Manitou Gear Box Serie C+ Repair Manual 647020 - PDF DOWNLOAD

647020EN (01/07/2008)

GEAR BOX SERIE C+ Repair manual

MANITOU BF B.P 249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 (01/07/2008) www.manitou.com

MR647020FR

2

GEAR BOX COMPACT PLUS 1st date of issue : 01 / 07 / 2008

ISSUE 01 / 07 / 2008

- 1st ISSUE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY. MR647020EN

(01/07/2008)

TRANSMISSION CONTROL AND ADJUSTMENT GAER BOX COMPACT PLUS

pages GEAR BOX AND CONVERTER(DETAILS 4WD VERSION) . . . . . . . . . . . . . . . . . . . . . . . 5 GEAR BOX AND CONVERTER (WITH BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 GEAR BOX AND CONVERTER(WITHOUT BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 GEAR BOX (ELECTRICAL CONTROL VALVE DETAILS) . . . . . . . . . . . . . . . . . . . . . . . . 22 TRANSMISSION HYDRAULIC CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PRESSURE CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 PRESSURE READING ON GEAR BOX -TURNER COMPACT PLUS- . . . . . . . . . . . . . . . . 30 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SHAFT AND GEAR END FLOAT TOLERANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DIS-ASSEMBLY / RE-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 – GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 – 1 - TRANSMISSION DIS-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 – 2 - INPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY . . . . . . . . . . . . . . . . . . . 40 – 3 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT . . . . . . . . . . . 45 – 4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE REVERSE IDLER SHAFT . . . . . . 45 – 5 - OUTPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY . . . . . . . . . . . . . . . . . . 46 – 6 - SPRUNG-ON 4 WHEEL DRIVE DIS-ASSEMBLY AND RE-ASSEMBLY . . . . . . . . 50 – 7 - PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY . . . . . . . 54 – 8 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE OIL PUMP . . . . . . . . . . . . . . . . 55 – 9 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE VALVE. . . . . . . . . . . . . . . . . . . 56 – 10 - GEAR LEVER HOUSING DIS-ASSEMBLY AND RE-ASSEMBLY . . . . . . . . . . . 57 – 11 - TRANSMISSION RE-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 INSTALLATION AND ADJUSTEMENT OF SPEED PROBE . . . . . . . . . . . . . . . . . . . . . . . 66 TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

(01/07/2008)

4

Transmission control and adjustment

(01/07/2008)

Transmission control and adjustment

GEAR BOX AND CONVERTER (DETAILS 4WD VERSION)

(01/07/2008)

5

57

60

59

58

42

43

56

41

61

40

62

33

35

39

36

44

37 38

32

30 30

31

46

1

34

29 28 27 26 3 4

22

3 4

5

24

21 23

3 4

18

20

19

8

25

8

6

11 10

17

74

7

3 4 88 3 4 16

70

73

2

3

50

14

3

12

15

9

4

4

13

54 55

49

71

53

72

48

51

52

69

68

66

65

63

67

64

6 Transmission control and adjustment

(01/07/2008)

Transmission control and adjustment

1– 2– 3– 4– 5– 6– 7– 8– 9– 10 – 11 – 12 – 13 – 14 – 15 – 16 – 17 – 18 – 19 – 20 – 21 – 22 – 23 – 24 – 25 – 26 – 27 – 28 – 29 – 30 – 31 – 32 – 33 – 34 – 35 – 36 –

Complete gear box Transmission housing Plug «O» ring Screw Centering pin Screw «O» ring Pipe Nut Olive Plug «O» ring Drain plug «O» ring Air breather Transmission oil pressure switch Electrical control valve Screw Solénoid Filtrer housing Gasket Connection Oil filter Screw Ball Spring «O» ring Plug Plug Plug Complete pump Seal «O» ring Screw Washer

(01/07/2008)

37 – 38 – 39 – 40 – 41 – 42 – 43 – 44 – 46 – 48 – 49 – 50 – 51 – 52 – 53 – 54 – 55 – 56 – 57 – 58 – 59 – 60 – 61 – 62 – 63 – 64 – 65 – 66 – 67 – 68 – 69 – 70 – 71 – 72 – 73 – 74 –

Oil temperature sensor «O» ring Suction trainer Washer «O» ring Cover Screw Valve Over pressure valve Seat Gear lever foot Pin Clamp Dust cover Clamp Screw Washer Converter Complete converter drive plate Converter drive plate Converter reinforcement plate Screw Washer Screw Pipe «O» ring Screw Washer Clamp Hose Clamp Pipe Screw Washer Plug Gauge

7

39

24

40

2

38

78

23 79

22 21 20 21

37

77

73

49

35

36 34 51 50

79

75

76 74 73

17 16 15 18 19

12 14 13

32

73

72

47

65

68

6

27

31 58 67

70

69

74

71

10 9 8 11 7

5

66

33

64

34 62

63

41

61

26

6 6

42

44

28

52

45

53

43 43

29

6 29

9

11 12 13 8 10 7

30

14

54

56

46

29 28

15

2

55

58

55

57

48 29 30 47

19

1

59

49

59

60

17 18 16

2

3

51

24 23 21

3

4

SHAFT 4WD

50

21 25

22

3

3 2

4

8 Transmission control and adjustment

(01/07/2008)

Transmission control and adjustment

1– 2– 3– 4– 5– 6– 7– 8– 9– 10 – 11 – 12 – 13 – 14 – 15 – 16 – 17 – 18 – 19 – 20 – 21 – 22 – 23 – 24 – 25 – 26 – 27 – 28 – 29 – 30 – 31 – 32 – 33 – 34 – 35 – 36 – 37 – 38 – 39 – 40 –

Reverse idler gear Bearing Shim Spacer Input shaft Seal Seal (inner) «O» ring Seal (outer) «O» ring Piston Clutch disc Friction disc Piece Circlips Spring Bushing Circlips Thrustwasher Forward primary gear Roller bearing Spacer Bearing Bracket Reverse primary gear Countershaft Bearing Bearing Shim Spacer Out put shaft 3rd gear 2nd gear Coupling 3rd and 4th synchro assy Circlips 4th gear Washer Bearing Plug

(01/07/2008)

