ5059

–UN–01JUL03

The transmission gear pump draws oil from the transmission sump through a suction screen. It travels through an internal suction tube to the inlet side of the pump. The pump is an internal gear pump with fixed clearance. The gear shafts are supported by bushings.

The pump is driven by a gear train directly coupled to the engine and has a minimum flow of 63.5 L/m (16.8 gpm) at 1000 engine rpm. It must maintain operating pressure and deliver maximum flow of 208 L/m or (55 gpm) at 2240 engine rpm. Nominal flow at 2100 engine rpm is 190 L/m (50 gpm)

Newer Style Transmission Oil Pump

YZ07927,000002D –19–15AUG03–2/2

CTM168 (10DEC07)

03-20-16

18-Speed PST Repair Manual 121007

PN=244

Theory of Operation

Oil Filter Head

YZ1990

–UN–30NOV00

03 20 17

A—System Pressure (filtered) Oil

B—Bypass Valve C—Pressure Switch

D—Oil from Oil Pump

From the pump the oil is directed to a filter assembly.

Under normal operation the oil flows into the filter head (D) down through the filter (not shown) and out the system pressure port (A). Under extreme cold or when the filter element is at or near its capacity, the bypass valve (B) will open and allow unfiltered oil to pass into the lube circuit by flowing out the bypass oil port (E).

The bypass valve works by sensing the pressure on the inlet side of the filter (D) and the outlet side of the

E—Bypass Oil (unfiltered) to Lube

filter (A). If the difference in pressure is greater than 415 kPa (60 psi) the bypass valve will open and allow unfiltered oil to pass only to the lube circuit (E). This will reduce the inlet pressure to protect the filter from over-pressurization. The filter head also contains a pressure switch (C) that senses the same pressures the bypass valve (B) does. Before the bypass valve opens, the pressure switch will activate at 345 kPa (50 psi) and warn the operator of impending filter bypass.

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CTM168 (10DEC07)

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18-Speed PST Repair Manual 121007

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Theory of Operation

Main Regulator Valve

The oil cooler is supplied the remaining oil, and that oil is cooled before being returned to the transmission to be used to lubricate all of the clutches, and bearings. The oil cooler is supplied by the vehicle manufacturer and must be able to flow up to 55 gpm oil at a pressure up to 2000 kPa (290 psi). It should be sized to provide sufficient cooling in maximum ambient operating temperatures.

YZ3981

–UN–09APR03

Filtered oil from the filter assembly is directed into the rear transmission housing. The main regulator valve is teed into the main system pressure along with the proportional solenoids and the pressure sensor. The main regulator works to give the regulated pressure circuit priority over the cooler circuit. Any oil not needed to maintain 1790-1930 kPa (260-290 psi) is allowed to flow through the regulator valve and into the cooler circuit. The 03 regulated pressure is used to fill and engage clutches, 20 and make up the leakage in engaged clutches and the 18 proportional solenoids.

A—Main Regulator Valve

YZ07927,000010F –19–30JUN03–1/1

CTM168 (10DEC07)

03-20-18

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PN=246

Theory of Operation

03 20 19

CTM168 (10DEC07)

03-20-19

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Theory of Operation

Main Regulator Valve Operation

YZ5083

–UN–06AUG03

03 20 20

A—Spool B—Cooler Pressure Port C—Sump Port

D—Shims Springs E—Outer Compression Spring F—Inner Compression Spring

System pressure oil (J) flows from the transmission oil filter and enters the pressure regulator valve at the inlet port (I). The cooler pressure port (B) remains closed until sufficient pressure is reached. The regulated pressure acts on the open end of the spool (A). The force from on the spool is counter acted by the springs on the opposite side of the spool. The pressure is determined by the preload of the springs

G—O-ring (Dampening Seals) H—Snap Ring I—Inlet Port

J—System Pressure Oil K—Low Pressure Oil L—Pressure Free Oil

captured between the spool and the plug at the other end of the cartridge. Once the regulated pressure is met, the spool will open and let all of the extra oil into the cooler circuit. Any drops in regulated pressure will cause the spool to close the cooler port to try and maintain regulated pressure. Any oil that leaks past the spool is returned to tank through the sump port (C).

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CTM168 (10DEC07)

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Theory of Operation

03 20 21

CTM168 (10DEC07)

03-20-21

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PN=249

Theory of Operation

Proportional Solenoid Valve Operation

YZ3426

–UN–24JUL01

03 20 22

A—Solenoid Coil B—Armature C—Push Pin D—Ball E—Seat

F—Sump Port G—Spool H—Clutch Port I—Inlet Supply

J—Spring K—Screen L—Orifice M—Pilot Cavity

The proportional solenoid valve (P) is a pilot operated, pressure-reducing cartridge valve. Its function is to provide a regulated pressure to the clutch port that can be controlled by the Powershift Control Unit (PCU) to a pressure less than the supply pressure. Variations in inlet pressure will not affect the regulated pressure setting as long as the inlet pressure remains higher than the desired regulated pressure.

