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DF180 Series

Powershift
Transmission
Repair Manual

TECHNICAL MANUAL
DF180 Series Powershift
Transmission Repair Manual
CTM308 15FEB05 (ENGLISH)

Funk Manufacturing Company


LITHO IN U.S.A.
Introduction
Foreword

This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
Transmission. They are on-the-job guides containing
only the vital information needed for diagnosis,
This is the safety-alert symbol. When you see this
analysis, testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.

DX,TMIFC –19–29SEP98–1/1

CTM308 (15FEB05) DF180 Series Powershift Transmission


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Introduction

Technical Information Feedback Form

We need your help to continually improve our technical


publications. Please copy this page and FAX or mail your
comments, ideas and improvements.

SEND TO: John Deere Dubuque Works


P.O. Box 538
Attn.: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

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THANK YOU!

TX,TM,FAX –19–03JUL01–1/1

CTM308 (15FEB05) DF180 Series Powershift Transmission


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Introduction

CTM308 (15FEB05) DF180 Series Powershift Transmission


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Contents
01
SECTION 01—General Information PTO Housing
Group 005—Safety Group 445—Specifications for Transmission Tests
Group 015—Transmission Identifications and
General Procedures
02
SECTION 02—Repair and Adjustments -
Transmission
Group 025—Repair Procedures and Repair Stand
Group 027—Winch Drive - Remote Mount
Group 029—Park Brake
Group 031—Output Seals 03
Group 033—Suction Tube
Group 035—Charge Pump and Idler Gears/Shaft -
Remote Mount
Group 036—Charge Pump and Idler Gears/Shaft -
Engine Mount 04
Group 037—Control Valve
Group 039—Input Yoke - Remote Mount
Transmission
Group 040—Input Drive Hub - Engine Mount
Transmission
Group 041—Front and Rear Housing and Clutch 05
Assembly Group
Group 043—Gears, Bearings, and Shafts
Group 045—Drive Plate and Torque Converter
Assembly
Group 047—Torque Converter PTO Housing 06

SECTION 03—Theory of Operation


Group 100—Transmission Operation

SECTION 04—Diagnostics
INDX
Group 200—Transmission Diagnostics and Tests
Group 225—Transmission Tests

SECTION 05—Tools and Other Materials


Group 300—Essential Tools
Group 325—Dealer Fabricated Service Tools

SECTION 06—Specifications
Group 400—Bolt and Cap Screw Specification
Group 415—Transmission Specification
Group 425—Specifications for Drive Plate and
Torque Converter Assembly
Group 435—Specifications for Torque Converter

All information, illustrations and specifications in this manual are based on


the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual

CTM308 (15FEB05) i DF180 Series Powershift Transmission


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Contents

01

02

03

04

05

06

INDX

CTM308 (15FEB05) ii DF180 Series Powershift Transmission


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01

Section 01
General Information
Contents

Page

Group 005—Safety . . . . . . . . . . . . . . . . . . . .01-005-1

Group 015—Transmission Identifications and


General Procedures
Remote Mount Direct Drive Transmission
Configuration . . . . . . . . . . . . . . . . . . . . . . . .01-015-1
Remote Mount Converter Drive Transmission
Configuration . . . . . . . . . . . . . . . . . . . . . . . .01-015-1
Engine Mount Direct Drive Transmission
Configuration . . . . . . . . . . . . . . . . . . . . . . . .01-015-2
Transmission Specifications1 . . . . . . . . . . . . .01-015-3
Identification Plate . . . . . . . . . . . . . . . . . . . . . .01-015-5
General Repair Procedures . . . . . . . . . . . . . . .01-015-6
Sealants and Adhesives Cross-Reference
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-015-7
Sealing Instructions . . . . . . . . . . . . . . . . . . . . .01-015-8
Cold Weather Operation . . . . . . . . . . . . . . . .01-015-10
Oil Temperature Warning Signal . . . . . . . . . .01-015-11
Recommended Lubricants. . . . . . . . . . . . . . .01-015-12
Lubricant Storage . . . . . . . . . . . . . . . . . . . . .01-015-13
Mixing of Lubricants . . . . . . . . . . . . . . . . . . .01-015-13
Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . .01-015-14
Alternative and Synthetic Lubricants . . . . . . .01-015-14
Check and Service Transmission
Regularly . . . . . . . . . . . . . . . . . . . . . . . . . .01-015-15
Intervals For Changing Transmission Oil
And Filters . . . . . . . . . . . . . . . . . . . . . . . . .01-015-16
Drain Transmission Oil . . . . . . . . . . . . . . . . .01-015-17
Fill The Transmission With Oil. . . . . . . . . . . .01-015-18
Check Oil Lines and Fittings . . . . . . . . . . . . .01-015-19
Hydraulic Connections. . . . . . . . . . . . . . . . . .01-015-19
Transmission Storage . . . . . . . . . . . . . . . . . .01-015-20
Transmission Removal From Storage . . . . . .01-015-20
Towing The Vehicle. . . . . . . . . . . . . . . . . . . .01-015-21

