PowerSynchro Transmission

Parts Manual
Models
TH336, TH337,
TH406, TH407,
TH414, TH514,
TH417
S/N TDE00100 & After
S/N TDF00100 & After
S/N TBX00100 & After
S/N TBY00100 & After
S/N TBZ00100 & After
S/N TBW00100 & After
S/N TBT00100 & After
31200493
Original
June 25, 2008
Product and Dealer Information
Delivery Date:
Product Information
Model:
Product Identification Number:
Transmission Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
GENERAL INFORMATION
1. MACHINE IDENTIFICATION
Caterpillar machines are identified by Product
Identification Numbers (PIN). Some components
included in a machine may be identified by Serial
Numbers (S/N). Typical components that will be
serialized include engines, transmissions, bulldozers,
and rippers. The machine and engine are further
identified by arrangement numbers and in some cases
modification numbers. These numbers are shown on
the product identification plate(s) and on the master
plate in the operators compartment.
Caterpillar dealers need all of these numbers to
determine accurate parts identification.
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) will change from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The PIN
plates and frame marking will display the 17 character
PIN. The new format will look like the following:
Where:
1. Caterpillars World Manufacturing Code (characters
1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Machines and generator sets produced before First
Quarter 2001 will maintain their 8 character PIN format.
Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Serial Number (S/N).
2. ORDERING PARTS
Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world. Their
parts inventories are up to date and include all
parts normally required to protect your investment in
Caterpillar machines. Dealers may offer repair kits or
remanufactured parts to allow selection of the most
effective repair alternative for a particular situation.
When ordering parts, your order should specify the
quantity, part number, part name, and the serial
number/product identification number of the machine
for which the parts are needed.
3. PARTS MANUAL ORGANIZATION
Product information in this manual is presented
as "information elements" that represent all of
the components for the specific model. Engine
Arrangement and Seat Group are examples of
information elements.
4. TABLE OF CONTENTS
A table of contents (TOC) is found at the beginning
of the manual. The TOC lists each section of the
manual with a complete list of all information elements
organized as they appear in the manual.
GENERAL INFORMATION
5. CAPTIONS
Captions located at the top of each page of an
information element identify the part number and part
name along with additional descriptive information.
PIN and S/N information found in each caption should
be used to select correct information for a specific
machine. Field replacement options, identification of
optional attachment components, and where used
("part of") information is also provided.
The first line of a caption is shown in larger type font
to indicate the beginning of an information element.
Captions for additional pages that may be required
to illustrate an information element will be shown in
standard type font and will include the term (contd.).
6. NON-SERVICED PARTS
In some instances it is necessary to display
non-serviced parts that are a link to a lower level
serviceable consist lists. These non-serviced part
numbers are shown in italic type indicating that they
are not available.
7. PARTS LIST REFERENCE NUMBERS
Numbers shown in the Ref No column correspond
to numbers used in the associated graphic(s). An
alphabetic suffix may be added to a reference number
to identify lower level consist items. Numbers shown
in the Graphic Ref column refer to the graphic number
identifier displayed in the lower left corner of each
illustration. The Graphic Ref number may be used in
combination with the item Ref No to determine the
correct part number. There may be intentional omission
of a Ref No in a consist list as information is updated
to reflect the latest serviceable part numbers.
8. INDENTED PART NAMES
When a part name is indented in a parts list, it is part
of (included in) the group or assembly under which it is
indented.
9. ILLUSTRATION REFERENCE LETTERS
When necessary, illustrations contain reference letters
(A, B, C etc.) that are intended to track lines and
harnesses from one point to another. They are also
used to show where to reconnect illustrations that have
been separated.
10. ABBREVIATIONS AND SYMBOLS
O.D. Outside Diameter
I.D. Inside Diameter
A Not Part Of This Group
B Use As Required
C Change From Previous Type
D Order By The Meter
E Order By The Centimeter
F Not Shown
G Order By The Inch
I See Hose Fabrication Guide
M Metric Part
R Remfg Part May Be Available
Y Separate Illustration
Z Not Serviced Separately
NOTE:
Continuing improvement and advancement of product
design may cause changes to your machine which
may not be included in this publication. Whenever a
question arises regarding your Caterpillar product or
this publication, please consult your Caterpillar dealer
for the latest available information.



