20-547792 en

GROUP 20
GEAR BOX /
CONVERTER
GEAR BOX / CONVERTER DISASSEMBLY

GEAR BOX "POWER SHIFT"
20-3-5EN
TABLE OF CONTENTS
T12000 TRANSMISSION ASSEMBLY
HOW THE UNITS OPERATE
SECTIONAL VIEWS AND PARTS IDENTIFICATION
Transmission Case and Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. A
Converter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. B
Forward - Reverse and 1st - 2nd Clutch Group . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. C
High - 3rd and Output Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. D
Control Valve GroupDual Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. E
Control Valve GroupSingle Modulation,
Mechanical Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. F
Assembly Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fig. G, H, I, J, K
DISASSEMBLY OF TRANSMISSION
REASSEMBLY OF TRANSMISSION
60
CLUTCH ENGAGEMENT (POWER FLOW) 3 SPEED
78
CLUTCH ENGAGEMENT (POWER FLOW) 4 AND 6 SPEED
79
DRIVE PLATE INSTALLATION
80
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
81
SPECIFICATIONS AND SERVICE DATA
82
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL
83
EXTERNAL PLUMBING AND PRESSURE CHECK POINTS
84, 85
CLEANING AND INSPECTION
86
PARKING BRAKE SERVICE
87
TROUBLESHOOTING GUIDE
88
CONVERTER STALL PROCEDURE
89
DESCRIPTION
91
T12000
TRANSMISSION ASSEMBLY
The transmission and hydraulic torque converter portion of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to
fisrt understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system. It
is necessary to consider both units in the study of their function and operation.
The electric shift control valve is located in the vehicle's operator compartment. The function of the control is
to energize the selected solenoid valves thus directing the oil under pressure to the selected directional and range
(gear) clutches. The purpose of the range or directional clutches is to direct the power flow through the gear train
to provide the desired speed range and direction.
An axle disconnect is optional and is located on the output shaft. The drive to the front axle can be disconnected or connected by manual, pneumatic, or hydraulic shifting.
When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through
the direction selector solenoid to the oil sump. The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with slots and a bore to receive a hydraulically
actuated piston. The piston is "oil tight" by the use of sealing rings. A steel disc with external tangs is inserted into
the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs are
alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring.
A hub with O.D. splines is inserted into a splines of discs with teeth on the inner diameter. The discs and hub are
free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, the electric shift control lever is placed in the desired position. This energizes the selected direction and range (gear) solenoids allowing the oil under pressure to flow through tubes and passages to the
selected clutch shafts. Oil sealing rings are located on the clutch shaft. These rings direct oil under pressure
through a drilled passageway in the shaft to a desired clutch. Pressure of the oil forces the piston and discs against
the heavy back-up plate. The discs with tangs on the outer diameter clamping against discs with teeth on the inner
diameter enables the hub and clutch shaft to be locked together and allows them to drive as a unit.
There are bleed balls in the clutch piston or clutch drum which allow quick escape for oil when the pressure to
the piston is released.
HOW THE UNITS OPERATE

With the engine running, the transmission charging pump draws oil from the transmission sump through the
oil suction tube and screen and directs it through the pressure regulating valve and oil filter.
The pressure regulating valve maintains pressure to the transmission solenoid valves for actuating the direction and speed clutches. This regulator valve consists of a hardened valve spool operating in a closely fitted bore.
The valve spool is spring loaded to hold the valve in the closed position. When a specific pressure is achieved, the
valve spool works against the spring until an exhaust port is exposed along the side of the bore. This sequence of
events provides the proper system pressure. This requires a small portion of the total volume of oil used in the system.
The remaining volume of oil is directed out through an external oil cooler and into the lube inlet port. From the
lube inlet port oil goes through the forward-reverse shaft, lubricating the forward and reverse clutches, with the
remainder going to the torque converter. After entering the converter, the oil is directed through the converter blade
cavity and exits in the passage between the turbine shaft and impeller hub. The oil then lubes the impeller hub
bearing with the remainder going to the 3rd-4th clutch shaft and 1st-2nd clutch shaft to lubricate those clutches and
shaft bearings. The oil then gravity drains to the transmission sump.
The hydraulic torque converter consists basically of three elements and their related parts to multiply engine
torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller
cover. This element is the pump portion of the hydraulic torque converter and is the primary component which
starts the oil flowing to the other components which results in torque multiplication. This element can be compared
to a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the
torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed by
the impeller out into the particular design of blading in the turbine and reaction member is the means by which the
hydraulic torque converter multiplies torque.
The reaction member of the torque converter is located between and at the center of the inner diameters of
the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the
turbine and change its direction to allow correct entry for recirculation into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output
shaft is at zero R.P.M. Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing.
With the engine running and the electric shift control lever in neutral position, oil pressure from the regulating
valve is blocked at the solenoid control valves, and the transmission is in neutral. Movement of the control lever will
energize the forward or reverse solenoid valves and selected range (gear) solenoid, directing oil under pressure to
the selected direction and range (gear) clutches.
Figure A
T12000 TRANSMISSION CASE AND PLATE GROUP

(FIGURE A)
ITEM
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
Sensor Port Plug . . . . . . . . . . . . . . . . . . . . .
25
Sensor Adjusting Bushing . . . . . . . . . . . . . . . .1
Sensor Port Plug Washer . . . . . . . . . . . . . . . . 1
26
Oil Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spacer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27
Oil Baffle Screw . . . . . . . . . . . . . . . . . . . . . . . 3
Pipe Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
28
Oil Baffle Screw Lockwasher . . . . . . . . . . . . . 3
Outlet Temperature Port Plug . . . . . . . . . . . . . 1
29
Tube and Screen Assembly . . . . . . . . . . . . . . 1
Plate to Transmission Case Gasket . . . . . . . . 1
30
Oil Supply Tube Seal Ring . . . . . . . . . . . . . . . 1
Plate to Transmission Case Dowel Pin . . . . . 1
31
Magnetic Drain Plug . . . . . . . . . . . . . . . . . . . . 1
Transmission Case . . . . . . . . . . . . . . . . . . . . . 1
32
Plate to Transmission Case Dowel Pin . . . . . 1
Filler Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33
Converter Safety Valve Poppet . . . . . . . . . . . 1
10
Diverter Sleeve . . . . . . . . . . . . . . . . . . . . . . . . 1
34
Seat Snap Ring . . . . . . . . . . . . . . . . . . . . . . . 1
11
Pipe Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
35
Plate to Transmission Case Screw

Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . .2
12
Inlet Pressure Port Plug . . . . . . . . . . . . . . . . . 1

36
Plate to Transmission Case Screw . . . . . . . . . 2
13
Auto Shift Sensor Port Plug . . . . . . . . . . . . . . 1

37
14
Sensor Port Plug "O" Ring . . . . . . . . . . . . . . . 1

Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . .2
15
Sensor Adjusting Bushing . . . . . . . . . . . . . . . 1
38
16
Air Breather . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39
Safety Valve Seat . . . . . . . . . . . . . . . . . . . . . . 1
17
Dipstick Port Plug . . . . . . . . . . . . . . . . . . . . . . 1
40
Safety Valve Spring . . . . . . . . . . . . . . . . . . . . 1
18
Pipe Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
41
Poppet Retainer Washer . . . . . . . . . . . . . . . . .1
19
Plug "O" Ring . . . . . . . . . . . . . . . . . . . . . . . . . 2
42
20
Oil Level Plug . . . . . . . . . . . . . . . . . . . . . . . . . 2
43

Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . .3
21
Plug Sealing Ring . . . . . . . . . . . . . . . . . . . . . . 1

44
Dipstick Housing . . . . . . . . . . . . . . . . . . . . . . . 1
22
Speed Sensor Plug . . . . . . . . . . . . . . . . . . . . . 1

45
Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23
Speed Sensor Plug . . . . . . . . . . . . . . . . . . . . . 1
24
Sensor Port Plug "O" Ring . . . . . . . . . . . . . . . 1
Figure B
T12000 CONVERTER GROUP

(Figure B)
ITEM
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
Pump Drive Idler Thrust Washer . . . . . . . . . . 1
40
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Gear Bearing . . . . . . . . . . . . . . . . . . . . . 1
41
Reverse Idler End Plate Capscrew . . . . . . . . 1
Pump Drive Idler Gear . . . . . . . . . . . . . . . . . . 1
42
End Plate Capscrew Washer . . . . . . . . . . . . 1
Pump Drive Idler and Pilot Shaft . . . . . . . . . . 1
43
End Plate to Shaft Roll Pin . . . . . . . . . . . . . . 1
Pump Drive Idler and Pilot Shaft Dowel. . . . . 1
44
Reverse Idler Gear Bearing . . . . . . . . . . . . . . 1
Pump Drive Idler Thrust Washer . . . . . . . . . . 1
45
Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . 1
Pump Drive Gear Retainer Snap Ring . . . . . 1
46
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pump Drive Gear . . . . . . . . . . . . . . . . . . . . .
47
Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Charging Pump Gasket. . . . . . . . . . . . . . . . . 1
48
Ball Check Valve . . . . . . . . . . . . . . . . . . . . . . 1
10
Charging Pump . . . . . . . . . . . . . . . . . . . . . . . 1
49
"O" Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11
Pump Mounting Screw Lockwasher . . . . . . . 1
50
Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12
Pump Mounting Screw . . . . . . . . . . . . . . . . . 1
51
Regulator Pressure Port Plug . . . . . . . . . . . . 1
13
Pump Mounting Screw. . . . . . . . . . . . . . . . .
52
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14
53
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15
Pump Mounting Screw . . . . . . . . . . . . . . . . . 4
54
16
Converter Housing to Plate

Screw Lockwasher . . . . . . . . . . . . . . . . . . . . . 6
17
Filter Assembly . . . . . . . . . . . . . . . . . . . . . .
55
Converter Housing to Plate Screw . . . . . . . . . 6
18
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
56
Converter Housing to Plate

Screw Lockwasher . . . . . . . . . . . . . . . . . . . . . 1
19
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
57
Converter Housing to Plate Screw . . . . . . . . . 1
20
Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
58
21
Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Converter Housing to Transmission

Case Screw Lockwasher . . . . . . . . . . . . . . . .10
22
Converter Housing Oil Seal . . . . . . . . . . . . . . 1
59
23
Oil Distributor Ring "O" Ring . . . . . . . . . . . . . 1
Converter Housing to Transmission

Case Screw . . . . . . . . . . . . . . . . . . . . . . . . . .10
24
Oil Distributor Ring . . . . . . . . . . . . . . . . . . . . 1
60
Turbine Hub Snap Ring . . . . . . . . . . . . . . . . . 1
25
Oil Distributor Ring "O" Ring . . . . . . . . . . . . . 1
61
Torque converter Assembly . . . . . . . . . . . . . . 1
26
Torque Converter Bearing . . . . . . . . . . . . . . . 1
62
Turbine Hub Snap Ring . . . . . . . . . . . . . . . . . 1
27
Impeller Hub Gear . . . . . . . . . . . . . . . . . . . . . 1
63
Torque Converter Plug "O" Ring . . . . . . . . . . 1
28
Stator Support Snap Ring . . . . . . . . . . . . . . . 1
64
Torque Converter Plug . . . . . . . . . . . . . . . . . 1
29
Stator Support Piston Ring . . . . . . . . . . . . . . 1
65
Plug Snap Ring . . . . . . . . . . . . . . . . . . . . . . . 1
30
Stator Support Piston Ring Expander . . . . . . 1
66
Drive Plate Weld Nut Assembly . . . . . . . . . . . 1
31
Stator Support . . . . . . . . . . . . . . . . . . . . . . .
67
Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
32
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ; 1
68
Drive Plate Backing Ring . . . . . . . . . . . . . .
33
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
69
Drive Plate Mounting Screw Lockwasher . .
34
Impeller Hub Gear Washer . . . . . . . . . . . . . . 1
70
Drive Plate Mounting Screw . . . . . . . . . . . .
35
Idler shaft Snap Ring . . . . . . . . . . . . . . . . . . . 1
71
Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
Idler and Pilot Shaft . . . . . . . . . . . . . . . . . . . . 1
72
Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
Housing to Plate Gasket . . . . . . . . . . . . . . . . 1
73
Converter Housing . . . . . . . . . . . . . . . . . . .
38
Stator Support Snap Ring. . . . . . . . . . . . . . . 1
74
Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
Reverse Idler Gear . . . . . . . . . . . . . . . . . . . . 1
V.
RE
D.
W
F
d
2n
t
1s
Figure C
T12000 FORWARD-REVERSE AND 1ST-2ND CLUTCH GROUP

(Figure C)
ITEM
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
44
45
46
47
48
49
50
DESCRIPTION
QUANTITY
Turbine Shaft Front Bearing . . . . . . . . . . . .