In operation, supply pressure enters the inlet supply port (I) where it is blocked by a spool (G) which prevents the flow from going to the clutch port (H). The inlet supply must pass through a filter screen (K) before reaching the orifice (L). The filter screen is used

to trap large particles, preventing them from contaminating the orifice. The orifice is used to meter the inlet flow into the pilot cavity (M). The passage from the inlet supply port is always open to the pilot cavity, regardless of the spool position, to maintain a pressure source to the pilot cavity.

Pilot cavity operation enables the valve to work at a current level that the PCU is capable of controlling.

The armature (B), push pin (C), and ball (D) configuration controls the pilot cavity pressure which in turn provides the force required to move the main spool.

Continued on next page

CTM168 (10DEC07)

N—System Pressure Oil O—Pressure Free Oil P—Proportional Solenoid Valve—De-Energized

03-20-22

YZ07927,0000021 –19–01FEB01–1/2

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PN=250

Theory of Operation With the solenoid valve de-energized, flow is free to travel from the clutch port (H) to the sump port (F).

The orifice (L) is used to meter the flow into the pilot cavity (M). Flow coming into the pilot cavity then passes through the seat (E) and past the ball (D) which is in the open position when the solenoid coil (A) is de-energized. This flow then travels out through slots on the outside threads of the valve to connect to the sump port (F).

Because the ball has no restriction to the flow of fluid exiting the pilot cavity, no pressure is built up in the pilot cavity to act against the spool end. A bias spring (J) is located on the opposite end of the spool to maintain spool position and prevents any slight pressure build up from actuating the clutch. The bias spring requires a nominal pressure of 83 KPa (.008273 bar) (12 psi) to start spool movement.

To provide proportional control, the solenoid coil (A) is energized by the use of a pulse-width-modulated (PWM) signal by a varying duty cycle of 0% to 100%.

The increased duty cycle acts to increase the effective current in the solenoid coil windings (A) causing an increase in the magnetic force. As the duty cycle

increases, the magnetic force on the armature (B) increases, causing the push pin (C) to push against the ball (D) to restrict flow exiting the pilot cavity (M).

This restriction causes a rise in pressure in the pilot cavity (M) and applies a force on the end of the main spool (G), causing it to move and compress the spring (J). As the spool (G) moves, it closes the passage from the clutch port (H) to the sump port (F) and begins to open slightly the supply pressure port (I).

The flow of oil causes the pressure in the clutch to rise.

The clutch port pressure is fed to the spring end of the main spool via the feedback passage causing the main spool to close as the clutch pressure and spring force becomes equal to the pilot cavity pressure. The output pressure from the valve is zero at zero current and increases to within 103 kPa (1 bar) (15 psi) of the inlet pressure as the current to the coil is increased. At approximately 100% duty cycle, the ball (D) rests against the seat (E); the flow past the seat is essentially stopped; and the pressure in the pilot cavity (M) is the same as the supply pressure at the inlet supply port (I) minus the bias pressure from the spring.

YZ07927,0000021 –19–01FEB01–2/2

CTM168 (10DEC07)

03-20-23

18-Speed PST Repair Manual 121007

PN=251

03 20 23

Theory of Operation

Powershift Control Unit The Powershift Control Unit (PCU) controls the transmission. Its main functions are:

designed algorithm to determine the best fill time and hold pressures for each.

1. Clutch control for shifting and calibration 2. Park brake control 3. Monitoring transmission solenoids, sensors and operator commands 4. Communication with other devices on the tractor 03 • Engine Control Unit (ECU).

20 • Chassis Control Unit (CCU).

24 • Armrest Control Unit (ACU).

• Instrument Cluster Unit (ICU).

• Corner Post Display (CPD).

5. Reporting operational status and diagnostics information.

Park Brake Control The PCU controls the tractor’s park brake based on present operating conditions and the operator’s command, as received from the ACU. The park brake is spring-applied and hydraulically released.

Clutch Control for Shifting and Calibration • The PCU uses electrohydraulic proportional valves to engage and disengage the transmission clutches, which are arranged in a 3 x 3 x 3 design: • 1, 2, R - Directional • A, B, C - Speed • L, M, H - Range The solenoid on each valve is driven by a pulse-width modulated signal from the PCU that produces proportional pressure changes. The electrical current in each solenoid is monitored by the PCU and is increased or decreased to maintain the commanded setpoint, and therefore the proper clutch pressure.

Modulating the solenoid drive signal and monitoring the solenoid current greatly enhances shift quality.

Shift commands from the operator are sent by the ACU to the PCU via the CCD bus. Based on the command and the present operating conditions, the PCU will engage and disengage the appropriate clutches.

