Spare Parts Catalogue Getman Part 2

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Beschnitt Beschnitt
S1057
DEUTZ AG
Service-Technik
Instandhaltungstechnik Motoren
Deutz-Mlheimer Str. 147-149
D-51057 Kln
Tel.: ++49 (0)2 21-8 22-0
Fax: ++49 (0)2 21-8 22-53 58
U4_Impr_2012_9957
http: //www.deutz.de
Printed in Germany
All rights reserved
1st Edition, 11/02
We move your world. Order No.: 0312 0836
Beschnitt MAGENTA = HKS 14K SCHWARZ Beschnitt

F1012
F1012
F1012
F1012
DEUTZ 2012 FUEL & OIL 13715
FILTERS Page 1 of 1
ITEM PART # DESCRIPTION QTY.

1 44238 ENGINE OIL FILTER ELEMENT (SPIN ON) 1
2 44235 PRE FILTER ASSEMBLY (FUEL/WATER SEPARATOR) 1
3 44236 CARTRIDGE ONLY FOR 44235 (ITEM 2) 1
4 44239 GASKET SET ONLY FOR 44235 (ITEM 2) 1
5 44237 FUEL FILTER ELEMENT (SPIN ON) 2
6* 44252 FAN BELT (DEUTZ 2012) 1
*ITEMS NOT SHOWN Updated:

03/08/07
17096
RADIATOR INSTALLATION
Page 1 of 2

08/22/07
17096
RADIATOR INSTALLATION
Page 2 of 2
1 465112 RADIATOR ASSEMBLY 1
2 43GH250 CLAMP 6
4 43GH400 CLAMP 4
5 12567-05 HUMP HOSE 2
6 19125-13 CHARGE AIR TUBE (RH) 1
7 12567-07 HUMP HOSE 1
8 43GH300 CLAMP 2
9 NA HOSE 2 ID A/R
11 605726 TUBE (COOLANT) A/R
12 12350-01 CHARGE AIR TUBE (LH) 1
15 605726 TUBE (COOLANT) A/R
16* 1185-09 WASHER (MOUNTING) 8
17* 84229 PRESSURE CAP 1
18* 10592-07 FLANGE (ADAPTER) 1
19* 465271 FAN (BLOWER) 1
20* 534606 SIGHT GAUGE 1
22* 18483-01 TANK (SURGE) 1
23* 12457-05 TUBE, SURGE TANK (OPTIONAL) 1

08/22/07
AIR INTAKE & EXHAUST 13753
SYSTEMS Page 1 of 1

1 94653 HOSE (3 ID) 1
2 12457-09 TUBE WELDMENT 1
3 12346-01 TUBE WELDMENT 1
4 604117 AIR INLET HOOD 1
5 604116 AIR CLEANER (10) 1
6 604119 RUBBER ELBOW REDUCER (5 4) 1
7 12456-01 EXHAUST FLANGE WELDMENT 1
8 19188-08 ELBOW (4) 1
9 19188-07 EXHAUST TUBE WELDMENT 1
10 594993 PURIFIER 1
11 594570 SILENCER 1
12 15951-01 DIFFUSER WELDMENT 1
Updated:
01/03/07
11968
AIR CLEANER
Page 1 of 1

604116 AIR CLEANER (INCLUDES ITEMS 1-8) 1
1 604795 CUP/ASSEMBLY 1
2 604796 CLAMP ASSEMBLY 1
3 604797 PRIMARY ELEMENT 1
4 284052 SAFETY ELEMENT 1
5 604264 VACUATOR VALVE 1
6 604798 BAFFLE ASSEMBLY 1
7 604708 NUT ASSEMBLY 1
8 604799 O-RING 1
9 604464 INDICATOR 20 (DEUTZ 912W) 1
605505 INDICATOR 30 (3304, 3006 PCT) 1
605512 INDICATOR 25 (3304, 3306 PCNA) 1
10 604117 INLET HOOD 1
11 604687 PRECLEANER 1
12 604118 MOUNTING BAND 2

05/25/07
S1020
S1020
MANUAL INDEX
A-64 DUNBAR ANFO
MINERA BISMARK
S/N 6964
11/02/07
5. DRIVE TRAIN
17055 TRANSMISSION
16922 TRANSMISSION MOUNTS
S1036 TRANSMISSION MAINTENANCE & SERVICE
MANUAL
17101 DRIVELINE INSTALLATION
17055
TRANSMISSION ASSEMBLY
Page 1 of 35
Updated:
05/25/07
17055
Page 2 of 35

CONVERTER HOUSING GROUP
465425 TRANSMISSION ASSEMBLY 1
1 244451 CONVERTER HOUSING ASSEMBLY 1
2 244452 SLEEVE (CONVERTER HOUSING) 2
3 244314 PIPE PLUG 1
4 244453 PIPE PLUG 1
5 244454 GASKET (CONVERTER HOUSING) 1
6 244455 SCREW (CONVERTER HOUSING) 18
7 244321 LOCKWASHER 18
8 244456 PIN (CONVERTER HOUSING) 1
9 244457 CLIP 2
10 24474 SCREW (CLIP) 2
11 244458 LOCKWASHER (CLIP) 2
12 24240 AIR BREATHER 1
13 244312 PLUG (INCLUDES ITEM 14) 5
14 24830 O-RING 5
15 244459 PIPE PLUG 1
16 244460 O-RING 1
17 244461 SCREW 1
Updated:
05/25/07
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Updated:
05/25/07
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Page 4 of 35

CASE & REAR GROUP
1 244462 TRANSMISSION CASE (INCLUDES ITEMS 2-9) 1
2 244463 SUCTION TUBE (INCLUDES ITEM 7) 1
3 244464 O-RING (SUCTION TUBE) 1
4 24245 TUBE (LOW SPEED) 1
5 24337 SLEEVE 4
6 244465 TUBE (3RD) 1
7 244466 CLIP 1
8 24436 SCREW 1
11 24461 O-RING 1
13 244402 O-RING 1
14 244468 REAR COVER ASSEMBLY (INCLUDES ITEM 15) 1
16 24461 O-RING 1
17 244469 OIL BAFFLE 1
18 244470 GASKET (TRANSMISSION CASE) 1
19 24467 O-RING (CLUTCH PRESSURE TUBE) 4
20 24080 O-RING (CLUTCH PRESSURE) 1
21 244456 PIN (TRANSMISSION CASE) 2
22 244195 SCREW (REAR COVER) 20
23 244321 LOCKWASHER (REAR COVER) 20
24 24339 PLUG (MAGNETIC DRAIN) 2
25 23033 PLUG (DRAIN) 1
26 244459 PLUG (SPEED PORT) 2
27 244460 O-RING (SPEED PORT) 2
28 244461 SCREW (SPEED PORT) 2
30 244471 COVER 1
Updated:
05/25/07
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Page 5 of 35
31 244472 GASKET (COVER) 1
32 24191 SCREW (COVER) 2
33 244154 LOCKWASHER (COVER) 2
34 24255 DIPSTICK TUBE 1
35 24256 DIPSTICK 1
Updated:
05/25/07
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Updated:
05/25/07
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TURBINE SHAFT GROUP
1 244473 TURBINE SHAFT ASSEMBLY (INCLUDES ITEM 2) 1
2 24497 RETAINER RING 1
3 244474 BEARING 1
4 24258 SNAP RING 1
5 24257 WASHER 1
6 24086 RING 1
7 244475 RING (PISTON) 1
8 244476 SUPPORT (STATOR) 1
9 244477 SCREW (STATOR SUPPORT) 6
11 244669 OIL BAFFLE ASSEMBLY (INCLUDES ITEM 12) 1
12 244480 SEAL (OIL BAFFLE) 1
13 244481 RING (OIL BAFFLE SEAL) 1
14 244128 RING (OIL BAFFLE RETAINING) 1
Updated:
05/25/07
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Page 8 of 35

DRIVE PLATE GROUP
1 244443 DRIVE PLATE ASSEMBLY KIT (INCLUDES ITEMS 1-4) 1
2 NSS DRIVE PLATE 5
3 NSS DRIVE PLATE BACKING RING 1
4 NSS DRIVE PLATE MOUNTING SCREW & LOCKWASHER 10
Updated:
05/25/07
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Page 9 of 35

TORQUE CONVERTER
1 244482 TORQUE CONVERTER ASSEMBLY 1
2 24265 BEARING 1
3 244483 RING 1
4 24342 PLUG (TORQUE CONVERTER) 1
5 24077 O-RING 1
6 24524 RING (SNAP) 1
7 244484 RING (RETAINING) 2
Updated:
05/25/07
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Page 10 of 35

GEAR GROUP
1 244485 GEAR (REVERSE) 1
2 244670 GEAR (1ST) 1
3 244487 GEAR (LOW) 1
4 244488 GEAR (IDLER REAR) 1
5 244489 GEAR (IDLER FRONT) 1
6 244490 GEAR (OUTPUT) 1
Updated:
05/25/07
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Page 11 of 35

AUXILIARY PUMP DRIVE
1 244491 PUMP DRIVE BEARING SUPPORT 1
2 244492 BEARING SUPPORT SCREW 1
3 244493 PIN (BEARING) 1
4 244494 BEARING 1
5 24083 DRIVE GEAR BEARING RETAINING RING 1
6 244495 GEAR (AUX PUMP DRIVE) 1
7 244496 COVER (PUMP) 1
8 244497 GASKET (COVER) 1
9 244270 SCREW (COVER) 2
10 244498 LOCKWASHER (COVER) 2
Updated:
05/25/07
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Page 12 of 35

PUMP DRIVE GROUP
1 244491 PUMP DRIVE BEARING SUPPORT 1
2 244492 PIN (BEARING) 1
3 244493 SCREW (BEARING) 1
4 244494 BEARING 1
5 24083 RING (DRIVE GEAR) 1
6 244499 GEAR (CHARGING) 1
7 244500 GEAR (PUMP DRIVE) 1
8 24767 SHAFT (IDLER GEAR) 1
9 244501 BALL 1
10 24540 BEARING 1
11 24081 RING (BEARING LOCATING) 2
12 24227 RING (BEARING RETAINING) 2
Updated:
05/25/07
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Updated:
05/25/07
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FORWARD SHAFT GROUP
1 244502 FORWARD SHAFT DRUM ASSEMBLY 1
2 24280 CLUTCH PISTON (INCLUDES ITEMS 3, 4) 1
3 24206 CLUTCH PISTON SEAL (OUTER) 1
4 24207 CLUTCH PISTON SEAL (INNER) 1
5 24208 CLUTCH INNER DISC 8
6 24209 CLUTCH OUTER DISC 8
7 24277 SPACER (PISTON) 1
8 24279 CLUTCH DISC BACKING PLATE 1
9 24278 SNAP RING (BACKING PLATE) 1
10 24523 DISC SPRING ASSEMBLY (INCLUDES 5 WASHER) 1
11 24276 SNAP RING (SPRING RETAINING) 1
12 24347 FORWARD SHAFT PISTON RING 2
13 24275 FORWARD SHAFT PILOT BEARING 1
14 244503 BEARING 1
15 24283 GEAR RETAINING RING 1
16 244504 BEARING RETAINING RING 1
17 244670 GEAR (1ST DRIVE) 1
Updated:
05/25/07
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Page 15 of 35

REVERSE IDLER GROUP
1 244505 REVERSE IDLER SHAFT 1
2 24090 REVERSE IDLER GEAR BEARING 1
3 244506 WASHER 1
4 244507 NUT (BEARING RETAINER) 1
5 244508 WASHER (BEARING) 1
6 24872 LOCKBALL (IDLER SHAFT) 1
8 244510 O-RING (SHAFT) 1
Updated:
05/25/07
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Page 16 of 35
Updated:
05/25/07
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Page 17 of 35

ND
REVERSE & 2 SHAFT GROUP
ND
1 244511 REVERSE & 2 SHAFT DRUM ASSEMBLY 1
2 24280 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3 & 4) 1
3 24206 OUTER CLUTCH PISTON SEAL 1
4 24207 INNER CLUTCH PISTON SEAL 1
5 244331 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 6 & 7) 1
12 24277 PISTON RETURN SPRING SPACER 1
14 24278 BACKING PLATE SNAP RING 2
15 24296 PISTON RETURN SPRING 1
16 24297 RETAINER (SPRING) 1
17 24523 DISC SPRING ASSEMBLY (INCLUDING 5 WASHER) 1
18 24298 SNAP RING (SPRING) 1
19 24293 BEARING (GEAR) 1
21 24292 RING (GEAR) 2
22 244512 BEARING 1
23 244190 RING (RETAINING) 1
24 24290 SNAP RING 1
27 244513 HUB (2ND CLUTCH) 1
28 24298 RING (2ND CLUTCH) 1
29 244514 BEARING 1
Updated:
05/25/07
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Page 18 of 35
30 244515 RETAINER (RING) 1
31 244516 RING (LOCATING) 1
32 244517 SPACER 1
Updated:
05/25/07
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Updated:
05/25/07
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Page 20 of 35

LOW SPEED SHAFT GROUP
1 244518 LOW SHAFT HUB DRUM ASSEMBLY 1
2 24280 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3, 4) 1
3 24206 SEAL (CLUTCH PISTON OUTER) 1
4 24207 SEAL (CLUTCH PISTON INNER) 1
8 24300 BACKING PLATE RETAINING RING 1
9 24278 DISC SPRING ASSEMBLY (INCLUDES 7 WASHER) 1
10 24298 SNAP RING (SPRING RETAINER) 1
11 244520 SPACER (WASHER) 1
14 244522 RING (GEAR BEARING) 2
16 244524 BEARING 1
17 244525 SPACER (GEAR) 1
18 244526 BEARING 1
20 244527 RETAINER (WASHER) 1
21 244487 GEAR (LOW CLUTCH) 1
Updated:
05/25/07
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Page 21 of 35
Updated:
05/25/07
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Page 22 of 35

RD
3 SHAFT CLUTCH GROUP
RD
1 244529 3 CLUTCH SHAFT, DRUM & PLUG ASSEMBLY 1
2 244331 CLUTCH PISTON ASSEMBLY (INCLUDES ITEMS 3, 4) 1
7 24279 DISC BACKING PLATE 1
8 24278 BACKING PLATE SNAP RING 1
9 24296 PISTON RETURN SPRING 1
10 24297 SPRING RETAINER 1
11 24298 SPRING RETAINER SNAP RING 1
12 244190 FRONT BEARING RETAINING RING 1
13 244512 BEARING 1
14 24290 FRONT BEARING SNAP RING 1
RD
16 24347 HUB (3 CLUTCH) 1
RD
17 24300 RING (3 DISC HUB) 1
18 244514 BEARING 1
Updated:
05/25/07
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Page 23 of 35

IDLER SHAFT GROUP
1 244524 SHAFT (IDLER) 1
2 244474 BEARING 1
3 24258 SNAP RING (BEARING) 1
4 244530 BEARING 1
5 24064 NUT 1
6 24063 WASHER 1
7 24321 SPACER 1
8 24556 SNAP RING 1
9 244488 GEAR 1
10 244489 GEAR 1
Updated:
05/25/07
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Updated:
05/25/07
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OUTPUT SHAFT GROUP
1 244531 SHAFT OUTPUT 1
2 244532 BEARING OUTPUT SHAFT REAR 1
3 244533 BEARING OUTPUT SHAFT FRONT 1
4 244534 RING OUTPUT SHAFT REAR BEARING 1
5 24575 RING OUTPUT SHAFT REAR BEARING RETAINING 2
6 244235 SEAL OUTPUT SHAFT 2
7 24318 STUD BEARING CAP 4
9 24488 NUT STUD 4
10 244537 CAP OUTPUT SHAFT REAR BEARING 1
11 24491 O-RING OUTPUT SHAFT REAR BEARING 1
12 24490 O-RING OUTPUT SHAFT REAR BEARING 1
13 244538 SPACER GEAR 1
14 24321 SPACER GEAR 1
15 24489 O-RING FLANGE 1
16 24063 WASHER FLANGE 1
17 24064 NUT WASHER 1
18 24324 SPACER BEARING TO FLANGE 1
19 244490 GEAR OUTPUT 1
20 244450 FLANGE FRONT 1
21 24062 FLANGE REAR 1
Updated:
05/25/07
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Page 26 of 35

CHARGING PUMP GROUP
1 244539 CHARGING PUMP 1
2 24079 GASKET- PUMP ASSEMBLY TO CONVERTER HOUSING 1
3 24080 O-RING 1
4 244540 PUMP MOUNTING SCREW 1
4A 244541 PUMP MOUNTING SCREW 4
5 244321 PUMP MOUNTING SCREW LOCKWASHER 5
Updated:
05/25/07
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Page 27 of 35

OUTPUT FLANGE GROUP
1 24106 OUTPUT FLANGE (FRONT) 1
2 24062 OUTPUT FLANGE (REAR) 1
Updated:
05/25/07
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Page 28 of 35

REMOTE FILTER GROUP
244447 FILTER & ADAPTOR ASSEMBLY (INCLUDES ITEMS 1, 2) 1
1 244449 FILTER ADAPTOR 1
2 244448 FILTER (ELEMENT) 1
Updated:
05/25/07
17055
Page 29 of 35

CONTROL VALVE GROUP
(BEFORE TRANSMISSION S/N HBEA235758)
1 244671 ELECTRIC CONTROL VALVE ASSEMBLY 1
2 244335 GASKET 1
3 244334 SCREW 9
Updated:
05/25/07
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Page 30 of 35
Updated:
05/25/07
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Page 31 of 35

CONTROL VALVE ASSEMBLY
(BEFORE TRANSMISSION S/N HBEA235758)
244671 CONTROL VALVE ASSEMBLY ELECTRIC (12 VOLT) 1
(INCLUDES ITEMS 1-32)
244722 CONTROL VALVE ASSEMBLY ELECTRIC (24 VOLT) 1
(INCLUDES ITEMS 1-32)
1 244672 CONTROL VALVE HOUSING ASSEMBLY 1
2 244354 COVER CONTROL VALVE 1
3 244355 GASKET CONTROL VALVE COVER 1
4 244338 SPOOL FWD. & REV. SHIFT 2
5 244339 SPRING 2
RD
6 244361 SPOOL RANGE (3 ) 1
7 244467 VALVE HOUSING PLUG (INCLUDES ITEM 8) 2
8 244402 O-RING 2
9 244358 STOP SPOOL 1
10 244673 PIN 1
11 244360 PLUG STOP 1
12 244356 SPOOL RANGE (1ST & 2ND) 1
13 244339 SPRING 1
14 244542 PIPE PLUG 8
15 244453 PLUG 1
16 244674 SCREW 1
17 24495 SCREW 2
19 244675 SPOOL STOP 1
20 244676 FORWARD & REVERSE DECLUTCH SPOOL 1
21 244677 SPRING DECLUTCH 1
23 244159 O-RING 1
24 244139 CARTRIDGE BALL VALVE (INCLUDES ITEMS 25-27) 4
25 244682 O-RING 4
26 244406 O-RING 4
Updated:
05/25/07
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Page 32 of 35
27 244172 O-RING 4
28 244678 COIL (12 VOLT) 4
244408 COIL (24 VOLT) 4
29 244679 NUT 4
30 244407 O-RING 8
31 244680 COVER SOLENOID 1
32 244681 SPACER COVER 2
Updated:
05/25/07
17055
Page 33 of 35

1 244778 CONTROL VALVE ASSEMBLY 1
(STARTING WITH TRANSMISSION S/N HBEA235758)
2 244778-01 GASKET 1
3 244674 CAPSCREW 4
4 244289 CAPSCREW 3
5 244150 CAPSCREW 2
Updated:
05/25/07
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Page 34 of 35
Updated:
05/25/07
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Page 35 of 35

244778 CONTROL VALVE ASSEMBLY 1
(STARTING WITH TRANSMISSION S/N HBEA235758)
1 244776 DEUTSCH SOLENOID 24V (INCLUDES ITEMS 1A-1D) 4
1A 244776-01 O-RING 4
1B 244776-02 O-RING 4
1C 244776-03 O-RING 4
1D 244776-04 O-RING 4
2 244453 PLUG 8
3 NSS BODY 1
4 244778-02 SOLENOID COVER 1
5 244778-03 CAPSCREW 10
6 NSS EXPANSION PLUG 9
Updated:
05/25/07
16922
TRANSMISSION MOUNTS
Page 1 of 1

1 16954-03 TRANSMISSION MOUNT 1
2 16954-02 TRANSMISSION MOUNT 1
3 01GC10056 BOLT 4
4 02GE12 WASHER 8
5 01GC120128 BOLT 8
6 34014 RUBBER MOUNT 4
7 1185-08 WASHER 4
8 68GD10 NUT 4
Updated:
03/08/07
S1036
S1036
FOREWORD
This manual has been prepared to provide the customer and the maintenance personnel with information
and instructions on the maintenance and repair of the SPICER OFF-HIGHWA Y PRODUCTS product.
Extreme care has been exercised in the design, selection of materials, and manufacturing of these units.
The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection
at stated intervals, and such adjustments as may be indicated wiii be reimbursed many times in low cost
operation and trouble free service.
In order to become familiar with the various parts of the product, its principle of operation, troubleshooting
and adjustments, it is urged that the mechanic studies the instructions in this manuai carefuiiy and uses it as
a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only SPICER OFF-HIGHWAYPRODUCTS

approved parts as listed in the applicable parts manual should be used. Use of "wiii-fit" or non-approved parts
may endanger proper operation and performance of the equipment. SPICER OFF-HIGHWA YPRODUCTS
does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not
supplied by or approved by SPICER OFF-HIGHWA Y PRODUCTS.
IMPORTANT
ALWAYS FURNiSH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS.
When checking the difference between a 6-speed with range shift, a 3-speed standard ratio and a 3-speed
deep ratio, you would notice that the difference is only on the idler and the output shaft.
.. ---"-'-A-3'~spe-e-c:r-'iIa'ncia-rdrs--si"iTlnaf-to-a--o-iweErd-Witlrrange-shift-w he n-- h igh--ran g e.. 1s-s el ected. ._._.

