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12/12/06
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Service Manual
C
CM
MY
CY
CMY
DP 8000 Series
Off-Highway
SM1228EN
SM1228EN_spine.pdf
12/12/06
1:53:30 PM
CM
MY
CY
CMY
Service
Manual
SM1228EN
200611
Service
Manual
2004 FEBRUARY
REV. 1 2006 NOVEMBER
SM1228EN
Allison Transmission
DP 8860, 8861
DP 8960, 8961, 8962, 8963
M 8610A, 8610AR
S 8610A, 8610M, 8610AR, 8610MR
Printed in USA
INTRODUCTION
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Allison DOC For PCService Tool is a trademark of General Motors Corporation.
Amojell is a registered trademark of the Amoco Oil Corporation.
Biobor JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax and
Chemical Corporation.
Borzon is a registered trademark of Norton Abrasive Company.
DEXRON is a registered trademark of General Motors Corporation.
Loctite is a registered trademark of the Loctite Corporation.
Lubriplate is a registered trademark of the Fiske Brothers Refining Co., Newark, New Jersey.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Contact with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
TransmissionsTruck, Tractor, etc.
ii
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
iii
LIST OF WARNINGS
This manual contains the following Warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
Arc welding equipment requires dangerously high currents and voltages which cannot be sufficiently
reduced to permit it to be used for jump-starting. To help avoid injury or equipment damage, DO NOT
attempt to jump-start the equipment using an arc welder.
To help avoid injury and property damage caused by sudden and unexpected vehicle movement, do not
perform maintenance or service procedures until you
Put the transmission in N (Neutral).
Set the parking brake and service brakes, and make sure they are properly engaged.
Chock the wheels and take any other steps necessary to keep the vehicle from moving.
The vehicle must be positively prevented from moving when conducting a stall test. The parking and
service brakes must be applied, and the vehicle should be blocked to prevent movement forward or
reverse. Keep people safely away from the vehicle path. Do not maintain the stalled condition longer
than thirty seconds due to rapid heating of the transmission fluid. With the transmission in neutral, run
the engine at 1200 to 1500 rpm for two minutes to cool the fluid between tests. Do not allow the
converter-out temperature to exceed 275F (135C). Keep a close check to prevent overheating of the
engine cooling system.
Be sure to shut off the engine, set the vehicle brakes, and block the wheels before ANY troubleshooting of
the electric-shift solenoids. It is important that electricity NEVER, under any circumstance, be applied
to any electric valve body component while the vehicle engine is running and while the mechanic is under
the vehicle. Failure to shut off the engine and set the brakes could cause the vehicle to run away when the
solenoids were activated by an external power supply. Removal of the power supply would not stop the
run away vehicle because of the fail protection system. The vehicle could only be stopped by applying the
vehicle brakes or shutting down the engine.
Shutoff the power supply from the vehicle electrical system before removing the wiring harnesses. This
will prevent any unexpected shifts.
Removing the wiring harnesses from the transmission while the equipment power supply is ON can
cause unexpected shifts resulting in sudden, uncontrolled vehicle or equipment movement. To help avoid
injury or property damage, power from the equipment electrical system must be switched OFF before
disconnecting the transmission wiring.
Never dry bearings with compressed air. A spinning bearing can disintegrate. Also, spinning a bearing
without lubrication can damage the bearing.
Do not handle heated or chilled parts with bare hands, always use appropriate hand protection.
Toxic gases are produced by burning Teflon. Exposure to these gases is extremely hazardous and can
be fatal. DO NOT BURN discarded Teflon sealrings.
To prevent personal injury and/or transmission damage, use a hoist and lifting fixture when lifting,
removing, or installing a transmission. Be sure the lifting equipment can properly support the weight of
the transmission.
Lifting the torque converter drive housing from the transmission can dislodge lockup clutch parts from
the housing or assembly. To avoid injury from falling parts, stay clear of the area beneath the raised
components and do not attempt to hold the parts in the assembly using your hands.
iv
vi
TABLE OF CONTENTS
Paragraph
Section 1.
Page
GENERAL INFORMATION
11. SCOPE
a. Coverage . . . . . . . . . . . . . . . . . . . . . . . . . 11
b. Illustrations . . . . . . . . . . . . . . . . . . . . . . . 11
c. Maintenance Information. . . . . . . . . . . . . 11
12. SUPPLEMENTARY INFORMATION . . . . 13
13. ORDERING PARTS
a. Transmission Nameplate.. . . . . . . . . . . . . 13
b. Models With Commercial Electronic
Controls 1 (CEC1) . . . . . . . . . . . . . . . . . . 14
c. Models With Commercial Electronic
Controls 2 (CEC2) . . . . . . . . . . . . . . . . . . 14
d. Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . 14
14. DESIGN FEATURES
a. Transmission-to-Engine Coupling. . . . . . 15
b. Torque Converter . . . . . . . . . . . . . . . . . . . 15
c. Lockup Clutch . . . . . . . . . . . . . . . . . . . . . 15
d. Planetary Gearing. . . . . . . . . . . . . . . . . . . 15
e. Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . 15
f. Hydraulic System. . . . . . . . . . . . . . . . . . . 15
g. Power Takeoff . . . . . . . . . . . . . . . . . . . . . 15
h. Hydraulic Retarder. . . . . . . . . . . . . . . . . . 15
i. Dual Torque Path . . . . . . . . . . . . . . . . . . . 16
15. SHIFT CONTROL SYSTEMS
a. Manual-Electric Shift. . . . . . . . . . . . . . . . 16
b. Automatic-Electric Shift . . . . . . . . . . . . . 17
c. Electronic-Control Shift (CEC1) . . . . . . . 17
d. Electronic-Control Shift (CEC2) . . . . . . . 17
e. Manual-Hydraulic Shift. . . . . . . . . . . . . . 18
16. OPTIONS
a. Hydraulic Retarder. . . . . . . . . . . . . . . . . . 18
b. Parking Brake. . . . . . . . . . . . . . . . . . . . . . 18
c. Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
d. Speedometer Drive . . . . . . . . . . . . . . . . . 18
e. Power Takeoff . . . . . . . . . . . . . . . . . . . . . 18
17. OPERATING INSTRUCTIONS
a. Operators Manual. . . . . . . . . . . . . . . . . . 19
b. Manual Mode (CEC1) . . . . . . . . . . . . . . . 19
c. Manual Mode (CEC2) . . . . . . . . . . . . . . . 19
d. Cold Weather Starts (CEC1) . . . . . . . . . . 19
e. Cold Weather Starts (CEC2) . . . . . . . . . . 19
f. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
18. SPECIFICATIONS AND DATA . . . . . . . . . 19
Paragraph
Page
vii
TABLE OF CONTENTS
Paragraph
Page
28
28
28
28
211
211
211
211
212
212
212
212
213
213
213
Paragraph
Page
213
213
214
215
215
216
216
216
216
217
223
223
223
224
224
225
225
225
TABLE OF CONTENTS
Paragraph
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
Page
Paragraph
Page
ix
TABLE OF CONTENTS
Paragraph
Page
313
313
313
313
314
318
318
321
322
322
322
322
322
322
Paragraph
Page
327
327
327
327
328
328
TABLE OF CONTENTS
Paragraph
Page
Paragraph
Page
Section 5. DISASSEMBLY OF
TRANSMISSION
51. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
52. GENERAL INFORMATION FOR
DISASSEMBLY OF THE TRANSMISSION
a. Preparation for Disassembly . . . . . . . . . . 51
b. Removing Control Components . . . . . . . 51
c. Disassembly Information. . . . . . . . . . . . . 51
d. Lifting, Handling . . . . . . . . . . . . . . . . . . . 51
53. TRANSMISSION DISASSEMBLYALL
MODELS
a. Removing Exterior Components . . . . . . . 52
b. Removing and Disassembling Torque
Converter Housing Assembly . . . . . . . . . 58
c. Removing Converter Housing
Accessories. . . . . . . . . . . . . . . . . . . . . . . 514
d. Removing Splitter Gearing, Clutches . . 517
e. Removing Transmission Output . . . . . . 519
xi
TABLE OF CONTENTS
Paragraph
Page
Paragraph
Page
61. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
xii
TABLE OF CONTENTS
Paragraph
Page
Paragraph
Page
xiii
TABLE OF CONTENTS
Paragraph
Page
Paragraph
Page
711
714
720
722
724
725
725
727
7-28
81
81
81
81
81
81
81
TABLE OF CONTENTS
LIST OF FOLDOUT ILLUSTRATIONS
(Back of Service Manual)
CROSS-SECTION VIEWS
1
HYDRAULIC SCHEMATICS
3
DP 8000 Series Transmission Manual-Hydraulic System With Integral Lockup Trimmer Valve
Schematic View
EXPLODED VIEWS
7A
7B
Input Flange, Front Cover, and Converter Drive Housing Flexplate Drive and Flywheel
8A
Lockup Clutch
8B
9A
9B
10A
10B
Torque Converter Housing, Turbine Shaft, and Retarder Rotor (Straight-Through Models)
11A
Torque Converter Housing, Turbine Shaft, and Retarder Rotor (Dropbox Models)
11B
12A
Splitter-Low Clutch
12B
Splitter-High Clutch
13A
13B
14A
High-Range Clutch
14B
15A
Intermediate-Range Clutch
15B
16A
Second-Range Clutch
16B
17A
First-Range Clutch
17B
18A
Reverse-Range Clutch
18B
19A
xv
TABLE OF CONTENTS
EXPLODED VIEWS (contd)
xvi
19B
Parking Brake
20A
20B
21A
21B
Auxiliary Pump
22.
23.
24A
24B
25
26A
26B
27A
27B
28A
28B
29
30A
30B
31
32
33
Remote Filters
SCOPE
a. Coverage
1. This Service Manual describes the operation,
maintenance, and overhaul procedures for the
Allison Transmission DP 8000 and M/S 8610
Series transmissions (Figure 11 through 14).
A description of the major components of the
transmission, the function and operation of the
hydraulic system, wear limits, inspection procedures, and torque specifications are given
with each assembly step and on the exploded
view foldouts at the back of this manual.
2. Instructions apply generally to all models
because of the similarity between models.
Instructions for specific models are given when
procedures vary.
HIGH EFFICIENCY
FILTERS
ELECTRONIC CONTROL
MAIN VALVE BODY
SOLENOID COVER
MAIN-PRESSURE
REGULATOR
VALVE BODY
ELECTRONIC CONTROL
LOCKUP VALVE BODY
ASSEMBLY
REAR COVER
PARKING BRAKE
MAIN-PRESSURE
TRANSFER TUBE
ASSEMBLY
FIRST-RANGE
CONTROL
VALVE BODY
DRAIN PLUG
STRAINER ASSEMBLY
HEATER
ELEMENT PLUG
(EARLIER MODELS)
INPUT PRESSURE
AND SCAVENGE
PUMP ASSEMBLY
PTO COVER
VH04656.01.00
11
SOLENOID COVER
MAIN PRESSURE
REGULATOR
VALVE BODY
MANUAL ELECTRIC'AUTOMATIC
ELCTRIC, 0R ELECTRONIC
CONTROL VALVE BODY
REAR COVER
LOCKUP TRIMMER
VALVE BODY
INHIBIT OR
PRESSURE
SWITCH
PARKING BRAKE
SPEEDOMETER DRIVE
PTO COVER
MOUNTING PAD
DRAIN PLUG
STRAINER ASSEMBLY
FIRST-RANGE
CONTROL
VALVE BODY
HEATER
ELEMENT PLUG
VH08961.00.00
Figure 12. DP 8000 Series TransmissionRemote Mount With Manual Electric, Automatic Electric,
or Electronic Control Valve Body
PTO COVER
FILTERS
REAR COVER
PARKING BRAKE
FRONT COVER
TRUNNION
MOUNT
MOUNTING PAD
INPUT FLANGE
INPUT PRESSURE
AND SCAVENGE
PUMP ASSEMBLY
FLUID LEVEL
SIGHT GAUGE
RETARDER
CONTROL
VALVE BODY
OIL PAN
VH08962.00.00
12
GENERAL INFORMATION
BREATHER
FILTERS
MAIN PRESSURE
REGULATOR
VALVE BODY
PARKING BRAKE
FRONT COVER
MOUNTING PAD
MANUAL-HYDRAULIC
CONTROL VALVE BODY
INPUT FLANGE
DRAIN PLUG
MAIN PRESSURE
TUBE
STRAINER ASSEMBLY
HEATER ELEMENT PLUG
(EARLIER MODELS)
LOCKUP VALVE BODY
INPUT PRESSURE
AND SCAVENGE
PUMP ASSEMBLY
VH08963.00.00
Figure 14. DP 8000 Series TransmissionRemote Mount With Manual-Hydraulic Control Valve Body (Right-Front View)
OM
OB
ILE AEROSPAC
DA
UT
MODEL
NO.
IM
PART NO.
XXXXX
ICULTURA
OF
SUPPLEMENTARY
INFORMATION
AGR
UAW
933
WORKERS
12.
ENT
SERIAL NO.
AN
EM
DIVISION OF
GENERAL MOTORS
CORPORATION
INDIANAPOLIS
INDIANA
PL
Service organizations and individuals are encouraged to contact their local AT Distributor for information and guidance in completing any of the tasks
outlined herein.
UNITE
NOTE:
a. Transmission Nameplate
CA
ORDERING PARTS
ERI
13.
AM
XXXXXXX
XX XXXXX
V01251
13
M/S
Mobile/Stationary
0, 1, 2
3. Label bands are attached to the wiring harnesses just behind the connectors at the ECU.
These labels show the harness part numbers.
4. The shift selector is identified by a part number
on a label attached to one end of the selector
body.
c. Models With Commercial Electronic
Controls 2 (CEC2)
1. In addition to serial number, part number (assembly number), and model number, which are
located on the transmission nameplate, there
are identifying labels on the components of the
electronic-control models.
2. Label bands are attached to the wiring harnesses just behind the connectors at the ECU
(Figure 17). These labels show the harness
part numbers.
3. The shift selector is identified by a part number
on a label attached to one end of the selector
body.
d. Parts Catalog. Do not order by illustration item
numbers on the foldouts in the back of this manual.
Parts are listed in the current Parts Catalog
PC1249EN. Order all replacement parts from your
distributor or dealer.
IDENTIFICATION
LABELS
AY
GR
AC
BL
UE
BL
UE
BL
S HARNESS
RECEPTACLE
SECONDARY MODE
HARNESS CONNECTION (J3)
T HARNESS RECEPTACLE
V HARNESS
RECEPTACLE
V06723
H00688.01
14
GENERAL INFORMATION
14.
DESIGN FEATURES
NOTE:
For 8860 and 8861 models, refer to Foldout 2.
For 8960, 8961, 8962, 8963, and M/S 8610 models,
refer to Foldout 1.
a. Transmission-to-Engine Coupling
1. The direct-mounted transmission has a SAE
size 0 flange on converter housing 5
(Foldout 1) which is bolted to the engine
flywheel housing. Flexplate assembly 39
connects the engine crankshaft to the
transmission input.
2. The remote-mounted transmission has front
cover 2. Customer-selected flange 1 connects
the engine to the splined hub of converter drive
housing 3.
b. Torque Converter. The torque converter is a single-stage, polyphase, three-element unit, consisting of
pump 8, stator 7, and turbine 6. The converter provides
maximum torque when load conditions demand. Hydraulic fluid for converter charging pressure comes
from the sump and is supplied by one section of a twosection pump. The other pump section supplies fluid
for the remainder of the hydraulic system.
c. Lockup Clutch
1. For DP 8861 models, the lockup clutch includes a single internal-splined clutch plate, a
piston, and a backplate.
2. For DP 8961, 8962, 8963, and M/S 8610
models, the lockup clutch includes two
internal-splined clutch plates, one externalsplined clutch plate, piston, and backplate.
3. The internal-splined clutch plate(s) is splined
to the hub of the converter turbine. When the
clutch is applied, the converter turbine and the
converter pump are locked together and rotate
as a unit. Engine power is transmitted to the
transmission gearing at a 1:1 ratio.
4. Models may have lockup in all ranges, or in all
ranges except neutral, first, second, or reverse.
For electronic control and automatic-electric
models, lockup is activated by a solenoid. For
manual-hydraulic and manual-electric models,
15
SELECTOR LEVER
GATE PIN
SWITCHES
SHIFT GUIDE
15.
a. Manual-Electric Shift
16
FUSE
DOWNSHIFT
INHIBITOR
VH04948.00.00
GENERAL INFORMATION
NOTE:
The conditions resulting from power or solenoid
failure cited in the previous section apply only if the
failure occurs during operation in the selector position given and the selector is neither moved nor the
engine stopped after the failure. If the selector is
moved or the engine is stopped after the electrical or
solenoid failure, new shift situations result. Refer to
the Troubleshooting Chart, Table 310.
b. Automatic-Electric Shift
1. The automatic-electric system includes electrically-controlled valve body assembly 9 (Foldout 22) on the transmission (Figure 12). The
system also includes automatic-electric shift
selector assembly 1 (Foldout 24,B), Shift Pattern Generator (SPG) 1 (Foldout 24,A), cab
and vehicle wiring harnesses 4, and may include either fourth-range restrictor harness 20
or fifth-range restrictor harness 21, all located
in the cab. In addition the system includes
throttle potentiometer assembly 7 on the engine throttle control mechanism and magnetic
pickup 9 (Foldout 31) on the transmission rear
cover. Some models include range indicator 5
(Foldout 24A).
2. The SPG-controlled components work together with eight electro-magnetic solenoid
valves to provide automatic shifting in all forward ranges, and for neutral and reverse operation.
3. Electrical power for actuation of the control
system is supplied by the vehicle electrical
system. Electrical components to match the
system voltage (12V dc or 24V dc) are
provided in the control system. If an integral
SFE 9A fuse is not provided in the shift
selector, a disconnect switch, such as a key
switch or on/off switch, is required in the input
conductor of the shift selector assembly.
4. Lock-in-range provides for the transmission to
continue to operate in the forward range in
which it is operating at the time of an electrical
failure. Refer to Paragraph 224e, f, and g.
17
16.
OPTIONS
GENERAL INFORMATION
17.
OPERATING INSTRUCTIONS
WARNING!
Arc welding equipment requires dangerously
high currents and voltage which cannot be sufficiently reduced to permit it to be used for jumpstarting. To help avoid injury or equipment
damage, DO NOT attempt to jump-start equipment using an arc welder.
a. Operators Manual. Refer to the current Allison
Transmission publications:
OM1318EN Manual-Electric,
CAUTION:
DO NOT USE THIS FEATURE TO ACHIEVE
MANUAL SHIFTING FOR NORMAL OPERATION. Transmission life could be significantly
reduced if manual mode is utilized.
1. Manual mode is to be employed only for
service diagnostics or to limp-home under
low speed. Activation of this feature should
only be done by a trained technician.
2. To activate manual mode, activate the key
switch or physically connect wire 311 to wire
309 in the secondary mode wiring harness.
Secondary mode must also be selected by connecting wires 313 and 315 to wire 309.
c. Manual Mode (For CEC2 Models Only)
CAUTION:
DO NOT USE THIS FEATURE TO ACHIEVE
MANUAL SHIFTING FOR NORMAL OPERATION. Transmission life could be significantly
reduced if manual mode is utilized.
1. Manual mode is to be employed only for
service diagnostics or to limp-home at low
speed. Activation of this feature should only be
18.
19
8861
8961
8962, 8963,
M/S 8610
Units
2300
1800
550
800 (597)
2200 (2982)
2300
1800
550
975 (727)
3075 (4169)
5255 (7125)
2300
1800
550
975 (727)
3300 (4474)
5640 (7647)
rpm
rpm
rpm
hp (kW)
lb ft (Nm)
lb ft (Nm)
2300
1800
550
1104 (823)
3300 (4474)
5966 (8089)
rpm
rpm
rpm
hp (kW)
lb ft (Nm)
lb ft (Nm)
2300
1800
550
775 (578)
2960 (4013)
5300 (7186)
2300
1800
550
775 (578)
2960 (4013)
5300 (7186)
2300
1800
550
775 (578)
2960 (4013)
5300 (7186)
TRANSMISSION TYPE
ROTATION:
Input
110
rpm
rpm
rpm
hp (kW)
lb ft (Nm)
lb ft (Nm)
GENERAL INFORMATION
TORQUE CONVERTER:
Type
TC 840, 2.26:1
TC 860, 2.33:1
TC 880, 2.20:1
TC 890, 1.86:1
TC 1070, 1.73:1
LOCKUP CLUTCH
GEAR DATA
4.24:1
Second-range
2.32:1
Third-range
1.69:1
Fourth-range
1.31:1
Fifth-range
1.00:1
Sixth-range
0.73:1
Reverse
5.75:1
RANGE CLUTCHES
POWER TAKEOFF (TOP AND SIDE):
Mounting Flange
Rating (either or both locations)
Ratio
Gear Data
SPEEDOMETER DRIVE:
Size
1:1
PARKING BRAKE:
Type
Rating
Size
111
Sump
Integral
Dropbox Models
Filters
Preheat Opening
Converter-out pressure
Main Pressure
DP 8860, 8861:
Neutral, 1, 2, and Reverse
3, 4, 5, 6
3, 4, 5, 6
Lubrication Pressure
1500 rpm input speed, output stall; 3575 psi (241517 kPa)
HYDRAULIC RETARDER:
Maximum estimated absorption capacity at
1800 rpm rotor speed
Type
FLANGES:
Input (remote-mount models)
Output
SIZE (APPROXIMATE):
Length (direct-mount models)
112
GENERAL INFORMATION
MANUAL-ELECTRIC CONTROL SYSTEM:
Type
Vehicle cab
Integral
Downshift Inhibitor
Integral
Electrical System:
Power Source
Voltage
12V or 24V dc
Current Draw
12V
24V
Number of Solenoids
Solenoids Energized:
Neutral
Reverse
Forward Ranges
Wiring Harness:
Number of Conductors
16
Side Branches
Connectors
Downshift Inhibitor:
Type and Location
Activated by
113
Vehicle cab
Integral
Electrical System:
Power Source
Voltage
12V or 24V dc
Current Draw
Number of Solenoids
Solenoids Energized:
Neutral
Reverse
Forward Ranges
Wiring Harness:
Side Branches
Connectors
Equipment cab
Selector Sequence
R, N, D, 5, 4, 3, 2, 1 (typical)
Integral
Electrical System:
114
Power Source
Voltage
12V dc
Current Draw
Number of Solenoids
GENERAL INFORMATION
ELECTRONIC-CONTROL SYSTEM (DP 8963): (contd)
Solenoids Energized:
Neutral
Reverse
Forward Ranges
Equipment cab
Integral
Electrical System:
Power Source
Voltage
1.532V dc
Current Draw
Number of Solenoids
Solenoids Energized:
Neutral
Reverse
Forward Ranges
115
116
SCOPE
22.
a. Remote Mounting
1. Remote-mounted
transmissions
include
converter drive housing assembly 9 or 14
(Foldout 7,A) and transmission housing front
cover 6. The drive housing is bolted to and
encloses torque converter pump 27 (Foldout
8,B). It encloses the torque converter at its
forward end and retains the converter fluid.
The shaft on the converter drive housing
extends forward through the transmission front
cover, and is splined to receive flange 3, 19, or
20 (Foldout 7,A). The shaft of the converter
drive housing is supported on ball bearing 8.
23.
LOCKUP CLUTCH
21
24.
TORQUE CONVERTER
the
25.
HYDRAULIC RETARDER
b. Operation
b. Operation
1. The retarder rotor turns continuously at turbine
output shaft speed. However, the retarder
functions only when the cavity around the
retarder rotor is filled with fluid. A manual
valve directs fluid to the cavity when retarder
operation is desired. The churning of the fluid
by the retarder rotor resists the rotation of the
retarder rotor. Part of this energy is used to
circulate the fluid through a cooler to dissipate
the heat generated. When the control valve is
released, the retarder cavity is evacuated.
2. The retarder slows the vehicle on curves or
downgrades. Maximum retarder effect occurs
in the lowest range. Close the throttle when
using the retarder. Long, continuous retarder
application
raises
transmission
fluid
temperature. Short periods of full-release, to
interrupt continuous application, will prevent
overheating.
26.
NOTE:
Reference to up, down, left, or right refer to positions or movements of components on foldouts.
a. Description (Foldout 9,A)
1. Some transmissions include items 1 through 6
for a power takeoff drive at the top of the
torque converter housing.
2. When no power takeoff is provided, items 7
through 10 cover the top opening in the torque
converter housing.
3. Some transmissions provide a machined pad
for a power takeoff at the lower-right side of
the torque converter housing. Others have a
cast wall in this area. When the pad and
opening are provided, items 11 through 14 are
used when no power takeoff is mounted.
4. The provided power takeoff pads at either the
top or right side of the torque converter
SPLITTER CLUTCHES,
GEARING
23
29.
INTERMEDIATE-RANGE
CLUTCH, PLANETARY
a. Description
28.
HIGH-RANGE CLUTCH
Clutch drum 16
Three external-splined clutch plates 15
Four internal-splined clutch plates 14
High-range clutch piston assembly 9
High-range clutch hub assembly 4.
25
b. Operation
1. When the reverse-range clutch is applied,
clutch piston 10 (Foldout 18,A) compresses
clutch plates 3, 4, 6, and 7 against clutch
backplate 1. This holds ring gear 5 stationary.
Reverse-range sun gear assembly 2 (Foldout
17,B) is attached to first-range ring gear 7
(Foldout 16,B). The first-and reverse
planetaries are compounded to provide reverse
rotation in the first-range planetary, and further
speed reduction in the reverse-range planetary.
2. First-range sun gear 13 drives pinions 18 or 29
of planetary carrier assembly 15. The pinions
drive ring gear 7 in a reverse direction. Ring
gear 7, being connected to reverse sun gear
assembly 2 (Foldout 17,B), drives planetary
carrier assembly 6 in the reverse direction
within stationary reverse-range ring gear 5
(Foldout 18,A).
3. Reverse-range planetary carrier assembly 6
(Foldout 17,B) is splined to the transmission
output shaft (integral with first-range planetary
carrier assembly 15 (Foldout 16,B) and drives
it in the reverse direction. All of the
transmission torque is carried by transmission
main shaft assembly 16 (Foldout 11,B). The
splitter-low clutch is engaged but transmits no
torque. The reverse reduction ratio is 5.75:1.
a. Description
1. The reverse-range clutch includes:
Low-range clutch anchor 1 (Foldout 17,A)
(which also serves the first-range clutch)
Five internal-splined clutch plates 3 and 6
(Foldout 18,A)
Five external-splined clutch plates 4 and 7
Clutch piston 10.
2. Plates 3, 4, 6, and 7 compress against reverserange clutch backplate 1 (which also serves the
first-range clutch). Clutch piston 10 uses rear
cover 4 (Foldout 18,B) as its housing (straightthrough models) or rear cover assembly 14
(Foldout 19,A) in dropbox models.
3. The reverse planetary includes:
Sun gear assembly 2 (Foldout 17,B)
Planetary carrier assembly 6
Reverse ring gear 5 (Foldout 18,A).
26
in
dropbox
a. Description
1. The parking brake is a two-shoe, internallyexpanding configuration that is mechanically
operated.
a. Description
b. Operation
1. A lever is connected by linkage to camshaft
and lever 5 or 48 (Foldout 19,B). When the
brake is applied, the camshaft and lever rotate
and expand shoes 12 and 29 or shoes 56 and 71
against the inner surface of brake drum 43.
When the lever is released, springs 15 and 21
or springs 60 and 66 retract the shoes.
2. Parking brake adjustment is described in
Paragraph 311.
b. Operation
1. The pressure section (wider gears) draws fluid
from transmission sump (oil pan in straightthrough configuration, or rear cover assembly
in dropbox configuration) when the vehicle
engine is running. Separate outlets from the
pressure section direct fluid to the converter-in
circuit, and to the hydraulic system (Foldouts 3
through 6).
27
NOTE:
The booster plug in DP 8960, 8961, 8962, 8963, and
stroke) and produces a lower boosted main pressure. Refer to pressures given in Table 11.
d. Converter-Pressure Relief Valve
1. The converter-pressure relief valve includes
items 1, 2, 3, 4, and 10 (Foldout 13,B).
Converter pressure relief valve 3 and spring 4
are installed on pin 10 which is pressed into the
front of transmission housing 11. Valve 3,
spring 4, and converter pressure relief valve
seat 2 are attached by retaining ring 1.
2. The converter pressure relief valve (Foldouts 3,
4, 5, or 6) in DP 8861 models opens when
pressure in the converter-in circuit reaches 80 psi
(522 kPa) except those models after S/N 702, or
with a T stamped on the nameplate after the
assembly number. The pressure is 120 psi
(827 kPa) in all DP 8861 models after S/N 702,
or with a T stamped on the nameplate. All
DP 8961 and 8962 models have 120 psi
(827 kPa) valves. The fluid escaping through
the valve returns to the transmission sump.
Converter-in pressure is limited to 80 or
120 psi (522 or 827 kPa).
29
NOTE:
Since the 8000 uses a two area lockup piston that
softens lockup engagement, the lockup trimmer
valve assembly was determined to be redundant
and therefore was eliminated from production and
service use in 1985.
2. The lockup shift valve assembly includes items
15 through 34 and 39 (Foldout 27,A).
NOTE:
For models with non-electric lockup, proceed to
Step (3).
For models with electric lockup, proceed to
Step (6).
3. For models with non-electric lockup, the
hydraulically-actuated lockup-clutch shift
valve is controlled by pitot pressure to engage
the lockup clutch as a function of torque
converter turbine speed.
4. Flow of transmission fluid to and from the
lockup-clutch piston cavity is controlled by the
lockup-clutch shift valve 21 or 26. Movement
of this spool valve in its bore opens or closes
ports, to determine whether the lockup clutch
is engaged or disengaged. This valve is located
in lockup valve body 31 (Foldout 27,A).
Operation of the hydraulically-actuated lockup
valve occurs as a result of pitot-driven
hydraulic pressure acting on lockup-clutch
shift valve 21 or 26 at high turbine shaft speed.
5. The lockup shift valve is operative in neutral,
reverse and all forward ranges unless provided
with a valve body having passages to direct a
signal pressure to the upper end of the valve to
prevent it from moving up in neutral, reverse,
first, and second ranges. Lockup operation can
occur only in third- through sixth-ranges if the
signal passage is provided. See NOTE
following Figure 318.
6. For models with electric lockup, operation of
the electrically-actuated lockup valve is a
result of main pressure acting on lockup-clutch
shift valve 21 (Foldout 27,A) or 9 (Foldout
27,B). The SPG or ECU senses output shaft
speed and energizes the lockup solenoid. This
Its pressure operates the various control valves and applies the clutches.
j. Flow (Lockup Cutoff) Valve (Models With NonElectric Lockup). Flow valve 17 (Foldout 27,A),
located in lockup valve body 31, works in conjunction
with the lockup-clutch shift valve. This spool valve
momentarily interrupts the flow of main pressure to
the lockup clutch when shifts occur from one range to
another. When a shift (other than to neutral) occurs, a
rapid flow of fluid is required to engage the clutch.
This fluid must pass through the flow valve bore.
During the initial part of this flow, the valve moves
upward, cutting off main pressure to the lockup clutch
and exhausting the lockup-clutch circuit. When the
oncoming clutch is filled, the valve returns downward
and restores pressure to the lockup-clutch circuit. This
enables the torque converter to cushion full-power
shifts.
219. MANUAL-HYDRAULIC
CONTROL SYSTEM
b. System Schematics (Foldout 3 or 4). Colorcoded foldouts of the hydraulic systems are located in
the back of this manual. The illustrations represent
each system as it functions in neutral with the engine
idling.
c. Splitter Relay Valve (Earlier Valve Bodies)
NOTE:
References to up, down, left, or right refer to positions or movements of components on Foldout 3 or 4.
a. System Functions. The hydraulic system generates, directs and controls the pressure and flow of hydraulic fluid within the transmission. Hydraulic fluid
(transmission oil) is the power transmitting medium in
the torque converter. Its velocity drives the converter
turbine. Its flow cools and lubricates the transmission.
211
Neutral
Splitter-low clutch
220. MANUAL-HYDRAULIC
CONTROL SYSTEM CIRCUITS
(Earlier Models)
NOTE:
References to up, down, left, or right refer to positions or movements of components on Foldout 3.
a. System Functions. The hydraulic system generates, directs, and controls the pressure and flow of hydraulic fluid within the transmission. Hydraulic fluid
(transmission fluid) is the power transmitting medium
in the torque converter. Its velocity drives the converter turbine. Its flow cools and lubricates the transmission. Its pressure operates the various control
valves and applies the clutches.
b. System Schematics (Foldout 3). A color-coded
foldout of the hydraulic system is presented at the
back of this manual. The illustration represents the
system as it functions in neutral with the engine idling.
213
215
221. MANUAL-HYDRAULIC
CONTROL SYSTEM CIRCUITS
(Later Models, Foldout 4)
The explanation of the earlier hydraulic system (Paragraph 220) is applicable also to the later system. Although the end result is the same, note that the circuit
differences (Foldout 4) affect the way some actions are
accomplished.
NOTE:
References to up, down, left, or right refer to positions or movements of components on Foldout 5.
a. System Functions. The hydraulic system generates, directs, and controls the pressure and flow of hydraulic fluid within the transmission. Hydraulic fluid
(transmission oil) is the power transmitting medium in
the torque converter. Its velocity drives the converter
turbine. Its flow cools and lubricates the transmission.
Its pressure operates the various control valves and applies the clutches.
b. System Schematics (Foldout 5). A color-coded
foldout of the hydraulic system is presented at the
back of this manual. The illustration represents the
system as it functions in neutral with the engine idling.
c. Reverse Shift Valve
1. The reverse shift valve is a spool-type valve
which can move lengthwise in its bore. A
spring pushes the valve up when Solenoid B is
energized. Hydraulic pressure pushes the valve
down when Solenoid B is de-energized and its
valve closes.
2. In its up position, the reverse shift valve directs
hydraulic pressure to the reverse clutch. In its
down position, the clutch is exhausted.
d. Second-Range Shift Valve
1. The second-range shift valve is a spool-type
valve which can move lengthwise in its bore. A
spring pushes the valve up when Solenoid C is
energized. Hydraulic pressure pushes the valve
down when Solenoid C is de-energized and its
valve closes.
2. In its up position, the valve directs hydraulic
pressure to the second-range clutch. In its
down position, the valve exhausts the secondrange clutch.
e. Intermediate-Range Shift Valve
1. The intermediate-range shift valve is a spooltype valve which can move lengthwise in its
bore. A spring pushes the valve up when
Solenoid D is energized. Hydraulic pressure
pushes the valve down when Solenoid D is deenergized and its valve closes.
217
219
221
vehicle electrical system. The automaticelectric control has only 24V solenoids
because the circuit includes a 12-to-24V
converter for 12V vehicle systems or a 24V
overload protector for 24V vehicle systems.
t. Shift Selector Assembly
1. The shift selector assembly is manually
operated and has eight selector positions. The
selector positions are (from rear to front)
reverse, neutral, first-range, second-range,
third-range, fourth-range, fifth-range, and
sixth-range.