The PCU has a separate operating mode used during transmission calibration. During calibration the PCU controls the clutches automatically per a carefully

The PCU has a special and separate control system within it called the Park brake Backup Controller (PBC). The purpose of the PBC is to make sure that if power is lost to the PCU while the tractor is moving, the park brake will not engage until the tractor has slowed down. The PBC has its own separate supply voltage and output speed sensor, and drives one of the two park solenoids. The PCU monitors the other output speed sensor, controls the other park solenoid, and monitors the park brake pressure.

Both park solenoids must be on to release the park brake. The PCU and PBC maintain a system of checks-and-balances to ensure that the two output speed sensors are in agreement and that the status of the park solenoids is correct for the present operating conditions. Both solenoids must be off to engage Park.

Monitoring Transmission Solenoids, Sensors and Operator Commands • The PCU monitors all components critical to transmission operation and control: • Clutch solenoids • Speed sensors • Transmission oil temperature • Transmission system pressure • Park solenoids • Park brake pressure • Clutch pedal position • Clutch pedal switch states • CAN communications bus information • CCD communications bus information

Continued on next page

CTM168 (10DEC07)

03-20-24

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18-Speed PST Repair Manual 121007

PN=252

Theory of Operation Communication with Other Devices on the Tractor The PCU is only one of several controllers on the tractor, each having its own specific function. The PCU communicates with several of these devices by various means, receiving information from and/or supplying information to them.

1. With the ECU, via CAN bus • Engine speed and torque to the PCU. • Transmission sump temperature to the ECU. 2. With the CCU, via CCD bus • “PCU present and working” message, vehicle model and serial number information, engine speed, transmission oil temperature, status of clutch pedal, throttle position, and PTO • Output speed information to CCU via a frequency signal.

3. With the ACU, via CCD bus • Commanded gear and speedmatch gear 4. With the ICU, via CCD bus • Alarms, warnings, diagnostic codes to the ICU 5. With the CPD, via CCD bus • Present gear information, calibration diagnostic and status data to the CPD The CAN and CCD busses are critical serial communications lines that link the various controllers on the tractor. While the PCU can communicate using either bus, the other devices are capable of just one type. CAN is considerably faster than CCD. See “PCU System Interface” in “General References” for devices communicating with the PCU.

functions. The PCU generates a diagnostic code to indicate potential problems. Depending on the severity of the fault, the fault response and alarm level vary accordingly. A minor fault may result in only an informational indication to the operator, while a major fault may require the operator to stop the engine until the problem is resolved.

The PCU reports diagnostic codes related to these areas: 03 20 25

• The clutch solenoids • The transmission speed sensors • Transmission oil temperature and system pressure sensors • The park brake system • The clutch pedal and switches • Calibration • PCU self-checks • Shift lever position and relay logic The presently active diagnostic code may be viewed on the ICU during normal operation or while in diagnostic mode.

In addition to reporting diagnostic codes during normal operation, the PCU has a special diagnostic mode which provides the ability to perform first-step troubleshooting of the sensors, solenoids, clutch pedal, and relay logic. Diagnostic mode also makes it possible to retrieve certain information about the PCU, the tractor model and serial number, and any diagnostic codes that may have been stored.

Information is conveyed to the operator via the CPD while in diagnostic mode rather than via the ICU.

Reporting Operational Status and Diagnostics Information Reporting operational status and diagnostic information to the operator is one of the PCU’s most important

YZ07927,0000023 –19–03JUL03–2/2

CTM168 (10DEC07)

03-20-25

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PN=253

Theory of Operation

03 20 26

CTM168 (10DEC07)

03-20-26

18-Speed PST Repair Manual 121007

PN=254

Section 05

Tools and Other Materials Contents Page

Group 175—Special Tools Essential Tools For JDG9x20PST . . . . . . . . . .05-175-1 Essential Tools for JDG9x20PSTWB. . . . . . . .05-175-6 Other Material . . . . . . . . . . . . . . . . . . . . . . . . .05-175-8 Group 195—Dealer Fabricated Tools DFRW146 Relief Valve Removal Tool. . . . . . .05-195-1 Guide Pins For Front And Rear Housing . . . . .05-195-1 Guide Pin for Shims, Caps and Pump Housings . . . . . . . . . . . . . . . . . . . . . . . . . . .05-195-2

CTM168 (10DEC07)

05-1

05

18-Speed PST Repair Manual 121007

PN=1

Contents

05

CTM168 (10DEC07)

05-2

18-Speed PST Repair Manual 121007

PN=2

Group 175

Special Tools Essential Tools For JDG9x20PST Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company

YZ07927,00003E0 –19–05DEC07–1/26 RW37204 –UN–15JUN99

Engine Rollover Stand . . . . . . . . . . . . . . . . D05223ST 05 175 1

Disassemble and Assemble Transmission

YZ07927,00003E0 –19–05DEC07–2/26 RW25560 –UN–29AUG96

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . JDG19 Attach transmission assembly to lifting device

YZ07927,00003E0 –19–05DEC07–3/26 RW25383 –UN–02APR96

Yoke Holding Tool . . . . . . . . . . . . . . . . . . . . . JDG924 Remove and install yokes

YZ07927,00003E0 –19–05DEC07–4/26 RW25381 –UN–14JUN95

Bearing Installer . . . . . . . . . . . . . . . . . . . . . JDG926A Install input and output shaft oil seals. Use with JDG1487A Seal Installer Plate.