While a 3-speed deep ratio is similar to a 6-speed with range shift when low range is selected.
For this reason, we wiii use the 6-speed with range shift in most cases to explain the function of
the 3 different transmissions.
I
S1036
3-SPEED STANDARD RATIO

S1036
3-SPEED DEEP RATIO

S1036
6-SPEED RANGE SHIFT

S1036
Table of Contents
1. SAFETY PRECAUTIONS
2. CLEANING, INSPECTION AND LEGEND SYMBOLS

2.1 CLEANING 2-1
2.1.1 Bearings 2-1
2.1.2 Housings 2-1
2.2 INSPECTION 2-1
2.2.1 Bearings 2-1
2.2.2 Oil Seals, Gaskets, Etc 2-2
2.2.3 Gears and Shafts 2-2
2.2.4 Housing, Covers, etc 2-2
2.3 LEGEND SYMBOLS 2-2
3. TECHNICAL SPECIFICATIONS
3.1 IDENTIFICATION OFTHE UNIT 3-1
3.2 WEIGHT, DIMENSIONS, OIL CAPACITY 3-1
~~ .... _..... ~:J....ILG!:JIJ:J'!LN.G.I..QggI,JJ=....""'~.=c".c,'c,,.c".c,.c,.c"."c",,,,,,=,,,,,,,'c,,,,,,.c,:c.c,,,"c,,,,,,.,,,,,,:3~~ ....._
3.3.1 Torque specifications for lubricated or plated screw threads 32
3.3.2 Elastic stop nut torque 33
3.3.3 "0" ring port plug torque chart 33
3.3.4 Pipe plug torque chart 3-3
3.3.5 Permanent metric plug torque chart 33
3.3.5 Coil and cartridge torque 3-4
3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS 35
3.5 ELECTRICAL SPECIFICATIONS 3-6
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS 3-6
4. MAINTENANCE
4.1 OIL SPECIFICATION 4-1
4.1.1 Recommended lubricants 4-1
4.2 MAINTENANCE INTERVALS 4-3
4.2.1 Daily 4-3
4.2.2 Normal drain period 4-3
4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL 4-4
S1036
5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING 5-1
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 5-2
5.3 EXTERNAL PLUMBING 5-3
5.3.1 Optional: remote filter 5-3
5.3.2 Cooler & filter lines specifications 5-3
5.4 SPEED SENSOR INSTALLATION 5-4
6. OPERATION OF THE TRANSMISSION

6.1 THE TRANSMISSION ASSEMBLY 6-1
6.1.1 The converter, pump drive section and pressure regulating valve 6-2
6.1.2 The input shaft and directional clutches 6-3
6.1.3 The range clutches 6-4
6.1.4 The output section 6-4
6.1.5 The transmission controls (refer to hydraulic diagram) 6-5
6.2 ELECTRIC SOLENOID CONTROLS 6-6
6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT
6.3.1 Neutral, 3rd clutch engaged and high range selected 6-7
6.3.2 Forward 1st speed and high range selected 6-9
6.3.3 Forward 2nd speed and high range selected 6-11
6.3.4 Forward 3rd speed and high range selected 6-13
6.3.5 Reverse 1st speed and high range selected 6-15
6.3.6 Forward 1st speed and low range selected 6-17
6.4 GEAR AND CLUTCH LAY-OUT 6-19
6.4.1 3-Speed with standard ratio 6-19
6.4.2 3-Speed with deep ratio 6-20
6.4.2 6-Speed with range shift 6-21
7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION

7.1 T20000 TRANSMISSION 7-1
7.2 TROUBLESHOOTING PROCEDURES 7-1
7.2.1 Stall Test 7-1
7.2.2 Transmission pressure checks 7-2
7.2.3 Mechanical and electrical checks 7-2
7.2.4 Hydraulic checks 7-2
7.3 TROUBLESHOOTING GUIDE 7-3
7.3.1 Low clutch pressure 7-3
7.3.2 Low charging pump output 7-3
7.3.3 Overheating 7-3
7.3.4 Noisy converter 7-3
7.3.5 Lack of power 7-3
7.4 CHECK POINTS 7-4
7.5 SPEED SENSOR - STATIC STANDALONE TEST 7-7
S1036
8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

GROUP - CONVERTER HOUSING 8-2
GROUP - TRANSMISSION CASE AND REAR COVER 8-4
GROUP - TURBINE SHAFT 8-6
GROUP - DRIVE PLATE 8-8
GROUP - TORQUE CONVERTER 8-1 0
GROUP - AUXILIARY PUMP DRIVE 8-12
GROUP - PUMP DRIVE 8-14
GROUP - FORWARD SHAFT 8-16
GROUP - REVERSE AND 2ND SHAFT 8-18
GROUP - REVERSE IDLER 8-20
GROUP - LOW SPEED SHAFT 8-22
GROUP - 3RD SHAFT 8-24
GROUP - IDLER SHAFT {USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO} 8-26
GROUP - IDLER SHAFT {USED IN 3 SPEED STANDARD RATIO} 828
GROUP - OUTPUT SHAFT {6 SPEED} 8-30
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO) 11-32
GROUP - OUTPUT SHAFT ( 3 SPEED DEEP RATIO) 11-34
GROUP - HI & LOW RANGE SHIFT CONTROL 11-36
GROUP - CHARGING PUMP & FILTER 838
GROUP - ELECTRIC CONTROL VALVE MOUNTING 840
GROUP - ELECTRIC CONTROL VALVE ASSEMBLy 8-42
9. ASSEMBLY INSTRUCTIONS
10. DISASSEMBLY AND REASSEMBLY T20000 LD TRANSMISSION
11. OPTIONS
11.1 HYDRAULIC ACTUATED AXLE DISCONNECT 11-1
11.1.1 Seclional views and parts identificalion 11-1
11.1.2 Assembly instructions 114
11.1.3 Disassembly of output shall with axle disconnect 115
11. 1.4 Rea ssem bly of output sha II with axl e discon nect 11-8
11.1.5 Disassembly of axle disconnect 11-11
11.1.6 Reassembly of axle disconnect 11-14
11.2 PARKING BRAKES 11-18
11.2.1 Mechanical Brake 11-18
11.2. 1. 1 Section al views and pa rts id entification 11-18
11.2.1.2 Adjustment and rebuild criteria 11-23
11.2.1.3 Replacing friction pads 11-23
11.2.1.4 Disassembly 11-24
11.2.1.5 Cleaning and inspection 11-24
11.2.1.6 Assembly 1125
11.2.1.7 Replacing mount bushings 11-25
11.2.1.8 Servicing rolor assembly 11-25
S1036
11. OPTIONS (Continued)

11.2.2 Spring applied hydraulic released brake (high pressure) . 11-26
11.2.2.1 Seclionat views and pa rts identificalion 11-26
11.2.2.2 Operation 11-31
11.2.2.7 Assembly 11-32
11.2.2.8 Inslallalion 11-33
11.2.2.9 Torque specs 11-33
11.2.3 Spring applied hydraulic released brake (low pressure) 11-34
11.2.3.1 Sectional views and parts identification 11-34
11.2.3.2 Operation 11-39
11.2.3.7 Assembly 11-40
11.2.3.8 Installation 11-41
11.2.3.9 Torque specs 11-41
12. SERVICE TOOLS

12.1 REVERSE IDLER SHAFT NUT SOCKET (TG 1304-54)
S1036
1. SAFETY PRECAUTIONS
To reduce the chance of personal injury and/or property damage, the following instruction must be carefully
observed.
Proper service and repair are important 10 the safety of tine service technician and the safe. reliable operation
of the machine. If replaceme nt parts are required the part mu st be repla ced by a spare pa rt wh ich has the
same part number or with an equlvalenl part. Do not use a spare part of lesser qualily.
The service procedures recommended in this manual are effective methods for performing service and
repa ir. Some of these proced ures req uire the use of tools specifi cally design ed for tine purpose.
Accordingly, anyone whD inlends 10 use a spare part, service procedure or 1001, which is not recommended
by SPICER OFF-HIGHWA YPRODUCTS, must first detemrine Ihal neitine r his safely no r the safe operation of
tine machine will be jeopardized by the spare part, service procedure or tool selected.
IMPORTANT
IT IS IMr:rrITA."lT TO llOTE TH.....T THIS M~Jm~L corfI~rjS V.o.\RiOUS 'CAUTtONS' u.;-D 'NOTICES' TH.A.T MUST BE
CAREFUllY OBS~"iED I rl ORDE R TO REDtKE TH E RI SK OF FERSOU~ INJURY OU RING SERVlCE OR REPAJ R,
00 TH E POSSI 81 LIT'{ l"H.A.T I',l PROPER EERvrcE OR REPA1R MAY DA.~.t!J,GE THE Url fT OR REJ.'DER IT UN SAF E.
IT lS AlSO IMPORTAhl" TO urm:::RS-T.l.J..'O THAT T;-1ES:::: 'CAUTIONS' J.1m 'NOTICES' A~E ~jOT EXHAUSTIVE,
BEC...'ill Sf: IT" IS I Pol POSS BLE TO ,....N~N ABC UT ~ll ill E POSS IoLE HAZ..ARDa US CON S=:0 UENe ES TH.....T III GHT RESULT
i=ROM F/OJlURE TO FOlta'"'' THESE 1N5TRucnorlS.
S1036
2. CLEANING, INSPECTION AND LEGEND SYMBOLS
2.1 CLEANING
Clean all parts th orou ghly usi ng solvent type cle aning II uid. II is re commen ded th at pa rts be imm ersed in
cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts
are tho roughly clea ned.
CAUTION
CARE SHOULD BE EXERCiSED TO AvmD SKIN- RASHES~ FIRE H.AL.!JR.DS, N~D tNHA1ATlm-i Or VAPour:;:s "','t+EN USL",IG
:sOl.. .'Et~T TYPE ClEMl ERS.
2.1.1 Bearings
Rem ove beari ng s from c1ea ni ng lIu id and strike lIat ag ain st a block of wood to dislodge so Ii dill ed pa rticles of
lubricant immerse again in cleaning fluid to lIush out particies. Repeat above operation until bearings are
thoTOu ghly ciea n. 0 ry bea ri ng s using moi sture-free compressed air. Be careful to direct air stream across
bearing to avoid spinning. 00 not spin bearings when drying. Bearings may be rotated slowly by hand to
fa cilitate drying pTOces s.
2.1.2 Housings
Clean interior and exterior of housings. bearing caps, etc..., thoroughly. Cast paris may be cieaned in hot
solution tanks with mild alkali solutions providing these paris do not have ground or polished surfaces.
Parts sh ou Id rem ain in solution Ion g enough to be tho roughly clean ed and heated. Th is vliIi aid the eva po ration
of the c1ea ning solution and ri nse water. Pa rts c1ea ned in solu tion tan ks mu st be th oroughIy rinsed with clean
water to remove aII traces 01 aIka11. Cast pa rls may also be cI ea ned with steam c1ea ner.
CAUTION
C~'\RE SHOULD BE EXE RC IS EO TO AVO: D IN:-tALATlorl OF VAPOU RS AND SKIN R.!I,S HES .....~EN US ING Al.J{II,L1 ClE.'JRERS.
All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soli, Iintless
absorbent \~;ping rags free of abrasive materials such as metalllliings. contaminated oil, or lapping compound.
2.2 INSPECTION
The importance 01 carelul and thorough inspection of all parts cannot be overstressed. Replacement 01 all
parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
2.2.1 Bea rings

Carefully inspect all rollers: cages and cups lor wear, chipping, or nicks to detemnine fitness 01 bearings for
further use. 00 not replace a bearing cone or cup indiVidually without replacing the mating cup or cone at the
same lime. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or
paper to protect th emu ntil installed.
Cleaning, inspection and legend symbols
S1036
2.2.2 Oil Seals, Gaskets, Etc.

Replacement of spring load oil seals, "O"-rings, metal sealing rings, gaskets, and snap rings Is more economical
when unit is disassembled than premature overhaul to replace these parts at a luture time.
Further loss of lubricanl through a worn seal may result in failure of other more expensive parls 01 the
assembly. Sealing members shoutd be handled carefully, parlculariy when being installed. Culling, scratching,
or curlin gun der 0111p of seat seriously Impa Irs lIs elfid ency. When ass em bl ing new mela I type sea ling ring 5,
these should be lubricated with coat of chassis grease to stabilize rings In their grooves lor ease 01 assembly
of mating members. Lubricate all "O"-rings and seals wllh recommended type Automatic Transmission Fluid
before assem bl y.
2.2.3 Gears an d Sh afts

If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear,
pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or
cracked, replace wHh new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to
make cerla In th ey are not sprung, be nt, or splin es twisted, and lh at sh ails are true.
2.2-4 H0 us in g, Covers, etc.

Inspect housings, covers and bearing caps to ensure lhatthey are thoroughly clean and thai mating surfaces,
bearing bores, etc ..., are free from nicks or burrs. Check all parls carefUlly for evidence 01 cracks or conditions
which would cause subsequent oil leaks or failures.
2.3 LEGEND SYMBOLS
~
-Srrn-".3ggD di ~,.:.'1...."gn:q:::l
[}~:;aUBTl-ti of <Is..!E:-:":'lbt1 .;....cu;;.;;
11
-,
Mc-r:t<ggi-:o di psr&:r::-!t:ri ir.;;.crrtrciU E-.1tare tErrl ~ nu~-a!W. dar.r~ ai psm

Rai~~ ~ r"'r.l::!'..::l"l p215 -.',ti:tJ f:-ad ct!lh:dE..: j If-;:;u~rrl:}J C~..urd a;:;:::;O:.;.1 rrzt~i3t d.=rr~e, d=,-n=:-;;~ tu j:::-",rt3
! T= At:;-~tJre~~..,j P '" .r.;;r,:i
iT'" :S~-=-:It-~01 P '" fa:;!:
f------~-".,--I R;'",,,",,,,",,,,,= ~ m7""~'

~
__ rl;:.t: ,=,,rer.h::;~ -::.~ inl~=l,;;~al
:1 I C",,,";:~:~:=---c.:r-.'-r.;::J!-o-"-~~--J.::::;:--..;:.------f
i. rs~l rq:-:-:wro
1-~~----1r--~-'--'-'-~~'"
E"Ef":1..e'JT~tE- ri~'21:.t.i;b'' (U!~~.. J.H-E- ~-<:! neUF~".;J)
?c3.Sb'y s'!ii s~-..i-=-E-ilie, r=n",~- if r:-eCE""-5~f

S1036
3. TECHNICAL SPECIFICATIONS
SPICER OFFH/GHWAY
TEt~ nmEl..E 3
B-B200-
I3ELGlUr.l
O!
MODEL ..>'i
\ SERIAL ,'co
3.1 IDENTIFICATION OFTHE UNIT

1. Model and type of the unit.
2. Serial nu m ber.
3.2 WEIGHT, DIMENSIONS, Oil CAPACITY

Weight (dry): 174.6 kg (385 lb.)
Tmodel
Maximum length: 1015.6 mm (39.98")
Maximum width: 571.8 mm (22.51")
Max;mum heig hI: 1016.3 mm (40.01")
Oil capacity
18.9 I (5.0 US Gallon) without cooler and hydraulic iines.
Consult operator's manual on applicable machine for system capacity.
Technical specificaUons
S1036
3.3 TIGHTENING TORQUES
3.3.1 Torque specifications for lubricated or plated screw threads
tlOM. SIZE GRADE 5 ED

FINETHREAO COAHSETHREAD
LBF IT ~jm) LEF -IT INm)
.25W ~. \1 I !12-\5j 8-10 1\1-14]

.3125 16 - 20 I 122 - 27) 12 -16 1\6 - 22)
.3750 26 - 29 I 135 - 39j 23-25 (J\ - 34)
.4375 41-45 I 156 01) 37 - 4j 150- 56)
.50({~ 64-70 I 187 95) 57 -63 177 - 5)
5625 ~1-IW 1123 -13) 82-90 [1\1-122)
.620<1 118 -141 1174 -19\) 113 -124 1153 -le-5)
.15m 223 - 245 j301- 331) 200 - 21D [271-m)
tlOM. SIZE GRADES

1\
FINETHREAO COARSETHREAO
LSF -IT IRm) LEF - IT IN.m)
- -
i .25-00 11 -13 115-18) 9- 11 jl2-15)
.3125 28 - 31 130 - 43) 20-30 (JH1)
3750 37 -41 {~J - 56) 33 -:xl 145 - 49)
./315 ,9 - 64 [79-87) 51- 57 [71- 77)
.50(-:! &3 -!tJ 1\22 -134) BO- 19 {1(~ -11~)
5625 128 -14\ 1\74 - 1~\) m-m I {1'.fi172)

62503 11-03 -lga 1224 - 261) 159 - \7:i I 1118 - 237)
.75W 315 - 347 1m -4/G) 21-2 - 310 I 131-2 l 20)
NOM. SIZE GRADE a.a or 9,B GRAOE 10.9

cOARsETHREAD COARSE lli REAO
lBF - IT [N.mJ lBF - FT [NmJ
f.l6 1520 ti--[] ~ 25] 22 - 26 PO - 35J

J.!IO 31)37 [40 - ,(IJ 4-48 [eD - 65J
1.112 50~55 [65 -151 74 - 81 [IC'3 - 110J
Technical specifications
S1036
3.3.2 EI asHes10p nut lorque
THREAD SIZE lBFT (N.m!

I' - 20 150-2W 1203.4 - 271.1]
11,'4'-18 2W-150 12712 -338.9]
1112'-18 JfJll- 350 [4oo.a- 4745]
13'4'-18 4W-45O [)j2.4 -010.1]
3.3.3 "0" ring port plug torque chart
THREAD SIZE lBF fT (N.m]

9ft 0' -18 12 - 15 lla -2u]
J.r4~-16 20-25 [21 -34]
3.3.4 Pipe plug torque chart
TH READ IIPTF TORQUE

laF - IT [N.m]
li16-27 5-7 l7. H]

lIE - 27 7 -10 I'J- 14]
\.'4 -Ia 15 - 20 I ]20 - 27]
1'8-18 15 - 3lJ I 134 -41]
\"2-14 ~)-35
! 141-47]
l'4-W ~-45 I l)j -61]
I-Ulr2 55-50 ! [OB - 75]
1114-11112 &l-65 ! 151-18]
3.3.5 Permanent metric plug torque chart
THREAD SIZE TORQUE

lBF - IT [N.m]
M1ox1.5liH 25-)) I 1:>4-41]

1.118 x1.5 liH 45-50 I 161-6a]
Technical specifications
S1036
3.3.5 Coil and cartridge torque
... '. --..,~ .

.--/...
';. ;. ":-:~~.~~:
A: tighten cartridge 10 22-27 N.m (16-20 LBF-FT)

B: tighten cartridge nuisio 5-7 N.m {4-5 LBFFTj
Technical specificalions
S1036
3.4 PRESSURE AND TEMPERATURE SPECIFICATIDNS

Normal operating temperature 70 - 120 "C (158 - 248 F) measured at temperature check port
converter out (port 71 - ").
Maximum allowed transmission temperature 120'C (248 F).
Transmission regulalor pressure (') - (neulral) - port 31 (").
- At 600 RPM min. 16.5 bar (240 PSI) minimum.
- At 2200 RPM: 19.3 bar (280 PSI) maximum.
Pump ncm(')
- At 1800 RPM in neutral: 54.9 Umin. minimum (14.5 GPM).
Ciutch pres 5U res (')

- 1st clutch: port 41 (").
- 2nd clutch: port 42 (").
- 3rd clutch: port 43 (").
- Forward cI utch: pori 45 (").
- Reve rse c1u lch: port 46 (").
At 2000 RPM:
- 16.5 - 19.3 bar (240 - 280 PSI) clutch activated.
- 0 - 0.2 bar (0 - 3 PSI) c1ulch released.
Filter bypass valve set at 1.5 - 1.7 bar n (22 - 24 PSI).