CTM308 (15FEB05) 01-1 DF180 Series Powershift Transmission


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Contents

01

CTM308 (15FEB05) 01-2 DF180 Series Powershift Transmission


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Group 005
Safety
01
Recognize Safety Information 005
1

This is a safety-alert symbol. When you see this symbol


on your machine or in this manual, be alert to the
potential for personal injury.

–UN–07DEC88
Follow recommended precautions and safe operating
practices.

T81389
DX,ALERT –19–29SEP98–1/1

Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near


heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not


incinerate or puncture pressurized containers.

–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn

TS227
spontaneously.

DX,FLAME –19–29SEP98–1/1

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from


the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object


across the posts. Use a volt-meter or hydrometer.
–UN–23AUG88

Do not charge a frozen battery; it may explode. Warm


battery to 16°C (60°F).
TS204

DX,SPARKS –19–03MAR93–1/1

CTM308 (15FEB05) 01-005-1 DF180 Series Powershift Transmission


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Safety

01
005 Prepare for Emergencies
2

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
DX,FIRE2 –19–03MAR93–1/1

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong


enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.


2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.


2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.

–UN–23AUG88
If acid is swallowed:

1. Do not induce vomiting.


2. Drink large amounts of water or milk, but do not TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.

DX,POISON –19–21APR93–1/1

CTM308 (15FEB05) 01-005-2 DF180 Series Powershift Transmission


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Safety

01
Handle Chemical Products Safely 005
3

Direct exposure to hazardous chemicals can cause


serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.

–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.

TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical


products used with John Deere equipment.)

DX,MSDS,NA –19–03MAR93–1/1

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin


causing serious injury.

Avoid the hazard by relieving pressure before

–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands

X9811
and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid


injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.

DX,FLUID –19–03MAR93–1/1

CTM308 (15FEB05) 01-005-3 DF180 Series Powershift Transmission


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Safety

01
005 Park Machine Safely
4

Before working on the machine:

• Lower all equipment to the ground.


• Stop the engine and remove the key.
• Disconnect the battery ground strap.

–UN–24MAY89
• Hang a ’DO NOT OPERATE’ tag in operator station.

TS230
DX,PARK –19–04JUN90–1/1

Support Machine Properly

Always lower the attachment or implement to the ground


before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment. If left in a raised position,
hydraulically supported devices can settle or leak down.

–UN–23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.

TS229
Follow recommended procedures in this manual.

When implements or attachments are used with a tractor,


always follow safety precautions listed in the implement
operator’s manual.

DX,LOWER –19–17FEB99–1/1

Wear Protective Clothing

Wear close fitting clothing and safety equipment


appropriate to the job.

Prolonged exposure to loud noise can cause impairment


or loss of hearing.
–UN–23AUG88

Wear a suitable hearing protective device such as


earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206

Operating equipment safely requires the full attention of


the operator. Do not wear radio or music headphones
while operating machine.

DX,WEAR –19–10SEP90–1/1

CTM308 (15FEB05) 01-005-4 DF180 Series Powershift Transmission


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Safety

01
Work in Clean Area 005
5

Before starting a job:

• Clean work area and machine.


• Make sure you have all necessary tools to do your job.

–UN–18OCT88
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.

T6642EJ
DX,CLEAN –19–04JUN90–1/1

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,


scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.

–UN–23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

TS228
DX,LOOSE –19–04JUN90–1/1

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is


necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.

–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area

TS220
DX,AIR –19–17FEB99–1/1

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a


portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
–UN–23AUG88
TS223

DX,LIGHT –19–04JUN90–1/1

CTM308 (15FEB05) 01-005-5 DF180 Series Powershift Transmission


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Safety

01
005 Replace Safety Signs
6

Replace missing or damaged safety signs. See the


machine operator’s manual for correct safety sign
placement.

–UN–23AUG88
TS201
DX,SIGNS1 –19–04JUN90–1/1

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe


injury or machine damage.

Follow recommended procedure for removal and


installation of components in the manual.