Clutch Gear Thrust Washer . . . . . . . . . . . .
Clutch Gear Thrust Washer Bearing. . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Clutch Gear . . . . . . . . . . . . . . . . .
End Plate Snap Ring . . . . . . . . . . . . . . . . .
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
Retainer Snap Ring . . . . . . . . . . . . . . . . . .
Snap Ring Retainer . . . . . . . . . . . . . . . . . .
Disc Spring . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Piston Wear Plate . . . . . . . . . . . . . .
Clutch Piston. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Piston SealOuter . . . . . . . . . . . . .
Clutch Piston SealInner. . . . . . . . . . . . . .
Turbine Shaft, Drum and Plug Assembly . .
Clutch Piston SealInner. . . . . . . . . . . . . .
Clutch Piston SealOuter . . . . . . . . . . . . .
Clutch Piston. . . . . . . . . . . . . . . . . . . . . . . .
Disc Spring . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Clutch Gear . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine Shaft Rear Bearing . . . . . . . . . . . .
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Distributor Sleeve . . . . . . . . . . . . . . . . .
Retainer Screw . . . . . . . . . . . . . . . . . . . . . .
Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . .
3rd Driven Gear . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
1
1
5
1
1
1
1
1
1
1
1
1
5
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
ITEM
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
92
93
94
95
96
97
98
DESCRIPTION
QUANTITY
Gear Hub Snap Ring . . . . . . . . . . . . . . . . . 1

2nd Clutch Gear Hub Snap Ring . . . . . . . . 1
Clutch Gear Thrust Washer . . . . . . . . . . . . 1
Clutch Gear Thrust Washer Bearing. . . . . . 1
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2nd Clutch Gear . . . . . . . . . . . . . . . . . . . . . 1
End Plate Snap Ring . . . . . . . . . . . . . . . . . 1
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Outer Disc . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Retainer Snap Ring . . . . . . . . . . . . . . . . . . 1
Snap Ring Retainer . . . . . . . . . . . . . . . . . . 1
2nd Clutch Disc Spring . . . . . . . . . . . . . . . . 5
Clutch Piston Wear Plate . . . . . . . . . . . . . . 1
Clutch Piston. . . . . . . . . . . . . . . . . . . . . . . . 1
Clutch Piston SealOuter . . . . . . . . . . . . . 1
Clutch Piston SealInner. . . . . . . . . . . . . . 1
1st and 2nd Shaft, Drum and Plug
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clutch Piston SealInner. . . . . . . . . . . . . . 1
Clutch Piston SealOuter . . . . . . . . . . . . . 1
Clutch Piston. . . . . . . . . . . . . . . . . . . . . . . . 1
Clutch Piston Wear Plate . . . . . . . . . . . . . . 1
1st Clutch Disc Spring . . . . . . . . . . . . . . . . 7
Snap Ring Retainer . . . . . . . . . . . . . . . . . . 1
Retainer Snap Ring . . . . . . . . . . . . . . . . . . 1
Outer Disc1st Clutch . . . . . . . . . . . . . . . . 10
Inner Disc1st Clutch . . . . . . . . . . . . . . . . 10
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 1
End Plate Snap Ring . . . . . . . . . . . . . . . . . 1
1st Clutch Gear . . . . . . . . . . . . . . . . . . . . . . 1
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing and Seal Assembly . . . . . . . . . . . . 1
Bearing Retaining Snap Ring . . . . . . . . . . . 1
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sleeve Locating Screw . . . . . . . . . . . . . . . . 1
Oil Distributor Sleeve . . . . . . . . . . . . . . . . . 1
H
HIG
4th
3rd
BRAKE OPTION
Figure D
T12000 HIGH 3RD AND OUTPUT SHAFT GROUP

(Figure D)
ITEM
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
Sleeve Locating Screw . . . . . . . . . . . . . . . .
32
Clutch Piston and Ball Seat Assembly . . . .
Oil Distributor Sleeve . . . . . . . . . . . . . . . . .
33
Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . .
34
Disc Washer (Spring) Assembly . . . . . . . . .
Bearing and Seal Assembly . . . . . . . . . . . .
35
1st Drive Gear. . . . . . . . . . . . . . . . . . . . . . .
36
Gear Hub Snap Ring . . . . . . . . . . . . . . . . .
37
Outer Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
7*
Gear Hub Snap Ring . . . . . . . . . . . . . . . . .
38
Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
8*
39
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
9*
40
10* Clutch Gear Thrust Washer . . . . . . . . . . . .
41
11* Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
12* Bearing Spacer . . . . . . . . . . . . . . . . . . . . . .
43
13* Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
Thrust Washer Retaining Snap Ring . . . . .
14* 4th Clutch Gear. . . . . . . . . . . . . . . . . . . . . .
45
3rd Clutch Gear Bearing . . . . . . . . . . . . . . .
46
3rd Gear and Shaft . . . . . . . . . . . . . . . . . . .
16* Clutch Gear Thrust Washer Bearing. . . . . .
47
Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . .
48
Rear Bearing Retaining Snap Ring. . . . . . .
18* End Plate Snap Ring . . . . . . . . . . . . . . . . .
49
Output Shaft Bearing Snap Ring . . . . . . . .
19* End Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
50
20* Inner Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Output Shaft Flange Bearing . . . . . . . . . . .
21* Outer Disc . . . . . . . . . . . . . . . . . . . . . . . . . .
52
Oil Seal Sleeve . . . . . . . . . . . . . . . . . . . . . .
22* Retainer Snap Ring . . . . . . . . . . . . . . . . . .
53
Ouput Shaft Oil Seal . . . . . . . . . . . . . . . . . .
23* Snap Ring Retainer . . . . . . . . . . . . . . . . . .
54
Output Shaft Sleeve "O" Ring . . . . . . . . . . .
24* Disc Washer (Spring) Assembly . . . . . . . . .
55
25* Clutch Piston Wear Plate . . . . . . . . . . . . . .
56
Output Flange . . . . . . . . . . . . . . . . . . . . . . .
26* Clutch Piston and Ball Seat Assembly . . . .
57
Flange Plug. . . . . . . . . . . . . . . . . . . . . . . . .
27* Clutch Piston Outer Seal . . . . . . . . . . . . . .
58
Caliper Assembly Capscrew Locking Nut . .
28* Clutch Piston Inner Seal . . . . . . . . . . . . . . .
59
Caliper Brake Assembly . . . . . . . . . . . . . . .
60
Caliper Assembly Mounting Capscrew . . . .
61
Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . .
62
Brake Disc Capscrew Lockwasher . . . . . . .
63
Brake Disc Capscrew . . . . . . . . . . . . . . . . .
29
Clutch, Drum, Shaft, and Plug Assembly

(4 and 6 Speed Clutch Drum Shown) . . . . .
30
Clutch Piston Inner Seal . . . . . . . . . . . . . . .
31
Clutch Piston Outer Seal . . . . . . . . . . . . . .
*Used in 4 and 6 speed only.

See Figure E for 3rd and output shaft with disconnect.
T12000
ELECTRIC CONTROL GROUP
DUAL MODULATION
Figure E
T12000 CONTROL VALVE GROUP

(Figure E)
ITEM
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
Modulator Valve Housing . . . . . . . . . . . . . .
22
Coil to Cartridge "O" Ring . . . . . . . . . . . . . .
Modulator Housing "O" Ring . . . . . . . . . . . .
23
Valve Cartridge, 2 Way, Used at

Rev. and Fwd. Incl. Items 24, 25, 26 . . . . .
Stop Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
24
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
Spring Inner . . . . . . . . . . . . . . . . . . . . . .
2
25
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
Spring Middle . . . . . . . . . . . . . . . . . . . . .
2
26
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
Sleeve "O" Ring . . . . . . . . . . . . . . . . . . . . .
2
27
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
Modulation Housing Sleeve . . . . . . . . . . . .
2
28
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
Modulation Housing Sleeve Snap Ring . . .
2
29
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
Regulator Spool . . . . . . . . . . . . . . . . . . . . .
2
30
10
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Bore Plug,

Used with 3 Speed only . . . . . . . . . . . . . . .
11
Spring Retainer . . . . . . . . . . . . . . . . . . . . . .
31
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
12
Spring Retainer Snap Ring . . . . . . . . . . . . .
32
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
13
Accumulator Spool Snap Ring . . . . . . . . . .
33
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
14
Accumulator Spool . . . . . . . . . . . . . . . . . . .
34
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
15
Spring Outer . . . . . . . . . . . . . . . . . . . . . .
35
16
Cover Screw Lockwasher . . . . . . . . . . . . . .
Valve Cartridge, 4 Way, Used at

1st and 2nd-3rd, Incl. Items 31, 32,
33, 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Cover Screw . . . . . . . . . . . . . . . . . . . . . . . .
36
Coil to Cartridge "O" Ring . . . . . . . . . . . . . .
18
Protective Cover . . . . . . . . . . . . . . . . . . . . .
37
Solenoid Coil. . . . . . . . . . . . . . . . . . . . . . . .
19
Valve Cartridge Retainer Nut . . . . . . . . . . .
38
Nut to Coil "O" Ring . . . . . . . . . . . . . . . . . .
20
Nut to Coil "O" Ring . . . . . . . . . . . . . . . . . .
39
21
Solenoid Coil. . . . . . . . . . . . . . . . . . . . . . . .
SINGLE MODULATION
MECHANICAL INCHING
Figure F
ITEM
T12000
CONTROL VALVE GROUP WITH SINGLE MODULATION, MECHANICAL INCHING
(Figure F)
DESCRIPTION
QUANTITY
ITEM
DESCRIPTION
QUANTITY
Modulator Valve Housing . . . . . . . . . . . . . .
26
Inching Actuator Rod . . . . . . . . . . . . . . . . .
Modulatot Housing "O" Ring . . . . . . . . . . . .
27
Inching Regulator Spring . . . . . . . . . . . . . .
Stop Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Inching Sleeve . . . . . . . . . . . . . . . . . . . . . .
Spring Inner . . . . . . . . . . . . . . . . . . . . . .
29
Inching Sleeve "O" ring . . . . . . . . . . . . . . . .
Spring Middle . . . . . . . . . . . . . . . . . . . . .
30
Inching Spool . . . . . . . . . . . . . . . . . . . . . . .
Spring Outer . . . . . . . . . . . . . . . . . . . . . .
31
Cover Screw Lockwasher . . . . . . . . . . . . . .
Accumulator Spool . . . . . . . . . . . . . . . . . . .
32
Cover Screw . . . . . . . . . . . . . . . . . . . . . . . .
Modulation Housing Sleeve . . . . . . . . . . . .
33
Protective Cover . . . . . . . . . . . . . . . . . . . . .
Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
10
Regulator Spool Stop . . . . . . . . . . . . . . . . .
35
Nut to Coil "O" Ring . . . . . . . . . . . . . . . . . .
11
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
Solenoid Coil. . . . . . . . . . . . . . . . . . . . . . . .
12
Regulator Spool . . . . . . . . . . . . . . . . . . . . .
37
Coil to Cartridge "O"' Ring . . . . . . . . . . . . .
13
Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
Valve Cartridge . . . . . . . . . . . . . . . . . . . . . .
14
Regulator Spool Sleeve . . . . . . . . . . . . . . .
39
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
15
Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
16
Spool Sleeve "O" Ring . . . . . . . . . . . . . . . .
41
Cartridge "O" Ringl . . . . . . . . . . . . . . . . . . .
17
Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
18
Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . .
43
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
19
Sleeve "O" Ring . . . . . . . . . . . . . . . . . . . . .
44
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
20
Shuttle Spool . . . . . . . . . . . . . . . . . . . . . . .
45
Solenoid Bore Plug (Used with 3 Speed Only) 1
21
Shuttle Sleeve. . . . . . . . . . . . . . . . . . . . . . .
46
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
22
Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
23
Inching Housing . . . . . . . . . . . . . . . . . . . . .
48
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
24
Inching Housing "O" Ring . . . . . . . . . . . . . .
49
Cartridge "O" Ring . . . . . . . . . . . . . . . . . . .
25
Inching Return Spring . . . . . . . . . . . . . . . . .
50
Valve Cartridge . . . . . . . . . . . . . . . . . . . . . .
3 SPEED
ASSEMBLY INSTRUCTION
Oil filter
REVERSE IDLER
VIEW H
View T
View K
REV.
View F
FWD.
View H
3rd
Expander
Piston ring
VIEW T
1st 2nd
SECTION A-A
(See reference Figure K)
Figure G
4 - 6 SPEED
ASSEMBLY INSTRUCTION
Oil filter
View F
View T
REV.
FWD.
View K
View H
4th/
3rd
HL
VIEW F
Enlarged view of seal
1st
2nd
VIEW K
SECTION A-A
(See reference Figure K)
Figure H
Assemble oil filter and tighten to 20-25 lbfft

[27-34 Nm].
Teflon seals must be sized prior to assembly.
10 outer steel plates 10 inner plates Alternately

assemble, starting with outer steel plate.
6 outer steel plates 6 inner plates Alternately
5 outer steel plates 5 inner plates alternately

24 Use 5/16-18 x 3.250 screw.

25 Use 8/16-18 x 2.00 screw.
23 Use 3/8-16 x 5.00 screw.
26 Use 3/8-18 x 3.250 screw.

27 Use 5/16-24 nut.
28 Use 5/16-24 nut.
29 Use 3/8-24 nut.
30 Tighten all cartridge nuts to 4-5 lbfft [5-7 Nm].
Shield bearing assemble with shield as shown.