41 – 42 – 43 – 44 – 45 – 46 – 47 – 48 – 49 – 50 – 51 – 52 – 53 – 54 – 55 – 56 – 57 – 58 – 59 – 60 – 61 – 62 – 63 – 64 – 65 – 66 – 67 – 68 – 69 – 70 – 71 – 72 – 73 – 74 – 75 – 76 – 77 – 78 – 79 –

1st and 2nd synchro assy Output shaft 1st gear Bearing Spacer Coupling Out put shaft drive gear Seal End yoke «O» ring Washer Screw Out put shaft «O» ring Gear (37 teeth) Roller bearing Spacer Thrustwasher Bearing Shim Spacer Seam «O» ring Coupling «O» ring Seal Spring Spring bracket Circlips Spacer End yoke 1st and 2nd shift rod 3rd and 4th shift rod Ball Spring Plug «O» ring 1st and 2nd shift fork 3rd and 4 th shift fork Dog point screw

9

10

Transmission control and adjustment

(01/07/2008)

Transmission control and adjustment

GEAR BOX AND CONVERTER (WITH BRAKE)

(01/07/2008)

11

43

42

45

58

41

S

57

56

33

40

INT JO DE E Z T ET AT S CH GS TA PO HTUNE JUN E C DI GO D ON IZI E JU L KIT ARN A U SE IE G R SE

39

35

36

44

38

37

32

30

30

46

S INT JO DE E Z T ET AT S CH GS TA PO HTUNE JUN E DIC GO D ON IZI E JU L KIT ARN A U SE IE G R SE

31

47

1

34

3 26 4

27

28

29

BP 203

5

22

4

3

24

23

21

4

3

18 19

10

8 9

17 80 8

25

20

76

6

16

77

13

12

55

3 4

54

4

3

77

75

2

15

4

4

48

14

3

3

77

11

53

51

52

79

78

76

50

49

77

77

62

61

60

59

12 Transmission control and adjustment

With brake

(01/07/2008)

Transmission control and adjustment With brake

1– 2– 3– 4– 5– 6– 7– 8– 9– 10 – 11 – 12 – 13 – 14 – 15 – 16 – 17 – 18 – 19 – 20 – 21 – 22 – 23 – 24 – 25 – 26 – 27 – 28 – 29 – 30 – 31 – 32 – 33 – 34 – 35 – 36 –

Transmission housing Transmission rear case Plug «O» ring Screw Stud-bolt Screw «O» ring Plug Seal Brake assy Plug «O» ring Drain plug «O» ring Air breather Transmission oil pressure switch Complete electrical control valve Screw Plug Filtrer housing Gasket Connection Oil filter Screw Ball Spring «O» ring Plug Plug Plug Complete pump Seal «O» ring Screw Washer

(01/07/2008)

37 – 38 – 39 – 40 – 41 – 42 – 43 – 44 – 45 – 46 – 47 – 48 – 49 – 50 – 51 – 52 – 53 – 54 – 55 – 56 – 57 – 58 – 59 – 60 – 61 – 62 – 70 – 71 – 72 – 73 – 74 – 75 – 76 – 77 – 78 – 79 – 80 –

Oil temperature sensor «O» ring Suction trainer Washer «O» ring Cover Screw Valve (Pressure regulation) Seal kit Over pressure valve Seal kit Upper seat Gear lever foot Pin Clamp Dust cover Clamp Screw Washer «O» ring Plate Screw Oil level «O» ring Connection «O» ring Pumpe kit Small parts kit Seal kit Seal kit Repaire kit Kit (Brake lining + Spring) Kit (Screw + Nut) Kit brake lining Gasket «O» ring «O» ring

13

39

24

40

2

23

22 21 21

38

67

68

20

37

18 19

68

64

36

34

66

65 63 62

17 16

15

35

62

14 13 12

32

62

63

11

51

60 61

50

31

27

49

59

33

34

47

58

55

41

42

44

28

6 26

6

5

6 6

52

43

29

29

43

45

11 12 13

30

54

14 15

28

48

19

1

55

46

56

56

57

29 29 30

2

47

16

17

18

2

49

3

25

22

3

3

50

21 21

3

4

51

2 24 23

4

14 Transmission control and adjustment

With brake

(01/07/2008)

Transmission control and adjustment With brake

1– 2– 3– 4– 5– 6– 7– 8– 9– 10 – 11 – 12 – 13 – 14 – 15 – 16 – 17 – 18 – 19 – 20 – 21 – 22 – 23 – 24 – 25 – 26 – 27 – 28 – 29 – 30 – 31 – 32 – 33 – 34 – 35 – 36 – 37 – 38 – 39 – 40 –

Reverse idler gear Bearing Shim Spacer Input shaft Seal Seal (inner) «O» ring Seal (outer) «O» ring Piston Clutch disc Friction disc Piece Circlips Spring Bushing Circlips Thrustwasher Forward primary gear Roller bearing Spacer Bearing Stop washer Backward primary gear Countershaft Bearing Bearing Shim Spacer Out put shaft 3rd gear 2nd gear Coupling sleeve Synchro assy Circlips 4th gear Washer Bearing Plug

(01/07/2008)

41 – 42 – 43 – 44 – 45 – 46 – 47 – 48 – 49 – 50 – 51 – 52 – 54 – 55 – 56 – 57 – 58 – 59 – 60 – 61 – 62 – 63 – 64 – 65 – 66 – 67 – 68 –

Synchro assy Output shaft 1st gear Bearing Spacer Coupling Out put shaft drive gear Seal Coupling flange «O» ring Washer Screw Out put shaft Gear (37 teeth) Bearing Shim Spacer Spacer End yoke 1st and 2nd shift rod 3th and 4th shift rod Ball Spring Plug «O» ring 1st and 2nd shift fork 3th and 4th shift fork Screw

15

16

Transmission control and adjustment

(01/07/2008)

Transmission control and adjustment

GEAR BOX AND CONVERTER (WITHOUT BRAKE)

(01/07/2008)

17

43

42

45

58

41

57

56

S

33

40

INT JO DE E Z T ET AT S CH GS TA PO HTUNE JUN E DIC GO D ON IZI E JU L KIT ARN A U SE IE G R SE

39

35

36

44

S

38

37

32

30

30

46

INT JO DE E Z T ET AT S CH GS TA PO HTUNE JUN E DIC GO D ON IZI E JU L KIT ARN A U SE IE G R SE

31

47

1

34

3 26 4

27

28

29

BP 203

5

22

4

3

24

23

21

4

3

18 19

10

9

25

20

17

6

16 13

12

55

3 4

54

4

3

2

15

4

4

48

14

3

3

53

51

52

79

78

50

49

62

61

60

59

18 Transmission control and adjustment

Without brake

(01/07/2008)

