Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
7-1
3-SPEED POWERSHIFT TRANSMISSION
7-2
3-SPEED POWERSHIFT TRANSMISSION
1. Specifications
7-3
3-SPEED POWERSHIFT TRANSMISSION
2. Description
2.1 Torque Converter
7 5
2
1
8
To oil cooler
200550
7-4
3-SPEED POWERSHIFT TRANSMISSION
2.2 Transmission
11
10
2 F
R
5
3 1
6
212191
7-5
3-SPEED POWERSHIFT TRANSMISSION
(58)
(58)
(35)
(46)
(24)
(56) (34)
Forward 3rd
(58)
(35)
(53)
(34)
(58)
(59)
(58)
(32)
212192
7-6
3-SPEED POWERSHIFT TRANSMISSION
(58)
(34)
Reverse 2nd
(35) (46)
(58)
(24)
(58)
(58)
(54)
(56) (34)
(58)
Reverse 3rd (35)
(53)
(34)
(58)
(59)
(35)
(58)
(32)
212193
7-7
3-SPEED POWERSHIFT TRANSMISSION
Section A - A
A A
4
B
B 5
Section B - B
1
212194
10 9 8
7 6 5 4 3 2 1
212195
7-8
Transmission hydraulic circuit
2.6 Hydraulic Controls
Accumulator valve
Torque converter Pressure at start of
charging 0.3 MPa
Speed selector valve (3.1kgf/cm 2 )[43.5 psi]
Chassis area Last chance filter Pressure at end of
S2 (2nd /3rd speed)
charging 0.76 MPa
(7.8kgf/cm 2 )[110 psi]
Orifice: Diam. 0.8 mm
(0.031 in.) Main orifice: Diam. 2.2 mm(0.087 in.)
Torque converter Orifice: Diam. 0.8 mm(0.031 in.) Differential valve
Oil cooler bypass orifice: Setting: 0.2 MPa
Diam. 4.0mm (0.157 in.) (2.0kgf/cm 2 )
Speed selector valve [29 psi]
S1 (1st speed)
Last chance
filter 2 3
Torque converter
inlet relief valve Oil filter
Setting: 0.15 to 0.69 MPa
(1.53 to 7.0 kgf/cm 2 )
[21.8 to 100 psi] Tap (plug) for
torque converter
inlet pressure 1
Oil pump (marked "T")
Capacity: 70liters T/C in Oil filter for forward/ PS
(18.5 US gal.)/min reverse clutches
at 2300rpm (marked S)
PM (particle size )
Tap (plug) for
main pressure
Lubrication (marked "M") PD
line (marked D)
Main regulator valve
Suction strainer Setting: 0.88 to 1.08 MPa
C2 CF R C 3 C1 (9.0 to 11.0 kgf/cm )
with magnet 100mesh
[127.6 to 145 psi)
F R
Transmission oil reservoir
Solenoid valve Solenoid valve
(direction selection) (direction selection)
Last chance filter Last chance filter
Orifice: Diam. 0.8 mm(0.031 in.) Orifice: Diam. 0.8 mm(0.031 in.)
212196
7-9
3-SPEED POWERSHIFT TRANSMISSION
3-SPEED POWERSHIFT TRANSMISSION
Power
source Transmission Travel speed select switch
shift lever
To meter panel VCM
Solenoid valve
212197
Location of components
Automatic 3-speed transmission system consists of the
torque converter and 3-speed transmission. The speed con-
trol system consists of the travel speed sensor, VCM (Vehi-
cle Control Module) and solenoid valves.
The truck speed can be changed from automatic speed
mode to fixed 1st speed mode by the travel speed selector
switch to select the optimum truck speed according to the
working condition.
7-10
3-SPEED POWERSHIFT TRANSMISSION
N 9
F To meter panel
5
1
4 7
3
8
4 2
212198
7-11
3-SPEED POWERSHIFT TRANSMISSION
3.1 Removal
3.1.1 Transmission removal
(1) To separate the transmission from the engine, put the
engine on a stable stand, and support the transmission
with wood blocks.