Fwd. Rev. 2nd and 3rd, clutch return disc springs.
Concave side of first disc spring to be placed against
clutch piston wear sleeve. Remaining four springs to
be stacked alternately as shown.
ASSEMBLY NOTES :
Use Permatex and Loctite only where specified.
All lead in chamfers for oil seals, piston rings, and
"O" rings must be smooth and free from burrs.
Inspect before assembly.
Lubricate all piston ring grooves and "O" rings
with oil before assembly.
Apply a thin coat of grease between seal lips on
lip type seals prior to assembly.
Low clutch return disc springs concave side of first

disc spring to be placed against clutch piston wear
sleeve. Remaining six springs to be stacked alternately as shown.
Apply a thin coat of Permatex No. 2 or Loctite

No.641 to O.D. of all oil seals before assembly.
Apply a thin coat of Loctite No. 592 or No. 506
Dryseal to all pipe plugs.
Where precoated pipe plugs are not used, apply a
thin coat of Loctite No. 592 or No. 506 Dryseal to
pipe plugs.
10 Clearance between clutch piston and steel separator
plate to be .048-.108 [1.22-2.74]. If over .108 [2.74]

clearance, add one steel outer disc under end plate.
11 Clearance between clutch piston and steel separator
plate to be .080-.135 [2.03-3.43]. If over .135 [3.43]

clearance, add one steel outer disc under end plate.
13 Tighten regulator sleeve to 45-50 lbfft [61-68 Nm].
14 Use solenoid bore plug in middle position for 3-speed
version only.
15 Solenoid cartridge to be assembled and tightened to
16-20 lbfft [22-27 Nm].

16 Assemble speed sensor adjusting bushing using
Loctite No. 262 or No. 270 and stake threaded area

three places equally spaced.
19 M10 x 1.17 - 1.20.
After assembly of parts using Loctite or Permatex,

there must not be any free or excess material
which might enter the oil circuit.
Clean mounting surfaces and tap19 & 20
ped holes with solvent. Dry thoroughly, being certain tapped holes are dry and clean. Install components and special self-locking screws. Tighten
screws to proper torque per chart.
NOTE :
Assembly of components must be completed
within a fifteen minute period from start of screw
installation. The special screw is to be used for
one installation only. If the screw is removed for
any reason it must be replaced. The epoxy left in
the tapped holes must be removed with the proper tap and cleaned with solvent. Dry holes thoroughly and use a new screw for reinstallation.
If special capscrews are not available, clean
epoxy away from threads and dry thorougly.
Apply Loctite #262 thread locker to threads.
Install capscrews in the proper locations and
tighten to specified torque (See Torque Chart).
20 M10 x 2.32 - 2.40.

21 Use 5/16-18 x 5.00 screw.
22 Use 5/16-18 x 3.500 screw.
Figure I
TORQUE SPECIFICATION FOR LUBRICATED

OR PLATED SCREWS AND NUTS
NOMINAL
SIZE
GRADE 8.8 or 9.8

COARSE THREAD
lbfft
[nm]
30-37
[40-50]
50-55
[65-75]
M10
M12
GRADE 10.9
COARSE THREAD
lbfft
[nm]
44-48
[60-65]
74-81
[110-110]
PIPE PLUG TORQUE CHART

TORQUE
THREAD NPTF
lbfft
[Nm]
1/16-27
1/8-27
1/4-18
3/8-18
1/2-14
3/4-10
5-7
7-10
15-20
25-30
30-35
40-45
[7-9]
[9-14]
[20-27]
[34-41]
[41-47]
[54-61]
PERMANENT PLUG METRIC

TORQUE
THREAD SIZE
M18 x 1.5 6H
M26 x 1.5 6H
lbfft
25-30
45-50
[Nm]
[34-41]
[61-68]
Figure J
Section B - B
s
ed
e
sp n
or p t i o
f
o
ing
sh
u
tb
tpu
u
O
s
en
or-
uto
sh
ift
Charging pump SAE-A
Charging pump SAE-B

Optional
Filter plug
Input sensor location

for Auto shift
Breather
After curing of Loctite-speed

sensor bushing must be
secure with 40 lbfft [54.2
Nm] torque.
Soleniod bore
plug
1,397 (35,48)
43T
1,383 (35,13)
1,067 (27,10) 46T
1,053 (26,75)
Bushing for speedometer speed

sensor - option.
REAR VIEW
Stake 3 places approx. equally

spaced
Charging pump SAE-C

Optional
TORQUE SPECIFICATION FOR LUBRICATED OR PLATED SCREWS AND NUTS

NOMINAL
SIZE
GRADE 5
FINE THREAD
lbfft
.2500
.3125
.3750
.4375
.5000
.5625
.6250
.7500
9-11
16-20
26-29
41-45
64-70
91-100
128-141
223-245
[Nm]
[12-15]
[22-27]
[35-39]
[56-61]
[87-95]
[123-136]
[174-191]
[302-332]
GRADE 8
COARSE THREAD
lbfft
8-10
12-16
23-25
37-41
57-63
82-90
113-124
200-220
[Nm]
[11-14]
[16-22]
[31-34]
[50-56]
[77-85]
[111-122]
[153-168]
[271-298]
Figure K
FINE THREAD
lbfft
11-13
28-32
37-41
58-64
90-99
128-141
180-198
315-347
[Nm]
[15-18]
[38-43]
[50-56]
[79-87]
[122-134]
[174-191]
[224-268]
[427-470]
COARSE THREAD
lbfft
9-11
26-30
33-36
52-57
80-88
115-127
159-175
282-310
[Nm]
[12-15]
[35-41]
[45-49]
[71-77]
[108-119]
[156-172]
[216-237]
[382-420]
MAINTENANCE AND SERVICE

The instructions contained herein cover the disassembly and reassembly of the transmission in a
sequence that would normally be followed after the
unit has been removed from the machine and is to
be completely overhauled. It must also be understood that is a basic T12000 3, 4, or 6 speed short
drop output transmission with many options. The unit
are very similar to troubleshoot, disassemble, repair,
and reassemble.
CAUTION : Cleanliness is of extreme importance
and an absolute must in repair and overhaul of this
unit. Before attempting any repairs, the exterior of
the unit must be thoroughly cleaned to prevent the
possibility of dirt and foreign matter entering the
mechanism.
DISASSEMBLY
Figure 1
Side view of T12000 short drop transmission.
Figure 3
Remove drive plate attaching capscrews and
washers. Remove drive plate and backing ring.
Figure 2
Rear view showing disc brake and electric control.
Figure 4
Remove torque converter plug retainer ring.
-1-
Figure 5
Remove plug and "O" ring.
Figure8
Remove torque converter to shaft locating ring.
Figure 6
Remove torque converter to turbine shaft retainer
ring.
Figure 9
Remove filter assembly.
Figure 7
Remove torque converter assembly.
Figure 10
Remove pressure regulator and regulator sleeve.
NOTE : Special tool can be fabricated. (See Figure
388A).
-2-
Figure 11
Remove charging pump permanent pump hole
cover. (Not used when auxiliary pump is used.)
Figure 14
Remove converter housing and gasket.
Figure 15
Remove impeller hub gear.
Figure 12
Remove pump mounting bolts and washers.
Remove pump and gasket.
Figure 16
Remove solenoid valve cartridge retainer nut and
"O" ring.
Figure 13
Remove converter housing to transmission case
bolts and washers.
-3-
Figure 20
Remove bore plug and "O" rings. This plug is used in
the middle bore position in the 3 speed version only.
Figure 17
Remove solenoid coil and "O" ring.
Figure 21
Remove spacer plate bolts and washers.
Figure 18
Loosen solenoid valve cartridge.
Figure 22
Pry spacer plate away from transmission case at
dowel pin holes. Remove spacer plate and gasket.
Note aligning studs to facilitate spacer removal.
Figure 19
Remove valve. Repeat procedures Figures 16
through 19 for remaining solenoid valves. See figure
20.
-4-
Figure 23
Remove 1st and 2nd clutch assembly.
Figure 26
Remove 3rd speed clutch shaft pilot bearing.
Figure 24
Remove forward and reverse clutch assembly.
Figure 27
Remove oil baffle capscrew and washer.
Figure 25
Remove 3rd clutch assembly.
NOTE : A 4 and 6 speed transmission will have a
4th-high clutch on the clutch shaft also.
Remove oil baffle.
Figure 28
-5-
Figure 29
Remove oil supply tube "O" ring.
Figure 32
Remove 1st and 2nd clutch shaft rear roller bearing.
Remove 3rd gear roller bearing.
Figure 30
Remove supply tube and screen assembly.
Figure 33
Remove roller bearing locating ring.
Figure 34
Remove inner case set screw plug. Remove clutch
shaft distributor sleeve set screw.
Figure 31
Remove 3rd clutch gear and output shaft.
-6-
Figure 38
Remove inner, middle, and outer valve springs and
valve stop pin.
Figure 35
Use a hammer puller (or any suitable puller) as
shown to remove distributor sleeve and shaft pilot
bearing.
Figure 36
Pilot bearing and distributor sleeve removed.
Figure 39
Remove accumulator spool.
FOR SINGLE MODULATION AND MECHANICAL
INCHING SEE PAGE 70.
Figure 40
Remove modulation housing sleeve and "O" ring.
Figure 37
Remove dual modulator housing sleeve and "O"
ring.
-7-
Figure 41
Remove diverter sleeve.
NOTE : Diverter sleeve has a 5/16-24 threaded hole
in end of it. A threaded rod screwed into end of it will
facilitate removal of diverter sleeve.
Figure 44
Remove output flange to bearing retainer ring.
Figure 45
Tap output flange from rear bearing.
Figure 42
Remove parking brake caliper assembly bolts from
brake and housing.
NOTE : Brake is an option and will not be on all
units.
Figure 42
Remove brake caliper assembly.
Figure 46
Remove output flange and brake disc.
-8-
Figure 50
Remove bearing locating ring.
DISASSEMBLY AND REASSEMBLY OF

LOW (1ST) AND 2ND CLUTCH
Figure 47
Remove output seal sleeve retainer ring.
DISASSEMBLY
LOW (1ST) BEING DISASSEMBLED
Figure 48
Remove seal sleeve, seal and "O" ring.
Figure 51
Remove clutch shaft oil sealing rings.
Figure 52
Remove front bearing retainer ring.
Figure 49
Remove output flange bearing.
-9-
Figure 56
Clutch gear and bearings removed.
Figure 53
Remove front bearing.
Figure 54
Remove outer thrust washer, bearing, and inner
thrust washer.
Figure 57
Remove outer thrust washer, thrust bearing, and
inner thrust washer.
Figure 55
Remove clutch gear and disc hub.
Figure 58
Remove clutch disc end plate retainer ring.
- 10 -
Figure 59
Remove clutch disc end plate.
Figure 62
Remove retainer ring retainer.
Figure 60
Remove inner and outer clutch discs.
Fogure 63
Remove disc springs.
Note : See page 77.
Figure 61
Compress disc springs and remove retainer ring.
Figure 64
Remove clutch piston wear plate.
- 11 -
Figure 68
Remove gear from shaft.
Figure 65
Turn clutch over and tap clutch shaft on a block of
wood to remove clutch piston.
2ND CLUTCH DISASSEMBLY
Figure 66
Using a gear puller as shown, remove gear and rear
bearing inner race.
Figure 69
Remove gear locating ring from shaft.
Figure 67
Remove inner race from shaft.
Figure 70
Remove thrust bearing and clutch gear retainer ring.
- 12 -
Figure 74
Remove clutch disc end plate retainer ring.
Figure 71
Figure 75
Remove end plate.
Figure 72
Remove clutch gear and hub and gear bearings.
Figure 73
Remove outer thrust washer, thrust bearing and
Figure 76
Remove clutch discs.
- 13 -
Figure 80
Figure 77
Figure 81
Remove clutch piston.
REASSEMBLY OF LOW (1ST) CLUTCH