Lube pressure (') (pori 33) 0.7 - 1.4 bar (1G - 20 PSI) at 54.9 Ilmin. (14.5 GPM) pump flow
(1800 RPM).
Safely valve: cracking pressure n 8.2 - 12.1 bar {120 - 175 PSI}.
Converter oul pressure (') (port 32) 1.7 bar min. {25 PSI} at 2000 RPM and max. 4.8 bar (70 PSI) at no
load governed spe ed.
(') All pressures and ftows to be measured ",ith oil temperalure of 82-93 C (18D-200 F)
(,,) Refer 10 section 7 "Troubleshooting" for check port identification.
S1036
3.5 ELECTRICAL SPECIFICATIONS

Solenoid (forward, reverse, 1st and 2nd).
Goil resi stan ce:
- 12V: 9.79.Q 0.5 Q.
- 24V: 39.3 Q 2 Q.
Speed sens or:

- Type: rna 9neto res istive se nsor.
- Sensing djstance: 0 - 1.8 rnrn (0' - O.OT).
- Se nsor s ig nal: gene rates a sq ua re cu rrent with a fixe d amplitu de cha n9jng betwee n 7 and 14 rnA
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS

Mnimum 19 mrn (.75-) internal diameter for fines and fittings.
Suitable for operation from ambjentto 120 cG (248 F) continuous operating temperature.
Must withstand 20 bar (290 PSI) continuous pressure and with 40 bar (580 PSi) intermittent surges.
Conform SAE J1019 and SAE J517, 100RI.
S1036
4. MAINTENANCE
4.1 OIL SPECIFICATION
4.1.1 Recommended lubricants

1. Catmpillar TO-4.
2. John Deere J20C, O.
3. Military MIL-PRF-2104G.
4. Allison C-4.
5. Dexmn' II Equivalenl- See nole below.
Note
DE)Roroi:~ II EOUWALENT IS ACCEPTI'...ELE; Hm'iPlER IT IS NOT COMPATiBlE WITH TOROUE cmNERTERS OR
TRqlSWSSION-S- EQUiPPED "','rrH C...ft.'\PHItlC FRICTION p.,V..TERlAL CLUTCH PLA.TES.
Caution
DE'RON' III, ENGirlE O1L OR GL-5 OILS flRE NOT RECO,",ME"OED.
PREFERRED OIL VISCOSITY

II is recommended that the highest viscosity monograde lubricant available be used for lhe anlicipaled
ambient temperature. Typically this will be a CAT TO-4 qualified lubricant. When large swings In ambient
temperature are probable, J20 C, 0 mulUgrades are recommended. Multigrade lubricants should be applied
at the lower viscosity rating lor the prevailing ambienl temperature, I.e. a 10W20 should be used where a
10W monog rade is use d. If a C -4 multig ra de is used instead of J20 Iubricant ~ is recom me nded that lhe
viscosity span no more than 10 points, I.e. 10W20.
Caution
SYNTH31C lU BR ICNfTS ARE APPRcP....EO IF Q Ll,!J,!J;:1 ED BY OKE OF Ttl E ABOVE SP ECLFICATlON-S.
OIL VISCOSITY GU IOEUN ES .APPLY, BUT SYr-.,,7H Ell C M JlTlGR"'DES UAY SPNI MORE TW.N 10 POL~rrs.
FOR flRE RESiSTANT FLUID RECm,~EllDAnO"S PLEASE CO"TACT SPICER OFF-HIGHWAYPRODUCTS.
: I I . I
W~~~11~'~~f~:i~~~~m ~-i~!il
I' "@.sAt'A'i"'b;1
I I
: p;
CElli -4) l) ) II }j
;::i'rE-l;.~t -4J n 11 53 ,I
Maintenance S1036
SUMP PREHEATERS
Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up.
NORMAL OIL CHANGE INTERVAL

Drain and refill system every 1000 hours for average environmental and duty cycle conditions. Severe or
su stai ned high ope raling te mperat ure or ve ry dusly atm os pheric eond jji 0 ns wi II re su II ina eeel erated
deterioration or contamination. Judgement must be used to determine the required change intervals lor
extreme eond itions.
EXTENDED OIL CHANGE INTERVAL

Extended oil service lile may result when using synthetic fluids. Appropriate change intervals shouid be
determined lor each transmission by measuring oil oxidation and wear metals, over time, to determine a
baseline. Wear melal analysis can provide useful inlormation but a transmission should not be removed from
service based solely on this analysis.
FILTERS
Service 0 Hfi Iters eIem ent every 500 hours und er normal enviro nmental and duty cycle conditions.
'Dexron is a registered trademark 01 GENERAL MOTORS CORPORATION.

Maintenance
S1036
4.2 MAINTENANCE INTERVALS
4.2.1 Daily
Check oil level daily wilh engine running al idle (600 RPM) and oil al82 - 93C (180-200 Fl.
Maintain oil level al full mark.
4.2.2 Normal drain period

Norm al d rain period an d oil filter el ement ch ange are for averag e environment and dUly cycle can dition.
Severe or suslained high operating lemperature or very dusty atmospheric conditions wiil cause accelerated
delerioralion and contam in ation.
For extreme conditions jUdgement musl be used 10 delermine the required change inlervals.
Every 500 hours
Cha nge oil fi Iler elem ent.
Every 1000 hours
orain and refill syste m as follows (0 ra in with oil at 65 - 93'C (150 - 200 F)):
1. 0 rain trans mi ssion.
2. Remove and discard filter. Install new filter.
3. Refi II transmission to FUll mark.
4. Ru n eng ine aI 500 - 600 RPM to prim a converto rand lines.
5. Recheck leval with engine running al500 - 600 RPM and add oil to bring leval to lOW mark.
When oil temperalure is hal 82.2 - 93.3 "C (180- 200 F) make final oilleval check and adjust if
ne cess aty 10 bring 0 illevel to FU II mark.
Nole
l T is I1ECOh'lMBlD ED TI-'AT 01 L FI LTER BEe H'.J!.lm~ "FTER 100 HOU R-S OF OP ERo\TlON mi II EW ~
REBU It.T 00 REP,.\] RED U rl fT.
Maintenance
S1036
4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL

The transmission, torque converter, and ils allied hydraulic system are imporlant links in the driveline bBtween
Ihe engine and the wheels. The proper operation of either unit depends greatly on the condition and operation
olthe olher. Therefore, whenever repair or overhaul of one unit is performed, the balance of Ihe system must
be considered before the job can be considered complele.
Aller the overhauled or repaired transmission has been installed in the machlne,lhe oil cooler, and connecting
hydraUlic system must be thoroughly cleaned, This can be accomplished In several manners and a degree 01
j udg eme nt mu sl be exercised as to the method employed.
The follo",ing are considered the minimum steps to be laken:

1. Drai n e nti re syste m lhoro ug hIy,
2. Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed from machine
lor cleanin g.
3. Replace oil filler element.
4. The oil cooler musl bB lhoroughly cleaned. The cooler should be "back lIushed" with oil and compressed
air until all foreign material has been removed, Flushing in direction 01 normal olillow will not adequately
c1ea n the cooler. If necessa ry, cooler as sem bly sho uld be rem oved from machin e lor cI eanin g, usi ng oil,
com press ed air, and stea mclean er for that pu rpcse.
IMPORTANT
Da NOT USE FlU5hlN G CCM?ot'NDS FOR C lEAtn~G Hi RPOSES.
_~--~--5.-Roassemblenll,cDmpollenI5-0nd-use-only-typeoil-{Seechapler-4A",1,'"Recommended-!ubrfcanI5"j-,
~_ ..
Fii I the tran 8m iss Ion lh rou gh fi IIer 0 pen ing until II uid com es up to FULL mark on tra nsmission dipstick.
Remove filler plug and fill oil until FULL mark.
Run engine two mlnules at 500 - 600 RPM to prime torque convertor and hydraulic lines.
Rech eck level of IiuId in tra nsm IS5 ion wllh en 9Ine run ning aI Idle (500 .. 600 RPM),
Add quantity necess a ry to bri ng II uid level to LOW ma rk on dipstick.
Recheck with hot oil 82.2 - 93, 3e (180 - 200 F).
Adjusl oil level to FULL mark on dipstick.
6, Recheck all drain plugs, lines, connections, etc ...., for leaks and tighten where necessary.
S1036
5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING

Mea su re theA" dim enslon (bolt cI rei e d ia meter) and order drive plate ki t listed below. Note th ree (3) kits
have two (2) Intermediate drive plates and one (1) drive ptate and weld nut assembty. Three (3) kits with
three inte rmed iate d rive pia tes.
"A" Dimension (Boll cireie diameter) "A" Dimension (Boll circle diameter)
11.380" (288,900 mm) diameter 11.380 (288.900 mm) diameter
Kit No. 814978. Kil No. 814979.
13.125" (333,38 mm) diameter 13.125" (333.38 mm) diameter
Kit No. 814977. Kit No. 814980.
13.500" (342.90 mm) diameter 13.500" (342.90 mm) diameter
Kit No. 814975. Kit No. 814981.
Each kit will ineiu de the followl ng pa rts: Each kit will in cl ude the 1011owl ng pa rts:
2 Interm ed iate d rive plates. 3 Intermediate drive plates.
1 Drwe plate and weld nut assembiy. 1 Backin g ring.
1 Backing ring. 6 Mounting screws.
6 Mounting screws. 6 lockwashers.
6 lockwa sh ers. 1 Instruction sh eel.
1 Instruction sheel
Position drive plate and weld nul assembly on lorque converter assembly with weld nuts toward converter.
Align intermediate drive plates and backing plate wilh holes in torque converter assembly.
Nole
T'1't'O on.1PlS 180<:: ~PA~T Ir, BACKING Rlrw MUST BE OUT TO'....ARO ENGINE FLYWHEEL
{Hotlm'/ SIDE Ft..C1NG TORQUE CONVERTER ASSEMBLY}. [NSTAlL CAP SCRE\.','S .AND lOCKY'iASHERS.
TIGHTEN CAP SCREWS TOROUE 40 - 50 N,M. (30 - 37 lEF. FT.).
Installation delai/s
S1036
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Re move aII burrs from flywheel rno unting face and

nose pilol bore. Clean drive plate surface with
solvent.
2. Check engin e flywheel & hou sing fo r con forma nce
to standard SAE No.3 per SAE J927 and J1 033
tolerance specifications for pilot bore size, pilot
bore ru nout an d mou ntin g fa ce fl atn ess. Mea sure
and re co rd en gine cran ks!] aft en d play (Rg. 1).
3. Inslaillwo 63,50 mm {2.50"} long transmission 10
lIywheel housing guide sluds in Ihe engine
flywheel housing as shown. Rotale Ihe engine
flywheel to align a drive piate mounting screw hole FIG.1
with the flywheel hous Ing access hole
(Fig. 2).
'4. Install a 101,60 mm (4.00") long drive plate
locating stud .3750-24 fine Ihread in a drive plate
nul. Align the locating st ud in th e drive pi ate with
Ihe flywheel drive plate mounting screw hole
positioned in step No.3.
C""1i~",m
5. Rotale Ihe transmission lorque converter to align
!he loca Ii ng slud in the drive plale with the flywh eel
"ne ; W,
, i)'
drive plale mou nti ng screw hole pos itio ned In slep
NO.3. Lo cate tran smissi on on flywhee I h 0 using.
:t{
:
.. --~--- ....'AligmngdrivEfjjialetollywneel aniflransmlsslon

,,1
rt-------~ . ~.-.-.-.-.-.-.~
to flywheel housing guide sluds. Install 1\

transmission 10 flywheel housing screws. Tighten
screws 10 specified torque. Remove lransmission
to eng in e g uide slu ds. In sta II remaining screws
and lighten to specified torque.
'6. Remove drive plale locating stud. .:FE:';,o..L s:"LO........ 'S-.i'l ,!.NO
:::ELF L'X~: .'lJT rLF~~:~-I-::0
,,'-.......... i-ffl '...;:lu:;.r ~3 3"( J'.:GrE rJ .......F ...::TUi".E
7. In sta II drive plate allac hing screw and wash ef.
Snug screw bul do nol Iighlen. Some engine
flywheel housings have a hole located on the
lIywheel housing circumference in line with Ihe
drive plate screw acce ss hole. A screwdriver or
pry bar used 10 hold Ihe drive plale against the
flywh eel wili fecilitate Inslallation of !h e drive pIate
screws. Rotate the eng Ine flY'iheel an d In sta It th e
remaining seven (7) flywheel to drive plate
attaching screws. Snug screws bul do not lighten.
After all eighl (8) screws are installed.
Torq ue each on e 35 to 39 N. m. (25.. 29ft.! bs.). This
wi II requIre lighlen Ing each screw and rotali ng th e
en gin e flywh eel un Ii I the full amo unl of eig ht (8)
screws have been tig hte ned to sp eciITed torqu e.
8. Measure engine crankshaft end play after
transmission has been completely Installed on
engine lIywheel. This value must be within
0,025 mm (0.00l") of lhe end play recorded in
step No.2.
Does not apply to units having 3 Intermediate dri,'e
plates. See Fig.4.
lnstalla lion delails
S1036
5.3 EXTERNAL PLUMBING
F'OT =::F..,r t.:J

1r~~lliU1 if;
5.3.1 Optional: remote filter
-375(1..1 S FJU: 23 Tr;J-

M[n.J;)rr---=-7~~S
5.3.2 Cooler & filler lines specifications

Minimum 19 mm (.75 inch) internal diameter for lines and fillings.
Suitable lor operation from ambient to 120 "C (248 F) continuous operating temperalure.
Mu sl with sta nd 20 bar (290 psi) con Iinuou s pressu re ano with 40 ba r (580 psi) i nte rmitlent surges.
Conform SAE J1 019 and SAE J517,1 OORI.
Installation details S1036
5.4 SPEED SENSOR INSTALLATION
;:~/
On the senSDr bDdy there is a small plastic triangular pDsitiDn
sign. Make sure the pDsitiDn sign Dn the senSDr pDints as shDwn
Position sign
belDw in the directiDn Df the mDvement Df the gearteeth (Teeth
rotatiDn as shDwn).
r
Teeth rolation
Plug Screw
nghlen 10 5.9 7.4lbl-1\
"O".rin~ 18-IONml
ditl~
Sensor Inslalled Hole plugged
Sensor position on transmission

Turbine speed sensor location
Engine speed sensor location

Installation details
S1036
5.4 SPEED SENSOR INSTALLATION (Continued)
Position sign
~
Pin 2 I . ) Pin 1 I + )
~
The magneto resistive sensor generates a square wave current with a fixed amplitude changing
between 7 mA and 14 mA.
The sensor has an integrated AMP superseal2 pin connector.
The two pins are numbered 1 and 2.
Foilowing table shows the relation between wire colour. pin number and connection.
COLOUR PIN NUMBER FUNCTION CONNECTION

BROWN 1 Currenl input Hot wire
BLUE 2 Current output Ground wire
Note
THE SENSOR WIRES HAVE A POLARITY.
BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES, AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR!
S1036
6. OPERATION OF THE TRANSMISSION
6.1 THE TRANSMISSION ASSEMBLY
Basically the transmission is composed of five main assemblies:

1. p"" . ","e! The converter, pump drive section and pressure regulating valve.
2. f & The input shaft and directional clutches.
3. M'M The range clutches.
4. "*;;;;;;;;;;J The output section.
5. I" -.""o,m The transmission control valve.
Operation of the transmission
S1036
6.1.1 The converter, pump drive section and pressure regulating valve
Engine power is transmitted from Ihe engine ftywheelto the impeller through the impeller cover.
This etement is the pump porlion of the hydraulic torque converter and is the primary component which starts
the oil flowing to the other components which resulls in torque mulliplicalion. This element can be compared
to a centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the
torque converter. This element receives fluid at its outer diameter and discharges it at its centre.
The reaclion member of the torque converter is located between and at the centre of the inner diameters of
the impeller and turbine elements. Its function is to take the fluid which is exhausling from the inner portion of
the turbine and change its direction to allow correct entry for recirculation into the impeller element.
This recirculation will make the converter to mulliply torque.
The torque mulliplicalion is funclion of the blading (impeller, turbine and reaclion member) and the converter
output speed (turbine speed). The converter will mulliply engine torque to its designed maximum mulliplication
ratio when the turbine shaft is at zero RPM (stall).
Therefore we can say that as the turbine shaft is decreasing in speed, the torque mulliplication is increasing.
The hydraulic pump is connected with the pump drive gear. This pump drive gear is driven by the impeller hub
gear. Since the impeller hub gear is connected with the impeller cover, the pump speed is in direct relation
with the engine speed.
Note
THE PRESSURE REGULATOR VALVE AND SAFETY VALVE ARE MOUNTED BEHIND THE FILTER,
IN THE FILTER ADAPTER HOUSING.
I I THE CONVERTER, PUMP DRIVE SECTION AND PRESSURE REGULATING VALVE

Operation of the transmission S1036
6.1.2 The input shaft and directional clutches

The turbine shaft driven from the turbine transmits power to the forward or reverse clutch.
These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston.
The piston is oil tight by the use of sealing rings. The steel discs with external splines, and friction discs
with internal splines, are alternated until the required total is achieved.
A back-up plate is then inserted and secured with a retainer ring. A hub with outer diameter splines is
inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in
speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, the solenoid will direct oil under pressure through tubes and passages to the selected
clutch shafts.
Oil sealing rings are located on the clutch shafts. These rings direct the oil through a drilled passage in the
shaft to the desired clutch.
Pressure of the oil forces the piston and discs against the back-up plate. The discs with splines on the outer
diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked
together and allows them to drive as one unit.
When the clutch is released, a return spring will push the piston back and oil will drain back via the shift spool,
the bleed valve or holes in the clutch piston into the transmission sump.
These bleed valves will only allow quick escape of oil when the pressure to the piston is released.
As an option the engagement of the directional clutches can be modulated. This means that clutch pressure
is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is still moving
and will allow smooth engagement of drive. The modulation is done hydraulically.
~ THE INPUT SHAFT AND DIRECTIONAL CLUTCHES

S1036
6.1.3 The range clutches

Once a directional clutch is engaged power is transmitted to the range clutches (1 st, 2nd or 3rd).
Operation and actuation of the range clutches is similar to the directionat clutches.
The engagement of the range clutches are not modulated.
6.1.4 The output section

With a range clutch engaged, power is finally transmitted to the output shaft.
Output rotation is opposite as the engine rotation when the forward clutch is engaged.
A front and/or rear axle disconnect is optional and is located on the output shaft. The drive to the front and/
or rear axle can be disconnected or connected by manual shifting.
Note
To ENGAGE DR DISENGAGE THE AXLE DISCONNECT, THE VEHiCLE IS NOT ALLOWED TO DRIVE,
BUT NEEDS TO BE AT STANDSTILL.
The 6-speed range shift transmission has a manual shifting to select low or high range.
Note
To SHIFT THE RANGE SHIFT, THE VEHiCLE IS NOT ALLOWED TO DRIVE,
BUT NEEDS TO BE AT STANDSTILL.
~ THE RANGE CLUTCHES it44-' THE OUTPUT SECTION

6.1.5 The transmission controls (refer to hydraulic diagram)

The transmission is controlled by the control valve. The control valve assembly is mounted direclly on the
side of the converter housing. The function of the control vaive assembly is to direct oil under pressure to
the desired directional and speed clutch. A provision is made on certain models for inching or declutch
when the brakes are applied.
Thi s is accompi ished th rough use of a brake actu ated va Ive.
The controt valve has 4 soienoids and 4 shift spools.
Operation of the valve
Forward can be seiected by activating the fonvard solenoid. The forward solenoid will then alimv pilot pressure
to move th e forward sh ill spool. 0 ue to th is movement of the shift spool th e fo rwa rd clutch is fed with oil
pressure.
When the reverse solenoid is a ctivated, pilot pressure will move the reverse shilt spool.
The reve rse clu tch wi II be fed with 0 iI pre ssure.
The sh in spools 01 forward and reve rse are loca ted opposite each othe r se parated by a retu rn spring.
Thi 5 ens ures th at only on e direction can be selected.
tlll _. l I
t;--: '-~'---.-J THE 1R~SMISSION CONTROLS
Selection of range
II the ra ng e solenoids 1st an d 2n d are activated, reg ulated pressu re is fed throu 9h th e sh iIt spo 01 s to the
1st clutch.
If th e ra nge soleno id 2nd is activated, reg ulated pres sme is fed th rou gh the shill spools to th e 2nd cI utch.
If no range solenoids ere activated, the reguiated pressure is fed to the 3rd clutch.
S1036
6.2 ELECTRIC SOLENOlD CONTROLS
Transmission gear Activated solenoids Activate d cl utches

Forward 3 Forward Forward. 3rd
Forward 2 Forward. 2n d Forward. 2nd
Forward 1 Forward. 1st, 2nd Forward. 1st
Neutral 3 - 3rd
Neutral 2 2nd 2nd
Neutral 1 1st, 2nd 1st
Reverse 3 Reverse Revers e, 3rd

Reverse 2 Revers e. 2n d Revers e. 2nd
Reverse 1 Revers e. 1st, 2nd Revers e. 1st
6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT
6.3.1 Neulral, 3rd clutch engaged and high range selected
Ii
ji
NEUTRAL 3rd .;pOolERFWNj

HIGH RANGE
;1M- S'FPLY
REiERSE -l-w--
-+--"1
ITD
o
1- ?
NEUTRAL 3rd {P,C1P;,'JED SOLE\GOSAliD ,POOLS)

HiGH RANGE
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T20000 TRANSMISSION HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
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3AND 6SPEED WITH RANGE SHIFT TRANSMISSION PIlF~!iIIRE mlP~RATUnli
GIIU[;E l;AUCf. par r.HF.r.K p'JRT
NEUTRAL AND 3RD CLUTCH ENGAGED Z ~,
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S1036
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Operation of Ihe transmission S1036
6.3.2 Forward 1st speed and high range selected
-~~J~~~~~~
CIT~_n 11
L.J.B::-r---
a;j
S'PHY
, '1
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HiGH RANGE
T20000 TRANSMISSION HYDRAULIC DIAGRAM
"""'''''''''''''''_._'---
OPERATOR COMPARTMENT
.. ""w .'
I
3AND 6SPEED WITH RANGE SHIFT TRANSMiSSION
FORWARD AND 1ST CLUTCH ENGAGED
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S1036
I. I
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II ~'" 14.5114 PSII cllJlcll ("l.lfWI t'.wrr.l! ctUTCIt CllfTCl1
S1036
6.3.3 Forward 2nd speed and high range selected
-!--- 1ST
@::J
FORWARD 2nd (ACTl'lATED SCtEl,OOS AN 0 SPOC~s I

HIGH RANGE
!"
I~
T20000 TRANSMISSION HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
'"
3AND 6SPEED WITH RANGE SHIFT TRANSMISSION
FORWARD AND 2ND CLUTCH ENGAGED
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S1036
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(1 ~<lr ~ 14.5ll4 PSI) cI.I.ll01 l:urrrJI CLIITCIt CLUICH Gl.UICH
S1036
6.3.4 Forward 3rd speed and high range selected
Cl ...
- SUPPLY
i>m'j;-+-- I ST
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FORWARD 3rd (~miArtD W.!HWS ,m SF{K:tSi