(2) Remove the hydraulic pump from the transmission.
(3) The transmission has three lifting eyes, two eyes on the
differential side and one eye on the torque converter
side.
To lift the transmission, fasten two slings to the differ-
ential side eyes and one sling (chain with lever block) to
the torque converter side eye. Balance the transmission
with the lever block and lift it at three points just enough
to take the weight of the transmission.
(4) Remove the bolts that hold the flexible plates through
the access hole in the torque converter housing.
(5) Separate the transmission from the engine by lifting it
with a hoist.
212199
NOTE
Remove the drain plug of the torque converter and drain the
oil.
7-12
3-SPEED POWERSHIFT TRANSMISSION
R solenoid
S2 solenoid S1 solenoid
212200
7-13
3-SPEED POWERSHIFT TRANSMISSION
3 6
7
3
4
212201
(1) Sequence
1 Bolts, Spring washers, Plain washers 5 Thrust washers, Thrust bearing
2 Flexible plates, Pilot boss, O-ring, Bolts, 6 Stator, Rollers, Hub, Springs, Spring caps,
Spring washers Thrust washers
3 Bolts, Drive cover, Ball bearing, Drain plug, 7 Ball bearing, O-ring, Pump boss, Pump (impeller), Bolts,
Seal washers Toothed washers
4 Thrust washer, Turbine
7-14
3-SPEED POWERSHIFT TRANSMISSION
204530
4.1.2 Inspection
(1) Pump (impeller)
(a) Check for cracks.
(b) Check for oil leaks due to looseness of the bolts hold-
ing the boss to the pump, or defective O-ring.
(c) Check the face of the pump boss in contact with the oil
seal for wear.
(d) Check the face of the pump boss in contact with the
seal ring.
7-15
3-SPEED POWERSHIFT TRANSMISSION
(2) Stator
(a) Check the blades for cracks. Also check the fit of the
stator on the clutch cam.
(b) Check the clutch hub and cam for wear or flaws.
(c) Check the springs for damage. Also check the spring
caps for wear or distortion.
(d) Check the rollers for flaws, distortion or flat spots due
to wear.
(e) Check the clutch hub splines for defects.
(f) Check the thrust washers for wear or other defects.
7-16
3-SPEED POWERSHIFT TRANSMISSION
(3) Turbine
(a) Check the vanes for cracks.
(b) Check the fit of the turbine boss in the turbine.
(c) Check the turbine boss splines for wear or other
defects.
200411
7-17
3-SPEED POWERSHIFT TRANSMISSION
4.1.3 Reassembly
10 1
13
11
4
2
9
3
12 7
13 5
212202
(1) Sequence
1 Pump (impeller) 8 Thrust washer
2 Pump boss, O-ring, Bolts, Toothed washers 9 Thrust bearing, Thrust washers
3 Ball bearing 10 Turbine
4 Stator assembly 11 Drive cover, O-ring, Bolts, Washers
5 Springs, Spring caps 12 Thrust washer, Ball bearing, Pilot boss, O-ring, Bolts,
Washers
6 Rollers 13 Flexible plates, Bolts, Plain washers,
Spring washers
7 Hub
7-18
3-SPEED POWERSHIFT TRANSMISSION
7 202885A
205922
7-19
3-SPEED POWERSHIFT TRANSMISSION
4.2 Transmission
4.2.1 Disassembly
(1)Control valve and external parts
7
4 3
5
7
6 2
1
13
16
10
15
17
14
8 11
8
12
212204
(a) Sequence
1 Air breather 9 Oil filter
2 Oil level gauge, Oil filler, O-ring, Stay, Clamp, Bolts, 10 Travel speed sensor, O-ring
Spring washers, Plug, Gasket, Nuts 11 Thermo unit
3 Oil pipe, Eye bolt, Gaskets 12 Drain plug, Gasket
4 Main regulator valve, Gasket, Bolts, Washers 13 Suction pipe, O-rings, Bolts, Spring washers
5 Oil pipe, O-rings, Bolts, Spring washers 14 Cover, O-ring, Bolts, Spring washers
6 Control valve, Gasket, Bolts, Spring washers 15 Magnet strainer assembly
7 Oil pipes, Eye bolts, Gaskets 16 Bracket, Bolts, Spring washers
8 Oil pipes, Eye bolts, Gaskets 17 Bracket, Bolts, Spring washers
7-20
3-SPEED POWERSHIFT TRANSMISSION
12
13
23
24
22
21
20
11
4
16 19
17 14
15
18 9
8
6
10
4
3
5
1, 2
212205
1 Servo case, O-ring, Bolts, 7 Output gear (2nd speed) 16 Travel speed sensor gear,
Washers 8 Output gear (3rd speed) Washers, Bolts
7-21
3-SPEED POWERSHIFT TRANSMISSION
205629
Output shaft 15 removal
Turn a sliding hammer in the M8 1.25 hole in the end of
the output shaft, and remove the shaft together with out- Output gear (1st speed)
put gear 18, ball bearing 17 and travel speed sensor gear Sliding hammer
16.