4 Speed Transmission
323-8993-00 ............................. 2
323-8994-00 ............................. 22
5 Speed Transmission
Table of Contents


POWERSYNCHRO TRANSMISSION
4 SPEED
323-8993
2
POWERSYNCHRO TRANSMISSION - 4 SPEED
323 - 8993 TRANSMISSION AR
ENGINEERING MODEL: PT070 SERIAL NUMBER PREFIX: LKT
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
311-4066 1 TRANSMISSION AR
Y 217-7217 1 DRIVE GP - FLEX 5
230-7551 1 CONVERTER AS
293-5003 1 TC GP - BASIC
Y 312-3580 1 XMSN GP - DIRECT DRIVE 6
Y - SEPARATE ILLUSTRATION
<END>
4
POWERSYNCHRO TRANSMISSION - 4 SPEED
217 - 7217 DRIVE GP - FLEX
PART OF 311-4066 TRANSMISSION AR
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 6V-8455 6 BOLT
2 1 117-9713 1 PLATE
3 1 111-7906 1 PLATE
GRAPHIC # 1
<END>
5
POWERSYNCHRO TRANSMISSION - 4 SPEED
312 - 3580 XMSN GP - DIRECT DRIVE
PART OF 311-4066 TRANSMISSION AR
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 206-4395 1 CASE AS - FRONT
9W-0717 4 PLUG
147-0268 2 PLUG
178-8231 1 XMSN CASE
205-9244 1 PLUG
2 1 221-6780 1 CASE AS - REAR
9W-0717 5 PLUG
3 2 8T-7942 2 DOWEL
4 3,4 7T-3253 4 DOWEL
5 3 206-4397 1 HOUSING
6 1 316-1932 1 PLATE - COVER
7 1 4F-4585 1 PLUG - CORE
8 1 191-8304 1 SENSOR GP - SPEED
9 1 178-8127 1 FLANGE
10 1 178-8229 1 PLATE
11 1 216-2277 1 PLATE - COVER
12 3,4 216-2278 2 HOUSING AS
147-0268 4 PLUG
13 3,4 200-6210 4 VALVE GP - SOL
200-2371 1 SEAL KIT
212-0061 1 FLANGE
14 1 121-7396 1 VALVE GP - CONVERTER RELIEF
6V-4589 1 SEAL - O-RING
8L-2746 1 SEAL - O-RING
15 4 296-6617 1 HOUSING AS - VALVE
Y 16 1,4 252-9715 3 VALVE GP - MDL 19
17 1 264-4297 1 SENSOR - TEMP
18 1 206-4377 1 PLATE - COVER
19 1 206-4382 1 HOUSING
20 1 6V-5215 3 BOLT
21 1,2 6V-5217 12 BOLT
22 1,3 8C-5748 5 BOLT
23 4 6V-5220 4 BOLT
24 3,4 6V-5221 4 BOLT
25 3 6V-5842 6 BOLT
26 4 8T-0276 5 BOLT
27 3,4 8T-0100 6 BOLT
28 1 6V-5815 1 BOLT
29 1 237-5185 4 PLUG 9/16"
3J-1907 1 SEAL - O-RING
9S-8004 1 PLUG - HEX SOCKET
30 1,3,4 9S-4191 16 PLUG - STOR
31 1 189-5746 1 SENSOR GP - SPD - A
32 1 117-1385 2 SEAL - O-RING
33 1,2,3 6V-5215 5 BOLT
34 1 132-5789 3 CLIP - LADDER
35 1 085-8091 22 BOLT
36 2 178-8159 1 REACTOR AS
37 2 178-8169 2 WASHER - THRUST
38 2 178-8166 1 GEAR AS
195-7657 1 SEAL - O-RING
(1 of 7)
6
POWERSYNCHRO TRANSMISSION - 4 SPEED
312 - 3580 XMSN GP - DIRECT DRIVE
(contd)
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
39 2 178-8162 1 COVER GP
178-8164 1 SEAL - OIL
221-6782 1 COVER AS - SUB
Y 40 2 178-8201 1 SHAFT AS - INPUT 13
Y 41 2 178-8203 1 DRIVE AS - FAN 14
Y 42 3 206-4379 1 SHAFT AS - PUMP DRIVE 15
Y 43 4 178-8205 1 SHAFT AS - FORWARD / REVERSE 16
44 4 178-8138 1 GEAR - IDLER