HIGH R.!NGE
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T20000 TRANSMiSSiON" HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
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FORWARD AND 3RO CLUTCH ENGAGED
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S1036
I I
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[;l.l!TCH CWICH l~lJrr.H cwmt CLVJt::H
6.3.5 Reverse 1st speed and high range selected
REVERS Elsi ,PC','iCRRO,','1

HIGH RANGE ' ~"t1~~~~i:i~
.J
'(RIiARDlfi0r~'-'~ H;-+f--JRJ
REiERSE I
-----f"*'-~y
--+--IST
-SUFr::'Y
REVERS E1sl !;.G,r,mm SOLWJI ['S PliO SFOOLS)

HIGHR~rWE
m
OPERATOR COMPART'MENT .l
''""
moDo TRANSMISSION HYDRAULIC DIAGRAM I
o I 'Q"l
REVERSE AND 1ST CLUTCH ENGAGED
rru:ssunE
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S1036
1=1 -'-1= 1-''''''1
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ClUTCIl (;l.UTCH CUItCH l:tlJml ClUTeI'!
6.3.6 Forward 1st speed and low range selected
REVERSE ----J--+t--.n
!iF' -t-- I 8T
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FORWARD 151 !ICli.. .ATEiJ 80310D8 IMSPOC'lSi

WI/RANGE
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T2DDDD TRANSMISSION. HYORAULIC DIAGRAM OPERATOR COMPARTMENT
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FORWARD AND 1ST CLUTCH ENGAGED
f) OD
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S1036
I ,__"!!c.:,,j=
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(1 b:lf:a1Igo1 F!SI) cl.lJlr:11 cWTCl1 CLUlCti CLU1CI1 Cl.lJf(;~
Operation of Ihe transmission
S1036
6.4 GEAR AND CLUTCH LAY-OUT
6.4.1 3 -S pl!l! d with sta nd ard rati 0
1~;;AI ;:~(,j.Yd
r:'::-:;',,--::-;~;:l 1~.1r.j ~-,j F,';-,'e-:!l
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S1036
6.4.2 3-g pee d w ilh dee p ra lio

Operation of the Iransmjssion
S1036
6.4.2 6-Speed with range shift
I::.t~",-~;;g-:l ;:::;.. ~~
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1'2 ,cc"C';c1 R, ! , dOl
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S1036
7. TROU BLESHOOTIN G GUIDE FOR TH E T20000 TRANSMISS ION
The following information is presented as an aid to isolating and determining the specific problem area in a
!fa nsmis sion th at is not functioni ng co rrectly.
When troubleshooting a "transmission" problem, it should be kept in mind thatlhe transmission is only the
central unit of a group of related powertrain components. Proper operation of the transmission depends on
the condHion and correct functioning 01 the other components of the group. Therefore, to properly diagnose
a suspected pro blem in the tra nsm ission, il is nece ssary to co ns id er the trans mis sion flu id, cha rg ing pum p,
torque converter, transmission assembiy, oil cooler, filler, connecting lines, and controls, inciuding the engine,
as a co mplele syslem.
By analysing the principles of operation logelher wilh the information in this section, it should be possible to
identify and correct any malfu nction which may occur in the system.
7,1 T20000TRANSMISSION
T20000 (power shift with torque converler transmission) troubles fall into Ihree general categories:
1. Mecha nical probiems.
2. Hydraulic problems.
3. Electrical pro blem s.
In addition to the mechanical and electrical components, all of which must be ill the proper condition and
functioning correctly, the correel functioning of the hydraulic circuit is most important. Transmission fluid is
the "life blood" of the transmission. It musl be supplied in an adequate quantity and delivered to the syslem
at the correct press ures to ells UTe co nverte rope ratioll, 10 enga ge and hold th e cI utches from slippillg, and 10
cool and iubricate the working components.
7.2 TROUBLESHOOTING PROCEDURES
7.2.1 Stall Test

A stall test to id entifles trans miSSiOIl, conve rler, or engin e probl em s.
Use following procedure:
1. Put Ihe vehicle against a solid barrier, such as a wall, and/or apply Ihe parking brake and block the
wheels.
2. Put the directional control lever in FORWARD (or REVERSE, as applicable).
3. Select the highest speed.
With ti,e engine running, slowly increase engine speed to approximately one-half throttie and hold until
transmission (converler oullel) oil lemperature reaches the operating range.
CAUTION
Do rmT OPERATE THE CQt.,;VERTER AT ST~'\l.L COrlDLTlON lmmrn IHM~ 30 S~COr-..:DS AT ONE Tl~.E, SHLFT TO hEUTfu\L
FOR 15 SECOfo..US AND RPE~T THE PROCEDURE urml [JESIRED TEMPERATURE 1-S REACHED.
EXCESS IVE TWP ERATU RE 120 "C (250 F) JlAXI", L~l "" Ll CAJJ SE OAI.'AGE TO TRM s~, SS 10" CLUTC HES, R. U'D,
COU\tERTER, ,hnD S Eft!.S.
Troubleshooting guide S1036
7.2.2 Transmission pressure checks

Transmission problems can be Isolated by the use of pressure tests. When the stall test Indicates slipping
clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch
plate friction material failure.
In addition, converter charging pressure and transmission lubrication pressure can also be measured.
7.2.3 Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical
and electrical checks should be made:
Check the parking brake and inching pedal for correct adjustment.
Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points.
The controls are actuated electrically. Check the wiring and electrical components.
Be sure that all components of the cooling system are in good condition and operating correctly.
The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and
transmission. Air clean the radiator, if necessary.
The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle
and maximum noload governed speed specifications.
7.2.4 Hydraulic checks

Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for
pressure and rate of oil flow, it is important to make the following transmission fluid check:
Check oil level in the transmission. The transmission fluid must be at the correct (full level).
i ._~ AILclutcb.e.s.and.tb.e.c.on'leLteLa nd.its.fl.uid.circuiUioes..m.u.st.b.e.fuILY..cbarged.WILed).at.all.tim.e.S ~~ _~.~~.~
Note
THE TRANSMISSION FLUIO MUST BE AT OPERATING TEMPERATURE OF 82 . 93 C (180 . 200 F) TO OBTAIN
CORRECT FLUID LEVEL AND PRESSURE READINGS.
Do NOT ATTEMPT TO MAKE THESE CHECKS WITH COLD OIL
To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the
engine with converter at "stall" (Refer to 7.2.1 "Stall test").
CAUTION
BE CAREFUL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND
CONVERTER AT STALL RPM.
Troubleshooting guide
S1036
7.3 TROUBLESHOOTING GUIDE

Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
7.3.1 Low clutch pressure
CAUSE REMEDY
1. Low oil level. 1. Fill to proper level.

2. Clutch pressure regulating valve stuck open. 2. Clean valve spool and housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings.
5. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly.
7.3.2 Low charging pump output
CAUSE REMEDY

2. Suction screen plugged. 2. Clean suction pump.
3. Defective charging pump. 3. Replace pump.
7.3.3 Overheating
Cause Remedy
1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter

assembly.
2. Worn charging pump. 2. Replace charging pump.
4. Dirty oil cooler. 4. Clean cooler.
5. Restriction in cooler lines. 5. Change cooler lines.
7.3.4 Noisy converter
Cause Remedy
1. Worn charging pump. 1. Replace charging pump.

2. Worn or damaged bearings. 2. A complete disassembly will be necessary to
determine which bearing is faulty.
7.3.5 Lack of power
Cause Remedy
1. Low engine RPM at converter stall. 1. Tune engine check governor.
2. See "Overheating" and make same checks. 2. Make corrections as explained in "Overheating".
7.4 CHECK POINTS
GRAVITY DRAIN PLUG PORTJJ

111,5NPTF CHECK PORT.\.UBE PRESSURE
.5625-HiUNF2B
SAE '0'RING PORT
FRONT VIEW
L1FWIGHOlE
.7511ll-1D UNC - 38 THO DEEP L12
PORTl1
CHECK PORT CONVERTER OUT TEMPERATURE
1/Z-14NPTF
PORT 32
CHECK PORT CONVERTER QUT PRESSURE
lIE -27 NPTF
AIMIYDRAULIC HIGHLOW RANGE SHIFT

OPERATING PRESSURE 4.1-10.3 BAR l60-150 PSI)
ENERGIZE FOR LOW RANGE
MAGNET DRAIN PLUG

314 -14 tJPTF THO
REAR VIEW
S1036
7.4 CHECK POINTS (CONTINUED)

EliGIiJE SPEED SEtJSOR PROVISION
PUMP DRIVER GEAR BREATHER
TURfllllE SPEED SENSOR PROVISION

fORWARD CLUTCH ORUI.l GEAH -----.~~ PORT31
CLUTCH PRESSURE
5G2S-WUNF-211
SAE '0 - RING PORT
PORT45
~f~~~-~'~
CHECK PORT FORWARD ClUTCH PRESSURE
.5625 WUNF -28 -,
SAE '0' RJrJG PORT
"'
::11 --------- PORT42
CHECK PORT - 2ND CLUrCH PRESSURE
WWUPTF
PORH1
CHECK PORT - ISrCltJlCH PRESSURE
.56251BUfJF21l
SAE 0' RING PORT PORT 46
CHECK PORT REVERSE GLUTCf1 PRESSURE
lIS.27IiPTF
PORT 43
CHECK PORT 3RDCUJTCfl PRESSURE
,5f,25-18UNF-211
SAE '0 - RING PORT
RIGHT SIDE VIEW
PORT 11
TO COOLER
1.0625 12 Wi -2i1
SAE '0' RING PORT
PORT 12
FROM COOLER
1,0625 -12 Wi -25
SAE '0 -RING PORT
._._. _. -11-1'11'" l-H~ AIR/HVORAULIC flIGH lOW RANGE SHIFT

OPERATING PRESSURE 4.1-10.3 bill (6(1-150 PSI)
ENGINE FOR HIGH RANGE
LEFT SIDE VIEW

7.4 CHECK POINTS (CONTINUED)
PORT 31 _ ______.
CLUTCH PRESSURE DIPSTICK
.5625-1fiUNF-2B
SAE'O' - RING PORT
TOP VIEW
S1036
7.5 SPEED SENSOR - STATIC STANDALONE TEST
In order to be able to sense the currents, a series resistor of e.g. 200 Ohms must be used. This resistor is
integrated in the controller, but when the sensor is to be tested, it must be connected externally.
The idea is to connect the sensor to an external power source and measure the DC voltage across the series
resistor.
The voltage reading should be either 1.2V-1.6V (for the 7mA 1mA current level) or 2.6-3.0V
(for the 14mA 1mA current level)
If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.
t12V
tf------'
n
sensor
200 Ohm 1 Wall

S1036
8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

S1036
GROUP" CONVERTER HOUSING
t;V 12
S1036
GROUP - CONVERTER HOUSING
Item Description Quantity
1 Housing - Converter 1
2 Sleeve - Converter housing 2
3 Plug - pipe 1
4 Plug - pipe 1
5 Gasket - Converter housing to tD transmissiDn case 1
6 Screw - Converter housing tD transmission case 18
7 LDckwasher - Converter hDusing to transmission case screw 18
8 Pin - Converter housing to transmission case dowel 1
9 Clip 2
10 Screw - Clip 2
11 LDckwasher - Clip screw 2
12 Air - Breather 1
13 Plug 5
14 "O"-ring 5
15 Plug - Speed senSDr port 1
16 "O"-ring - Speed sensor 1
17 Screw - Speed senSDr 1
S1036
GROUP . TRANSMISSION CASE AN D REAR COVER
35
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34
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S1036
GROUP -TRANSMISSION CASE AND REAR COVER
1 Assembly - Transmission case 1

2 Assembly - Suction tube 1
3 "O"-ring - Suction tube assembly 1
4 Tube - Low speed pressure 1
5 Sleeve - Clutch pressure tube 4
6 Tube - 3rd clutch pressure 1
7 Clip 1
8 Screw - Tube clip 1
9 Lockwasher - Tube clip screw 1
10 Plug 1
11 "O"_ring 1
12 Plug 2
13 "O"-ring 1
14 Cover - Rear 1
15 Plug 1
16 "O"-ring 1
17 Oil - Baffle 1
18 Gasket - Transmission case to rear cover 1
19 "O"-ring - Clutch pressure tube 4
20 "O"-ring - Clutch pressure 1
21 Pin - Transmission case to rear cover dowel 2
22 Screw - Rear cover to transmission case 20
23 Lockwasher - Rear cover to transmission case 20
24 Plug - Magnetic drain 2
26 Plug - Speed sensor port 2

27 "O"-ring - Speed sensor 2
28 Screw - Speed sensor 2
29 Plug - Dipstick hole 1
30 Cover 1
31 Gasket - Cover 1
32 Screw - Cover 2
33 Lockwasher - Cover screw 2
34 Assembly - Dipstick hole 1
35 Dipstick 1
S1036
GROUP TURBINE SHAFT
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S1036
GROUP - TURBINE SHAFT
1 Assembly - Turbine shaft & hub 1

2 Ring -Retainer 1
3 Bearing - Ball 1
4 Snap ring - Bearing 1
5 Washer - Bearing support 1
6 Ring - Bearing retaining 1
7 Ring - Piston 1
8 Support - Stator 1
9 Screw - Stator support 6
10 Ring - Piston 1
11 Baffle - Oil 1
12 Seal - Oil baffle 1
13 Ring - Oil baffle seal 1
14 Ring - Oil baffle retaining 1
S1036
GROUP - DRIVE PLATE
2
Cl \l
/
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/
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Cl
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S1036
GROUP - DRIVE PLATE
1 Assembly - Drive plate 1

2 Drive - Plate 2
3 Ring - Drive plate bacldng 1
4 Screw - Drive plate mounting 6
5 Lockwasher - Drive plate mounting 6
___________========-~G;;R~O~U;-.;P::.-:;:TO:R:::-:-----
S1036
QUE CONVERTER
'-:;;:~\\\,
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2
S1036
GROUP-TORQUE CONVERTER
1 Assembly - Torque converter 1

2 Bearing - Impeller hub gear 1
3 Ring - External snap 1
4 Plug - Torque converter 1
5 "O"-ring - Torque converter plug 1
6 Ring - Snap 1
7 Ring - Turbine retaining 2
S1036
GROUP" AUXILIARY PUMP DRIVE

S1036
GROUp AUXILIARY PUMP DRIVE
1 Support Pump drive bearing 1

2 Screw - Bearing support 1
3 Pin - Bearing support 1
4 Bearing - Ball 1
5 Ring - Drive gear bearing retaining 1
6 Gear Auxiliary pump drive 1
7 Cover - Pump mounting permanent 1
8 Gasket - Shipping cover 1
9 Screw Pump mounting permanent cover 2
10 Lockwasher - Pump cover screw 2
S1036
GROUP -PUMP DRIVE

S1036
GROUP PUMP DRIVE
1 Support - Pump drive bearing 1

2 Pin - Bearing support 1
3 Screw - Bearing support 1
4 Bearing - Ball 1
5 Ring - Drive gear bearing retaining 1
6 Gear - Charging pump drive 1
7 Gear - Pump drive idler 1
8 Shaft - Idler gear stub 1
9 Ball - Idler shaft lock 1
10 Bearing - Ball 1
11 Ring - Idler gear bearing location 2
12 Ring - Idler gear bearing retaining 2
S1036
GROUP - FORWARD SHAFT
13
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S1036
GROUP - FORWARD SHAFT
1 Assembly - Forward shaft and drum 1

2 Piston - Clutch 1
3 Seal - Clutch piston (Outer) 1
4 Seal - Clutch piston (Inner) 1
5 Disc - Clutch (Inner) 8
6 Disc - Clutch (Outer) 8
7 Spacer - Piston return spring 1
8 Plate - Clutch disk backing 1
9 Snap ring - Backing plate 1
10 Assembly - Disc spring 1
11 Snap ring - Spring retaining 1
12 Ring - Forward shaft piston 2
13 Bearing - Forward shaft pilot 1
14 Bearing - Ball 1
15 Ring - Gear retaining 1
17 Gear - First drive 1
S1036
GROUP - REVERSE AND 2ND SHAFT
S1036
GROUP - REVERSE AND 2ND SHAFT
1 Assembly - Reverse, 2nd shaft & drum 1

2 Piston - Clutch 1
4 Seal - Ciutch piston (Inner) 1
5 Piston - Clutch 1
12 Spacer - Piston return spring 1
13 Plate - Clutch disc backing 2
14 Snap ring - Backing plate 2
15 Spring - Piston return 1
16 Retaining - Spring 1
17 Assembly - Disk spring 1
19 Bearing - Clutch driven gear 1
20 Bearing - Clutch driven gear 1
21 Ring - Reverse clutch gear bearing 2
22 Bearing - Ball 1
23 Ring - Front bearing retaining 1
25 Ring - Piston 3
27 Hub - 2nd clutch 1
28 Ring - 2nd clutch disc hub retaining 1
29 Bearing - Needle 1
30 Retainer - Retaining ring 1
31 Ring - Retainer location 1
32 Spacer - Reverse clutch gear 1
33 Gear - Reverse clutch 1
S1036
GROUP REVERSE IDLER
S1036
GROUP - REVERSE IDLER
1 Shaft - Reverse idler 1

2 Assembly - Reverse idler bearing 1
3 Washer 1
4 Nut - Bearing retaining 1
5 Washer - Bearing retaining 1
6 Lockball - Idler shaft 1
7 Gear - Reverse idler 1
8 "O"-ring - Idler shaft 1
S1036
GROUP - LOW SPEED SHAFT

S1036
GROUP - LOW SPEED SHAFT
1 Assembly - Low shaft, hub and drum 1

2 Piston - Clutch 1
7 Plate - Clutch disc backing 1
8 Ring - Backing plate retaining 1
9 Assembly - Disc spring 1
10 Snap ring - Spring retainer 1
11 Spacer - Belleville washer 1
12 Bearing - Low speed gear 1
13 Bearing - Low speed gear 1
14 Ring - Low speed gear location 2
15 Ring - Low shaft piston 1
16 Bearing - Ball 1
17 Spacer - Low speed gear bearing 1
18 Bearing - Ball 1
19 Snap ring 1
20 Retainer - Belleville washer 1
21 Gear - Low clutch 1
S1036
GROUp 3RD SHAFT
3 4
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1
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5
S1036
GROUP - 3RD SHAFT
1 As sem bly - 3rd sh all & drum 1

2 As sem bly - Clutch pislo n 1
3 Seal- Clutch piston (Outer) 1
4 Sea I - CI utch pisto n (I nn er) 1
5 Disc - Clutch {Inner) 6
7 Plate - Clute h dis c ba eking 1
8 Sna pring - Ba eking pia Ie 1
9 Spring - Pistan retu m 1
10 Retainer - Spring 1
12 Ring - Front bearing retaining 1
13 Bearing - Ball 1
14 Snap ri ng - Front bea rin g 1
15 Ring - Piston 2
16 Hub - 3rd c1ulch 1
17 Ring - 3rd clutch disc hub retaining 1
18 Bearing - Needle 1
-_.~::=----
GROUP -10 LER SHAFT (USED IN 6 SPE ED AND 3 SPEED
;~
S1036
WITH DEEP RATIO)
5
6
HI 8 4
"
, ,7,
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- ;~
S1036
GROUP - IDLER SHAFT (USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO)
1 Shaft - Idler 1
2 Bearing - Ball 1
4 B earing - Roll er 1
5 NuI - Bearing 1
6 Washer - Bearing nut 1
7 Spa cer - Idle r shall gea r 1
8 Snap ring 1
9 Gear - Idler 1
10 Gear - Idler 1
S1036
GROUP - IDLER SHAFT (USED IN 3 SPEED STANDARD RATIO)
7. ~
l\'~/Y
1
:~~
S1036
GROUP IDLER SHAFT (USED IN J SPEED STANDARD RATIO)
1 Sh all - Idier 1
2 Bearing Ball 1
4 B earl ng Roller 1
5 Nut Be aring 1
6 Wa sher - Bearin g nut 1
7 Spacer IdIe r sh aft gear 1
8 Snap ring 1
9 Gea r - Idler shaft 1
S1036
GROUP - OUTPUT SHAFT (6 SPEED)
/ :-~"~:-_::?'~~: , ~,
,} ::.:~. '..:..~;
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21 9 I /'
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.)'$l'~11'8/17
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S1036
GROUP - OUTPUT SHAFT (6 SPEED)
1 Shalt - Oulput 1
2 Bea ri ng - Ou Ip ut sh aft fro nt 1
3 Bearing - Ou lpul shaft re ar 1
4 Snap ring - Front bearing relaining 2
5 Ring - Output shalt rear bearing retaining 1
6 Bearing - HilLow gear 4
7 Spacer - B ea ri ng 1
8 Spa ce r - Bea ring 1
9 Washer - Gear thru 5t 2
10 Hub - Range shilt 1
11 Cap - Rear bearing 1
12 Gasket - Rea r bearing cap 1
13 Stud - Rear bearing cap 4
14 Lockwasher - Rear bearing cap stud 4
15 Nut - Rear bearing cap stud 4
16 Seal - 0 utput sh all 2
17 "0'-ring - Output Ita nge 2
18 Washer - Outpu lit an ge 2
19 Nul- Oulput !tange 2
20 Gear - Low fa nge 1
21 Gear - High range 1
22 Fi an ge - Output fro nt 1
23 FI ange - Output re ar 1
S1036
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO)
,.. . :; <.-'. ,'0. ~.