YZ07927,00003E0 –19–05DEC07–5/26

Engine Rollover Stand Bracket. . . . . . . . . . . . JDG1476

RXA0051546

–UN–12FEB01

Install transmission to engine rollover stand

Continued on next page

CTM168 (10DEC07)

05-175-1

YZ07927,00003E0 –19–05DEC07–6/26

18-Speed PST Repair Manual 121007

PN=257

Special Tools RW25388 –UN–15JUN95

Seal Installer Plate . . . . . . . . . . . . . . . . . . JDG1487A Install input and output shaft seals. Use with JDG926A Bearing Installer.

YZ07927,00003E0 –19–05DEC07–7/26

Pump Drive Gear Installer . . . . . . . . . . . . . . JDG1472A

–UN–20FEB01

Install pump drive gear to input shaft

RXA0051452

05 175 2

YZ07927,00003E0 –19–05DEC07–8/26

Pump Drive Gear Puller . . . . . . . . . . . . . . . . JDG1473

RXA0051547

–UN–13FEB01

Remove pump drive gear from input shaft

YZ07927,00003E0 –19–05DEC07–9/26 RXA0051446 –UN–20FEB01

Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . JDG1106 Remove and install clutch stage shafts to nest fixture

YZ07927,00003E0 –19–05DEC07–10/26 RXA0051447 –UN–20FEB01

Eyebolt . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1112 Remove and install output shaft to transmission front housing Continued on next page

CTM168 (10DEC07)

05-175-2

YZ07927,00003E0 –19–05DEC07–11/26

18-Speed PST Repair Manual 121007

PN=258

Special Tools Clutch Stack Nest Fixture . . . . . . . . . . . . . . . JDG1470

RXA0051448

–UN–20FEB01

Hold clutch shaft assemblies for access for disassembly

YZ07927,00003E0 –19–05DEC07–12/26

Clutch Stack Lifting Fixture . . . . . . . . . . . . . . JDG1471 05 175 3

RXA0051450

–UN–20FEB01

Remove and install clutch shaft assemblies to transmission front housing

YZ07927,00003E0 –19–05DEC07–13/26 RXA0051456 –UN–20FEB01

Roller Ball Bearing Installer . . . . . . . . . . . . . . JDG1474 Install roller ball bearings to clutch shafts. Use with JDG1485 Clutch Piston Return Spring Compressor.

YZ07927,00003E0 –19–05DEC07–14/26 RXA0051458 –UN–20FEB01

Clutch Disk Alignment Guide . . . . . . . . . . . . . JDG1475 Align clutch disks for clutch shaft assembly

YZ07927,00003E0 –19–05DEC07–15/26

Puller Legs . . . . . . . . . . . . . . . . . . . . . . . . JDG1477

RXA0051462

–UN–20FEB01

Remove roller ball bearings from clutch shafts

Continued on next page

CTM168 (10DEC07)

05-175-3

YZ07927,00003E0 –19–05DEC07–16/26

18-Speed PST Repair Manual 121007

PN=259

Special Tools RXA0051466 –UN–20FEB01

Sealing Ring Sleeve Installer . . . . . . . . . . . . . JDG1479 Install sealing ring sleeves in transmission rear housing

YZ07927,00003E0 –19–05DEC07–17/26 RXA0051470 –UN–20FEB01

Input Shaft Alignment Fixture. . . . . . . . . . . . . JDG1481 Position input shaft during bearing endplay setting rotating procedure YZ07927,00003E0 –19–05DEC07–18/26 RXA0051472 –UN–20FEB01

Shaft Protector . . . . . . . . . . . . . . . . . . . . . . JDG1482 Protect sealing ring end of clutch shaft assemblies during disassembly YZ07927,00003E0 –19–05DEC07–19/26

Clutch Rotation Tools. . . . . . . . . . . . . . . . . . JDG1486

A

Engage shaft clutches to allow clutch shaft rotation A—JDG1486-1 Hose Assembly B—JDG1486-2 Input Fitting Assembly C—Quick Coupler Fitting (Dealer Furnished)

B C

–UN–30APR01

B

RXA0052923

05 175 4

YZ07927,00003E0 –19–05DEC07–20/26 RXA0051463 –UN–23FEB01

Transmission Rear Cover Lifting Bracket . . . . . JDG1489 Remove and install transmission rear housing to front housing YZ07927,00003E0 –19–05DEC07–21/26 RXA0051548 –UN–12FEB01

Sealing Ring Sleeve Remover . . . . . . . . . . . . JDG1490 Remove sealing ring sleeves from transmission rear housing Continued on next page

CTM168 (10DEC07)

05-175-4

YZ07927,00003E0 –19–05DEC07–22/26

18-Speed PST Repair Manual 121007

PN=260

Special Tools JDG1974 Bore Sleeve Puller Kit. . . . . . . . . . . JDG1974

YZ6251

–UN–11OCT05

Remove Sealing ring sleeves from transmission rear housing.