The
shift
indicator
is
correspondingly marked R, N, 1, 2, 3, 4, 5, and
6. Each shift position is gated, and the selector
lever must be pushed right or left, alternately,
to clear the gate separating each shift position
from the adjoining position.
2. Eight microswitches are operated by a cam
attached to the manual selector lever. Each
position of the lever opens and closes the
proper combination of switches required to
energize or de-energize the proper combination
of solenoids for that selector position.
3. A solenoid which has its axis on a line with the
axis of the switch-operating cam acts as a
downshift inhibitor. It is energized when the
transmission lockup clutch engages. Lockup
clutch pressure closes a pressure-actuated
switch (Paragraph 222r) which in turn
energizes the inhibitor solenoid. The inhibitor
solenoid engages a dog clutch arrangement
which prevents the selector lever from being
moved to a lower range position. It may be
upshifted.
NOTE:
The inhibitor solenoid is not to be confused with the
nine solenoids used in the valve body assembly.
a. System Functions. The hydraulic system generates, directs, and controls the pressure and flow of hydraulic fluid within the transmission. Hydraulic fluid
(transmission oil) is the power transmitting medium in
the torque converter. Its velocity drives the converter
turbine. Its flow cools and lubricates the transmission.
Its pressure operates the various control valves and applies the clutches.
5. At the reverse shift valve, Solenoid B is deenergized and its valve is closed. This retains
solenoid pressure, and the valve is pushed down
against its spring. The reverse clutch is exhausted
through the spring-loaded check valve.
NOTE:
References to up, down, left, or right refer to positions or movements of components on Foldout 5 or 6.
c. Neutral
1. The shift selector is in neutral, the equipment
engine is idling, and the transmission fluid
temperature is normal at 180200F (8393C).
The input pump, driven when the engine is
operating, picks up transmission fluid from the
sump and pumps it into the hydraulic system.
6. At the first-range shift valve, Solenoid H is deenergized and its valve is closed. Solenoid I is
energized and its valve is open. Solenoid
pressure at the upper end of the valve holds it
down against its spring. The first-range clutch is
exhausted through the bore of the second-range
shift valve and the spring-loaded check valve.
223
225
m. Fifth-Range Operation
1. When the selector lever is moved from 4
(Fourth-range) position to 5 (Fifth-range)
position, Solenoids D and G are de-energized,
and Solenoids E and F are energized.
2. When Solenoid D is de-energized, its valve
closes and solenoid pressure acts upon the
226
227
SELECTOR LEVER
LOCK-IN-RANGE
INDICATOR
LIGHT
5 AUTOMATIC SHIFTING,
FIRST- THROUGH FIFTH-RANGES
RANGE
INDICATOR
SHIFT SELECTOR
GATE PIN
DR (DRIVE) AUTOMATIC SHIFTING,
FIRST- THROUGH SIXTH-RANGES
N (NEUTRAL)
R (REVERSE) NO AUTOMATIC SHIFTS
228
VH00692.00.01
229
b. Shift Selector
1. The two types of electronic control shift
selectors are pushbutton (Figure 23) and shift
lever (Figure 24).
NOTE:
For models with pushbutton selector, proceed with
Step (2).
For models with lever shift selector, proceed to
NOTE:
Only the system components that differ from those
Step (4).
in the manual-electric system and circuits (Paragraph 222 and 223) are described.
References to up, down, left, or right refer to positions or movements of components on Foldout 6.
For electronic control hydraulic system functions,
refer to Paragraph 218a.
For electronic control hydraulic system schematics,
refer to Paragraph 218b.
a. Electronic Control Unit (ECU). The Electronic
Control Unit (ECU) (Figure 22) contains a
microcomputer which receives and processes signals
from various switches and sensors. The ECU controls
transmission operation by actuating the appropriate
solenoids. The ECU also performs diagnostic
functions and identifies electronic system problems
with a displayed code.
SHIFT SELECTOR
H00695.01
ELECTRONIC
CONTROL
UNIT
IDENTIFYING
(ECU)
LABELS
BEZEL
SCREW (4),
6-32 x 58 in.
SELECTOR LEVER
SECONDARY MODE
HARNESS CONNECTION (J3)
H00930.01
H00688.01
230
231
ECU CONNECTOR
(J1B)
SPEED
SENSOR
CONNECTOR
ELECTRIC LOCKUP CONNECTOR
(MODELS WITH ELECTRIC LOCKUP)
THROTTLE
SENSOR CONNECTOR
LOW-RANGE CONNECTOR
MAIN CONTROL
VALVE BODY
CONNECTOR
232
H00699
MAIN
TO LOCKUP CLUTCH
LOCKUP SOLENOID
MAIN PRESSURE
EXHAUST OR SUMP
DIAGNOSTIC TOOL
CONNECTOR
ORIFICE
V00701.00.00
VH00698.01.01
ECU
CONNECTOR
(J3)
233
IDENTIFICATION
LABELS
AY
GR
AC
BL
S HARNESS
RECEPTACLE
UE
BL
UE
BL
V HARNESS
RECEPTACLE
T HARNESS RECEPTACLE
V06723
SE
LE
MODE ID
DE
MO
MODE
IDENTIFICATION LABEL
V06724
235
R
MODE
N
D
MODE BUTTON
5
4
MODE ID
3
2
1
DIGITAL DISPLAY
DISPLAY MODE/
DIAGNOSTIC BUTTON
FINAL ASSEMBLY LABEL
SIX-SPEED, RIGHT-HAND
LEVER SELECTOR
WITH REVERSE TO FRONT
V06725
236
B
C
THROTTLE
POSITION
SENSOR
V00628
INPUT
(EXTERNAL)
TURBINE
(EXTERNAL)
OUTPUT
(EXTERNAL)
V06589
237
V
CONNECTOR
(GRAY)
VIWV
CONNECTOR
T
CONNECTOR
(BLUE)
SELECTOR (S)
HARNESS
J 1939
CONNECTOR
(OPTIONAL)
S
CONNECTOR
(BLACK)
VIWS
CONNECTOR
DIAGNOSTIC TOOL
CONNECTOR
TPS
CONNECTOR
(OPTIONAL)
DEUTSCH
DIAGNOSTIC TOOL
CONNECTOR
(OPTIONAL)
VIM
CONNECTORS
SCI (J 1587)
CONNECTOR
(OPTIONAL)
TRIM
BOOST
CONNECTOR
TEMP SENSOR/
LOCKUP
CONNECTOR
SHIFT
SELECTOR
CONNECTOR
OUTPUT
SPEED SENSOR
CONNECTOR
THROTTLE POSITION
SENSOR (TPS)
CONNECTOR
TURBINE
SPEED SENSOR
CONNECTOR
INPUT (ENGINE)
SPEED SENSOR
CONNECTOR
TRANSMISSION
MAIN VALVE
BODY
CONNECTOR
238
1
TO ENGINE-OIL
PRESSURE SWITCH
(+ INPUT FROM EQUIPMENT)
GREEN TO
REVERSE SIGNAL
EQUIPMENT
FRAME GROUND
BLUE TO
EQUIPMENT
LIGHT SWITCH
TO GROUND TERMINAL () OF
EQUIPMENT BATTERY
RED
BLACK
TERMINAL #
1
2
3
4
BLACK
RED
FROM SHIFT
SELECTOR
VOLTAGE
+12
12
+24
24
V00725.02.00
Figure 216. Negative Ground SystemConnections for 12/24 Volt Converter or 24/24 Volt Overload Protector
239
1
TO GROUND
TERMINAL (+)
OF EQUIPMENT
BATTERY
GREEN TO
REVERSE SIGNAL
EQUIPMENT
FRAME GROUND
BLUE TO
EQUIPMENT
LIGHT SWITCH
RED
BLACK
TO ENGINE-OIL PRESSURE
SWITCH ( INPUT FROM EQUIPMENT)
TERMINAL #
1
2
3
4
BLACK
VOLTAGE
+12
12
+24
24
RED
FROM SHIFT
SELECTOR
240
CAUTION:
NOTE:
It is assumed the engine is operating at its normal
output torque and speed in all power flows discussed. Even though two clutches are applied, the
vehicle should not move (except possibly to creep) if
the engine is idling. The torque converter will not
transmit sufficient torque at low-idle speed to move
the vehicle at more than a creep. The direction of rotation is determined by viewing the transmission
from the front (input) end.
b. Lockup Operation
1. Power is transmitted mechanically through the
lockup clutch. Application of the lockup clutch
occurs automatically as a function of front
governor (pitot) pressure.
2. When the lockup clutch is applied, the
converter elements rotate as a unit at engine
speed. This provides a direct drive from the
engine to the turbine shaft.
241
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FIRST-RANGE (COMBINING)
PLANETARY
FLEX
PLATE
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
INPUT PRESSURE PUMP
CLUTCH APPLIED
SPLITTER PLANETARY
SCAVENGE PUMP
V04785.02.01
242
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FLEX
PLATE
FIRST-RANGE (COMBINING)
PLANETARY
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
CLUTCH APPLIED
SPLITTER PLANETARY
V04785.01.00
3. When the first-range clutch is applied, the firstrange ring gear is held stationary and becomes
243
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FLEX
PLATE
FIRST-RANGE (COMBINING)
PLANETARY
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
V08499.01.00
CLUTCH APPLIED
SPLITTER PLANETARY
244
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FLEX
PLATE
FIRST-RANGE (COMBINING)
PLANETARY
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
CLUTCH APPLIED
V08242.00.00
SPLITTER PLANETARY
245
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FLEX
PLATE
FIRST-RANGE (COMBINING)
PLANETARY
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
CLUTCH APPLIED
V08243.00.00
SPLITTER PLANETARY
246
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FLEX
PLATE
FIRST-RANGE (COMBINING)
PLANETARY
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
CLUTCH APPLIED
V08244.00.00
SPLITTER PLANETARY
247
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FLEX
PLATE
FIRST-RANGE (COMBINING)
PLANETARY
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
CLUTCH APPLIED
V08245.00.00
SPLITTER PLANETARY
248
SPLITTER-HIGH CLUTCH
TORQUE
CONVERTER
POWER
TAKEOFF
SPLITTER-LOW
CLUTCH
HIGH-RANGE CLUTCH
INTERMEDIATE-RANGE CLUTCH
SECOND-RANGE CLUTCH
HYDRAULIC
RETARDER
REVERSE-RANGE
CLUTCH
FIRST-RANGE CLUTCH
OUTPUT
SHAFT
REVERSE-RANGE
PLANETARY
TURBINE
SHAFT
FLEX
PLATE
FIRST-RANGE (COMBINING)
PLANETARY
SECOND-RANGE PLANETARY
INTERMEDIATE-RANGE PLANETARY
MAIN SHAFT
CLUTCH APPLIED
V08246.00.00
SPLITTER PLANETARY
SCAVENGE PUMP
249
250
SCOPE
32.
GENERAL INSPECTION
AND CARE
33.
WARNING!
To help avoid injury and property damage
caused by sudden and unexpected vehicle movement, do not perform maintenance or service
procedures until you:
Put transmission in N (Neutral).
Set the parking brake and service brakes and
make sure they are properly engaged.
Chock the wheels and take any other steps
necessary to keep the vehicle from moving.
CAUTION:
To avoid transmission housing damage and fluid
leakage, refer to Paragraph 413c before removing or installing fluid level check plugs.
31
Install with
knurled plug up
RED LINE
NO RED LINE
VISIBLE (OVERFILL)
SAFE
OPERATIONAL
LEVEL AREA
FULL MARK
(CENTER)
34.
NO FLUID VISIBLE
(UNDERFILL)
CHANGING FLUID
AND FILTERS
CAUTION:
H00711.01
c. Hot Test
1. A hot fluid check is made to determine if there
is sufficient fluid for operation of the
transmission. This test is made, while the
engine is running, after a few minutes
operation at engine idle (approximately
650 rpm), the equipment standing level, the
32
Containers or fillers that have been used for antifreeze or engine coolant solution must not be
used for transmission fluid.
b. Fluid Capacity. Straight-through configuration
transmissions require approximately 21 U.S. gallons
(79 liters) for initial filling, plus the additional amount
needed in the external system (cooler, filter, external
lines). Dropbox configurations require approximately
34 gallons (129 liters) initially (plus external system).
For refill, approximately 2 gallons (7 liters) less will
be required for each configuration.
PREVENTIVE MAINTENANCE
BREATHER
INTERMEDIATE-RANGE
PRESSURE TAP
SECOND-RANGE
PRESSURE TAP
REVERSE-RANGE
PRESSURE TAP
PIPE PLUG
(2)
LUBRICATION
PRESSURE
TAP
PITOT
PRESSURE
TAPS
SPLITTER-LOW
PRESSURE TAP
FLUID LEVEL
PLUG
FLUID FILLER HOLE
FIRST-RANGE
PRESSURE TAP
PIPE PLUG
LOCKUP
TRIMMER
PRESSURE TAP
OIL
STRAINER
ASSEMBLY
NEUTRAL TRIMMER
PRESSURE TAP
VH08500.00.00
Figure 32. DP 8000 Series Transmission Fluid Level Plug and Pressure TapsManual-Hydraulic Models
33
CAUTION:
Disregarding minimum fluid temperature limits
can result in transmission malfunction or reduced life.
Table 31. Minimum Operating Temperature
Without Preheat
Fluid
SAE OW-30 or TranSynd RD
SAE OW-20 (Arctic Oil)
DEXRON-III
SAE 10W
SAE 15W-40
SAE 30
SAE 40
F
22
22
18
4
5
32
50
C
30
30
28
20
15
0
10
CAUTION:
These products are not approved for use in any
Allison Transmission automatic and/or powershift transmission and must not be used.
d. Cold Weather Start-Up. Listed in Table 31 are
the minimum fluid temperatures at which the
transmission may be safely operated in a forward
range or reverse. When ambient temperature is below
the minimum fluid temperature limit and the
transmission is cold, preheat is required. If auxiliary
heating equipment is available, preheat the fluid to the
minimum temperature limit. If auxiliary heating
equipment is not available, run the engine at low idle
for at least 20 minutes with the transmission in neutral
before operating in a forward or reverse range. Failure
to observe the minimum fluid temperature limit can
result in transmission malfunction or reduced
transmission life.
e. Transmission Fluid Change Intervals
1. Fluid analysis is the preferred method to determine transmission fluid change intervals. Monitor the oxidation level according to the measurement limits shown in Table 32. The fluid
is usable if it meets both limits. If fluid analysis
34
Limits
+/-25% change from new fluid
contamination
Fluid analysis indicates the fluid is oxidized
beyond the limits in Table 32.
Table 33. Standard Fluid Change Intervals
(by Fluid Type)
Transmission
Model
Fluid
Recommendation
TranSynd RD
DP 8000 Series
C-4 Fluids
Drain
Intervals
(Hours)
4000
1200
PREVENTIVE MAINTENANCE
Continued operation after the indication point
will cause the filter bypass valve to open,
allowing unfiltered fluid to circulate into the
transmission.
CAUTION:
For Allison High-Efficiency direct and remote
mount transmission main circuit filters, the integral bypass valves are located in the filter base
(Figure 33 and 34). Inspect the bypass valves
whenever the filter elements are changed. A visual inspection must show the bypass valve
squarely seated in the filter housing (Figure 35).
If the valve is cocked, loose, or missing, replace
the filter head.
FILTER BASE
BYPASS VALVE
VH05003.00.01
FILTER BASE
BYPASS VALVE
H05004
35
0.100 in.
0.75016 STRAIGHT THREAD
(PORT CONTOUR CUTTER)
45
0.100 in.
0.811 in.
0.500 in.
TEST PROCEDURE:
1. Remove P switch from filter and
install in test block.
2. Reconnect wiring harness to
warning light.
3. Pump up pressure to test block and
watch for warning light indication.
4. AT switch P/N 23018846 should
indicate at 16 psi ( 3 psi).
Switch P/N 29529657 should
indicate at 35 psi ( 3 psi).
1.250 in.
0.640 in.
PRESSURE RELEASE
VALVE
18 in.
J 33884-4
PIPE ADAPTER
V05408.01.01
36
PREVENTIVE MAINTENANCE
6. Due to the significant cost-to-operation
advantage that can be achieved by monitoring
the p switch system, it is recommended that
the proper function of this system be
monitored on a periodic preventive
maintenance schedule. A test block to activate
the switch is shown in Figure 36.
7. For detailed information on transmission fluid
characteristics, analysis, and selection, refer to
GN2005EN, Technicians Guide, Automatic
Transmission Fluid Understanding/Analysis. It
is available from any Allison Distributor or
Dealer.
8. Test procedure for p switch test block:
Remove p switch from filter and install in
test block.
Reconnect wiring harness to warning light.
Pump up pressure to test block and watch
for warning light indication.
Allison Transmission switch P/N 23018846
should indicate at 16 psi, 3 psi (110.3 kPa,
20.7 kPa).
Allison Transmission switch P/N 29529657
should indicate at 35 psi, 3 psi (241.3 kPa,
20.7 kPa).
g. Procedures
1. The transmission should be at operating temperature (after about one hour of operation).
2. Remove the fluid drain plugs from the sump
and oil filters (Figure 32, 37) and drain the
fluid. Replace the plug.
37
MAIN-PRESSURE TAP
PITOT
PRESSURE
TAP
BREATHER
LOCKUP
PRESSURE
TAP
FLUID LEVEL
PLUG
INHIBITOR
PRESSURE
SWITCH
SPLITTER-LOW
PRESSURE TAPS
VH08247.00.00
Figure 37. DP 8000 Series Transmission Fluid Level Plug and Pressure TapsElectric-Shift Models
35.
FLUID CONTAMINATION
PREVENTIVE MAINTENANCE
NOTE:
Some C-4 transmission fluids will give a positive indication because of additives in the fluid. When
test results are questionable, test a clean (unused)
sample of the same type or brand to confirm results.
d. Cooler Circuit Filter
1. An auxiliary filter may be installed in the
cooler line circuit. Converter-out pressure must
not exceed 65 psig (447 kPa) under the following conditions:
Transmission at operating temperature
Wide open throttle in the highest range
Retarder OFF.
36.
BREATHER
37.
DETERMINING FLUID
PRESSURES, TEMPERATURES
39
38.
LINKAGE
PTO COVER
TRUNNION
MOUNT
REAR COVER
INPUT
FLANGE
PARKING
BRAKE
FRONT
COVER
MOUNTING PAD
RETARDER CONTROL
VALVE BODY
LIQUID LEVEL
INDICATOR
OIL PAN
V08248.00.00
Figure 38. DP 8000 Series TransmissionFluid Temperature and Pressure Check Points
310
PREVENTIVE MAINTENANCE
b. Maintaining Proper Adjustment
1. The manual selector valve linkage is properly
adjusted when the detents correspond exactly
with those in the transmission.
2. Periodic inspections should be made for the
following:
Bent or worn parts
Loose threaded connections
Loose bolts
Accumulation of grease and dirt.
39.
a. External Lines. Inspect for loose or leaking connections and worn or damaged hoses.
b. Oil Cooler
1. Examine the radiator coolant for traces of
transmission fluid. This condition indicates a
faulty heat exchanger.
2. Abnormally high operating temperatures can
cause clogging of the oil cooler as well as
transmission failure. The oil cooler system
should be thoroughly cleaned after each
rebuild. Failure to do so may cause poor
performance, overheating, and transmission
311
WARNING!
311. ADJUSTING PARKING BRAKE
a. The internal, expanding shoe type parking brake
is mounted at the rear of the transmission at the output.
b. Brake drums can be turned to remove signs of
wear up to 0.100 inch (2.54 mm) diametral.
c. Adjust the brake shoes for proper drum clearance.
Remove probe hole cover 73 and adjusting hole cover
74 (Foldout 19,B). Tighten the brake adjusting screw
until the brake lining is tight against the drum. Then
back off the adjusting screw three full turns. Replace
both covers.
d. Adjust the vehicle brake linkage by releasing the
hand lever fully, and adjusting the connecting linkage
so that it can be freely connected to the apply lever on
the brake. All slack should be taken out of the brake,
without actually moving the brake shoes, when the
linkage adjustment is made.
e. New drums and brake shoe linings need to be
burnished. Refer to the brake manufacturer's
instructions.
CAUTION:
Do not overburnish the brake.
312
PREVENTIVE MAINTENANCE
attained to the speed specified by the vehicle
manufacturer as normal for those conditions.
An engine speed above or below the specified
range by more than 150 rpm may indicate a
malfunction in the engine or transmission.
NOTE:
Engine power will decrease with an increase in
elevation (altitude), becoming more pronounced at
greater elevation. This will result in a lower engine
speed under converter stall conditions.
313
NOTE:
For transmissions with manual-electric shift con-
to Paragraph 316.
4. If the transmission was prepared for storage
without fluid, drain the residual fluid and
replace the oil filter elements. Refill the
transmission to the proper level with C-4
transmission fluid.
314
PREVENTIVE MAINTENANCE
315. LUBRICATION OF SHIFT
SELECTORELECTRIC
CONTROL
CAUTION:
Do not over lubricate. Do not apply any lubricant
to any point on or near the switches or switch assembly.
a. Time Intervals
1. Shift selectors should be lubricated after the
first 500 hours of operation and after each
2500 hours of operation thereafter.
2. The 2500 hour intervals may be shortened if
operating conditions are extremely dusty or
dirty.
b. Clean Before Lubricating. Using compressed
air, thoroughly clean the area to be lubricated. Work
the shift handle from side to side while applying the
air blast.
c. Lubrication Points
1. Refer to Figure 644 for the area to be lubricated. The shift handle 16 (Foldout 23), where
it swivels in rotary key 39, and at its point of
contact with leveler 4 should be lubricated with
Lubricate No. 107 (or equivalent). Also, lubricate the right end of leveler 4, where it reciprocates in rotary key 39.
2. The lubrication points may be reached by a
pump-type applicator (Eagle No. 33F or
equivalent). Access to the parts to be lubricated
is available from the top of the shift selector,
through the opening in which the shift handle
moves, as well as through an opening at the
bottom of the shift selector (Figures 644 and
649). Use both access points to be sure of
complete lubrication. Some disassembly is
necessary to lubricate other points.
3. Apply lubricant sparingly. Excess lubricant
tends to retain dust and dirt, or may seep into
areas where it would be harmful.
315
GROUND
TO LIGHT
YELLOW
TO INHIBITOR
FROM
INHIBITOR
L A
K
J
I
MATING
CONNECTORS
B
N C
M
P
D
J
O
I
E
H
F
G
K
C
D
P
N E
H O F
M
G
BRANCHES TO
EXTERNAL POINTS
N TO EQUIPMENT STARTER
CIRCUIT (WHITE)
M POWER INPUT (RED)
(24V)
L TO EQUIPMENT LIGHT
CIRCUIT (BLUE)
P TO EQUIPMENT GROUND
(BLACK)
K
SWITCH SECTION
PRESSURE
SWITCH
ON LOCKUP
VALVE BODY
MAIN HARNESS
BRANCH TO 8-PIN CONNECTOR
BRANCH TO 2-PIN CONNECTOR
A
G
C
D
E
F
MATING
CONNECTORS
I
MATING
CONNECTORS
B TO SOLENOID B
B TO SOLENOID I *
H
B
A
WIRING HARNESS
(SELECTOR TO VALVE BODY)
A TO SOLENOID A *
G TO SOLENOID G *
B
A
G
A TO SOLENOID H
C TO SOLENOID C
C
D
D TO SOLENOID D
E
F
E TO SOLENOID E
F TO SOLENOID F
* Not present on Lock-in-neutral models
3.Manual-Electric
Field Test Kit P/N 1920 can be purchased from NoelSmyser Engineering Corp., 4005 Industrial Blvd., Indianapolis, IN 46254
PREVENTIVE MAINTENANCE
3. Test each receptacle terminal of the wiring
harness for delivery of electrical signals at the
proper time by positioning the shift selector
control in each selector position and checking
each pin socket. Touch each pin socket with
the ungrounded lead of the test lamp. The pin
receptacles should be energized in each range
according to Table 34.
Table 34. Selector Position and Associated
Pin Receptacles
Selector Position
R
N
1
2
3
4
5
6
Pin Receptacles
A,B,F,I
A,F,I
F,H
F,C
F,D
G,D
F,E
G,E
NOTE:
H and I are the pin receptacles in the two pin connector at the valve body but are marked A and B. A
should be regarded as H; B should be regarded as I.
4. Only the pin receptacles listed should be
energized in the selector positions shown. If
any others are energized, or if those listed are
not all energized, a malfunction of either the
shift selector or wiring harness is indicated.
5. If the tests in Paragraph 316b(3) are
satisfactory, the shift selector assembly should
be tested separately (refer to Paragraph 318). If
the shift selector is faulty, it may be rebuilt (refer
to Paragraph 635). If the shift selector tests
satisfactory (wiring harness disconnected) but
trouble is evident in tests in Paragraph 316b(3),
the wiring harness is faulty and must be
replaced.
NOTE:
If the wiring harness is cut or worn, reroute the new
harness to avoid recurrence of the fault.
6. Test the valve body internal circuits with an
ohmmeter as outlined in Steps (7) and (8).
317
4.Automatic-Electric
Field Test Kit P/N 1948 can be purchased from NoelSmyser Engineering Corp., 4005 Industrial Blvd., Indianapolis, IN 46254
PREVENTIVE MAINTENANCE
Table 35. Continuity Between Pin Sockets
Selector Position
R
N
DR
5
4
3
2
1
Any position (ground)
If any of these checks show an open circuit, replace the cab harness.
319
JUMPER
(IN LATER MODELS
JUMPER IS INTERNAL)
+
EQUIPMENT
BATTERY
3
2
THROTTLE
POTENTIOMETER
ENGINE OIL
PRESSURE SWITCH 201 BLACK
2-PIN CONNECTOR
202 BLACK
209
200 RED
A
219
210
B
C V
D
B
19-PIN CONNECTOR
A
E
P
N
R
F
M
S
TU
L
G
K
H J
SHIFT PATTERN
GENERATOR
(SPG)
17-PIN
CONNECTOR
SEE NOTE
J
H
F
E
RED
205 RED
203 BLUE
204 GREEN
TO EQUIPMENT
LIGHT SWITCH
J
LK
16-PIN
CONNECTOR
206 BLACK
218
217
216
215
214
213
212
211
208
WHITE
P
H
TO
REVERSE
SIGNAL
G
B
F
D N
207 WHITE
In series with equipment
starter circuit
17-PIN
SOCKET
L
110
M
T
S N
R P
C
RANGE INDICATOR
SHIFT
SELECTOR
100
101
A
T D
17-PIN CONNECTOR
102
B
A
111
MAGNETIC
PICKUP
107
106
105
104
TRIM BOOST
VALVE BODY
F H
103
8-PIN CONNECTOR
108
2-PIN
CONNECTORS
MAIN
VALVE
BODY
109
NOTE: For models with range indicator, connect main valve body harness to range indicator harness.
For models without range indicator, connect main valve body harness directly to shift pattern generator.
320
V08665.00.00
PREVENTIVE MAINTENANCE
SHIFT PATTERN
GENERATOR (SPG)
17-PIN CONNECTOR
S
R
F
24V DC
POWER
T
N
P
E D C
RED
A
104
105
106
107
108
109
110
111
112
113
E D C
RANGE
INDICATOR
SHIFT
SELECTOR
15
1
4
5
8
11
16
17
14
3
2
P
R
S
H
J
N
T
K
M
L
17-PIN SOCKET
Connects to main valve
body wiring harness
V03489
321
PREVENTIVE MAINTENANCE
are available from Allied Electronics or any
similar source.
FuseSFE 9 (1)
Switch, SPSTCutler-Hammer
NOTE:
Sufficient wire and cable covering should be obtained to allow a five foot minimum length from the
16-pin connector to the box.
Switch, DPDTCutler-Hammer
Cable coveringPVC
J
I
H
G
LM
E
I
E
PG O F
SPST
SWITCH (X)
C
B
ON
OFF
12V AUTO
BATTERY
SFE 9 FUSE
AUTO MANUAL
DPDT SWITCH (Y)
V03490
323
CAUTION:
Firm, complete connection of each connector is
important. The pins must not be bent or otherwise damaged. Align the index key and slot. Push
the cable end of the connector firmly into the
socket. Tighten the retainer nut as tightly as possible by hand. Do not use any tool to fasten the
connectors. Push again on the cable end while
working it slightly from side to side. Re-tighten
the nut. Continue pushing the cable end and
tighten the nut until the connection is firm, and
the nut will not tighten further.
4. Test the SFE 9A fuses in both the shift selector
assembly and the lamp bank. If either is blown,
replace it. If the new fuse blows, there is a
ground or short circuit in the shift selector
assembly that must be corrected before
proceeding.
NOTE:
Earlier shift selector assemblies had no integral
fuse. The fuse was in the power input lead (between
the vehicle power circuit and wiring harness conductor M). The fuse in the lamp bank will protect
both the shift selector assembly circuit and the lamp
bank if there is a short circuit.
5. Test the shift selector lamp. Note that the lamp
circuit is independent of the fuse in the shift
324
PREVENTIVE MAINTENANCE
Table 36. Test Light Pattern
Selector Position
R
N
1
2
3
4
5
6
Lamps Lighted
A,B,F,I,J
A,F,I,N
F,H
C,F
D,F
D,G
E,F
E,G
MICROSWITCH SEQUENCE
GAUGE J 24710
H00717
325
VIEW
ROTATION
FROM
THIS END
TAP WITH
HARDWOOD
DOWEL TO
ADJUST
COUNTER
CLOCKWISE
TAP WITH
HARDWOOD
DOWEL TO
ADJUST
CLOCKWISE
VH08249.00.00
CAUTION:
Firm, complete connection of each connector is
important. The pins must not be bent or otherwise damaged. Align the index key and slot. Push
the cable end of the connector firmly into the
socket. Tighten the retainer nut as tightly as possible by hand. Do not use any tool to fasten the
connectors. Push again on the cable end while
working it slightly from side to side. Re-tighten
the nut. Continue pushing the cable end and
tighten the nut until the connection is firm, and
the nut will not tighten further.
326
Lamps Lighted
A,J
C,N
H,I
G,I
F,I
E,I
D,I
C,I
PREVENTIVE MAINTENANCE
tions, but provides a tolerance of movement
sufficient for complete switching transition
from one shift position to the next. All changes
in the light pattern should occur within the
movement tolerance. Table 39 indicates the
light patterns at each test position.
Table 39. Test Lamp Lighting Corresponding to
Shift Pattern
Lamps Lighted When Selector Lever is Pushed
Toward:
Midpoint Test
Upshift
Downshift
Position
Direction
Direction
12
D,I
C,I
23
E,I
D,I
34
F,I
E,I
45
G,I
F,I
5DR
H,I
G,I
DRN
C,N
H,I
NR
A,J
C,N
If the indicated light pattern is not obtained, but a satisfactory
pattern is obtained, angular misalignment of the switch assembly is
indicated.
319. TROUBLESHOOTING
a. Before Removal or Operation
tions at the transmission and cooler. Fluid leakage at splitlines may be caused by loose
mounting bolts or defective gaskets. Tighten
all bolts, plugs and connections where leakage
is found. Test the shift linkage for proper operation (Paragraph 38).
2. The engine and transmission must be regarded
as a single package during troubleshooting. A
thorough study of the description and operation
of the components and hydraulic system will be
helpful in determining the cause of trouble.
b. During Operation
1. If inspection (Paragraph 319a) does not
reveal the cause of trouble, and the vehicle is
operational, further troubleshooting is
necessary. Do not remove the transmission
from the vehicle until the causes of trouble are
compared with the troubleshooting chart.
2. To make a thorough test of the vehiclemounted transmission, be sure the engine is
properly tuned and the fluid level in the
transmission is correct. Refer to Paragraph 33
for checking the fluid level.
c. After Removal from Vehicle. When the
malfunction of the transmission is not ascertained by
tests or inspections before removal from the vehicle,
the transmission may be mounted in a test stand and
checked (if a test stand is available). Particular
attention should be given to proper fluid level and to
correct linkage adjustment in every transmission test.
d. Troubleshooting Chart. Table 310 outlines the
possible causes of transmission troubles and their
remedies as follows:
Capital lettersindicate the symptoms
Numerals following the symptomindicate
possible causes
Corresponding numerals in the right column
indicate remedies for the causes and manual
references.
NOTE:
327
328
WARNING!
Be sure to shut off engine, set the vehicle brake,
and block the wheels before ANY troubleshooting of the electric-shift solenoids. It is important
that electricity NEVER, under any circumstances, be applied to any electric valve body
component while the vehicle engine is running
and the mechanic is under the vehicle. Failure to
shut off the engine and set the brakes could cause
the vehicle to run away if the solenoids are activated by an external power supply. Removal of
the power supply would not stop the run away
vehicle because of the fail-protection system. The
vehicle could only be stopped by applying the vehicle brakes or shutting down the engine.
PREVENTIVE MAINTENANCE
Table 310. Troubleshooting Chart
CAUSE
A.
REMEDY
TRANSMISSION OVERHEATS
Refer to B
Vehicle overloaded
Reduce load
Fluid leaking
Refer to V
Refer to U
Clutch slipping
Water in fluid
329
REMEDY
Overhaul transmission
Driveline failure
Refer to V
Inspect linkage
F.
330
PREVENTIVE MAINTENANCE
Table 310. Troubleshooting Chart (contd)
CAUSE
REMEDY
G. SHIFTING IS ERRATIC
Power source voltage under 18V or faulty 24V overload Test for the following voltages:
protector (24V system); or, power source voltage under
Test terminals 1 and 2 (Figure 216 and 217) of
9V or faulty 12/24V converter (12V system)
overload protector (24V systems). If under 18V,
restore power source.
Test terminals 1 and 2 (Figure 216 and 217). If
under 9V, restore power source.
Test voltage at terminals 3 and 4 (Figure 216
and 217) of the 24V overload protector or the
12/24V converter. If under 18 volts and the power
source voltage is OK, replace the overload protector or converter.
Wiring harness(es) or mating connectors faulty
Faulty SPG*
331
REMEDY
Overhaul transmission
Overhaul transmission
Overhaul transmission
Overhaul transmission
EQUIPMENT WILL OPERATE IN FIRST, THIRD, AND FIFTH RANGES, BUT WILL NOT
OPERATE CORRECTLY IN ALL OTHER RANGES. SOLENOIDS OK.
Splitter-low clutch wont release or splitter-high clutch Overhaul transmission. Inspect splitter clutches for
wont apply, slipping
worn components.
332
PREVENTIVE MAINTENANCE
Table 310. Troubleshooting Chart (contd)
CAUSE
REMEDY
Foaming fluid
Refer to B
Overhaul transmission
Refer to V
Engine malfunction
Aerated fluid
Refer to B
Refer to T
Refer to S
S.