) ~I ,;--;-0- .,,_ '''..' _~-' ' "
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,,';' ;' :"'._. ,+ 1 '
,~ .'/, .- '. ,
:~k;~\;~j;~: ,
.~~.'~T'Y<. . . : ,1",/
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.'$l.\~ll ~:I 7 . I J~
/ 16I 15 14
18 ~1)~
/
S1036
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO)
Item Des c ripli 0 n Quantity
1 Shaft - Outpu I 1
2 Bea ring - Ou Iput sh aft rea r 1
3 Bearing - Output shaft front 1
4 Rin g - Output s hall rear bea ri ng 1
5 Ring - Output shall front bearing retaining 2
6 Was her - Ou Ip ut shaft rea r bearin g 1
7 Seal - Output shaft 2
8 Siud - Bearing cap 4
9 Lockwash er - Bea rin g ca p screw 4
10 Nut - Siud 4
11 Cap - Outp ut sh aft rea r beari ng 1
12 Ga sket - Oulput bearing ca p 1
13 Spacer - Gea r 1
14 O"-ring - Flange 2
15 Washer - Flan ge 2
16 Nul- Flange 2
17 Gear - Outpu I 1
18 Front - Flange 1
19 Re er - Fie nge 1
S1036
GROUP - OUTPUT SHAFT (3 SPEED DEEP RATIO)
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1,
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S1036
GROUP - OUTPUT SHAFT (3 SPEEO DEEP RATIO)
Item Des cri pti 0 n Quantity
1 Shaft - 0 utpu t 1
2 Bearing - a utp ut sh aft rear 1
3 Bearing - au Ip ut sh aft front 1
4 Ring - Output shaft rear 1
5 Ring - Output shaft fro nt bearin g retainin g 2
6 Seal - a utpu t shaft 2
7 Stud - Bearing cap 4
8 Lockwa she r - Bearing cap screw 4
9 Nut- Stud 4
10 Ca p - Output shaft rea r bea ring 1
11 Gasket - Outp ut bearing cap 1
12 Spacer - Gea r 1
13 Spacer - Gea r 1
14 "O'-ring - Flange 2
15 Wa sher - Flan ge 2
16 Nut - Flange 2
17 Gea r - Outpu t 1
18 Front - Flan 9e 1
19 Rear - Flange 1
S1036
GROUP - HI & lOW RANGE SHIFT CONTROL
, "
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S1036
GROUP - HI & LOW RANGE SHIFT CONTROL
1 Fork - Shift 1
2 Screw - Shift fork 1
3 Lockwasher - Shift fork 1
4 Assembly - Air shift cylinder 1
5 "O"-ring 1
6 Stud - Pump mounting 2
7 Nut 2
8 Lockwasher 2
9 Body - Cylinder 1
10 Seal - Piston rod 1
11 "O"-ring - Seal 1
12 Tube - Cylinder 1
13 Rod - Piston 1
14 "O"-ring 1
15 Piston 1
16 Cup - Seal 2
17 Nut 1
18 "O"-ring 1
19 Cap - Cylinder end 1
S1036
GROUP - CHARGING PUMP & FILTER
';-
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,
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-------
S1036
GROUp CHARGING PUMP & FILTER
1 Pump Charging 1
2 Assembly - Hydraulic spin on filter 1
3 Gasket Pump assembiy to converter housing 1
4 "O"ring 1
5 Screw - Pump mounting 5
6 Lockwasher - Pump mounting screw 5
S1036
GROUP - ELECTRIC CONTROL VALVE MOUNTING
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S1036
GROUp ELECTRIC CONTROL VALVE MOUNTING
1 Assembly - Electric control valve 1

2 Gasket - Control valve to front cover 1
3 Screw - Valve to converter housing 9
4 Lockwasher - Valve to converter housing screw 9
S1036
GROUP ELECTRIC CONTROL VALVE ASSEMBLY
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S1036
GROUP - ELECTRIC CONTROL VALVE ASSEMBLY
1 Housing control valve 1

2 Cover - Control valve 1
3 Gasket - Control valve cover 1
4 Spool - Forward and reverse shift 2
5 Spring 2
6 Spool - Range (3rd) 1
7 Valve housing plug 2
8 Valve housing plug "O"-ring 2
9 Spool stop 1
10 Pin 1
11 Plug stop 1
12 Spool- Range (1st and 2nd) 1
13 Spring 1
14 Pipe plug 8
15 Piug 1
16 Screw 1
17 Screw 2
18 Lockwasher 3
19 Stop - Spool 1
20 Forward and reverse deciutching spool 1
21 Spring - Deciutch 1
22 Plug 1
23 "O"-ring - Plug 1
24 Cartridge - Ball valve 4
26 "O"-ring - Cartridge 4
27 "O"-ring - Cartridge 4
28 Coil12V 4
29 Nut - Solenoid 4
30 "O"-ring 8
31 Cover - Soienoid 1
32 Spacer - Cover 2
S1036
9. ASSEMBLY INSTRUCTIONS
Assembly instructions
S1036
9. ASSEMBLY INSTRUCTIONS (CONTINUED)
-----.
;-
t=r
S1036
~--
GROUND DRIVEN
_~Qi--+l%~:r-- EMERGENCY STEERING
. PUMP DRIVE
OPTIONAL DISC BRAKE

LJ----- MOUNTING
@\
\-+J DRUM PARKING BRAKE
BRAKE ACTUATING LEVER
~~='='==i===~' ~. . __
- DRAIN PLUGS
S1036
FROM FILTER ---------~?~~--------TOFILTER

~~J
-Ei-i -"~~------------~------~------------"~-----
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S1036
HYDRAULIC DISCONNECT
FRONT AND REAR OUTPUT
AIR DISCONNECT
FRONT AND REAR OUTPUT
~--~~
~~--
~----~II -v- ----et

MANUAL DISCONNECT
FRONT AND REAR DISCONNECT
S1036

All lead in chamfers for oil seals, piston rings, and "O"-rings must be smooth and free from burrs.
Inspect at assembly.
Lubricate all piston ring grooves and "O"-rings with oil before assembly.
Apply a thin coating of grease between seal lips on lip type seals prior to assembly.
Use only precoated pipe plugs. On uncoated pipe plugs apply a light coat of Loclile no. 592.
After assembly of parts using Loctite, there must not be any free or excess material
which might enter the oil circuil.
Apply a light coat of Loctite no. 262 or no. 270 to all thru hole stud holes.
~ Tighten oil filter to 20-25Ibf.ft [27-34 N.m].
~ Fwd. and rev. with standard piston & low clutch. 8 Outer steel discs and 8 inner friction discs.
Insert one (1) Steel disc. Insert one (1) friction disc. Alternate steel and friction discs until proper
amount of discs are installed. First disc next to the piston is steel, last disc installed is friction.
~ Low clutch springs concave side of first belleville spring to be placed against clutch piston. Remaining
six springs of each clutch to be stacked alternately reversed as shown.
~ Must be loose internal fit bearing with a no. 3 etched on the bearing.
~ Shields must be sized prior to assembly.
~ Two clutches (2nd & 3rd). 6 Outer steel discs and 6 inner friction discs.
Start with outer steel disc alternate friction and steel.
~ Tighten to 200 - 250 Ibf.ft [271.2 - 339.0 N.m].
~ Shielded bearings, be sure that bearing shield is on the outside.
~ Forward and reverse clutch springs concave side of first belleville spring to be placed against clutch
piston. Remaining four springs of each clutch to be stacked alternatly reversed as shown.
S1036
~ Stator support screw assembly:
1. Clean stator support mounting surface and tapped holes with solvent. Dry thoroughly.
Being certain tapped holes are clean and dry.
2. Install 6 special stator support screws. Tighten screws to 12 -16Ibf.ft [16.3 - 21.7 N.m] torque.
Note
ASSEMBLY OF STATOR SUPPORT TO CONVERTER HOUSiNG MUST BE COMPLETEO WITHiN A 15 MINUTE PERiOO FROM
START OF SCREW INSTALLATION. THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION ONLY. IF SCREW IS
REMOVED FOR ANY REASON iT MUST BE REPLACED. THE LOCTITE LEFT IN THE HOLES MUST BE REMOVED WITH THE
PROPER TAP AND CLEANED WITH SOLVENT. DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION.
~ Torque screws of pump cover up to 20 - 25 Ibtft [27 - 34 N.m].
~ Tighten to 91 - 100 Ibf.ft [123.4 - 135.6 N.m].
~ Snap ring is to be assembled with sharp edges to front.

Disassembly and reassembly T20000 LD transmission
S1036
Disassembly T20000 LD transmission
S1036
Figure 1 Figure 4
Front view of the T20000 series long drop Remove pressure regufating valve and charging
transmission.The transmission being disassembled pump bolts.
is the 6-speed version.
Figure 2 Figure 5
Loosen filter assembly. Remove valve and pump assembly.
Figure 3 Figure 6
It is recommended a small pan be used to catch the Remove drive plate mounting screws and washers.
oil left in the filter element. Remove filter element.
S1036
Figure 7 Figure 10
Remove drive plate and backing ring. Though bore plug hole, remove turbine retaining ring.
Figure 8 Figure 11
Remove impeller cover bore plug retainer ring. Remove torque converter assembly.
Figure 9 Figure 12
Using two small screw drivers as shown, remove Remove turbine locating ring.
plug.
S1036
Figure 13 Figure 16
Using slots provided in converter Ilousing. Remove idler gear and bearing assembly.
Remove oil baffle retaining ring.
Figure 14 Figure 17
Baffle and sealing ring removed. Remove pump drive idler gear locating ring.
Figure 15 Figure 18
Remove pump drive idler gear retaining ring. From the rear through the pump drive hole, remove
pump drive bearing support screw.
See figure 281.
S1036
Figure 19 Figure 22
From the front, tap pump drive gear and bearing From the front, tap pump drive gear and bearing
support from housing. from housing.
Figure 20 Figure 23
From the rear, remove pump hole cover, screws, Remove solenoid protection cover screw and
lockwashers and gasket. lockwashers.
Figure 21 Figure 24
Remove auxiliary pump drive bearing support Protection cover removed.
screws. See figure 284.
S1036
Figure 25 Figure 28
Remove control valve bolts and lockwashers. Support converter housing with a chain hoist.
Remove remaining bolt.
Figure 26 Figure 29
Remove control valve and gasket. Separate converter housing from
transmission case assembly.
NOTE: Reverse and 2nd and 3rd clutch
will remain in converter housing.
Figure 27 Figure 30
Remove all bolts but one securing transmission to Using spreading type snap ring pliers, spread ears
converter housing. on the reverse clutch front bearing retaining ring.
S1036
Figure 31 Figure 34
!-blding snap ring open pry reverse and Remove output snaft front flange nJt, washer,
2nd clutch assembly from convener h<}using. 'O'-ring "od flange.
Figure 32 Figure 35
Using spreadiog type snap ring p',ers, spread ears Rem:::Jv8 OJtpu! stmft rear flange nut, ...o'asnsr, ~O'!'-ring
0'1the 3rd ciJtch front bearing reta~ning ring. and fiange.
Figure 33 Figure 36
Ha'di1g snap ring open tao 3rd clutch Rem-:J'~'e pump hde cove!, cover gasket sere.vs and
from converter hDusing. !De k\vas hers.
Disassembly T20000 LD Iransmission
S1036
Figure 37 Figure 40
Remml6 output :)ha!t rear bearing cap nuts and Remove pi sl on md nut.
Iackwasn ers.
Figure 38 Figure 41
o utp ut shall rear bear;ng cap ",moved. Ranove shift cylinder mcunting nuts and
Ioc kt.. as hem.
Figure 39 Figure 42
Remove shift cylinder end cap. Shin cy:inder removE{f.
S1036
Figure 43 Figure 46
Remove fear cover scre...Js and !ock'Nashers. Remove low clJlch rear bearir,g.
Figure 44 Figure 47
Using pry slots provided, pry cover from Remove 3rd crutch disc a'ld retaining ling.
transmissicn housing. Using a she-a hammer tap on
idler and output shafts to prevenl cover hcm binding.
Figure 45 Figure 4B
Rear cover rEmoved.NOTE: O'JtpJt and idier shaH Removs 2nd clutch disc hub, retaining ring, retaining
bearing outer races remaining h cover. ring reta;nef and retainer lecating r;ng.
S1036
~-!.~'@"
"@
(~)

Figure 49 Figure 52
Open ears on idfer shaft front bearing 1ccating ring so Tap the rear sufficiently so that bearirg groove is
that it is nut of tflli groove. past snap fing i.e. Vlst snap ring remain ill open
"'Ine
pas iti Oi'l 01- the b ea ri ng outer dia meter nil is
refeased.
Figure 50 Figure 53
Tap to U"'.8 re-::J st.tni CIe ntty so til:::.t Ul s- b 8ari:rg g rCDve is Remo"e the khV (1st) clutch and tile idler shaft
past snap rirg Le. ttmt snap remain- ill OPEf1 positicn en- tcgelhef.
the bearl1g Dute-r diameter '1','Tlen it is released.
NOTE: jl DEaring -SBB1""IS difficult to mDve rechBck
locating ring, being su'e ring is clear of me ring groove
if f)
t@
(~)

Figure 51 Figure 54
Open ears en low shaft fre-nt bear-:ng !ocaling rillgs so Remove snift fork.
that it is out of the groove.
S1036
Figure 55 Figure 58
From the front tap output shaft from the front bearing, From the front tap output shaft bearing from housing.
bearing remains in transmission case.
Figure 56 Figure 59
Remove output shaft assembly from housing. Open ears on forward shaft rear bearing locating
ring.
Figure 57 Figure 60 [t
Remove output shaft front bearing locating ring. While holding locating ring open, use a hammer ;j;
J
puller to remove forward shaft and clutch assembly.
Internal THO MiG x 1.5 deep 15mm.
Disassembly of low (1st) clutch
S1036
Figure 61 Figure 64
Remove low gear and hub, low shaft front bearing Turn clutch over. Remove inner and outer clutch
and clutch gear outer bearing. discs.Do not mix low clutch friction discs with friction
discs in other clutches.
Figure 62 Figure 65
Remove end plate retainer ring. Remove low speed gear bearing spacer.
Figure 63 Figure 66
Remove end plate. Remove low speed gear inner bearing.
Disassembly of low (1st) clutch
S1036
Figure 67 Figure 70
Remove clutch piston return spring, A 1-1/2 x 1 sleeve with a portion Remove clutch sheft piston ring.
removed is recommended for removing the clutch piston spring, washer and
retainer ring. Sleeve shown is a common pipe with a 1-1/1 x (39.0 x 26.0mm)
opening. The pipe is 6 x 3-1/4 x 2- 3/4 (155.0 x 85,0 x 78,0 mm).
Compress spring retainer washer. Through opening remove spring retainer
snap ring. Release tension on spring retainer.
Figure 68
Remove snep ring reteiner end reteining ring, disc
spring end specerNOTE: Do not mix disc springs
with eny other disc springs es they ere metched
spring pecks. SEE PAGE 10-60.
Figure 69
Turn clutch over end tep clutch sheft on e block of
wood to remove clutch piston.
Reassembly of low (1st) clutch
S1036
Figure 71 Figure 74
ReIer to tile "Cleaning and Inspection" pages. The bleed valve in tllC Inslall piston spring spacer and piston relurn
clutch drum must bl:! deiln Clnd froe of any foreign material. In~;lall
clutch piston outer seal ring. NOTE: Fling must be sized before
installing in clutch drum. SiZing is besl uccornplis!1od by rowling
clutch While holding a round object againsllhe now seal ring.
9R springs. First spring wilh large diameter
toward spacer (see figure 77). Alternate seven (7)
springs. See note in figure 68.
ROlate piston unlit sCiJl ring is !lush with outer diameter of piston.
11
Figure 72 Figure 75
Install clutch piston inner seal ring and size as Posilion spring snap ring. Compress spring and
described in figure 71. inslall snap ring.
Figure 73 Figure 76
Position piston in low clutch drum as shown. tnstall snap ring retainer.
Use caution as not to damage inner and outer
piston scaling rings.
Reassembly of low (1st) clutch S1036
Figure 77 Figure 80
Install clutch disc end plate.
Figure 78 Figure 81
Install one steel disc. Install end plate retainer ring.
Figure 79 Figure 82
Inslall one friction disc NOTE: the friction discs in the low clutch has a higher Install low speed gear inner bearing.
co-efficient rating than the friction discs in the olher clutches therefore the
discs musl not be mixed.The fow clutch friction disc has a yellow make of
non-soluble paint on the ouler diameter for permanent identification.Alternate
steel and friction discs unlillhe proper amount of discs are installed First disc
next to the piston in sleel last disc installed is friction
Reassembly of low (1st) clutch
S1036
Figure 83 Figure 86
Install low speed gear bearing spacer. Install low shaft font bearing with bearing groove up.
Figure 84 Figure 87
Install clutch driven gear and hub into clutch Install low shaft sealing ring.
drum.Align splines on clutch hub with internal
teeth of friction discs. Tap gear into position.
Do not force this operation. Gear splines must be in full
position with internal teeth of all friction discs.
Figure 85
tnstalilow speed gear outer bearing.
NOTE: outer bearing has a shieid in it, this shield
must be up.
Disassembly of reverse clutch
S1036
Figure 88 Figure 91
Remove clutch shaft piston rings. Pry reverse gear from clutch assembly far enough to
use a gear puller.
Figure 89 Figure 92
Remove clutch shaft front bearing retainer ring. Remove reverse clutch gear and outer bearing.
Figure 90 Figure 93
Remove clutch shaft front bearing. Remove clutch gear bearing spacer.
S1036
Figure 94 Figure 97
Remove end plate retainer ring. Remove clutch gear inner bearing.
Figure 95 Figure 98
Remove end plate. Compress piston return disc springs. Remove return
spring retainer ring.
Figure 96 Figure 99
Remove inner and outer discs. Remove piston return disc springs and piston
spacer. See note in figure 68.
S1036
Figure 100
Remove clutch piston,2nd being disassembled,
Disassembly of 2nd clutch
S1036
Figure 101 Figure 104

Remove end plate retainer ring, Compress piston return spring, Remove retainer ring,

Remove end plate, Remove return spring, spring retainer and retainer
ring,

Remove inner and outer clutch discs, Remove clutch piston, Reverse and 2nd clutch
reassembly 2nd being assembled,
Reassembly 2nd clutch
S1036

Refer to the "Cleaning and Inspection" pages. Compress return spring and install retainer ring.
The bleed valve in the clutch piston
must be clean and free of any foreign material.
Install clutch piston outer seal ring.
Size as explained in figure 71.

Install clutch piston inner seal ring. Install one steel disc.
Size explained in figure 71.
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

Position piston return spring, spring retainer and Alternate steel and friction discs until the proper
retainer ring. amount of discs are installed. First disc next to the
piston is steel, last disc installed is a friction disc.
Reassembly 2nd clutch
S1036
Figure 113
Install end plate and retainer ring.
Reassembly of reverse clutch
S1036

Refer to the "Cleaning and Inspection" pages, Position spring snap ring,
The bleed valve in the clutch piston must be Compress spring,
clean and free at any foreign material. Install Install snap ring,
clutch piston outer seal ring,
Size as explained in figure 71,

Install clutch piston inner seal ring,
Size as explained in figure 71,
Install clutch piston in clutch drum,
Use caution as not to damage sealing rings,

Position spring spacer and piston return springs, Install one steel disc.
First spring with large diameter toward spacer,
see figure 118, Alternate five (5) springs,
See note in figure 68.
S1036

Install one friction disc. Alternate steel and friction Install clutch gear inner bearing.
discs until the proper amount of discs are installed. NOTE: this bearing does not have a shield in it.
First disc next to the piston is steel, last disc installed
is a friction disc.

Install end plate. Install clutch gear bearing spacer.

Install end plate retainer ring. Install reverse gear into clutch drum.
Align splines on reverse gear with internal
teeth of friction discs. Do not force this operation.
Gear splines must be in full position with internal
teeth of all friction discs.
S1036

Install clutch gear outer bearing. Install clutch shaft piston rings.
NOTE: outer bearing has a shield in it, this shield
must be up.
Figure 127
Install clutch shaft front bearing.
NOTE: bearing outer diameter locating groove
must be up.
Figure 128
Install bearing retainer ring.
Disassembly 3rd clutch
S1036

Remove end plate retainer ring. Compress piston return spring and spring retainer.
Remove retainer ring.

Remove end plate. Remove return spring, spring retainer and
retainer ring.

Remove inner and outer discs. Remove clutch piston.
Disassembly 3rd clutch
S1036
Figure 136
Remove clutch shaft piston rings.
Figure 137
Remove clutch shaft front bearing retainer ring.
Figure 138
Remove clutch shaft front bearing.
Reassembly 3rd clutch
S1036

Refer to the "Cleaning and Inspeclion" pages. Install clutch piston outer seal ring.
The bleed valve in the clutch drum musl be Size as explained in figure 71.
clean and free 01 any foreign material. Inslall
clutch shaft front bearing. NOTE: bearing outer
diameter localing ring groove must be up.

Install clutch shaft front bearing relainer ring. Install clutch piston inner seal ring.
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

Install clutch shaft piston rings. Position piston return spring, spring retainer and
retaining ring.
Reassembly 3rd clutch
S1036

Compress return spring and install retainer ring. Install end plate.

Install on steel disc. Install end plate retainer ring.
Figure 147
Install one friction disc. Alternate steel and friction
discs until the proper amount of discs are installed.
First disc next to the piston is steel, last disc installed
is a friction disc.
Disassembly of forward clutch
S1036

Remove end plate retainer ring. Compress piston return disc springs.
Return spring retainer ring.

Remove end plate. Remove piston return disc springs and piston
spacer. See note in figure 68.