45 3 178-8217 1 COUNTERSHAFT AS
7T-2646 1 SPACER
8T-1580 1 CUP - RLR BRG
8T-1581 1 CONE - RLR BRG
123-8907 1 CONE - SPL TAPERED
123-8908 1 CUP - SPL TAPERED
178-8139 1 CONTERSHAFT
178-8218 1 SPACER
6T-9163 1 SHIM
6T-9164 1 SHIM
6T-9165 1 SHIM
6T-9166 1 SHIM
46 2 206-4396 1 TUBE AS
47 2 206-4381 1 TUBE AS
48 2 206-4375 1 TUBE AS
49 2 206-4399 1 FORK - SHIFT
50 2 206-4400 1 FORK - SHIFT
51 2 238-7561 2 SCREW - CAP
52 2 214-8970 SENSOR AS
151-9274 1 RECEPTACLE KIT
204-0728 1 SEAL - O-RING
9X-3401 4 PIN - C0NNECTOR
53 2 8T-0328 4 WASHER
54 2 238-7562 16 SCREW - CAP
55 1 5P-4484 1 PLUG - MAGC O-RING
56 2 216-2280 1 GUARD AS
57 3 178-8237 1 PUMP GP - CHARGE
58 3 178-8236 1 PUMP GP - SCAVENGE
59 3 216-2283 1 INLET - SCAV PUMP
60 3 216-2282 1 BAFFLE
Y 61 3 216-2275 1 SHAFT AS - OUTPUT 18
62 3 9P-9150 2 WASHER
63 2 6V-8675 2 BOLT
64 2,3 238-7563 9 SCREW - CAP
65 3 7T-3195 2 WASHER
66 3 122-6787 2 YOKE AS
123-1377 1 GUARD
67 3 6V-3668 2 BOLT
68 1 237-5188 1 PLUG - EXPANSION
69 3 5P-8347 2 BOLT
70 3 206-4403 1 RAIL - SHIFT
71 3 206-4402 1 RAIL - SHIFT
72 3,4 216-2264 2 PISTON
73 3,4 221-6768 2 PISTON - INTO GEAR
(2 of 7)
7
POWERSYNCHRO TRANSMISSION - 4 SPEED
312 - 3580 XMSN GP - DIRECT DRIVE
(contd)
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
74 3,4 221-6767 2 PISTON - NEUTRAL
75 3,4 216-2265 2 PISTON
76 4 014-5645 6 BALL
77 4 216-2271 1 PLUG
78 4 6Y-1341 2 SPRING
79 3,4 178-8209 4 PISTON SEAL
80 3,4 178-8210 2 PISTON SEAL
81 3,4 221-6769 2 PISTON SEAL
82 2 138-1645 2 PIN - SPRING
83 1 4P-7582 1 CLIP - LADDER
84 1 6V-8177 1 BOLT
85 2 120-9762 20 SEAL - O-RING
86 2 238-6531 2 SEAL - O-RING
87 4 005-0469 2 CUP - RLR BEARING
88 4 7T-3034 1 SPACER
89 3 302-8432 2 SEAL - LIP TYPE
90 2 206-4392 1 PLATE - COVER
91 2 206-4393 1 PLUG
92 2 178-8171 1 QUAD RING
Y 93 1 278-0214 1 VALVE GP - RLF 20
98 1 191-8303 1 SENSOR GP - SPD A
99 1 178-8137 1 WASHER
100 1 6V-4248 1 BOLT
101 1 5F-7054 1 SEAL - O-RING
103 3 4P-7581 2 CLIP - LADDER
SERVICE
REPAIR
104 4 6T-9144 1 SHIM
105 4 6T-9146 1 SHIM
106 4 6T-9147 1 SHIM
107 4 6T-9145 1 SHIM
109 2 214-8970 SENSOR AS
Y - SEPARATE ILLUSTRATION
(3 of 7)
8
POWERSYNCHRO TRANSMISSION - 4 SPEED
312 - 3580 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 1 (4 of 7)
9
POWERSYNCHRO TRANSMISSION - 4 SPEED
312 - 3580 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 2 (5 of 7)
10
POWERSYNCHRO TRANSMISSION - 4 SPEED
312 - 3580 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 3 (6 of 7)
11
POWERSYNCHRO TRANSMISSION - 4 SPEED
312 - 3580 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 4 (7 of 7)
<END>
12