–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when


handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers

–UN–23AUG88
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as TS220

airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for


cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.

Keep bystanders away from the area.

DX,DUST –19–15MAR91–1/1

CTM308 (15FEB05) 01-005-6 DF180 Series Powershift Transmission


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Safety

01
Avoid Heating Near Pressurized Fluid Lines 005
7

Flammable spray can be generated by heating near


pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be

–UN–15MAY90
accidentally cut when heat goes beyond the immediate
flame area.

TS953
DX,TORCH –19–03MAR93–1/1

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated


by welding, soldering, or using a torch.

–UN–23AUG88
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.

Remove paint before welding or heating:

TS220
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.

DX,PAINT –19–03MAR93–1/1

CTM308 (15FEB05) 01-005-7 DF180 Series Powershift Transmission


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Safety

01
005 Use Proper Tools
8

Use tools appropriate to the work. Makeshift tools and


procedures can create safety hazards.

Use power tools only to loosen threaded parts and


fasteners.

–UN–08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping

TS779
wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR –19–17FEB99–1/1

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When


constructing tools, use proper, quality materials, and good
workmanship.

–UN–01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.

LX1016749
DX,SAFE,TOOLS –19–10OCT97–1/1

CTM308 (15FEB05) 01-005-8 DF180 Series Powershift Transmission


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Safety

01
Dispose of Waste Properly 005
9

Improperly disposing of waste can threaten the


environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.

TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.

Air conditioning refrigerants escaping into the air can


damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste


from your local environmental or recycling center, or from
your John Deere dealer.

DX,DRAIN –19–03MAR93–1/1

Live With Safety

Before returning machine to customer, make sure


machine is functioning properly, especially the safety
systems. Install all guards and shields.

–19–07OCT88
TS231
DX,LIVE –19–25SEP92–1/1

CTM308 (15FEB05) 01-005-9 DF180 Series Powershift Transmission


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Safety

01
005
10

CTM308 (15FEB05) 01-005-10 DF180 Series Powershift Transmission


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Group 015
Transmission Identifications and General Procedures
01
Remote Mount Direct Drive Transmission 015
1
Configuration

Remote mounted transmission is conveniently mounted in


the vehicle away from the engine. Direct Drive
transmission requires a torsional damper mounted to the
flywheel and a drive shaft from the torsional damper to the
transmission.

–UN–21OCT04
YZ6031
Remote Mount Direct Drive Transmission Configuration

YZ03225,00000A2 –19–19OCT04–1/1

Remote Mount Converter Drive Transmission


Configuration

The converter PTO assembly is mounted directly to the


engine. The transmission is conveniently mount in the
vehicle away from the engine and connected to the
converter PTO assembly with a drive shaft.

–UN–21OCT04
YZ6033

Remote Mount Converter Drive Transmission Configuration

YZ03225,00000A3 –19–19OCT04–1/1

CTM308 (15FEB05) 01-015-1 DF180 Series Powershift Transmission


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Transmission Identifications and General Procedures

01
015 Engine Mount Direct Drive Transmission
2
Configuration

The transmission is mounted directly to the engine. Direct


Drive transmission requires a torsional damper mounted
to the flywheel.

–UN–21OCT04
YZ6034
Engine Mount Direct Drive Transmission Configuration

YZ03225,00000A4 –19–19OCT04–1/1

CTM308 (15FEB05) 01-015-2 DF180 Series Powershift Transmission


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Transmission Identifications and General Procedures

01
Transmission Specifications1 015
3

Item Measurement Specification

DF180 Remote Mount Weight 521.6 Kg (1150 lbs)

DF180 Engine Mount Weight 567 Kg (1250 lbs)

DF180 Remote Mount Input-to-Output 500 mm (19.68 in)

DF180 Engine Mount Input-to-Output 582 mm (22.91 in)

DF180 Remote Mount Direct Drive Rating (Depending on application) Input power (maximum) - 134.2 kW
(180 SAE hp)
Input no load speed (maximum) -
2600 rpm
Torque (maximum) - 949.1 N•m (700
lb-ft)

DF180 Remote Mount Converter Rating (Depending on application) Input power (maximum) - 134.2 kW
Drive (180 SAE hp)
Input no load speed (maximum) -
2600 rpm
Turbine torque (maximum) - 1355.8
N•m (1000 lb-ft)

DF180 Engine Mount Direct Drive Rating (Depending on application) Input power (maximum) - 149.1 kW
(200 SAE hp)
Input no load speed (maximum) -
2600 rpm
Torque (maximum) - 1220.2 N•m
(900 lb-ft)

DF180 Mountings Available Remote


Engine

DF180 Remote Mount Converter Torque Converters Available 298.5 mm (11.75 in)
Drive 323.8 mm (12.75 in)
355.6 mm (14.00 in)

DF180 Clutches Fully modulated, oil cooled,


multi-disc, hydraulic actuated and
self-adjusting.