Remove inner and outer clutch discs. Remove clutch piston.
Disassembly of forward clutch
S1036

Remove forward clutch shaft piston rings. Remove forward clutch shaft rear bearing.
Figure 157
Remove 1st drive gear retaining ring.
Figure 158
Remove 1st drive gear.
Reassembly of forward clutch
S1036

Refer to the "Cleaning and Inspeclion" pages. Inslall forward clutch shaft pislon rings.
The bleed valve in Ihe clutch drum must be clean
and free of any loreign material. Install forward
~
clutch shaft rear bearing. NOTE: bearing ouler
diameter locating ring groove must be down. i1

Install 1st drive gear. Install clutch piston outer seal ring.
NOTE: with hub of gear down. Size as explained in figure 71.

fnstal11st drive gear retaining ring. Install clutch piston inner seal ring.
Install clutch piston in clutch drum, use caution as
not to damage sealing rings.
S1036

Position spring spacer and piston return springs. Install one steel disc.
First spring with large diameter toward spacer, see
figure 168. Alternate five (5) springs: see note in
figure 68.

Posifion spring nap ring. Compress spring. Install one friction disc. Alternate steel and friction
Install snap ring. discs, until the proper amount of discs are installed.
First disc next to the piston in steel, last disc installed
is a friction disc.

Install end plate.
S1036
Figure 172
Install end plate retainer ring.
Disassembly of converter housing
S1036

Straighten tang on reverse idler bearing retainer nut Remove idler gear and outer taper bearing from idler
lockplate. shaft.

Remove idler shaft bearing retainer nut. Remove idler gear bearing spacer.
Use TG 1304-54. See section 12: "Service tools".

Remove idler shaft bearing retainer nut, lockplate. Remove idler gear inner taper bearing.
S1036

Remove idler gear inner taper bearing spacer. Remove stator support screws.

Remove idler shaft, use caution as not to lose shaft Tap stator support from converter housing.
lock ball.
Figure 181 [t Figure 184

Using spreader type pliers spread ears on the +J Remove oil sealing rfng sleeve retainer and washer.
turbine shaft bearing snap ring. Remove steeve lock.
Tap turbine shaft and baring from converter housing.
S1036
Figure 1B5 Figure 1BB

Using a sleeve puller like the one shown, Remove turbine shaft oil sealing ring.
remove sleeve.
Figure 1B6 Figure 1B9

Remove support bearing retaining ring. Remove turbine shaft bearing retaining ring
and washer.
Figure 1B7 Figure 190

Remove bearing from support. Remove support oil Remove turbine shaft bearing.
seal ring.
Reassembly of converter housing
S1036
~
Refer to the "Cleaning and Inspection" pages. Install new stator support oil sealing ring.
Press turbine shaft bearing into position. Press support bearing into position.
Bearing groove must be down.
~ NOTE: bearing pari number must be up.

Position bearing spacer and bearing retaining ring. When installing a new sleeve it is recommended a
press or a driver be used to prevent damage to the
sleeve and be sure the notch in the sleeve is aligned
with sleeve lock notch.

Install new turbine shaft oil sealing ring. Install sleeve lock and cap screw, tighten screw to
specified torque (see torque chart).
S1036

Clean stator support mounting surface and tapped GJ With new "O"-ring on shaft, position idler
holes with solvent. Dry thoroughly, being certain tapped shaft in converter housing. Tap shaft into position.
holes are clean and dry. Position support in converter Install lock ball.
housing aligning holes in support with holes in housing.
Tap support into position.

Install 6 special stator support scrEWS. Tighten screws \0 12 - 16 Ibs. Ft (16.3 - 21.6
Nm.) torque. NOTE: assembly of Ihe stator suppor\10 converter housing must be
fnstall idfer shaft spacer.
completed within a 15 minute period from start of screw installation. Tile special
scrsw is 10 be used lor one installalion only. If Ihe screw is I8moved for any leason it
musl be replaced. The LocHia lell in the holes must be removed with Ihe proper tap
and cleaned with solvent. Dry hole thoroughly <lnc! use a screw for reinstallation.

Spread ears on turbine shaft bearing retainer GJ Install idler gear inner taper baring in shaft with large
ring located in reaction member support. Tap turbine diameter of taper down.
shaft and bearing into position, being certain bearing
snap ring is in full position in snap ring groove.
S1036

Position bearing spacer on shaft. Install reverse idler baring retainer nut fockplate
as shown.

Position idler gear on bearing with hub of gear up. Install reverse idler bearing nut with chamfer down.
Figure 205 Figure 20B

fnstall taper bearing on shaft with large diameter of Tighten nut 200 to 250 ft. Ibs.
taper up. Torque (271.2 - 338.B Nm.). Use TG 130~-54.
S1036

Bend over tag of lock plate that aligns with one of the Spread ears on 3rd clutch front bearing locating
slots of the lock nut, to secure it (See figure 210). ring. Tap clutch assembly into converter housing.
Align the snap ring groove in the front bearing with the
snap ring in the housing, being certain bearing snap
ring is in full position in snap ring groove.

Position the 2nd speed clutch shaft and 3rd speed
clutch pilot bearings on clutch shaft, a light coat of
good quality grease will hold bearing in position on
shaft.
Figure 211
Spread ears on reverse clutch front bearing
locating ring. Tap reverse and 2nd clutch assembly
into converter housing.Align the snap ring groove in
the bearing with the snap ring in the housing, being
certain bearing snap ring is in full position in snap
ring groove.
Disassembly of idler shaft
S1036

6-Speed cross section. The idler shaft being Remove idler shaft, rear bearing inner race spacer.
disassembled is a 6-speed (see figure above).
For 3-speed cross section see figure 215.

3-Speed cross section. Remove idler shaft gear (rear) and rear bearing inner
race.

Remove idler shaft nut. Remove idler shaft gear (front).
Disassembly of idler shaft
S1036
Figure 220
Remove idler shaft gear spacer.
Figure 221
Remove idler shaft front bearing.
Reassembly of idler shaft
S1036

Refer to the "Cleaning and Inspection" pages. Install idler shaft gear (rear) with long hub of
Install idler shaft lront bearing. gear down.
NOTE: snap ring groove in front bearing
must be up.

Install idler shaft gear spacer. Install idler shaft rear bearing inner race.

Install idler shaft gear (front) with long hub at gear up I Position bearing inner race washer and retainer nut.
Reassembly of idler shaff
S1036
Figure 228
Tighten retainer nut to 200 - 250 Ibs.ft. torque.
(271.2 - 338.8 Nm.).
Disassembly of output shaft
S1036

6-Speed cross section. The output shaft being Remove low range gear.
disassembled is a 6-speed (see figure above).
For a 3-speed cross section see figure 230.

3-Speed cross section Remove low range gear bearings and spacer.

Remove low range gear thrust washer. Remove range shaft hub.
Disassembly of output shaft S1036
Figure 235
Remove high range gear, gear thrust and rear
bearing inner raCB.
Figure 236
Remove high range gear bearings.
Reasssembly of output shaft
S1036
Figure 237 ~ Figure 240

Refer to the "Cleaning and Inspection" pages. -s ..'. Install range shift hub.
Install high range gear bearings. ~

Install high range gear. Install low range gear bearings and spacer.

Install high range gear thrust washer and rear Install low range gear.
bearing inner race.
Reasssembly of output shaft
S1036
Figure 243
Install low range gear thrust washer.
Reassembly of transmission
S1036

Refer to the "Cleaning and Inspection" Install low clutch shaft and idler shaft front bearing
pages. Install forward clutch shaft rear retaining ring.
bearing retaining ring.
[~J
Position forward assembly into transmission From the front install new output shaft seal with lip of
bearing bore. seal towards bearing side. From the rear install
output shaft front bearing and outer retaining ring.

Spread rear bearing retaining ring. Align snap ring Install front bearing inner retaining ring.
grove with snap ring, release snap ring in groove
being sure snap ring is in full position in ring groove.
S1036

Install output shaft assembly. GJ Install low clutch shaft rear bearing.

Install shaft fork and rod as an assembly
[~J Position new gasket and "O"-ring on rear of
on shift hub. transmission housing. A thin coat of chassis
grease will hold the gasl<et and "O"-ring in place.

The low clutch (1 51) and the idler shalt must be installed
[~J Install rear cover and bearing Quler races as an assembly.
[~J
in the transmission case together. The help of an assistant or NOTE: two aligning studs facilitate cover to housing
by replacing the transmission case on the front face may facilitate
this step. Spread ears on low and idler shafl front bearing retaining
ring. From the rear, lap low and idler shaft into position being sure
assembly. Tap cover bores in place aligning shaH bearings
with bearing bores. Use caution as not to damage
low clutch shalt sealing ring.
!tl
snap rings are in full position in ring grooves. Remove aligning studs and install cover bolls and locl,washers.
S1036

Tighten rear cover screws to specified torque Press new seal in bearing cap with lip of sealloward
bearing side of bearing cap. Position new gasket on
(see torque chart). bearing cap.
NOTE: some units will have uO"-rings between the cap and the cover.

Install pump hole cover, gasket, screws and Instaillockwashers and stud nuts.
lockwasher. Tighten nuts to specified torque (see torque chart).

Tighten screws to specified torque Install output flange, "O"-ring, washer and nut.
(see torque chart).
S1036
Figure 262 ~) Figure 265

Block flange to prevent turning. Tighten flange ~ Install new piston rod "O"-ring, position shift
nut 200- 250 Ibs. ft. (271.2 - 339.0 Nm.). cylinder assembly on piston rod.
Before installing shaft cylinder assembly replace all Use caution as not to damage piston rod
"O"-rings and sealing rings (see figure 263 and 264). sealing ring.

Install piston retaining lock nut.

Tighten lock nut to 26 - 29 Ibs. ft. (35 - 39 Nm.).
S1036

Position new cylinder end cap "O"-ring into Install forward clutch pilot bearing.
end cap.

Install cap and "O"-ring on cylinder tube. Install 2nd disc hub, hub retaining ring, retaining ring
Tighten cap securely. retainer and retainer locating ring. See figure 273.

Install cylinder body lockwashers and stud nuts.
Tighten nut 37 - 41 ft. Ibs. torque (50.2 - 55.5 Nm.).
Reassembly 01 transmission
S1036

Install 3rd clutch disc hub and relaining ring. PcsitiDil new 0" -Mng and gasket on front of
transmissiDn hcusing. A fg1t coat of chassis
grease ".111 held ~O-,ing and gasket in place.

Install frDilt output flange, "O"-ring, washer and :r-c,
1":-3 X-3 :r' ':::.'L'.-1 'T'-=;; ~.i I b:::1 L!:-l! o;:"i;'cn) "1"= =~,.-.:r= 'Y-,-,,=i--g x-It e ::.:n,i,..'-:.., r~-';l g
I:-~":.d :=.l r:H r ~'--~T'J ""="'-'7U.. t: :-.. r::.rh" cr ~'-"':-3"'li)", ~sf\] ~a~""-3 ::'~:7I 3; t::: d:;n-;-'"
flange nut. ::'l-1::'; :t= ':1:- d.nt d...:: td_-~. A.~..." d.r.::1 ;:dn E"E<";'" d~= -ojj,;, t..:T tu ;."t....-3 ~ i..o'\ u:::
-r
:r.::.J:: "~-3""::::U-~ 3': !:::.-T. T.... t ... 1 t~p "-"'"'" l1 01. -E: ,ULf E-'-,,~ .~:~ ~.t_, t.3 d~: -..n"
D':J r..o-' Fl:)-"(:E ~d.'; ~"'-:-~Jl 'f~u", it dJ':d-E:~ a=, ..-:c~-t,. dg-08i "1 ~ :;....-r.U:-3 'l:::_"'>i
,. ~ t'~:ij;"1 3-~3r~ -;-'" -;:-3 1011 torJ' t".... S.,.;; ... ,,:d- ~,'.'I: t=-"h] 1: "U..<':l-Q Clf""=.... s 3.j
<::.,"'"z.s.. .
_~ ~ R3"'>:.",3 3:;r>~J r.r....::~ r l.>.1 ""..";i "-<;1 (".rz:",,,,~ a-u ;::'","=-H~
Figure 276 Ffgure 279

Block flange to prevent turning. Tighle.~ lIange nut TightEn cap screws to spEcified torque
2GO - 250 Ibs. ft. (371.2 - 339.0 Nrn.). (see torque chart).
S1036

Position B.ux=liary pump drive gear irl converter Posilion cllarging pump dfi'.'e gear (see ligure 2M)
housing. See l;gure 281. and instal! cap scre-."j . . vith Lochte No. 243.
l1gtlten -cap screv, to specif~ed turque
{see toque chart}.
Figure 282 Agure 285

Instali cap screw with Loelite No. 243. Tigr,ten cap Using a new gasKet and "O"-,ing, posiliDn
sc re'N to 3 pee il, ed trnq ue (see tmq LJ e ci1 art). charging pump assembly. Insta!1 cap sere,...s
an d :OcKwas 118 rs.
T,gnten screws to spec,lfed torque (se8 toque chart).
Reassembly of fransmiss;"n
S1036

Irlstaii ca p sc rews and I[}C h'.ns hEf s: Instat1 idle! gear bBaring retain'ng ring.
!ighte~ sere'""s to specified torque (see torque chart).
Figure 267 Figure 29ll

Instal; new oil filter. Tighten 20 to 25 ft. Ibs torqJS Pcsi!ion pump idler gear and bearing
(27.1 - 33.9 N.m.). NOTE: i, is r8ccmmsnded I'm, the i~stab shalt.
filter cartridge be changed afte! 1C8 hours 0;
operation Oil fie'"","' and r-ebuilt or repaired units.

1l1s rail pump h ofe CQ'~' r, fl 8'.....8 ga sket sc rmvs
I tnstal' idler gear bearing losating rrng.
and locK'Nashers. Tigtlte-n screViS to specified
torque (see torque chart).
S1036
Figure 292
Press new seal in baffle . . iitrl lip of sBal to\.. . ard
Figure 295
Pos iti on con'y' 61 16 r ass-a rn b1y all stato r sup-po rt
r!,;'
:,..tI
impe!l6i" hub bearing. and turbine shafL
Positioll n",',' a-oj baffle sealing ring O~l oil baffle. NOTE: use extrem-a caution as nol to cut,
break or untlOok the- Gil sHaJing ring in tt18 support.

Fositiun oil baffle in housing and install letain'ng ring. Inslall converter assembly retaining ling.
Be sure ring is h full posi~iGn in .rlr'Jg grG-2-V9.

PositiGfl jnn-ar turbine locating ri1g en turbine 8'13ft. '''~Ih new "0 "ng in place, install bare plug.
S1036
Figure 2SB
Install bore plug retaining ring.
Figure 301
P08,tioo conlrol valv" assembly on
[~J
argrling studs.

See special seclioo on page 5-1 for drive plate fnsta'i contml va~ve to comre-rter housing scre',','s an.d
installa!ien. !cCk'liBshers, tight8!l- sere',','s to specified toque
(see torque chart).
Figure 301l Figure 3113

To insta'l control varve assembf,., It is Install p,otecticn cover, scre'.... s and be'viashe,s.
,ecommended t",o aligning studs be used Ie Tighten sere....s to specil;ed tc,que (see to'qUB
~>Q.slti:Jn ne','.' control ....ar-'...e gasket chart).
Disassembly and reassembly of the T20000 LD transmission
S1036
'&Note:
CLUfCH HETURN lJiSG SPR:rm Pl"CKS lJ.F.:E CEHTIFJED AGCGFlDlrlG TO COMPHESSIOU WEIGHT SPEC,FICATIONS AND ARE
PREPACKED N QUMHLTiES TO REPl.. IFl ONE (1) SPECIFIC ClUfCt~.
The disc spring pac~s are to be used as complete assemblies and care should be ta~en not to intermix the
Ind ivldual disc sp ring s with d iac spri ngs in anoth er clu Ic h or disc spring pac~.
Each disc spring assembly is made up of selected springs to precisely match each part within this assembly.
Failure to replace all pis Ion return springs can result in unequal deflection within the spring pack.
The result of this imbalance may adversely alfect overall life ot springs.
S1036
11. OPTIONS
11.1 HYDRAULIC ACTUATED AXLE DISCONNECT

The information contained herein must be used in conjunction wilh a T20000 LD section.
11.1.1 Sectional views and parts Identification

Refer to following pages.
S1036
GAOUpHYDAAULlC ACTUATED AXLE DISCONNECT

S1036
GROUP HYDRAULIC ACTUATED AXLE DISCONNECT
Uem Descriplion Quanlily
1 Shaft - Output 1
2 Bushing 1
3 Bearing - Output sh aft Iron I 1
4 Bearing - Output shaft rear 1
5 Snap ri ng - Fro nt wari ng retaining 2
6 Ring - Output shaft rear bearing retain ing 1
7 Beari ng - Hi Low ge ar 4
8 Spacer - Bea ri ng 1
9 Spacer - Bearing 1
10 Washer - Gear thrust 2
11 Ri ng - Output sh aft rear retai ning 1
12 Hub - Range shift 1
13 Housing - Dlconnect 1
14 'O"-ring - Dieonneet housing 1
15 "O"-ring - Dkonneet housing 1
16 Plu g - Dieon nect hou sl ng 1
17 'O"-ring - Bore plug 1
18 "a'-ring - Bore plug 1
19 RI ng - Bo re plug retal ning 1
20 Shat! - Dkonnect 1
21 Stud - Disconnect housing cap 4
22 Lockwasher - Discon neet hou sing stud 4
23 Nut - Disconnect housing stud 4
24 Plug - Disconnect housing 1
~~-~~::=-:::::::::~=="----------------7----~.- ..... -.-.. -
~ ~~ 1
27 Seal - Output shaft 2
28 Piston - Hydraulic actuator 1
29 "a'-ring - Piston 1
30 Sp ri ng - AIrihydrau Iic actu ala r piston - 0 uler 1
31 Spring - Airihydrauiic actuator piston - inner 1
32 Ring - Piston seal giyd 1
33 Locksc rew - Shift fork 1
34 Hub - Shift 1
35 Fork 1
36 "O"-ring - Disconnect housing 1
37 Plug - Shipping 1
38 "a'-ring - Output flange 2
39 Washer - Oulput !lange 2
40 Nut - a utp ut II ange 2
41 Gear - Low range 1
42 Gear - High range 1
43 Flange - Output (front) 1
44 Flange - Output {rear) 1
Options
S1036
11.1.2 Assembly instructions
g
~
~Jc==:t~==~ llGfflElI SB:UREtY AliD LOCK WiRE
TO PREVEtlT LOOS E1UIG
APPLY AliGHT COAT OF LOenTE 557
TO THE ()IJT!H DIAMETER OF THE IlOOSIIKl PlUG.
S1036
11.1.3 Disassembly of output shaft with axle disconnect

Disassembly of oulput shaft with axle disconnect
S1036
Figure 1 Figure 4
6-Speed cress section '\'"ith ax1e disconnect. RemDve fo'"" range gear bBarings and spacer.
Figure 2 Figure 5
R8ffiDve tow range gear thrust ',',lasher. Remove range shilt flUb.
Figure 3 Figure 6
Remove 1m-,' range gear. Remove be ar ing j nnef rae e retai ni ng ri ng.
Disassembly of output shaff with axle disconnect
S1036
Figure 7
Remove high range gear, gear thru51 ','lasher, bearing
spacer and baaring inner race.
Figure 8
REmove tlig-'l range gear bearings.
S1036
11.1.4 Reassembly of output shall with axle disconnect

Reassembly 01 oulpuf shaff with axle disconnect
S1036
Fi[lure 9 Figure 12
Refer to the Cleaning and inspection" pages. Inslall, l1;g~ range gear tl1rust wasl1ar,
II bJshing wem out, install new busl1ing. bearing spacm and bearing inner mce.
Figure 10 Figure 13
Installiligh range gear bearing,. tnsta'i rear bearing inner face retainirlg rjng.
Figure 11 Figure 14
Install l1igl1 range gear. Install range shift hub.
Reassembly of output shalt with axle disconnect
S1036
FIgure 15
lnstall !ow range gear bearings and ~-pacer.
Figure 16
Install low range gear.
Figure 17
InstalI1G.....' ran.ge gear thrust '.... asher.
S1036
11.1.5 Oi sass emb Iy of axIe dise llnn eel

Disassembly of axle disconnect
S1036
Figure 18 Figure 21
Remove Ule inner and outer actuator piston springs. Remove piston bore P~U[l relair::er ring.
Figure 19 Figure 22
The c-utp ut d I SB al mU3t be de stroye d by LJ sin g a Remove disconnect stmfl ou~r bearing reta:ner ring.
punch to d,i"e through the oil seal housing and
picking the dl seal out at tne discoonect hcusing.
Figure 211 Ftgure 23

Re move di scon ned -h 0 J srng p1u g. Remove the shift fm~ JocK scrm...
Disassembly of axle disconnect
S1036
Figure 24 Figure 27
RBmove disconnect w.AJ3ing plug. Sn if! and snif! fork removed.
Figure 25
Remove actuator pistc-n.
Figure 26
TaD disCGnnect shaft and ooaring from hnusing.
S1036
11.1.6 Reassembly of axle dlsconnecl