CAUTION
Be careful not to strike the travel speed sensor Travel speed
sensor gear
gear against the transmission case when remov-
ing the output shaft.
205480
The travel speed sensor gear will be deformed.
Tooling
205630
7-22
3-SPEED POWERSHIFT TRANSMISSION
7
8
9 13
2 1 18
3 12
19
4
3
15
14
16
17
11
20
23
21
10
22
212206
(a) Sequence
1 PTO cover, O-ring, Bolts, 9 Ball bearing 17 Stator shaft, Seal ring, Bolts,
Spring washers Spring washers
2 Snap ring 10 Torque converter housing, 18 Pump idler gear
Gasket, Flanged bolts
3 Pump drive gear, Seal rings 11 Oil seal 19 Roller bearing
4 Ball bearing 12 Idler gear shaft 20 Roller bearing (outer race)
5 Pump case, O-ring, Bolts, 13 Roller bearing 21 Roller bearing (outer race)
Spring washers
6 Pump plate, O-ring, Gasket 14 PTO drive gear 22 Roller bearing (outer race)
7 Internal gear 15 Ball bearing 23 Transmission case, Dowels
8 Pump drive gear 16 Ball bearing
7-23
3-SPEED POWERSHIFT TRANSMISSION
210188
210193
7-24
3-SPEED POWERSHIFT TRANSMISSION
7-25
3-SPEED POWERSHIFT TRANSMISSION
5 12
13
15
4
14
3
2 16
1
14
15
13
12
11
10
6
7
11
11 8
9
10
11
212207
(a) Sequence
1 Seal rings 9 Thrust washer, Snap ring
2 Ball bearing 10 Snap rings, Pressure plates
3 Thrust washer 11 Friction plates, Mating plates
4 Gear (2nd-speed drive), Needle roller bearings 12 Snap rings, Retainers
5 Thrust washer 13 Clutch springs
6 Roller bearing 14 Clutch pistons, Piston seals
7 Thrust washer 15 Seal rings
8 Gear (forward drive), Needle roller bearings 16 Forward clutch shaft
NOTE
Do not attempt to remove the screws from the forward
clutch shaft
7-26
3-SPEED POWERSHIFT TRANSMISSION
207504
7-27
3-SPEED POWERSHIFT TRANSMISSION
5 12
13
4 15
14
3
2 16
1
14
15
13
12
11
10
6
11 11 7
8
9
10
11
212208
(a) Sequence
1 Seal rings 9 Thrust washer
2 Ball bearing 10 Snap rings, Pressure plates
3 Thrust washer 11 Friction plates, Mating plates
4 Gear (3rd-speed drive), Needle roller bearings 12 Snap rings, Retainers
5 Thrust washer 13 Clutch springs
6 Roller bearing 14 Clutch pistons, Piston seals
7 Thrust washer 15 Seal rings
8 Gear (1st-speed drive), Needle roller bearings 16 1st-speed/3rd-speed clutch shaft
7-28
3-SPEED POWERSHIFT TRANSMISSION
9
10
12
11
13
2
1
3
4
8 5
6
7
212209
(a) Sequence
1 Seal rings 8 Friction plates, Mating plates
2 Ball bearing 9 Snap ring, Retainer
3 Roller bearing 10 Clutch spring
4 Thrust washer 11 Clutch piston, Piston seal
5 Gear (reverse drive), Needle roller bearings 12 Seal ring
6 Thrust washer, Snap ring 13 Reverse clutch shaft
7 Snap ring, Pressure plate
7-29
3-SPEED POWERSHIFT TRANSMISSION
4.2.2 Inspection
(1) Oil pump
(a) Put the internal gear and pump gear in the pump case,
and measure top clearance 2.