Refer to U
Foaming fluid
Refer to B
333
REMEDY
Foaming fluid
Refer to B
334
PREVENTIVE MAINTENANCE
Table 310. Troubleshooting Chart (contd)
CAUSE
REMEDY
Replace resistor
335
REMEDY
336
PREVENTIVE MAINTENANCE
14
13
2
14
10
12
13
15
11*
12
3
7
3
11
10
4
9
5
4
8
16
17
21
20
18
6
19
* (NO
PASSAGE)
V08250.00.00
1. Second-range clutch
2. Exhaust
3. Intermediate-range
14. Main
4. Reverse clutch
5. First-range clutch
6. Exhaust
7. Exhaust
18. Exhaust
8. Splitter-low clutch
19. Exhaust
9. Splitter-high clutch
10. High-range
21. Exhaust
337
2
23
22
2
10
14
9
13
1
3
11
10
13
14
3
9
7
15
21
4
7
1
16
21
7
17
25
16
20
26
12
20
4
3
7
16
24
15
1
12
14
17
21
19
1
18
14
14
19
14
18
20
18
19
6
20
6
VH08501.00.00
Figure 316. Fluid PassagesOuter Side of Oil Transfer Plate and Control Valve Body
338
1. Second-range clutch
14. Main
2. Exhaust
3. Intermediate-range clutch
4. Reverse clutch
5. First-range clutch
18. Exhaust
6. Exhaust
19. Exhaust
7. Exhaust
8. Splitter-low clutch
21. Exhaust
9. Splitter-high clutch
22. Exhaust
PREVENTIVE MAINTENANCE
1
2
2
3
4
4
V08251.00.00
Figure 317. Fluid PassageTorque Converter Housing and Retarder Control Valve
339
2
1
A
2
7
B
7
8
4
6
5
10
VH07945.01.00
Figure 318. Fluid PassagesTorque Converter Housing and Lockup Shift Valve
NOTE:
When hole is at A, lockup can occur in all ranges and neutral. When hole is at B, lockup can occur only in
third, fourth, fifth, and sixth ranges. When holes are at both locations, lockup can occur in only third, fourth,
fifth, and sixth ranges.
340
PREVENTIVE MAINTENANCE
1
2
3
4
HOUSING
5
6
VALVE BODY
VH07946.00.00
1. Exhaust
2. From oil filter (main)
3. Lubrication
341
2
1
VH07947.00.00
342
PREVENTIVE MAINTENANCE
8
(NO PASSAGE)
1
6
7
6
7
8
9
14
13
5
4
15
9
14
10
13
10
16
11
17
18
19
12
11
20
21
12
V08254.00.00
Figure 321. Fluid PassagesTransmission Housing and Inner Side of Oil Transfer Plate
1. Second-range clutch
12. Exhaust
2. Intermediate-range clutch
3. Exhaust
4. High-range clutch
5. Main
16. Exhaust
7. Exhaust
8. Pitot (governor)
9. Splitter-high clutch
20. Exhaust
11. Exhaust
343
19,92
20,23
73,89
15,77
16,18
17
74
21
6
8,12,40,52,57,61
13,68
9
70,71
75
5,50
4,7
3
11,14
69
10
1,58
22
59,60
2,53
24
25,27
94,95
88,93
66
26
47
48
28
46,51,54
87
86,91
64
83
44,49,56
31,34
29,30,32,35,41,42
43,45,55,65,67
76,78,82,84,85
36,79
33,90
81
38,39,62,63
37,72,80
2
1
6
5
8 10 12 14 16
9 11 13 15 17
18
20
21
19
59
58
57
56
55
54
53
68
67
66
52
51
50
49
48 47
70
71
65
61
46
63
45
44
43
91
90
69
60
62
89
72
73
92
74
75
22
23
94
88
26
27
95
86
76 85
77
28
29
87
64
78 79
81
84
83
80
24
25
93
82
30
31
42
41 40 39 38 37 36
35
34 33 32
Figure 322. Fluid PassagesOuter Side of Oil Transfer Plate and Inner Side of Separator Plate
344
PREVENTIVE MAINTENANCE
1. Exhaust
65. Exhaust
2. Splitter-low solenoid
3. Main
35. Exhaust
67. Exhaust
4. Splitter-high exhaust
68. High-range
69. Main
7. Splitter-high
8. Main
40. Main
41. Exhaust
10. Main
42. Exhaust
11. Exhaust
12. Main
76. Exhaust
45. Exhaust
14. Exhaust
46. Splitter-low
78. Exhaust
48. Exhaust
82. Exhaust
83. Exhaust
84. Exhaust
85. Exhaust
54. Splitter-low
86. Low-range
55. Exhaust
24. Reverse-range
57. Main
58. Exhaust
26. First-range
28. Low-range
61. Main
29. Exhaust
30. Exhaust
95. Main
32. Exhaust
345
4 5,6
2
1
9 11 13
15
73
91 90 20
10 13 14,55 16,69
68 72
17 18 74 89 19 21
59
57
58
60
54
92
22
23
93
52
51,53
49
48,58
94
24
25
47,50
26
88
27
28,86
71
45
70
84 29
30,32,35
82,83,85
43,44
42
31,33
46
66
67
76
34
36
79,80,81
61,95
41
62,64 63 39 40
75 37
65 78 38 77,87
19
20
22
23
24
17
18
15 14 12 10 8 6 4 2
5 3 1
68 13 11 9 7
16
91
90
59
60
58
72
92
93
94
25
26
95
27
28
29
87
88
75
86 77 76
66 67
65
64
84
82
30
57
56
55
54
53
52
51
49 50
48
47
46
45
69
70
73
74
71
89
83
85
81 80
78
61
63
62
44
31
79
43
42
32
33
34 35 36 37 38
39
40
41
V08256.00.00
Figure 323. Fluid PassagesOuter Side of Separator Plate and Inner Side of Valve Body
346
PREVENTIVE MAINTENANCE
1. Exhaust
65. Exhaust
2. Splitter-low solenoid
3. Main
35. Exhaust
67. Exhaust
4. Splitter-high exhaust
68. High-range
69. Main
7. Splitter-high
8. Main
40. Main
41. Exhaust
10. Main
42. Exhaust
11. Exhaust
12. Main
76. Exhaust
45. Exhaust
14. Exhaust
46. Splitter-low
78. Exhaust
48. Exhaust
82. Exhaust
83. Exhaust
84. Exhaust
85. Exhaust
54. Splitter-low
86. Low-range
55. Exhaust
24. Reverse-range
57. Main
58. Exhaust
26. First-range
28. Low-range
61. Main
29. Exhaust
30. Exhaust
95. Main
32. Exhaust
347
3
9
4
2
2
4
5
5
7
7
V08258.00.00
Figure 324. Fluid PassagesOuter Side of Oil Transfer Plate and Inner Side of First-Range Valve Body
348
1.
First-range clutch
2.
Range main
3.
Range main
4.
Range main
5.
6.
Splitter-low
7.
Second-range signal
8.
Exhaust
9.
Exhaust
PREVENTIVE MAINTENANCE
4
4
5,10
5
1
2
3
6
7
6
8
7
8
9
10
13
12
11
11
Figure 325. Fluid PassagesOuter Side Valve Body and Inner Side of Oil Transfer Plate
349
350
SCOPE
42.
PROCEDURES SUBJECT
TO CHANGE
43.
WELDING PROCEDURES
FOR ELECTRONIC
CONTROL EQUIPMENT
CAUTION:
The ECU will be damaged by improper welding
procedures.
1. In sequence, first disconnect the negative, then
disconnect the positive wiring connections
from the battery.
2. If additional electronic system ground wires
are connected to the frame, be sure they are
disconnected.
3. Cover electronic components and wiring to
protect them from damage.
4. Do not connect welding cables to electronic
components.
44.
REMOVAL, INSTALLATION
OF TRANSMISSION
45.
REMOVING WIRING
HARNESSESELECTRIC
SHIFT MODELS
WARNING!
Shut off the power supply from the vehicle electrical system before removing the wiring harnesses. This will prevent any unexpected shifts.
1. Loosen and remove the nuts that attach wiring
harness 140 (Foldout 22) at both of the two-pin
and eight-pin connectors at the first-range shift
and main valve bodies.
2. Pull the socket-type connectors off the valve
body pin connectors.
3. Remove the wire from inhibitor pressure
switch 38 (Foldout 9,B).
4. Loosen and remove the nut which retains wiring harness 140 (Foldout 22) at the bottom of
the selector assembly in the vehicle cab.
5. Pull the sixteen-pin socket off the shift selector
assembly connector.
6. Remove the five conductors (or as many as are
used) from the vehicle power source, ground,
light system, starter circuit, and reverse signal
circuit.
NOTE:
These conductors are identified in Figure 41 as J,
L, M, N, and P. Tag the leads and the corresponding
connection points using the same letters.
41
WARNING!
Shut off the power supply from the vehicle electrical system before removing the wiring harnesses. This will prevent any unexpected shifts.
1. Disconnect all branches (9 leads) of the cab
harness from their connections (Figure 42 or
43 as applicable).
BLACK
TO SWITCH
FRAME
GROUND
TO LIGHT
YELLOW
TO INHIBITOR
FROM
INHIBITOR
L A
K
J
I
MATING
CONNECTORS
B
M N C
P
D
J
O
I
E
H
F
G
K
C
D
P
N E
H O F
M
G
BRANCHES TO
EXTERNAL POINTS
N TO EQUIPMENT STARTER
CIRCUIT (WHITE)
M POWER INPUT (RED)
(24V)
L TO EQUIPMENT LIGHT
CIRCUIT (BLUE)
P TO EQUIPMENT GROUND
(BLACK)
K
SWITCH SECTION
PRESSURE
SWITCH
ON LOCKUP
VALVE BODY
MAIN HARNESS
BRANCH TO 8-PIN CONNECTOR
BRANCH TO 2-PIN CONNECTOR
A
G
C
D
E
F
MATING
CONNECTORS
I
MATING
CONNECTORS
B TO SOLENOID B
B TO SOLENOID I *
H
B
A
WIRING HARNESS
(SELECTOR TO VALVE BODY)
A TO SOLENOID A *
G TO SOLENOID G *
B
A
G
A TO SOLENOID H
C TO SOLENOID C
C
D
D TO SOLENOID D
E
F
E TO SOLENOID E
F TO SOLENOID F
* Not present on Lock-in-neutral models
42
1
TO ENGINE-OIL
PRESSURE SWITCH
(+ INPUT FROM EQUIPMENT)
GREEN TO
REVERSE SIGNAL
EQUIPMENT
FRAME GROUND
BLUE TO
EQUIPMENT
LIGHT SWITCH
RED
BLACK
TO GROUND TERMINAL () OF
EQUIPMENT BATTERY
TERMINAL #
1
2
3
4
BLACK
RED
VOLTAGE
+12
12
+24
24
FROM SHIFT
SELECTOR
V00725.02.00
Figure 42. Negative Ground SystemConnections for 12/24 Volts Converter, or 24 Volt Overload Protector
12V-TO-24V CONVERTER
WHITE Connect in
series with equipment
starter circuit
1
TO GROUND
TERMINAL (+)
OF EQUIPMENT
BATTERY
GREEN TO
REVERSE SIGNAL
EQUIPMENT
FRAME GROUND
BLUE TO
EQUIPMENT
LIGHT SWITCH
RED
BLACK
TO ENGINE-OIL PRESSURE
SWITCH ( INPUT FROM EQUIPMENT)
TERMINAL #
1
2
3
4
BLACK
VOLTAGE
+12
12
+24
24
RED
FROM SHIFT
SELECTOR
43
5. If removal of shift selector 13 or 14 is necessary, remove the attaching hardware and the
shift selector. Refer to Paragraph 639 or Paragraph 640 for rebuild.
6. For replacement, remove the attaching hardware that retains throttle position sensor 20.
Remove the cable hold down and hitch pin.
WARNING!
Removing the wiring harnesses from the transmission while the equipment power supply is ON
can cause unexpected shifts resulting in sudden,
uncontrolled vehicle or equipment movement. To
help avoid injury or property damage, power
from the equipment electrical system must be
switched OFF before disconnecting the transmission wiring.
1. If present, disconnect secondary mode harness
10 (Foldout 25) from ECU 1 and, if necessary,
from any secondary mode or special function
components.
CAUTION:
When removing the harness, disconnect in sequence first the negative, and then the positive,
connections from the battery.
2. Disconnect cab harness 11 from ECU 1 and
shift selector 13 or 14. Disconnect harness 11,
in proper sequence, from the equipment electrical system.
3. Disconnect chassis harness 15 from ECU 1,
throttle position sensor 20, speed sensor 17,
electric lockup valve body assembly 16, main
control valve body assembly 19, and firstrange shift valve body 18.
4. If removal of ECU 1 is necessary, remove the
attaching hardware and the ECU. Do not remove cover 5 or break seal 6 until referring to
Paragraph 641 for CAUTION and instructions.
44
46.
REMOVING LOCKUP
(INHIBITOR) PRESSURE SWITCH
47.
REMOVING REMOTE
COMPONENTS
JUMPER
(IN LATER MODELS
JUMPER IS INTERNAL)
+
EQUIPMENT
BATTERY
3
2
THROTTLE
POTENTIOMETER
ENGINE OIL
PRESSURE SWITCH 201 BLACK
2-PIN CONNECTOR
202 BLACK
209
200 RED
A
219
210
B
C
V
D
B
19-PIN CONNECTOR
A
E
P
N
R
F
M
S
TU
L
G
K
H J
SHIFT PATTERN
GENERATOR
(SPG)
17-PIN
CONNECTOR
SEE NOTE
J
H
F
E
RED
205 RED
203 BLUE
204 GREEN
TO EQUIPMENT
LIGHT SWITCH
J
LK
16-PIN
CONNECTOR
206 BLACK
218
217
216
215
214
213
212
211
208
WHITE
P
H
TO
REVERSE
SIGNAL
G
B
F
E
D N
207 WHITE
In series with equipment
starter circuit
17-PIN
SOCKET
L
110
M
T
S N
R P
C
RANGE INDICATOR
SHIFT
SELECTOR
100
101
A
T D
17-PIN CONNECTOR
102
B
A
111
MAGNETIC
PICKUP
107
106
105
104
TRIM BOOST
VALVE BODY
F H
103
8-PIN CONNECTOR
108
2-PIN
CONNECTORS
MAIN
VALVE
BODY
109
NOTE: For models with range indicator, connect main valve body harness to range indicator harness.
For models without range indicator, connect main valve body harness directly to shift pattern generator.
V08665.00.00
45
INSTALLING REMOTE
ELECTRIC SYSTEM
COMPONENTS
4. Refer to Figure 43, 44, or 45 for identification of branches if not marked at removal.
5. Connect the branches to the equipment leads.
CAUTION:
CAUTION:
installation.
Hand tighten the retaining nut until the connector is completely installed in its socket. Do not
use any tool to tighten the connector.
a. Electronic Control Models
1. If removed, install throttle position sensor 19
(Foldout 30) and attaching hardware. Install
the cable hold down and hitch pin.
2. If removed, install shift selector 13 or 14 and
attaching hardware.
3. If removed, install ECU 1 and attaching hardware.
CAUTION:
When installing the harness, connect in sequence
first the positive, and then the negative, connections to the battery.
4. Connect the chassis harness (Figure 46) to the
ECU (Figure 47), throttle position sensor 19,
magnetic pickup 17, electric lockup valve body
assembly 16, and main control valve body assembly 18.
5. Connect cab harness 11 (Figure 48) to the
ECU (Figure 47) and shift selector 13 or 14.
Connect wiring harness 11 to the equipment
power supply by connecting the positive wire
first, then the negative wire.
6. If removed, install the secondary mode harness
(Figure 49) to the ECU (Figure 47) and to
any previously installed secondary mode or
special function components.
b. Manual-Electric and SPG-Control Models
1. Refer to Figure 43, 44, or 45. Install the
wiring harnesses onto the equipment.
2. Replace all supports and fasteners.
3. Replace all equipment components removed
for access to the wiring harnesses.
46
SHIFT PATTERN
GENERATOR (SPG)
17-PIN CONNECTOR
S
R
F
24V DC
POWER
T
N
P
E D C
RED
A
104
105
106
107
108
109
110
111
112
113
E D C
RANGE
INDICATOR
SHIFT
SELECTOR
15
1
4
5
8
11
16
17
14
3
2
P
R
S
H
J
N
T
K
M
L
17-PIN SOCKET
Connects to main valve
body wiring harness
V03489
47
TOOLS, EQUIPMENT
CAUTION:
Caustic cleaning compounds will damage some
transmission parts. Use only mineral spirits or
cleaning solvents such as PD 680-2 (or equivalent).
Mineral spirits
Retaining ring pliers (internal and external)
Impact wrench
Arbor press
Clean, lint-free shop cloths (do not use waste)
Container for parts
Wood blocks
Oil-soluble grease (for transmission interior)
such as MIL-W-P236 or Amojell
petrolatum (Amoco Oil Co) or equivalent
(refer to Paragraph 413d)
High-temperature grease (for transmission
exterior only) such as MIL-G-81322 Mobile
Grease No. 28 (Mobil Oil Co.), Aeroshell
Grease No. 22 (Shell Oil Co.) or equivalent.
48
Fig. Item
Kent-Moore Tools*
J 7441
46
1
Description
Belleville Spring Compressor
J 7470-A
J 22158-15
46
46
2
3
J 23547
J 23556
J 23559
J 24315-1
4-6
46
46
46
4
5
6
7
J 24315-2
J 24710
46
46
8
9
J 24711
J 24712
J 29853
J 29854
J 29855
J 29852
BT-8639-B
J 35889-A
J 26995
4-6
46
46
46
46
46
46
46
4-6
10
11
12
13
14
15
16
17
18
Fabricated Tools: **
None
47
1
None
47
2
None
47
3
None
47
4
Ref. Paragraph
621a(3), 621b(3),
627a(2), 627b(4)
73c(1)
53c(22), 73i(7)
5-3c(19)
73g(1)
73i(7)
53a(7), 73h(26),
73k(4), 73l(2), 73m(8)
73j(5)
318 c(13)
6-35b(14)
312b(4)
615b(5), 73i(5)
53h(2), 73a(6)
52d
643a(1), 643b(1)
641a(3)
As required
53b(1)
416a(5)
53b(11), 53f(8),
73e(9), 73j(5)
* These tools are manufactured by Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066, and may be obtained
through your local Allison Transmission dealer or distributor.
** These tools are not available from Kent-Moore.
*** These tools are essential for transmission repair or rebuild.
49
1. BELLEVILLE SPRING
COMPRESSOR
5. SUPPORT LEGS
4. CONVERTER TURBINE
PULLER ASSEMBLY
3. SPANNER WRENCH
2. CLUTCH SPRING
COMPRESSOR
16. ANTI-STATIC
WRIST BAND
14. TRANSMISSION
LIFTING FIXTURE
13. CLUTCH AND DRUM
ASSEMBLY LIFTER
18. CHATILLION
MST-50 SPRING
TESTER
410
48 in.
(120 cm)
78 in.
(200 cm)
TROUGH
16-GAUGE SHEET STEEL
112 in. (35 mm) DEEP
112 in. (35 mm) WIDE
24 in.
(60 cm)
2 x 6 in. BOARD
(5 x 15 cm)
FOR TOP FRAME
AND LEG BRACKETS
TRANSMISSION
FLUID DRAIN
(BOTH SIDES)
4 x 4 in. LEGS
(10 x 10 cm)
1. WORK TABLE
0.625 in. (15.9 mm)
HOLE DIA
APPROX
1.5 in.
(38 mm) 0.75 in.
(19.1 mm)
Locate bolt
holes to match
type flange to
be pulled
1.44 in.
(36.6 mm)
R
APPROX
2.5 in. (64 mm)
2. HOLDING FIXTURE
OUTPUT SHAFT
NUT USED
3. FLANGE PULLER
WELD 2 PLACES
4. LIFTING NUT
V08259.00.00
411
WARNING!
Do not burn discarded Teflon seals. Toxic gases
are produced by burning.
The following parts are normally replaced at each
transmission overhaul:
Gaskets
Lockstrips
c. Cleaning Bearings
WARNING!
Never dry bearings with compressed air. A spinning bearing can disintegrate. Also, spinning a
bearing without lubrication can damage the
bearing.
1. Bearings that have been in service should be
thoroughly washed in cleaning solvent.
2. If the bearings are particularly dirty or filled
with hardened grease, soak them in mineral
spirits before trying to clean them.
3. Before inspection, lubricate the bearings with
the same type of fluid that will be used in the
transmission.
d. Inspect Bearings
1. Inspect bearings for roughness of rotation. Replace a bearing if the rotation is still rough after cleaning and lubricating.
2. Inspect bearings for scored, pitted, scratched,
cracked, or chipped races, and excessive wear
of rollers and balls. If one of these defects is
found, replace the bearing.
b. Cleaning Parts
1. Use only mineral spirits on friction-faced
clutch plates and bearings. All other metallic
parts should be cleaned thoroughly with
mineral spirits or by steam-cleaning. Do not
use caustic soda solution for steam-cleaning.
412
CAUTION:
Any bearing that has been subjected to metal
contamination (Paragraph 35b) must be closely
inspected for metal particles. Metal particles will
cause failure of the bearing.
NOTE:
Some torque converters have casting irregularities
near the outer edge of the turbine vanes. These
shut marks are not detrimental to the operation
of the transmission.
6. Inspect all machined surfaces for damage that
could cause fluid leakage or other malfunction
of the part. Rework or replace defective parts.
7. Some parts (especially planetary carriers) may
be discolored (straw colored up to blue). If
only the part itself is discolored (e.g., a carrier
but not the spindles) the color is from manufacturing and does not indicate a problem. But,
if the parts in the area are all discolored
(e.g., both a carrier and spindles), it indicates
excessive heat has occurred and the parts must
be replaced.
g. Inspecting Bushings, Thrust Washers
1. Inspect bushings for scores, burrs, roundness,
sharp edges, and evidence of overheating. Remove scores with crocus cloth. Remove burrs
and sharp edges with a scraper or knife blade.
If bushing is out-of-round, deeply scored, or
excessively worn, replace it, using the proper
size replacer tool. Whenever it is necessary to
cut out a defective bushing, do not damage the
bore into which the bushing fits.
2. Inspect thrust washers for distortion, scores,
burrs, and wear. Replace if defective or worn.
h. Inspecting Oil Seals, Gaskets
1. Replace all sealrings (except hook-type), oil
seals, and composition gaskets.
NOTE:
Do not discard sealrings, oil seals, or composite gaskets until transmission has been rebuilt. Use them
for reference during rebuild.
2. Inspect hook-type sealrings for wear, broken
hooks, or distortion.
3. Install a new hook-type sealring if the ring
shows any wear on the outside circumference,
or if there is excessive side wear. The sides of
413
414
LEVEL SURFACE
CLUTCH PLATE
V00778
CAUTION:
Be sure gasket is in place when using this procedure
Inspect pump gears for end clearance (Figure 49) and
diametrical clearance (Figure 410). End clearance between gears and pump cover is determined by measuring the distance between the gear and a steel straightedge placed across the gear and housing as illustrated
in Figure 49. Diameter clearance between gears and
housing is determined by measuring the distance between the gear teeth and housing (in several places) using a narrow feeler gauge as illustrated in Figure 410.
Replace gears with excessive clearance (refer to Wear
Limits, Section 8).
1. To determine serviceability (Figure 411), inspect the internal gear teeth and external
splines of the ring gear. Part replacement is required for:
Internal teeth:
Scuffed
Nicked
Pitted
Burred
Broken teeth
Teeth with embedded material
Teeth with altered original shape.
STRAIGHT EDGE
External splines:
DRIVE GEAR
Nicked
Burred
Notching deeper than 0.020 inch
(0.51 mm) due to movement of friction
plates
FEELER GAUGE
PUMP BODY
V04053
FEELER GAUGE
DRIVE GEAR
PUMP BODY
PUMP IDLER
GEAR
V04052
415
Melt-through
in weld
RETAINER
V04054
416
CAUTION:
Installing a pipe fitting or plug into a straight-
assembly step and on the exploded views. Inaccurate torque can cause leakage and cracked
housings. Straight-thread O-ring plugs and fittings require different installation torques than
NPTF plugs and fittings. Refer to Table 43 for a
comparison of torque specifications.
4. Reused or Uncoated Plugs, Hydraulic Fittings. Prepare the threads with a small amount
of nonhardening sealant, such as Loctite Pipe
Sealant with Teflon, or equivalent. Do not
use Teflon tape.
Fitting
Description
NPTF
Torque for NPTF
O-ring,
Tapered- Tapered-Thread Fittings StraightThread
Thread
Fitting
English
Metric
Fitting SAE
Size (inch)
(lb ft)
(N.m)
Size (inch) #
English
Metric
20
4753 lb ft
6470 N.m
From-Cooler Connection
114
NPTF
95105
129142
158-12
To-Cooler Connection
114 NPTF
95105
129142
158-12
20
4753 lb ft
6470 N.m
Governor (Converter)
Pressure Tap
18
1012
1416
38-24
2832 lb in.
18
NPTF
1012
1416
38-24
2832 lb in.
3.23.6 N.m
3.23.6 N.m
14
NPTF
1416
1921
12-20
5863 lb in.
114 NPTF
95105
129142
158-12
20
4753 lb ft
34
NPTF
3337
4550
1116-12
12
2426 lb ft
34
NPTF
3337
4550
1116-12
12
2426 lb ft
38
1822
2529
916-18
7080 lb in.
114 NPTF
95105
129142
158-12
20
4753 lb ft
114
95105
129142
158-12
20
4753 lb ft
38
NPTF
1822
2529
916-18
7080 lb in.
Temperature Gauge
Connection
12
NPTF
2327
3236
34-16
38
NPTF
1822
2529
916-18
NPTF
NPTF
NPTF
6.57.1 N.m
6470 N.m
3235 N.m
3235 N.m
7.99.0 Nm
6470 N.m
6470 N.m
7.99.0 N.m
7.99.0 Nm
417
SEALING
SURFACE
MALE
O-RING
PORT
END
O-RING SEAL
(Threads provide holding power
to resist pressure blowout)
FEMALE
O-RING
PORT
METAL-TO-METAL SEAL
(Accomplished by wedging action
of tapered pipe threads)
418
CAUTION:
Do not use gasket-type sealing compounds, fi-
CAUTION:
Do not use high temperature grease on other
transmission internal parts.
2. Precoated Seals. The circumference of some
seals is precoated with a dry sealant. The sealant is usually colored for easy identification.
The precoated seals do not require any additional sealant before installation.
3. Uncoated Seals. Prepare the circumference of
uncoated seals with a non hardening sealant
such as Permatex No. 2, or equivalent before
installation.
g. Interference-Fit Parts
WARNING!
Do not handle heated or chilled parts with bare
hands, always use appropriate hand protection.
Assembly of interference-fit parts may be
accomplished by heating and chilling the respective
parts. Either one or both parts may require this thermal
process. The expanding part can be heated in a rod
oven to 300F (149C). The contracting part can be
chilled in dry ice. If the chill process is used for a
ferrous alloy part, coat the components with
419
d. Install Transmission
1. Reconnect all items during installation that
were removed in Paragraph 44. Use Loctite
Pipe Sealant with Teflon, or equivalent, for
thread sealing on hydraulic, air, and other
threaded fittings. DO NOT USE Teflon tape.
Loose slivers of tape can plug orifices, cause
valves to stick, interfere with check ball operation, and insulate components that are
grounded through threaded connections.
2. A transmission jack is convenient to raise the
transmission into mounting position. Fill the
transmission with fluid (Paragraph 34). Do a
running test of the transmission after installation into the equipment.
SCRIBE MARKS
INPUT
NUT
RETAINER
PLATE
INPUT FLANGE
H00782
OUTPUT
FLANGE
HOLDING
BAR
H03961
CAUTION:
A puller placed on the OD of the flange may de-
CAUTION:
Do not use a pry bar or hammer to force the
flange at disassembly.
CAUTION:
Install the flange immediately after it is removed
b. Installing Flanges
OUTPUT FLANGE
TORQUE
WRENCH
HOLDING
BAR
HOLDING BOLTS
H04051
421
WARNING!
Toxic gases are produced by burning Teflon.
Exposure to these gases is extremely hazardous
and can be fatal. DO NOT BURN discarded
Teflon sealrings.
NOTE:
These instructions apply to the installation of both
lip-type Teflon sealrings and Teflon sealrings that
require expanders.
Typical external
type seal expander
Typical internal
type seal expander
VIEW A
VIEW B
V03502
a. Removal
1. Insert a thin, bladed tool into the sealring
groove and work one edge of the sealring out,
where it can be grasped with the fingers. Replace all sealrings during transmission overhaul.
2. If present, remove the sealring expander.
3. Clean the groove thoroughly and make sure
there are no burrs or rough spots in the groove
sides or bottom.
b. Installation (Sealrings With Expanders)
1. Lightly coat the piston housing and the piston
hub seal surface with Type C-4 fluid or oilsoluble grease, but do not pack the sealring
groove with grease.
2. Coil the expanders as shown in Figure 416.
Inspect the ends for curvature toward the
bottom of the groove (inward for external
grooves; outward for internal grooves). If
necessary bend the ends 0.25 inch (6 mm)
minimum radius so the sharp ends will not
gouge the seal.
CAUTION:
If lip-type sealrings are installed incorrectly, the
clutches will not operate properly.
1. Lightly coat the piston housing and the piston
hub seal surface with Type C-4 fluid or oilsoluble grease, but do not pack the sealring
groove with grease.
422
Read backlash
on indicator
Hold
indicator
stationary
TRANSMISSION
HOUSING
PITCH LINE
(APPROX. MIDDLE
OF TOOTH)
1
INDICATOR CONTACT
CAUTION:
The backlash in power takeoff (PTO) installations should be carefully tested. Excessive or insufficient backlash can result in damage to the
transmission and PTO assembly.
When instructions are not immediately available from
the vehicle manufacturer, use the following method to
determine proper backlash.
PTO OUTPUT
PTO HOUSING
Read backlash
on indicator
3
Hold
indicator
stationary
PITCH LINE (APPROX.
MIDDLE OF TOOTH)
INDICATOR CONTACT
V02781.02
MEASUREMENT POINT
R Radius equivalent
to radius of PTO
input drive gear
STEEL STRAP
R
R
PTO OUTPUT
SHAFT
PTO
HOUSING
3
CLAMP
TRANSMISSION
HOUSING
V02780.02
1
Hold transmission
drive gear
V02782.02
423
424
SCOPE
Paragraph
Title
635
Shift Selector
Manual-Electric Control
636
637
638
639
640
641
CAUTION:
642
643
52.
a. Preparation for Disassembly. Before disassembling the transmission, disconnect all hydraulic, electrical, electronic and mechanical lines, sensors, and
harnesses that may be attached to the transmission.
Remove transmission-related components from the
equipment cab and/or chassis as necessary.
b. Removing Control Components
Title
49
Tools, Equipment
WARNING!
410
Replacement Parts
Removing the wiring harnesses from the transmission while the equipment power supply is ON
can cause unexpected shifts resulting in sudden,
uncontrolled equipment movement. To help
avoid injury or property damage, power from
the equipment electrical system must be
switched OFF before disconnecting the transmission wiring.
411
Careful Handling
412
Cleaning, Inspection
413
Assembly Procedures
417
Tight-Fit Flanges
81
82
Spring Data
CAUTION:
d. Lifting, Handling
WARNING!
51
53.
TRANSMISSION DISASSEMBLY
ALL MODELS
TOP PTO
MOUNTING PAD
REAR HOUSING
TORQUE
CONVERTER
HOUSING
MAIN HOUSING
LOCKWASHER (5)
AND NUT (5), 12-13
BOLT (11), 12-13 x 314 in.
AND LOCKWASHER (11)
INPUT BEARING
RETAINER
VH03979.00.03
Figure 51. DP 8000 Transmission with Lifting Fixture Attached to Lifting Pad
52
DISASSEMBLY OF TRANSMISSION
4. The parking brake can be serviced while
installed on the transmission or can be
removed as an assembly. Remove ten bolts 39
and 41 (Foldout 19,B), ten flat washers 40, ten
nuts 1, ten lockwashers 2, and ten flat
washers 3 (Figure 55). Lift off the brake
assembly. Refer to Paragraph 633 and 634
for rebuild.
5. Remove bolts 27 (Foldout 18,B) and
lockwashers 26. Remove cover 38 or the
speedometer drive assembly 22 (Figure 56).
Remove washer 21 and shaft and gear 19.
Remove and discard gasket 20.
LIFTING
PAD
OUTPUT
FLANGE
MOUNTING
YOKE
BOLT (8),
34-16 x 112 in.
ROLLOVER
STAND
BRAKE
DRUM
VH03963.00.00
INPUT
NUT
RETAINER
PLATE
INPUT FLANGE
BRAKE ASSEMBLY
VH03964.00.00
VH00782.00.01
53
OUTPUT
FLANGE
BEARING
RETAINER
PLATE
NOTE:
For models with filters attached to the transmis-
Step (11).
VH08326.00.00
RETARDER
CONTROL
VALVE
GASKET
VH03966.00.00
NOTE:
For electronic control models, proceed with
Step (14).
For models with non-electric or SPG-control
DISASSEMBLY OF TRANSMISSION
FILTER
FILTER BASE
BOLT
MAIN-PRESSURE
REGULATOR
VALVE
GASKET
DRAIN PLUGS
MAIN-PRESSURE
REGULATOR VALVE
SPLIT
FLANGE
GASKET
VH03967.00.00
HIGH-EFFICIENCY
FILTERS
VH03968.00.00
FILTER
BASE
DRAIN
PLUG (2)
GASKET
MAIN-PRESSURE
REGULATOR
VALVE BODY
BOLT AND
FLAT WASHER (3),
7 16-14 x 31 2 in.
VH00792.00.02
55
SPLIT FLANGE
GASKET
BOLT (4)
OIL TRANSFER
PLATE
GUIDE PIN (2)
J-24315-1
MAIN-PRESSURE
TRANSFER TUBE
ASSEMBLY
A
BOLTS
GASKET
SIDE PTO
PAD COVER
LOCKUP
CLUTCH
CONTROL
VALVE
BODY
SPLIT FLANGE
HYDRAULIC
CONTROL
VALVE BODY
VH08260.00.00
GUIDE BOLTS
GASKET
GASKET
MAIN-PRESSURE
TRANSFER TUBE
ASSEMBLY
SPLIT
FLANGE
SIDE PTO
PAD COVER
GASKET
VH03970.00.00
SPEEDOMETER
DRIVE
GASKET
VH08261.00.00
DISASSEMBLY OF TRANSMISSION
25. Remove four bolts that attach the oil transfer
plate. Remove the oil transfer plate, gasket,
and headless guide bolts (Figure 513). Remove check valve components 3 through 6
(Foldout 21,A) from the transfer plate.
HOSE
JUMPER TUBE
BOLT
VH00800.00.00
GASKET
STRAINER
ASSEMBLY
DRAIN PLUG
BOLT (4), 38-16 x 5 in.
AND LOCKWASHER (4)
BOLT (24), 38-16 x 118 in.
AND LOCKWASHER (24)
VH03976.00.00
31. If the four long bolts (Figure 516) are not accessible, remove them in Step (32).
32. Remove oil pan 3. Remove and discard
gasket 1. From the underside of the transmission, remove two bolts and lockwashers that
secure the torque converter housing to the
transmission housing (Figure 517) Remove
the sump return tube.