Transmission control and adjustment Without brake

1– 2– 3– 4– 5– 6– 7– 8– 9– 10 – 12 – 13 – 14 – 15 – 16 – 17 – 18 – 19 – 20 – 21 – 22 – 23 – 24 – 25 – 26 – 27 – 28 – 29 – 30 – 31 – 32 – 33 – 34 – 35 – 36 –

Transmission housing Transmission rear case Plug «O» ring Screw Stud-bolt Screw «O» ring Plug Seal Plug «O» ring Drain plug «O» ring Air breather Transmission oil pressure switch Complete electrical control valve Screw Plug Filtrer housing Gasket Connection Oil filter Screw Ball Spring «O» ring Plug Plug Plug Complete pump Seal «O» ring Screw Washer

(01/07/2008)

37 – 38 – 39 – 40 – 41 – 42 – 43 – 44 – 45 – 46 – 47 – 48 – 49 – 50 – 51 – 52 – 53 – 54 – 55 – 56 – 57 – 58 – 59 – 60 – 61 – 62 – 78 – 79 –

Oil temperature sensor «O» ring Suction trainer Washer «O» ring Cover Screw Valve (Pressure regulation) Seal kit Over pressure valve Seal kit Upper seat Gear lever foot Pin Clamp Dust cover Clamp Screw Washer «O» ring Plate Screw Oil level «O» ring Connection «O» ring «O» ring «O» ring

19

39

24

40

2

23

22 21 21

38

67

68

20

37

18 19

68

64

36

34

66

65 63 62

17 16

15

35

62

14 13 12

32

62

63

11

51

60 61

50

31

27

49

59

33

34

47

58

55

41

42

44

28

6 26

6

5

6 6

52

43

29

29

43

45

11 12 13

30

54

14 15

28

19

1

55

46

56

56

57

29 29 30

2

47

49

16

17

50

18

2

3

51

25

22

3

3

21 21

3

4

2 24 23

4

20 Transmission control and adjustment

Without brake

(01/07/2008)

Transmission control and adjustment Without brake

1– 2– 3– 4– 5– 6– 7– 8– 9– 10 – 11 – 12 – 13 – 14 – 15 – 16 – 17 – 18 – 19 – 20 – 21 – 22 – 23 – 24 – 25 – 26 – 27 – 28 – 29 – 30 – 31 – 32 – 33 – 34 – 35 – 36 – 37 – 38 – 39 – 40 –

Reverse idler gear Bearing Shim Spacer Input shaft Seal Seal (inner) «O» ring Seal (outer) «O» ring Piston Clutch disc Friction disc Piece Circlips Spring Bushing Circlips Thrustwasher Forward primary gear Roller bearing Spacer Bearing Stop washer Backward primary gear Countershaft Bearing Bearing Shim Spacer Out put shaft 3rd gear 2nd gear Coupling sleeve Synchro assy Circlips 4th gear Washer Bearing Plug

(01/07/2008)

41 – 42 – 43 – 44 – 45 – 46 – 47 – 49 – 50 – 51 – 52 – 54 – 55 – 56 – 57 – 58 – 59 – 60 – 61 – 62 – 63 – 64 – 65 – 66 – 67 – 68 –

Synchro assy Output shaft 1st gear Bearing Spacer Coupling Out put shaft drive gear Seal «O» ring Washer Screw Out put shaft Gear (37 teeth) Bearing Shim Spacer Spacer End yoke 1st and 2nd shift rod 3th and 4th shift rod Ball Spring Plug «O» ring 1st and 2nd shift fork 3th and 4th shift fork Screw

21

22

Transmission control and adjustment

2

1

3

4

2

GEAR BOX (ELECTRICAL CONTROL VALVE DETAILS)

(01/07/2008)

Transmission control and adjustment GEAR BOX (ELECTRICAL CONTROL VALVE DETAILS)

1– 2– 3– 4–

Complete electrcal control valve Solenoid Seal kit Plug

(01/07/2008)

23

D

CONVERTER RELIEF VALVE (6,5 ± 1,5 bar)

A

PRESSURE REGULATOR VALVE (14,5 ± 1 bar)

TEMPERATURE SENDER

OIL COOLER

LUBE PRESSURE TEST

FORWARD TEST POINT

SUMP

SUCTION STRAINER

CONVERTER PRESSURE TEST POINT

CLUTCH RUNNING FORWARD

B

PUMP

REVERSE TEST POINT CLUTCH RUNNING BACKWARD

B

RUNNING FORWARD AND BACKWARD VALVE

TORQUE CONVERTEUR

4WD CLUTCH

OIL FILTRER

4WD SOLENOID VALVE

TRANSMISSION LUBRIFICATION

COLD START VALVE (26 bar)

4WD PRESSURE TEST

C

LUBE TEST POINT

PUMP TEST POINT

24 Transmission control and adjustment

TRANSMISSION HYDRAULIC CIRCUIT

(01/07/2008)

Transmission control and adjustment

25

DESCRIPTION OF THE TRANSMISSION SHAFT HYDRAULIC CIRCUIT

CLUTCH CIRCUIT The oil is sucked into the casing via the suction strainer.

The oil leaving the pump passes into the filter and is directed towards the clutch circuit.

The filter is protected by a cold start valve calibrated to 26 bars.

On the filter outlet, the pressure regulator mark A maintains a pressure of 14 +/- 1 bar in the clutch circuit. The same regulator supplies the converter circuit.

The electrovalves mark B enable the pressure to be directed towards the front and reverse gear clutches, and in neutral gear they enable the clutches to be decompressed towards the casing.

On the 4WD «sprung on» version, the clutch is engaged by a spring. When the 4WD electrovalve mark C is fed, the pressure is applied on the piston which pushes the spring back and frees the 4WD clutch.

CONVERTER CIRCUIT The oil passes into the converter circuit through the pressure regulator mark A. The pressure limiter mark D maintains a pressure of 6.5 +/- 1.5 bar in the circuit.