POWERSYNCHRO TRANSMISSION - 4 SPEED
178 - 8201 SHAFT AS - INPUT
PART OF 312-3580 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 6Y-1192 1 RING - SEAL
2 1 178-8117 1 SHAFT - INPUT
3 1 178-8118 1 GEAR - 47 TEETH
4 1 178-8214 1 CIRCLIP
5 1 190-1570 1 BRG - SPL NEED THR
6 1 190-1572 1 RACE - THRUST
7 1 209-3766 1 BEARING - SPL AS
GRAPHIC # 1
<END>
13
POWERSYNCHRO TRANSMISSION - 4 SPEED
178 - 8203 DRIVE AS - FAN
PART OF 312-3580 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 095-0941 1 RING - RETAINING
2 1 104-3288 1 SHIM
3 1 121-2059 1 SHIM
4 1 121-2060 1 SHIM
5 1 121-2061 1 SHIM
6 1 122-1878 1 RING - SEAL
7 1 122-1879 1 SPACER - BRG
8 1 221-6795 1 GEAR - 38 TEETH
9 1 178-8125 1 GEAR - 38 TEETH
10 1 178-8129 1 WASHER - THRUST
11 1 178-8208 1 SEAL - OIL
12 1 190-1576 1 BRG AS - SPL TPR
13 1 206-4383 1 THRUST WASHER
14 1 209-3764 1 BEARING - SPL AS
15 1 221-6781 1 SHAFT AS
16 1 7T-3035 1 PIN
17 1 123-8905 1 CONE - SPL TAPERED
18 1 123-8906 1 CUP SPL TAPERED
GRAPHIC # 1
<END>
14
POWERSYNCHRO TRANSMISSION - 4 SPEED
206 - 4379 SHAFT AS - PUMP DRIVE
PART OF 312-3580 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 6V-9097 1 BOLT - LOCKING
2 1 7T-3195 1 WASHER
3 1 061-7539 1 SEAL - O-RING
4 1 095-0942 1 RING - RETAINING
5 1 178-8120 1 GEAR - 44 TEETH
6 1 178-8122 1 WASHER - THRUST
7 1 178-8238 1 SHAFT
8 1 190-1574 2 BRG - SPL CGD R AS
9 1 206-4378 1 WASHER - THRUST
10 1 209-3768 1 BEARING - SPL AS
11 1 221-6796 1 GEAR - 44 TEETH
12 1 238-7568 2 RING - RETAINING
13 1 7T-3035 1 PIN
14 1 5P-3132 1 BEARING - ROLLER
GRAPHIC # 1
<END>
15
POWERSYNCHRO TRANSMISSION - 4 SPEED
178 - 8205 SHAFT AS - FORWARD / REVERSE
PART OF 312-3580 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 104-3288 1 SHIM
2 1 121-0694 1 WASHER - THRUST
3 1 121-2059 1 SHIM
4 1 121-2060 1 SHIM
5 1 121-2061 1 SHIM
6 1 121-2500 2 WASHER - THRUST
7 1 122-1879 1 SPACER - BRG
8 1 122-1880 12 DISC - FRICTION
9 1 122-1881 12 PLATE - CLUTCH
10 1 122-1882 2 PLATE - END
11 1 122-1886 3 RING - SEAL
12 1 122-3649 2 RING - RET INT
13 1 123-8913 4 BEARING - CAGED
14 1 172-5317 2 BEARING - SPL
15 1 178-8189 1 SHAFT AS
16 1 178-8131 1 GEAR - 47 TEETH
17 1 178-8132 2 PISTON - SEAL
18 1 178-8134 2 SPRING
19 1 178-8135 1 GEAR - 31 TEETH
20 1 178-8136 1 GEAR - 34 TEETH
21 1 178-8151 1 SPACER
22 1 178-8193 1 SPACER
23 1 178-8200 2 SPRING - RETAINER
24 1 178-8215 2 SLEEVE
25 1 6V-8757 2 RING - RETAINING
26 1 8T-1580 1 CUP - RLR BRG
27 1 8T-1581 1 CONE - RLR BRG
28 1 123-8905 1 CONE - SPL TAPERED
29 1 123-8906 1 CUP - SPL TAPERED
(1 of 2)
16
POWERSYNCHRO TRANSMISSION - 4 SPEED
178 - 8205 SHAFT AS - FORWARD / REVERSE (contd.)