1
Weights will vary depending on installed options.
Continued on next page YZ03225,0000044 –19–03FEB05–1/2

CTM308 (15FEB05) 01-015-3 DF180 Series Powershift Transmission


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Transmission Identifications and General Procedures

01
015 Item Measurement Specification
4

DF180 Gearing Constant mesh, in line, high contact


ratio ground gears. Up to eight
speeds forward and four speeds
reverse.

DF180 Oil Hydraulic transmission fluid J20C or


J20D

DF180 Filter Remote mounted spin-on type filter.

DF180 Remote Mount Direct Drive Maximum Input Speed 2600 rpm
Test Input Speed 2000 rpm

DF180 Remote Mount Converter Maximum Input Speed 2600 rpm


Drive Test Input Speed 2000 rpm

DF180 Engine Mount Direct Drive Maximum Input Speed 2600 rpm
Test Input Speed 2000 rpm

Transmission Operating Conditions Maximum Continuous Operating 110°C (230°F)


Temperature
Maximum intermittent Operating 121°C (250°F)
Temperature
Normal Operating Temperature 38—93°C (100—200°F)

Pressures and Flows at Control Pump Pressure 1758—1965 kPa (255—285 psi)
Valve Pump Flow 87—102 L/min (23—27 gpm)
Clutch Pressure 1655—1931 kPa (240—280 psi)
Lube, In Pressure 138—414 kPa (20—60 psi)

YZ03225,0000044 –19–03FEB05–2/2

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Transmission Identifications and General Procedures

01
Identification Plate 015
5

–UN–24APR98
Remote Mount

The identification plate is located in the upper left on the


rear housing of the transmission. Should repair parts be

YZ1502
required, please specify the model, specification, and
serial number of your transmission.

Engine Mount

The identification plate is located on the upper lower left


side on the rear housing of the transmission (Viewed from
the rear of transmission, control valve side). Should repair
parts be required, please specify the model, specification,
and serial number of your transmission.

YZ03225,0000045 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-5 DF180 Series Powershift Transmission


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Transmission Identifications and General Procedures

01
015 General Repair Procedures
6

NOTE: Before beginning the repair, review the Inspect tapered bearings and roller bearing surfaces
following guidelines. These are provided to for distortion, roughness, and scoring.
emphasize the need for attention to detail and
care when servicing the Transmission When installing bearing cups and cones, make sure
assembly. they are fully seated.

Thoroughly clean the outside before disassembly. Cups and cones are properly seated if a 0.05 mm
(0.002 in.) feeler gauge will NOT pass for a 360°
circular sweep between cone or cup mounting surface.
CAUTION: Some part have sharp edges.
Shafts
Handle parts carefully to prevent nicking or burring
machined surfaces.
Inspect the shaft bearing surfaces for wear or damage.
Inspection Before Disassembly.
Inspect shafts and replace if excessively worn or
damaged.
Inspect the gears, shafts and bearing before removal
as follows:
Gear Assemblies
1. Wipe the lubricant from the internal working parts
Examine the gear teeth for excessive wear or unusual
and visually inspect the parts for excessive wear or
wear. Replace as necessary.
damage.
Fasteners and Tightening
2. Inspect the gears for roughness.
Fasteners must be tightened to the specified torque.
3. Inspect the gear teeth for signs of scoring,
abnormal wear, or nicks/chips.
Fasteners must be replaced with the same property
class (grade).
Heating Bearings
Follow the specified tightening pattern when listed.
IMPORTANT: Heat bearings in a bearing heater.
Use a thermometer and DO NOT
Different models of transmission and Early Version
exceed 150°C (300°F).
Transmissions may have a different torque
specification and fastener than Later Version
Cleaning and Inspection
Transmissions. Check the model number and/or the
fastener removed and use the correct torque
Clean all parts with clean solvent and use
specification and fastener.
moisture-free air for drying.
Assembly
Bearings
Use the specified grease when installing seals.
Never dry bearings with compressed air. Spinning a
bearing without lubrication can damage the bearing.
During assembly, each part should be lubricated with
clean hydraulic oil.
Clean bearings with clean solvent, dry thoroughly, and
oil before inspection. Inspect bearings for roughness of
rotation of rollers.