COOLING AND LUBRICATION CIRCUIT The oil returning from the converter passes via the inside of the pump’s hollow shaft, heads towards the oil cooler and then returns into the transmission shaft to lubricate the gears and the bearings on the inlet shaft.

(01/07/2008)

26

Transmission control and adjustment

TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT clutch running forward

clutch running backward

P2

P3 modulation valve

valve running forward / running backward clutch pressure regulation

4wd clutch 4wd valve

relief valve

P4 14,5 ± 1 bar

P5

6,5 ± 1,5 bar

P1 filter by-pass valve

oil filter

cold start valve

T1

pump

26 bar

torque converter

oil cooler

suction strainer P6

P1 = Oil pump pressure test point(14,5 ± 1 bar).

P2 = Forward clutch pressure test point (14,5 ± 1,5 bar).

P3 = Reverse clutch pressure test point (14,5 ± 1,5 bar).

P4 = Converter relief pressure test point (6,5 ± 1,5 bar).

P5 = Four wheel drive pressure test point (14,5 ± 1,5 bar).

P6 = Lubrification pressure test point (1,5 ± 1 bar).

T1 = Temperature test.

(01/07/2008)

Transmission control and adjustment

27

TRANSMISSION MAINTENANCE Recommanded lubricants : Oils used in this transmission must all meet the following specifications : GRADE

SPECIFICATION

CLASSIFICATION

10W30

API GL 4 ALLISON C3

MIL-L-2105B

OPERATING TEMPERATURE : 85° - 90° C

OIL LEVEL

In order to ensure a good lubrication and a good operating temperature it is important to use the specified oil and to maintain the correct level.

The level must be checked always with the oil gauge dipstick, with the engine idling.

OIL AND FILTER CHANGING It is recommanded to change the oil at the following intervals : After the first 50 hours of work.

Then every 800 hours maximum afterward.

Always clean the strainer when changing the oil.

* Do not pour oil over the upper mark as this could cause overheating due to oil splashing through the pinions (emulsion and deterioration of the oil). This could also cause external leaks.

Oil changing is also necessary to eleminate the metal particles of the transmission components. The particles result from a normal use.

Replace the filter after the first 50 hours of work and every 400 hours afterward.

Many factors having an influence on the oil changing require to increase the oil changing frequency.

CAPACITY (GEAR BOX only) : 15,5 L

OIL USED BY MANITOU : MANITOU oil automatic transmission shaft.

1 L - Réf.

25 L - Réf.

56 L - Réf.

215 L - Réf.

(01/07/2008)

62 148 487 655 545 557 490 207

PRECAUTION To prevent a lack of lubrication in the transmission when towing the machine on long distances, it is recommended to uncouple the gear box out put shaft.

28

Transmission control and adjustment

PRESSURE CHECKING - The transmission oil, (Shell Donax TA), should be at an approximate temperature of 80 degrees C during pressure tests.

- The handbrake must be applied.

- All test ports have a 9 / 16» UNF thread.

- A manometer of 0-20 bar minimum is necessary.

- For the P / N° of pressure connections, manometers or hoses, please refer to «Gauge Box» catalogue P / N° 547 037.

- Forward, reverse and 4WD clutch pack pressures should not be more than 1 bar lower than the oil pump pressure.

Oil pump pressure test port.

Pressure should be 14,5 ± 1 bar at maximum engine speed (approx. 2500 RPM).

Converter relief pressure test point.

Pressure should be 6,5 ± 1,5 bar at maximum engine speed (approx. 2500 RPM).

Forward clutch pressure test point.

Pressure should be 14,5 ± 1,5 bar at maximum engine speed (approx. 2500 RPM).

Reverse clutch pressure test point.

Pressure should be 14,5 ± 1,5 bar at maximum engine speed (approx. 2500 RPM).

(01/07/2008)

Transmission control and adjustment

Lubrication pressure test point.

Pressure should be 1,5 ± 1 bar at maximum engine speed (approx. 2500 RPM).

29

Four wheel drive pressure test point.

Pressure should be 14 ± 1,5 bar at maximum engine speed (approx. 2500 RPM).

STALLING SPEED OF TORQUE CONVERTER A - 1980 ± 50 tr/mn : For the previous machines to S / N° 125084 (BORG WARNER torque converter).

B - 1600 ± 50 tr/mn : From machine N°125084 (MANNESMAN SACHS torque converter).

(01/07/2008)

30

Transmission control and adjustment

PRESSURE READING ON GEAR BOX -TURNER COMPACT PLUSMACHINE TYPE and N° : .....................................

GEAR BOX TYPE and N° :

N° of HOURS : .........................

.....................................................................................

(To be carried out with gear box oil at 80° mini).

NEUTRAL

FORWARD GEAR

REVERSE GEAR

Mini r.p.m.

PUMP Maxi r.p.m.

Mini r.p.m.

CONVERTER Maxi r.p.m.

Mini r.p.m.

DRAINAGE Maxi r.p.m.

Mini r.p.m.

FORWARD GEAR Maxi r.p.m.

Mini r.p.m.

REVERSE GEAR Maxi r.p.m.

Mini r.p.m.

4 WD Maxi r.p.m.

COMMENTS : ........................................................................................................................ .............................................................................................................................................

BREACKDOWN AT THE ORIGIN : ............................................................................................ .............................................................................................................................................

DETERMINED CAUSE OF THE BREACKDOWN : ........................................................................ .............................................................................................................................................

(01/07/2008)

Transmission control and adjustment

31

SPECIAL TOOLS

NUMBER

DESIGNATION

-

Hand press.

Input & Rev. Idler shaft brg. removal collet.

4WD brg removal collet.

Out put shaft front brg. removal collet.

C / shaft and output shaft rear brg. removal collet.

C / shaft front bearing removal collet.

Input shaft spring compressor.

Shimming Adapter

479307 479309 563390 563391 563392 563394 563393 563395

Recommended tube sizes for replacing bearings Ø INTERIOR

Ø EXTERIOR

C / shaft, Output shaft rear & 4WD brg.

41 mm

47 mm

Reverse idler, output shaft front & input shaft brgs.

36 mm

41 mm

Output shaft 1st gear brg. sleeve

50,5 mm

55 mm

The dummy plug for re-fitting inner detent spring & ball can be made using a piece of bar 18mm dia. x 25 mm long.