(b) Using a dial indicator, measure side clearance 1
between the gears and pump case.
0.040 to 0.078
Side clearance 1 Standard value
(0.00157 to 0.00307)
mm (in.)
Service limit 0.09 (0.0035) 2
0.3 to 0.345
Top clearance 2 Standard value
(0.0118 to 0.0136)
mm (in.) 1
Service limit 0.35 (0.0138) 205486
7-30
3-SPEED POWERSHIFT TRANSMISSION
7-31
3-SPEED POWERSHIFT TRANSMISSION
205635
(6) Gears
(a) Check each gear for worn teeth or splines.
(b) Check the needle bearing sliding surfaces of the gear
for wear or damage.
(7) Magnet strainer assembly
Disassemble and clean the strainer. Replace the strainer
if defective.
(8) Transmission cover and torque converter housing oil
seals
Replace the oil seals with new ones.
7-32
3-SPEED POWERSHIFT TRANSMISSION
4.2.3 Reassembly
(1) Forward clutch shaft subassembly
(1st-speed/3rd-speed clutch shaft subassembly/reverse clutch shaft subassembly)
5 10 9 7 8 4 7 8 4 9 10 5 11
16 6
14 15
6
21
20 19 17
12 13
18 2 3 2
212211
(a) Sequence
1 Forward clutch shaft, 1st-speed/3rd-speed clutch shaft, 11 Thrust washer
or reverse clutch shaft 12 Needle roller bearings
2 Sealing rings, Piston seals 13 Gear (forward drive)
3 Clutch pistons 14 Thrust washer
4 Clutch springs 15 Roller bearing
5 Retainers 16 Thrust washer
6 Snap rings 17 Needle roller bearings
7 Mating plates 18 Gear (2nd-speed drive)
8 Friction plates 19 Thrust washer
9 Pressure plates 20 Ball bearing
10 Snap rings 21 Seal rings
NOTE
The reassembly sequence and suggestions for the reverse
clutch shaft subassembly are similar to the forward clutch
shaft subassembly as far as the clutch is concerned.
7-33
3-SPEED POWERSHIFT TRANSMISSION
Piston installation
When putting pistons 3 in the clutch drum, apply ATF
(automatic transmission fluid) to their seal ring contact
surfaces.
207504
Friction and mating plate installation
Make sure that the position and number of the plates are Mating plate
correct. Install the plates while applying ATF to them.
Friction plate
When replacing the friction plates, replace the mating
plates, too.
207516
Thrust washer installation
Install thrust washers 11, 14, 16 and 19 with the side that
has oil grooves toward the gear.
203800
Piston testing
After reassembling the clutch, apply pressure air of
approximately 690 kPa (7 kgf/cm2) [100 psi] to the oil
hole to make sure that the piston move freely without any
sign of air leaks.