YZ07927,00003E0 –19–05DEC07–23/26

Clutch Gear Puller—2nd Stage Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . JDG1480

05 175 5

RXA0051549

–UN–12FEB01

Remove clutch gear from clutch shaft

YZ07927,00003E0 –19–05DEC07–24/26

Clutch Piston Return Spring Compressor . . . . . JDG1485

YZ7112

–UN–20JAN05

Install roller ball bearings to clutch shafts

YZ07927,00003E0 –19–05DEC07–25/26 RXA0051474 –UN–20FEB01

Eyebolt . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1484 Lift shaft to measure shaft end play

YZ07927,00003E0 –19–05DEC07–26/26

CTM168 (10DEC07)

05-175-5

18-Speed PST Repair Manual 121007

PN=261

Special Tools

Essential Tools for JDG9x20PSTWB Pry Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1803

YZ6219

–UN–29JUN05

Use for all pivot and pull blocks to help set end play on all shaft assemblies.

YZ07927,0000441 –19–16JUN05–1/10

Seventh Stage End Play Adjustment Shaft . . . . JDG1795

YZ6224

–UN–29JUN05

Use with JDG1797 to help set end play on the 7th stage shaft assembly

YZ07927,0000441 –19–16JUN05–2/10

Seventh Stage End Play Pivot Block . . . . . . . . JDG1797

YZ6223

–UN–29JUN05

Use with JDG1795 to help set end play on the 7th stage shaft assembly

YZ07927,0000441 –19–16JUN05–3/10

Second, Third, and Fourth Stage End Play Adjustment Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1793 –UN–29JUN05

Use with JDG1754 to help set end play on the 2nd, 3rd, and 4th shaft assemblies

YZ6226

05 175 6

Continued on next page

CTM168 (10DEC07)

05-175-6

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18-Speed PST Repair Manual 121007

PN=262

Special Tools Second, Third, and Fourth Stage End Play Pivot Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1754

YZ6227

–UN–29JUN05

Used with JDG1793 to help set end play on the 2nd, 3rd, 4th, 5th, and 6th shaft assemblies

YZ07927,0000441 –19–16JUN05–5/10

Fifth and Sixth Stage End Play Adjustment Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1794

YZ6225

–UN–29JUN05

Used with JDG1754 to help set end play on the 5th and 6th shaft assemblies

YZ07927,0000441 –19–16JUN05–6/10

Internal Brake Piston Spacer Installer . . . . . . . JDG1918

YZ6229

–UN–29JUN05

Used to install brake piston spacer on 18-speed PST transmissions used on 9020 series tractors. Used to install brake piston spacer on DF230 Series Transmission in 870D and 872D Series Motor Grader.

YZ07927,0000441 –19–16JUN05–7/10

EYEBOLT - 20 MM . . . . . . . . . . . . . . . . . . . JDG1798

YZ6222

–UN–29JUN05

Use with JDG1799 to set output shaft end play

Continued on next page

CTM168 (10DEC07)

05-175-7

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PN=263

05 175 7

Special Tools Output End Play Pivot Block . . . . . . . . . . . . . JDG1799

YZ6221

–UN–29JUN05

Use with JDG1798 to set output shaft end play

YZ07927,0000441 –19–16JUN05–9/10

Theaded Shaft . . . . . . . . . . . . . . . . . . . . . . JDG1802

–UN–29JUN05

Use to help set end play on the output shaft assembly.

YZ6220

05 175 8

YZ07927,0000441 –19–16JUN05–10/10

Other Material Other Material Number

Name

Use

T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)

Thread Lock and Sealer (Medium Strength)

Retain yoke retaining cap screws

TY16021 (U.S.) TY9484 (Canadian) 17430 (LOCTITE)

High Flex Form-In-Place Gasket

Seal pump drive cover-to-front housing joint

TY16021 (U.S.) TY9484 (Canadian) 17430 (LOCTITE)

High Flex Form-In-Place Gasket

Seal transmission rear housing-to-front housing joint

LOCTITE is a trademark of Loctite Corp.

CTM168 (10DEC07)

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05-175-8

18-Speed PST Repair Manual 121007

PN=264

Group 195

Dealer Fabricated Tools RXA0052902 –UN–23APR01

DFRW146 Relief Valve Removal Tool

B

A

C

Material Required: • 3/4 in. x 10 Threaded Rod • 3/4 in. x 10 Nut (2 used)

D

Cut threaded rod (A) to 165 mm (6.5 in.) length.

A—Washer B—Nut C—Nut D—Threaded Rod

Weld one nut (C) to end of threaded rod.