MAIN
HOUSING
TORQUE
CONVERTER
HOUSING
VH03978.00.00
57
CAUTION:
Be careful not to damage the sealing surfaces between the converter housing and input bearing
retainer when separating the components.
4. Separate the torque converter housing from the
input bearing retainer (Figure 520). Remove
and discard gasket 21 (Foldout 20,B).
CAUTION:
Be careful not to damage the converter housing
studs when lowering the assembly onto wood
blocks.
5. For remote-mount models, attach a hoist and
fabricated lifting nut with hook (Figure 47) to
the turbine shaft. For direct-mount models,
attach a second sling. Lower the converter
housing assembly onto 4 x 4 inch wood blocks
(Figures 521 and 522). Remove the slings
and lifting devices from the converter housing
assembly.
6. Remove nine bolts 1 (Foldout 10,A) and
lockwashers 2 from the outer bolt circle of
main and scavenge pump assembly 16 (Figure
522). Loosen the nuts at the torque converter
housing ends of the transfer tubes. For earlier
58
NOTE:
For remote-mount models, proceed with Step (7).
For direct-mount models, proceed to Step (12).
HOLDING
FIXTURE
INPUT BEARING
RETAINER
MAIN
HOUSING
VH03980.00.00
DISASSEMBLY OF TRANSMISSION
TOP PTO
MOUNTING PAD
REAR HOUSING
TORQUE
CONVERTER
HOUSING
MAIN HOUSING
LOCKWASHER (5)
AND NUT (5), 12-13
BOLT (11), 12-13 x 314 in.
AND LOCKWASHER (11)
INPUT BEARING
RETAINER
VH03979.02.00
ACCESS HOLES
(EARLIER MODELS ONLY)
GASKET
VH08503.00.00
59
TORQUE
CONVERTER
HOUSING
FRONT COVER
LIFTING
HOOK
LIFTING NUT
GASKET
TORQUE
CONVERTER
HOUSING
STUD (5)
WOOD
BLOCKS (2)
4 x 4 in.
VH03984.00.00
VH03982.00.00
.
BOLT (16),
12-20
212 in.
FRONT COVER
TORQUE
CONVERTER
DRIVE HOUSING
ASSEMBLY
LOCKWASHER (16)
AND NUT (16)
GASKET
PTO OPENING
WOOD
BLOCKS (2)
4 x 4 in.
TRANSFER TUBE
ASSEMBLIES
510
VH03985.00.00
VH03983.00.00
DISASSEMBLY OF TRANSMISSION
10. Remove twenty-four bolts 22 and flat washers 21
(Foldout 7,A) from torque converter drive
housing 10 (Figure 524).
LIFTING NUT
TORQUE
CONVERTER
DRIVE
HOUSING
WARNING!
Lifting the torque converter drive housing from
the transmission can dislodge lockup clutch
parts from the housing or assembly. To avoid
injury from falling parts, stay clear of the area
beneath the raised components and do not
attempt to hold the parts in the assembly using
your hands.
11. Attach a fabricated lifting nut (Figure 47) to
the input shaft (Figure 525). Slightly lift the
torque converter drive housing using a hoist.
Tap the housing with a plastic-faced hammer to
loosen the lockup clutch plates. Remove the
torque converter drive housing and attached
parts. Refer to Paragraph 629 to rebuild the
torque converter drive housing.
12. For direct-mount models, remove twelve
bolts 1 (Foldout 7,B), flexplate assembly 2,
and gasket 24, if present. Refer to Paragraph
630 to rebuild the flexplate assembly.
STEP-JOINT SEALRING
TORQUE CONVERTER
TURBINE SHAFT
RETAINING RING
LOCKUP
CLUTCH
PLATES
LOCKUP CLUTCH
BACKPLATE
VH03986.00.00
FLYWHEEL
ASSEMBLY
TORQUE CONVERTER
HOUSING
BOLT (36)
PTO OPENING
VH03987.00.00
WARNING!
Lifting the flywheel assembly from the transmission can dislodge lockup clutch parts from the
housing or assembly. To avoid injury from falling
parts, stay clear of the area beneath the raised
components and do not attempt to hold the parts
in the assembly using your hands.
15. Attach a sling to the flywheel assembly (Figure
527) and, using a hoist, slightly lift the flywheel assembly. Tap the flywheel assembly
with a plastic-faced hammer to loosen the
lockup clutch plates. Remove the flywheel assembly. Refer to Paragraph 631 to rebuild the
flywheel assembly.
511
FLYWHEEL
ASSEMBLY
TORQUE CONVERTER
TURBINE SHAFT
LOCKUP CLUTCH
BACKPLATE
STEP-JOINT SEALRING
RETAINING
RING
LOCKUP CLUTCH
PLATES
VH03988.00.00
TURBINE
PULLER
J 23547
BEARING
RACE
PRESS
TOOL
TORQUE
CONVERTER
TURBINE
CAUTION:
Later models use a bolted turbine assembly for
increased reliability. Upgrade to the bolted turbine is recommended at overhaul, and the earlier
riveted turbine must be replaced at overhaul if:
Input power for the specific transmission application exceeds 800 hp.
Loose rivets are observed when the assembly is
heated to normal transmission operating temperature (160275F; 71135C).
Total operating hours on the turbine assembly
have reached the limits suggested for parts replacement (refer to Table 42).
VH08515.00.00
SPANNER NUT
VH03990.00.00
DISASSEMBLY OF TRANSMISSION
TORQUE
CONVERTER
STATOR
ASSEMBLY
STATOR FREEWHEEL
ROLLER RACE
TORQUE CONVERTER
PUMP
SPANNER WRENCH
J 22158-15
THRUST
WASHER
STATOR
BACKPLATE
VH03994.00.00
TORQUE CONVERTER
PUMP ASSEMBLY
VH03991.00.00
STATOR ASSEMBLY
TOOL J 29853
SPINDLE
BALL
BEARING
OIL PUMP
DRIVER IDLER
GEAR
SPINDLE
BOLT AND
LOCKWASHER
POWER
TAKEOFF
GEAR
BALL
BEARING
STATOR RACE
VH03995.00.00
VH03992.00.00
TORQUE CONVERTER
STATOR ASSEMBLY
STATOR ASSEMBLY
TOOL J 29853
VH03993.00.00
513
TORQUE CONVERTER
HOUSING
SELF-LOCKING
BOLT (6), 12-13 x 3 in.
VH03996.00.00
SLING
NOTE:
POWER TAKEOFF
MOUNTING PAD
ROTOR
RETAINER
PLATE
RETARDER
ROTOR
(EARIER
MODELS)
GUIDE BOLT
OIL PUMP
DRIVER
IDLER GEAR
SEALRING
BOLT
(6)
VH08264.00.00
VH04284.00.00
514
DISASSEMBLY OF TRANSMISSION
RETARDER ROTOR
SEALRING
SEALRING
TORQUE
CONVERTER
TURBINE
SHAFT
TURBINE SHAFT
SLEEVE
BEARING RETAINER
VH04073.00.00
TORQUE
CONVERTER
GROUND
SLEEVE
TORQUE
CONVERTER
HOUSING
10. If necessary for parts replacement, remove retarder rotor 33, retainer 32, bearing 31, and turbine shaft sleeve 28 from turbine shaft 27.
Press the retarder rotor from the turbine shaft.
ACCESSORY DRIVE
GASKET
RETAINING
RING
ACCESSORY
DRIVE COVER
VH03997.00.00
515
OIL PUMP
DRIVE GEAR
HUB
TORQUE CONVERTER
HOUSING
BEARING
CONVERTER HOUSING
BEARING
VH03998.00.00
VH08265.00.00
516
DISASSEMBLY OF TRANSMISSION
MUST BE CLEAN AND FREE FROM BURRS
0.5290.541
6 PLACES
AS SHOWN
A
3.938
(in.)
0.375
0.529
0.541
1.090
1.229
1.856
2.007
2.656
4.372
4.750
1.856
1.229
SURFACE
SECTION
8.500 DIA
BC
100.03
109.35
111.05
116.54
120.65
128.80
130.05
215.90
4.588
X
CAUTION:
SPOTFACE
CLEANUP
MUST NOT
EXCEED
THE 5.071 IN.
DIMENSION
EVEN IF
COMPLETE
CLEANUP
IS NOT
ACHIEVED
AA
REF
B
B
2.007
9.53
13.44
13.74
27.69
31.22
47.14
50.98
67.46
(mm)
(in.)
3.938
4.305
4.372
4.588
4.750
5.071
5.120
8.500
2.656
2.656
(mm)
0.375 R
MIN
5.0715.120
2.007
SURFACE
SECTION
BB
V08266.00.00
HOLDING
FIXTURE
INPUT
BEARING
RETAINER
LOCKSTRIP
PITOT TUBE
RETAINING
BOLT (2)
MAIN HOUSING
VH03999.00.00
517
GASKET
SPLITTER-HIGH CLUTCH
AND DRUM ASSEMBLY
VH04253.00.00
SPLITTER-LOW
CLUTCH
ASSEMBLY
RETAINING
RING
SPLITTER
PLANETARY
CARRIER
ASSEMBLY
CLUTCH
HUB
VH08267.00.00
DISASSEMBLY OF TRANSMISSION
SPLITTER
CLUTCH
HUB
PRESS
RAM
RETAINING RING
SPLITTER-HIGH PISTON
CLUTCH ANCHOR
PRESS
TOOL
KEY
VH04003.00.00
SPLITTER-HIGH
BACKPLATE
VH08269.00.00
SPLITTER-HIGH
CLUTCH PLATE (8)
SPACER RETAINER AND BOLT
VH08268.00.00
9. Remove fourteen piston return springs 2 (Foldout 12,B) and spring guides 6.
10. Remove the retaining ring from the forward
end of the splitter output shaft (Figure 548).
Remove the two keys, clutch anchor, and
splitter-high piston and piston housing.
11. Turn splitter-high clutch piston housing 18
(Foldout 12,B) with the piston down and bump
the housing on the work table to remove
splitter-high clutch piston 16. Remove oil
seal 15 and 17 from the piston.
519
SOCKET WRENCH
TYPICAL
OUTPUT
FLANGE
BEARING
RETAINER
BOLT (12)
TRANSMISSION
REAR COVER
BOLT (27)
VH08271.00.00
WOOD BLOCKS
VH08270.00.00
WARNING!
Removing the rear housing from the transmission can dislodge the piston. To avoid injury from
falling parts, support the piston while transferring the housing to the work surface.
520
BEARING RETAINER
SEAL
GASKET
VH04278.00.00
DISASSEMBLY OF TRANSMISSION
REVERSE-RANGE
PISTON
SPEEDOMETER
DRIVE GEAR
BEARING
SEAL
TRANSMISSION
REAR COVER
KEYWAY (2)
MAGNETIC
PICKUP PLUG
TRANSMISSION
REAR COVER
VH08272.00.00
VH08517.00.00
1. Remove two bolts from the reverse-range planetary carrier assembly. Attach the lifting sling
and remove the carrier assembly (Figure 555).
Remove the reverse-range ring gear and eight
clutch plates. Refer to Paragraph 623 to rebuild the reverse-range planetary carrier.
2. Remove four external-splined clutch plates 7
and four internal-splined clutch plates 6
(Foldout 18,A) reverse-range clutch plates
from reverse-range ring gear.
3. Remove one remaining external-splined clutch
plate 4 and one internal-splined clutch plate 3.
GASKET
VH08516.00.00
4. Remove retaining ring 2 that secures the firstand reverse-range clutch backplate (Figure 5
56). Remove the backplate. Remove the
remaining retaining ring 10 (Foldout 17,A).
5. Remove sixteen spring guide pins from the firstand reverse-range clutch anchor (Figure 557).
6. Attach the lifting sling to the first- and reverserange clutch anchor and remove the anchor
(Figure 558). Remove sixteen springs. Some
earlier models use springs 5 (Foldout 17,A)
and guide pins 4. Refer to Parts Catalog,
PC1249EN.
7. Remove six internal and six external-splined
first-range clutch plates 8 and 9 (Figure 558).
521
FLUID
COLLECTOR
RING
BOLT WITH
WASHER (6)
SPRING
GUIDE PIN
(16)
ANCHOR
REVERSE-RANGE
PLANETARY
CARRIER
ASSEMBLY
SUN GEAR
VH04013.00.00
VH08273.00.00
RETAINING
RING
SPACER
REVERSERANGE SUN
GEAR
RETAINING
RING
SPRING
(16)
FIRST-RANGE
CLUTCH PLATE
V06889.00.00
VH08519.00.00
522
DISASSEMBLY OF TRANSMISSION
8. Remove the retaining ring, reverse-range sun
gear, and spacer from the shaft (Figure 558).
Attach the fabricated lifting nut (Figure 47,
Item 4) to the first-range carrier assembly.
Remove the assembly carefully, watching the
underneath side for parts which might drop out
(Figure 559).
FABRICATED
LIFTING NUT
FIRST-RANGE
PLANETARY
CARRIER
ASSEMBLY
FIRST-RANGE
RING GEAR
10. Remove the first-range sun gear from the firstrange carrier assembly (Figure 560). Remove
bronze thrust washer 14 (Foldout 16,B) from
carrier assembly. Refer to Paragraph 624 to
rebuild the first-range planetary assembly.
11. Install a T-bar or bolt to act as a retainer to hold
the clutch pack in position (Figure 561). Remove four housing bolts. Be sure to loosen
them evenly because of clutch spring force.
Tap on the low-range clutch piston housing
with a soft hammer to loosen it.
12. Attach the lifting sling to the first-and secondrange clutch piston housing and remove the
piston housing, first-range ring gear, and
second-range carrier, as an assembly (Figure
562). Remove the gasket.
VH08274.00.00
FIRST-RANGE
PLANETARY
CARRIER
ASSEMBLY
FIRST-RANGE
SUN GEAR
13. Lower the first-and second-range clutch piston housing and assembled parts onto the
work bench. Remove the retaining ring that
secures the hub of the second-range carrier
(Figure 563).
14. Using the lift sling, lift the piston housing and
ring gear as an assembly from the secondrange carrier (Figure 564). Refer to Paragraph
625 to rebuild the second-range planetary assembly.
SLEEVE
BEARING
VH08275.00.00
523
FIRST-RANGE
CLUTCH PISTON
LOW-RANGE
PISTON HOUSING
SECOND-RANGE
PLANETARY CARRIER
RETAINING RING
FIRST-RANGE
RING GEAR
PISTON
HOUSING
T-BAR
MAIN
HOUSING
VH08276.00.00
FIRST-RANGE
RING GEAR
PISTON
HOUSING
FIRST-RANGE
CLUTCH
PISTON
FIRST-RANGE
RING GEAR
GASKET
SPRING
GUIDE PINS
SPLITTER
SHAFT
SUN GEAR
SECONDRANGE
PLANETARY
CARRIER
PISTON HOUSING
T-BAR
VH08509.00.00
SECOND-RANGE
PLANETARY CARRIER
VH08277.00.00
DISASSEMBLY OF TRANSMISSION
18. Remove bearing 13 (Foldout 16,A) and bearing retainer 14 from first-range ring gear hub 6
(Foldout 16,B).
WARNING!
If greater than OSHA approved compressed
shop air is required to remove the first-range
clutch piston (Figure 566) from its bore, bolt a
steel bar across the housing and apply increased
air pressure (100 psi (689 kPa) maximum). Failure to install the steel bar to restrain the piston
could allow the piston to fly out of its housing
bore.
21. Position the piston housing on its side and apply compressed air in the piston-apply oil port.
Remove second-range piston 9 (Foldout 16,A).
Remove seals 7 and 8 from piston 9.
NOTE:
On later models, second-range piston 9 has two lubrication orifices: the piston in earlier models does
not. It is recommended that the piston used in earlier models be replaced with the improved piston.
22. Remove fourteen second-range piston return
springs 5. Remove guide pins, if present.
23. Remove eight self-locking bolts that secure
the retainers and oil collector ring to the intermediate-range planetary carrier (Figure 567).
Remove the four retainers.
24. Remove the second-range ring gear (Figure
567).
PISTON
HOUSING
FIRST-RANGE
CLUTCH PISTON
VH04026.00.01
SECOND-RANGE
CLUTCH ANCHOR
SECOND-RANGE
RING GEAR
KEY (2)
FIRST-RANGE
RING GEAR
RETAINER (4)
PISTON
HOUSING
FIRST-RANGE
CLUTCH PISTON
CLUTCH APPLY
PORT
VH04027.00.01
VH08278.00.00
525
BEARING RACE
(EARILIER MODELS)
SUN
GEAR
VH08280.00.00
INTERMEDIATE-RANGE
PLANETARY ASSEMBLY
CLUTCH PLATE
RING GEAR
KEY (2)
HIGH-RANGE
CLUTCH
ASSEMBLY
SUN GEAR
VH08279.00.00
526
VH08497.00.00
DISASSEMBLY OF TRANSMISSION
7. Remove the two keys from the transmission
housing (Figure 570).
8. Place the splitter output shaft and intermediaterange carrier assembly on the work bench in a
horizontal position (Figure 571). Holding the
carrier with one hand, tap on the splitter shaft
with a soft hammer to remove the shaft, the
collector ring, ball bearing, and the bearing
inner race (earlier models). Refer to Paragraph
626 to rebuild the intermediate-range
planetary assembly.
9. Remove bearing 11 (Foldout 14,B) and oil
collector ring 14 from the splitter shaft. If
necessary, remove the bearing race (earlier
models) with a pry bar or a bearing puller.
Remove the sealring from the carrier (Figure
571).
h. Removing High-Range Clutch, Gearing
1. Remove intermediate-range sun gear 1 (Foldout 14,B) from the transmission housing.
2. Using lifter J 29854 (Figure 572), or other
suitable lifter, remove the high-range clutch
assembly (Figure 572).
3. Refer to Paragraph 627 to rebuild the highrange clutch assembly.
CAUTION:
Hub 20 (Foldout 13,B) may fall free when the
bolts are removed from bearing retainer 18
(Foldout 13,A).
6. Through the access holes provided in the
splitter ring gear hub, remove six retainer bolts
from the bearing retainer (Figure 573).
Remove, as a unit, splitter-high ring gear 10
(Foldout 13,A), splitter-high ring gear hub 14,
bearing retainer 18, and bearing 19. Tap on
hub 20 (Foldout 13,B) to remove it from the
transmission housing. Refer to Paragraph 628
to rebuild the transmission main housing
assembly.
7. Remove retaining ring 15 (Foldout 13,A) to
separate splitter-high ring gear 10 from
splitter-high ring gear hub 14. Remove bearing
retainer 18, bearing 19, and sealring 13 from
hub 14.
8. Conduct a stack and runout check of the rear
components as described in Paragraph 632.
SPLITTER
OUTPUT
SHAFT
PLANETARY
CARRIER
ASSEMBLY
HIGH-RANGE CLUTCH
AND DRUM ASSEMBLY
BEARING RACE
(EARLIER MODELS)
OIL COLLECTOR RING
SEALRING
VH08520.00.00
VH04033.00.00
527
RETAINER
BOLTS (6)
VH08521.00.00
HOSE
54.
TRANSMISSION DISASSEMBLY
REMOTE-MOUNT MODELS
WITH DROPBOX
BOLT
VH00800.00.00
7. Remove
twenty-eight
bolts
23
and
lockwashers 22. Remove oil drain cover 18.
Remove hose clamps 19 and 21 and drain
hose 20.
8. Remove eight bolts and lockwashers from the
power takeoff (PTO) cover and remove the
cover (Figure 511). Remove and discard the
gasket.
9. Attach a sling to the power takeoff mounting
pad and support the converter housing with the
hoist.
10. Remove bolts 30 (Foldout 13,B) and the two
bolts reached through the bottom opening of
the transmission housing (Figure 517). Remove the sump return tube.
11. Remove five nuts 15 (Foldout 13,B) and lockwashers 14. Remove thirteen remaining bolts
that retain the torque converter housing and
bearing retainer.
DISASSEMBLY OF TRANSMISSION
12. Remove as a unit, the torque converter housing
and attached parts (Figure 520). Tap on the
converter housing with a soft hammer to
loosen the converter housing. Remove and discard the gasket.
WARNING!
13. Lower the converter housing and attached parts
onto 4 x 4 wood blocks using care that the converter housing studs and the hydraulic retarder
rotor are clear of the blocks and work table
(Figure 521).
14. Using a 318 inch socket wrench, remove the
input flange nut and washer, remove the flange.
Refer to Paragraph 411.
15. Remove nine bolts 1 (Foldout 10,A) and lockwashers 2. Remove pump assembly 16 and
gasket 37. Remove screen 36 from the pump.
Refer to Paragraph 613 to rebuild the pump
assembly.
16. Remove items 38 through 47, items 53 through
63, and items 65 through 69 from the converter
housing.
17. Remove sixteen nuts 13, lockwashers 12, and
bolts 5 (Foldout 7,A) that attach the transmission front cover 6 (Figure 522).
18. Follow the procedures in Paragraph 53b(11)
through 53c(11).
19. Remove items 1 through 6 (Foldout 11,A)
from the converter housing. Remove items 67
through 72.
20. Follow the procedures in Paragraph 53c(3)
through (10).
21. Remove items 26 through 32 (Foldout 11,A)
and items 65 and 66. Remove items 59 through
62, items 52 through 58, and items 63 and 64.
Refer to Paragraph 618 to rebuild the converter housing.
22. Follow the procedures in Paragraph 53d Steps
(1) through (12) to remove splitter-low
clutches.
23. Attach the lifting sling to the mounting pads of
the transmission rear cover assembly 14 (Foldout 19,A), and position the transmission, front
down, on wood blocks (Figure 549).
55.
TRANSMISSION DISASSEMBLY
DIRECT-MOUNT MODEL
a. Model Variation. The disassembly of the directmount model is the same as described in Paragraph 53,
except for removing the flywheel (Paragraph 55b).
Refer to Paragraph 630 to remove and rebuild the
flexplate assembly.
b. Removing Flywheel
1. Follow the steps in Paragraph 53a(1) through
53b(5), and 53b Steps (7), (8), and (9).
529
WARNING!
The lockup clutch piston and sealring may stay
with the flywheel or with the lockup clutch in the
converter housing. When handling the flywheel,
use care that the lockup clutch piston not fall out
and injure personnel.
BRAKE
DRUM
56.
TRANSMISSION DISASSEMBLY
PARKING BRAKE MODEL
VH08522.00.00
a. Model Variation. The disassembly of the parking brake model is the same as described in Paragraphs 53, 54, or 55, except for removing the
parking brake (Paragraph 56b).
BOLT AND
LOCKWASHER
(10)
BRAKE ASSEMBLY
VH03964.00.00
DISASSEMBLY OF TRANSMISSION
57.
NOTE:
Go to Paragraph 53a(12).
531
B
BOLT, 38-16 x 5 in. (2 MARKED E)
2632 lb ft (3643 Nm) TORQUE
FLAT WASHER,
38 in. (3)
GASKET Q
OIL TRANSFER
PLATE P
G
G
C
BOLT
COPPER WASHER (2)
(2 MARKED R)
VALVE BODY H
GASKET I
OIL TRANSFR
PLATE J
GASKET M
B
D
F
B
GASKET K
BOLT,
38-16 x 114 in.
(2 MARKED F)
2632 lb ft
(3643 Nm)
TORQUE
GASKET O
FLAT WASHER,
38 in. (2)
A
A
D
VALVE BODY L
BOLT
COPPER WASHER (1)
(1 MARKED S)
COPPER WASHER, 38 in. (8)
BOLT, 38-16 x 16 in. (8 MARKED D)
2632 lb ft (3643 Nm) TORQUE
SEPARATOR
PLATE N
S
D
7.400 in.
3.080 in.
V08282.00.00
532
DISASSEMBLY OF TRANSMISSION
2.800
(71.12)
1.500 (38.10)
1.100 (27.94)
9.280
(235.71)
V08283.00.00
533
534
SCOPE
62.
63.
Title
49
Tools, Equipment
410
Replacement Parts
411
Careful Handling
412
Cleaning, Inspection
413
Assembly Procedures
418
Teflon Sealrings
420
Torque Specifications
81
82
Spring Data
HYDRAULIC RETARDER
CONTROL VALVE ASSEMBLY
NOTE:
valve
valve
61
FILTER ASSEMBLY
(Earlier Models)
65.
FILTER ASSEMBLY
(High-Efficiency Filters)
a. Disassembly
1. Unscrew and remove differential pressure (P)
switch 52 (Foldout 28,A) or 3 (Foldout 33)
from the filter base.
2. For models with transmission-mounted filters,
remove filter shells 55 (Foldout 28,A), filter
elements 54, and sealrings 53. Discard
elements 54 and sealrings 53. For models with
remote filters, remove filter shells 7
(Foldout 33), filter elements 6, and sealrings 5.
Discard sealrings 5 and elements 6.
3. If present, remove manifold assemblies 1
(Foldout 33).
b. Assembly
1. If removed, install manifold assembly 1 (Foldout 33).
2. For models with remote filters, install new
sealrings 5, new filter elements 6, and shells 7.
For models with transmission-mounted filters,
install new sealrings 53 (Foldout 28,A), new
filter elements 54, and shells 55.
3. Install differential pressure (P) switch 52
(Foldout 28,A) or 3 (Foldout 33) to a
maximum height of 2.25 inch (57.2 mm) above
the filter base.
REBUILD OF SUBASSEMBLIES
66.
MAIN-PRESSURE REGULATOR
VALVE ASSEMBLY
EX
EX
EX
67.
AREA OF
INSPECTION FOR
RESTRICTION
MAIN FLUID
PRESSURE
LOCKUP
VALVE BODY
ASSEMBLY
5.98 in.
(151.9 mm)
3.16 in.
(80.3 mm)
V08285.00.00
63
68.
NOTE:
Use a thin-wall deep-socket wrench with a
0.630 inch (16.00 mm) maximum OD to remove and
install solenoid bolts.
WIRING HARNESS
CONNECTOR
WIRING HARNESS
NUT
SOLENOID
PLATE
VH04057.00.00
REBUILD OF SUBASSEMBLIES
69.
CAUTION:
To avoid transmission housing damage and fluid
leakage, refer to Paragraph 413c prior to removing or installing pressure taps.
NOTE:
SOLENOID
COVER
WIRING
HARNESS
CONNECTOR
GASKET
LOCKUP
SOLENOID
GROUND
LEAD
VH04058.00.00
65
112
BOLT (2),
x
in.
FLAT WASHER (2)
SOLENOID COVER
ELECTRONIC CONTROL
LOCKUP VALVE BODY
ASSEMBLY
VH00942.00.02
WIRING HARNESS
PIN
SOLENOID COVER
HEAT SENSOR
PLUG (2)
NOTE:
Discard the lockup-trimmer valve assembly and
gasket.
VH00943.00.01
REBUILD OF SUBASSEMBLIES
2. Install trimmer valve 4 (closed end first) into
lockup trimmer valve body 3. Trimmer valve
and the related parts that follow (refer to
Foldout 9,B) may be deleted from the
transmission assembly during any repair,
rebuild, or overhaul.
SELECTOR VALVE
BOLT (6)
CAUTION:
The valve body assembly contains springs and
other parts, some of which are similar and can be
mistakenly interchanged. If parts are not installed in the same locations from which they
were removed, the valve body calibration functions will be lost. Tag each part at removal with
its item number in Foldout 21,A for correct assembly of valve body components.
1. Remove one bolt 14 and lockwasher 15 from
each end of cover 16 and install a
38-16 x 5 inch bolt into each bolt hole (Figure
66). This will prevent the springs from being
lost when cover 16 (Foldout 21,A) is freed.
2. Remove the six remaining bolts 14 and
lockwashers 15 from top cover 16.
3. Remove the long bolts, and top cover 16.
Remove and discard gasket 17.
4. Remove valve spring 87, splitter relay
valve 86, and splitter-relay valve plug 85 from
control valve body 84.
5. Remove spring guide 18, inner spring 20, outer
spring 22, intermediate-range long trimmer
valve 24, inner spring 26, outer spring 28, and
intermediate-range short trimmer valve 30.
TOP
COVER
LONG BOLTS
VH08286.00.00
67
SELECTOR VALVE
SPRING
CHECK VALVE
CHECK VALVE
SELECTOR VALVE
COVER
LONG
BOLTS
GASKET
VH08287.00.00
BOTTOM COVER
68
REBUILD OF SUBASSEMBLIES
A
DETENT
BALL (2)
PLUG
DETENT
SPRING (2)
E (LOCKUP TRIMMER)
D (12 OVERLAP)
V08504.00.00
69
11. Install splitter-relay valve plug 85 (smaller diameter first) into bore C in control-valve
body 84. Refer to Figure 68 for location.
12. Into the same bore, install splitter-relay
valve 86 (Foldout 21,A) (wide land first) and
spring 87.
13. Install a new gasket 17 onto top cover 16 and
install the cover on top of valve body 84 by
compressing the valve springs and installing
two 3/8-16 x 5 inch bolts into each side of the
cover to keep assembly in place. Compress the
springs by evenly tightening the bolts (Figure
66). Make sure the valve springs and gasket
are properly positioned against the cover and
the springs do not damage the gasket.
14. Continue compressing the valve springs until
two 38-16 x 114 inch bolts 14 (Foldout 21,A)
and lockwashers 15 can be installed. Remove
the two long bolts and install the remaining
six bolts and lockwashers. Tighten the bolts to
2632 lb ft (3543 Nm).
15. Position control valve body 84, bottom end up.
16. Install the first-to-second-range overlap
valve 64 (short land first) and spring 66 into
bore D in control-valve body 84, or install
lockup-trimmer short valve 63 (Foldout 21,A),
into bore E in control-valve body 84. Refer to
Figure 68 for location. Into the same bore install outer spring 65 (Foldout 21,A), inner
spring 67, lockup trimmer long valve 68 (short
land first), outer spring 69, inner spring 70 and
spring guide 71.
17. Install neutral trimmer valve 62 (Foldout 21,A)
into bore F in control-valve body 84. Refer to
Figure 68 for location.
18. Into the same bore install outer spring 60
(Foldout 21,A), inner spring 58, neutral-trimmer valve plug 55, neutral plug spring 53, and
spring guide 52.
610
REBUILD OF SUBASSEMBLIES
28. Cover the assembled valve body with a clean
lint-free cloth or paper and place it in a clean
place until installation onto the transmission.
SCAVENGE
PUMP BODY
SCAVENGE TUBE
INPUT PUMP
BODY
CONVERTER-IN TUBE
VH04060.00.00
611
DRIVE GEAR
PUMP IDLER
GEAR
GASKET
PUMP BODY
SCAVENGE
PUMP BODY
BEARING
STRAIGHT EDGE
DRIVE GEAR
INPUT PUMP
IDLER GEAR
SCAVENGE PUMP
IDLER GEAR
GASKET
GASKET
PLATE
ASSEMBLY
FEELER GAUGE
PUMP BODY
V08288.00.00
VH04061.00.00
612
REBUILD OF SUBASSEMBLIES
B
SURFACE
SURFACE
A
A
SEPARATING PLATE
SECTION
SECTION
B-B
A-A
COUNTERBORE
0.4300.433 in. (10.9211.00 mm)
SECTION
BODY REWORK
(9 PLACES)
A-A
V08289.00.00
Figure 612. Oil Pump Body Rework for Star Tolerance Rings
SCREEN
INPUT PUMP
DRIVE GEAR
BEARING
VH04062.00.00
613
INPUT PUMP
IDLER GEAR
b. Assembly
NEEDLE
ROLLER
WARNING!
Do not attempt to weld repair the brazed joints of
the hose fittings (Figure 615). Welding the cadmium plated material produces toxic yellowbrown fumes which are extremely hazardous and
can be fatal.
1. Cut the customer-supplied hose to 13.03 inches
(331.0 mm).
PUMP PLATE
ASSEMBLY
VH04063.00.00
NOTE:
Do not lubricate the OD of the hose.
NOTE:
If earlier (black) transfer tube assemblies show
signs of excessive wear or chafing, replace them
with the later (blue) transfer tube assembly. Later
(blue) transfer tube assemblies require repair at a
facility which has equipment for hydraulic hose
repair. Refer to Parts Catalog PC1249EN.
30.0030.24 in.
(762.0768.1 mm)
SOCKET
NIPPLE
SOCKET
NIPPLE
HOSE FITTING
HOSE FITTING
HOSE TO WITHSTAND
C4 TRANSMISSION
FLUID AT 275F (135C)
BRAZE
BRAZE
0.125 in. (3.18 mm) MAX GAP
NIPPLE
SOCKET
614
V06889.00.00
REBUILD OF SUBASSEMBLIES
5. Repeat Steps (2) through (4) for the other end
of the hose.
6. Either end fitting may be backed out of the
socket up to 12 turn to properly align the ends.
For best results, each end fitting should be
backed off one half the total required amount.
STATOR CAM
STATOR THRUST
PLATE
STATOR VANE
LEADING EDGE
SPRING
CLIP
V08505.00.00
SPRING
PIN
CAM
CUP
ROLLER
CAM
POCKET
1. Place stator 17 on the work table with the leading edge (thicker part of vane) of the stator
vane up (Figure 616).
2. Install stator cam 11 into the stator so that the
deep end of the cam pockets are
counterclockwise (Figure 617).
STATOR
V04213.00.00
RACE
SPRING
ASSEMBLY
STATOR
STATOR
ASSEMBLY
TOOL
J 29853
ROLLER
VH08291.00.00
615
CAUTION:
If accessory drive gear 31 or 32 is being reused,
be sure to install the same length bolts (24) as
were removed. If new accessory drive gear 31 or
32 is being installed, use 12-20 x 134 inch bolts 24.
3. Install four retainers 26, eight lockstrips 25,
and sixteen 12-20 x 138 inch bolts 24. Tighten
the bolts to 96115 lb ft (130155 Nm). Bend
the corners of the lockstrips against the bolt
heads.
1. If converter ground sleeve 23 must be removed, place converter housing 13 on its rear
surface and press the ground sleeve from its
bore.
TORQUE CONVERTER
PUMP ASSEMBLY
BOLT (16)
RETAINER (4)
LOCKSTRIP (8)
BALL BEARING
ASSEMBLY
BEARING
ASSEMBLY
RING
616
REBUILD OF SUBASSEMBLIES
3. If removed, install 12 inch pipe plug 14.
Tighten plug 14 to 2327 lb ft (3236 Nm).
Plug 14 must be flush with or below the
surface of housing 13.
4. If removed, install 14 inch pipe plug 15.
Tighten plug 15 to 1416 lb ft (1921 Nm).
Plug 15 must be flush with or below the
surface of housing 13.
5. If removed, install 38 inch pipe plug 55.
Tighten plug 55 to 1822 lb ft (2529 Nm).
Plug 55 must be flush with or below the
surface of housing 13.
6. If removed, install 114 inch plugs 18 and 20.
Tighten plugs 18 and 20 to 95105 lb ft
(129142 Nm).
7. If pin 12 was removed, install a new one.
Press the pin to a depth of 0.790.81 inch
(20.0620.57 mm) below the mounting
surface.