(See Cleaning and Inspection Page)
Figure 78
Figure 82
Two bleed valves in clutch drum must be clean and
free of any foreign material.
Figure 79
Note : See page 77.
- 14 -
Figure 86
Position clutch piston wear plate on piston.
Figure 83
Install clutch piston outer seal ring.
Figure 84
Install clutch piston inner seal ring. Note : Ring must
be sized before installing in clutch drum. Sizing is
best accomplished by rotating piston while holding a
round object against the new seal ring. Rotate piston
until seal ring is flush with outer diameter of piston.
Figure 87
Install piston return disc springs. First spring with
large diameter of bevel toward wear plate. Alternate
seven (7) springs.
Note : See page 77.
Figure 85
Position piston in low clutch drum as shown. Use
caution as not to damage inner and outer piston sealing rings.
Figure 88
Position return spring retainer on clutch shaft.
- 15 -
Figure 89
Start ring on shaft with snap ring pliers.
Figure 92
Install first friction (inner) clutch disc. Alternate steel
and friction until ten (10) steel and ten (10) friction
discs are in position.
Figure 90
Use a sleeve with the proper inner diameter to fit
over shaft and against retainer ring. A sharp blow
with a soft hammer will compress springs and seat
retainer ring. Be sure ring is in full position in groove.
Figure 93
Install clutch disc end plate.
Figure 91
Install first steel (outer) clutch disc.
Figure 94
Install end plate retainer ring.
- 16 -
Figure 98
Install outer thrust bearing washer against bearing.
Figure 95
NOTE : Low (1st) clutch pack must be checked for
clutch disc clearance.
With the clutch assembly on end, the clutch discs will
fall to the piston.
Measure the distance between the clutch end plate
and end plate retainer ring by inserting a feeler
gauge or taper gauge through the slots in the clutch
drum.
The required clearance is .080-.135 [2,03-3,43 mm].
If the clearance is greater than .135 [3,43 mm], add
one steel disc under the end plate.
Figure 99
Press bearings in clutch gear and disc hub, being
certain bearings are pressed flush with face of gear
on both sides.
Figure 96
Position thrust bearing inner washer on clutch shaft.
Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs.
Be sure the clutch hub is in full position in the clutch
assembly. Do not force this operation.
Figure 97
Position thrust bearing on clutch shaft against inner
thrust bearing washer.
Figure 100
Position inner thrust washer on shaft.
- 17 -
Figure 104
Install front bearing retainer ring.
Figure 101
Position thrust bearing on shaft.
Figure 105
Install clutch shaft oil sealing rings. Grease rings to
facilitate reassembly into front housing.
Figure 102
Position outer thrust washer on shaft.
2ND CLUTCH REASSEMBLY
Figure 103
Install clutch shaft front bearing.
NOTE : Bearing has a shield in it. This shield must
be up.
Figure 106
Install inner and outer clutch piston seal rings. Size
inner ring as explained in Figure 84.
- 18 -
Figure 110
Position return spring ring retainer on clutch shaft.
Figure 107
Position piston in clutch drum, using caution as not
to damage piston sealing rings.
Figure 11
Start ring on shaft with snap ring pliers. Use a sleeve
with the proper inner diameter to fit over shaft and
against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring. Be
sure ring is in full position in groove.
Figure 108
Install clutch piston wear plate.
Figure 109
five (5) Springs.
Note : See page 77.
Figure 112
- 19 -
Figure 113
and friction until five (5) steel and five (5) friction
Figure 116
Figure 117
Figure 114
Figure 118
Install outer thrust bearing washer against thrust
bearing.
Figure 115
- 20 -
Figure 122
Figure 119
Press needle bearings in clutch gear and disc hub,
being certain bearings are pressed flush with face of
gear on both sides. Install the clutch gear in the clutch
assembly by aligning the clutch hub teeth with the
clutch inner discs. Be sure the clutch hub is in full
position in the clutch assembly. Do not force this
operation.
Figure 123
Install thrust washer retainer ring.
Figure 120
Figure 121
Figure 124
Install clutch shaft gear locating ring.
- 21 -

3RD AND 4TH (HIGH) CLUTCH
4TH CLUTCH USED ON
4 AND 6 SPEED MODELS ONLY
DISASSEMBLY
Figure 125
Install clutch shaft gear on clutch shaft with long hub
of gear down.
Figure 128
Figure 129
Using a gear puller as shown, remove clutch gear
and front bearing.
Figure 126
Install rear bearing inner race on clutch shaft with
bearing race shoulder down.
Figure 130
Remove clutch gear locating ring. For 3 speed
models proceed to Figure 144.
Figure 127
Position rear bearing on bearing race.
- 22 -
4TH CLUTCH (HIGH) DISASSEMBLY
Figure 134
Remove bearings and spacer from clutch gear.
Figure 131
Remove outer thrust washer retainer ring.
Figure 132
Figure 135
Figure 133
Figure 136
Remove end plate retainer ring.
- 23 -
Figure 140
Figure 137
Remove end plate.
Figure 141
Note : See page 77.
Figure 138
Figure 142
Figure 139
- 24 -
Figure 143
Figure 146
Remove end plate.
DISASSEMBLY OF 3RD CLUTCH
Figure 144
Remove thrust washer retainer ring. Remove outer
thrust washer, thrust bearing, and inner thrust
washer.
Figure 147
Figure 145
Figure 148
- 25 -
Figure 152
Figure 149
REASSEMBLY OF 4TH (HIGH) CLUTCH

(See Cleaning and Inspection Page.)
FOR 3 SPEED PROCEED TO FIGURE 176
Figure 150
Note : See page 77.
Figure 153
Clutch piston bleed ball must be clean and free of
any foreign material.
Figure 154
inner ring as explained in Figure 84. Install clutch
piston in clutch drum. Use caution as not to damage
sealing rings.
Figure 151
- 26 -
Figure 155
Figure 158
Figure 156
large diameter of bevel toward wear plate . Alternate
five (5) springs.
Note : See page 77.
Figure 159
Figure 157
Figure 160
- 27 -
3rd
Gauge
4th
Figure 161
and friction until six (6) steel and six (6) friction discs
are in position
Figure 163A
NOTE : 4th (high) clutch pack must be checked for
Stand the clutch assembly on end. The clutch discs
on the bottom will fall to the end plate.
Measure the distance between the clutch piston and
the first steel disc by inserting a feeler gauge or
taper gauge through the slots in the clutch drum.
Figure 162

Figure 163
Figure 164
- 28 -
Figure 165
Figure 168
Figure 166
Figure 169
Figure 167
Press one bearing in clutch gear. Install bearing spacer
next to bearing. Press second bearing in gear, being
certain bearings are pressed flush with face of gears on
both sides. Install the clutch gear in the clutch assembly
by aligning the clutch hub teeth with the clutch inner
discs. Be sure the clutch hub is in full position in the
clutch assembly. Do not force this operation
Figure 170
- 29 -
Figure 174
Install clutch shaft front bearing.
NOTE : Bearing has a shield in it. This shield must
be up.
Figure 171
Install thrust washer retainer ring.
Figure 175
Figure 172
Install clutch shaft gear locating ring.
3RD CLUTCH REASSEMBLY

Use procedures in Figure 172, 173, 174 and 175 for
3rd speed clutch shaft gear and bearing installation.
Figure 176
Clutch piston bleed ball must be clean and free of
Figure 173
Position gear on clutch shaft.
- 30 -
Figure 180
Figure 177
sealing rings.
Figure 181
Figure 178
Figure 182
Figure 179
five (5) springs.
Note : See page 77.
- 31 -
Figure 183
Figure 186
Figure 184
and friction until five (5) steel and five (5) friction
Figure 187
Figure 188
Figure 185
- 32 -
Figure 189
bearing. Install thrust washer retainer ring.
Figure 192
Figure 190
Install 3rd clutch pilot bearing on clutch shaft. A coat
of high quality grease will hold pilot bearing in position.

FORWARD AND REVERSE CLUTCHES
NOTE : A 3 SPEED TRANSMISSION WILL NOT
HAVE EXTERNAL GEAR TEETH ON THE FORWARD AND REVERSE CLUTCH DRUM.
REVERSE CLUTCH BEING DISASSEMBLED
Figure 193
Figure 194
Figure 191
- 33 -
Figure 195
Figure 198
Figure 196
Figure 199
Figure 197
Figure 200
Note : See page 77.
Remove end plate.
- 34 -
Figure 201
Figure 204
Figure 202
Figure 205
DISASSEMBLY OF FORWARD CLUTCH
Figure 206
Figure 203
- 35 -
Figure 207
Figure 210
Figure 208
Figure 211
Figure 209
Figure 212
Remove end plate.

Note : See page 77.
- 36 -
REASSEMBLY OF FORWARD CLUTCH

Figure 213
Note : See page 77.
Figure 216
Clutch piston bleed orifice must be clean and free of
Figure 214
Figure 217
sealing rings.
Figure 215
Figure 218
- 37 -
Figure 219
large diameter of bevel toward wear plate . Alternate
five (5) springs.
Note : See page 77.
Figure 222
Figure 220
Figure 223
Install first steel (outer) clucth disc.
Figure 221
Start ring on clutch with snap ring pliers.
Figure 224
are in position.
- 38 -
Figure 225
Figure 227
Figure 226
REV.
FWD.
Gauge
Figure 226A
NOTE : Forward clutch pack must be checked for
Stand the clutch assembly on end. The clutch discs
Figure 228

- 39 -
Figure 229
bearing.
Figure 232
Figure 230
Press one bearing in clutch gear, flush with face of
gear. Install bearing spacer next to bearing. Press
second bearing in gear, flush with face of gear.
Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs.
Figure 233
Figure 234
Figure 231
- 40 -
REVERSE CLUTCH REASSEMBLY
Figure 235
Clutch piston bleed orifice must be clean and free of
Figure 238
five (5) springs.
Note : See page 77.
Figure 236
sealing rings.
Figure 239
Position return spring ring retainer in clutch shaft.
Figure 240
Figure 237
- 41 -
Figure 244
Figure 241
Figure 245
REV.
FWD.
Figure 242
Gauge
Figure 245A
NOTE : Reverse clutch pack must be checked for
Stand the clutch assembly on end. The clutch disc
Figure 243
are in position.

- 42 -
Figure 246
Figure 249
Press one bearing in clutch gear, flush with face of
gear. Install bearing spacer next to bearing. Press
second bearing in gear, flush with face of gear.
Install the clutch gear in the clutch assembly by alig
ning the clutch hub teeth with the clutch inner discs.
Figure 247
Figure 250
Position inner thrust waher on shaft.
Figure 248
Figure 251
- 43 -
REASSEMBLY
(See Cleaning and Inspection Page.)
Figure 255
Install pressure regulator valve spring and regulator
valve piston as an assembly into regulator valve
sleeve.
Figure 252
REGULATOR VALVE
DISASSEMBLY AND REASSEMBLY
DISASSEMBLY
Figure 256
Compress valve spring and valve and install pin into
regulator valve sleeve.
Figure 253
Tap pin from regulator valve sleeve. Use caution as
valve spool is under spring pressure.