Assemble nut (B) and washer (A) to threaded rod.

05 195 1 OURX078,000000C –19–11APR01–1/1

Guide Pins For Front And Rear Housing M16 Guide pins to be used when installing rear housing onto front housing.

Material required: • Two M16 cap screw cut to 200 mm (7.875 in) length.

Remove hex head of cap screw to give 200 mm (7.875 in) length.

Chamfer end of cap screw to 30°.

YZ6230

–UN–30JUN05

A—6 mm (.236 in.)

B—30° Angle C—16 mm (.629 in.)

D—M16 thd E—25 mm (.984 in.)

F—200 mm (7.783 in.)

YZ07927,0000442 –19–30JUN05–1/1

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05-195-1

18-Speed PST Repair Manual 121007

PN=265

Dealer Fabricated Tools

Guide Pin for Shims, Caps and Pump Housings Guide Pins to be used when installing shims, caps and pump housing onto front housing.

Material required: • Two M10 cap screw cut to 100 mm (3.936 in.) length.

Remove hex head of cap screw to give 100 mm (3.936 in.) length.

Chamfer end of cap screw to 30°.

–UN–30JUN05

A—100 mm (3.936 in.)

B—6 mm (.236 in.)

C—30° Angle D—10 mm (.393 in.)

E—8.40—8.35 mm (.330—.328 in.)

F—25 mm (.984 in.)

YZ6231

05 195 2

YZ07927,0000443 –19–30JUN05–1/1

CTM168 (10DEC07)

05-195-2

18-Speed PST Repair Manual 121007

PN=266

Section 06

Specifications Contents Page

Group 205—Torque Value Metric Bolt and Screw Torque Values . . . . . . .06-205-1 Unified Inch Bolt and Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-205-2 Fittings, O’ring and Hose. . . . . . . . . . . . . . . . .06-205-3

06

CTM168 (10DEC07)

06-1

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PN=1

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06

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06-2

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PN=2

Group 205

Torque Value

8.8

9.8

10.9

12.9

12.9

4.8

8.8

9.8

10.9

12.9

12.9

TS1670

4.8

–UN–01MAY03

Metric Bolt and Screw Torque Values

Bolt or Screw

Class 4.8 Lubricateda

Class 8.8 or 9.8 Dryb

Lubricateda

Class 10.9

Dryb

Lubricateda

Size

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

M6

4.7

42

6

53

8.9

79

11.3

100

N•m 13 N•m

M8

11.5

102

14.5 N•m

M10

23 N•m

204

128 lb-ft

22 N•m

194 lb-ft

27.5 N•m

243

lb-in 115 lb-ft

Class 12.9 Dryb

N•m 16.5 N•m

Lubricateda

lb-in 146 lb-ft

N•m 15.5 N•m

lb-in 137 lb-ft

Dryb N•m

lb-in

19.5

172

N•m

lb-ft

32

23.5

40

29.5

37

27.5

47

35

lb-ft

29

21

43

32

55

40

63

46

80

59

75

55

95

70

lb-ft

M12

40

29.5

50

37

75

55

95

70

110

80

140

105

130

95

165

120

M14

63

46

80

59

120

88

150

110

175

130

220

165

205

150

260

190

M16

100

74

125

92

190

140

240

175

275

200

350

255

320

235

400

300

M18

135

100

170

125

265

195

330

245

375

275

475

350

440

325

560

410

M20

190

140

245

180

375

275

475

350

530

390

675

500

625

460

790

580

M22

265

195

330

245

510

375

650

480

725

535

920

680

850

625

1080

800

M24

330

245

425

315

650

480

820

600

920

680

1150

850

1080

800

1350

1000

M27

490

360

625

460

950

700

1200

885

1350

1000

1700

1250

1580

1160

2000

1475

M30

660

490

850

625

1290

950

1630

1200

1850

1350

2300

1700

2140

1580

2700

2000

M33

900

665

1150

850

1750

1300

2200

1625

2500

1850

3150

2325

2900

2150

3700

2730

M36

1150

850

1450

1075

2250

1650

2850

2100

3200

2350

4050

3000

3750

2770

4750

3500

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C zinc flake coating. b

“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.