NOTE:
Be sure lubrication-pressure regulator valve 9 has
the later model configuration (three equally spaced
holes). If present, replace an earlier valve 9 (without
holes) with the later valve 9 (with holes).
8. Install spring 10 and valve 9 (convex side up)
onto the pin. Install valve seat 8, compress the
spring, and install retaining ring.
9. If converter ground sleeve 23 was removed,
install two headless guide bolts into the rear of
converter housing 13.
10. Chill the ground sleeve in dry ice for several
hours and, using gloves, install it into the converter housing, using the guide bolts to index
the bolt holes.
617
PLUG
TRANSMISSION
MAIN
SHAFT
NOTE:
Be sure lubrication-pressure regulator valve 23 has
the later model configuration (three equally spaced
holes). Replace an earlier valve 23 (without holes)
with the later valve 23 (with holes).
INPUT BEARING
RETAINER
BOLTS (5)
12. Install spring 22 and lubrication-pressure regulator valve 23 (convex side upward) onto the
pin. Install valve seat 24, compress the spring,
and install retaining ring 25.
13. If converter ground sleeve 34 was removed, install two headless guide bolts into the rear of
converter housing 8.
14. Chill the converter ground sleeve in dry ice for
several hours and, using gloves, install it into
the converter housing, using the guide bolts to
index the bolt holes.
CAUTION:
Do not hit plug end of shaft (Figure 620) with a
hammer. Only lightly tap out shaft from large
end.
2. Lift out transmission main shaft assembly 16
with the inner race and roller bearings 19 in
place. If shaft assembly 16 will not lift out,
support input bearing retainer assembly 3 on
its edge and, using a soft hammer, tap lightly
on the large diameter end of main shaft
assembly 16 to drive shaft assembly 16 and
bearing 19 from retainer assembly 3.
618
HUB
VH08292.00.00
REBUILD OF SUBASSEMBLIES
INPUT BEARING
RETAINER ASSEMBLY
INPUT BEARING
RETAINER ASSEMBLY
HUB
BEARING ASSEMBLY
HUB
BEARING ASSEMBLY
0.230 in.
(5.84 mm)
5.250 in.
(133.35 mm)
DIA
4.7247 in.
(120.00 mm)
DIA
0.06 in.
(1.5 mm) R
MAX
EARLIER MODELS
LATER MODELS
V08293.00.00
619
620
NOTE:
Planetary pinions are a matched set. If one pinion
requires replacement, the remaining pinions must
also be replaced, as well as the spindles, bearings,
and thrust washers.
REBUILD OF SUBASSEMBLIES
Make this area
easy to grab
0.005 inch
(0.127 mm)
smaller in
diameter
than spindle
Rounded
tip with
no point
2"
PINION
SUBASSEMBLY
4 X 4 WOOD BLOCKS
V07390.00.00
V07491.00.00
SPINDLE (4)
CARRIER
BEARING
CAUTION:
THRUST
WASHER
4 X 4 WOOD BLOCKS
V07389.00.00
NOTE:
DO NOT USE A HAMMER to drive the spindle
into the bore. Use only a light tapping to push the
spindle flush with the surface of the carrier if
necessary.
8. While holding spindle 7 over the carrier bore
(Figure 624), align the location ball with the
locating ball slot in the carrier. Drop the
spindle into the bore making sure the location
ball goes into the locating ball slot. Be sure to
push down on the spindle until it is flush with
the surface of the carrier. Do not force it into
position.
621
516-24
RETAINER (3)
NOTE:
DO NOT USE A HAMMER to remove a stuck or
cocked spindle. Use a press. DO NOT HAMMER on
the plug end of a spindle.
PITOT
COLLECTOR
RING OR TONE
WHEEL
SPLITTER-LOW
CLUTCH
DRUM
VH04075.00.00
NOTE:
DO NOT USE A HAMMER to remove a stuck or
cocked spindle. Use a press.
RETAINING
RING
HUB
11. Inspect the bore and spindle for nicks and burrs
and remove them with crocus cloth or soft
stone. If spindle has damage that can not be
corrected, replace it.
12. Reheat the carrier assembly with the seated
pinion subassemblies in place and cool the removed spindle to ambient temperature.
SEALRINGS
VH04076.00.00
CLUTCH
DRUM
REBUILD OF SUBASSEMBLIES
5. Remove splitter-low clutch piston 12 from the
splitter-low clutch hub assembly 7. Remove
seal 10 and sealring 11 from hub 9.
6. Refer to Paragraph 62.
PRESS RAM
SPRING
COMPRESSOR
J 7441
CLUTCH
PLATE
PISTON
SPRING
VH08294.00.00
0.4100.430 in.
(10.4110.92 mm)
DIA B
2.9532.955 in.
(75.0075.05 mm)
OIL PASSAGES
V08295.00.00
623
WELD AREA
RETAINING RING
SUN GEAR
REBUILD OF SUBASSEMBLIES
623. REVERSE-RANGE PLANETARY
CARRIER ASSEMBLY
a. Disassembly (Foldout 17,B)
NOTE:
General practice for planetaries dictates
replacement of spindles, bearings, and thrust
washers each time a transmission is overhauled.
1. Remove six bolts 11 and lockwashers 10 that attach oil collector ring 9 to carrier 7. Remove the
oil collector ring and sealring 8 from the carrier.
2. Position the carrier 7 with hub down and press
out six spindles 12. Removing the spindles will
allow six location balls 13 to fall free.
3. Remove six pinions 15, bearings 16, and thrust
washers 14 and 17. Remove bearings 16 from
pinions 15.
4. Discard bearings, spindles, and thrust washers
if transmission is being overhauled.
5. Clean the carrier, pinions, and location balls.
6. After inspection, place pinions and balls to the
side if condition does not require replacement.
Nicks and burrs can be removed using crocus
cloth or soft stone.
7. Refer to Paragraph 62.
b. Assembly (Foldout 17,B). Assembly of a
planetary carrier requires an oven to heat the carrier to
a maximum uniform temperature of 425F (218C)
and a special tool (Figure 622) to align the pinions,
bearings, and thrust washers in the carrier pockets.
Read all of the instructions before beginning this
procedure.
CAUTION:
The carrier is very hot (425F) when removed
from the oven and during the pinion subassembly installation procedure. Use extreme care
when handling the heated carrier. Always use
hand protection such as heavy gloves.
5. Remove the carrier from the oven and set on two
4x4s. A metal surface will cause the carrier to
cool too fast, possibly requiring the carrier to be
reheated before all spindles have been installed.
6. Orientate the carrier so a carrier bore and carrier
pocket are between the 4x4s (Figure 630).
7. Install one pinion subassembly (Figure 630)
in a carrier pocket that is between the 4x4s.
Slide the special aligning tool (Figure 622)
perpendicularly through the top carrier bore,
thrust washer, bearing and pinion, second
thrust, and bottom bore (Figure 630).
Carefully and quickly remove the aligning tool
in a perpendicular motion to maintain the
alignment of the components.
LOCATION BALL
SPINDLE (6)
CARRIER
THRUST
WASHER
PINION
NOTE:
Planetary pinions are a matched set. If one pinion
requires replacement, the remaining pinions must
also be replaced. Install new needle bearings, thrust
washers, and spindles when rebuilding a planetary
carrier assembly.
1. Inspect pinions in accordance with the general
provisions of Section 4. Replace if necessary.
2. Heat carrier in an oven to bring carrier to a
maximum uniform temperature of 425F
(218C).
BEARING
THRUST
WASHER
CARRIER
POCKET
4 X 4 WOOD BLOCKS
V07386.00.00
625
REBUILD OF SUBASSEMBLIES
c. Assembly (Foldout 16,B)
Assembly of a carrier requires an oven to heat the carrier to a maximum uniform temperature of 425F
(218C) and a special tool (Figure 622) to align the
pinions, bearings, and thrust washers in the carrier
pocket. Read all of the instructions before beginning this procedure.
NOTE:
Planetary pinions are a matched set. If one pinion
requires replacement, the remaining pinions must
also be replaced. Install new needle bearings, thrust
washers, and spindles when overhauling a
planetary carrier assembly.
LOCATION BALL
SPINDLE (6)
PINION SUBASSEMBLY
THRUST
WASHER (6)
CARRIER
PINION (6)
CAUTION:
The carrier is very hot when removed from the
oven and during the pinion subassembly installation procedure. Use extreme care when handling
the heated carrier. Always use hand protection
such as heavy gloves.
BEARING (6)
THRUST
WASHER(6)
CARRIER
POCKET (3)
LOCATING BALL SLOT
4 X 4 WOOD
BLOCKS
V07492.00.01
627
RETAINING
RING GAP
RETAINING
RING
PLANETARY
0.250.29 in.
(6.357.36 mm)
SECTION B-B
B
5.150 in.
(128.27 mm)
DRILL
0.3100.318 in.
(7.888.07 mm)
DIA. HOLE
0.7600.820 in.
(19.3120.82 mm)
DEEP
V04259.00.00
HUB
SPINDLE (4)
NOTE:
General practice for planetaries dictates
replacement of spindles, bearings, spacers, and
thrust washers each time a transmission is
overhauled.
PINION GEAR (4)
V08297.00.00
REBUILD OF SUBASSEMBLIES
b. Rework Procedure (Before S/N 2118)
RETAINING RING
GROOVE A
1.8901.910 in.
(48.0148.5 mm)
3.54113.5423 in.
(89.94489.974 mm)
DIA F
1.7271.747 in.
(43.8744.37 mm)
DIA
CARRIER B
DIAMETER
CHUCK
LOCATE SURFACE
V08298.00.00
629
NOTE:
DO NOT USE A HAMMER to drive the spindle
into the bore. Use only a light tapping to push the
spindle flush with the surface of the carrier if
necessary.
LOCATION BALL
SPINDLE (4)
CARRIER
THRUST
WASHER
PINION
15. Install internal retaining ring 13 to secure spindles 11 in carrier 16 ring gear.
BEARING
THRUST
WASHER
4 X 4 WOOD BLOCKS
V07389.00.00
630
626. INTERMEDIATE-RANGE
PLANETARY CARRIER
ASSEMBLY
NOTE:
General practice for planetaries dictates
replacement of spindles, bearings, and thrust
washers each time a transmission is overhauled.
REBUILD OF SUBASSEMBLIES
a. Disassembly (Foldout 14,B)
1. Position carrier assembly 2 on the oil collector
ring side (tapped holes) and press out four
spindles 4. Removing the spindles will allow
four location balls 5 to fall free.
2. Remove four pinions 8 with bearings 7, and
thrust washers 6 and 9.
3. Remove bearings 7 from pinions 8.
4. If transmission is being overhauled, discard the
bearings, thrust washers, and spindles.
5. Clean the carrier, pinions, and location balls.
6. Refer to Paragraph 62.
b. Assembly (Foldout 14,B). Assembly of a carrier
requires an oven to heat the carrier to a maximum
uniform temperature of 425F (218C) and a special
aligning tool (Figure 622) to align the pinions,
bearings, and thrust washers in the carrier pocket.
Read all of the instruction before beginning this
procedure.
NOTE:
Planetary pinions are a matched set. If one pinion
requires replacement, the remaining pinions must
also be replaced. Install new needle bearings, thrust
washers, and spindles when rebuilding a planetary
carrier assembly.
CAUTION:
The carrier is very hot when removed from the
oven and during the pinion subassembly installation procedure. Use extreme care when handling
the heated carrier. Always use hand protection
such as heavy gloves.
5. Remove the carrier from the oven and set on
4x4s with the oil collector ring side down. A
metal surface will cause the carrier to cool too
fast, possibly requiring the carrier to be
reheated before all spindles have been
installed.
6. Orientate the carrier so the carrier bore and
carrier pocket are between the 4x4s (Figure
636).
7. Install one pinion subassembly (Figure 636)
in the carrier pocket between the 4x4s. Slide
the special aligning tool perpendicularly
through the top carrier bore, thrust washer,
bearing and pinion, second thrust washer, and
bottom carrier bore. Carefully and quickly
remove the aligning tool in a perpendicular
motion to maintain the alignment of the
components.
LOCATION BALL
SPINDLE
CARRIER
PINION
SUBASSEMBLY
THRUST
WASHER
PINION (4)
BEARING
THRUST
WASHER
CARRIER POCKET
4X4
WOOD
BLOCKS
INTERMEDIATE-RANGE
PLANETARY CARRIER
ASSEMBLY
V07522.00.00
631
RETAINING
RING
HUB
NOTE:
Do not use a hammer to remove a stuck or cocked
spindle. Use a press.
11. Inspect the bore and spindle for nicks and
burrs, and remove them with crocus cloth or
soft stone. If a spindle has damage that can not
be corrected, replace it.
12. Reheat the carrier assembly with the seated
pinion subassemblies in place and cool the
spindle to ambient temperature.
SEALRINGS
VH04076.00.00
PRESS RAM
SPRING
COMPRESSOR
J 7441
CLUTCH
PLATE
PISTON
SPRING
RETAINING RING
VH08294.00.00
REBUILD OF SUBASSEMBLIES
b. Assembly (Foldout 14,A)
1. Place high-range clutch hub assembly 4 (Foldout 14,A) on the work table with the flat side
down and install sealring 8 on the small diameter of the hub.
2. Install oil seal 7 into the groove in clutch hub
assembly 4, with the lip facing piston 11. Refer
to Paragraph 413.
633
WARNING!
When handling the converter drive housing, be
sure the lockup clutch piston does not fall out and
injure personnel.
Measure dowel
pin height from
this surface
TORQUE CONVERTER
DRIVE HOUSING *
DOWEL
PIN (8)
a. Disassembly
1. DP 8861 Models. If present, remove lockup
clutch piston 5 (Foldout 8,A), with its outer
sealring 3 and expander 4, from the converter
drive housing. Remove the sealring and expander from the piston. Remove inner
sealring 1 and expander 2 from the hub of the
converter drive housing. Go to Step (3).
2. DP 8961, 8962 Models. If present, remove
lockup clutch piston 14 (Foldout 8,A), with its
outer sealring 12 and expander 13, from the
converter drive housing. Remove the sealring
and expander from the piston. Remove
sealrings 8 and 10 and expanders 9 and 11
from the hub of the converter drive housing.
634
RETAINING
RING
BEARING ROLLERS
AND OUTER RACE *NOTE: Configuration of components
ASSEMBLY
same for flywheel assembly VH04064.00.00
REBUILD OF SUBASSEMBLIES
b. Assembly (Foldout 7,B)
TORQUE CONVERTER
DRIVE HOUSING
INPUT SHAFT
BEARING
VH04065.00.00
a. Disassembly
635
NOTE:
A free running nut may be made by removing the
locking insert from a used retainer nut.
b. Assembly
1. If removed, install two plugs 19 (Foldout 7,B).
Tighten the plugs to 1012 lb ft (1416 Nm).
2. If removed, install two pins 20. Press the pins
to a depth of 0.0100.030 inch (0.250.76 mm)
and stake securely.
3. If removed, install eight new dowel pins 15 or 21.
For TC 800 torque converter, press the dowel
1. Excessive output flange runout will have a detrimental effect on the transmission rear components. To prevent excessive output flange
runout and subsequent problems, make a stack
measurement of the rear section before reassembling the transmission.
2. Assemble the following parts. Place first-range
planetary carrier 15 (Foldout 16,B) on a flat
surface (output shaft up) and install a new
planetary spacer 1 (Foldout 17,B). Install
reverse-range planetary carrier assembly 6,
speedometer drive gear assemblies 30 (Foldout
18,B) or 10, and bearing 11. Install the output
flange and a new flange plate retainer.
636
REBUILD OF SUBASSEMBLIES
FLANGE PILOT
DIAMETER
FLANGE
RETAINER NUT
RETAINER PLATE
DIM
FACE (E1)
SPACER
FACE (F)
FIRST-RANGE
PLANETARY CARRIER
V08498.00.00
SHOULDER
F*
F
INDICATES FACE FOR
* MACHINE
GRIND OPERATION
SURFACE
SURFACE
SURFACE
E1*
E2 *
D*
SURFACE
C*
D
D = 1.360 in. (34.54 mm) MIN
1.109 in. (28.17 mm) MIN
WITH MAGNETIC GEAR INSTALLED
SPEEDOMETER GEAR
C
C 4.225 in. (107.31 mm) MIN
OUTPUT FLANGE
V08301.00.00
637
NOTE:
These instructions are for earlier self-adjusting
brakes, using later replacement parts. See Parts
Catalog PC1249EN.
CAUTION:
Brake linings must be kept free from oil, grease,
or other contamination.
4. Coat the backplate ledges, where the shoe rims
rest, with Lubriplate or equivalent.
5. Coat the brake shoe webs with Lubriplate or
equivalent on the surfaces where they contact
the anchor block and adjusting screw and put
shoes 71 and 56 in place, with self-adjusting
spring 66 installed (white earlier models, green
later models).
NOTE:
If the actuating lever is activated from the left side,
the adjusting screw assembly should be installed
with the star wheel at the right end of the assembly.
If the actuating lever is activated from the right
side, the adjusting screw assembly should be
installed with the star wheel at the left end of the
assembly.
6. Lubricate and assemble adjusting screw
components 61, 62, 63, and 64, and install the
components as an assembly.
7. Engage connecting links 50 and 52 with the
brake shoes.
REBUILD OF SUBASSEMBLIES
8. Install two new yellow springs 60 and
anchor pin 57. Tighten the anchor pin to
150250 lb inch (1728 Nm).
9. If removed, install shoe holddown pins 72
through backplate 49.
10. Coat the shoe webs underneath spring cups 68
with Lubriplate or equivalent. Install two
spring cups 68, two black springs 70 (removed
in Paragraph a(1)) and two more shoe holddown spring cups 68 onto shoe holddown
pins 72 and into the place where discarded
shoe holddown springs 69 were removed. Depress the shoe holddown cups against spring
force and rotate the shoe holddown cups to attach the spring.
11. Temporarily install probe hole covers 73 and
adjusting hole cover 74.
12. Refer to Paragraph 311 for parking brake adjustment.
CAUTION:
Brake linings must be kept free from oil, grease,
or other contamination.
4. Coat the backplate ledges, where the shoe rims
rest, with Lubriplate or equivalent.
5. Coat the brake shoe webs with Lubriplate or
equivalent on the surfaces where they contact
the anchor block and adjusting screw and put
shoes 71 and 56 in place, with spring 66
installed.
NOTE:
If the actuating lever is activated from the left side,
the adjusting screw assembly should be installed
with the star wheel at the right end of the assembly.
If the actuating lever is activated from the right
side, the adjusting screw assembly should be
installed with the star wheel at the left end of the
assembly.
639
CAUTION:
Brake linings must be kept free from oil, grease,
or other contamination.
5. Coat the backplate ledges, where the shoe rims
rest, with Lubriplate or equivalent.
6. Set brake shoes 12 and 29 in place, lining up
brake actuator connecting links 31 and 37 to
engage the brake shoes and the reinforcement
plate. Install shoe-to-shoe spring 13.
NOTE:
If the actuating lever is activated from the left side,
the adjusting screw assembly should be installed
with the star wheel at the right end of the assembly.
If the actuating lever is activated from the right
side, the adjusting screw assembly should be
installed with the star wheel at the left end of the
assembly.
7. Lubricate and assemble adjusting screw
components 18, 20, and 27 and lay the
components in place as an assembly.
8. Retain the adjusting screw assembly by
installing pivot pins 16 and 28 (heads toward
backing plate) through the screw assembly and
brake shoes and installing cotter pins 17 and
26. Bend the ends of the cotter pins around the
ends of the pivot pins.
9. Install adjusting screw spring 19.
10. Coat the shoe webs underneath spring cups 25
with Lubriplate or equivalent. If removed, install spring pins 38. Install spring cups 25,
springs 24, and spring cups 23 over spring
pins 38. Depress cups 23 against spring force
and install cotter pins 22 through the holes in
pins 38. Spread the cotter pins to attach hold
down pins 38.
REBUILD OF SUBASSEMBLIES
11. Set the arrow heads on the ends of anchor
pins 11 and 30 pointing toward each other and
install anchor-to-shoe springs 15 and 21 around
the end of the anchor pins and in the shoe
webs. Tighten nuts 6 and 7 to 300325 lb ft
(407440 Nm).
FUSE
HOLDER
BODY
INDEX
KEY
LUBRICATION
ACCESS
VH00916.00.01
NOTE:
The manual-electric shift selector has two types of
shift leversT-handle and knob. The T-handle
lever section is nonserviceable, whereas, the
components of the knob-type lever are serviceable.
Refer to Foldout 23 and Parts Catalog PC1249EN
for identification of serviceable/nonserviceable
parts.
INHIBITOR
SOLENOID
COVER
TERMINAL,
WITH SHRINK
TUBING
BULB
NO. 1816
CAUTION:
Do not use liquid or vapor cleaning methods on
any electrical components.
1. Remove four screws 49 that attach light socket
plate assembly 45 (Figure 644).
2. Carefully pull the plate assembly from shift
selector body 8 (Figure 645). If necessary,
remove light bulb 47 and O-ring 48 from the
socket.
3. If the light socket plate assembly or wiring is
to be replaced, cut the heat-shrink tubing from
the wire connectors and disconnect the plate
assembly.
4. If resistor 42 (in 24V systems) requires
replacement, remove it (Figure 645).
RESISTOR
PLATE ASSEMBLY, 24V
PLATE
ASSEMBLY,
12V
O-RING, 38 in.
H00917.01
641
12. Remove screw 70 and lockwasher 71 that attach body cover 74 (Figure 648).
10. Remove inhibitor outer clutch 78 from the solenoid housing (Figure 648). Remove
O-ring 64. Remove guide pins 62 from the solenoid housing if new pins are required.
SOLENOID LEADS
SOLENOID
COIL
INDICATOR
LIGHT LEAD
WIRING
HARNESS
LEADS
SOLENOID
HOUSING
ADJUSTING SCREW
SOLENOID
COVER
WASHER
PLUNGER
GASKET
VH00918.00.00
RETAINER
RING
SOLENOID
HOUSING
SPRING SEAT
SOCKET-HEAD
SCREW (2)
LOCKWASHER (2)
O-RING,
1516 in.
SOLENOID
COIL
CLUTCH SPRING
COVER
GUIDE PIN (2)
O-RING
BODY
SOLENOID
LEADS
BODY
SHIFT
INDICATOR
VH00919.00.01
642
SCREW,
LOCKWASHER
SOLENOID
HOUSING
OUTER
CLUTCH
VH00920.00.01
REBUILD OF SUBASSEMBLIES
O-RING, 118 in.
SHIFT
SELECTOR
BODY
FUSE
LEAD
FUSE
HOLDER
SWITCH
COVER
INNER CLUTCH
KEY
COVER SEAL
SOCKET-HEAD
SCREW (3),
LOCKWASHER (3)
LUBRICATION
POINTS
WIRING
HARNESS
SWITCH
ASSEMBLY
MOUNTING
BRACKET
POWER LEAD
COVER
MOUNTING
BRACKET
VH00921.00.01
VH00922.00.00
O-RING
SWITCH SHAFT
SHIM (AR)
21. Remove four screws 28 and washers 27 that attach switch cover 26 (Figure 650; Foldout 23).
Remove switch cover 26 and cover seal 25.
22. Loosen set screw 37 that secures drive
adapter 18 on microswitch assembly shaft 24
(Figure 649; Foldout 23). Remove drive
adapter 18. Remove shims 19 from the switch
shaft.
4-PIN SOCKET
MOUNTING
BRACKET
DRIVE
ADAPTER
SWITCH
ASSEMBLY
SCREW (2),
WASHER (2)
WIRING
HARNESS
LEADS
SET
SCREW
VH00923.01.00
CAUTION:
Do not use acid or acid core solder. Use only rosin
core solder.
1. If four-pin socket 36 was removed from
mounting bracket 23, install a new socket 36
(Foldout 23). Refer to Figure 652. Push the
socket into the flat side of the mounting
bracket until it is flush with the adjacent area.
Note the projection on the socket body that indexes with a notch in the mounting bracket.
643
CAUTION:
Hand tighten all mating connectors. Use of tools
will damage the components.
NOTE:
16-PIN CONNECTOR
WIRING HARNESS
4-PIN SOCKET
INDEX
KEY
MOUNTING BRACKET
VH00924.00.00
C
16-PIN CONNECTOR
BLACK
1
2
8
C
YELLOW
L A
YELLOW
B
M C D
P O N
I
E
H G
F
BLACK
3
SFE9
FUSE
GROUND TO
SWITCH FRAME
DIRECT
CONNECTION
(12V SYSTEM)
C
4
7
C
6
C
2
1
5
C
X = NOT CONNECTED
4-PIN CONNECTOR
SWITCHES
644
LIGHT
INHIBITOR
SOLENOID
V03579.00.00
REBUILD OF SUBASSEMBLIES
4. Inspect the connections to make sure they are
correct. Looking at the back of the socket
(where wires enter), the light-colored lead
from pin K should be nearest the index lug on
the socket. Moving clockwise, the separate
lead with four connectors is next; then another
light-colored lead to pin M; and last, a dark
lead to pin L.
5. Install microswitch assembly 24 onto
mounting bracket 23 (Figure 654). Position
the switch assembly on the mounting bracket
so the switch numbers (1 through 8) are not
inverted. Attach the assembly with two
6-32 x 34 inch screws 21 (Foldout 23) and
lockwashers 22. The screw holes in the switch
assembly should be approximately midway in
the elongated holes in the mounting bracket
when the screws are tightened.
6. Follow the wiring diagram (Figure 653) to
connect the wiring harness leads to the switch
assembly. Connect the two jumper leads from
terminal 1 of switch 1, to common terminal of
switch 4; and from terminal 1 of switch 6, to
common terminal of switch 7. Note that four
switch terminals have no leads connected to
them.
7. Install one shim 19 (Foldout 23) (darker side
first) onto the switch shaft (Figure 651). More
shims may be required. This will be
determined in Step (10).
SWITCH
ASSEMBLY
MOUNTING BRACKET
VH00926.00.00
645
O-RING (2)
4-PIN
CONNECTOR
SHIFT
SELECTOR
BODY
MOUNTING
BRACKET
4-PIN
SOCKET
VH00927.00.01
21. If guide pins 62 were removed from the solenoid housing, install new pins (Figure 648).
Press the pins until they are flush with the surface of the housing inner hub.
22. Install O-ring 64 onto solenoid housing 63
(Figure 646). Coat the outer surface of the
outer clutch lightly with grease (Marfak
No. 2, or equivalent). Install inhibitor outer
clutch 78, flat end first, into the solenoid housing. The clutch must move freely, endways,
when engaged with the guide pins.
23. Install the assembled solenoid housing onto
shift indicator support 76 (Figure 648).
24. Install two socket-head screws 80 and lockwashers 79 to attach the solenoid housing (Figure 647; Foldout 23).
25. Install override spring 61 (Foldout 23) into the
center bore of solenoid housing 63.
26. Install spring seat 60 and retainer ring 59 (Figure 647). Install O-ring 58 into the housing
counterbore.
27. Determine the angular position of the solenoid
housing (Figure 656). Push the spring seat
down. While holding the seat down, push the
shift handle in the upshift direction against a
gate pin and then in the opposite direction. The
inhibitor clutch should engage, but should allow the shift handle to move away from the
gate pin contacted to a maximum of 0.060 inch
(1.52 mm) and to a minimum of 0.040 inch
(1.01 mm) when pull force on the handle knob
does not exceed 15 lb (67 N). This 0.060 inch
(1.52 mm) maximum movement applies to the
gate pin where the least movement is found
REBUILD OF SUBASSEMBLIES
when all positions have been measured. As a
result of tolerances in manufacturing, clearance at some gate pins can exceed 0.060 inch
(1.52 mm) when the clearance is correctly adjusted at the position where least movement
occurs. Determine the movement at all gate
pins.
28. Too great a clearance requires a counterclockwise adjustment of the solenoid housing to reduce the clearance; too little requires
clockwise adjustment. To adjust the solenoid
housing, loosen the two screws, rotate the
housing, and retighten the screws.
NOTE:
When clearance is excessive, a clockwise
adjustment may be necessary to engage the
inhibitor properly.
29. Install solenoid coil 57 into the solenoid housing (Figure 647). Thread the solenoid leads
through two holes in the solenoid housing, indicator support, and body cover until they can
be pulled out of the bottom opening in the
body (Figure 646).
30. Install solenoid plunger 55 and washer 56 into
the solenoid coil (Figure 646). Install solenoid housing cover 52 and gasket 53. Attach
the cover with three screws 50 and lockwashers 51 (Figure 645; Foldout 23).
SCREW (2)
SOLENOID
HOUSING
SHIFT
HANDLE
37. Install switch cover 26 and cover seal 25 (Figure 650; Foldout 23). Attach the cover with
four screws 28 and washers 27.
CLEARANCE
VH00928.00.00
647
CAUTION:
17. Remove four screws 26 and washers 25 that attach switch cover 24. Remove switch cover 24
and switch cover seal 23.
18. Loosen set screw 35 that secures drive
adapter 16 on the switch shaft. Remove drive
adapter 16. Remove the shim(s) 17 from the
switch shaft.
19. Disconnect all of the wiring harness leads from
the switch assembly. Remove two screws 19
and washers 20 that attaches microswitch assembly 22. Remove microswitch assembly 22.
The microswitch assembly is not a serviceable
assembly.
20. Remove four-pin socket 34 if replacement is
necessary.
21. Remove four screws 28 that secure 16-pin connector and wiring harness 29. Remove 16-pin
connector 30 from mounting bracket 21.
22. Remove O-ring 27 from 16-pin connector 30.
23. Refer to Paragraph 62.
b. Assembly (Foldout 24,B)
1. If four-pin socket 34 was removed from
mounting bracket 21, install a new socket 34.
Push the socket into the flat side of mounting
bracket 21 until it is flush with the adjacent
area (Figure 651). Be sure the projection on
the socket body indexes with a notch in the
mounting bracket.
2. Install O-ring 27 over the wires and onto the
shoulder of 16-pin connector 30 (Foldout
24,B). Insert the wires through the bottom of
mounting bracket 21. Push 16-pin connector 30
into mounting bracket 21 and position the index
key according to Figure 644. Attach the
connector with four new 6-32 x 38 inch selftapping screws 28.
NOTE:
Note the view in the wiring diagram (Figure 657) is
at the front (mating side) of the socket, and the
order of installation is counterclockwise.
REBUILD OF SUBASSEMBLIES
7. Install one shim 17 (Foldout 24,B), darker side
first, onto the switch shaft. More shims may be
required. This will be determined in Step (10).
C
1
1
2
2
1
10
C
L
K
9
C
N
O
E
F
YELLOW
16-PIN CONNECTOR
4-PIN
CONNECTOR
RESISTOR
(24V SYSTEM)
DIRECT
CONNECTION
(12V SYSTEM)
8
C
7
C
SFE9A
FUSE
C
LIGHT
BLACK
C
2
J
I
GROUND TO
SWITCH FRAME
6
C
X = NOT CONNECTED
SWITCHES
V03580.00.00
649
25. Test the circuitry and operation of the shift selector assembly as outlined in Paragraph 318.
26. Install switch cover 24 and cover seal 23. Attach cover 24 with four screws 26 and
washers 25.
shift
REBUILD OF SUBASSEMBLIES
638. SPG-CONTROL THROTTLE
POTENTIOMETER
NOTE:
For testing refer to Paragraph 316e.
651
BEZEL
SCREW (4),
6-32 x 58 in.
SELECTOR LEVER
END CAP COVER
VH00930.00.01
NOTE:
To remove magnet holder and range indicator
assembly 14, dowel pin 13 must be removed. If
dowel pin 13 is not exposed enough to grip it with
pliers, grip the shift selector and lever assembly and
squeeze the lever against the selector body to release
the force from dowel pin 13. If end cap 34 has not
been removed, to gain access to dowel pin 13, it may
also be necessary to lift up on the shift latch to
release the force from spring 33 and rod 32.
11. Being careful not to damage the electrical connector at the base of the selector body, bump
shift selector assembly body 8 against the work
table to expose dowel pin 13 enough to grip the
it with pliers. Remove dowel pin 13.
12. Remove magnet holder and range indicator
assembly 14 from shaft 18 while removing
selector lever 29 along with attached parts
from the other side.
13. Remove two 6-32 x 38 inch screws 15 and
range indicator 16 from magnet holder assembly 17 if replacement is necessary.
652
REBUILD OF SUBASSEMBLIES
3. If removed, install bearing 19. Lubricate the ID
of bearing 19 with Lubriplate.
14. Lubricate shift positioning rod 32 with Lubriplate. Install shift positioning rod 32 into selector lever 29. Install spring 33.
15. Install end cap 34 and two 4-40 x 516 inch
patchlock screws 35 (Figure 660). Begin to
tighten the screws with a torque wrench. If the
running torque is less than 5 lb inch (0.6 Nm),
the screw must be replaced with a new screw
Tighten screws 35 to 68 lb inch (0.72.6 Nm).
16. If shift latch half covers 31 were removed, install dowel pin 30 and one half-cover (Figure
660). Put the other half-cover in place using
just enough Loctite Super Bonder (No. 495)
to hold the two halves together. Be sure the Super Bond does not get on selector lever 29.
Clamp the two halves together until the adhesive is dry.
17. For smooth operation, apply Lubriplate to selector lever 29 where shift latch 31 moves.
18. Install new lamps 20 by pushing them straight
into the sockets.
NOTE:
To attach shaft 18 and magnet holder assembly 17,
dowel pin 13 must be installed. If the pin hole in
shaft 18 is not aligned well enough to install dowel
pin 13, grip the shift selector and lever assembly
and squeeze the lever against the selector body to
align the holes. If selector lever end cap 34 is in
place, it may also be necessary to lift up on shift
latch 31 to release the force from spring 33 and
rod 32.
653
GASKET
SELECTOR
LEVER
END
CAP
SCREW (2),
6-32 x 12 in.
BEZEL
VH00931.00.01
NOTE:
If a lamp or lamp circuit board assembly replacement is required, do Steps (1) through (6). If only
the cover assembly needs to be replaced, do
Steps (1) and (7).
1. Place the shift selector (Figure 661) on a flat
surface, face side down (Figure 662). Remove
four screws 1 and star washers 2 that attach
cover assembly 8 to shift selector body assembly 3.
2. Carefully separate the cover assembly and
housing assembly just enough to permit removal of lamp circuit board assembly 9 or 10
(Figure 663).
SELECTOR LEVER
SHIFT LATCH
HALF-COVER
END CAP
PIN
SCREW (2), 4-40 x 516 in.
VH00932.00.01
SHIFT SELECTOR
VH00695.00.01
654
REBUILD OF SUBASSEMBLIES
SCREW (4),
6-32 x 1 2 in.