GRAPHIC # 1 (2 of 2)
<END>
17
POWERSYNCHRO TRANSMISSION - 4 SPEED
216 - 2275 SHAFT AS - OUTPUT
PART OF 312-3580 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
7T-2646 1 SPACER
7T-6655 2 BEARING - RLR AS
8T-1580 1 CUP - RLR BRG
8T-1581 1 CONE - RLR BRG
123-8907 1 CONE - SPL TAPERED
123-8908 1 CUP - SPL TAPERED
178-8144 1 DISC
178-8145 1 SPACER
178-8146 1 GEAR - 24 TEETH
178-8147 1 SYNCHRONIZER
178-8148 1 GEAR - 31 TEETH
178-8149 1 GEAR - 40 TEETH
178-8150 1 SYNCHRONIZER
178-8152 1 GEAR - 48 TEETH
178-8153 1 WASHER - THRUST
178-8220 1 SPACER
190-1575 4 BRG - SPL CGD R AS
196-0187 1 RING - RETAINING
206-4398 1 SHAFT - OUTPUT
209-3765 2 BEARING - SPL AS
238-7569 1 RING - RETAINING
238-8539 1 RING - RETAINING
6T-9163 1 SHIM
6T-9164 1 SHIM
6T-9165 1 SHIM
6T-9166 1 SHIM
NO GRAPHIC
<END>
18
POWERSYNCHRO TRANSMISSION - 4 SPEED
252 - 9715 VALVE GP - MODULATING
PART OF 312-3580 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 164-2108 1 WASHER
2 1 218-2373 1 NUT
3 1 226-9629 1 COIL AS
4 1 253-0247 1 CARTRIDGE AS
108-2148 1 SEAL KIT
GRAPHIC # 1
<END>
19
POWERSYNCHRO TRANSMISSION - 4 SPEED
278 - 0214 VALVE GP - RELIEF
PART OF 312-3580 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 7X-4744 1 SEAL
2 1 6V-9178 1 SEAL
3 1 106-9586 1 SEAL
GRAPHIC # 1
<END>
20
POWERSYNCHRO TRANSMISSION
5 SPEED
323-8994
22
POWERSYNCHRO TRANSMISSION - 5 SPEED
323 - 8994 TRANSMISSION AR
ENGINEERING MODEL: PT070 SERIAL NUMBER PREFIX: LKT
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
311-4067 1 TRANSMISSION AR
Y 217-7217 1 DRIVE GP - FLEX 25
230-7551 1 CONVERTER AS
293-5003 1 TC GP - BASIC
Y 312-3581 1 XMSN GP - DIRECT DRIVE 26
Y - SEPARATE ILLUSTRATION
<END>
24
POWERSYNCHRO TRANSMISSION - 5 SPEED
217 - 7217 DRIVE GP - FLEX
PART OF 311-4067 TRANSMISSION AR
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 6V-8455 6 BOLT
2 1 117-9713 1 PLATE
3 1 111-7906 1 PLATE
GRAPHIC # 1
<END>
25
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE
PART OF 311-4067 TRANSMISSION AR
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 206-4395 1 CASE AS - FRONT
9W-0717 4 PLUG
147-0268 2 PLUG
178-8231 1 XMSN CASE
205-9244 1 PLUG
2 5 8T-7942 2 DOWEL
3 5 7T-3253 4 DOWEL
4 1 206-4394 1 CASE AS - REAR
9W-0717 5 PLUG
5 5 206-4397 1 HOUSING
6 4 178-8127 1 FLANGE
7 4 206-4391 1 ACTUATOR AS
123-2920 1 PLUG
178-8235 1 ACTUATOR
8 4 200-6210 1 VALVE GP - SOL
200-2371 1 SEAL KIT
212-0061 1 FLANGE
9 4,5 216-2278 2 HOUSING AS
147-0268 4 PLUG
10 3 200-6210 1 VALVE GP - SOL
200-2371 1 SEAL KIT
212-0061 1 FLANGE
11 4 200-6210 1 VALVE GP - SOL
200-2371 1 SEAL KIT
212-0061 1 FLANGE
12 3 200-6210 1 VALVE GP - SOL