(01/07/2008)

32

Transmission control and adjustment

SHAFT AND GEAR END FLOAT TOLERANCES SHAFT END FLOATS All shaft end floats should be 0,0254 à 0,0762 mm.

GEAR END FLOATS Input shaft forward and reverse primary gears : 0,061 à 0,41 mm.

Output shaft gears : 4th Gear : 3rd Gear : 2nd Gear : 1st Gear :

0,20 0,38 0,36 0,33

à à à à

0,56 0,84 0,56 0,51

mm. mm. mm. mm.

4 wheel drive : 0,051 à 0,28 mm.

(01/07/2008)

Transmission control and adjustment

DIS-ASSEMBLY / RE-ASSEMBLY

(01/07/2008)

33

34

Transmission control and adjustment

GENERAL INFORMATION

We recommend that the procedures as outlined in this manual be followed when performing maintenance work on this transmission.

TOOLS This transmission can be repaired with ordinary mechanics hand tools however this procedure is not only slow but may damage otherwise serviceable parts. To reduce maintenance costs and vehicle downtime, we recommend that the special tools listed in this manual be procured from a tool manufacturer, as stated.

CLEANLINESS Transmission should be steam cleaned externally prior to disassembly. Seal all opening before cleaning to prevent entry of dirt and water which can damage serviceable parts.

Dirt is abravise and will cause premature wear and failure of clutch plates, hydraulic valves and bearings. * Due to the nature of opération of the hydraulic system cleanliness is of prime importance and the following guidelines should be observed :

BEARINGS When a transmission is removed at relativity low mileage, bearings should be removed with pullers designed for the purpose. Wrap the bearings to keep our dirt.

Clean, inspect and lubricate all bearings just prior to reassembly. If accumulated mileage is over 1500 hours we suggest that all bearings be replaced.

REPLACEMENT PARTS The exploded views of sub-assemblies which are incorporated in this manuel are for the mechanic’s convenience and show the latest material. The parts are arranged in their correct order and may also be used as a reference for assembly or disassembly of this unit.

SHIMS When inserting shim packs, it is essential that the thinnest shims are placed between the thicker shims to prevent any possible damage to the shims.

SEALS 1 – Not lint or cotton rags should be used in order to prevent any possible clogging.

2 – When fitting new clutch plates they should be soaked in clean new oil as recommended for 3 hours.

The seals which have been removed on the disassembly shall be replaced by new on reassembly.

3 – All parts should be thoroughly cleaned and lubricated with new oil prior to reassembly.

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Transmission control and adjustment

35

1 - TRANSMISSION DIS-ASSEMBLY 1-1

Invert the transmission on a suitable bench. For convenience the bench top should have a hole in it to accommodate the input shaft and pump. Remove 3 screws and withdraw the gear shift lever assembly.

1-3

Remove the Converter Relief Valve.

1-5

Remove the cold start housing, spring and ball

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1-2

Remove 4 capscrews and withdraw the direction control valve.

1-4

Remove the Pressure Regulator Valve.

1-6

Remove the temperature sender.

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Transmission control and adjustment

1-7

Remove the bolt, washer and «O»ring and withdraw the output yoke.

1-9

Remove 17 screws and using a suitable hoist take off the rear transmission case.

Note : The bearing cones and shims may fall from the rear case during removal.

1-11

Tilt the countershaft and withdraw the input shaft assembly.

1-8

4WD VERSION : Remove the bolt, washer and «O»ring and withdraw the 4 wheel drive yoke and spacer. (Not fitted on 2 wheel drive model).

1-10

4WD VERSION : Remove the 4 wheel drive shaft assembly. (Not fitted on 2 wheel drive model).

1-12

Remove the assembly.

reverse

idler

shaft

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Transmission control and adjustment

1-13

Remove the outer detent plug, spring and ball.

1-15

Withdraw the 1st / 2nd shift rod from the housing. Then using a magnetic probe remove the interlock ball from the detent bore.

1-17

Turn the 3rd / 4th shift rod through 90 degrees and withdraw from the housing.

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1-14

Ensure both synchronisers are in the neutral position then remove the 1st / 2nd shift fork screw.

1-16

Remove the 3rd / 4th shift fork screw.

Safety Note : before attempting to remove the 3rd / 4th shift rail, replace the detent plug as the ball and spring may shoot out and cause injury.

1-18

Remove the detent plug, inner detent ball and spring.

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Transmission control and adjustment

1-19

Remove the counter shaft assembly.

1-21

Remove the output shaft assembly.

1-23

Remove 2 screws and withdraw the strainer cover, «O»ring, spacer and strainer.

1-20

Remove the 1st / 2nd and 3rd / 4th shift forks.

1-22

Remove the 4th gear lock out screw. (If fitted).

1-24

Using a strap wrench remove and discard the oil filter.

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Transmission control and adjustment

1-25

Remove 2 bolts and withdraw oil filter housing and gasket.

1-27

4WD VERSION : Remove the 4 wheel drive solenoid spool.

1-29

Invert the case. Remove 4 screws and copper washers then withdraw the pump assembly and sealing ring.

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1-26

4WD VERSION : Remove the 4 wheel drive solenoid coil and retaining nut.

1-28

Remove and discard the expansion plug from the shimming access hole.

40

Transmission control and adjustment

2 - INPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY DIS-ASSEMBLY 2-1

Position the shaft in a soft jawed vice as shown.

2-3

Using the appropiate bearing puller remove the rear bearing.

2-5

Remove the reverse primary gear.

2-2

Remove and discard the 3 sealing rings.

2-4

Remove the thrust washer and needle bearing.

2-6

Remove the bearing, spacer, bearing and thrust washer.

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Transmission control and adjustment

2-7

Remove the clutch pack retaining ring.

2-9

Remove the clutch pack.

2-11

Remove the circlip, retainer and spring.

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41

2-8

Remove the clutch pack retaining plate.

2-10

Using the appropriate tool compress the piston spring and release the circlip.

2-12

Using pliers, as shown, pull the piston out of the drum.

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Transmission control and adjustment

2-13

Invert the shaft and remove the sealing ring. Repeat steps 2,3 to 2,12 to dismantle the forward clutch pack.

2-14

Remove and discard the piston sealing rings and «O»rings.