WASHER (4)
COVER
ASSEMBLY
HOUSING
ASSEMBLY
COVER
CONNECTOR
CONNECTOR
PINS
HOUSING
ASSEMBLY
VH00933.00.01
VH00935.00.00
COVER
ASSEMBLY
LAMP CIRCUIT
BOARD ASSEMBLY
(EARLIER MODELS)
CONNECTOR
HOUSING
ASSEMBLY
VH00934.00.00
655
SERVICEABLE LAMP
LOCATION
LAMP HOLDER
CLIPS (REMOVABLE
IN EARLIER MODELS)
FRONT VIEW
REMOVABLE
LAMP HOLDERS
NON-REMOVABLE
LAMP HOLDERS
NON-REMOVABLE
LAMP HOLDERS
(EARLIER MODELS)
(INTERIM MODELS)
(LATER MODELS)
BACK VIEW
656
VH00936.00.00
REBUILD OF SUBASSEMBLIES
lamp side of circuit board assembly 9 or 10 is
facing the cover assembly. Align the circuit
board assembly connector with its mating pins
in the housing. Press the connector onto the
pins as far as possible.
LAMP CIRCUIT
BOARD ASSEMBLY
LAMP HOLDER
ASSEMBLY
LAMP
SOCKET
LOCKTABS
VH00937.00.01
NOTE:
When installing a new cover assembly, it may be
desirable to remove the lamp circuit board
assembly. This will provide free access to mate the
cover assembly connector to its mating connector in
the housing assembly.
NOTE:
Record any diagnostic codes prior to removal of
NOTE:
Removal and replacement of a PROM should be
necessary only if correcting a diagnostic code 34
(PROM
check)
or
if
a
replacement
(remanufactured) ECU is being installed.
Remanufactured ECUs are shipped without Lamp
Circuit Board Assembly Configurations (CEC1)
PROMs and the PROM from the removed ECU
should be reused.
a. Removing PROM (Foldout 25)
1. If authorized by Allison Transmission remove
the four PROM cover screws 9, lockwashers 8,
and seals 7 (Figure 667).
657
ELECTRONIC
CONTROL
UNIT (ECU)
SA1951
SEAL
NOTICE
PROM COVER
AND GASKET
CAUTION:
658
REBUILD OF SUBASSEMBLIES
PROM AND
RETAINER ASSEMBLY
ELECTRONIC CONTROL
UNIT (ECU)
NARROW
SLOT
NARROW
TAB
J 35889-A
CAUTION: Press on
PROM retainer only.
V02143.00.00
V05260.00.00
659
3. Depress circuit board connector locking tab toward connector body and remove circuit board
connector (Figure 670).
NOTE:
Record any diagnostic codes prior to removal of
the lever shift selector from the vehicle.
Disassemble the shift selector only to the extent
necessary for access to replacement parts.
Torx
SE
LE
C
T
9. Remove gasket 5.
D
Push here toward
connector body
V04721.00.00
660
REBUILD OF SUBASSEMBLIES
7
4
V04723.00.00
NOTE:
Be sure only one (1) retaining ring is used per post.
8. Reassemble the pushbutton faceplate/bezel assembly to the selector housing using four slotted Torx R-head (T-10) screws 11.
9. Tighten the screws to 810 lb inch (3.03.7 Nm).
661
A
FIRST-RANGE VALVE
BODY ASSEMBLY
GROUND RING
INSTALL TO SHOULDER
2.22 in.
(56.4 mm)
2.00 in.
(50.8 mm)
J
J
0.13 in. R
(3.3 mm R)
SECTION
0.90 in.
(22.9 mm)
0.20 in. R
(5.1 mm R)
J-J
0.88 in. R
(22.4 mm R)
V08507.00.00
662
REBUILD OF SUBASSEMBLIES
b. Rework (Before S/N 1084) (Foldout 22)
1. If there has been a problem with the transmission (before S/N 1084 only), going into a
3-hold condition when a sudden 31 downshift is made, follow Steps b(2) through (5).
2. Replace first-range shift valve body 113 with a
new one.
3. Inspect valve body 45 for the presence of the
hole indicated in Figure 674. If the hole is not
present, either replace the body with a new one
or rework the body as indicated in Figure 674.
Remove all drill debris.
4. Inspect transfer plate 102 (Foldout 22) for the
presence of the irregular hole indicated in
Figure 673. If the hole is not present, either
replace the plate with a new one or rework the
transfer plate. First, use a 14 inch diameter drill
for the 0.130 inch R (3.3 mm R) area by
drilling through the plate where the 2.220 inch
(56.4 mm) and the 0.880 inch (22.4 mm)
coordinates intersect. Use a 1332 inch drill for
the 0.200 inch R (5.1 mm R) area by drilling
through where the 2.00 inch (50.8 mm) and the
0.900 inch (22.9 mm) coordinates intersect.
Use a file to complete the shape in Figure 673.
Remove all drill debris.
5. Install new transfer plate gaskets 98
(Foldout 22) and valve body gasket 104 that
conform to the reworked holes.
V08302.00.00
663
SOLENOID PLATE
SOLENOID I
TERMINAL LEAD I
(MARKED B)
V08303.00.00
45
NOTE:
Solenoid cover and plate assembly 16 is spring
loaded.
1. Remove four bolts 12, flat washers 10, and harness guard 13 if present. Remove fourteen
bolts 11 and flat washers 10.
2. Remove solenoid cover and plate assembly 14.
Remove and discard gasket 26.
3. Remove two flathead screws 25 and carefully
lift solenoid cover 16 until the solenoid leads
and ground wire are accessible.
4. Remove one bolt 18, washer 19, and the
ground wire terminal. Remove seven wiring
harness leads from the solenoid leads. Remove
solenoid cover 16 and gasket 17.
5. Inspect valve body internal wiring harness 15
for the presence of hole A (Figure 676). If
hole A is not present, or if replacement is
necessary, remove wiring harness 15 from
cover 16.
6. If not present, drill hole A in wiring harness 15
(Figure 676).
664
CAUTION:
The valve body assembly contains springs and
other parts, some of which are similar and can be
mistakenly interchanged. If parts are not reinstalled in the same locations from which they
were removed, the calibration of valve body
functions will be lost. Tag each part, at removal
with its item number in Foldout 22, to simplify
correct reassembly of valve body components.
8. From the bores in valve body 45, remove steel
balls 41 and 38, regulator valve spring 27,
solenoid pressure regulator valve 28, splitter
shift valve 29, shift valve spring 30, outer
REBUILD OF SUBASSEMBLIES
spring 31, inner spring 32, priority valve 33,
high-range shift valve 34, shift valve spring 35,
intermediate-range shift valve 36, shift valve
spring 37, second-range shift valve 39, shift
valve spring 40, reverse-range shift valve 42,
and shift valve spring 43.
NOTE:
Cover 84 is spring-loaded and must be restrained
while the bolts are being removed.
9. Position the valve body, top down, and remove
fourteen bolts 86 and lockwashers 85.
10. Remove valve body cover 84. Remove and discard gasket 83.
11. From the bores in valve body 45, remove valve
stop 82, outer spring 81, inner spring 80,
splitter-low trimmer lower valve 79, inner
spring 78, outer spring 77, and splitter-low
trimmer upper valve 76; spring 75, trimmer
regulator boost valve 74, trimmer regulator
boost valve plug 73, and trimmer regulator
valve spring 72; valve stop 71, outer spring 70,
inner spring 69, intermediate-range trimmer
lower valve 68, inner spring 67, outer
spring 66, and intermediate-range trimmer
upper valve 65; valve stop 64, outer spring 63,
inner spring 62, second-range trimmer lower
valve 61, inner spring 60, outer spring 59, and
second-range trimmer upper valve 58; valve
stop 57, outer spring 56, inner spring 55, firstand reverse-range trimmer lower valve 54,
inner spring 53, outer spring 52, and first-and
reverse-range trimmer upper valve 51.
14. To be sure the complete removal of dirt and debris from internal oil passages, remove plug 48
from valve body 45. If plug 48 is a two-piece
aluminum expansion plug (earlier models) drill
and remove the plug. Use a drill bit that is
smaller than the OD of the plug. Do not damage the bore surface during removal of the plug
(approximately 0.500 inch (12.7 mm) long).
Tap a 18 NPTF thread at the opening. Remove
all drill and tap debris and burrs.
15. For some early models before S/N 3428, locate
and drill a 0.250 inch (6.35 mm) hole to a
depth of 0.300 inch (7.62 mm) in valve
body 45 (Figure 677). Remove all drill debris
and burrs. Some later models have a passageway already drilled (Figure 677).
16. Some later models before S/N 3428 have a
18 inch pipe plug 48 (Foldout 22). Remove the
plug. Some later models have a passageway already drilled as shown in Figure 677.
17. If the hole is present, direct air under pressure
into the hole to clean the passageway thoroughly (Figure 677).
18. For models after S/N 3427, no rework is required.
19. Refer to Paragraph 62.
12. Remove four plugs 46 from valve body 45. Remove plug 49 and oil screen assembly 50. Do
not attempt to remove five orifice plugs 47.
13. Do not remove pin 87, check valve 88 or valve
spring 89 from valve body 45 unless parts replacement is necessary.
NOTE:
Earlier assemblies used an 18-coil valve spring 89.
This should be replaced by a 15-coil valve spring.
Refer to the spring chart for a description of the
new spring.
0.920 in.
(23.37 mm)
BASE
LINE
2.200 in.
(55.88 mm)
ORIFICE PLUG(S)
V08508.00.00
665
SOLENOID PLATE
EARLIER MODELS
SOLENOID PLATE
LATER MODELS
SOLENOID E
SOLENOID PLATE
V08306.00.00
666
V08305.00.00
REBUILD OF SUBASSEMBLIES
pinched between the cover and plate. The
weight of the cover should close the gap between the gasket and coverno force is required. Secure the cover with two flathead
screws 25. Tighten the screws to 2436 lb inch
(34 Nm).
NOTE:
Inspect the position of all components,
configuration of all valves and plugs, and
identification of all springs before installation.
Refer to Figure 663, Foldout 22, and the spring
chart in Section 8. All valves, when dry, should
move freely by their own weight in their bores.
12. Position valve body assembly 44 (Foldout 22)
in an upright position.
13. Install shift valve spring 43 and reverse-range
shift valve 42 into bore A (Figure 681).
TERMINAL PINS
E
GROUND
D
B
WIRING HARNESS
C
SOLENOID C
SOLENOID D
SOLENOID B
SOLENOID A*
GROUND WIRE
TERMINAL
SOLENOID F
SOLENOID E
CABLE TIE
SOLENOID LEAD
LOCKWASHER (2)
(EACH SOLENOID)
SOLENOID G*
SOLENOID
PLATE
GASKET
Figure 680. Main Valve Body Solenoid Cover and Plate Assembly
667
VH04211.00.00
668
REBUILD OF SUBASSEMBLIES
assembly 14. Headless 14-20 guide bolts
installed into valve body 45 will aid in this
assembly.
CAUTION:
Do not damage the threads and contact pins of
the electrical connector.
21. Install harness guard 13 (if used) and four
bolts 12 and flat washers 10. Install fourteen
bolts 11 and flat washers 10. Tighten the
eighteen bolts evenly to 911 lb ft (1314 Nm).
29. Install
fourteen
bolts
86
and
lockwashers 85. Tighten the bolts evenly to
911 lb ft (1314 Nm).
30. If plugs 46 are straight-thread plug, check the
condition of the O-ring and plug, replace as
necessary.
31. Install plugs or plug assemblies into valve
body 45. Tighten later 3/8-24 straight-thread
plug and O-ring assembly to 2832 lb inch
(3.23.6 Nm). Tighten earlier 1/8 inch NPTF
pipe plug to 1012 lb ft (1416 Nm).
NOTE:
669
SECTION
(2) SLOTS
15
15
POLISH SURFACE
IN DIRECTION SHOWN
TURBINE
BACKPLATE
D IR
OF E CT
PO IO
LI N
S
BOLT (24)
LOCKSTRIP (12)
HUB
SURFACE
DIM. B
670
V08307.00.00
SCOPE
Title
49
410
412
416
417
418
419
420
82
Tools, Equipment
Replacement Parts
Careful Handling
Assembly Procedures
Tight-fit Flanges
Teflon Sealrings
Determining PTO Backlash Limits
Torque Specifications
Spring Data
HUB
DRIVE TOOL
BEARING
RETAINER
SEALRING
VH04244.00.00
SPLITTER RING
GEAR
CAUTION:
If hub 20 (Foldout 13,B) is loose fitting into the
main housing, place wood blocks under the hub
to hold it in place when the transmission housing
is positioned front end up.
2. Install splitter-high ring gear hub 14 (Foldout
13,A) into splitter-high ring gear 10 and install
retaining ring 15 into the ring gear. Install
bearing retainer 18 and press bearing 19 onto
hub 14. Install sealring 13 onto hub 14.
SEALRING
VH04245.00.00
71
VH08308.00.00
HIGH-RANGE CLUTCH
AND DRUM ASSEMBLY
72
VH04033.00.00
ASSEMBLY OF TRANSMISSION
BEARING INNER RACE
(EARILIER MODELS)
SUN GEAR
OIL
COLLECTOR
RING
EXTERNAL-SPLINED
CLUTCH PLATE
CLUTCH ASSEMBLY
INTERMEDIATE
-RANGE
PLANETARY
SPLITTER
OUTPUT
SHAFT
INTERNAL-SPLINED
CLUTCH PLATE
SEALRING
VH08311.00.00
VH08309.00.00
INTERMEDIATE-RANGE
CLUTCH ANCHOR
INTERMEDIATE-RANGE
RING GEAR
KEY
VH08310.00.00
73
CLUTCH SPRING
COMPRESSOR
TOOL
J 7470-A
APPLY HOLE
KEYWAY (2)
T-BAR
CONTROL
VALVE
MOUNTING
PAD
VH08313.00.00
VH08312.00.00
INTERNAL-SPLINED
CLUTCH PLATE (7)
SECOND-RANGE
RING GEAR
SPRING PIN
(14)
SPRING
(14)
EXTERNAL-SPLINED
CLUTCH PLATE (7)
RETAINER
SECOND-RANGE
CLUTCH
ANCHOR
VH08314.00.00
ASSEMBLY OF TRANSMISSION
of the piston housing and tap it into place
(Figure 711).
5. Place first-range ring gear hub 6 (Foldout
16,B) on the work table, smaller clutch piston
diameter up, and install bearing retainer 14
(Foldout 16,A) onto the hub. Heat bearing 13
and press it onto the hub.
6. Turn first-range ring gear hub 6 (Foldout 16,B)
so bearing 13 (Foldout 16,A) is down. Place
first-range ring gear 7 (Foldout 16,B) onto gear
hub 6 and align the retaining ring grooves of
both. Install retaining ring 8 into the aligned
grooves to secure the hub in the gear.
FIRST-RANGE CLUTCH PISTON
CAUTION:
When installing the piston housing and its
assembled parts (Figure 716) be careful to not
damage the splitter shaft or bearing in the bore
of the second-range planetary carrier assembly.
PISTON HOUSING
VH04262.00.00
PISTON
HOUSING
PISTON
HOUSING
CLUTCH
APPLY PORT
VH08316.00.00
VH08315.00.00
75
PISTON
HOUSING
SECOND-RANGE
PLANETARY CARRIER
RETAINING RING
FIRST-RANGE
RING GEAR
PISTON
HOUSING
SECOND-RANGE
PLANETARY
CARRIER
VH08317.00.00
VH04024.00.01
FIRST-RANGE
RING GEAR
PISTON
HOUSING
FIRST-RANGE
CLUTCH
PISTON
GASKET
SPRING
GUIDE PINS
SPLITTER
SHAFT
SUN GEAR
SECONDRANGE
PLANETARY
CARRIER
T-BAR
NOTE:
The notch flats MUST BE turned inward so that the
retaining ring installed in Steps (9) and (11) will seat
properly and retain the pins.
76
VH08509.00.00
ASSEMBLY OF TRANSMISSION
2. Install 16 springs 2 (Foldout 17,A) into the
anchor. Install 16 spring pins 3 into the anchor,
notch end first, with the notch flat facing
inward. Some earlier models use springs 5 and
pins 4 (Foldout 17,A) See Parts Catalog
PC1249EN.
FIRST-RANGE
RING GEAR
FIRST-RANGE
CLUTCH PISTON
LOW-RANGE
PISTON HOUSING
CAUTION:
MAIN
HOUSING
VH08276.00.00
CLUTCH ANCHOR
SPRING
clutch
backplate
CAUTION:
Retaining ring 2 must be installed so the
retaining ring ends are between the two piston
spring holes which have four spline teeth
between them (Figure 721). Installing the
retaining ring in any other position will result in
failure to securely engage every spring pin with
the retaining ring.
VH08320.00.00
77
NOTCH PLATE
SPRING PIN (16)
CLUTCH
PLATE
CLUTCH PLATE
RING GEAR
REVERSE-RANGE
SUN GEAR
FOUR
SPLINES
LOCATING
RING
VH08322.00.00
VH08524.00.00
FABRICATED
LIFTING NUT
FIRST-RANGE
CARRIER
ASSEMBLY
FIRST-RANGE
RING GEAR
VH08321.00.00
78
ASSEMBLY OF TRANSMISSION
REVERSE-RANGE
PISTON
SPACER
SPRING PIN
RING GEAR
SEAL
KEYWAY (2)
ENTERNALSPLINED
CLUTCH
PLATE
TRANSMISSION
REAR COVER
VH08517.00.00
VH08323.00.00
REVERSE-RANGE
CLUTCH PLATE
REVERSE-RANGE
PLANETARY CARRIER
ASSEMBLY
REVERSERANGE
RING
GEAR
VH08324.00.00
79
BEARING
TRANSMISSION
REAR COVER
SPRING PIN
GUIDE
REAR
HOUSING
SPEEDOMETER
DRIVE GEAR
MAGNETIC
PICKUP GEAR
GASKET
VH04277.00.00
VH08516.00.00
KEY (2)
KEYWAY (2)
GASKET
TRANSMISSION REAR HOUSING
FIRST- AND REVERSE- RANGE
CLUTCH ANCHOR
VH08510.00.00
NOTE:
Flange for models with parking brake should not be
installed at this time. Refer to Paragraph 76.
ASSEMBLY OF TRANSMISSION
SLING
BEARING RETAINER
TRANSMISSION
HOUSING
SEAL
GASKET
VH04278.00.00
OUTPUT
FLANGE
BEARING
RETAINER
PLATE
711
RETAINING
RING
TRANSMISSION
HOUSING
VH08328.00.00
SIDE
SUPPORT
LEG (2)
J 23556
CENTER
SUPPORT
LEG
RETAINING RING
KEY
OUTPUT SHAFT
VH08329.00.00
VH08331.00.00
ASSEMBLY OF TRANSMISSION
7. Install the splitter-high clutch piston and piston
housing, housing first into the transmission,
aligning the piston housing with the keys. Note
the word TOP marked on the piston housing.
SPRING GUIDE
SPRING
SPLITTER-HIGH
CLUTCH
BACKPLATE
SPLITTER-HIGH
CLUTCH PLATE
VH08333.00.00
VH08332.00.00
713
TRANSMISSION
MAIN SHAFT
SPLITTER-LOW
CLUTCH
ASSEMBLY
BOLT (2)
PITOT TUBE
INPUT BEARING
RETAINER
VH08334.00.00
SPLITTER-LOW
CLUTCH ASSEMBLY
STEEL STOCK
VH08335.00.00
714
ASSEMBLY OF TRANSMISSION
INPUT BEARING
RETAINER
GASKET
SPLITTER-HIGH
PLANETARY
CARRIER
ASSEMBLY
SPLITTER HUB
SPLITTER-LOW
CLUTCH DRUM
TRANSMISSION
MAIN SHAFT
SPLITTER
CLUTCH
HUB
VH08511.00.00
RETAINING
RING
SPLITTER-LOW
CLUTCH
ASSEMBLY
VH08337.00.00
SPLITTER
PLANETARY
CARRIER
CLUTCH
HUB
DOWEL
PIN
(2)
TORQUE
CONVERTER
HOUSING
BEARING
BOLT (6), LOCKWASHER (6)
ACCESSORY COVER
VH08336.00.00
GASKET
V08512.00.00
715
TORQUE
CONVERTER
GROUND
SLEEVE
TORQUE
CONVERTER
HOUSING
TORQUE
CONVERTER
HOUSING
HUB
HUB
BEARING
ACCESSORY DRIVE
VH04281.00.00
GASKET
ACCESSORY
DRIVE COVER
VH03997.00.00
RETAINING
RING
CAUTION:
Do not allow the remaining parts to shift
position.
12. Leaving the two bolts tight, use a depth
measuring tool and measure the distance from
the top face of retainer plate 38 (Foldout 10,B;
Figure 746) to the end of turbine shaft 27
through the third hole in the retainer plate.
716
NOTE:
Shims are available in 0.025 and 0.005 inch (0.63
and 0.12 mm) thicknesses.
16. Install shims 37, to equal thickness determined
in Step (15), in front of turbine shaft 27
(Foldout 10,B).
ASSEMBLY OF TRANSMISSION
TURBINE SHAFT
SHIM PACK
RETAINING PLATE
C
A
V08338.00.00
717
SLING
POWER TAKEOFF
MOUNTING PAD
TORQUE CONVERTER
HOUSING
ROTOR
RETAINER
PLATE
RETARDER
ROTOR
(EARIER
MODELS)
718
BOLT
(6)
VH08264.00.00
ASSEMBLY OF TRANSMISSION
25. Install oil strainer assembly 8 and gasket 6
(Foldout 20,A) into the oil pan (Figure 749).
Attach the strainer with six bolts 9 and
lockwashers 14. Tighten the bolts to 2632 lb ft
(3540 Nm).
MAIN
HOUSING
TORQUE
CONVERTER
HOUSING
BOLTS (4)
GASKET
VH03978.00.00
VH08339.00.00
STRAINER SHIELD
SPINDLE
OIL PAN
OIL PUMP
DRIVER IDLER
GEAR
GASKET
OIL STRAINER ASSEMBLY
VH04283.00.00
VH08525.00.00
719
VH08340.00.00
TORQUE CONVERTER
PUMP ASSEMBLY
GUIDE BOLT
OIL PUMP
DRIVER
IDLER GEAR
POWER
TAKEOFF
GEAR
BALL
BEARING
SEALRING
VH04284.00.00
VH03995.00.00
720
OIL PUMP
DRIVER IDLER
GEAR
SPINDLE
BOLT AND
LOCKWASHER
ASSEMBLY OF TRANSMISSION
STATOR RACE
STATOR BACKPLATE
SPANNER
WRENCH
J 22158-15
TORQUE CONVERTER
STATOR ASSEMBLY
VH04285.00.00
VH08341.00.00
VH08342.00.00
VH03993.00.00
THRUST WASHER
STATOR
VH00812.00.01
721
TORQUE CONVERTER
DRIVE HOUSING
SEALRING
BACKPLATE
BEARING
INNER
RACE
LOCKUP CLUTCH
PISTON
CLUTCH
BACKPLATE
VH08753.00.00
VH08513.00.00
NOTE:
Locate the slots in reference to the bolt holes, and
carefully center the piston.
722
ASSEMBLY OF TRANSMISSION
Attach the lifting sling to the front cover and
lower it onto the converter housing (gasket in
place), aligning the bolt holes.
9. Install sixteen bolts 5 (Foldout 7,A), nuts 13,
and lockwashers 12 that attach the front cover
to the converter housing. Tighten the nuts to
83100 lb ft (113135 Nm).
TORQUE
CONVERTER
DRIVE HOUSING
ASSEMBLY
CAUTION:
PTO OPENING
VH03985.00.00
FRONT COVER
LIFTING NUT
TORQUE CONVERTER
DRIVE HOUSING
ASSEMBLY
BOLT (26),
38-24 x 334 in.
GASKET
GUIDE BOLT (2)
TORQUE
CONVERTER
HOUSING
LOCKUP CLUTCH
BACKPLATE
SPACE FOR
DOWEL PIN
LOCKUP CLUTCH
PLATES
VH04286.00.00
VH03984.00.00
723
FRONT COVER
HYDRAULIC RETARDER
CONTROL VALVE
LOCKWASHER (16)
AND NUT (16)
GASKET
WOOD
BLOCKS (2)
4 x 4 in.
TRANSFER TUBE
ASSEMBLIES
GASKET
VH03983.00.00
VH08343.00.00
724
ASSEMBLY OF TRANSMISSION
l. Installing Control Valve
ComponentsManual-Hydraulic
1. Install three oil jumper tubes and hoses into the
control valve assembly mounting pad
(Figure 768). On earlier models, if the jumper
tubes do not fit tightly, squeeze the larger OD
end of them slightly out-of-round to ensure a
tight metal-to-metal fit.
2. Install the oil transfer plate gasket and two
38-16 headless guide pins J 24315-1 onto the
transmission housing (Figure 769). Install the
oil transfer plate.
3. Install four bolts 11 (Foldout 21,A) and
lockwashers 10 into the holes marked G
(Figure 771). Tighten the bolts to 2632 lb ft
(3643 Nm).
GUIDE PINS J 24315-1
LOCKUP CLUTCH
CONTROL VALVE
ASSEMBLY
GASKET
VH08344.00.00
OIL TRANSFER
PLATE
JUMPER TUBE AND HOSE (3)
GASKET
VH00799.00.00
VH08345.00.00
725
VH08514.00.00
B
BOLT, 38-16 x 5 in. (2 MARKED E)
2632 lb ft (3643 Nm) TORQUE
FLAT WASHER,
38 in. (3)
GASKET Q
OIL TRANSFER
PLATE P
G
G
C
VALVE BODY H
GASKET I
OIL TRANSFR
PLATE J
GASKET M
F
B
VALVE BODY L
BOLT
COPPER WASHER (1)
(1 MARKED S)
COPPER WASHER, 38 in. (8)
S
D
726
GASKET K
BOLT,
38-16 x 114 in.
(2 MARKED F)
2632 lb ft
(3643 Nm)
TORQUE
GASKET O
FLAT WASHER,
38 in. (2)
ASSEMBLY OF TRANSMISSION
9. Install gasket I and valve body H onto the
guide pins.
10. Install the following bolts, all with copper
washers:
Four 38-16 x 414 inch, marked C
Eight 38-16 x 6 inch, marked D
MAIN-PRESSURE
REGULATOR
VALVE
GASKET
SPLIT
FLANGE
VH03968.00.00
2. Install gasket 23 (Foldout 20,B) and mainpressure regulator valve assembly 15 onto the
converter housing (Figure 773). Secure the
valve assembly with two 716-14 x 312 inch
bolts 10 and lockwashers 11. Tighten the bolts
to 4250 lb ft (5767 Nm).
FILTER BASE
GASKET
MAIN-PRESSURE
REGULATOR VALVE
V08717.00.00
727
FILTER
BASE
DRAIN
PLUG (2)
GASKET
MAIN-PRESSURE
REGULATOR
VALVE BODY
BOLT AND
FLAT WASHER (3),
7 16-14 x 31 2 in.
VH00792.00.02
o. Output
Flange
Runout
Measurement.
Excessive output flange runout will have a detrimental
effect on the transmission rear components. Measure
the runout after final assembly. The reading taken at
the pilot diameter of the flange should not exceed
0.010 inch (0.25 mm). Refer to Paragraph 632c.
ASSEMBLY OF TRANSMISSION
with two 516-18 x 78 inch bolts and
lockwashers. Tighten the bolts to 1316 lb ft
(1821 Nm).
13. Position the transmission on the rear of the rear
cover so that the converter end of the
transmission is facing upward. While the
transmission is horizontal, install the retaining
ring onto the splitter output shaft. Now, follow
Paragraph 73g(4) through (20).
14. Install items 26 through 32 (Foldout 11,A) and
52 through 66 into converter housing
assembly 7. Follow procedures as outlined in
Paragraph 73h(1) through (6).
15. Install turbine shaft sleeve 41 (Foldout 11,A),
small diameter first, onto turbine shaft 38.
Install bearing 42 and retainer 43 onto the front
side of rotor 44.
16. Press the rotor assembly onto the rear of
turbine shaft 38, making sure it is firmly seated
against sleeve 41. Install retaining ring 50 into
its groove inside the hub of rotor 44.
17. Install rotor hub retainer plate 48, smaller
diameter first, into the hub of retarder rotor 44.
Install two retainer bolts 46 and tighten them to
10 lb ft (14 Nm). This will seat the parts.
CAUTION:
Do not allow the remaining parts to shift
position.
18. Follow steps in Paragraph 73h(12) through
(16) to determine the thickness of shims
(Figure 746) required between the retainer
plate and the turbine shaft.
NOTE:
Shims are available in 0.025 and 0.005 inch
(0.63 and 0.12 mm) thicknesses.
19. Install shims 49 (Foldout 11,A) onto turbine
shaft 38.
20. Install retainer plate 48, smaller diameter first,
against the shims. Install lockplate 47 and two
12-20 x 114 inch bolts 46 into shaft 38. Tighten
the bolts to 83100 lb ft (113135 Nm). Bend
the ends of lockplate 47 against the bolt heads.
729
ASSEMBLY OF TRANSMISSION
b. Installing Parking Brake
1. Apply sealant with Teflon, or equivalent, onto
the threads of magnetic pickup plug 29 (Foldout 18,B). Thread the pickup plug into the
58-18 tapped hole in the transmission rear
cover (Figure 775) until the end contacts the
tip of the gear tooth. Then back it out 34 of a
turn. Hold the pickup plug and tighten the
locknut to 1316 lb ft (1821 Nm). Be sure
the output shaft will rotate without interference
between the pickup gear and the magnetic
pickup. On electric-shift models, install the
magnetic pickup guard 32 (Foldout 18,B) so that
it covers the magnetic pickup (Figure 775).
2. Install the speedometer drive assembly and
gasket (Figure 775). Secure the assembly
with two 516-18 x 78 inch bolts and
lockwashers. Tighten the bolts to 1316 lb ft
(1821 Nm).
3. If seal 12 (Foldout 18,B) was removed, press a
new seal, spring-loaded lip last, into
retainer 14.
4. Install gasket 13 and bearing retainer 14 onto
the transmission rear cover. Secure the retainer
with twelve 58-11 x 134 inch bolts 16 and
lockwashers 15. (Automatic-electric models
use two 58-11 x 178 inch bolts 34 and
lockwashers 33 and ten 58-11 x 134 inch
bolts 16 and lockwashers 15.) Tighten the bolts
to 164192 lb ft (159189 Nm).
BOLT AND
LOCKWASHER
(10)
MAGNETIC PICKUP
GASKET
SPEEDOMETER DRIVE
COMPONENTS
REAR HOUSING
BRAKE ASSEMBLY
VH03965.00.00
VH03964.00.00
731
732
NOTE:
When more than one spring part number is listed
for the same location, refer to Parts Catalog
PC1249EN to determine which spring is used in
your specific assembly number.
81
Foldout 8,A
5, 14
6,15,17
7,18
16
Description
LOCKUP CLUTCH
Piston, maximum face wear
Friction-faced clutch plate:
Thickness, minimum
Cone, maximum
Groove depth, minimum
Backplate, maximum face wear
Steel clutch plate:
Thickness, minimum
Cone, maximum
Minimum clutch plate pack thickness (DP8861, 8961, 8962, 8963,
and M/S 8610 with 800 series converter; measure with 50 lb
minimum preload)
Wear Limit
in.
(mm)
0.010
0.25
0.190
0.012
0.010
0.010
4.83
0.30
0.25
0.25
0.184
0.030
4.67
0.76
0.583
14.81
Foldout 8,B
8,20
10,18
22
TORQUE CONVERTER
Stator thrust washer, minimum thickness
Stator thrust plate, maximum ID
Stator roller race, minimum OD
0.246
4.773
4.749
6.25
121.23
120.62
Foldout 9,A
27
0.006
0.15
Foldout 9,B
4
6
19
28
0.003
0.003
0.004
0.004
0.08
0.08
0.10
0.10
Foldout 10,A
29,31
29,31
30
30
0.25
0.30
0.25
0.30
Foldout 12,A
14
17
SPLITTER-LOW CLUTCH
Piston, maximum face wear
Friction-faced clutch plate:
Thickness, minimum
Cone, maximum
Groove depth, minimum
82
0.010
0.25
0.190
0.012
0.010
4.83
0.30
0.25
Foldout 12,A
18
19
Foldout 12,B
1
7
Description
Foldout 13,A
2,5
3
SPLITTER PLANETARY
Thrust washer, minimum thickness
Pinion, maximum end play
Foldout 14,A
11
14
HIGH-RANGE CLUTCH
Piston, maximum face wear
Friction-faced clutch plate:
Thickness, minimum
Cone, maximum
Groove depth, minimum
Steel clutch plate:
Thickness, minimum
Cone, maximum
Minimum clutch pack thickness (measure with 50 lb minimum
preload)
Clutch drum, maximum face wear
15
16
Foldout 14,B
6,9
8
INTERMEDIATE-RANGE PLANETARY
Thrust washer, minimum thickness
Pinion, maximum end play
in.
Wear Limit
(mm)
0.1076
0.030
2.73
0.76
0.805
20.45
0.010
0.25
0.010
0.25
0.190
0.012
0.010
4.83
0.30
0.25
0.1076
0.030
2.73
0.76
1.256
31.90
0.055
0.055
1.39
1.39
0.010
0.25
0.190
0.012
0.010
4.83
0.30
0.25
0.1076
0.030
2.73
0.76
1.143
29.0
0.010
0.25
0.055
0.055
1.39
1.39
83
17
Foldout 15,A
1
Description
Foldout 15,B
5,10
7
SECOND-RANGE PLANETARY
Thrust washer, minimum thickness
Pinion, maximum end play
Foldout 16,A
1
SECOND-RANGE CLUTCH
Friction-faced clutch plate:
Thickness, minimum
Cone, maximum
Groove depth, minimum
Steel clutch plate:
Thickness, minimum
Cone, maximum
Minimum clutch pack thickness (measure with 50 lb minimum
preload)
Foldout 16,B
14
17,21,27,34
18,29
FIRST-RANGE PLANETARY
Thrust washer, minimum thickness
Thrust washer, minimum thickness
Pinion, maximum end play
Foldout 17,A
8
FIRST-RANGE CLUTCH
Steel clutch plate:
Thickness, minimum
Cone, maximum
Friction-faced clutch plate:
Thickness, minimum
Cone, maximum
Groove depth, minimum
84
in.
Wear Limit
(mm)
0.020
0.51
0.190
0.012
0.010
4.83
0.30
0.25
0.1076
0.030
2.73
0.76
1.586
40.28
0.010
0.25
0.055
0.055
1.39
1.39
0.190
0.012
0.010
4.83
0.30
0.25
0.1076
0.030
2.73
0.76
2.170
55.12
0.117
0.085
0.055
2.97
2.16
1.39
0.1803
0.030
4.58
0.76
0.190
0.012
0.010
4.83
0.30
0.25
Description
REVERSE-RANGE PLANETARY
Thrust washer, minimum thickness
Pinion, maximum end play
Foldout 18,A
1
3,6
REVERSE-RANGE CLUTCH
Backplate, maximum face wear on either side
Friction-faced clutch plate:
Thickness, minimum
Cone, maximum
Groove depth, minimum
Steel clutch plate:
Thickness, minimum
Cone, maximum
Minimum clutch pack thickness (measure with 50 lb minimum
preload)
4,7
in.