YZ03225,00000E0 –19–14DEC04–1/1

CTM308 (15FEB05) 01-015-6 DF180 Series Powershift Transmission


021505
PN=24
Transmission Identifications and General Procedures

01
Sealants and Adhesives Cross-Reference 015
7
Chart
U.S. PART CANADIAN COLOR SIZE DESCRIPTION LOCTITE SIMILAR
NUMBER PART NUMBER NUMBER LOCTITE
PRODUCT

Bonding
TY15435 TY15702 BLACK AND 4 gm Epoxy Adhesive 445 453
WHITE
TY21517 TY16173 CLEAR 3 gm Instant Gel Adhesive 454 416, 409, or 495

Gasketing
T43514 TY9475 RED 50 ml Plastic Gasket 568 —
TY6304 TY9484 PURPLE 50 ml Flexible Form-in-Place 515 518
Gasket
TY15934 — BROWN 16 oz General Purpose Gasket — Permatex #3
Dressing
TY16100 TY6337 BROWN 4 oz General Purpose Gasket — Permatex #3
Dressing
TY16021 TY16112 BLUE 50 ml High-Flex Form-in-Place 21887 —
Gasket
TY16099 TY16113 BURGUNDY 16 oz High Tack Gasket — Permatex #98
Dressing
TY16135 TY15705 SILVER BLUE 3 oz Ultra Blue RTV Silicone 587 Permatex #77
Form-in-Place Gasket

Priming
TY16285 TY9485 GREEN 4.5 oz Cure Primer 7649 —

Retaining
TY8311 TY15801 SILVER 50 ml Quick Metal Press Fit 660 —
TY15969a TY16039 GREEN 50 ml Maximum Strength 680 635
TY15941 TY16040 GREEN 50 ml High-Temperature 620

Threadlocking and Threadsealing


T43512 TY9473 BLUE 50 ml Medium Strength 242 241 or 243
TY9370 TY9477 BLUE 6 ml Medium Strength 242 241 or 243
T43513 TY9474 CLEAR 50 ml High Strength 271 262 or 609
TY9371 TY9478 CLEAR 6 ml High Strength 271 262 or 609
TY9374 TY9481 WHITE 6 ml Pipe Sealant w/TEFLON 592 565 or 567
TY9375 TY9480 WHITE 50 ml Pipe Sealant w/TEFLON 592 565 or 567
a
TY15969 replaces T43515

LOCTITE is a trademark of Loctite Corporation


QUICK METAL is a trademark of Loctite Corporation
TEFLON is a trademark of Du Pont Company YZ03225,0000046 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-7 DF180 Series Powershift Transmission


021505
PN=25
Transmission Identifications and General Procedures

01
015 Sealing Instructions
8

Disassembly

On disassembly, the dowel pin holes provide a slip fit with


a normal depth of 15 mm (0.6 in.).

Measure the length of protrusion to insure dowel pins will


not prevent the housing from being drawn up tight.

If dowel pins protrude more than 15 mm (0.6 in.) from the


components, remove the dowel pins, clean the holes, and
reinstall the dowel pins to the specified depth.

Cleaning

IMPORTANT: DO NOT use clean and cure primer to


clean the surfaces. The primer action
will cause the new sealer to set up TOO
fast to allow adequate assembly time.

Clean surfaces with a brass brush or scraper to remove


old sealer material. Gel-type paint removers containing
ethylene chloride or LOCTITE “Chisel” may be used.

Clean surfaces using rubbing alcohol to remove oil and


grease residue.

Test for clean surface by applying a few drops of cool


water to the surfaces. If water puddles or forms beads,
repeat the cleaning procedure.

A file should be passed on the joint faces to insure no


nicks are present.

Keep surfaces clean and oil free after cleaning.

Application and Assembly

Front Housing-to-Rear Housing:

LOCTITE is a trademark of Loctite Corporation Continued on next page YZ03225,0000047 –19–03FEB05–1/2

CTM308 (15FEB05) 01-015-8 DF180 Series Powershift Transmission


021505
PN=26
Transmission Identifications and General Procedures

01
IMPORTANT: Do not use an excessive amount of 015
9
sealant.

Apply a THIN even layer of flexible gasket sealant to ONE


surface of the joint. Sufficient amount should be applied
so excess is seen around the outside edge of the flange.
Narrow overlap areas must be covered with gasket
material.

IMPORTANT: Temperature of adjoining parts and


gasket material must be 13°C (55°F) or
above.