7-34
3-SPEED POWERSHIFT TRANSMISSION
15 16
12
18
17
19
14 20
1 13
3
9
10
4
6
5 11
205638
(a) Sequence
1 Transmission case, Dowels 8 Idler gear shaft 15 Pump plate, O-ring, Gasket,
Bolts, Spring washers
2 Roller bearing 9 Roller bearing 16 Ball bearing
3 Idler gear 10 Oil seal 17 Pump drive gear, Seal rings
4 Stator shaft, Seal ring, Bolts, 11 Torque converter housing, 18 Ball bearing
Spring washers Gasket, Flanged bolts
5 Ball bearing 12 Pump case, O-ring, Bolts, Spring 19 Snap ring
washers
6 PTO drive gear 13 Internal gear 20 PTO cover, O-ring, Bolts,
7 Ball bearing 14 Pump gear Spring washers
NOTE
The dowels fitted into the transmission case should not been
removed. These dowels are for locating the pump case,
torque converter housing and transmission cover subassem-
bly for installation.
7-35
3-SPEED POWERSHIFT TRANSMISSION
pump drive gear with the Pump drive gear holder (special
tool), or have someone press the gear with a copper bar or
the like, in order to prevent the gear from coming off.
Special tool needed
Pump drive gear holder (to be made by dealer)
)
39
(0. 1)
10 (0.
3
8
)
39 10
)
(0. (1.
10 28
205492
7-36
3-SPEED POWERSHIFT TRANSMISSION
25 1
17
19 4
26
7
27
2
18
24
23 22 21 20 14 16 9 15 10 11 12 13
212212
7-37
3-SPEED POWERSHIFT TRANSMISSION
(a) Sequence
1 Roller bearing (outer race) 15 Baffle plate, Bolts, Spring washers
2 Roller bearing (outer race) 16 Baffle plate, Bolts, Spring washers
3 Roller bearing (outer race) 17 Forward clutch shaft subassembly
4 Ball bearing 18 1st-speed/3rd-speed clutch shaft subassembly
5 Input shaft 19 Reverse clutch shaft subassembly
6 Snap ring 20 Output gear (3rd speed)
7 Input gear 21 Output gear (2nd speed)
8 Lock nut 22 Ball bearing
9 Output shaft 23 Oil seals
10 Snap ring 24 Transmission cover subassembly, Gasket, Bolts,
11 Output gear (1st speed) Spring washers, O-rings
7-38
3-SPEED POWERSHIFT TRANSMISSION
205494
10 (0.39) 28 (1.10)
170 (6.69) 1.5 (0.06)
205495
205640
7-39
3-SPEED POWERSHIFT TRANSMISSION
8
12 13
11
8
10 14
15
6
17
1
16
2
7 4
7
3
212213
(a) Sequence
1 Magnet strainer assembly 10 Control valve, Gasket, Bolts, Spring washers
2 Cover, O-ring, Bolts, Spring washers 11 Oil pipe, O-rings, Bolts, Spring washers
3 Plug, Gasket 12 Main regulator valve, Gasket, Bolts, Spring washers
4 Thermo unit 13 Oil pipe, Eye bolt, Gaskets
5 Travel speed sensor, O-ring 14 Oil level gauge, Oil filler, O-ring, Stay, Clump, Bolts,
Spring washers, Plug, Nut
6 Suction pipe, O-rings, Bolts, Spring washers 15 Air breather
7 Oil pipe, Eye bolt, Gaskets 16 Bracket, Bolts, Spring washers
8 Oil pipe, Eye bolt, Gaskets 17 Bracket, Bolts, Spring washers
9 Oil filter
7-40
3-SPEED POWERSHIFT TRANSMISSION
1
2
3
4
5
18 17
19 4
A
17 6
2 A
1
15
13
14
7
16 13
10
9
12
11
212214
(1) Sequence
1 Solenoid valves, O-rings 7 Snap ring, Plug, O-ring 13 Pin, Seat, O-ring
2 Springs, Spring seats 8 Inching dummy spool 14 Oil filter, O-rings
3 Direction valve 9 Snap ring, Plug, O-ring 15 Last chance filters (four)
4 Solenoid valves, O-rings 10 Spring, Differential valve 16 Roller bearing, Plug
5 1st-speed valve, Spring 11 Plate, O-ring, Bolts, Washers 17 Roller bearing, Plug
6 2nd-speed/3rd-speed valve, 12 Accumulator valve piston, 18 Plug, O-ring
Spring Springs (inner and outer) 19 Valve body, Gasket
CAUTION
Slowly loosen each bolt and solenoid valve so that
the spring and plunger do not suddenly jump out.