Wear Limit
(mm)
2.282
57.96
0.055
0.055
1.39
1.39
0.010
0.25
0.190
0.012
0.010
4.83
0.30
0.25
0.1803
0.030
4.58
0.76
1.950
49.53
Foldout 18,B
6
0.377
9.57
Foldout 19,B
43
PARKING BRAKE
Brake drum, maximum wear on surface
0.100
2.54
Foldout 20,B
16
0.004
0.10
Foldout 21,A
24,30,31,
43,61,62,
63,64,68,86
25,55,56
85
0.003
0.08
0.003
0.08
Foldout 22
28,29,33,
34,37,40,
42,51,54,
58,61,65,
68,74,76,
79
73
111
0.003
0.08
0.003
0.003
0.08
0.08
85
86
15
12
12,A
12,B
13,B
14,A
17
9,B
22
9,B
11,A
9,B
10
16
8,B
10,B
Ref.
Foldout
Lockup valve
Stator
Spring
White Stripe
6758597
No Code
Green Stripe
6833247
6756042
No Code
No Code
6835742
6769344
No Code
No Code
No Code
6776586
6756042
6776324
No Code
Red Stripe
6758475
6776324
Yellow Stripe
Green
No Code
No Code
No Code
Color
Code
6775812
6769252
6835362
6833937
6830063
Part No.
Belleville
12
13
9.5
12
Belleville
19.5
19.5
13
13.5
14
14
13
15
40
No.
Coils
0.080
(2.03)
0.105
(2.67)
0.105
(2.67)
0.120
(3.05)
0.023
(0.58)
0.054
(1.37)
0.135
(3.43)
0.080
(2.03)
0.078
(1.98)
0.079
(2.01)
0.128
(3.25)
0.091
(2.31)
0.091
(2.31)
0.250
(6.35)
0.680
(17.27)
0.945
(24.00)
0.690
(17.53)
0.690
(17.53)
0.690
(17.53)
0.794
(20.17)
0.562
(14.27)
0.562
(14.27)
10.710
(272.03)
0.625
(15.88)
0.625
(15.88)
0.710
(18.03)
0.710
(18.03)
10.710
(272.03)
2.32
(58.9)
3.15
(80.0)
3.01
(76.5)
2.65
(67.3)
2.56
(65.0)
2.84
(72.1)
2.81
(71.4)
2.72
(69.0)
2.72
(69.0)
0.41
(10.4)
1.77
(45.0)
1.43
(36.3)
2.35
(59.7)
2.20
(55.9)
0.41
(10.4)
1.31
(33.3)
1.32
(33.5)
1.75
(44.4)
1.68
(42.7)
1.52
(38.6)
1.70
(43.2)
1.85
(47.0)
1.62
(41.1)
1.62
(41.1)
1.58
(40.1)
2.11
(53.6)
2.00
(50.8)
2.00
(50.8)
14.918.2
(6780)
14.421.6
(6596)
42.046.0
(187204)
60.377.7
(269345)
0.91.0
(4.04.4)
4.96.0
(2226)
90.0100.0
(401444)
21.123.3
(94103)
19.221.4
(8695)
26.028.0
(116124)
57.263.4
(254282)
25.230.8
(113137)
25.230.8
(113137)
Approx.
Free
Wire Dia. Spring OD Length
Length Under Load
mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
13
15, 21
19
24
60
66
67
69
19,B
19,B
19,B
19,B
19,B
19,B
19,B
19,B
* Tension spring
17,A
16,A
18
14,B
17,A
Ref.
Foldout
Brake shoe-to-shoe
Brake self-adjuster
Brake anchor-to-shoe
Intermediate-range
piston return
Second-range piston return
Spring
No Code
6833203
6837806
6837805
6883721
6883738
6831514
6831508
6831515
6831511
6758503
Orange
Brown
Green
Yellow
Black
Red
Red
Black
No Code
No Code
No Code
6777897
6833203
No Code
No Code
Color
Code
6758503
6833203
Part No.
5.75
14
20
19.5
25
20.5
21
20
16.5
16
16
20
20
16
No.
Coils
0.091
(2.31)
0.091
(2.31)
0.091
(2.31)
0.091
(2.31)
0.091
(2.31)
0.112
(2.84)
0.091
(2.31)
0.113
(2.87)
0.142
(3.61)
0.105
(2.67)
0.120
(3.05)
0.135
(3.43)
0.105
(2.67)
0.120
(3.05)
0.120
(3.05)
0.625
(15.87)
0.625
(15.87)
0.625
(15.87)
0.625
(15.87)
0.625
(15.87)
0.625
(15.87)
0.625
(15.87)
0.750
(19.05)
0.780
(19.81)
0.810
(20.57)
0.970
(24.64)
0.840
(21.34)
0.750
(19.05)
0.750
(19.05)
0.970
(24.64)
2.65
(67.3)
3.20
(81.3)
3.20
(81.3)
2.65
(67.3)
2.65
(67.3)
2.72
(69.1)
3.20
(81.3)
3.78
(96.0)
5.89
(149.6)
5.81
(147.6)
1.23
(31.2)
5.59
(142.0)
4.79
(121.7)
8.91
(226.3)
1.44
(36.6)
1.94
(49.3)
2.38
(60.5)
2.38
(60.5)
1.94
(49.3)
1.94
(49.3)
2.24
(56.9)
2.38
(60.5)
4.56
(115.8)
6.48
(164.6)
6.75
(171.5)
0.88
(22.4)
6.16
(156.5)
5.36
(136.1)
9.15
(232.4)
0.88
(22.4)
27.934.1
(125151)
27.934.1
(125151)
27.934.1
(125151)
27.934.1
(125151)
27.934.1
(125151)
49.860.8
(222270)
27.934.1
(125151)
45.055.0*
(201244)
72.088.0*
(321391)
27.033.0*
(121146)
40.050.0
(178222)
54.066.0*
(241293)
27.033.0*
(121146)
45.055.0*
(201244)
67.582.5
(301367)
Approx.
Free
Wire Dia. Spring OD Length
Length Under Load
mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
87
88
21
22
23
26
27
28
29
35, 38
21,A
21,A
21,A
21,A
21,A
21,A
21,A
21,A
46
20,B
20
29
20,B
21,A
18
20,B
5, 82
70
19,B
21,A
Ref.
Foldout
6770860
6778008
6770531
6830240
6777972
5575091
5577420
6758508
6831514
Part No.
Intermediate-range short
trimmer valve, outer
Second-range short trimmer
valve, outer
Detent ball
No Code
No Code
6835736
No Code
No Code
No Code
No Code
No Code
No Code
No Code
No Code
No Code
No Code
No Code
No Code
Black
Color
Code
6774328
6759964
6759964
Intermediate-range short
6835357
trimmer valve, inner
Second-range trimmer valve, inner 6835357
Intermediate-range long
trimmer valve, inner
Second-range trimmer
valve, inner
Intermediate-range long
trimmer valve, outer
Second-range trimmer valve, outer
Check valve
Filter retainer
Spring
9.5
15
15
10
10
24
11
16
18
7.8
11
20
No.
Coils
0.120
(3.05)
0.136
(3.45)
0.109
(2.77)
0.120
(3.05)
0.041
(1.04)
0.092
(2.34)
0.091
(2.31)
0.102
(2.59)
0.091
(2.31)
0.091
(2.31)
0.091
(2.31)
0.062
(1.57)
0.062
(1.57)
0.062
(1.57)
0.072
(1.83)
0.970
(24.64)
0.800
(20.3)
1.133
(28.78)
1.172
(29.77)
0.600
(15.24)
0.769
(19.53)
0.732
(18.59)
1.070
(27.18)
1.060
(26.92)
0.685
(17.40)
0.685
(17.40)
0.850
(21.59)
0.850
(21.59)
0.450
(11.43)
0.450
(11.43)
1.23
(31.2)
4.50
(114.3)
4.59
(116.6)
2.31
(58.7)
0.47
(11.9)
3.78
(96.0)
2.49
(63.3)
3.28
(83.3)
7.00
(177.8)
2.35
(59.7)
2.35
(59.7)
4.50
(114.3)
4.50
(114.3)
1.10
(27.9)
1.09
(27.7)
0.88
(22.4)
3.79
(96.2)
2.66
(67.6)
1.50
(38.1)
0.42
(10.7)
1.85
(47.0)
1.58
(40.1)
2.57
(65.3)
4.80
(121.9)
1.88
(47.8)
1.88
(47.8)
1.03
(26.1)
1.03
(26.1)
0.76
(19.3)
0.76
(19.3)
40.050.0
(178222)
60.866.8
(271297)
35.142.7
(156189)
31.538.2
(141169)
0.30.4
(1.41.7)
38.042.0
(170186)
23.826.2
(106116)
12.215.0
(5566)
10.411.6
(4751)
9.510.5
(4346)
9.510.5
(4346)
11.213.6
(5060)
11.213.6
(5060)
16.217.8
(7379)
23.726.3
(106116)
Approx.
Free
Wire Dia. Spring OD Length
Length Under Load
mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
60
65
66
67
69
70
21,A
21,A
21,A
21,A
21,A
21,A
57
21,A
59
54
21,A
21,A
53
21,A
58
46
21,A
21,A
Ref.
Foldout
No Code
No Code
6830240
No Code
No Code
6778009
6778008
6769825
No Code
6835357
No Code
6835384
No Code
No Code
No Code
No Code
No Code
No Code
Yellow Stripe
Yellow Stripe
No Code
Color
Code
6759964
6759964
6759964
6835357
6835357
6779016
6779016
6770531
Part No.
Spring
18
16
11
12
10
12
16
15
15
15
10
10
12
12
16
No.
Coils
0.091
(2.31)
0.127
(3.23)
0.127
(3.23)
0.091
(2.31)
0.091
(2.31)
0.062
(1.57)
0.062
(1.57)
0.062
(1.57)
0.058
(1.47)
0.047
(1.19)
0.072
(1.83)
0.047
(1.19)
0.102
(2.59)
0.105
(2.67)
0.092
(2.34)
0.732
(18.59)
1.060
(26.92)
1.060
(26.92)
0.685
(17.40)
0.685
(17.40)
0.850
(21.59)
0.850
(21.59)
0.850
(21.59)
0.850
(21.59)
0.667
(16.94)
0.685
(17.40)
0.667
(16.94)
1.070
(27.18)
0.750
(19.0)
0.769
(19.53)
2.49
(63.1)
3.22
(81.8)
3.22
(81.8)
2.35
(59.7)
2.35
(59.7)
4.50
(114.3)
4.50
(114.3)
4.50
(114.3)
4.24
(107.7)
3.26
(82.8)
2.35
(59.7)
3.26
(82.8)
3.28
(83.3)
3.32
(84.3)
3.78
(96.0)
1.58
(40.1)
2.79
(70.8)
2.79
(70.8)
1.88
(47.8)
1.88
(47.8)
1.03
(26.1)
1.03
(26.1)
1.03
(26.1)
1.03
(26.2)
2.22
(56.4)
1.88
(47.8)
2.22
(56.4)
2.57
(65.3)
3.05
(77.5)
1.85
(47.0)
23.826.2
106116)
18.522.6
(83100)
18.522.6
(83100)
9.510.5
(4346)
9.510.5
(4346)
11.213.6
(5060)
11.213.6
(5060)
11.213.6
(5060)
6.98.5
(3137)
2.83.3
(1314)
9.510.5
(4346)
2.83.3
(1314)
12.215.0
(5566)
11.412.6
(5156)
38.042.0
(169186)
Approx.
Free
Wire Dia. Spring OD Length
Length Under Load
mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
89
810
35
37
40
43
52
53
55
22
22
22
22
22
22
22
30
22
32
27
22
22
87
21,A
31
78
21,A
22
Ref.
Foldout
Check valve
Spring
No Code
No Code
6839279
No Code
No Code
No Code
No Code
No Code
No Code
6830240
6769825
6759964
6832304
6832304
6832304
6832304
No Code
No Code
6833223
6830243
No Code
No Code
No Code
No Code
No Code
Color
Code
6832305
6832304
6835394
6757375
6778007
Part No.
15
18
12
15
11
11
11
11
32
9.5
9.5
11
12
12
No.
Coils
0.041
(1.04)
0.092
(2.34)
0.062
(1.57)
0.085
(2.16)
0.102
(2.59)
0.101
(2.57)
0.071
(1.80)
0.085
(2.16)
0.085
(2.16)
0.085
(2.16)
0.085
(2.16)
0.062
(1.57)
0.047
(1.19)
0.092
(2.34)
0.113
(2.87)
0.600
(15.24)
1.062
(26.97)
0.440
(11.17)
0.700
(17.78)
0.830
(21.08)
0.830
(21.08)
0.565
(14.35)
0.700
(17.78)
0.700
(17.78)
0.700
(17.78)
0.700
(17.78)
0.850
(21.59)
0.667
(16.94)
0.769
(19.53)
0.754
(19.15)
0.97
(24.6)
2.18
(55.4)
1.56
(39.6)
1.83
(46.5)
2.02
(51.3)
1.78
(45.2)
4.94
(125.5)
1.83
(46.5)
1.83
(46.5)
1.83
(46.5)
1.83
(46.5)
4.50
(114.3)
3.26
(82.8)
3.78
(96.0)
3.02
(76.7)
0.80
(20.3)
0.68
(17.3)
1.02
(25.9)
1.22
(31.0)
1.26
(32.0)
1.26
(32.0)
2.60
(66.0)
1.22
(31.0)
1.22
(31.0)
1.22
(31.0)
1.22
(31.0)
1.03
(26.1)
2.22
(56.4)
1.85
(47.0)
1.80
(45.7)
0.30.4
(1.41.7)
2834
(125151)
19.523.5
(87104)
21.025.0
(94111)
38.042.0
(170186)
26.128.9
(117128)
22.527.5
(101122)
21.025.0
(94111)
21.025.0
(94111)
21.025.0
(94111)
21.025.0
(94111)
11.213.6
(5060)
2.83.3
(1314)
38.042.0
(170186)
82.691.4
(368406)
Approx.
Free
Wire Dia. Spring OD Length
Length Under Load
mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
63
66
67
69
70
72
22
22
22
22
22
60
22
22
59
22
62
56
22
22
Ref.
Foldout
Intermediate-range
trimmer lower valve, outer
Intermediate-range
trimmer upper valve, outer
Intermediate-range
trimmer upper valve, inner
Intermediate-range
trimmer lower valve, inner
Second-range trimmer
upper valve, outer
Second-range trimmer
upper valve, inner
Second-range trimmer lower
valve, inner
Spring
No Code
Green Stripe
6830237
6759964
No Code
No Code
6830240
6830014
No Code
No Code
6830236
6769825
No Code
No Code
6830014
6759964
Green Stripe
No Code
6830240
6776676
No Code
No Code
6778593
6769825
No Code
No Code
6883534
6759964
Red Stripe
Color
Code
6830241
Part No.
15
18
13
12
15
12
18
14.5
12
15
7.5
12
No.
Coils
0.120
(3.05)
0.120
(3.05)
0.062
(1.57)
0.047
(1.19)
0.105
(2.67)
0.092
(2.34)
0.135
(3.43)
0.112
(2.84)
0.062
(1.57)
0.047
(1.19)
0.079
(2.01)
0.092
(2.34)
0.112
(2.84)
0.120
(3.05)
0.062
(1.57)
1.060
(26.92)
1.060
(26.92)
0.850
(21.59)
0.667
(16.94)
0.750
(19.05)
0.769
(19.53)
1.060
(26.92)
1.060
(26.92)
0.850
(21.59)
0.667
(16.94)
0.756
(19.20)
0.769
(19.53)
1.060
(26.92)
1.06
(16.92)
0.850
(21.59)
3.57
(90.7)
1.95
(49.5)
4.50
(114.3)
3.26
(82.8)
2.84
(72.1)
3.78
(96.0)
3.29
(83.6)
1.60
(40.6)
4.50
(114.3)
3.26
(82.8)
3.01
(76.5)
3.78
(96.0)
1.60
(40.6)
2.06
(52.3)
4.50
(114.3)
1.90
(48.3)
1.22
(31.0)
1.03
(26.1)
2.22
(56.4)
1.58
(40.1)
1.85
(47.0)
2.95
(74.9)
1.06
(26.9)
1.03
(26.1)
2.22
(56.4)
1.85
(47.0)
1.85
(47.0)
1.06
(26.9)
1.06
(16.92)
1.03
(26.1)
5763
(254280)
4252
(187231)
11.213.6
(5060)
2.83.3
(1314)
63.670.4
(283313)
38.042.0
(170186)
18.023.2
(81103)
2733
(121147)
11.213.6
(5060)
2.83.3
(1314)
1921
(8593)
38.042.0
(170186)
2733
(121146)
5763
(254280)
11.213.6
(5060)
Approx.
Free
Wire Dia. Spring OD Length
Length Under Load
mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
811
812
81
89
112
61
77
22
22
23
23
23
24,B
78
22
22
77
22
80
75
22
22
Ref.
Foldout
Splitter-low trimmer
upper valve, outer
Splitter-low trimmer
upper valve, inner
Splitter-low trimmer
lower valve, inner
Spring
6839318
6839321
6839323
6839318
6832304
No Code
No Code
No Code
No Code
No Code
No Code
Green Stripe
6830237
6834536
No Code
No Code
6830240
6830014
No Code
No Code
6778009
6769825
No Code
No Code
6832306
6759964
No Code
Color
Code
6830240
Part No.
56
4.5
11
15
18
16
12
15
15
18
No.
Coils
0.092
(2.34)
0.102
(2.59)
0.062
(1.57)
0.047
(1.19)
0.105
(2.67)
0.092
(2.34)
0.112
(2.84)
0.120
(3.05)
0.020
(0.51)
0.085
(2.16)
0.045
(1.14)
0.045
(1.14)
0.038
(0.97)
0.045
(1.14)
0.769
(19.53)
0.760
(19.30)
0.850
(21.59)
0.667
(16.94)
0.750
(19.05)
0.769
(19.53)
1.060
(26.92)
1.06
(16.92)
0.330
(8.38)
0.700
(17.78)
0.300
(7.62)
0.600
(15.24)
0.480
(12.19)
0.300
(7.62)
3.78
(96.0)
3.00
(76.2)
4.50
(114.3)
3.26
(82.8)
3.32
(84.3)
3.78
(96.0)
1.60
(40.6)
2.06
(52.3)
1.25
(31.8)
1.83
(46.5)
0.56
(14.3)
0.75
(19.0)
0.88
(22.4)
0.56
(14.3)
1.85
(47.0)
2.25
(57.2)
1.03
(26.1)
2.22
(56.4)
3.05
(77.5)
1.85
(47.0)
1.06
(26.9)
1.06
(16.92)
0.94
(23.9)
1.22
(31.0)
0.46
(11.7)
0.65
(16.5)
0.56
(14.2)
0.46
(11.7)
38.042.0
(170186)
30.533.5
(136149)
11.213.6
(5060)
2.83.3
(1314)
11.412.6
(5156)
38.042.0
(170186)
2733
(121146)
5763
(254280)
0.10.2
(0.50.8)
21.025.0
(94111)
6.98.5
(3137)
1.31.7
(67)
5.06.0
(2326)
6.98.5
(3137)
Approx.
Free
Wire Dia. Spring OD Length
Length Under Load
mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
OWNER ASSISTANCE
areas
Complete parts support
Sales teams to help determine your power
requirements
Product information and literature
Refer to the Worldwide Sales and Service Directory
(SA2229EN) or the Allison transmission web site
www.allisontransmission.com for a current listing of
Allison Transmission authorized distributor and service
dealers. This directory is available from SGI, Inc.
Normally, any situation that arises in connection with
the sale, operation, or service of your transmission will
be handled by the distributor or dealer in your area
(check the telephone directory for the Allison
Transmission service outlet nearest you).
We recognize, however, that despite the best intentions
of everyone concerned, misunderstandings may occur.
To further assure your complete satisfaction, we have
developed the following three-step procedure to be
followed in the event you have a problem that has not
been handled satisfactorily.
Step OneDiscuss the problem with a member of
management from the distributorship or
dealership. Complaints are frequently the result of a
breakdown in communication and can be quickly
resolved by a member of management. If you have
already discussed the problem with the Sales or
Service Manager, contact the General Manager. All AT
dealers are associated with an AT distributor. If the
problem originates with a dealer, explain the matter to
a management member of the distributorship with
whom the dealer has his service agreement. The dealer
will provide his AT distributors name, address, and
telephone number on request.
Step TwoIf your problem cannot be resolved
readily at the distributor level without additional
assistance, contact the Allison Transmission
Regional Office responsible for your local
2006
or dealer
Type and make of equipment
Transmission model number, serial number,
and assembly number
Transmission delivery date and
accumulated miles and/or hours of
operation
Nature of problem
Chronological summary of unit's history
Step ThreeIf you contacted a regional office and
you are still not satisfied, present the entire matter in
writing or by phone to the Home Office:
Manager, Warranty Administration
Allison Transmission
P. O. Box 894, Mail Code 462-470-PF9
Indianapolis, IN 46206-0894
Phone: 1-800-252-5283
The inclusion of all pertinent information will assist
the Home Office in expediting the matter. If an
additional review by the Home Office of all the facts
involved indicates that some further action can be
taken, the Regional Office will be advised.
When contacting the Regional or Home Office, please
keep in mind that ultimately your problem will likely
be resolved at the distributorship or dealership
utilizing their facilities, equipment, and personnel.
Therefore, it is suggested that you follow the above
steps in sequence when experiencing a problem.
Your purchase of an Allison Transmission product is
greatly appreciated, and it is our sincere desire to
assure complete satisfaction.
91
92
OM1318EN
OM2034EN
OM3540EN
PC1249EN
SM1228EN
SM2035EN
SM2035EN
Foldout 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Foldout 1
Input flange
Converter housing front cover
Torque converter drive housing
Lockup clutch plate
Converter housing
Turbine
Stator
Torque converter pump
PTO gear
Retarder rotor
Pitot tube (front governor)
Splitter-low clutch
Splitter-high clutch
Transmission main housing
High-range clutch
Intermediate-range clutch
Second-range clutch
First-range clutch
Reverse-range clutch
Transmission rear cover
Parking brake
Output flange
Output shaft
Speedometer drive
Reverse-range planetary
First-range planetary
Second-range planetary
Intermediate-range planetary
Transmission main shaft
Splitter planetary
Oil pan
Oil pump idler gear
Accessory drive cover
Oil pump drive gear (PTO)
Pressure pump
Scavenge pump
Turbine shaft
Flywheel
Flywheel flexplate assembly
F OLDOUT 1
5
6
10
11
12
13
14
15
16
17
18
19
20
21
22
4
3
2
32
39
37
38
23
37
24
26
32
33
25
33
36
35
34
31
36
35
30
29
34
28
27
VH08482.00.00
Foldout 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Foldout 2
Input flange
Converter housing front cover
Torque converter drive housing
Lockup-clutch plate
Converter housing
Turbine
Stator
Torque converter pump
PTO gear
Retarder rotor
Pitot tube (front governor)
Splitter-low clutch
Splitter-high clutch
Transmission main housing
High-range clutch
Intermediate-range clutch
Second-range clutch
First-range clutch
Reverse-range clutch
Transmission rear cover
Parking brake
Output flange
Output shaft
Speedometer drive
Reverse-range planetary
First-range planetary
Second-range planetary
Intermediate-range planetary
Transmission main shaft
Splitter planetary
Oil pan
Oil pump idler gear
Accessory drive cover
Oil pump drive gear (PTO)
Pressure pump
Scavenge pump
Turbine shaft
F OLDOUT 2
5
6
10
11
12
13
14
15
16
17
18
19
20
21
4
3
2
22
37
24
26
23
25
32
27
33
28
31
36
35
30
29
34
A
Foldout 2. DP 8861 Transmission, Straight-Through Model
VH08483.00.00
F OLDOUT 3
SPLITTER-HIGH
ORIFICE
SPLITTER-LOW
INTERMEDIATE
-RANGE
PITOT
TO RETARDER
FROM RETARDER
HIGH-RANGE
LOCKUP
FROM CONVERTER
ORIFICE
TO CONVERTER
VALVE ASSY
LOCATED ON SIDE OF
CONVERTER HOUSING
TORQUE LIMITER VALVE
SAFETY BLOWOFF
VALVE
PLUG VALVE
FIRST
RANGE
ORIFICE
PITOT
R, N, 1, 2, SIGNAL
FIRST-RANGE
MAIN
REVERSE
ORIFICE
ORIFICE
FLOW VALVE
MANUAL SELECTOR
VALVE
NEUTRAL
TRIMMER VALVE
R, N, 1, 2, SIGNAL
VALVE ASSY
LOCATED ON TOP OF
CONVERTER HOUSING INPUT PUMP
FIRST-RANGE
TRIMMER VALVE
ORIFICE
MAIN
MAIN PRESSURE
LOCKUP
TRIMMER VALVE
MAIN
OIL
COOLER
CHECK VALVE
SECOND-RANGE
EXHAUST
SPLITTER-HIGH SIGNAL
ORIFICE
CONVERTER OUT
REGULATOR
VALVE
SECOND
RANGE
SECOND-RANGE
TRIMMER VALVE
ORIFICE
MAIN-PRESSURE
REGULATOR VALVE
TO FILTERS
FILTER BYPASS VALVE
OPENS AT 20 PSI
DIFFERENTIAL
BOOSTER PLUG
INTERMEDIATE
-RANGE
INTERMEDIATERANGE OVERLAP &
TRIMMER VALVE
CHECK VALVE
20 PSI DIFFERENTIAL
HIGH-RANGE
CHECK VALVE
SPLITTER RELAY
VALVE
SPLITTERHIGH EXHAUST
WARNING SWITCH
SET AT 15 PSI
DIFFERENTIAL PRESSURE
FROM FILTERS
HYDRAULIC RETARDER
CONTROL VALVE
OFF
REVERSE
LOCKUP
LUBRICATION
ON
6
5
4
3
2
1
NEUTRAL
REVERSE
CONVERTER-IN
CONVERTER-OUT
LOCKUP
SHIFT VALVE
OPTIONAL LOCKUP SHIFT
VALVE LINE TO PROVIDE
NO LOCKUP IN R, N, 1, 2
MAIN
LUBRICATION
R, N, 1, 2 SIGNAL
EXHAUST OR SUMP
PLATE ASSY, VALVE ASSY
LOCATED ON SIDE OF TRANSMISSION HOUSING
NEUTRAL SIGNAL
R, N, 1, 2, SIGNAL
PITOT PRESSURE
SPLITTER-LOW
OIL SUMP
X DENOTES EXHAUST
NEUTRAL SIGNAL
VH08718.00.00
Foldout 3. DP 8000 Series Transmission Manual-Hydraulic System With Integral Lockup Trimmer ValveSchematic View
F OLDOUT 4
HIGH-RANGE
SPLITTER-HIGH
SPLITTER-LOW
FROM CONVERTER
ORIFICE
INTERMEDIATERANGE
PITOT
TO RETARDER
LOCKUP
FROM RETARDER
INTERMEDIATE-RANGE
OVERLAP & TRIMMER VALVE
LOCKUP
ORIFICE
FIRST-RANGE
SECOND-RANGE
TRIMMER VALVE
LUBRICATION
OFF
HYDRAULIC RETARDER
CONTROL VALVE
TO CONVERTER
CHECK VALVE
CHECK VALVE
ORIFICE
FROM FILTERS
SECOND-RANGE
REVERSE
MAIN
CONVERTER PRESSURE
RELIEF VALVE
CHECK VALVE
20 PSI DIFFERNTIAL
PLUG VALVE
SPLITTERHIGH
SIGNAL
ORIFICE
ORIFICE
PITOT
MAIN-PRESSURE
REGULATOR VALVE
TO FILTERS
FIRSTRANGE
REVERSE
SECOND-RANGE
EXHAUST
ORIFICE
ORIFICE
CONVERTER-OUT
REGULATOR
VALVE
HIGH-RANGE
INTERMEDIATE-RANGE
WARNING SWITCH
SET AT 15 PSI
DIFFERENTIAL PRESSURE
ON
6
5
4
3
2
1
NEUTRAL
REVERSE
ORIFICE
ORIFICE
FLOW VALVE
NEUTRAL
TRIMMER
VALVE
R, N, 1, 2 SIGNAL
VALVE ASSY
LOCATED ON TOP OF
CONVERTER HOUSING
FIRST-RANGE
TRIMMER VALVE
MAIN
MANUAL
SELECTOR
VALVE
MAIN
ORIFICE
R, N, 1, 2 SIGNAL
MAIN PRESSURE
CONVERTER-IN
INPUT PUMP
MAIN
OIL COOLER
LOCKUP TRIMMER
VALVE
LOCKUP
SHIFT
VALVE
LUBRICATION
OVERLAP VALVE
EXHAUST OR SUMP
MAIN
VALVE
LOCATED ON SIDE OF
CONVERTER HOUSING
OPTIONAL LOCKUP SHIFT
VALVE LINE TO PROVIDE
NO LOCKUP IN R, N, 1, 2
CONVERTER-OUT
NEUTRAL SIGNAL
CHECK VALVE
R, N, 1, 2, SIGNAL
PLATE ASSY, VALVE ASSY
LOCATED ON SIDE OF TRANSMISSION HOUSING
OIL SUMP
PITOT PRESSURE
SPLITTER-LOW
NEUTRAL SIGNAL
VH08719.00.00
Foldout 4. DP 8000 Series Transmission Manual-Hydraulic System With 12 Overlap ValveSchematic View
F OLDOUT 5
SPLITTERLOW
A (CONNECTS TO SOLENOID H)
B (CONNECTS TO SOLENOID I)
SPLITTER-HIGH
FIRSTRANGE
SHIFT
SELECTOR * SOLENOIDS
POSITION ENERGIZED
REVERSERANGE
FRONT
GROUND
1
2
3
4
5
6
N
R
D
E
G
ELECTRICAL CONNECTORS
TOP VIEW
LOCKUP
HYDRAULIC RETARDER
CONTROL VALVE
OFF
VALVE ASSEMBLY
LOCATED ON SIDE OF
CONVERTER HOUSING
FROM
FILTERS
LUBRICATION
CHECK VALVE
20 PSI DIFFERENTIAL
TO RETARDER
FROM COOLER
VALVE ASSEMBLY
LOCATED ON TOP
OF CONVERTER
HOUSING
TO CONVERTER
SOLENOID
D
FLOW
VALVE
PRIORITY
VALVE
ORIFICE
ORIFICE
EXHAUST PORT HERE
ON S/N 655 AND AFTER
ORIFICE
SPLITTER
SHIFT VALVE
SOLENOID I
FIRST-RANGE
SHIFT
VALVE
SECOND-RANGE
SHIFT VALVE
MAIN
MAIN
EXHAUST
CHECK
VALVE
INPUT PUMP
LOCKUP
TRIMMER
VALVE
LOCKUP
SHIFT VALVE
VALVE ASSEMBLY
LOCATED ON SIDE OF
CONVERTER HOUSING
OPTIONAL LOCKUP SHIFT
VALVE LINE TO PROVIDE
NO LOCKUP IN REV., NEU.,
1ST AND 2ND
SOLENOID
REGULATOR
VALVE
ORIFICE
ORIFICE
TO LUBE
OIL SUMP
SOLENOID
C
PITOT
NO LONGER
REQUIRED
BOOSTER
PLUG
SOLENOID F
SOLENOID E
REVERSE
SHIFT VALVE E
TORQUE LIMITER
CONVERTER OUT
REGULATOR
SOLENOID H
SHIFT VALVE
SOLENOID B
WARNING
SWITCH
SET AT 15 PSI
DIFFERENTIAL
PRESSURE
TO FILTERS
FILTER BYPASS
VALVE - OPENS AT
20 PSI DIFFERENTIAL
OIL
FILTER
SOLENOID PRESSURE
TO RETARDER
ON
FIRST-RANGE, SPLITTER-LOW
SECOND-RANGE, SPLITTER-LOW
INTERMEDIATE-RANGE, SPLITTER-LOW
INTERMEDIATE-RANGE, SPLITTER-HIGH
HIGH-RANGE, SPLITTER LOW
HIGH-RANGE, SPLITTER-HIGH
SPLITTER-LOW
REVERSE-RANGE, SPLITTER-LOW
SPLITTER-LOW
REVERSE
FROM RETARDER
FROM CONVERTER
FROM
RETARDER
F, H
C, F
D, F
D, G
E, F
E, G
A, F, I
A, B, F, I
CLUTCHES
ENGAGED
ORIFICE
ORIFICE
INTERMEDIATERANGE
SOLENOID G
ORIFICE
ORIFICE
INTERMEDIATERANGE TRIMMER
VALVE
ORIFICE
HIGH-RANGE
SHIFT VALVE
MAIN PRESSURE
CONVERTER-IN
TRIMMER
REGULATOR
VALVE
CONVERTER-OUT
LUBRICATION
EXHAUST OR SUMP
R, N, 1, 2 BOOSTER
ORIFICE
SPLITTER-LOW
TRIMMER VALVE
PITOT PRESSURE
SPLITTER-LOW
SOLENOID PRESSURE
X - DENOTES EXHAUST
R, N, 1, 2 BOOSTER
V08720.00.00
Foldout 5. DP 8000 Series Transmission Electric Control-Hydraulic SystemSchematic View (Earlier Models)
F OLDOUT 6
SPLITTERLOW
SPLITTER-HIGH
FIRSTRANGE
SOLENOIDS
SHIFT
OPERATION ENERGIZED
REVERSERANGE
1
2
3
4
5
6
N
R
F, H
C, F
D, F
D, G*
E, F
E, G*
A*, F, I
A*, B, F, I*
CLUTCHES
ENGAGED
FIRST-RANGE, SPLITTER-LOW
SECOND-RANGE, SPLITTER-LOW
INTERMEDIATE-RANGE, SPLITTER-LOW
INTERMEDIATE-RANGE, SPLITTER-HIGH
HIGH-RANGE, SPLITTER LOW
HIGH-RANGE, SPLITTER-HIGH
SPLITTER-LOW
REVERSE-RANGE, SPLITTER-LOW
SPLITTER-LOW
SOLENOID PRESSURE
TO RETARDER
LOCKUP
HYDRAULIC RETARDER
CONTROL VALVE
ON
OFF
LUBRICATION
VALVE ASSEMBLY
LOCATED ON SIDE OF
CONVERTER HOUSING
EARLIER
MODELS
OIL
FILTER
30 PSI
CONVERTER-OUT
REGULATOR
TO RETARDER
FROM COOLER
TO CONVERTER
FROM FILTERS
VALVE ASSEMBLY
LOCATED ON TOP
OF CONVERTER
HOUSING
PRIORITY
VALVE
PITOT
FLOW
VALVE
FIRST-RANGE
SHIFT
VALVE
NO LONGER
REQUIRED
TO LUBE
BOOSTER
PLUG
SECOND-RANGE
SHIFT VALVE
MAIN
SPLITTER
SHIFT VALVE
A
INTERMEDIATERANGE SHIFT VALVE
HIGH-RANGE
SHIFT VALVE
MAIN PRESSURE
MAIN
EXHAUST
CHECK
VALVE
INPUT PUMP
LOCKUP
TRIMMER
VALVE
OIL SUMP
SOLENOID
REGULATOR
VALVE
REVERSE
SHIFT VALVE
CHECK VALVE
20 PSI DIFFERENTIAL
TO FILTERS
FILTER BYPASS
VALVE - OPENS AT
20 PSI DIFFERENTIAL
REVERSE
FROM RETARDER
FROM CONVERTER
FROM
RETARDER
LOCKUP
SHIFT VALVE
VALVE ASSEMBLY
LOCATED ON SIDE OF
CONVERTER HOUSING
ORIFICE
ORIFICE
FIRST & REVERSE
TRIMMER
VALVE
INTERMEDIATERANGE TRIMMER
VALVE
CONVERTER-IN
TRIMMER
REGULATOR
VALVE
CONVERTER-OUT
LUBRICATION
EXHAUST OR SUMP
R, N, 1, 2 BOOSTER
SECOND-RANGE
TRIMMER VALVE
PITOT PRESSURE
SPLITTER-LOW
TRIMMER VALVE
SPLITTER-LOW
SOLENOID PRESSURE
X
R, N, 1, 2 BOOSTER
DENOTES EXHAUST
ORIFICE
+ ORIFICE BLOCKED FOR
LOCK-IN NEUTRAL
Foldout 6. DP 8000 Series Transmission Electric Control-Hydraulic SystemSchematic View (Later Models)
V08721.00.00
Foldout 7
Self-locking nut, A
Flange retainer plate
Flange, M9C
Oil seal
Bolt, 12-20 x 212 inch (16)
Transmission housing front cover
Gasket
Ball bearing
DP 8861 converter drive housing assembly
Torque converter housing
Dowel pin (8)
Lockwasher, 12 inch (16)
Nut, 12-20 (16), B
DP 8961 converter drive housing assembly
Torque converter housing
Plug, 18 inch NPTF (2), C
Pin, 516 x 516 (2)
Dowel pin (8)
Flange, S1850 or S1950
Flange, S1880
Flat washer, 38 inch (24)*
Bolt, 38-24 x 334 inch (24)*, D
Torque
A
B
C
D
lb ft
7001000
83100
1012
4149
Nm
9491355
113135
1416
5666
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Foldout 7
lb ft
96115
8197
1012
4149
Nm
131155
110131
1416
5666
F OLDOUT 7
1
19
4
5
6
2
3
6
4
5
7
8
20
10
11
10
11
13
14
22
12
21
23
22
15
24
12
13
15
V08691.00.00
16
14
17
18
17
18
V08484.00.00
19
16
20
21
Foldout 7A. Input Flange, Front Cover, and Converter Drive Housing
Foldout 7B. Input Flange, Front Cover, and Converter Drive Housing Flexplate Drive and Flywheel
Foldout 8
Teflon sealring
Sealring expander
Teflon sealring
Sealring expander
Lockup-clutch piston
Lockup-clutch plate
Lockup-clutch backplate
Teflon sealring
Sealring expander
Teflon sealring
Sealring expander
Teflon sealring
Sealring expander
Lockup-clutch piston
Internal-splined lockup-clutch plate
External-tanged lockup-clutch plate
Internal-splined lockup-clutch plate
Lockup-clutch backplate800 series torque
converter
19 Lockup-clutch backplate1000 series
torque converter
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
* Early Models
** Late models
Foldout 8
lb ft
275325
96115
1012
Nm
372440
130155
1416
F OLDOUT 8
A
1
2
3
4
DP 8860, 8861
5
8
9
10
6
9
11
7
12
10
13
11
12 13 14
15
14
19
16
16
17
20
18
21
17
22
16
23
17
24
25
18
26
27
28
29
30
31
19
32
V08687.00.00
V08686.02.00
Foldout 9
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
A
Bolt, 12-13 x 334 inch, A
Lockwasher, 12 inch
Idler gear spindle
PTO idler gear*
Double-row ball bearing
Retaining ring
Bolt, 716-14 x 78 inch (8), B
Lockwasher,78 inch (8)
PTO cover
Gasket
Bolt, 716-14 x 78 inch (8), B
Lockwasher, 716 inch (8)
PTO cover
Gasket
Gasket
Lockwasher, 38 inch (11)
Bolt, 38-16 x 4 inch (11), C
Retarder control valve assembly
Plug assembly, 34-16, G; Plug, 12 inch, D
(earlier models)
Oil seal
Retaining ring
Retarder control valve body
Gasket
Torque limiter valve assembly, E**
Gasket
Converter-out regulator valve assembly, E
Retarder control valve
Gasket
Cover
Lockwasher, 38 inch (6)
Bolt, 38-16 x 118 inch (6), C
Plug assembly, 34-16, G; Plug, 38 inch, D
(earlier models)
Manifold
Plug
Torque
A
B
C
D
E
F
G
H
Foldout 9
lb ft
6780
4250
2632
2327
80120
1822
1213
lb in.