Remote Mount:

Apply flexible gasket sealant to the front housing


machined surface.

Install rear housing onto front housing.

Engine Mount

Apply flexible gasket sealant to the rear housing machined


surface.

Install front housing onto rear housing.

Tighten cap screws to the specified torque starting from


center and working toward top and bottom.

Allow the assembly to cure one hour minimum before


filling with oil.

YZ03225,0000047 –19–03FEB05–2/2

CTM308 (15FEB05) 01-015-9 DF180 Series Powershift Transmission


021505
PN=27
Transmission Identifications and General Procedures

01
015 Cold Weather Operation
10

IMPORTANT: Preheat procedures are required when


operating transmission below the oil’s
MINIMUM critical temperature which is
viscosity grade dependent and will
effect shift performance.

NOTE: See Transmission Oil Warm-Up Procedure

PREHEAT TRANSMISSION FLUID WITH AUXILIARY


SOURCE

• Preheat the transmission fluid to the MINIMUM


temperature before operating.

NOTE: See Transmission Oil Warm-Up Procedure

ALTERNATE WARM-UP PROCEDURE:

• Operate transmission in neutral for approximately 20


minutes or until oil is warmed to the MINIMUM
temperature.

HOT WEATHER OPERATION

Refer to AIR TEMPERATURE RANGE in the operators


manual for:

• Ambient temperatures consistently above 30°C (86°F).


• Frequent stop-and-go driving in hot weather.
• High grade climbing in hot weather.

YZ03225,0000048 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-10 DF180 Series Powershift Transmission


021505
PN=28
Transmission Identifications and General Procedures

01
Oil Temperature Warning Signal 015
11

• The oil temperature sensor measures system oil


temperature. If temperature rises to 115°C (230°F) or
the transmission oil temperature warning light comes
on, stop the vehicle immediately. Shift to neutral and

–UN–30JAN01
run the engine at 1000—1200 rpm.

IMPORTANT: Do not stop the engine when the


transmission is overheating if the

YZ3008A
cooling system is known to be in
working order.
Temperature Sensor
• The transmission oil temperature should soon lower to
the engine water temperature, or if an air-to-oil
exchanger is used, the temperature should soon lower
to ambient air temperature across the heat exchanger.
If the temperature does not lower, trouble is indicated.
• Correct overheating problem before the vehicle is
operated again.

YZ03225,000004A –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-11 DF180 Series Powershift Transmission


021505
PN=29
Transmission Identifications and General Procedures

01
015 Recommended Lubricants
12

–UN–23APR98
YZ1500
AMBIENT AIR TEMPERATURE CHART • John Deere Standard JDM J20C
• John Deere Standard JDM J20D
Select an oil viscosity, from the chart, based on the air
temperature range expected between oil changes. Some fluids that contain the following additive
packages have been shown to meet the specification
NOTE: The words “oil”, “fluid” and “transmission fluid” requirements of J20 C and/or J20 D. Inclusion of the
are used in this manual to mean, HYDRAULIC following additive packages does not constitute blanket
TRANSMISSION FLUID, the operating and approval of the oil for these applications.
lubricating oil for this transmission.
Supplier Additive
Chevron Ornite OLOA 9725X
Standard and Low viscosity HY-GARD Transmission
Lubrizol Lubrizol 9990
fluids are available through the John Deere dealer
network worldwide. Other oils may be used if they
meet one of the following:

HY-GARD is a trademark of Deere & Company. YZ03225,000004B –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-12 DF180 Series Powershift Transmission


021505
PN=30
Transmission Identifications and General Procedures

01
Lubricant Storage 015
13

Equipment can operate at top efficiency only if clean


lubricants are used.

Use clean containers to handle all lubricants.

Store lubricants and containers in an area protected from


dust, moisture, and other contamination. Store containers
positioned to avoid water and dirt accumulation.

Make certain all containers are correctly marked to identify


contents.

Properly dispose of all old containers and any residual


lubricant.

YZ03225,000004C –19–03FEB05–1/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil.


Oil manufacturers blend additives to their oils to meet
certain specifications and performance requirements.

Mixing different oils can interfere with the proper


functioning of these additives and degrade lubricant
performance.

Refer to Recommended Lubricants and/or Transmission


Specifications for lubricant specifications to obtain specific
information and recommendations.

YZ03225,000004D –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-13 DF180 Series Powershift Transmission


021505
PN=31
Transmission Identifications and General Procedures

01
015 Oil Analysis
14

Oil analysis is best used by sampling at regular intervals


to establish a baseline analysis for the oil and operation
conditions present. Changes from this baseline may
indicate unusual wear.