200-2371 1 SEAL KIT
212-0061 1 FLANGE
13 3 200-6210 1 VALVE GP - SOL
200-2371 1 SEAL KIT
212-0061 1 FLANGE
Y 14 3 278-0214 1 VALVE GP - RLF 41
15 3 121-7396 1 VALVE GP - CONVERTER RELIEF
6V-4589 1 SEAL - O-RING
8L-2746 1 SEAL - O-RING
16 5 296-6617 1 HOUSING AS - VALVE
17 4 206-4377 1 PLATE - COVER
18 4 206-4382 1 HOUSING
Y 19 3 252-9715 3 VALVE GP - MDL 40
20 4 239-7344 3 SCREW - CAP
21 4,5 8C-5748 5 BOLT
22 4,5 6V-5220 4 BOLT
23 4,5 6V-5221 4 BOLT
24 5 6V-5842 6 BOLT
25 4 6V-5815 1 BOLT
26 3 237-5185 4 PLUG - 9/16"
27 3,4,5 9S-4191 18 PLUG - STOR
28 1,4 6V-5217 9 BOLT
29 4 9S-4182 1 PLUG - O-RING
30 4 189-5746 1 SENSOR GP - SPD - A
31 5 191-8304 1 SENSOR GP - SPEED
32 4 191-8303 1 SENSOR GP - SPD A
33 4 117-1385 2 SEAL - O-RING
34 3,4,5 6V-5215 7 BOLT
(1 of 8)
26
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE
(contd)
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
35 3 132-5789 3 CLIP - LADDER
36 4 085-8091 22 BOLT
37 1 178-8159 1 REACTOR AS
38 1 178-8169 2 WASHER - THRUST
39 1 178-8166 1 GEAR AS
195-7657 1 SEAL - O-RING
40 1 178-8162 1 COVER GP
178-8164 1 SEAL - OIL
221-6782 1 COVER AS - SUB
Y 41 1 178-8201 1 SHAFT AS - INPUT 34
Y 42 1 178-8203 1 DRIVE AS - FAN 35
Y 43 1 206-4379 1 SHAFT AS - PUMP DRIVE 36
Y 44 1 178-8205 1 SHAFT AS - FORWARD / REVERSE 37
45 2 178-8138 1 GEAR - IDLER
46 1 178-8206 1 COUNTERSHAFT AS
7T-2646 1 SPACER
8T-1580 1 CUP - RLR BRG
8T-1581 1 CONE - RLR BRG
123-8907 1 CONE - SPL TAPERED
123-8908 1 CUP - SPL TAPERED
123-8913 2 BEARING - CAGED
178-8139 1 CONTERSHAFT
178-8140 1 GEAR - 46 TEETH
178-8141 1 SYNCHRONIZER
178-8218 1 SPACER
6T-9163 1 SHIM
6T-9164 1 SHIM
6T-9165 1 SHIM
6T-9166 1 SHIM
47 5 206-4396 1 TUBE AS
48 5 206-4381 1 TUBE AS
49 5 206-4375 1 TUBE AS
50 1 206-4399 1 FORK - SHIFT
51 1 206-4400 1 FORK - SHIFT
52 3,4 214-8970 3 SENSOR AS
151-9274 1 RECEPTACLE KIT
204-0728 1 SEAL - O-RING
9X-3401 4 PIN - C0NNECTOR
53 2 206-4401 1 FORK - SHIFT
54 3,4 8T-0328 6 WASHER
55 3,4,5 238-7562 18 SCREW - CAP
56 4 5P-4484 1 PLUG - MAGC O-RING
57 4 216-2280 1 GUARD AS
58 5 178-8237 1 PUMP GP - CHARGE
59 5 178-8236 1 PUMP GP - SCAVENGE
60 5 216-2283 1 INLET - SCAV PUMP
61 5 216-2282 1 BAFFLE
Y 62 1 216-2276 1 SHAFT AS - OUTPUT 39
63 5 9P-9150 2 WASHER
64 4 6V-8675 2 BOLT
65 1,3 238-7563 9 SCREW - CAP
66 4 238-7564 1 SCREW - CAP
(2 of 8)
27
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE
(contd)
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
67 5 8T-0100 6 BOLT
68 1 7T-3195 2 WASHER
69 1 122-6787 2 YOKE AS
123-1377 1 GUARD
70 1 6V-3668 2 BOLT
71 1 5F-7054 1 SEAL - O-RING
72 1 178-8137 1 WASHER
73 1 6V-4248 1 BOLT
74 3 237-5188 1 PLUG - EXPANSION