RE-ASSEMBLY 2-15

Re-new the piston sealing rings and «O»rings. To assist assembly bend the inner sealing ring into a heart shape as shown.

2-17

Replace the spring, retainer and circlip as shown.

2-16

Using transmission fluid to lubricate the seals push the piston into the drum.

2-18

Using the appropriate tool compress the spring and locate the circlip ingo its groove.

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2-19

Replace an externally splined (plain) disc and then an internally splined (friction) disc alternately until six of each have been replaced.

NOTE: New friction discs should be soaked in transmission fluid for a minimum of 3 hours prior to assembly.

2-21

Replace the thrust washer, bearing, spacer and bearing.

2-23

Using an appropriately sized tube replace the bearing as shown.

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2-20

Replace the clutch pack retaining plate and re-fit the retaining clip.

2-22

Line up the clutch plate splines and replace the primary gear. Then replace the needle bearing anhd thrust washer as shown.

2-24

Invert the shaft and repeat steps 2:15 to 2:23. Then fit a new sealing ring as shown.

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Transmission control and adjustment

2-25

Finally fit 3 new sealing rings to the rear of the shaft as shown.

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45

3 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT 4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE REVERSE IDLER SHAFT DIS-ASSEMBLY 3-1

The countershaft assembly.

3-2

Using the appropriate bearing puller remove the countershaft front and rear bearings.

RE-ASSEMBLY 3-3

4-1

Using an appropriately sized tube replace the countershaft front and rear bearings.

The reverse idler assembly.

DIS-ASSEMBLY

RE-ASSEMBLY

4-2

Using the appropriate bearing puller remove the front and rear bearings.

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4-3

Using an appropriately sized tube replace the front and rear bearings.

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Transmission control and adjustment

5 - OUTPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY

DIS-ASSEMBLY 5-1

Position the shaft assembly in a softjawed vice as shown.

5-3

Remove the thrust washer and 4th gear.

5-5

Remove the circlip and synchro hub.

5-2

Using the appropriate bearing puller remove the front bearing.

5-4

Remove the assembly.

3rd

/

4th

synchro

5-6

Remove the 3rd gear.

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5-7

Invert the shaft and using the appropriate bearing puller remove the rear bearing.

5-9

Remove the 1st gear.

5-11

Remove the 1st / 2nd synchroniser assembly.

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5-8

4WD VERSION : Remove the 4 wheel drive gear.

2WD VERSION : On 2 wheel drive models a spacer is fitted in place of a gear.

5-10

Remove spacer.

the

needle

bearings

and

5-12

Using a suitable bearing puller or press.

Remove the bearing sleeve , synchro hub and 2nd gear.

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Transmission control and adjustment

RE-ASSEMBLY 5-13

Removal of the bearing sleeve, synchro hub and 2nd gear.

5-15

Using an appropriately sized tube refit the 1st gear bearing sleeve.

5-17

Replace the 1st gear needle bearings and spacer as shown.

5-14

Replace the 2nd gear and synchro hub.

5-16

Replace the 1st / 2nd synchroniser assembly.

5-18

Replace the 1st gear.

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Transmission control and adjustment

5-19

Replace the 4 wheel drive gear using stop threaded product (P / N° 548110).

Note : The gear should be fitted with the fluted boss against the 1st gear. (On 2 wheel drive models a spacer is fitted in place of the gear).

5-21

Invert the shaft and refit the 3rd gear, synchro hub and circlip.

5-23

Refit the 4th gear and thrust washer as shown.

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5-20

Using an appropriately sized tube refit the rear bearing.

5-22

Re-fit the 3rd / 4th synchroniser assembly.

5-24

Using an appropriately sized tube replace the front bearing.

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Transmission control and adjustment

6 - SPRUNG-ON 4 WHEEL DRIVE DIS-ASSEMBLY AND RE-ASSEMBLY DIS-ASSEMBLY 6-1

The sprung on 4 wheel drive assembly.

6-3

Using the appropriate bearing puller remove the rear bearing.

6-5

Remove the 4 wheel drive gear.

6-2

Position the shaft in a soft jawed vice and remove the sealing ring.

6-4

Remove the thrust washer.

6-6

Remove the two needle bearings and spacer.

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Transmission control and adjustment

6-7

Invert the shaft and using the appropriate bearing puller remove the front bearing.

6-9

Remove the circlip, retainer, and spring.

6-11

Remove the piston seal and «O»ring from the shaft and discard.

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6-8

Using the appropriate tool compress the spring and release the circlip.

6-10

Remove the piston drum assembly.

6-12

Remove and discard the piston seal and «O»ring from the piston drum.

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Transmission control and adjustment

RE-ASSEMBLY 6-13

Fit a new «O»ring and sealing ring to the shaft.

See (fig. 6-11).

6-15

Lubricate the seals with a light grease and refit the piston to the shaft.

6-17

Using the appropriate tool compress the spring and retainer and refit the circlip.

6-14

Fit a new «O»ring and sealing ring into the piston. Bend the sealing ring into a heart shape as shown to assist assembly.

6-16

Replace the piston spring and retainer.

6-18

Using an appropriately sized tube refit the front bearing.

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Transmission control and adjustment

6-19

Invert the shaft and refit the two needle bearings and spacer as shown.

6-21

Replace the thrust washer.

6-23

Fit a new sealing ring.

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6-20

Replace the 4 wheel drive gear.

6-22

Using an appropriately sized tube replace the rear bearing.

54

Transmission control and adjustment

7 - PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY DIS-ASSEMBLY 7-1

The permanent 4 wheel drive shaft.

7-2

Using the appropriate bearing puller remove the front and rear bearings.

RE-ASSEMBLY 7-3

Remove the 4 wheel drive gear.

7-4

Replace the 4 wheel drive gear using stop threaded product (P / N° 548110), on the shaft splines . Then using a suitably sized tube re-fit the front and rear bearings.

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8 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE OIL PUMP

Note : Individual components of the oil pump are non serviceable. The pump may, however, be stripped for cleaning and examination purposes.

8-1

View showing assembly.

8-2

The pump oil seal may be replaced using an approprietely sized tube.

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a

dismantled

pump

56

Transmission control and adjustment

9 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE VALVE

Nota : Dis-assembly of the control valve is not generally recommended as, with the exception of the solenoids, individual parts are non serviveable. It may however be dismantled for cleaning and examination.