7-41
3-SPEED POWERSHIFT TRANSMISSION
4.3.2 Inspection
(1) Check the oil holes in the valve body for restriction.
(2) Check the valves for wear or damage. Make sure the
valve moves freely.
(3) Replace all oil seals with new ones.
(4) Replace oil filter 16 with a new one.
(5) Wash oil filter 15, or replace it with a new one.
7-42
3-SPEED POWERSHIFT TRANSMISSION
4.3.3 Reassembly
(1) Preparation
Wash the oil passages in the control valve thoroughly
and make sure they are not restricted.
17 3 16 17
18
18
4 5 13
Section A - A
12
A A
19
11
15
10
9 B 15
B
8
14
Section B - B
6
7
2 1
212216
(2) Sequence
1 Valve body 11 Inching dummy spool
2 Plug, Roller bearing 12 Plug, O-ring, Snap ring
3 Plug, Roller bearing 13 1st-speed valve, Spring
4 Last chance filters (four) 14 2nd-speed/3rd-speed valve, Spring
5 Oil filter, O-ring 15 Solenoid valves, O-rings (two)
6 Seat, O-ring, Pin 16 Direction valve
7 Springs (inner and outer), Accumulator piston 17 Spring seats, Springs
8 Plate, O-ring, Bolts, Spring washers 18 Solenoid valves, O-rings (two)
9 Differential valve, Spring 19 Plug, O-ring
10 Plug, O-ring, Snap ring
7-43
3-SPEED POWERSHIFT TRANSMISSION
2
5
6 4 3
212217
(1) Sequence
1 Cover, O-ring, Bolts, Sprig washers 4 Spring
2 Slug 5 Cover, O-ring, Bolts, Sprig washers
3 Spool 6 Body
CAUTION
Slowly loosen bolts 1 so that the spring, spool and
slug do not suddenly jump out.
7-44
3-SPEED POWERSHIFT TRANSMISSION
5. Adjustment
5.1 Brake pedal and inching pedal adjustment
(1) Set inching pedal 1 at 45 by using bolt 2 and nut 3.
le)
e)
(2) Place brake pedal 4 at the same height as inching pedal
ang
k
tro
1 by using bolt 5 and nut 6.
(S
ting
(3) Eliminate the clearance between inching pedal 1 and
22
set
brake pedal 4 by using bolt 7 and nut 8.
dal
8 1
(Pe
45
7
2 3
212218
4 1
5, 6 2, 3
212219
Cutoff point
212220
7-45
3-SPEED POWERSHIFT TRANSMISSION
CAUTION
Front tires rotate during the measurement. Build a
fence around the truck to prevent access to it.
NOTE
Always perform pedal adjustments before oil pressure mea-
surement.
NOTE
Parts marked with an asterisk (*) are included in the gauge
kit 64309 - 17701. 212221
(2) Idle the engine and check that the transmission oil is up
to the specified level.
(3) Warm up the engine to raise the transmission oil tem-
perature.
(4) Keep the engine idling (at between 1000 and 1500
rpm).
(5) Under the above condition, perform the oil pressure
measurement.
Main oil pressure 0.88 to 1.08 MPa
Standard
(with engine idling at (9.0 to 11.0 kgf/cm2)
value
1500100 rpm) [128 to 157 psi]
NOTE
Monitor the idling speed through engine tachometer during
measurement.
7-46
3-SPEED POWERSHIFT TRANSMISSION
NOTE
Use the same special tools as used for main oil pressure
measurement.
(2) Lift the front tires off the floor by either of the follow-
ing methods.
(a) The front axle housing is jacked up.
(b) The mast is tilted all the way backward first. With a 212222
7-47
3-SPEED POWERSHIFT TRANSMISSION
(2) Idle the engine and check that the transmission oil is up
to the specified level.