75 5 5P-8347 2 BOLT
76 2 206-4403 1 RAIL - SHIFT
77 2 206-4402 1 RAIL - SHIFT
78 2 206-4404 1 RAIL - SHIFT
79 2 178-8128 1 ROD
80 2 216-2264 3 PISTON
81 2 221-6768 2 PISTON - INTO GEAR
82 2 221-6767 2 PISTON - NEUTRAL
83 2 216-2265 2 PISTON
84 2 178-8171 1 QUAD RING
85 2 014-5645 7 BALL
86 2 216-2271 1 PLUG
87 2 6Y-1341 3 SPRING
88 2 178-8209 4 PISTON SEAL
89 2 178-8210 3 PISTON SEAL
90 2 221-6769 2 PISTON SEAL
91 1,2 138-1645 3 PIN - SPRING
92 2,5 120-9762 22 SEAL - O-RING
93 5 238-6531 2 SEAL - O-RING
94 2 005-0469 2 CUP - RLR BEARING
95 2 7T-3034 1 SPACER
96 1 302-8432 2 SEAL - LIP TYPE
97 3 4F-4585 1 PLUG - CORE
98 5 4P-7581 3 CLIP - LADDER
99 4 316-1932 1 PLATE - COVER
100 4 6V-8177 1 BOLT
101 5 8T-0276 5 BOLT
SERVICE
REPAIR
104 2 6T-9144 1 SHIM
105 2 6T-9145 1 SHIM
106 2 6T-9146 1 SHIM
107 2 6T-9147 1 SHIM
Y - SEPARATE ILLUSTRATION
(3 of 8)
28
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 1 (4 of 8)
29
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 2 (5 of 8)
30
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 3 (6 of 8)
31
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 4 (7 of 8)
32
POWERSYNCHRO TRANSMISSION - 5 SPEED
312 - 3581 XMSN GP - DIRECT DRIVE (contd)
GRAPHIC # 5 (8 of 8)
<END>
33
POWERSYNCHRO TRANSMISSION - 5 SPEED
178 - 8201 SHAFT AS - INPUT
PART OF 312-3581 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 6Y-1192 1 RING - SEAL
2 1 178-8117 1 SHAFT - INPUT
3 1 178-8118 1 GEAR - 47 TEETH
4 1 178-8214 1 CIRCLIP
5 1 190-1570 1 BRG - SPL NEED THR
6 1 190-1572 1 RACE - THRUST
7 1 209-3766 1 BEARING - SPL AS
GRAPHIC # 1
<END>
34
POWERSYNCHRO TRANSMISSION - 5 SPEED
178 - 8203 DRIVE AS - FAN
PART OF 312-3581 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 095-0941 1 RING - RETAINING
2 1 104-3288 1 SHIM
3 1 121-2059 1 SHIM
4 1 121-2060 1 SHIM
5 1 121-2061 1 SHIM
6 1 122-1878 1 RING - SEAL
7 1 122-1879 1 SPACER - BRG
8 1 221-6795 1 GEAR - 38 TEETH
9 1 178-8125 1 GEAR - 38 TEETH
10 1 178-8129 1 WASHER - THRUST
11 1 178-8208 1 SEAL - OIL
12 1 190-1576 1 BRG AS - SPL TPR
13 1 206-4383 1 THRUST WASHER
14 1 209-3764 1 BEARING - SPL AS
15 1 221-6781 1 SHAFT AS
16 1 7T-3035 1 PIN
17 1 123-8905 1 CONE - SPL TAPERED
18 1 123-8906 1 CUP SPL TAPERED
GRAPHIC # 1
<END>
35
POWERSYNCHRO TRANSMISSION - 5 SPEED
206 - 4379 SHAFT AS - PUMP DRIVE
PART OF 312-3581 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 6V-9097 1 BOLT - LOCKING
2 1 7T-3195 1 WASHER
3 1 061-7539 1 SEAL - O-RING
4 1 095-0942 1 RING - RETAINING
5 1 178-8120 1 GEAR - 44 TEETH
6 1 178-8122 1 WASHER - THRUST
7 1 178-8238 1 SHAFT
8 1 190-1574 2 BRG - SPL CGD R AS