DX,TORQ2 –19–24APR03–1/1

CTM168 (10DEC07)

06-205-1

18-Speed PST Repair Manual 121007

PN=269

06 205 1

Torque Value

Unified Inch Bolt and Screw Torque Values TS1671 –UN–01MAY03

Bolt or

SAE Grade 2a

SAE Grade 1 b

Screw

Lubricated

Size 1/4

5/16

c

Lubricatedb

Dry

SAE Grade 5, 5.1 or 5.2

Dryc

Lubricatedb

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

3.7

33

4.7

42

6

53

7.5

66

9.5

84

12

106

7.7

68

9.8

13.5

120

17.5 N•m

7/16

22 N•m

06 205 2

Lubricatedb

N•m

86

12

106

15.5

137

19.5 N•m

3/8

SAE Grade 8 or 8.2

Dryc

194

155 lb-ft

22 N•m

194 lb-ft

27 N•m

240

172 lb-ft

25 N•m

221

N•m

lb-in

Dryc N•m

13.5

120

17

N•m

lb-ft

N•m

lb-in 150 lb-ft

28

20.5

35

26

lb-ft

35

26

44

32.5

49

36

63

46

56

41

70

52

80

59

100

74

lb-ft

28

20.5

35

26

44

32.5

lb-ft

1/2

34

25

42

31

53

39

67

49

85

63

110

80

120

88

155

115

9/16

48

35.5

60

45

76

56

95

70

125

92

155

115

175

130

220

165

5/8

67

49

85

63

105

77

135

100

170

125

215

160

240

175

305

225

3/4

120

88

150

110

190

140

240

175

300

220

380

280

425

315

540

400

7/8

190

140

240

175

190

140

240

175

490

360

615

455

690

510

870

640

1

285

210

360

265

285

210

360

265

730

540

920

680

1030

760

1300

960

1-1/8

400

300

510

375

400

300

510

375

910

670

1150

850

1450

1075

1850

1350

1-1/4

570

420

725

535

570

420

725

535

1280

945

1630

1200

2050

1500

2600

1920

1-3/8

750

550

950

700

750

550

950

700

1700

1250

2140

1580

2700

2000

3400

2500

1-1/2

990

730

1250

930

990

730

1250

930

2250

1650

2850

2100

3600

2650

4550

3350

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. b

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C zinc flake coating. c

“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.

DX,TORQ1 –19–24APR03–1/1

CTM168 (10DEC07)

06-205-2

18-Speed PST Repair Manual 121007

PN=270

Torque Value

Fittings, O’ring and Hose The scope is for parts or components that are connected or attached by use of fasteners.

The purpose is to provide a procedure for identifying torque requirements for Funk Product.

The reference is Funk Quality Manual, Section 4.0.

QSO4.01.3 Engineering Specification TORQUES FOR SAE J1926 O-RING PORT SUTDS AND LOCK NUTS WRENCHING SYSTEM ACCURACY = +15% -20% REFERENCE: JOHN DEERE STANDARD JDV 14 THREAD

METRIC (N•m)

ENGLISH (lb-ft)

SIZE

THD

DASH SIZE

Ttarget

Tmin

Tmax

Ttarget

Tmin

Tmax

3/8

24

-3

8.0

6.4

9.2

6.0

4.8

6.9

7/16

20

-4

12.0

9.6

13.8

9.0

4.8

6.9

1/2

20

-4

16.0

12.8

18.4

12.0

9.6

13.8

9/16

18

-6

24.0

19.2

27.6

18.0

14.4

20.7

3/4

16

-8

46

37

53

34

27

39

7/8

14

-10

62

50

71

46

37

53

1 1/16

12

-12

102

82

117

75

60

86

1 3/16

12

-14

122

98

140

90

72

104

1 5/16

12

-16

142

114

163

105

84

121

1 5/8

12

-20

190

152

219

140

112

161

1 7/8

12

-24

217

174

250

160

128

184

06 205 3

YZ07927,00000A3 –19–24APR03–1/1

CTM168 (10DEC07)

06-205-3

18-Speed PST Repair Manual 121007

PN=271

Torque Value

06 205 4

CTM168 (10DEC07)

06-205-4

18-Speed PST Repair Manual 121007

PN=272

Index Page

A Adhesives and sealants . . . . . . . . . . . . . . . . .01-10-3 Axle General repair procedures . . . . . . . . . . . . .01-10-2 Sealing instructions . . . . . . . . . . . . . . . . . . .01-10-4

Page

Shims Caps Pump Housing . . . . . . . . . . . . . . . . . .05-195-2

H Hydraulic pump, transmission. . . . . . . . . . . .03-20-16

B Bearing adjustment output shaft Rear housing bearing adjustment output shaft Output shaft bearing adjustment rear housing . . . . . . . . . . . . . . . . . . . . . . .02-35-99 Bearing Adjustments to Clutch Stage Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-109 Bore sleeves . . . . . . . . . . . . . . . . . . . . . . . .02-35-16

I Inlet tube . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-4 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-31

L C

Lube relief bypass valve . . . . . . . . . . . . . . . . .02-25-7

Clutch actuation . . . . . . . . . . . . . . . . . . . . . . .03-20-3 Clutch Assemblies . . . . . . . . . . . . . . . . . . . .02-35-19 Cooler relief bypass valve . . . . . . . . . . . . . .02-25-10

M

D

Magnetic pickup sensor . . . . . . . . . . . . . . . .02-20-25 Main pressure regulator valve . . . . . . . . . . .03-20-20 Main regulator valve . . . . . . . . . . . . . . . . . . . .02-25-6