DUAL MODULATED VALVE ASSEMBLY
DISASSEMBLY
Figure 257
Remove inner, middle, and outer spring and stop pin
from modulation housing sleeve. Reference Figure 38.
Figure 254
Remove regulator valve piston and pressure regulator valve spring.
- 44 -
Figure 258
Remove accumulator spool. Reference Figure 39.
Figure 261
Remove regulator spool.
Figure 262
Remove 2nd sleeve pin.
NOTE : This pin is the longer of the two sleeve pins.
Figure 259
Remove cross pin from sleeve.
NOTE : This pin is the shortest of the two sleeve
pins.
REASSEMBLY
Figure 260
Remove regulator spool spring, retainer spring, and
spacer spring from housing sleeve.
Figure 263
Install the longer of the two pins in the end hole of
housing sleeve.
- 45 -
Figure 264
Check orifice in regulator spool to be free and clear
of any foreign material. Insert spool in sleeve housing with orifice end against cross pin.
Figure 267
Position accumulator spool in sleeve as shown.
Figure 265
Install spring spacer in spring retainer. Install spring
in spring retainer against spacer. Install spring retainer, spring, and spacer in housing sleeve and into
regulator spoool.
Figure 268
Install outer accumulator spring.
Figure 266
Compress regulator spool and spring in sleeve far
enough to install cross pin.
NOTE : This pin is the shortest of the two housing
sleeve pins. Install pin.
Figure 269
Install middle spring.
- 46 -
Figure 270
Install inner spring.
Figure 273
Install new "O" ring on modulator housing sleeve.
Figure 271
Install stop pin in inner spring.
Figure 274
If charging pump or pump drive gear are to be replaced, remove retainer ring and drive gear.
Figure 272
Install new "O" ring on modulator valve housing.
- 47 -

OF SPACER PLATE
DISASSEMBLY
Figure 275
Remove reverse idler gear end plate capscrew and
washer.
Figure 275
Remove reverse idler gear end plate capscrew and
washer.
Figure 279
Remove idler gear tanged thrust washer.
Figure 276
Remove end plate and dowel pin.
Figure 280
If reverse idler shaft is to be replaced, support spacer plate around idler shaft opening and press idler
shaft from spacer. Do not drive on idler shaft as
doing so may cause damage to spacer plate.
Figure 277
Remove reverse idler gear.
- 48 -
Figure 281
Idler shaft and locating ring removed.
Figure 284
Remove pump drive idler shaft and thrust washer.
Figure 282
Remove locating ring from idler shaft.
Figure 285
Remove stator support oil sealing ring. Remove sealing ring expander ring.
Figure 286
The stator support is held in place by two (2) retaining rings. Remove converter end retainer ring from
groove.
Figure 283
Tap pump drive idler shaft from spacer plate.
- 49 -
Figure 287
Remove thrust washer.
Figure 290
If support bushing is to be replaced, remove from
stator support. NOTE : Bushing must be removed
from same end as needle bearing.
Figure 291
If support bearing is to be replaced, remove from
stator support.
Figure 288
Push support toward transmission side far enough to
expose retainer ring. Remove retainer ring.
Figure 292
Compress converter safety valve spring and remove
retaining washer.
Figure 289
From converter end, remove stator support.
- 50 -
Figure 293
Remove safety valve spring.
Figure 296
Turn spacer over and position safety valve spring on
poppet. Compress spring and install poppet retaining
washer. NOTE : End of spring must go in recessed
side of washer.
Figure 294
Turn spacer plate over and remove safety valve poppet.
Figure 297
If stator support bushing was removed, install
bushing in support. Install needle bearing in stator
support.
REASSEMBLY OF SPACER PLATE

Figure 295
From transmission side of spacer plate, position
converter safety valve poppet in bore in spacer.
Figure 298
Install stator support in spacer plate.
- 51 -
Figure 302
Install support oil sealing ring expander ring. Install
oil sealing ring on expander ring. NOTE : Expander
spring gap to be 180 degrees from sealing ring hook
joint.
Figure 299
Install support locating ring.
Figure 300
Push support back through spacer until locating ring
shoulders in support bore. Turn spacer plate over
and position impeller hub gear washer on support.
Figure 303
Install locating ring on reverse idler shaft.
Figure 304
Support spacer plate and press idler shaft into position and tight against locating ring.
Figure 301
Install support retainer ring.
- 52 -
Figure 305
Turn spacer plate over and position tanged thrust
washer on shaft, being certain tang in washer is in
notch in spacer plate.
Figure 308
Position idler gear end plate and roll pin on idler
shaft, aligning roll pin with hole in idler shaft.
Figure 309
Install end plate capscrew and washer. Tighten to
specified torque. See torque chart.
Figure 306
Position idler gear needle bearing on shaft. Lubricate
bearing.
Figure 307
Position idler gear on bearing and shaft.
Figure 310
Position pump drive idler shaft washer on spacer
plate.
- 53 -
Figure 311
Install pump drive gear shaft through washer and
into spacer plate aligning shaft roll pin with hole in
spacer plate.
Figure 314
Install idler gear thrust washer on shaft, aligning hole
in washer with roll pin in shaft.

CONVERTER HOUSING
DISASSEMBLY
Figure 312
Position pump drive idler gear bearing on shaft.
Lubricate bearing.
Figure 313
Position idler gear on bearing.
Figure 315
Remove check valve ball assembly.
- 54 -
Figure 316
Remove torque converter bearing.
Figure 319
Remove converter housing plug. (3rd Clutch shaft on
3 speed and High and 3rd on 4 and 6 speed.)
Figure 317
Remove oil distributor and "O" rings.
Figure 320
Remove oil distributor sleeve set screw.
Figure 318
Remove converter oil seal.
Figure 321
Using a puller as shown, remove oil distributor sleeve. (3rd and High clutch shaft.)
- 55 -
REASSEMBLY OF CONVERTER HOUSING

Figure 322
Remove converter housing plug. (1st and 2nd clutch
shaft.)
Figure 325
Install 1st and 2nd clutch shaft oil distributor sleeve
in converter housing, with inside diameter chamfer
up, and the notch in the distributor aligned up with
the retaining set screw hole in the converter housing.
Figure 323
Remove oil distributor sleeve set screw.
Figure 326
Apply Loctite #243 to threads of sleeve set screw.
NOTE : This set screw has a hole in it. Use caution
as not to allow any Loctite to plug hole. Install set
screw in converter housing and in oil distributor.
Figure 324
Using a puller as shown, remove oil distributor sleeve. (1st and 2nd shaft.)
Figure 327
Install set screw plug.
- 56 -
Figure 328
Install 3rd and High clutch shaft oil distrisbutor sleeve in converter housing with inside diameter chamfer
up, and the notch in the distributor aligned up with
the retaining set screw hole in the converter housing.
Figure 331
Apply a very light coat of Permatex #2 to the outer
diameter of the converter housing oil seal. Press
seal in housing with lip of seal in.
Figure 332
Install new "O" rings on converter housing oil distributor. Install oil distributor in converter housing with
long hub toward oil seal.
Figure 329
Apply Loctite #243 to threads of sleeve set screw .
(NOTE : This set screw has a hole in it. Use caution
as not to allow any Loctite to plug hole.) Install set
screw in converter housing and in oil distributor.
Figure 333
Press converter bearing in housing against shoulder.
Figure 330
Install set screw plug.
- 57 -
Figure 337
Remove sleeve "O" ring.
REASSEMBLY
Figure 334
Position ball check valve assembly in converter housing as shown.
Fugure 338
Install a new "O" ring on oil seal sleeve.
Figure 335
Tap check valve assembly in position.
OUTPUT FLANGE OIL SEAL SLEEVE

DISASSEMBLY
Figure 339
Apply a very light coat of Permatex #2 to the outer
diameter of the output flange oil seal. Press oil seal in
oil seal sleeve. Oil seal must be flush with one side of
face of oil seal sleeve and lip of seal must be in.
Figure 336
Press output flange oil seal from seal sleeve.
- 58 -
OUTPUT FLANGE AND PARKING BRAKE DISC
REASSEMBLY
PARKING BRAKE IS AN OPTION AND WILL NOT

BE ON ALL UNITS
DISASSEMBLY
Apply Loctite 577 to plug O.D. prior
to insertion. Remove excess material. Plug must be inserted with
axial force equal to 6300 lbf (28024
N). Must be secure and oil tight.
Figure 342
If output flange plug was removed for any reason,
install new plug as follows : Apply a light coat of
Loctite #577 to outer edge of expansion plug. Install
plug in flange. NOTE : See Figure 342A for expansion plug installation tool fabrication.
Figure 340
If the output flange or brake disc is to be replaced,
remove brake disc capscrews and washers.
It is imperative plug be installed properly to prevent

oil leakage.
Figure 342A
NOTE : PARKING BRAKE DISC MUST BE REPLACED IF BRAKE PAD WEAR EXCEEDS .065 [1,65].
Brake disc thickness new is
.375 [9,52]
Maximum brake pad wear
.065 [1,65]
Min. thickness at brake pad wear .310 [7,87]
Figure 341
Remove brake disc.
Figure 343
Position bracke disc on output flange.
- 59 -
Figure 344
Install capscrew and washers. Tighten to specified
torque. See torque chart.
Figure 347
Install reverse and forward clutch shaft rear bearing
in transmission case.
REASSEMBLY OF TRANSMISSION
Figure 345
Install forward-reverse oil distributor sleeve in transmiision case with inside diameter chamfer out,
(toward front of transmission), and the notch in the
distributor aligned up with the retaining set screw
hole in the transmission case.
Figure 348
Install rear output bearing locating ring in transmission case.
Figure 346
Apply Loctite #243 and install set screw in transmission case and in oil distributor sleeve. Install set
screw plug.
Figure 349
Install output bearing against locating ring.
- 60 -
Figure 350
Position oil seal sleeve in transmission case with
recessed portion of oil seal toward output bearing.
This leaves a space between oil seal and output
bearing.
Figure 353
Install output flange to rear bearing retainer ring.
Figure 351
Install oil seal sleeve retainer ring.
Figure 354
Install 3rd gear shaft bearing locating ring.
Figure 352
Install output flange through oil seal and rear output
bearing. Use caution as not to damage seal.
Figure 355
Install 3rd gear shaft bearing.
- 61 -
Figure 359
Position oil baffle in transmission case.
Figure 356
Position 3rd gear and shaft through bearing and into
output flange.
Figure 360
Install oil baffle capscrews and tighten to specified
Figure 357
Position the oil suction tube and screen in transmission case.
Figure 361
Position the forward and reverse clutch assembly
shaft through the rear needle bearing and into the oil
distributor sleeve. Use extreme caution as not to
damage or break the clucth shaft oil sealing rings.
Figure 358
Push suction tube through opening in case and install "O" ring.
- 62 -
Figure 362
With the 3rd speed clutch shaft rear pilot bearing on
shaft, install 3rd clutch assembly in 3rd clutch gear
disc hub. Align splines on 3rd gear disc hub with
internal teeth of friction discs. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs. Use caution as not to
damage pilot bearing. NOTE : A 4 and 6 speed
transmission will also have a 4th High clutch on with
3rd clutch.
Figure 364
Position new transmission case to converter housing
gasket on transmission case. A light coat of grease
will hold gasket in position.
Figure 365
Install spacer plate assembly on transmission, aligning clutch shafts with opening in spacer plate. Use
caution as not to damage oil sealing rings. Spacer
plate must be tight against transmission case. Do not
use bolts to pull spacer plate and case together. Tap
spacer plate into position at dowel pins. Install spacer plate to transmission case capscrews.
Figure 363
With the rear clutch shaft roller bearing in position on
shaft, install the 1st and 2nd clutch assembly in
transmission case.
- 63 -
Figure 366
See "NOTE" on Figure I for proper capscrew installation and torque.
Figure 369
The use of aligning studs will facilitate converter housing to spacer installation. The transmission could be
laid down to align the end of the clutch shafts into
sealing ring sleeves in converter housing . Do not
force this operation. Converter housing must be tight
against transmission spacer.
NOTE : Do not use bolts to pull converter housing in place. Install converter housing to transmission case screws and lockwashers. See
Figures I and J for proper screw location and installation.
Figure 367
Position impeller hub gear on stator support.
Figure 368
Position spacer to converter housing gasket on spacer. A light coat of grease will hold gasket in place.
Figure 370
Tighten bolts to specified torque. See "NOTE" in
Figure 369. See Figures I and J for proper screw
location and installation.
- 64 -
Figure 371
Install converter locating ring on turbine shaft.
Figure 374
With new "O" ring in place, install bore plug in
converter assembly.
Figure 372
Position converter assembly on stator support and
turbine shaft.
Figure 373
Install converter assembly retainer ring.
Figure 375
Install bore plug retainer ring.
- 65 -
ELECTRIC CONTROL VALVE ASSEMBLY

A 4 and 6 speed transmission will have two (2) different length solenoid cartridges. Three (3) cartridges
will be used for speed selection in lower three holes
and two (2) cartridges will be used in upper two
holes for direction selection (Forward-Reverse). The
three (3) cartridges will be of same length but longer
than the two (2) direction cartridges.
A 3 speed transmission will have two (2) different
length solenoid cartridges. Two (2) cartridges will be
used for speed selection in lower two holes and two
(2) cartridges will be used in upper two holes for
direction selection (Forward-Reverse). The two (2)
speed cartridges will be of same length but longer
than the two (2) direction cartridges. A bore plug is
used in the center hole on 3 speed only.
Figure 378
Position a new cartridge to coil "O" ring on cartridge.
Figure 376
With new "O" rings in position on the solenoid cartridges, install cartridges as explained above. The
3.100 [78,74 mm] length cartridges go in the top two
holes, the 4.100 [104,14 mm] length cartridges go in
the two (2) or three (3) bottom holes depending on
speed of transmission.
Figure 379
Install coil and wire lead assembly on cartridge.
Figure 380
With new "O" ring in position, install coil to cartridge
nut.
Figure 377
Tighten cartridges to specified torque. See assembly
instruction drawing.
- 66 -
Figure 384
With new lower end "O" ring on modulation valve
sleeve, install sleeve and spring assembly in transmission case.
Figure 381
Tighten cartridge nut per assembly instruction drawing.
Figure 385
With new "O" ring in position, install modulator valve
housing over spring and sleeve assembly.
Figure 382
On 3 speed transmission only, position new "O"
rings on the center hole bore plug. Install plug and
tighten to specified torque.
DUAL MODULATION INSTALLATION