IMPORTANT: Change the oil and filter if an analysis


of the used transmission oil indicates
any of the following limits are
exceeded.

• Glycol (Antifreeze), must not exceed 0% by volume.


• Water, must not exceed 0.05% by volume.
• Viscosity increase at 38°C (100°F), not more than 40%
over new oil value.
• Total Acid Number (TAN) per ASTMD664, limit of 3.0
over new lubricant value.

YZ03225,000004E –19–03FEB05–1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require


lubricant recommendations different from those in this
manual.

Synthetic lubricants may be used if meeting the


performance requirements in this manual.

The temperature limits and service intervals apply to both


conventional and synthetic oils.

Refined base stock products may be used if the finished


lubricant meets the performance requirements.

YZ03225,000004F –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-14 DF180 Series Powershift Transmission


021505
PN=32
Transmission Identifications and General Procedures

01
Check and Service Transmission Regularly 015
15

Routine checks will help prevent down time. The operator


can aid in preventative maintenance by reporting signs of
leaks or malfunctions.

Because the transmission operates in and by oil, most of


the maintenance is concerned with oil replenishment and
oil cleanliness. The type of service and operating
conditions shall determine the maintenance interval.

NOTE: Engage park brake before checking oil level.

OIL LEVEL

IMPORTANT: The PST (Power Shift Transmission)


should always be in the PARK position
before starting the engine, or when the
vehicle is parked and the engine is
running.

CHECK THE OIL LEVEL DAILY

• Set parking brake.


• Put the gear selector lever in PARK position.
• Operate the engine at idle speed.
• Make sure the transmission oil temperature is above
38°C (100°F).
• Keep oil level at the “FULL” mark on the dipstick.

YZ03225,0000050 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-15 DF180 Series Powershift Transmission


021505
PN=33
Transmission Identifications and General Procedures

01
015 Intervals For Changing Transmission Oil And
16
Filters

IMPORTANT: Change oil and filter after the first 100


hours of transmission operation. The oil
and filter change intervals given here
are for normal service conditions. If the
transmission is to be operated in severe
conditions contact the Funk Service
Department for additional
recommendations.

FIRST OIL AND FILTER CHANGE:

• Change oil and filter after first 100 hours of transmission


operation.

ROUTINE OIL AND FILTER MAINTENANCE:

IMPORTANT: Some Transmission are equipped with


devices to alert the operator when oil is
bypassing the filter. Change the oil filter
if a “Filter Bypass Signal” is indicated
and the transmission is at normal
operating temperature.

• Change oil filter anytime the transmission is at normal


operating temperature and a “Filter Bypass Signal” is
indicated.
• Change oil and filter anytime there are signs of
contamination in the oil or the oil has a burnt odor.
• Change filter at every 750 hours or if indicator light
comes on. Change filter and oil every 1500 hours of
transmission operation or if indicator light comes on.

YZ03225,0000051 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-16 DF180 Series Powershift Transmission


021505
PN=34
Transmission Identifications and General Procedures

01
Drain Transmission Oil 015
17

Open Transmission Drain

• Open oil drain valve (A) (Remote Mount) or remove


drain plug (A) (Engine Mount).
• Check oil drain valve (A) (Remote Mount) or drain plug
(A) (Engine Mount) for contamination.

Close Transmission Drain

• Close oil drain valve (A) (Remote Mount) or install drain


plug (A) (Engine Mount) into housing.

A—Drain Valve

–UN–21OCT04
YZ6032
Remote Mounted Transmission Drain Valve

–UN–30SEP04
YZ5864
Engine Mounted Transmission Drain Plug

YZ03225,0000052 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-17 DF180 Series Powershift Transmission


021505
PN=35
Transmission Identifications and General Procedures

01
015 Fill The Transmission With Oil
18

AFTER INSTALLING TRANSMISSION IN VEHICLE:

1. Park machine on level surface.


2. Engage parking brake, block wheels.
3. Put transmission in PARK.
4. Remove oil filler cap from oil fill tube on transmission.
5. Begin filling operation by adding 18.9 L (5 gal) of
recommended oil.
6. Start the engine, run at idle speed to fill oil lines.
7. For Direct Drive transmissions shut off engine wait 20
minute. check oil level.
8. For Converter Drive transmissions start engine and let
oil heat up to 38° C (100° F), then check oil level.
9. After checking oil, add additional oil of necessary to
bring to proper oil level.