9-1

The retaining nut, coil and washers removed.

9-2

The modulation components removed.

9-3

There are 4 «O»rings fitted to the underside of the valve which may be renewed if necessary.

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10 - GEAR LEVER HOUSING DIS-ASSEMBLY AND RE-ASSEMBLY

10-1

Nota : Before re-assembly remove all traces of old sealant from the joint faces.

Remove the plastic ties from the rubber gaiter and pull the assembly apart as shown.

10-2

Apply a airtightness product (P / N° 562228) to the sealing face as shown.

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10-3

Lubricate the ball seating with a light grease and push the two halves of the assembly together. Secure the rubber gaiter with two new plastic ties.

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Transmission control and adjustment

11 - TRANSMISSION RE-ASSEMBLY Note : All shafts and bearing should be lubricated with transmission fluid prior to assembly.

To prevent possible contamination of hydraulic parts lint or cotton rags should not be used.

11-1

4WD VERSION : Position the front case as shown and using a suitably sized tube fit a new 4 wheel drive output shaft oil seal to a depth of 6mm below the housing face. Fill the seal lip with light grease.

11-2

Re-fit the oil pump assembly and sealing ring. Tighten 4 bolts to a torque of 1323 Ib / ft. New copper washers must be fitted under the bolt heads.

11-4

Invert the case and then re-fit the bearing cups if previously removed.

11-3

If previously removed, replace the two plug and «O»ring assemblies as shown and tighten to a torque of 30 to 40 Ibs /ft.

11-5

Using a suitable tool push the inner detent spring and ball into the case and secure in place with a dummy plug as shown. (ø 18 mm, lg. 25 mm).

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Transmission control and adjustment 11-6

Dummy plug in place

59

11-7

Replace the countershaft and reverse idler shaft assemblies.

11-8 11-9

Slide the 1st / 2nd fork onto the 3rd / 4th rail then refit the 3rd / 4th shift fork and tighten the screw to a torque of 13 to 18 Ibs / ft. Hold the forks and rail in place on the output shaft then re-fit the complete assembly into the case.

The shift rail should displace the dummy plug as it enters the bore.

Note : Check that the inner detent spring and ball have not become displaced and remove the loose dummy plug from the case sump.

Push the interlock ball into the detent bore.

11-10

11-11

Re-fit the 1st / 2nd shift rail and tighten the shift fork screw to a torque of 13 to 18 Ibs / ft. Check that the interlock ball is correctly positioned in between the two rails.

Replace the outer detent ball and spring.

Tighten the plug to a torque of 30 to 40 Ibs /ft.

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Transmission control and adjustment

11-12

11-13

4WD VERSION : Replace the 4 wheel drive shaft assembly. Lubricate the rear seal with a light grease.

Lubricate the input shaft front and rear seals a light grease and re-fit the shaft assembly into the case.

11-14

11-15

Rear case with all shaft assemblies fitted.

Position the rear case as shown and using a suitably sized tube fit a new output shaft oil seal to a depth of 6mm below the housing face. Fill the seal lip with a light grease.

11-16 11-17

Invert the case and replace the shim packs and bearing cups. The 2mm thick spacer shim should be fitted into the case first, then fit the remaining shims followed by the bearing cup. A light grease may be used to help hold the cups in the case.

Re-fit the rear case, (without sealant at this stage), and secure with at least 6 equally spaced bolts. When fitting the rear case be careful to avoid damaging the input shaft sealing rings.

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11-18

11-19

Position a D.T.I. on the end of the input shaft as shown, and using a suitable pry bar through the side access hole, measure and note the shaft end float.

Attach a suitable shimming tool, (with a 12mm thread), to the end of the reverse idler shaft. Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float.

11-20 11-21

Attach a suitable shimming tool, (with a 12mm thread), to the end of the countershaft. Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float .

11-22

Attach a suitable shimming tool, (with a 12 mm thread), to the end of the output shaft. Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float.

Remove the rear case and add or remove shims as necessary to give .001» to .003» end float on all shafts.

Repeat steps 11.17 to 11.22 until all shaft end floats are correct.

4WD VERSION : Attach a suitable shimming tool, (with a 12mm thread), to the end of the 4 wheel drive shaft.

Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float.

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Transmission control and adjustment

11-23

11-24

Replace the 4 «O»rings in the front case.

(There are only 3 fitted on the 2 wheel drive model).

Re-fit the rear case using an approved liquid gasket Taking care not to damage the input shaft sealing rings. Tighten the 17 bolts to a torque of 33 to 47 Ibs / ft.

11-25

11-26

Replace the shaft end plug and «O»ring assemblies. Note the special breather plug es fitted in the reverse idler position.

Tighten to a torque of 30 to 40 Ibs / ft.

Fit a new expansion plug to the shimming access hole using an approved sealant. Stop threaded product (P / N° 562227).

11-27

11-28

Replace the output yoke, «O»ring, washer and bolt. Then tighten to a torque of 50 to 65 Ibs / ft.

4WD VERSION : Replace the spacer, 4WD yoke, «O»ring, washer and bolt.

Then tighten to a torque of 50 to 65 Ibs / ft.

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Transmission control and adjustment

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11-29

11-30

Re-fit the cold start ball, spring and housing. Then tighten to a torque of 34 to 44 Ibs / ft.

Lubricate the seals with transmission fluid then re-fit the pressure regulator valve and tighten to a torque of 34 to 44 Ibs / ft.

11-31

11-32

Lubricate the seals with transmission fluid then re-fit the converter regulator valve and tighten to a torque of 17 to 22 Ibs / ft.

Re-fit the temperature sender and tighten to a torque of 15 to 20 Ibs / ft.

11-33

11-34

Ensure the 4 «O»ring are in place then refit the control valve assembly and tighten the 4 caps crews to a torque of 5.0 to 6.3 Ibs / ft. The valve can only be fitted one way round as it is located by a small dowel pin.

Re-fit the strainer, spacer, «O»ring and cover plate. Then tighten the two screws to a torque of 13 to 23 Ibs / ft.

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Transmission control and adjustment

11-35

11-36

Re-fit the drain plug and «O»ring assembly.

Tighten to a torque of 25 to 40 Ibs / ft.

Re-fit the 4th gear lock out screw, (when this feature is not required a shorter blanking screw is fitted). On some applications an additionnal sealing plug may be fitted.