Figure 386
Tighten modulator valve housing 60-65 lbfft [81-88 Nm].
Figure 383
Install modulation diverter in trans mision case.
- 67 -
1/8" fillet weld

1/2" drive socket
Figure 387
Install regulator valve assembly in converter housing.
Figure 388A
Figure 388
A special tool can be fabricated to tighten the regulator valve (See Figure 388A). Tighten valve assembly
sleeve 45-50 lbfft [61,1-67,7 Nm].
Figure 389
Install oil filter assembly on regulating valve. Tighten
filter 20-25 lbfft [27-34 Nm].
- 68 -
Figure 390
With new gasket in place, install charging pump in
converter housing.
Figure 393
Install caliper brake mounting screw through brake
assembly and through locknut. Apply Loctite #262 to
threads and install screw in transmission case.
Figure 391
Install charging pump to converter housing bolts and
washer and tighten to specified torque. See torque
chart.
Figure 394
Mounting screws to be installed to allow free movement of caliper pads to disc. Tighten jam nut. See
torque chart. See page 87 for brake information.
Figure 392
If auxiliary pump is used, it is not necessary to install
the permanent pump hole cover. With new gasket in
place, install pump hole cover on charging pump.
Install bolts and washers and tighten to specified
Figure 395
See special section on page 80 for drive plate installation.
- 69 -
SINGLE MODULATION
AND MECHANICAL INCHING
Figure 396
Remove inching valve housing.
Figure 399
Remove inching spool.
Figure 397
Remove inching return spring, actuator rod, and
regulator spring.
Figure 400
Remove modulator valve housing and "O" ring.
Figure 398
Remove inching sleeve and "O" ring.
Figure 401
Remove modulator valve outer, middle, and inner
springs and spring stop.
- 70 -
Figure 402
Remove modulation housing sleeve and accumulator spool.
Figure 405
Remove modulator valve outer, middle, and inner
springs and spring stop. Reference Figure 401.
Figure 406
Remove accumulator spool. Reference Figure 402.
Figure 403
Remove shuttle sleeve and spool.

MODULATOR VALVE ASSEMBLY
DISASSEMBLY
Figure 407
Remove modulator sleeve pin.
Figure 404
Remove modulator valve body "O" ring.
- 71 -
Figure 411
Remove regulator spool sleeve assembly. Remove
"O" ring.
Figure 408
Remove regulator spool assembly retainer ring.
Figure 409
Remove regulator spool stop, spring, and spool and
sleeve assembly.
Figure 412
Remove sleeve check ball retainer pin.
Figure 410
Remove regulator spool sleeve retainer ring.
Figure 413
Remove check ball.
- 72 -
REASSEMBLY
Figure 414
Install a new "O" ring on regulator spool sleeve.
Position check ball in sleeve.
Figure 417
Install sleeve retainer ring.
Figure 418
Install housing sleeve pin.
Figure 415
Install check ball retai,er pin.
Figure 416
Position sleeve and ball assembly in regulator spool
with check ball retainer pin up.
Figure 419
Install regulator spool stop, spring, and regulator
spool and sleeve assembly in housing sleeve.
- 73 -
Figure 423
Install inching regulator spool spring.
Figure 420
Compress regulator spool spring and install retainer
ring.
Figure 421
Position new "O" ring on modulation sleeve.
Figure 424
Install inching actuator rod over spring.
SINGLE MODULATION AND MECHANICAL

INCHING INSTALLATION
Figure 422
Install a new "O" ring on inching sleeve. Install
inching spool in sleeve. Install spool and sleeve in
inching control bore.
Figure 425
Install inching return spring.
- 74 -
Figure 426
With new actuator rod oil seal in position and new
"O" ring on inching housing, install housing over
actuator rod and thread into inching bore.
Figure 429
With new "O" ring in position, install modulation housing sleeve assembly in bore.
Figure 430
Install accumulator spool in housing sleeve as
shown.
Figure 427
Tighten inching valve housing to specified torque.
See assembly instruction drawing.
Figure 428
Position shuttle spool in shuttle sleeve.Install spool
and sleeve in modulator valve bore.
Figure 431
Install stop pin, inner, middle, and outer springs in
accumulator and housing sleeve.
- 75 -
Figure 432
Position a new "O" ring on modulator valve housing.
Thread housing into valve bore.
Figure 433
Tighten modulator valve housing to specified torque.
See assembly instruction drawing.
- 76 -
Note : The disc spring packs are to be used as complete assemblies and care should be taken not to
intermix the individual disc springs with disc springs
in another clutch or disc spring pack. Service replacement assemblies are banded together and must be
replaced as asembly.
NOTES
- 77 -
CLUTCH ENGAGEMENT
REV.
FWD.
3rd
CLUTCH ENGAGEMENT FOR 3 SPEED

T12000 POWER SHIFT TRANSMISSION
FORWARD
SHIFT
SPEED
DIRECTION
CLUTCH
SPEED
CLUTCH
1st
2nd
3rd
A
A
A
C
D
E
SHIFT
SPEED
DIRECTION
CLUTCH
SPEED
CLUTCH
1st
2nd
3rd
B
B
B
C
D
E
REVERSE
1st
- 78 -
2nd
CLUTCH ENGAGEMENT
CLUTCH ENGAGEMENT FOR 4 SPEED

T12000 POWER SHIFT TRANSMISSION
FORWARD
SHIFT
SPEED
DIRECTION
CLUTCH
SPEED
CLUTCH
1st
2nd
3rd
A
A
A
C
D
E
4th
DIRECTION
CLUTCH
SPEED
CLUTCH
B
B
B
C
D
E
REV.
FWD.
REVERSE
SHIFT
SPEED
1st
2nd
3rd
4th
1st
- 79 -
2nd
3rd
DRIVE PLATE INSTALLATION
Measure the "A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below.
Note : two (2) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Two (2) kits
with three intermediate drive plates.
ALIGNMENT HOLES
(1) drive plate and weld nut

assembly
Bolt circle dia.
(2) intermediate drive

plates
Bolt circle dia.
Backing ring
(3) intermadiate drive

plates
Backing ring
"A" Dimension (Bolt Circle Diameter)
"A" Dimension (Bolt Circle Diameter)
13.125" [333,38 mm] Diameter

Kit No. 802424
13.125" [333,38 mm] Diameter

Kit No. 802426
13.500" [342,90 mm] Diameter

Kit No. 802425
13.500" [342,90 mm] Diameter

Kit No. 802427
Each Kit will include the following parts :
Kit will include the following parts :
2 Intermediate Drive Plates.

1 Drive Plate and Weld Nut Assembly.
1 Backing Ring.
6 Mounting Screws.
6 Lock Washers.
1 Instruction Sheet.
3 Intermediate Drive Plates.

1 Backing Ring.
6 Mounting Screws.
6 Lock Washers.
1 Instruction Sheet.
TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES

(SEE ILLUSTRATION ABOVE : ALIGNMENT HOLES)
Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter. Align
intermediate drive plates and backing ring with holes in torque converter assembly, NOTE : Two dimples 180
apart in backing ring must be out (toward the engine flywheel). Install capscrews and washers. Tighten 26 to 29
lbfft torque [35 - 39 Nm]
- 80 -
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Remove all burrs from flywheel mounting face and

nose pilot bore. Clean drive plate surface with solvent.
Flywheel
housing
2. Check engine flywheel and housing for conformance to

standard SAE No. 3 per SAE J927 and J1033 tolerance specifications for pilot bore size, pilot bore runout
and mouting face flatness. Measure and record engine
crankshaft end play.
Engine
3. Install two 2.50 [63,500 mm] long transmission to flywheel housing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align a
drive plate mounting screw hole with the flywheel housing access hole.
Flywheel
pilot bore
Flywheel
FIG 1
*4. Install a 4.00 [101,60 mm] long drive plate locating

stud .3750 - 24 fine thread in a drive plate nut. Align
the locating stud in the drive plate with the flywheel
drive plate mounting screw hole positioned in step No.
3.
Converter
housing
Flywheel
4" stud
5. Rotate the transmission torque converter to align the

locating stud in the drive plate with the flywheel drive
plate mounting screw hole positioned in step No. 3.
Locate transmission on flywheel housing.
2" 1/2 aligning

studs
Aligning drive plate to flywheel and transmission to

flywheel housing guide studs, install transmission to
flywheel housing screws. Tighten screws to specified
torque. Remove transmission to engine guide studs.
Install remaining screws and tighten to specified
torque.
Flywheel housing
drive plate
FIG 2
*6. Remove drive plate locating stud.

7. Install drive plate attaching screw and washer. Snug
screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access
hole. A screwdriver or pry bar used to hold the drive
plate against the flywheel will facilitate installation of
the drive plate screws. Rotate the engine flywheel and
install the remaining seven (7) flywheel to drive plate
attaching screws. Snug screws but do not tighten.
After all eight (8) screws are installed torque each one
26 to 29 lbfft torque [35 - 39 Nm]. This will require
tightening each screw and rotating the engine flywheel
until the full amount of eight (8) screws have been tightened to specified torque.
Flywheel housing
Flywheel
Impeller cover
(3) intermediate drive
plates
8. Measure engine cranshaft end play after transmission

has been completely installed on engine flywheel. This
value must be within .001 [0,025 mm] of the end play
recorded in step No. 2.
FIG 3
*Does not apply to units having 3 intermediate drive

plates. See Fig. 4.
- 81 -
FIG 4
SPECIFICATIONS AND SERVICE DATA POWER SHIFT TRANSMISSION AND TORQUE CONVERTER
TRANSMISSION OUT
PRESSURE
With transmission outlet oil temperature, 180 -200 F. [82,3 - 93,3 C] and transmission in NEUTRAL. Operating specifications :
60 P.S.I. [4 bar] minimum pressure at 2000 R.P.M. engine speed AND a maximum of
120 P.S.I. [8 bar] outlet pressure with engine operating at no-load governed speed.
CONTROLS
Forward and Reverse Electric.

Speed Selection Electric.
CLUTCH TYPE
Multiple discs, hydraulically actuated, spring released, automatic wear compensation,

and no adjustment. all clutches oil cooled and lubricated.
CLUTCH INNER DISC
Friction.
CLUTCH OUTER DISC
Steel.
OIL FILTRATION
Full flow oil filter safety by-pass, also strainer screen in sump at bottom of transmission case.
CLUTCH PRESSURE
185 P.S.I. [13 bar] minimum With parking brake set (see note), oil temperature
180 - 200 F. [82,2 - 93,3 C], engine at idle (775 R.P.M.), shift thru direction and
speed clutches. All clutch pressure must be equal within 5 P.S.I., [0,35 bar]. If clutch
pressure varies in any one clutch more than 5 P.S.I., [0,35 bar] repair clutch.
Normal operating pressure 240 - 280 P.S.I. [16 19 bar] at 2000 R.P.M.
Note : ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE
CHECKS.
- 82 -
LUBRICATION
TYPE OF OIL
See Lube Chart.
CAPACITY
Consult Operator's Manual on applicable machine model for system

capacity.
Torque
Converter,
Treansmission, and allied hydrailic
system must be considered as a
whole to determine capacity.
CHECK PERIOD Check oil level DAILY with engine

running at 775 R.P.M. and oil at 180
to 200 F. [82,2 - 93,3C]. Maintain
oil level to FULL port.
*** NORMAL
DRAIN PERIOD
Every 400 hours, change oil filter.