Reassembly of axle disconnect S1036
Figure 28 Figure 31
Refer :athe uCl8an:rg and fr.sc-ect.jrJf1~ pa;]8S_ A!;g, hde in actuator p,ston wi!h hale in shit !ark
Position shif:: fork -CD shiH hub, fnser~ aouatcr Install shift ferk lock scm>'.'.
in~odisconnect Musing. TightEn securejy and lock ,.,,'ire to pre-vent toc-s-ening.
H~ld shift hub and fork in. n.::::u8ing. align srjf( fork and
actu atm Distcn. fnse rt piston in ~ hift fa rk.
Figure 29 Figure 32
!nstall O",ing and g1yd ring G~ actuator piston Align splines on discGnnect shaft \'"ith splines in
(88" figure 29). stci(t h:Jb.
Figure 30 Figure 33
Tap s1aft and bearing in pfacE.
Reassembly 01 axle disconnect
S1036
Figure 34 Figure 37
Install shaft bearing ollter wlainer ling. Sc-cLJre bme plug wilh retairr'ng ring.
Figure 35 Figure 38
Press seal in disconnec~ J1c.JJsing \ViUl lip of seal in. /l.pply a iight coat of loctite 577 te- the outer diamelm
of Ihe housing plug.
Tap plug into posilioo in housing.
Figure 36 Figure 39
PositicH twa new "G"-rings e-n piston bore plug. Install disconnect housing O"-rings in housing.
Al'g~ t1O!e rn p!ug"ith ho!e in he-using. install plug.
Reassembly of axle disconnect
S1036
Figure 40 Figure 43
Insert the actJator pislon in.oar and cuter return Install output flange O"-ring, wasner artd flartge nut
springs irt piston.
FIgure 41 Figure 44
Use new UO"-rjngs Oil assemb~l_ Posi:iDfl disconnect Bleck flange to prevenl turning. Tightert flange nut
assembly 0'1 discoo'lect m01Jnti'lg studs. to specified torque (see elastic step nu~ chart}.
Irtsta'i stud nuts and lock'Nashe's.
Figure 42
The actuatc-r p:stGn sprin-gs must be comprEssed
against the rear cover ~o start the stud nuts and
lock'.'iasller. TightEn stud nuts to speci'fBd torque
(see torque chart).
S1036
11.2 PARKING BRAKES
11.2.1 MechanIcal Brake
11.2.1.1 seclional views and paris Idenliflcatlon

S1036
GROUP - DISC BRAKE (MECHANICAL BRAKE)
1
S1036
GROUP - DISC BRAKE (MECHANICAL BRAKE)
1 Calipe r - Par king brake 1

2 Disc - Brake 1
3 Assem bly - Mo unti ng bracket 1
4 Screw - Bracket asse mbly 10 b rg cap mtg 4
5 Washer - Bracket assembly 10 brg cap mtg fiat screw 4
6 Screw - Flange 6
7 Screw - Caiiper 10 mounting bracket 2
8 Spacer 2
S1036
GROUP - MECHANICAL BR AKE
16
", . ~~
~:.~ .<~ )\Q).' ~~~-
tQ{,r:<~~ /~,q,~
.. 0/' _1",3_
< 0 , , -
4
. r.c.." -~/'-'
6\f'.11'=, . ,;':;,;(J ."
1 3
S1036
GROUp MECHANICAL BRAKE
Item Descrlp1ion auantily
1 Screw 1
2 Antirotalion clip 1
3 Washer 1
4 Lever 1
5 Spring 1
6 Shaft - Seal 1
7 Housing 1
8 "O"ring 4
9 Bustling 2
10 Ball 3
11 Ball - Spacer 1
12 Rotor 1
13 Plai n bearing 1
14 Rotor - Seal 1
15 Lever side pad 1
16 Carrier side path 1
S1036
11.2.1.2 Adjustment and rebuild criteria

1. Check to insure iloating parts move freely and that all other parts are mounted securely.
Tighten hardware as required.
2, Check actuator linkage to insure that there is adequate freedom of movement for positive brake
operation. Adjustment of pad gap is to be accomplished by adjusting the actuating cable or linkage.
If adju stmentl s used up, back off cable or II nkag e. Un be nd tab 0 n anti -rotation eli p and 100 se n screw
enough to disengage lever spline. Rotate the lever one tooth, in the direction opposite the actuation
directi 0 n. an d retorq ue the sc rew maki ng su re th e splin e teeth are prope rly eng aged.
Bend up a tab that aligns with one of the screw head flats, to prevent screw rotation.
Both lever and linkage musf be free to return to home position. An external return spring is required.
3. Check disc surface condition. Replace if it is badty warped, pilted, or below minimum recommended
thickne ss. C heck for loose mou nt bo Its. Retighten if necessary.
4. Check to insure friction pads are not worn to less than .039" (1 ,Omm) thick. Replace worn friction pads.
Generally, if the disc is still running true and the pad clearance is still adjustable,
no other maintenance is required. To check for wear, measure the distance from the carrier side casting
face to disc face. If the distance is less than .060" (1.5mm), replace the friction pads.
11,2.1.3 Replacing friction pads
Note
ST/I.MPED ON TIlE B;'.CK OF E..'.,C;-t FRiCTION PAD IS A CODE. THE FlRST 1 GR 2 CoH.~RACTERS 1S ANUM2EA THAT
SPECiFIES THE FHCTION MATERIAL TYPE. CHECK TO IJlSURE NEW PADS toRE THE S;'}~E AS THE \'i~N PlillS RElI.OVED.
L--~------~REPl:A"Cl:.-'FH1Cl1C11t-'ADS"ONLYlUr'Afr-lS.
To replace the friction pads it is necessary to release the brake and disconnect the actuator
fro m the brake Ieve r.
1. Remove one brake mounling bolt. Swing the brake up over the disc to expose the brake pads.
In close cleara nee application s th e brake may be re moved fro m the ve hicle.
Using a flat bladed screw driver, pry out the used brake pads from their respective positions.
The lever side triction pad is snapped onto the plastic actuator cover. Care should be used in removing
the friction pad from the plastic actuator cover so as not to break oflthe center snap tabs.
2, Place the new f~ction pads in their respective positions.
The lever side friction pad has a center hole which snaps over the plastic snap tabs of the acfuator
cover. The flaf on the lever side pad must align wifh the flat on the plastic rotor cover, allowing the pad
to sit flat.
If fhe snap tabs are gone dab some silicone gasket adhesive around the back edge of fhe friction pad
and press firmly into place aligned as desc~bed above. Before placing the carrier pad in postilion,
clean out excisting pad glue from fhe pad compartment.
Place a layer of silicone gasket adhesive all along the back edge of the car~er friction pad and press
firmly In place. Push fhe lever side pad info the brake as far as possible.
3. Swing the brake over the disc and install the mounting bolt and tighten all mounting bolts.
4. AIter friction pad rep Iaceme nt, the brake actu ati ng lever is no 10 nger in th e correct po sIti 0 n fo r th e
actuating linkage.
Unbe nd tab 0 n anti -rotall 0 n clip and Ioos en screw e nou gh to dise ngag e th e leve r spline.
Rotate the lever to the OEM and torque screw to 110 - 140 in.lbs.(12.4 -15.8 Nm}. Bend up a tab on the
anti rotation clip tl1at aligns with one of the screw head flats, to prevent screw rotation.
Altach actuating cable or linkage to the lever. Adjustment of pad gap is accomplished by adjusting
the actualing cable or linkage.
S1036
11.2.1.4 Disassembly
Perform disassembly on a clean work bench.
1. Disconnect lhe actuator cable or linkage and remove brake from ils mounting.
2. Remove 1rieti 0 n pads. (see" Replaci ng Fricti 0 n Pads")
3. Unbend anti-rolation clip lab away from lever holding screw. Remove screw, anti-rolalion clip, washers,
lever, and spring.
4. Push out rolor assembly from lhe casling.
Caution
BAll. SPAeEH NlO 3 BALL BEMl NG S MAY COME OUT ~"ITU lHE ROTOR. ASS EM.3 LY.
(FOil HOron OISASSEP/BLY SEE "SmVICNG RmOR ASSEMBLY").
5. RemovB 3 ball bearings and ball spacer.

6. Shan seal need only be replaced il excessively worn or cracked. If replacemenl is necessary, press oul
lhe plastic shaft seal trom inside lhe casling, using a sleel spacer block 1.078"{27.38mm) diameter by
2.5" (63.5 mm) Ion 9 and an arbor pres s.
Note
POPUL,.',R RI''lND NAM E 3/6" DR 1\' E 13/16 to HEX DEEP SOCKET "','OR KS WEU AS A SPACER BLOCK.
7. After the shaU seal is press ed 0 ut, rem ove the sl iver of plasli c lh at may be left in lh e
gro O\'e in th e casti ng.
This completes disassembly of lhe brake.
11.2.1.5 Cleaning and inspeclion

1. Clean all paris with denatured alcohol and either wipe dry with a clean linl free cloth
or blow dry with an air hose.
2. Examine all parts carefully tor signs of excessive wear, damage, or corrosion.
Replace any parts fou nd 10 be damag ed.
3. Cil eck rolor ass embly for cracks, Replace if nece ssa ry.
4. Inspecl til e ca sting ball po ckels for scoring, pi tti ng, cracks or corros ion.
A corroded or deeply sco red easti ng shou Id be repl aced_
Ughl scaring and stains may be removed.
5. Check to see lhal the disc is nol bent or misshaped.
6. Check lever sp ri ng fo r breakage.
S1036
11.2.1.6 Assembly
Pri 0 r to ass embly make su re all parts are clean and serviceable.
1. Install a new shaH seal by Inserting the seal from the outside of the casting with Ihe extended smooth
surface inserted first Using an arbor press, with a protective spacer block between the arbor press
and the seal, ga ntly pres s th e seal in u nti I il sn aps in 10 the groove In th e casti ng.
2. Coat wi Ih grease, th e ball po ckels In th e casting, Ih e shaft and bal I pockets of the rolor assem bIy.
3. Insert 3 ball bearings and ball spacer inlo the pockels in Ihe casting.
4. From Ihe inside of Ihe casting slide the shaft of the rolor assembly thru the shall seal and seal
I he ball po ckets ag ai nst Ih e ball bean ri ngs.
5. Place the spring over Ihe large diameler pllol on the oUlslde of Ihe castmg.
6. Install the lever, making sure Ihe small diameter at Ihe spring is piloted on the oUlside
01 Ihe 4 pins In the Ieve r. Set Ihe Iever in III e OEM position.
7. Instailihe washers and anli-rotalion clip with its lab Inserled inlo the lower hole in Ihe lever.
B. Insert screw Inlo rotor assembly shaft and tighlen 10 110 - 140 In.lbs.(12.4 - 15.BNm),
while guiding lever over rolor assembly spline.
9. Aller Ihe proper torque Is achieved and the lever is inlhe OEM position, bend up a tab on Ihe
anli-rolallon clip Ihal aligns wllh one of the screw head flals, to prevenl screw rolallon.
1O. Inslall th e I riclion pads onto Ihe rolo r asse mbly and carrie r. (s ee "Replacing Fricti 0 n Pad s").
11. Stroke lever In its proper direction. The lever must rolale thru 60 degrees of rotation.
Return lever 10 the OEM position and make sure Ihe lever side friction pad is fully rerurned.
11.2.1.7 Replacing mount bushings

1. Pu sh mou nt bush ing s co mplete Iy out of the brake castln g.
2. Remove the four (4) 'O"-rings from the grooves in the casting, being carefull not to damage the
grooves. Clean the grooves and the bore with denatured alcohol or cleaning solvent. Let dry.
Lubricate Ihe grooves and "O--rlngs with the grease furnished with the service kit.
Install the 'O"-rings into the grooves.
3. Coat the bushings with kil grease. Insert bushing through tlle "O"-ring.
Wi pe oil any exce ss grease.
11.2.1.6 Servicing rotor assembly

Disas sem ble brake as previ 0 usly desc rlbed.
1. Using a sharp knife, make several cuts through Ihe outside diameler of the rigid plastic rotor cover.
Sreak aparl Ih e plaslic, re move and disc ard.
2. Discard the plain bearing from under the pia sic cover
3. Thoroughly clean all dirt and grease residue trom the rotor.
4. Amply grease one face at the new plain bearing and place it into the new rotor cover, grease to plaslic.
Amply grease the olher lace 01 the insert.
5. To assemble Ihe new plastic rotor cover a bench vise is necessary.
Snap a fri cti 0 n pad 0 nto the piastic cover.
Place the plastic cover over rte rotor, place in a vice, amf slowly squeeze the cover and rotor until the
cover snaps In place. Remove the Iriction pad and reassemble the brake as previously described.
S1036
11.2.2 Sp rl ng app lied hydrau lie rei eased bra ke (h ig h press ure)
Note
PLEASE RE;'.D NSmUCllDrlS BELOW E!-EfCFlE ATTEMPllrlG M~Y WOHK ON THE BFlAKE.
11 .2.2.1 Seeti anal views and parts Ide n!iliealion

S1036
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE))
6~
(
,
t
S1036
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE))
Item De scrip lion auantity
1 Cal iper - Parki ng brake 1

2 Disc - Brake 1
3 Ass embly - M DU nti ng bracket 1
4 Screw - Bracket assembly to brg cap mtg 4
5 Was her - Bracket assembiy to brg cap mtg IIat screw 4
6 Screw - Flange 6
7 Spacer 4
S1036
~S~P~RI~N~G~A;;;PPLIED lie~~~~D~8~R~AK~E~(~HI~G~H~P~RE~S~S~U~RE)
RELEASE
_ _______ __ HYDRAU
__
, -
S1036
SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE)
1tem Description Quantity
1 Torque plate 1
2 Boll- Hex 2
3 Jamnul 2
4 Ho usin g - Spring 1
5 Plug 1
6 Bolt - Adju slment 1
7 Shim AR'
8 Spring disc 10
9 Piston 1
10 Seal- "O"-ring 1
11 Back-up ring 1
12 Piston 1
13 Seal - "O"-ring 1
14 Back-up ri ng 1
16 Wiper 1
17 Boll 1
18 Nut 1
19 Uning 2
20 Bleeder 1
21 Spring - Urethane 2
22 Was her - Flat 2
23 Cap - Plug 1
24 Seal- "O"-ring 1
AR': As Required
S1036
11.2.2.2 0 peralio n
Ten disc springs (B) are used to hold the park brake in the actuated state.
The springs (B) push lhe pislons (9, 12) into lhe lining and carrier assembly (19) which squeezes
a driveline mounted disc. The brake is released by fluid entering a SAE 7/16-20 lhreaded inlet
in lhe side oj the torque plale (1) which pushes1he pistons back and compresses the springs (8).
11.2.2.3 Adjustment and rebuild criteria

1. Apply hydraulic pressure to the brake.
2. Remove plug (5) and set running clearance (.020" - .030") using the adjustment boll (6).
3. Replace plug (5).
4. Even up running clearance on each side oj the disc by adjusting the carrier retaining bolt ( 17).
The brake should be rebuilt when one or more ot the Jollowing crileria are met
1. Any sign s ot tluid leakage.
2. Lining thickness less than .031".
3. C racked or c hipped Ii ~i ng s.
11.2.2.4 Replacing friction pads

1. Apply hydraulic pressure 10 the brake and remove plug (5) and carrier boll (17).
2. With pressure applied, back-oH adjustment bolt (6) until piston (12) isllush with piston (9),
3. Re Iease hydrau lic press ure from th e brake an d re move lining and carri er assemblies (1 9).
11.2.2.5 Disassembly
IF THE FAEK 8 R.,o'IKE IS BE NG 0 IS.t..S SEM SLED "'.HI.LE eN THE VEH: CLE, fT IS " PORTANT ro FOLlO'''' TH E DI RECTlO rl5
F.:EGARD NG THE RBWV;'.L OF THE SfiFUW3 HOUSING (4) AND THE L1NNG AND CAA.RIE:RS (19) VERY CLOSELY.
1. Apply hydraulic pressure to the brake and remove plug (5) and carrier bolt (17).
2. With pressure applied, back'oll adjustment bolt (6) until piston (12) is Hush with piston (9).
3. Release hyd raulic pressu re Jrom th e brake an d re move Ii ni ng an d carri er assemblies (1 9).
4. Using a press, compress springs (8) to reduce the Jorce on the spring housing (4).
5. Use a spanner wrench to remove lhe spring housing (4) (counter-clockwise direction).
6. The spring s (8) will be acces sible when 1Ill! sp rin g h 0 usi ng is re moved.
Note
THE SF-fliNG H-:J'-J-S-lrlG (4) MAY HE REM{)',IED WHHOLIT COP/PRESSING THE SPRINGS ~8},
HCWE.... ER IT lS tr:t"T RECOMMENDED DUE ro THE ~IGH TORQtE P.EQU flED.
7. The adjustment bolt (6) threaded part oj lhe way into the hydraulic piston (9) may be used
to remove the pistons (9 and12) iJ brake is mounled on the vehicle.
8. If brake is not mounted to the vehicle it is easier to press the pistons out from the lining a~d carrier (19)
side of the torque Plate (1).
Caulion
Do NOT DM,\AGE SEALS (10,13,15) en BACK-UP R"'GS (11,14) en THE WIPEA (16) ',','HEr,
Awe-miG THE PISTOIIS (9 IIND12).
9. Piston (12) may be removed Jrom piston (9) by pushing on piston (12) through adjustment bolt hole
with a small nut-river or similar device,
S1036
11.2.2.6 Cleaning and Inspecllon

1. Clean all metal p arts prior to as sembi y.
2. Blow excess cleaning solulion ofl of all parts and out of all fluid passages.
11.2.2.7 Assembly
1. Apply a thin coat off fluid (compatible with mineral oil based hydraulic fluid) to seals (1 0,13,15),
Backup rings (11,14) and the wiper (16).
2. Install seal (15) in seal groove on piston (12).
3. Slide the adjustment pislon (12) into the bore located in the hydraulic pislon (9) unlil it hits
the bollom of Ihe bore.
4. Install wiper (16), back-up ring (14), and seal (13) in the grooves located in the small hole in
the torque plale (t).
5. Install seai (10) and backup ring (11) in larger grooves in lorque piate (1).
6. Install pislon assembly into torque ptale. (1).
7. Thread adjuslment bolt (6) into the hydraulic piston (9) until the bolt contacls
the adjustment pislon (12).
8. Place springs (8) in the lorque plate (1).
Springs should be placed in an ailernating cupped face to cupped lace orientation.
The springs on the outside ends 01 the stack should be oriented cupped lace out.
9. If the brake contained a shim (7) when it was disassembled, place the shim (7) so il wiil be in the
bottom of Ihe spring housing (4) when il is inslalled. See illustration below lor a grapllical
representation.
Nole
SPfJNGS ARE '.-lATCHED AND PRETESTED. IF NE'N SPFlIrlGS ARE BEING liSTALlED ADD A S-HL\l ONlY -iF THE rlE'....
SPR rIGs A.RE SHlfPED ....JJTH ONE.
SHI~' -~
SPRIIlGS
10. Thread spring housing (4) into torque plate (1) about 3 turns or until il makes contact,
with the springs (8).
11. Using a press, compress springs (8) to reduce the force on lhe spring housing (4).
12. Use a spanner wrench to lighten springhousing until the face bottoms out on the counterbore lace
in the torque plate (1). Tighlen to 500 - 600 Ib,-in torque.
13. Assemble washer (22) and the urethane spring (21) on the mounling bolt (2) then slide mounting bolls
through bolt holes in Ihe torque Piate (1).
14. Thread jam nUUsleeve {3) onto mounting bolt.
The cylindrical part ollhe jam nut/sleeve should extend into the torque plate,
S1036
15. Ins la II lining and carrier assem biles (19).