Directional and speed clutch operation . . . . . .03-20-6

O E Engine rollover stand . . . . . . . . . . . . . . . . . . .02-15-2

F Fifth Stage Clutch Shaft Assembly . . . . . . . .02-35-44 Fifth stage magnetic pickup sensor . . . . . . .02-20-26 Filter by-pass valve . . . . . . . . . . . . . . . . . . . .02-25-5 Fourth Stage Clutch Shaft Assembly . . . . . .02-35-40

Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . .03-20-17 Oil and filter changes . . . . . . . . . . . . . . . . . . .01-10-9 oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-3 Oil filter head . . . . . . . . . . . . . . . . . .02-25-4, 02-25-6 Oil filter head pressure switch . . . . . . . . . . .02-20-28 Oil Filter Switch . . . . . . . . . . . . . . . . . . . . . . .02-25-5 Oil level sight glass . . . . . . . . . . . . . . . . . . .02-25-12 Oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-8 Oil pump gear assembly. . . . . . . . . . . . . . . . .02-30-5 Output magnetic pickup sensors. . . . . . . . . .02-20-27 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . .02-35-22

G P Gear Selection . . . . . . . . . . . . . . . . . . . . . . . .03-20-2 Gear train operation . . . . . . . . . . . . . . . . . . . .03-20-4 Guide Pin Front and Rear Housing . . . . . . . . . . . . . .05-195-1 CTM168 (10DEC07)

Proportional solenoid . . . . . . . . . .02-20-18, 02-20-20 Proportional Solenoid Valve Operation . . . . .03-20-22 Pump drive cover . . . . . . . . . . . . . . . . . . . . . .02-30-2

Index-1

18-Speed PST Repair Manual 121007

PN=1

Indx 1

Index

Page

R Range Clutch Operation . . . . . . . . . . . . . . . . .03-20-8 Rear housing . . . . . . . . . . . . . . . . . . . . . . . . .02-35-1 Recommended Lubricants . . . . . . . . . . . . . . .01-10-6

Page

Transmission oil pump . . . . . . . . . . . . . . . . . .02-30-9 Transmission pressure regulator. . . . . . . . . .03-20-20 Transmission pump operation. . . . . . . . . . . .03-20-16

V S

Valve Main regulator. . . . . . . . . . . . . . . . . . . . . .03-20-18

Sealants and adhesives . . . . . . . . . . . . . . . . .01-10-3 Sealing instructions . . . . . . . . . . . . . . . . . . . .01-10-4 Second stage clutch shaft . . . . . . . . . . . . . .02-35-32 Sensor and ports, front housing . . . . . . . . . .02-20-14 Sensor and ports, rear housing . . . . . . . . . .02-20-16 Seventh Stage Clutch Shaft Assembly . . . . 02-35-52, 02-35-54 Sixth Stage Clutch Shaft Assembly . . . . . . .02-35-48 Solenoid operation . . . . . . . . . . . . . . . . . . . .03-20-22 Speed clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . .03-20-6 Speed clutch operation. . . . . . . . . . . . . . . . . .03-20-6 Stand pipe . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-24 Suction screen . . . . . . . . . . . . . . . . . . . . . . . .02-25-2 Suction tube . . . . . . . . . . . . . . . . .02-35-27, 02-35-28 System pressure sensor . . . . . . . . . . . . . . . .02-20-29

W Wet brake assembly. . . . . . . . . . . . . . . . . .02-35-102

Y Yoke, install and remove . . . . . . . . . . . . . . . .02-15-6

Indx 2

T Temperature sensor . . . . . . . . . . . . . . . . . . .02-20-30 Theory of Clutch Actuation . . . . . . . . . . . . . . . . . . . . .03-20-3 Directional Clutch Operation . . . . . . . . . . . .03-20-6 Gear Selection . . . . . . . . . . . . . . . . . . . . . .03-20-2 Gear train operation . . . . . . . . . . . . . . . . . .03-20-4 Main Regulator Valve Operation . . . . . . . .03-20-20 Proportional Solenoid Valve Operation . . .03-20-22 Range Clutch Operation . . . . . . . . . . . . . . .03-20-8 Speed Clutch Operation . . . . . . . . . . . . . . .03-20-6 Transmission Operation . . . . . . . . . . . . . . .03-20-1 Transmission Pump Operation Oil Filter Head Main Regulator Valve. . . . . . . . . . . . .03-20-16 Theory of internal park brake Internal park brake . . . . . . . . . . . . . . . . . .03-20-10 Third Stage Clutch Shaft Assembly . . . . . . .02-35-36 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . .03-20-1 Transmission control unit operation . . . . . . .03-20-24 Transmission Hydraulic Diagram . . . . . . . . .03-20-12 Transmission Hydraulic Diagram - IPB . . . . .03-20-14 Transmission mounting bracket . . . . . . . . . . .02-15-2 CTM168 (10DEC07)

Index-2

18-Speed PST Repair Manual 121007

PN=2