Every 800 hours, drain and refill system as follows : Drain with oil at 150
to 200F. [82.2 - 93.3 C].
a) Drain transmission.
b) Oil filter, remove and discard.
Install new oil filter.
c) Refill transmission to low port.
d) Run engine at 775 R.P.M. to prime
converter and lines.
e) Recheck level with engine running
at 775 R.P.M. and add oil to bring
level to low port. When oil temperature is hot (180 - 200 F.) [82.2 93.3 C] make final oil level check.
BRING OIL LEVEL TO FULL
PORT
Note : It is recomended that oil filter
be changed after 50 and 100 hours of
operation on new and rebuilt or repaired units.
RECOMMENDED LUBRICANTS FOR POWER

SHIFTED
TRANSMISSION AND TORQUE CONVERTERS
Prevailing Ambient Temperature
(a) C-2 Grade 30
(b) C-3 Grade 30
Temperature
(c) Engine oil :
Grade 30 APIrange "1"
CD/SE
or
CD/SF
(d) MIL-L-2104CGrade 30
(e) MIL-L-2104DGrade 30
Temperature
range "2"
SHELL
DONAX TA
Temperature
range "3"
(a) Dexron
(b) Dexron II D
See caution
below.
Temperature
range "4"
(a) MIL-L-46167
(b) MIL-L-46167 A
Temperature
range "5"
(a) Conoco Highperformance

synthetic motor
oil Spec. N
6718
* Dexron is a registered trademark of general

motors corporation.
preferrred oil viscsity : Select highest oil viscosity
compatible with prevailing ambient temperatures and
oil application chart.
Temperature ranges "2" and "3" may be used to
lower ambient temperatures when sump preheaters
are used.
Temperature range "4" should be used only in
ambient temperature range shown.
***Normal drain periods and oil filter change intervals are

for aver-age environmental and duty-cycle conditions.
Severe or sustained high operating temperatures or
very dusty atmospheric conditions will cause acclerated deterioration and contamination. For extreme
conditions judgment must be used to determine the
required change intervals.
modulated shift transmissions : T12000, 18000,

24000, 28000, & 32000 series transmisions with
modulated shift use only C-3 or temperature range 3
items (a) & (b) *Dexron or *Dexron II D. see caution
below. 3000, 4000, 5000, 6000, 8000, 16000 &
34000 series transmission with modulated shift use
only C-3 or temperature range 3 item (a) only
*Dexron. Do NOT use *Dexron II D. see caution
below.
CAUTION : *Dexron II D is not compatible with graphitic clutch plate friction material UNLESS IT MEETS
THE APPROVED C-3 SPECIFICATIONS. *Dexron II
D cannot be used in the 3000, 4000, 5000, 6000,
8000, 16000, or 34000 series power shift transmissions, or the HR28000 & HR32000 series having
converter lock-up, or the C270 series converter
having lock-up UNLESS IT MEETS THE APPROVED C-3 SPECIFICATIONS.
- 82 A -
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL

The transmission, torque converter, and its
allied hydraulic system are important links in the driveline between the engine and the whells. The proper operation of either unit depends greatly on the
condition and operation of the other; Therefore, whenever repair or overhaul of one unit is performed, the
balance of the system must be considered before
the job can be considered complete.
5. Reassemble all components and use only type oil

recommended for lubrication section. Fill transmission through filler opening until fluid comes up
to LOW port on transmission.
After the overhauled or repaired transmission

has been installed in the machine, the oil cooler, and
connecting hydraulic system must be thoroughly
cleaned. This can be accomplished in several manners and a degree of judgment must be exercised as
to the method employed.
Run engine two minutes at 775 R.P.M. to prime

torque converter and hydraulic lines. Recheck
level of fluid in transmission with engine running
at idle (775 R.P.M.).
Remove LOWER check plug, fill until oil runs

from LOWER oil hole. Replace filler and level
plug.
Add quantity necessary to bring fluid level to run

freely from LOWER oil level check plug hole.
Install oil level plug. Recheck with hot oil (180200 F.) [82, 2-93, 3 C].
The following are considered the minimum

steps to be taken :
1. Drain entire system thoroughly.
Bring oil level to FULL port to run freely from

UPPER oil level plug hole.
2. Disconnect and clean all hydraulic lines.

Where feasible, hydraulic lines should be
removed from machine for cleaning.
6. Recheck all drain plugs, lines, connections, ect.,

for leaks and tighten where necessary.
3. Replace oil filter elements, cleaning out filter

cases thoroughtly.
4. The oil cooler must be thorougly cleaned.
The cooler should be "back flushed" with oil
and compressed air until all foreign material
has been removed. Flushing in direction of
normal oil flow will not adequately clean the
cooler. If necessary, Cooler assembly
should be removed from machine for cleaning, using oil, compressed air, and steam
cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes.
- 83 -
PRESSURE CHECK
1) Regulated clutch pressure :
(main pressure)
Adap. mark.64
2) Pressure towards cooler :

(converter pressure)
Adap. mark.64
3) Forward gear clutch pressure :
Adap. mark.65
4) Reverse gear clutch pressure :
Adap. mark.65
5) 1st gear clutch pressure :
Adap. mark.65
6) 2nd gear clutch pressure :
Adap. mark.65
7) 3rd gear clutch pressure :
Adap. mark.66
8) 4th gear clutch pressure :
Adap. mark.65
TOP VIEW
3
4
5
6
RIGHT SIDE VIEW
LEFT SIDE VIEW
62
63
63
63
63
63
63
63
63
Mark. 62 : Rf. 218 101 - CLARK box kit

T12000 speed short drop
Mark. 63 : Rf. 561 031 - Pressure gauge connection 1/4"
Mark. 64 : Rf. 561 032 - Adapter MB 1/8" N PTF
64
64
65
65
65
65
65
66
Mark. 65 : Rf. 561 033 - Adapter M.SAE 3/8" UNF

Mark. 66 : Rf. 561 079 - Adapter M.SAE 3/8" UNF
x MJ 7/16
Mark. 67 : Rf. 25 011 - O ring joint
67
67
67
67
67
67
- 84 -
Procedure
Before carrying out the pressure check, lift up and wedge the lift truck, making sure the main
wheels are not in contact with the ground.
- Fix the adapters and the pressure gauge connection onto the check ports :
The adapters Mark 64 of the kit are to be fixed onto the points 1 and 2.
The adapters Mark 65 of the kit are to be fixed onto the points 3-4-5-6 and 8.
The adapters Mark 66 of the kit is to be fixed onto the point 7.
- Bring the box oil to a temperature : 82 to 104C .
- Check the pressure with an engine speed of 2000 rpm.
- Transmission in neutral for the pressures 1 and 2.
1) Main pressure :
16 to 19 bar
Minimum pressure of 13 bar
2) Converter pressure :
4 to 8 bar
3) Forward gear pressure
4) Reverse gear pressure
5) 1st gear
Same pressure as main pressure
6) 2nd gear
7) 3rd gear
8) 4th gear
- The pressure of the reverser and gear clutches must be equal

to the main pressure. If this pressure in one of these clutches
differs from more than 0.35 bar, repair the corresponding clutch.
8
5
3
7
4
- 85 -
CONVERTER TIMING
Engine
1004-4T
Box
T12000
Speed
Short Drop
The engine r.p.m. on timing represents 2090 rpm whatever the ratio.
- 85-2 -
CLEANING AND INSPECTION

CLEANING
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed
in cleaning fluid and moved up and down slowly until
all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned.
CAUTION : Care should be exercised to avoid skin
rashes, fire hazards, and inhalation of vapors when
using solvent type cleaners.
INSPECTION
The importance of careful and thoroughinspection of
all parts cannot be overstressed. Replacement of all
parts showing indication of wear or stress will eliminate costly and avoiable failures at a later date.
BEARINGS
Carefully inspect all rollers : cages and cups for
wear, chipping, or nicks to determine fitness of bearings for futher use. Do not replace a bearing cone or
cup individually without replacing the mating cup or
cone at the same time. After inspection, dip bearings
in Automatic Transmission Fluid and wrap in clean
lintless cloth or paper to protect them until installed.
BEARINGS
Remove bearings from cleaning fluid and strike flat
against a block of wood to dislodge solidified partilcles of lubricant. Immerse again in cleaning fluid to
flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air
stream across bearing to avoid spinning. Do not spin
bearings when drying. Bearings may be rotated
slowly by hand to facilitate drying process.
OIL SEALS, GASKETS, ECT.

Replacement of spring load oil seals, "O" rings,
metal sealing rings, gaskets, and snap rings is more
economical when unit is disassembled than premature overhaul to replace these parts at a future time.
Further loss of lubricant through a worn seal may
result in failure of other more expensive parts of the
assembly. Sealing members should be handled
carefully, particularly when being installed. Cutting,
scratching, or curling under of lip of seal seriously
impairs its efficiency. Apply a thin coat of Permatex
No. 2 on the outer diameter of the oil seal to assure
an oil tight fit into the retainer. When assembling new
metal type sealing rings, same should be lubricated
with coat of chassis grease to stabilize rings in their
grooves for ease of assembly of mating members.
Lubricate all "O" rings and seals with recommended
type Automatic Transmission Fluid before assembly.
HOUSINGS
Clean interior and exterior of housings, bearing caps,
ect., Thoroughly. Cast parts may be cleaned in hot
solution tanks with mild alkali solutions providing
these parts do not have ground or polished surfaces.
Parts Should remain in solution long enough to be
thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water.
Parts cleaned in solution tanks must be thoroughly
rinsed with clean water to remove all traces of alkali.
Cast parts may also be cleaned with steam cleaner.
CAUTION : Care should be exercised to avoid inhalation of vapors and skin rashes when using alkali
cleaners.
All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft,
lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping compound.
GEARS AND SHAFTS

If magna-flux process is available, use process to
check parts. Examine teeth on all gears carefully for
wear, pitting, chipping, nicks, cracks, or scores. If
gear teeth show spots where case hardening is worn
through or cracked, replace with new gear. Small
nicks may be removed with suitable hone. Inspect
shafts and quills to make certain they are not sprung,
bent, or splines twisted, and that shafts are true.
HOUSING, COVERS, ECT.
Inspect housings, covers, and bearing caps to be
certain they are thoroughly clean and that mating
surfaces, bearing bores, ect., are free from nicks or
burrs. Check all parts carefully for evidence of cracks
or condition which would cause subsequent oil leaks
or failures.
- 86 -
T12000 CALIPER BRAKE ASSEMBLY

ITEM
1
2
3
4
5
6
7
DESCRIPTION
QUANTITY
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body (module) . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
ITEM
8
9
10
11
12
13
14
DESCRIPTION
QUANTITY
Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belleville Spring . . . . . . . . . . . . . . . . . . . . . . .
Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retainer Ring . . . . . . . . . . . . . . . . . . . . . . . . .
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
PARKING BRAKE LINING AND PISTON REPLACEMENT PROCEDURE

DISASSEMBLY
1. Loosen and remove lever retaining nut (item 9)
from brake module and piston assembly (item 13).
Remove lever (item 8).
2. Depress retainer (item 11) and remove retaining
ring (item 12) from lever end of brake module (item
7).
3. Remove retainer (item 11) and five (5) belleville
springs (item 10) from piston (item 13).
4. Remove piston (item 13), two cam plates (item 4),
and three balls (item 5) from brake module (item 7).
REASSEMBLY
5. Lubricate three new balls (item 5) with high compression grease and place in ramps of new cam
plates (item 4).
6. Install new cam plates (item 4) in brake module
(item 7) making sure locking lugs are aligned properly in brake module (item 7).
7. Install piston (item 13) in brake module (item 7)
making sure piston aligns properly on cam plates
(item 4).
8. Install five (5) belleville springs (item 10) and retainer (item 11) on lever end of piston (item 13).
9. Depress retainer (item 11) and install retaining ring
(item 12) in groove on piston (item 13).
10. Install brake module assembly (item 7) on housing
(item 1).
11. Position lever (item 8) in a convenient location for

actuation rod. Install lever (item 8) and lever retaining nut (item 9) on brake module assembly (item 7).
Snug lever retaining nut (item 9)
12. Adjust brakes per instructions.
PARKING BRAKE ADJUSTMENT (Mechanical
applied)
With the brake assembled on the transmission with a
free floating operation of the caliper, adjust caliper as follows :
Note : Do not use operating lever (item 8) as a means to
turn the module body (item 7). To use the lever will
cause the piston to extend and cause a false setting.
Module capscreww (item 14) must be loose before brake
adjustment.
1. Screw brake module (item 7) in until linings contact
disc. Back module (item 7) off until a flat on module
lines up with capscrew (item 14). Torque capscrews
(item 14) 8-10 lbfft [11-14 Nm].
2. Remove lever retaining nut (item 9).Remove lever
(item 8).
3. Reposition lever (item 8) to desired angle of operation.
4. Install retaining nut (item 9) and tighten to 10 lbfft
torque [13.6Nm].
- 87 -
TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION

The following information is presented as an aid to
isolating and determining the specific problem area in a
transmission that is not functioning correctly.
to consider the transmission fluid, charging pump,

torque converter, transmission assembly, oil cooler, filter, connecting lines, and controls, including the engine,
as a complete system.
When troubleshooting a "transmission" problem, it

should be kept in mind that the transmission is only the
central unit of a group of related powertrain components. Proper operation of the transmission depends on
the condition and correct functioning of the other components of the group. Therefore, to properly diagnose a
suspected problem in the transmission, it is necessary
By analyzing the principles of operation together

with the information in this section, it should be possible
to identify and correct any malfunction which may occur
in the system.
T12000 TRANSMISSION
T12000 (powershift with torque converter transmission troubles fall into two general categories :
mechanical problems and hydraulic problems).
is most important. Transmission fluid is the "life blood"

of the transmission. It must be supplied in a adequate
quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and
hold the clutches from slipping, and to cool and lubricate the working components.
In addition to the mechanical components, all of

which must be in the proper condition and functioning
correctly, the correct functioning of the hydraulic circuit
TROUBLESHOOTING PROCEDURES
Stall Test : Use a stall test to identify transmission,
converter, or engine problems.
Hydraulic Check : Also, before checking the transmission clutches, torque converter, charging pump, and
hydraulic circuit for pressure and rate of oil flow, it is
important to make the following transmission fluid
check :
Transmission Pressure Checks : Transmission problems can be isolated by the use of pressure tests.
When the stall test indicates slipping clutches, then
measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction
material failure. In addition, converter charging pressure and transmission lubrication pressure may also be
measured.
Check oil level in the transmission. The transmission

fluid must be at the correct (full level). All clutches and
the converter and its fluid circuit lines must be fully
charged (filled) at all times. See NOTE below.
NOTE : The transmission fluid must be at operating
temperature of [82-93 C] 180-200 F to obtain correct
fluid level and pressure readings. DO NOT ATTEMPT
TO MAKE THESE CHANGES WITH COLD OIL.
Mechanical checks : Prior to checking any parts of the

system for hydraulic function (pressure testing), the following mechanical checks should be made :
There are only two mechanical linkages available on
the transmission.
1. Mechanical inching from brake pedal to inching valve
on transmission.
2. Linkage from axle disconnect to disconnect actuator.
The raise the oil temperature to this specification it is

necessary to either operate (work) the vehicle or run
the engine with converter at "stall".
CAUTION : Be careful that the vehicle does not move
unexpectedly when operating the engine and converter
at stall R.P.M.
Check the parking brake and inching pedal for correct

adjustment and travel. Be sure the pedal moves freely
and returns fully.
Be sure all lever linkage is properly connected and
adjusted in each segment and at all connecting points.
The controls are actuated electrically. Check the wiring
and electrical components.
Be sure that all components of the cooling system are
in good condition and operating correctly. The radiator
must be clean to maintain the proper cooling and operating temperatures for the engine and transmission .
Air clean the radiator, if necessary.
The engine must be operating correctly. Be sure that it
is correctly tuned and adjusted to the correct idle and
maximum no-load governed speed specifications.
- 88 -
CONVERTER STALL PROCEDURE

1. Put the vehicle against a solid barrier, such as a
wall, and/or apply the parking brake and block the
wheels.
to approximately one-half throttle and hold until transmission (converter outlet) oil temperature reaches the
operating range.
2. Put the directional control lever in FORWARD (or

REVERSE, as applicable).
CAUTION : Do not operate the converter at stall condition longer than 30 seconds at one time, shift to neutral
for 15 seconds and repeat the procedure until desired
temperature is reached. Excessive temperature ([120
C] 250 F maximum) will cause damage to transmission
clutches, fluid, converter, and seals.
3. Put the speed control lever in 3rd (3 speed) (HIGH)

or 6th (6 speed).
With the engine running, slowly increase engine speed
TROUBLESHOOTING GUIDE
Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
LOW CLUTCH PRESSURE

CAUSE
REMEDY
1.Low oil level.
1. Fill to proper level.
2. Clutch pressure regulating valve stuck open.
2. Clean valve spool and housing.
3. Faulty charging pump.
3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings.
4. Replace sealing rings.
5. Clutch piston bleed valve stuck open.
5. Clean bleed valves thoroughly.
LOW CHARGING PUMP OUTPUT

1. Low oil level.
1. Fill to proper level
2. Suction screen plugged.
2. Clean suction pump.
3. Defective charging pump.
3. Replace pump.
OVERHEATING
1. Worn oil sealing rings.
1. Remove, disassemble, and rebuild converter

assembly.
2. Worn charging pump.
2. Replace.
3. Low oil level.
3. Fill to proper level.
4. Dirty oil cooler.
4. Clean cooler.
5. Restriction in cooler lines.
5. Change cooler lines.
NOISY CONVERTER
1. Worn charging pump.
1. Replace.
2. Worn or damaged bearings.
2. A complete disassembly will be necessary to determine what bearing is faulty.
LACK OF POWER
1. Low engine R.P.M. at converter shall.
1. Tune engine check governor.
2. See "Overheating" and make same checks.
2. Make corrections as explained in "Overheating".
- 89 -
ATTENTION: Certaines options de ce manuel ne sont pas montes sur les

chariots MANITOU
GEAR TRANSMISSION T12000

Speed short drop
- 91 -
MODEL DESCRIPTION
1101 T12 4 XX - XX
OUTPUT LOCATION AND RATIO
NUMBER OF SPEEDS
T12000 TRANSMISSION
CONVERTER
1106 F
F = FREE WHEEL
MANITOU MODEL:
1106 F : MLT
- 92 -
STANDARD
SPECIAL
10 - 19
50 - 59
20 - 29
40 - 49
60 - 69
90 - 99
T = HR MODEL
MT = MHR MODEL
S. D.
L. D.
I. D.
- 93 -
BOOST PUMP
EXTERNAL, LOCATED AT REAR SIDE OF TRANSMISSION
CHARGING PUMP
BOOST PUMP
46,2
ON TRANSMISSION
- 94 -
FILTER: SPIN-ON
MIN AT
1800
RPM
CONTROLS
SOLENOIDS ENERGIZED
FWD.
REV.
A, D, E
B, D, E
A, E
B, E
A, C
B
A
C
D
E
- ELECTRONIC SENSORS
3 - TURBINE SPEED SENSOR
- 95 -
MODULATION
A. MODULATION ON FWD AND REV
MODULATION
- 96 -
DUAL VALVE
MODULATION
vent
REV - CLUTCH
FWD - CLUTCH
- 97 -
T12000 MODULATOR VALVE

LONG MODULATION
BAR
21
20
CLUTCH PRESSURE - BAR
19
17
15,5
15
14
12
10
10
7
5
3,5
2
1,75
CYCLE TIME - SECONDS
- 98 -
HYDRAULIC CIRCUIT
DUAL MODULATION
CLUTCH PRESSURE
REGULATOR VALVE
FILTER
COOLER
SAFETY
PUMP
CONVERT.
- 99 -
MODULATION
MODULATION
VALVE
HYDRAULIC DIAGRAM
DUAL MODULATION
MODULATION
MODULATION
OPERATOR COMPARTMENT
TEMP.
PRESSURE
GAUGE
GAUGE
CLUTCH
PRESSURE
REGULATOR
VALVE
REV
HOSE
FWD slow
SAFETY
VALVE
FWD high
4th speed
COOLER
TORQUE
3rd speed
FILTER
CONVERTER
PUMP
2nd speed
HOSE
LUBRICATION
FILTER
AIR
BREATHER
1st speed
OIL SUMP
4 SPEED SHIFT DIAGRAM
FORWARD
REVERSE NEUTRAL
X = SOLENOID ENGAGED
REGULATOR AND SAFETY VALVE
PRESSURE REGULATOR
VALVE
SAFETY VALVE
TORQUE
CONVERTER
CONTROL VALVE
VIBRATION
FREQUENCY
- 101 -
SPEED
INPUT
REV
FWD
FWD
ST
INPUT
HI
ND
FWD
FWD
FORWARD 3TH
FWD
OUTPUT
ST
HI
HI
RD
RD
OUTPUT
ND
FORWARD 2ND
REV
FWD
RD
FORWARD 1ST
INPUT
REV
ST
INPUT
HI
REV
FWD
RD
FWD
OUTPUT
ND
FORWARD 4TH
- 102 -
ST
ND
OUTPUT
ENTRE
REV
FWD
FWD
ST
INPUT
HI
ND
FWD
FWD.
FWD
OUTPUT
REVERSE 2ND
REV
ST
HI
FWD
RD
REVERSE 1ST
INPUT
REV
RD
OUTPUT
ND
REVERSE 3TH
- 103 -
ST
ND
HI
RD
OUTPUT
- 104 -
TO STARTER
SOLENOID
START
PREHEAT
DRIVE
DECLUTCH
REQUEST ON/OFF
(ON PEDAL)
g/n
REVERSE
RELAY
TURBINE
SPEED
g/n
2x21w
j/vt
j/vt
bl
n/s
ro
g/n
COILS
ELECTRIC DIAGRAM: BRANCHEMENT EGS
bl
g/n
n/s
j
ro
r
jvt
jvt

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GROUP 20

GEAR BOX / CONVERTER DISASSEMBLY

CLUTCH ENGAGEMENT (POWER FLOW) 3 SPEED

CLUTCH ENGAGEMENT (POWER FLOW) 4 AND 6 SPEED

DRIVE PLATE INSTALLATION

TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

SPECIFICATIONS AND SERVICE DATA

SERVICING MACHINE AFTER TRANSMISSION OVERHAUL

EXTERNAL PLUMBING AND PRESSURE CHECK POINTS

CLEANING AND INSPECTION

PARKING BRAKE SERVICE

CONVERTER STALL PROCEDURE

HOW THE UNITS OPERATE

T12000 TRANSMISSION CASE AND PLATE GROUP

Sensor Port Plug . . . . . . . . . . . . . . . . . . . . .

Sensor Adjusting Bushing . . . . . . . . . . . . . . . .1

Sensor Port Plug Washer . . . . . . . . . . . . . . . . 1

Oil Baffle Screw . . . . . . . . . . . . . . . . . . . . . . . 3

Oil Baffle Screw Lockwasher . . . . . . . . . . . . . 3

Outlet Temperature Port Plug . . . . . . . . . . . . . 1

Tube and Screen Assembly . . . . . . . . . . . . . . 1

Plate to Transmission Case Gasket . . . . . . . . 1

Oil Supply Tube Seal Ring . . . . . . . . . . . . . . . 1

Plate to Transmission Case Dowel Pin . . . . . 1

Magnetic Drain Plug . . . . . . . . . . . . . . . . . . . . 1

Plate to Transmission Case Dowel Pin . . . . . 1

Converter Safety Valve Poppet . . . . . . . . . . . 1

Seat Snap Ring . . . . . . . . . . . . . . . . . . . . . . . 1

Plate to Transmission Case Screw

Inlet Pressure Port Plug . . . . . . . . . . . . . . . . . 1

Plate to Transmission Case Screw . . . . . . . . . 2

Auto Shift Sensor Port Plug . . . . . . . . . . . . . . 1

Sensor Port Plug "O" Ring . . . . . . . . . . . . . . . 1

Plate to Transmission Case Screw

Sensor Adjusting Bushing . . . . . . . . . . . . . . . 1

Plate to Transmission Case Screw . . . . . . . . . 2

Safety Valve Seat . . . . . . . . . . . . . . . . . . . . . . 1

Dipstick Port Plug . . . . . . . . . . . . . . . . . . . . . . 1

Safety Valve Spring . . . . . . . . . . . . . . . . . . . . 1

Poppet Retainer Washer . . . . . . . . . . . . . . . . .1

Plug "O" Ring . . . . . . . . . . . . . . . . . . . . . . . . . 2

Plate to Transmission Case Screw . . . . . . . . . 3

Oil Level Plug . . . . . . . . . . . . . . . . . . . . . . . . . 2

Plate to Transmission Case Screw

Plug Sealing Ring . . . . . . . . . . . . . . . . . . . . . . 1

Speed Sensor Plug . . . . . . . . . . . . . . . . . . . . . 1

Speed Sensor Plug . . . . . . . . . . . . . . . . . . . . . 1

Sensor Port Plug "O" Ring . . . . . . . . . . . . . . . 1

T12000 CONVERTER GROUP

Pump Drive Idler Thrust Washer . . . . . . . . . . 1

Idler Gear Bearing . . . . . . . . . . . . . . . . . . . . . 1

Reverse Idler End Plate Capscrew . . . . . . . . 1

Pump Drive Idler Gear . . . . . . . . . . . . . . . . . . 1

End Plate Capscrew Washer . . . . . . . . . . . . 1

Pump Drive Idler and Pilot Shaft . . . . . . . . . . 1

End Plate to Shaft Roll Pin . . . . . . . . . . . . . . 1

Pump Drive Idler and Pilot Shaft Dowel. . . . . 1

Reverse Idler Gear Bearing . . . . . . . . . . . . . . 1

Pump Drive Idler Thrust Washer . . . . . . . . . . 1

Pump Drive Gear Retainer Snap Ring . . . . . 1

Pump Drive Gear . . . . . . . . . . . . . . . . . . . . .

Charging Pump Gasket. . . . . . . . . . . . . . . . . 1

Ball Check Valve . . . . . . . . . . . . . . . . . . . . . . 1