9 1 206-4378 1 WASHER - THRUST
10 1 209-3768 1 BEARING - SPL AS
11 1 221-6796 1 GEAR - 44 TEETH
12 1 238-7568 2 RING - RETAINING
13 1 7T-3035 1 PIN
14 1 5P-3132 1 BEARING - ROLLER
GRAPHIC # 1
<END>
36
POWERSYNCHRO TRANSMISSION - 5 SPEED
178 - 8205 SHAFT AS - FORWARD / REVERSE
PART OF 312-3581 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 104-3288 1 SHIM
2 1 121-0694 1 WASHER - THRUST
3 1 121-2059 1 SHIM
4 1 121-2060 1 SHIM
5 1 121-2061 1 SHIM
6 1 121-2500 2 WASHER - THRUST
7 1 122-1879 1 SPACER - BRG
8 1 122-1880 12 DISC - FRICTION
9 1 122-1881 12 PLATE - CLUTCH
10 1 122-1882 2 PLATE - END
11 1 122-1886 3 RING - SEAL
12 1 122-3649 2 RING - RET INT
13 1 123-8913 4 BEARING - CAGED
14 1 172-5317 2 BEARING - SPL
15 1 178-8189 1 SHAFT AS
16 1 178-8131 1 GEAR - 47 TEETH
17 1 178-8132 2 PISTON - SEAL
18 1 178-8134 2 SPRING
19 1 178-8135 1 GEAR - 31 TEETH
20 1 178-8136 1 GEAR - 34 TEETH
21 1 178-8151 1 SPACER
22 1 178-8193 1 SPACER
23 1 178-8200 2 SPRING - RETAINER
24 1 178-8215 2 SLEEVE
25 1 6V-8757 2 RING - RETAINING
26 1 8T-1580 1 CUP - RLR BRG
27 1 8T-1581 1 CONE - RLR BRG
28 1 123-8905 1 CONE - SPL TAPERED
29 1 123-8906 1 CUP - SPL TAPERED
(1 of 2)
37
POWERSYNCHRO TRANSMISSION - 5 SPEED
178 - 8205 SHAFT AS - FORWARD / REVERSE (contd.)
GRAPHIC # 1 (2 of 2)
<END>
38
POWERSYNCHRO TRANSMISSION - 5 SPEED
216 - 2275 SHAFT AS - OUTPUT
PART OF 312-3581 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
7T-2646 1 SPACER
7T-6655 2 BEARING - RLR AS
8T-1580 1 CUP - RLR BRG
8T-1581 1 CONE - RLR BRG
123-8907 1 CONE - SPL TAPERED
123-8908 1 CUP - SPL TAPERED
178-8143 1 GEAR - 20 TEETH
178-8144 1 DISC
178-8145 1 SPACER
178-8146 1 GEAR - 24 TEETH
178-8147 1 SYNCHRONIZER
178-8148 1 GEAR - 31 TEETH
178-8149 1 GEAR - 40 TEETH
178-8150 1 SYNCHRONIZER
178-8152 1 GEAR - 48 TEETH
178-8153 1 WASHER - THRUST
190-1575 4 BRG - SPL CGD R AS
196-0187 1 RING - RETAINING
206-4398 1 SHAFT - OUTPUT
209-3765 2 BEARING - SPL AS
238-7569 1 RING - RETAINING
238-8539 1 RING - RETAINING
6T-9163 1 SHIM
6T-9164 1 SHIM
6T-9165 1 SHIM
6T-9166 1 SHIM
NO GRAPHIC
<END>
39
POWERSYNCHRO TRANSMISSION - 5 SPEED
252 - 9715 VALVE GP - MODULATING
PART OF 312-3581 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 164-2108 1 WASHER
2 1 218-2373 1 NUT
3 1 226-9629 1 COIL AS
4 1 253-0247 1 CARTRIDGE AS
108-2148 1 SEAL KIT
GRAPHIC # 1
<END>
40
POWERSYNCHRO TRANSMISSION - 5 SPEED
278 - 0214 VALVE GP - RELIEF
PART OF 312-3581 XMSN GP - DIRECT DRIVE
REF
NO
GRAPHIC
NO
PART NAME
SEE
PAGE NOTE PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL)
1 1 7X-4744 1 SEAL
2 1 6V-9178 1 SEAL
3 1 106-9586 1 SEAL
GRAPHIC # 1
<END>
41