7080
Nm
91108
5767
3643
3236
109162
2529
1618
7.59.0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
B
Lockup trimmer valve gasket*
Lockup trimmer valve assembly*
Lockup trimmer valve body*
Trimmer valve*
Spring*
Trimmer valve plug*
Spring*
Gasket*
Pin*
Plug, A*
Plug, 18 inch NPT, B*
Plug, 18 inch NPT, B*
Lockup shift valve body gasket
Lockup shift valve assembly
Sealring
Shift valve plug
Lockup shift valve spring
Shim, 0.025 inch (0.63 mm) (AR)
Lockup shift valve
Spring pin
Spring pin
Plug, 18 inch NPT B, plug assembly 38-24, E
Plug, 18 inch NPT B, plug assembly 38-24, E
Plug, 18 inch NPT B, plug assembly 38-24, E
Lockup shift valve body
Check valve
Plug, 18 inch NPT B (earlier models), plug
assembly 38-18, H
Flow valve (lockup cutoff)
Flow valve plug
Sealring
Lockwasher, 38 inch (7)
Bolt, 38-16 x 234 inch (7), C**
Bolt, 38-16 x 414 inch (7), C*
Bolt, 38-16 x 118 inch (2), C**
Bolt, 38-16 x 234 inch (2), C*
Lockwasher, 38 inch (2)
Plug, 12-14, D
Inhibitor pressure switch
Torque
A
B
C
D
E
lb ft
Tighten
sufficiently
1012
2632
2327
lb in.
2832
Nm
To prevent
leakage
1416
3643
3236
3.23.6
Straight-through models:
* May be deleted from the transmission assembly during any repair,
rebuild, or overhaul operation
** Earlier models
F OLDOUT 9
A
7
8
4
12
8
9
10
10
32
6
4
11
33
13
31
34
7
2
11
35
36
33
37
16
14
12
13
17
38
14
34
15
15
20
21
19
30
29
16
17
22
28
23
24
18
17
18
19
20
32
21
22
27
25
26
23
27
26
25
24
V08690.00.00
28
29
31
30
V08485.00.00
Foldout 9A. Retarder Control Valve and PTO Components, Lockup Clutch Trimmer
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
Retaining ring*
Connector assembly*
Sealring*
Connector, C*
Oil seal*
Connector nut, C*
Scavenge pump tube*
Self-locking bolt, 38-16 x 34 inch, A*
Elbow assembly**
Sealring**
Elbow, C**
Oil seal**
Connector nut, C**
Elbow assembly
Sealring
Elbow, C
Oil seal
Connector nut, C
Connector assembly
Sealring
Connector, C
Oil seal
Connector nut, C
Converter pressure transfer tube
Scavenge pump tube**
Connector assembly
Sealring
Connector, C
Oil seal
Connector nut, C
Torque
A
B
C
lb ft
Nm
2632
3543
4250
5767
Tighten sufficiently
to prevent leakage
Foldout 10
Etch Marks
0
1
2
3
4
37 Shims:
0.025 inch (0.63 mm) (AR)
0.005 inch (0.12 mm) (AR)
38 Retainer plate
39 Lockplate
40 Bolt, 12-20 x 114 inch (2), E
41 Bolt, 38-16 x 78 inch (6), F
42 Lockwasher, 38 inch (6)
43 Accessory cover
44 Gasket
45 Retaining ring
46 Ball bearing
47 Rear spacer
48 Pump drive hub
49 Lockwasher, 12 inch
50 Bolt, 12-13 x 3 inch, A
51 Oil pump drive gear
52 Front spacer
53 Ball bearing
54 Self-locking bolt, 12-13 x 3 inch (6), A
(later models)
55 Plug assembly, (916-18) straight-thread, I;
Pipe Plug, 38 inch NPTF (earlier models), J
56 Bolt, 716-14 x 78 (8), J
57 Lockwasher, 716 (8)
58 Gasket
59 Power takeoff pad cover
60 Gasket
61 Power takeoff pad cover
62 Lockwasher, 716 (8)
63 Bolt, 716-14 x 78 (8), J
Torque
A
B
C
D
E
F
G
H
I
J
lb ft
6780
2327
1416
95105
83100
2632
1822
1832
4250
lb in.
7080
Nm
91103
3236
1921
129142
113135
3643
2430
7.99.0
2529
5767
* Select studs to meet specifications of 1565 lb ft (2188 N.m) driving torque for a setting height of 2.9693.031 inch (75.576.9 mm)
F OLDOUT 10
A
63
62
60
17
18
20
21
19
10
28
22
23
29
24
7
8
9
10
54
2
3
4
26
35
27
25
21
11
12
13
59
14
58
31
33
8
53
34
32
11
56
20
30
10
15
51
52
16
57
12
7
5
18
19
13
24
14
15
65
69
68
50
16
3
67
66
49
36
64
23
37
25
48
26
47
63
60
58
59
46
45
38
62 61
22
55
17
29
27
53
28
44
30
43
57 56 55 54
42
41
31
32
33
39
40
52
48
51
49
50
42
34
43
44
45
35 36
41
37 38
39
40
47
46
V08689.00.00
V08688.00.00
Foldout 10B. Torque Converter Housing, Turbine Shaft, and Retarder Rotor (Straight-Through Models)
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Etch Marks
0
1
2
3
4
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
Retaining ring
Teflon sealring
Retaining ring
Sealring
Retainer
Oil seal
Ball bearing
Spacer
Pump drive hub
Gasket
Cover
Lockwasher, 38 inch (6)
Bolt, 38-16 x 38 inch (6), K
Oil pump drive gear
Ball bearing
Oil pump drive gear
Ball bearing
Retaining ring
Double-row ball bearing
Oil pump idler gear
Idler gear spindle
Lockwasher, 12 inch
Bolt, 12-13 x 334 inch, A
Self-locking bolt, 12-13 x 3 inch (6), H
(later models)
74 Bolt, 12-13 x 3 inch, A
75 Lockwasher, 12 inch
Torque
A
B
C
D
E
F
G
H
J
K
L
M
lb ft
6780
2327
1416
3337
95105
7585
3337
8197
83100
2632
4753
lb in.
7080
Nm
91103
3236
1921
4550
129142
102115
4550
110131
113135
3643
6470
7.59.0
Foldout 11
Torque
A
B
C
D
E
F
G
H
I
lb ft
1416
1822
2327
1012
6780
1213
lb in.
5363
7080
2832
Nm
1921
2529
3236
1416
91108
6.57.1
7.49.0
1618
3.23.6
Foldout 11
F OLDOUT 11
1
3
4
5
72
71
70
69
73
25
24
23
22
68
67
7
66
30
31
32
10
65
12
21
11
64
12
3
2
26
63
13 14
6
7
27
74
28
29
8
15
16
75
33
13
14
10
62
61
60
17
15
59
18
20
19
35
34
58
57
36
11
17
55
37
16
56
54
19
53
52
38
18
20
21
22
39
40
41
42
V08685.00.00
43
44
45
51
50
49
48
47
46
V08486.00.00
Foldout 11A. Torque Converter Housing, Turbine Shaft, and Retarder Rotor (Dropbox Models)
Foldout 12
Foldout 12
lb ft
1923
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Nm
2631
F OLDOUT 12
1
1
2
3
4
5
4
5
6
8
7
9
10
12
11
13
14
10
11
15
13
14
12
17
16
15
18
16
17
17
19
18
20
V08693.00.00
V08692.00.00
Foldout 13
Torque
A
lb ft
96115
Nm
131155
B
1
2
3
4
5
6
7
8
9
10
11
12
13
Retaining ring
Converter pressure relief valve seat
Converter pressure relief valve
Spring
Bolt, 38-16 x 34 inch (2), A
Retainer (2)
Transmission main housing assembly
Tube*
Tube
Pin
Transmission housing
Reducer, B
Breather, B
Foldout 13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Torque
A
B
C
D
E
lb ft
Nm
2632
3643
Tighten sufficiently to prevent leakage
6780
91108
117140
159189
6780
91108
F OLDOUT 13
B
7
8
13
9
10 11
38
37
36
10
12
35
14
11
15
34
12
16
17
13
18
19
14
15
16
17
18
2
7
9
20
21
19
3
4
26
33
32
25
23
22
24
6
31
27
28
29
V08694.00.00
30
V08695.00.00
Foldout 14
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Retaining ring
Teflon sealring
Teflon sealring
High-range clutch hub assembly
Dowel pin (8)
Hub
Teflon oil seal
Sealring
High-range clutch piston assembly
Ball, 14 (4) inch
Piston
Piston return spring
Retaining ring
Internal-splined clutch plate (4)
External-splined clutch plate (3)
Clutch drum
Crush ring
Spacer ring (earlier models)
Foldout 14
lb ft
4149
Nm
5666
F OLDOUT 14
B
A
1
2
3
5
6
3
8
10
12
11
13
14
5
10
15
9
8
7
11
6
12
13
14
16
15
16
17
18
17
18
19
20
V08696.00.00
V08490.01.00
Foldout 15
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Foldout 15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
F OLDOUT 15
B
1
2
15
14
16
13
12
11
10
9
8
7
6
6
7
8
1
4
9
10
11
2
12
13
14
V08697.00.00
V08491.00.00
Foldout 15B. Splitter Output Shaft and Second-Range Planetary Carrier Assembly
Foldout 16
A
1 Internal-splined clutch plate (7) (5 some models)
2 External-splined clutch plate (7)
(5, some models)
3 Second-range clutch anchor
4 Key
5 Piston return spring (14)
6 Spring guide pin (14)*
7 Teflon oil seal
8 Teflon oil seal
9 Second-range clutch piston
10 Low-range clutch piston housing assembly
11 Pin (2)
12 Housing
13 Ball bearing
14 Bearing retainer
15 Lockwasher, 12 inch (8)
16 Bolt, 12-13 x 78 inch (8), A
Torque
A
lb ft
6780
Nm
91108
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Teflon sealring
Sealring expander
First-range clutch piston
Sealring expander
Teflon sealring
First-range ring gear hub
First-range ring gear
Retaining ring
Retaining ring
Retaining ring
First-range sun gear sleeve
Ball bearing
First-range sun gear
Thrust washer
First-range planetary carrier assembly
Planetary carrier
Thrust washer (4)
Pinion (matched set of four)
Needle bearing (4)
Needle bearing (4)
Thrust washer (4)
Retaining ring
Ball, 316 inch (4)
Spindle assembly (4)
Spindle (4)
Spindle plug (4)
Thrust washer (4)
Spacer (4)
Pinion (matched set of four)
Roller (112)
Spacer (4)
Roller (112)
Spacer (4)
Thrust washer (4)
Spindle (4)
Ball (4)
Spring pin
* Not present on models with five plates 1 and five plates 2.
Foldout 16
F OLDOUT 16
A
1
2
2
3
6
7
9
10
3
11
12
13
5
6
14
22
37
9
11
36
10
35
15
23
24
12
25
26
16
21
20
19
13
14
18
34
15
16
33
17
32
31
30
29
28
27
V08698.00.00
V08492.01.00
Foldout 17
1 Spacer
3 Gear hub
5 Retaining ring
Foldout 17
lb ft
3340
Nm
4554
F OLDOUT 17
B
1
2
3
4
5
5
2
3
8
9
6
7
7
8
9
10
10
11
12
13
14
V08493.00.00
15
16
14
V08699.00.00
Foldout 18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Gasket
Transmission rear cover assembly
Plug, 14 inch, A; plug assembly 12-20, G
Rear cover
Plug, 38 inch NPTF, B;
plug assembly 916-18, H
Bushing
Flat washer
Bolt, 58-18 x 1 inch, C
Oil level check plug, 34 inch NPT, D;
Plug assembly 34-16, I
Speedometer drive gear (early models)
Ball bearing
Oil seal
Gasket
Bearing retainer
Lockwasher, 58 inch (12)
Bolt, 58-11 x 134 inch (12), E
Drive screw (4)
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Nameplate
Speedometer drive shaft
Gasket
Washer, 332 inch thk
Speedometer drive sleeve assembly
Seal
Washer
Sleeve
Lockwasher, 516 inch (2)
Bolt, 516-18 x 78 inch (2), A
Flange, S1950
Magnetic pickup plug*
Speedometer drive gear* (current models)
Magnetic pickup gear*
Magnetic pickup guard*
Lockwasher, 58 inch (2)
Bolt, 58-11 x 178 inch (2), E
Flange, J490
Flange plate retainer
Locknut, F
Cover
Speed sensor assembly
Bracket, speed sensor
O-ring
Screw, 516-18 x 12 inch
Torque
A
B
C
D
E
F
G
H
I
lb ft
1416
1822
134160
3337
117140
7001000
96115
1213
lb in.
7080
Foldout 18
Nm
1921
2529
182216
4550
159189
9491355
131135
7.59.0
1618
F OLDOUT 18
A
38
42
40
39
41
29
4
5
22
6
7 8
21
23
24
25
26
27
20
19
5
20
6
7
10
11
6
18 17
30
31
8
12
13
10
14
32
11
12
33
13
34
35
14
36
15
37
16
28
V08494.00.00
V08700.01.00
Gasket
Elbow, A
Hose
Elbow, A
Speedometer drive shaft
Gasket
Bolt, 516-18 x 78 inch (2,) B
Lockwasher, 516 inch (2)
Speedometer drive sleeve assembly
Sleeve
Washer
Seal
Washer, 332 inch thk
Transmission rear cover assembly (dropbox models)*
Bolt, 34-10 x 134 inch (2)*, C
Lockwasher, 34 inch (2)*
Shim (AR)*
Shim (AR)*
Shim (AR)*
Torque
A
B
C
lb ft
Nm
Tighten sufficiently to prevent leakage
1316
1821
180210
244284
Foldout 19
Foldout 19
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
Torque
A
B
C
D
E
* 150250 lb inch
lb ft
83100
300325
337385
7001000
150250*
Nm
113135
407440
456521
9491355
1728
F OLDOUT 19
1
2 3
75
40
41
42
43
39
4
44
1
5
45
46
7
9
6
3
19
10
6
18
17
11
47
12
32
37
36
34
38
35
13
33
31
13
16
12
11
10
30
14
29
15
21
28
48
15
16
20
17
27
18
19
49
14
26
24
25
23
22
74
52
51
73
V08703.00.00
56
54
55
50
57
58
53
60
72
59
67
68 69
68
71
65
66
61
62
68 70
63
68
64
V08704.00.00
Gasket
Transmission oil pan assembly
Oil pan
Heating element plug, A
Oil strainer shield
Gasket
Strainer and magnet assembly
Strainer assembly
Bolt, 14-20 x 58, B
Magnet
Magnet bracket
Lockwasher, 14
Bolt, 14-20 x 58, B
Lockwasher, 38 (6)
Bolt, 38-16 x 78 (6), C
Drain plug, 34, D
Gasket
Oil drain cover
Hose clamp
Drain hose
Hose clamp
Lockwasher, 38 (28)
Bolt, 38-16 x 78 (28), C
Bolt, 38-16 x 5 (4), C
Lockwasher, 38 (4)
Bolt, 38-16 x 118 (24), C
Lockwasher, 38 (24)
Strainer
Oil strainer gasket
Oil strainer cover
Locknut, 38-24
Torque
A
B
C
D
lb ft
Nm
Tighten sufficiently to prevent leakage
911
1314
2632
3643
3337
4550
Foldout 20
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Foldout 20
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
lb ft
4250
5465
3660 lb in.
1416
90100
2632
4555
3337
3842 lb in.
N.m
5767
7488
57
1921
123135
3643
6174
4550
4.34.7
F OLDOUT 20
A
B
1
2
3
13
51
31
24
29
11
9
30
10
28
12
21
10
18
11
1
12
16
19
22
25
20
17
37
36
35
7
6
14
2
15
15
14
4 5
13
29
27 28
30
26
31
33
32
34
17
23
39
40
38
16
27
26
42
43
44
45
25
46
47
24
41
18
22
23
48
49
50
21
20
19
V08705.00.00
V08495.01.00
Gasket
Oil transfer plate assembly
Retaining ring
Retainer
Valve spring
Check valve
Oil transfer plate
Plug 18-27, A
Plug 18-27, A
Lockwasher, 38 (4)
Bolt, 38-16 x 112 (4), B
Gasket
Control valve body assembly
Bolt, 38-16 x 114 (8), B
Lockwasher, 38 (8)
Cover
Gasket
Spring guide
Spring guide
Inner spring
Inner spring
Outer spring
Outer spring
Intermediate-range long trimmer valve
Second-range trimmer valve plug
Inner spring
Inner spring
Outer spring
Outer spring
Intermediate-range short trimmer valve
Second-range trimmer valve
Wiper-scraper seal
Lip-type oil seal
Plug, 18 NPTF (5), C
Detent ball spring
Detent ball
Detent ball
Detent ball spring
Gasket
Plug, 78 UNF, A
Manual selector valve assembly
Bushing
Valve assembly
Manual selector valve
Ball
Inner spring
Spring guide
Gasket
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
Cover
Lockwasher, 38 (4)
Bolt, 38-16 x 114 (4), B
Spring guide
Neutral plug spring
Outer spring
Neutral trimmer valve plug
First-range trimmer valve plug
Inner spring
Inner spring
Outer spring
Outer spring
First-range trimmer valve
Neutral trimmer valve
Lockup trimmer short valve
First-to-second-range overlap valve
Outer spring
Valve spring
Inner spring
Lockup trimmer long valve
Outer spring
Inner spring
Spring guide
Gasket
Cover
Lockwasher, 38 (8)
Bolt, 38-16 x 114 (8), B
Spring guide
Check valve
Check valve spring
Manual selector valve stop
Retaining ring
Retainer
Valve spring
Check valve
Control valve body
Splitter relay valve plug
Splitter relay valve
Valve spring
Lockwasher, 38 (20)
Bolt, 38-16 x 312 (20), B
Lockwasher, 38 (7)
Bolt, 38-16 x 234 (7), B
Torque
A
B
C
lb ft
Nm
Tighten sufficiently to prevent leakage
2632
3643
1012
1416
Foldout 21
Gasket
Seal
Hose adapter
Lockwasher, 716 (4)
Bolt, 716-14 x 234 (4), A
Connector, 12-14 NPT to 78-14 UNF, B
Reducing pipe bushing, 114-1, B
Hose assembly, B
Coupling
Gasket
Adapter
Bolt, Type C, 12-point (4), B
Gasket
Pump assembly
Connector, inlet, 1116-12 to 1516-12 UNF, B
Hose assembly, B
Hose clamp
Elbow, outlet, 78-14, B
Bolt, 38-16 x 114 (2), C
Lockwasher, 38 (2)
Torque
A
B
C
Foldout 21
lb ft
Nm
4250
5767
Tighten sufficiently to prevent leakage
2632
3643
F OLDOUT 21
B
A
14
15
16
91
90
17
18
88
89
20
19
2
1
21
13
22
26
87
23
24
25
27
86
12
2
1
6
45
78
28
29
85
30
10
11
31
32
33
34
84
79
83
82
81
80
35
36
77 78
76
37
38
39
40
8
62
61
63
64
65
42
10
13
60
11
59
58
57
56
66
67
68
41
43
44
45
55
54
53
69
52
70
14
15
12
20
19
46
16
47
71
48
72
49
50
51
73
74
75
17
18
V08707.00.00
V08706.00.00
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
Foldout 22
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
Torque
A
B
C
D
E
F
G
H
Foldout 22
lb ft
2632
3643
911
3035
1012
lb in.
2436
2024
2832
Nm
3643
4958
1314
4147
34
1416
2.32.6
3.23.6
F OLDOUT 22
107
122
105
106
128
123
108
127
109
140
110
126
111
112
102
23
24
90 22
13
18
19
20
21
10
133
28
32
30 33
119
114
34
100
35
40
42
98
38
41
43
50
117
99
15
39
37
139
138
44
14
93
46
47
89
88
87
116
115
118
136
36
124
129
130
131
137
25
48
49
101
134
17
29 31
121
135
26
27
120
132
11
10
16
113
125
12
91
103 104
45
92
95
6
5
3
96
94
97
4
76
77
78
79
80
72
66
73
67
68
74
81
82
65
61
51
52
53
54
69
75
58
59
60
70
62
55
5
63
4
3
2
1
83
84
85
86
71
64
56
57
V08708.00.00
Foldout 22. Electric Control Valve (Manual and Automatic-Electric Models) and Wiring
4
3
1
N
R
27 28
26
81
25
N
R
24
22
17
23
21
16
15
11
20
18 19
10
9
8
6
13
12 14
29
37
39 38
36
35
34
41
40
42
46
30
32
33
66
70
71
69
68
31
67
65
43
44
45
48
47
4 5
3
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
F OLDOUT 23
73
49
63
64 78
75
57
55
59 60
58
72
76
62
54
74
77
61
56
53
52
51
79
80
50
V08730.00.00
Foldout 24
Torque
A
B
lb ft
Nm
Hand tighten
1316
1821
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Foldout 24
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
F OLDOUT 24
A
N
R
3
1
21
63
25 26
24
20
2
23
N
R
15
22
20
14
18
16
17
12
11
6
4
21
19
13
10
27
35
37
36
2 3
34
38
52
56
57
55
54
41
42
43
28
53
51
28
30
45
31
44
40
33
32
6
7
39
11
59
10
60
50
46
49
61
62
10
18
58
12
13
48
14
17
47
22
16
15
V08710.01.00
V08709.01.00
F OLDOUT 25
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Torque
A
lb in.
2126
Nm
2.42.9
13
12
16
11
15
3
4
5
6
7
8
9
10
19
18
17
20
L04345
Foldout 26
Foldout 26
34
35
36
37
38
39
Tightening
Torque
1115 lb in.
(1.31.7 Nm)
8 lb in.
(0.9 Nm)
2 lb in.
(0.2 Nm)
1 lb in.
(0.1 Nm)
1923 lb in.
(2.12.6 Nm)
8 lb in.
(0.9 Nm)
2 lb in.
(0.2 Nm)
1 lb in.
(0.1 Nm)
3341 lb in
(3.74.6Nm)
12 lb in.
(1.4 Nm)
2.5 lb in.
(0.3 Nm)
1.5 lb in.
(0.2 Nm)
68 lb in.
(0.70.9 Nm)
5 lb in.
(0.6 Nm)
1 lb in.
(0.1 Nm)
0.5 lb in.
(0.005 Nm)
B
1
2
3
4
5
6
7
8
9
10
Torque
lb in.
Nm
1115
1.31.7
F OLDOUT 26
B
A
35
DOOTIFT
NH
S
33
34
36
32
31
30
31
10
25
26
29
24
22
23
21
20
28
25
19
18
14
11
10
27
16
12
17
15
37
38
13
2
9
1
39
V06735
E01203.01
Foldout 27
30
31
32
33
34
35
36
37
38
39
Gasket
Lockup trimmer valve assembly *
Plug, 14-18 (2)* A
Solenoid mounting plate*
Gasket*
24V lockup solenoid*
Lockwasher, 14 (2)*
Bolt, 14-20 x 58 (2)* B
Wiring harness* C
Solenoid cover*
Lockwasher, 14 (6)*
Bolt, 14-20 x 314 (6)* B
Gasket*
Lockup valve body assembly
Sealring
Plug
Flow valve (lockup cutoff)
Sealring*
Plug*
Spring*
Lockup shift valve*
Sealring**
Plug**
Spring**
Shim, 0.025 inch (0.64mm) (AR)**
Lockup shift valve**
Pin
Pin
Plug assembly, SAE No. 3 (38-24) straightthread F;
Pipe plug, 18 NPTF (earlier models) D
Plug assembly, SAE No. 3 (38-24) straightthread F;
Pipe plug, 18 NPTF (earlier models) D
Lockup valve body
Plug assembly, SAE No. 3 (38-24) straightthread F;
Pipe plug, 18 NPTF (earlier models) D
Check valve
Plug assembly, SAE No. 3 (38-24) straightthread F;
Pipe plug, 18 NPTF (earlier models) D
Lockwasher, 38 (2)
Bolt, 38-16 x 234*(2) E;
Bolt 38-16 x 114**(2) E
Lockwasher, 38 (7)
Bolt, 38-16 x 414*(7) E;
Bolt, 38-16 x 234**(7) E
Inhibitor switch***
Foldout 27
Torque
A
B
C
D
E
F
lb ft
1416
911
3035
1012
2632
2832 lb in.
Nm
1921
1314
4147
1416
3643
3.23.6
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Gasket
Bolt, 38-16 x 112 (5) A
Bolt, 38-16 x 3 (4) A
Flat washer, 38 (3)
Electric lockup valve body assembly
Sealring
Plug
Spring
Lockup valve
Spring pin
Lockup valve body
Plug assembly, SAE No. 3 (38-24)
straight-thread (2) E;
Pipe plug, 18 NPTF (2) (earlier models) B
Pressure tap plug assembly F
Gasket
Solenoid and sealring
Flat washer, 14 (2)
Bolt, 14-20 x 1 (2) C
Bolt, 14-20 x 112 (2) C
Flat washer, 14 (2)
Solenoid cover assembly
Wiring harness
Connector receptacle D
Sealring
Connector body
Connector terminal (2)
Temperature sensor
Torque
A
B
C
D
E
F
lb ft
2632
1012
911
68
2832 lb in.
3842 lb in.
Nm
3643
1416
1314
810
3.23.6
4.34.7
F OLDOUT 27
A
VH04343.00.00
VH04144.00.01
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
Gasket
Plug, C
Filter element assembly (2)
Sealring (2)
Filter element (2)
Shell and center stud assembly (2)
Retaining ring (2)
Retainer (2)
Seal (2)
Washer (2)
Spring (2)
Shell (2)
Gasket (2)
Center stud (2)
Plug (2)
Bolt, 716-14 x 134 (2(, A
Bolt, 716-14 x 312 (3, earlier models), F
Lockwasher, 716 (2)
Flat washer, 716 (3, earlier models)
Bolt, 716-14 x 412 (3), A
Bolt, 716-14 x 412 (2, earlier models), F
Lockwasher, 716 (3)
Flat washer (2, earlier models)
Filter assembly
Differential pressure switch
Sealring (2)
High efficiency filter element (2)
Filter shell (2)
Filter base
Torque
A
B
C
D
E
F
G
lb ft
lb in.
Nm
4250
1416
4555
5465
90100
3660
5863
5767
4.16.8
1921
6174
6.57.1
7488
123135
Foldout 28
Foldout 28
Torque
lb ft
lb in.
Nm
A
B
C
D
E
F
G
H
4250
1416
95105
4753
5465
90100
3660
5863
5863
5767
4.16.8
1921
6.57.1
129142
6470
7488
123135
F OLDOUT 28
A
47
49
48
50
B
55
13
3
51
52
12
11
56
10
3
9
2
53
15
8
7
54
4
15
5
15
16
17
18
14
20
14
7
13
12
8
11
10
31
9
32
33
30
25
21
24
19
22
23
26
27
28
29
35
36
34
38
39
40
41
42
L04337
43
37
44
45
46
L04336
F OLDOUT 29
1
3
AY
GR
K
AC
BL
BL
UE
4
2
BL
UE
26
25
5
22
23
24
7
21
20
19
17
8
18
6
15
14
16
CT
LE
SE
DE
MO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
13
24(ref)
10
12
11
Foldout 30
Torque
lb in.
Nm
810
0.91.1
Foldout 30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Torque
lb in.
Nm
A
B
810
1113
0.91.1
1.31.5
F OLDOUT 30
A
4
SE
LE
C
T
11
R
12
DE
10
MO
1
2
1
MO
DE
3
N
D
8
13
10
11
14
C
X
Y
13
14
12
15
16
17
18
24
15
19
16
17
18
19
23
22
20
21
20
22
21
V03620.01
V03617.03
F OLDOUT 31
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Gasket
Transmission rear housing assembly
Plug assembly, SAE 5 (12-20)
straight-thread, J;
Pipe plug, 14 NPTF (earlier models), A
Transmission rear cover
Plug assembly, SAE 6 (916-18) straightthread, K;
Pipe plug, 38 NPTF (earlier models), B
Bushing
Flat washer, 58
Bolt, 58-18 x 1, C
Magnetic pickup, D
Speedometer drive shaft and gear
Gasket
Cover
Washer, 332
Drive sleeve assembly
Seal
Washer
Drive sleeve
Lockwasher, 516 (2)***
Bolt, 516-18 x 78 (2)***, E
Speedometer drive gear assembly
Speedometer drive gear
Magnetic pickup gear
Plug assembly, SAE 12 (1116-12)
straight-thread, L;
Pipe plug, 34 NPTF (earlier models), F
Nameplate
Drive screw (4)
Single-row ball bearing (earlier models)
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Torque
A
B
C
D
E
F
G
H
J
K
L
Oil seal
Bearing retainer gasket
Bearing retainer
Magnetic pickup guard*
Lockwasher, 58 (2)*
Bolt, 58-11 x 178 (2)*, G
Lockwasher, 58 (10*)
Bolt, 58-11 x 134 (10*), G
Flange, Spicer S-1950
Flange, Spicer S-1950
Flange, twin disk J-490*
Output flange retainer plate
Nut, self-locking, H
Output bearing sleeve
Retainer
Output coupling
lb ft
lb in.
Nm
1416
1822
134160
**
1316
3337
117140
7001000
2426
5863
7080
1921
2529
182216
1821
4550
159189
9491355
6.57.1
7.99.0
3235
Foldout 32
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Foldout 32
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
Torque
lb ft
lb in.
Nm
A
B
C
D
E
F
G
H
J
K
L
M
6780
83100*
2632
4250
2327
1822
1416
1565**
95105
8197
4753
7080
91108
113135
3543
3236
3236
1921
1921
2188**
129142
110131
6470
7.99.0
F OLDOUT 32
Foldout 32. Power Takeoff, Torque Converter Housing, and Hydraulic Retarder
F OLDOUT 33
1
MOUNTING
SURFACE
4
INLET
OUTLET
MOUNTING
SURFACE
2
INLET
1
OUTLET
3
2
OUTLET
INLET
MOUNTING
SURFACE
1
2
3
4
5
6
7
Manifold assembly
(used with cooler circuit filters)
Filter assembly
Differential pressure switch
Filter head (configurations vary)
Sealring (AR)
Filter element (AR)
Filter shell
VH04333.00.00
SM1228EN_back.pdf
12/12/06
1:55:05 PM
CM
MY
CY
CMY
SM1228EN 200611
www.allisontransmission.com