(3) Warm up the engine to raise the transmission oil tem-
perature.
(4) Keep the engine idling (at between 1000 and 1500
212223
rpm), measure the torque converter inlet oil pressure.
Torque converter inlet
0.15 to 0.69 MPa
oil pressure Standard
(1.5 to 7.0 kgf/cm2)
(with engine idling at value
[22 to 100 psi]
1500100 rpm)
NOTE
Monitor the idling speed through engine tachometer during
measurement.
7-48
3-SPEED POWERSHIFT TRANSMISSION
CAUTION
Do not attempt to depress the inching pedal. Do
not continue operation in stall condition for more
than 30 seconds. Failure to follow this precaution
would result in destruction of the torque con-
verter.
NOTE
(a) Any stall speed within 10 rpm tolerance of the speci-
fication is satisfactory.
(b) If the engine or torque converter is changed, the stall
speed will vary since the stall speed is determined by
the combination of engine and torque converter.
7-49
3-SPEED POWERSHIFT TRANSMISSION
212224
7-50
3-SPEED POWERSHIFT TRANSMISSION
6. Troubleshooting
7-51
3-SPEED POWERSHIFT TRANSMISSION
7-52
3-SPEED POWERSHIFT TRANSMISSION
7-53
3-SPEED POWERSHIFT TRANSMISSION
Oil level too high or too low Keep correct oil level.
Oil strainer clogged Clean or replace.
Rubbing vanes of running members Repair or replace.
Stator freewheel defective Replace stator assembly.
Torque con- Air being sucked in Retighten or replace O-ring.
verter Water in oil Replace oil.
Restriction in oil pipe (resulting in reduced circulation Repair or replace.
flow)
Oil tem-
perature is Bearings worn or seized Repair or replace.
too high Instruments out of order Replace.
Clutches dragging Replace clutch plates.
Transmission
Bearings worn or seized Repair or replace.
Truck not operated properly Advice user to drive truck properly.
Others
Others Cooling fan belt damaged Replace.
Oil cooler clogged Clean or replace.
Brakes grabbing Check and readjust.
7-54
3-SPEED POWERSHIFT TRANSMISSION
Lack of engine power if the speed is slightly low in both Tune up engine.
forward and reverse drive
Stall speed out of specifi-
Stator and freewheel defective if the speed is excessively Replace stator assembly.
cation
low in both forward and reverse drive
Clutch slipping if the speed is too high Repair or replace.
Travel speed select switch in Fixed 1st speed position Move switch to 2 or D position.
Solenoid valve defective Replace.
No automatic shifting Solenoid valve inlet orifice clogged Clean or replace.
Solenoid valve spool or spring defective Repair or replace.
ECU control box internally defective Check or replace.
7-55
3-SPEED POWERSHIFT TRANSMISSION
7. Service Data
7.1 Stall Speed, Hydraulic
200721
7-56
3-SPEED POWERSHIFT TRANSMISSION
212225
1
212226
7-57
3-SPEED POWERSHIFT TRANSMISSION
7.5 Stator
3 4 1 2 5 6 7
212227
7-58
3-SPEED POWERSHIFT TRANSMISSION
200725
7-59
3-SPEED POWERSHIFT TRANSMISSION
7.7 Clutches
6 2 1 3
212228
7-60
3-SPEED POWERSHIFT TRANSMISSION
7.8 Forward Clutch Shaft, Reverse Clutch Shaft, 1st-Speed/3rd-Speed Clutch Shaft and Servo Case
1, 2 3 5, 6
7, 8
9 4
212230
7-61
3-SPEED POWERSHIFT TRANSMISSION
1 6
2 7
3
2
2
1
3
5
4
3 1
212229
7-62
3-SPEED POWERSHIFT TRANSMISSION
5 5
2 1
4
3
212231
7-63
3-SPEED POWERSHIFT TRANSMISSION
212232
7-64
3-SPEED POWERSHIFT TRANSMISSION
212233
7-65