11-37

11-38

Apply a bead of RTV joint compound (P / N° 562228) to the gear case as shown.

Re-fit the gear lever assembly and tighten the three bolts to a torque of 12 to 18 Ibs / ft.

11-39

11-40

Re-fit the filter housing and gasket.

Tighten the two bolts to a torque of 33 to 47 Ibs / ft.

Lubricate the seals with a light grease and screw on a new oil filter.

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Transmission control and adjustment

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11-41

11-42

4WD VERSION : Lubricate the seals with a light grease and re-fit the 4 wheel drive solenoid spool. Tighten to a torque of 15 to 20 Ibs / ft.

4WD VERSION : Re-fit the 4 wheel drive solenoid coil and nut. Tighten to a torque of 4 Ibs / ft maximum.

11-43

4WD VERSION : If previously removed re-fit the 4 wheel drive clutch supply pipe, apply air tightness product (P / N° 62175) to threads and thighten nuts to a torque of 5 to 7.5 Ibs / ft.

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Transmission control and adjustment

INSTALLATION AND ADJUSTEMENT OF SPEED PROBE Align a gear tooth directly in the centre of the threaded sensor opening. screw in by hand. The speed sensor (A) until it makes contact with the tooth (C). Unscrew the speed sensor by one half to three quarters of a turn (in an anti-clockwise direction).

This will set the gap (B) between the speed probe and the gear tooth to between 0,71 & 1,06 mm.

Tighten the lock nuts to a torque of between 2,5 to 5 Nm after adjustment is completed

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Transmission control and adjustment

TEST PROCEDURE

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68

Transmission control and adjustment

COMPACT PLUS TEST PROCEDURE TROUBLESHOOTING Whenever the transmission shaft is observed to malfunction, prior to dismantling anything or operating on the transmission shaft, you should first carry out a thorough inspection so as to determine the cause of the failure. The table below has been drawn up to make this task easier for you.

When checking pressures, please consult the section «CHECKING PRESSURES».

FAULT DIAGNOSIS HYDRAULIC SYSTEM FAULT Transmission fails to drive in either direction.

Transmission drives in one direction only.

POSSIBLE CAUSES Low or no pump pressure.

Low or no oil in transmission.

Mechanical failure in transmission.

Worn or broken input shaft sealing rings.

Pressure regulator valve faulty.

Direction control valve not operating.

Blockage in oil ports restricting flow.

Low oil pressure to clutch pack.

Clutch pack excessively worn.

Direction valve or coil faulty.

Mechanical failure in transmission.

Blockage in oil ports restricting flow.

Worn or damaged input shaft sealing ring.

Delay in taking up drive.

Low converter pressure.

Low oil level.

Low clutch pressure.

Faulty modulation in direction control valve .

Blockage in direction valve.

Blockage in oil ports restricting flow.

No drive from 4WD

4WD solenoid valve or coil not operating.

Mechanical failure in transmission .

Low pressure 4WD clutch pack pressure.

4WD clutch pack worn.

Transmission overheating

Oil level too high or low.

Restriction in cooler flow.

Low oil pressure.

Clutch packs slipping due to low pressure or wear.

Mechanical failure in transmission.

Excessive stall operation (01/07/2008)

Transmission control and adjustment

FAULT Difficult gear selection.

POSSIBLE CAUSES Fwd or Rev. clutch pack pressurised when not selected.

Direction valve faulty.

Input shaft sealing rings leaking.

Mechanical failure in transmission.

Fwd or Rev. clutch pack not releasing due to mechanical failure.

Vehicle moves with direction valve in neutral See» Difficult gear selection». position.

High stall speed.

Low oil level.

Air in oil.

Clutch plates slipping due to low pressure or wear.

Torque converter faulty.

Converter relief valve faulty.

Low stall speed.

Poor engine performance.

Torque converter defective.

Low pump pressure.

Worn or broken pump.

Leaking pump sealing ring or oil seal.

Blocked oil strainer or filter.

Blockage in oil ports between transmission sump and oil pump.

Pressure regulator valve stuck open.

Cold start valve stuck open.

High pump pressure.

Pressure regulator valve faulty.

Has normal operating oil temperature been reached ?

Faulty direction control valve or coil.

Piston seal or «O»ring leaking.

Input shaft sealing ring leaking.

Low forward or reverse clutch pack pressure.

Pression embrayage M. AV ou M. AR trop haute

Valve régulateur de pression défectueuse

Converter pressure low.

Converter relief valve faulty.

Leak in converter, oil cooler or connecting hoses.

Pump oil seal leaking.

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70

Transmission control and adjustment

FAULT

POSSIBLE CAUSES

Converter pressure high.

Converter relief valve faulty.

Blockage or restriction in oil cooler.

Low 4WD clutch pack pressure.

4WD piston seals leaking.

4WD shaft sealing ring leaking.

Leak from 4WD clutch supply pipe.

Faulty 4WD Solénoïd.

Blockage or restriction in 4WD clutch supply pipe.

High 4WD clutch pack pressure.

Pressure regulator valve faulty.

Low lubrication pressure.

Blockage or restriction in oil cooler.

Input shaft front sealing ring leaking.

FAULT DIAGNOSIS MECHANICAL SYSTEM FAULT Noise

POSSIBLE CAUSES Vehicle Driveline Problem : Axles, Propshafts, Engine, Engine mounts.

Mis-alignment of transmission / engine.

Bearings worn or damaged.

Gear teeth damaged or brocken.

Excessive end float of shafts or gears.

Clutch plate failure forward, reverse or 4WD. Incorrect grade of oil in transmission.

Low oil level.

Gear or thrust washer beginning to seize.

Difficult gear selection.

Shift rods worn or bent.

Synchroniser assemblies worn or damaged.

Clutch pack not releasing due to mechanical fault.

Clutch pack not releasing due to hydraulic fault.

Gear shift stub lever worn or damaged.

Incorrect grade of oil in transmission.

Low oil level.

Jumping out of Gear.

Detent springs worn or broken.

Synchroniser or gear dog teeth worn or damaged.

Synchroniser assemblies worn or damaged.

Shift forks worn, loose or twisted.

Restriction or wear in gear linkage or stub lever assy. not allowing gears to be fully selected.

Excess end float on output shaft assembly or gears.

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