Thread lining and carrier adjustment boil into hex nut (8) located in the slot in the
back side ollhe lorque plale {1).
16. lnslailihe bleeder (20) in lhe porllocaled on lhe lop side ot lhe lorque plale (1).
17. Afler brake is mounled and adjusted, snap plug (5) onlo spring housing (4).
11.2.2.8 Installation
1. Slide brake ove r disc and inlo lh e rno unli ng pos iIi 0 n.
2. Slart mounting bolls (2) into mounting surface far enough to jusl supportlhe brake,
3. Remove plug (5) and tighten adjustmenl boll (6) until linings (19) are clamped to the disc.
4. Tighlen mounling boils {2) unlit lhey make conlact wilh the urelhane springs {21},
then lighten 1 to 2l1als more.
5. Tighten jam nut/sleeve (3) againsl mounting surface to lorque shown in seclion 11.2.2.9.
Caution
BW..KE 1I~~!r~3S ,hRE SUSCEPTHLE TO CmITA1'.lINATION.
WI-lEU lNSTALUNG OR S.F..VICllG BRAKES KEEP;'lL OIL AND FlUDS ":I'.{A\( FE-OM THE l'N:rms.
POOR BRP.KE PEEFOFlMANCE PlAY RESULT.
6. Attach brake line to inlet porI localed on Ihe side of Ihe lorque plate (1).
7. Bleed brake sysle m 10 rem ove I rapped ai r as follows.
Note
USE BLEEDER HOSE Oil BlEEDER SCREV'/S (PREFERABLY CLEAR TUEmG) TO ROUTE FLU D A'NAY
FHOM THE BRAKE AND UN NGS.
Caulion
BRA;{E USES H:G~ PRESSURE, oral E-LEEO:='R SCREW (20) VERY SLC'o',"LY ...mEN PEFFORMI~~G 8LEED:rolG PROCEDURE.
8. Apply pressure 10 brake and slowly openlhe bleeder screw (20) observe any air bubbles
lhalliow from lhe brake.
9. Repeal above paragraph unlilno air is observed in the tluid from Ihe bleeder screl'! (20).
11.2.2.9 Torque specs
PART (ITEM 110,) THREAD SIZE DRYTORQUE

8LE E0ER SCRB'/ !20) 7.11620 2'){J 25(H LB-I Ni
JAI,lJWTISLEEVE 1:31 1'410 2>i)j18-Ni

S1036
11.2.3 Spr i n9 appli ed hydrau Ii c relea sed bra ke (low pres su re)
Nole
PLEASE HEAD IrlSlP,UCflOrlS- BELOW ElEFOJlE AnHlPtlNG MlY Vf()HK orl THE E!fV\~E.
11.2.3.1 SecUonal views and paris Idenliflcalion

S1036
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE))
?
L
/ : 6~
( t r
~-:;,.>\._ . _::'::'.;..~ . . _ :',">; _f_~~ __'~ f<',~~ _ I '. _~./' ., _
, . "\" '::'<.;' :.:.'.'.. ..6,:,' ~ J ;::: '.,::/ . \1

..- __ ~ '_.-..:r .\,..... .._.~.-,.':__.. , .~: \f ~~ / ,,~~_. :_~_._-:. . '::I ':I. !
" .:~::j):: '.. ," , ~,~~~]~;'"

:r\"\
{):\ . ,.':
"~~;,.i,:
.'
,,::~!.<i>:~: <:.~.>~~~.:/i R
I ,{,,','.
~,
;. 0i 18\/ "-4
, ~ ~.~
7 5
.. ';~~::;"):';';~"
,. -.... ," .~
-- -,'
(--'" -"
or... ,
S1036
GROUP - DISC BRAKE (SPRING APPLIED HYORAULIC RELEASED BRAKE (LOW PRESSURE))
Item Des cri pH 0 n Quantity
1 Caliper . Parking brake 1

2 Disc - Brake 1
3 As sembly Mounting bracket 1
4 Sc rew Bracket assembly to brg cap mig 4
5 Wa she r - Bracket assembly to brg ca p mtg II at screw 4
6 Sc rew Flang e 6
7 Spacer 4
RELEAS~E~D~B~::-:::-::-----
S1036
SPRING APPLIED HYDRAU Lie RAKE (LOW PRESSU REJ

S1036
SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE)
1 Torqu e plale 1
2 Boll - Hex 2
3 Jamnut 2
4 Hau sing - Sprln g 1
5 Plug 1
6 Boll- Adjustment 1
7 Shim AR'
8 Spring disc 10
9 Cam 1
10 Ball- Bearing 3
11 Cam 1
12 Bearing - Nee1Jle 1
13 Washer - Hardened 2
15 Piston 1
17 Lever 1
18 Ring - Retainer 1
19 Boll 1
20 Nut 1
21 Pin - Callers 1
22 Uning an d carri er as sembly 2
23 Cylinder - Hydraulic 1
24 Screw 2
25 Piston 1
26 Seal - STD po Iy pack 1
27 Sliding ring 1
28 Rod 1
29 Ring - Retain ing 1
30 Rod excluder 1
31 Jamnut 1
32 Clevis 1
33 Clevis pin 1
34 Pin - Dowel 3
35 Spring - Urelhane 2
36 Washer - Flat 2
37 Cap - Plug 1
38 Seal- "O"-ring 1
AR': As Require1J
S1036
11.2.3.2 Ope ra lion

Ten disc springs (8) are used 10 Ilold the park brake in the actualed slate.
TIle springs push tile cams (9.11) and pistOil (15) into Ille lining and carrier assembly (22)
which squeezes a driveline mounted disc.
Tile brake is released by tluid entering a SAE 7/16-20 tllreaded inlet in tile top of tile hydraulic cylinder
(23) which pushes the piston {25} down, thereby rotating the lever (17) and cam (11),
compressing the springs (8).
11.2.3.3 Adj u stm ent and re build criterla

1. Apply hydraulic pressure to the brake.
2. Remove plug (5) and set running clearance (.020" - .030") using the adjustment bolt (6).
3. Replace plug (5).
4. Even up running clearance on each side of the disc by adjusting the carrier retaining bolt ( 1!l).
The brake shou Id be rebu ill when on e or m ore of the following c riteria are met:
1. Any sigl1s ot fiuid leakage.
2. Lining thickness less than .031".
3. C racked or cll ipped lil1i ngs.
11.2.3.4 Replacing friction pads

1. Apply hydraulic pressure to the brake and remove plug (5) and carrier retaining boll (19).
2. Witll pressure appiied remove adjustment boll (6).
3. Release hydraulic pressure from Ihe brake and remove lining and carrier assemblies (22).
, 112.3.5__Disassembll' -------
Caution
IF T"r1E PAEK EEAKE IS BEING DISASSEMBLED ....'HiL ON THE VEHICLE, IT IS L'.lPDRTAJIT TO FOUO'N THE FOLlO.. .jl~jG
DIRECTONS BEGAFDNG THE REMOV'L OF THE SPR NG HOUSING (4) AND TIlE L"''''G & CARR'Ens (22) VERY
CLOSELY.
1. Apply hydraulic pressure to the brake and remove plug (5) and carrier retaining bolt (19).
2. With pres sure app Iied remove adjustmen I bolt (6).
3. Release hydraulic pressure from the brake and remove lining and carrier assemblies (22).
4. Use a spanner wrench to remove the spring housing (4) (counter-clockwise direction).
5. The springs (8) will be accessible when the spring housing is removed.
6. Remove hair pin (21) and pin (33) from Ihe clevis (32).
7. Remove hydraulic cylinder (23) from torque plate (1) by removing cylinder mounting bolts (24).
B. Remove retaining ring (1 B) and lever (17) trom the spline on Ihe cam (11).
9. The opposing cams (9, 11), adjuslmenl piston {15} and dowel pins (34) can be removed by pressing
them out of the torque plate (1) from the lining and carrier (22) side.
10. Remove balls (10) and adjustment piston (15) from cams (9, 11).
11. The 'O--ring seal (16) can be removed from the adjustment piston (15) If necessary.
12. Remove needle bearing (12), hardened washers (13), and 'O"-fing seal (14) from Ihe torque plate (1)
once the cams (9, 11) are removed.
13. Slide the rod (28) and clevis (32) out of the hydraUlic cylinder (23).
14. Remove the rod exciuder (30) from the hydraulic cylinder {23) by prying with a small screwdriver.
15. The retaining ring (29) may be removed once the rod excluder (3D) has been removed.
16. Press piston (25) out of the hydraulic cylinder (23) by pushing on Ihe top ot tile piston
with a long slender rod.
S1036
Note
Do rIDT S-cI\A CYLINDER 'NALLS OR. WCK HiE p,Srml DURING REMO'rlAl.
11.2.3.6 Cleaning and inspectlon

1. Clean all metal parts prior to assembly.
2. Blow excess cleaning solulion 011 of all parts and out of all fluid passages.
11.2.3.7 Assembly
1. Apply a thin coat of tluid to seals (14.16).
2. Install seal (16) in seal groove on adjustmenl piston {15}.
3. Slide the adjustment piston (12) into the bore located in lhe cam (t1) untillhe seal (16) is
inside the bore.
4. Install seal (14) in the grooves located in the small hote in the torque plate (1).
5. Install needle bearing (12) between tile two Ilardened washers (13).
6. With bearing and washers (12,13) in ptace, install cam (11) and balls (10) inlo torque plate (1).
7. Install cam (9) and dowel pins (34) into torque plate (1).
8. Thread adjustmenl bolt (6) into the cam (9) until the bolt contacts the adjustment piston (15).
9. Place springs (8) in the torque plate (1).
Springs shoutd be placed in an alternating cupped lace to cupped face orientation.
The springs on the outside ends of the stack should be oriented cupped face out
10. Replace th e sh im (7) in the bolto m of the spri ng hou sing (4) before add ing th e spring s if the brake
contained a shim when it was disassembled. See illustration below for a graphicat representation.
Note
SPilrms NlE 'lATCHED A.ND P,RETESTEO.
IF r-.~w SPFHNGS ME BEING INSTALLED ADD A ScU,l ONLY IF THE NB'J SPRlrlGS ~..RE SKIPPED \'itT=-!. orfE.
SHI~' -------., SPRIIIGS
11. Apply a thin coat of Never-Seez to the spring housing (4) threads.
12. Screw spring housing (4) onto torque ptate (1). Tighten with a spanner wrench until the spring
housing lace bolloms out on lhe counterbore face in the torque plate (1).
13. Assemble washer (36) and !he urethane spring (35) on the mounting bolt (2) then slide mounting
bolts through boll holes in the torque plate (1).
14. Thread jam nutlsleeve (3) onto mounting bolt.
The cylindrical part ot the jam nutlsleeve should extend into the torque plate.
15. Apply a thin coat of fluid to seal {25} and stiding ring (27).
16. Install seal (25) and the sliding Ring (27) on the Piston (25).
S1036
17. Install piston (25) into the hydraulic cylinder (23) wilh the Hat side facing the top of the cylinder.
18. Push the piston (25) to the top of the hydraulic cylinder (23) and install the retaining ring (29) in the
groove at the bolla m of the cyiin der.
Note
MAKE SURE :INLET PORT IS UNCAPPED ,,trla~ INSTAll!NG PiSTmJ {25)+
19. Press rod excluder (30) with the rubber side facing out of the hydraulic cylinder (23).
20. Thread clevis (32) with the 3/8-16 jam nut installed into the rod (28).
21. Insert the rod (28) and clevis (32) through the rod excluder (3D) into the hydraulic cylinder (23).
22. Position assembled hydraulic cylinder (23) onto torque plate (1) and install the cylinder mounling
bolts (24) into their respective holes.
23. Pin clevis (32) to the lever (17) with clevis pin (33) and hair pin (21).
24. Adjust rod (28) until it contacts the rod relaining hole in piston (25) and tighten the jam nut.
25. Install lever (17) on the spline of cam (11).
Th e ce nte r Ii ne of the leve r sh auld be 0 rienled parallel 10 the top olt he torqu e pi ate (1).
26. Install retaining ring (18) in groove on the cam (11).
27. Install lining and carrier assemblies (22).
28. Thread carrier adjustment boll (19) into hex nut (18) located in the siot in the back side
of the torque plate (1).
29. After brake is mounted and adjusted, snap plug (5) onto spring housing (4).
11.2.3.8 Installation
1. Slide brake over disc and inlo the mounting position (per vehicle specification).
2. Slart mou nting bolts (2) inlo rna unting surface far e nou gh to ju st su Pport the brake,
3. Remove piug (5) and tighten adjustment bolt (6) until linings (22) are ciamped to Ihe disc.
4. Tighten mounling bolls (2) untillhey make contact wilh the urethane springs (35),
III en tighten 1 to 2 flats more,
5. Tighten jam nut I sleeve (3) against mounting surface to torque shown in section 11.2,3.9.
Caution
BRAKE llN!tmS APE SUSCEPTIBLE TO corrrAMi~~Anou.
WHEN IN5TAU1NG OR SERVICING E.R/o..KES KEEP ALL OIL A~D flUIDS AW.~Y FADM THE UNI~ms.
POOR BRAo<.E PERFORMA~JCE M,A.Y RESULT.
6. Al1ach brake line to inlet port located on the top of Ihe hydraUlic cylinder (23).
11.2.3.9 Torque specs
PART (ITEM 110.) THREAOSIZE DRYTORQUE
PLUG-INLET (3 Ii 7116 - 20 12,'t7 {LBW)

,tAl.! lILIT,'SLEEVE 1:3:, H-W 2001LB-Ni
S1036
12. SERVICE TOOLS
12.1 REVERSE IDLER SHAFT NUT SOCKET (TG 1304 - 54)
Ma de from Sn ap-on 1M 662A Socket 2 1116" d Ii ve 3/4".
101"-,- - j
4 SLOTS
i
-ill- I
--,
I
I
S1036
17101
DRIVELINE INSTALLATION
Page 1 of 1

1 11827-01 END YOKE (STD.) 1
19495-01 END YOKE (FOR DRIVELINE DISC) 1
2 24106 FLANGE YOKE 1
3 24062 END YOKE 1
4 11827-01 END YOKE 1
5 364024 CROSS AND BEARING KIT 1
6 19201-58 DRIVELINE ASSEMBLY (INCLUDES ITEM 7) 1
7 362120 CENTER BEARING 1
9 464172 SLIP ASSEMBLY (INCLUDES ITEMS 8 & 10) 1
12 19200-14 DRIVELINE ASSEMBLY 1
Updated:
08/31/07
MANUAL INDEX
A-64 DUNBAR ANFO
MINERA BISMARK
S/N 6964
11/02/07
6. AXLE
10829 AXLE ORIENTATION

13335 AXLE ASSEMBLY
13332 AXLE CRADLE INSTALLATION
S1037 AXLE SERVICE & REPAIR MANUAL
13158 BRAKE ACTUATOR
S1023 BRAKE ACTUATOR INSTALLATION
17095 TIRE & RIM
S1007 TIRE SERVICE
10829
FORD AXLE ORIENTATION
Page 1 of 1
Updated:
12/11/06
13335
AXLE ASSEMBLY 464872
Page 1 of 9
Updated:
03/12/07
13335
Page 2 of 9
Updated:
03/12/07
13335
Page 3 of 9

464872 AXLE ASSEMBLY 1
1 444144 HOUSING - BRAKE OUTER 2
2 444196 HOUSING - INNER, R.H. 1
3 444193 HOUSING - INNER, L.H. 1
4 442010 DISC ASSEMBLY 8
5 442020 DISC 4
6 444707 DISC ASSEMBLY (INCLUDES ITEMS 7-10) 2
7 444428 LINK 4
8 444859 BALL 12
9 442050 SPRING RETURN 8
10 444708 PIN 2
11 444860 NUT 4
12 444861 BOLT 12
13 442090 STUD SCREW 4
14 444862 NUT 4
15 442110 PIN 2
16 11828-04 ROD CONTROL 2
17 01GF02048 PIN - COTTER 2
18 442130 PIN 2
19 444837 SEAL 2
---- ------------ BRAKE ACTUATOR (SEE SECTION 6) ----
Updated:
03/12/07
13335
Page 4 of 9
Updated:
03/12/07
13335
Page 5 of 9

1 444863 HOUSING ASSEMBLY, FRONT AXLE R.H. (DIFF. LOCK) 1
444864 HOUSING ASSEMBLY, REAR AXLE R.H. 1
444864 HOUSING ASSEMBLY, FRONT AXLE L.H. 1
444863 HOUSING ASSEMBLY, REAR AXLE L.H. (DIFF. LOCK) 1
(INCLUDES ITEMS 3, 6, 20A)
2 444865 PLUG LESS BRAKES 2
3 444115 GEAR-PLANET RING 2
4 ------------ SEE PAGE 3 OF 9
5 ------------ SEE PAGE 3 OF 9
6 442150 CUP - SHAFT BEARING 2
7 444841 O-RING 2
8 444191 BOLT 21
444866 BOLT, HEX HEAD 1
9 444867 STUD SCREW 4
10 444243 NUT, HEX 4
11 444801 SHIFT AND BOLT ASSEMBLY (INCLUDES ITEM 12) 2
12 444631 BOLT 16
13 272410 LUG NUT A/R
15 442180 CONE AND ROLLER ASSEMBLY (OUTER) 2
17 444800 SEAL (CASSETTE) 2
18 444868 CARRIER ASSEMBLY (INCLUDES ITEMS 20-25) 2
19 444245 RETAINER 2
20 442200 CONE AND ROLLER ASSEMBLY 2
20A 442140 CUP 2
21 444246 SHAFT 6
22 444869 GEAR, PLANET 6
23 444102 WASHER, THRUST 12
24 444248 KIT, PLANET GEAR (INCLUDES ITEM 32) A/R
25 444104 SPACER 6
26 444064 GEAR 2
Updated:
03/12/07
13335
Page 6 of 9
27 444205 SPACER, (.049/.050) A/R
444105 SPACER, (.053/.054) A/R
444118 SPACER, (.057/.058) A/R
444119 SPACER, (.061/.062) A/R
444120 SPACER, (.065/.066) A/R
444106 SPACER, (.069/.070) A/R
444122 SPACER, (.073/.074) A/R
444123 SPACER, (.077/.078) A/R
444145 SPACER, (.081/.082) A/R
444237 SPACER, (.085/.086) A/R
444097 SPACER, (.089/.090) A/R
28 444142 WASHER, RETAINING 2
29 444033 LOCK BOLT 2
30 444143 BOLT, HEX HEAD 2
31 ------------ BRAKE ASSEMBLY 2
32 444144 HOUSING, REAR BRAKE OUTER 2
33 444196 HOUSING, BRAKE INNER R.H. 1
444193 HOUSING, BRAKE INNER L.H. 1
34 444125 SHIM (.038/.040) A/R
444098 SHIM (.044/.046) A/R
444126 SHIM (.050/.052) A/R
444127 SHIM (.056/.058) A/R
444099 SHIM (.062/.064) A/R
444108 SHIM (.068/.070) A/R
444100 SHIM (.074/.076) A/R
444109 SHIM (.080/.082) A/R
35 444164 CUP BEARING 1
36 444177 CUP BEARING, R.H 1
37 444008 CONE AND ROLLER ASSEMBLY L.H. 1
38 444176 CONE AND ROLLER ASSEMBLY R.H. 1
39 444249 CASE ASSEMBLY 1
40 444250 SCREW, HEX 8
41 444251 GEAR SET-MATCHED 1
42 442210 BOLT 12
43 444110 NUT-HEX LOCK 12
44 444170 GEAR-SIDE 1
45 444171 GEAR-SIDE 1
46 444178 WASHER-THRUST 2
Updated:
03/12/07
13335
Page 7 of 9
47 444169 SPIDER-DIFFERENTIAL 1
48 444172 PINION ASSEMBLY-DIFFERENTIAL 4
49 444175 WASHER-THRUST 4
50 444173 BUSHING 2
51 444854 ADAPTER 1
52 444855 SPRING 1
53 444856 COUPLING 1
54 444252 WASHER 1
55 444092 RING-LOCKING 1
56 442220 BEARING ASSEMBLY 1
57 444850 LOCK RING 1
59 442250 RETAINER ASSEMBLY 1
60 442260 CUP-BEARING 1
61 442270 CUP-BEARING 1
62 444253 WASHER-LOCK 1
63 444782 BOLT-HEX HEAD 1
64 444111 SPACER (1.254/1.2545) A/R
444093 SPACER (1.256/1.2565) A/R
444255 SPACER (1.258/1.2585) A/R
444112 SPACER (1.260/1.2605) A/R
444114 SPACER (1.262/1.2625) A/R
444094 SPACER (1.264/1.2645) A/R
444128 SPACER (1.266/1.2665) A/R
444129 SPACER (1.268/1.2685) A/R
444130 SPACER (1.270/1.2705) A/R
444095 SPACER (1.272/1.2725) A/R
444131 SPACER (1.274/1.2745) A/R
444132 SPACER (1.276/1.2765) A/R
444133 SPACER (1.278/1.2785) A/R
444096 SPACER (1.280/1.2805) A/R
444134 SPACER (1.282/1.2825) A/R
65 442280 SEAL, O-RING 1
66 442290 SEAL, RETAINER 1
67 444851 RETAINER 1
69 444852 SEAL, ASSEMBLY 1
Updated:
03/12/07
13335
Page 8 of 9
70 11827-01 FLANGE (STANDARD) 1
19495-01 FLANGE (DISC BRAKE) 1
71 442310 SEAL, SALINE 1
72 442320 WASHER, RETAINER 1
73 442330 NUT, HEX SLOTTED 1
74 01GF03032 PIN, COTTER 1
76 442350 BLOCK, THRUST 1
77 04GE07 WASHER, LOCK 2
78 444258 BOLT, HEX HEAD 2
Updated:
03/12/07

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Spare Parts Catalogue Getman Part 2

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Formati disponibili

S1057

Beschnitt MAGENTA = HKS 14K SCHWARZ Beschnitt

ITEM PART # DESCRIPTION QTY.

*ITEMS NOT SHOWN Updated:

*ITEMS NOT SHOWN Updated:

*ITEMS NOT SHOWN Updated:

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*ITEMS NOT SHOWN Updated:

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Whenever repair or replacement of component parts is required, only SPICER OFF-HIGHWAYPRODUCTS

.. ---"-'-A-3'~spe-e-c:r-'iIa'ncia-rdrs--si"iTlnaf-to-a--o-iweErd-Witlrrange-shift-w he n-- h igh--ran g e.. 1s-s el ected. ._._.

3-SPEED STANDARD RATIO

3-SPEED DEEP RATIO

6-SPEED RANGE SHIFT

2. CLEANING, INSPECTION AND LEGEND SYMBOLS

6. OPERATION OF THE TRANSMISSION

7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION

8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

10. DISASSEMBLY AND REASSEMBLY T20000 LD TRANSMISSION

11. OPTIONS (Continued)

12. SERVICE TOOLS

2. CLEANING, INSPECTION AND LEGEND SYMBOLS

2.2.1 Bea rings

2.2.2 Oil Seals, Gaskets, Etc.

2.2.3 Gears an d Sh afts

2.2-4 H0 us in g, Covers, etc.

2.3 LEGEND SYMBOLS

[}~:;aUBTl-ti of <Is..!E:-:":'lbt1 .;....cu;;.;;

Mc-r:t<ggi-:o di psr&:r::-!t:ri ir.;;.crrtrciU E-.1tare tErrl ~ nu~-a!W. dar.r~ ai psm

! T= At:;-~tJre~~..,j P '" .r.;;r,:i

iT'" :S~-=-:It-~01 P '" fa:;!:

f------~-".,--I R;'",,,",,,,",,,,,= ~ m7""~'

E"Ef":1..e'JT~tE- ri~'21:.t.i;b'' (U!~~.. J.H-E- ~-<:! neUF~".;J)

?c3.Sb'y s'!ii s~-..i-=-E-ilie, r=n",~- if r:-eCE""-5~f

3.1 IDENTIFICATION OFTHE UNIT

3.2 WEIGHT, DIMENSIONS, Oil CAPACITY

3.3 TIGHTENING TORQUES

3.3.1 Torque specifications for lubricated or plated screw threads

tlOM. SIZE GRADE 5 ED

.25W ~. \1 I !12-\5j 8-10 1\1-14]

tlOM. SIZE GRADES