IMPORTANT: Do not overfill transmission. This will

–UN–21OCT04
cause overheating. Damage to the
transmission will result.

YZ6031
Remote Mounted Transmission Oil Fill

YZ03225,0000053 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-18 DF180 Series Powershift Transmission


021505
PN=36
Transmission Identifications and General Procedures

01
Check Oil Lines and Fittings 015
19

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

If an accident occurs, see a doctor immediately.


Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.

Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.

Tubing with dents may cause the oil to overheat. If you


find tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specified in torque


chart.

When you tighten connections, use two wrenches to


prevent bending or breaking tubing and fittings.

YZ03225,0000054 –19–03FEB05–1/1

Hydraulic Connections

There are several different combinations for hydraulic


lines and fittings for brakes, differential housings, and
lubrication lines.

Refer to the vehicle repair manual and/or parts information


for the actual application of a particular axle configuration.

YZ03225,0000055 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-19 DF180 Series Powershift Transmission


021505
PN=37
Transmission Identifications and General Procedures

01
015 Transmission Storage
20

This procedure applies to those transmissions and


components that have been tested according to Funk
Manufacturing test specifications and have had the oil
drained from them prior to shipment.

The following actions will help protect the unit and


component items from internal rust and corrosion damage
for approximately one year, provided the transmissions
are stored in a dry area:

• Seal all openings with moisture-proof covers or tape.


• Spray 113 mL (4 oz) of atomized NOX RUST1 VCI No.
10 oil or an equivalent into oil drain hole. This fluid is
covered and approved per (MIL-P-46002 and
MIL-I-23310).
• Dip, spray, or brush all exposed unpainted surfaces with
NOX RUST X-110 or equivalent.

1
NOX RUST is a trademark of Daubert Chemical Company.
YZ03225,0000056 –19–03FEB05–1/1

Transmission Removal From Storage

• Wash off all external grease with a safety solvent.


• Remove covers or tape from all openings.
• Drain transmission completely.
• Tag transmission to indicate it needs to be filled with oil
after installing in vehicle.

YZ03225,0000057 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-20 DF180 Series Powershift Transmission


021505
PN=38
Transmission Identifications and General Procedures

01
Towing The Vehicle 015
21

AVOID DAMAGE TO TRANSMISSION:

• Run engine at idle speed to lubricate the clutches.


— Do not exceed normal vehicle speeds while towing.
• If the engine cannot be run:
— Disconnect drive line from transmission.
• If drive line can not be disconnected:
— Do not exceed 5 km/h (3 mph)
— Tow no further than 2 km (1 mile)

YZ03225,0000058 –19–03FEB05–1/1

CTM308 (15FEB05) 01-015-21 DF180 Series Powershift Transmission


021505
PN=39
Transmission Identifications and General Procedures

01
015
22

CTM308 (15FEB05) 01-015-22 DF180 Series Powershift Transmission


021505
PN=40
Section 02
Repair and Adjustments - Transmission
Contents 02

Page Page

Group 025—Repair Procedures and Repair Stand Remove and Install Charge pump -
Transmission Repair Procedures. . . . . . . . . . .02-025-1 Remote Mount Direct Drive . . . . . . . . . . . . .02-035-3
Transmission Lifting and Mounting on Remove and Install Charge and Auxiliary
Repair Stand . . . . . . . . . . . . . . . . . . . . . . . .02-025-3 Pump Gear Train - Remote Mount Direct
Repair Stand Mounting - Remote Mount . . . . .02-025-6 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-035-7
Repair Stand Mounting - Engine Mount. . . . . .02-025-7 Pump Pad Covers and Idler Shaft -
Remote Mount Converter Drive . . . . . . . . .02-035-12
Group 027—Winch Drive - Remote Mount Remove and Install Cover Plates to Front
Winch Drive with 5C Yoke - Remote Housing - Remote Mount Torque Converter
Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-027-1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-035-13
Winch Drive with Universal Joint Yoke - Remove and Install Idler Shaft — Remote
Remote Mount . . . . . . . . . . . . . . . . . . . . . . .02-027-2 Mount Torque Converter Drive. . . . . . . . . .02-035-16
Winch Drive without Gears - Remote
Group 036—Charge Pump and Idler Gears/Shaft -
Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-027-3
Engine Mount
Remove Winch Drive - Remote Mount
Charge Pump For Engine Mount. . . . . . . . . . .02-036-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . .02-027-4
Charge Pump Group
Install Winch Drive - Remote Mount . . . . . . . .02-027-6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-036-2
Charge Pump Drive Idler Gears, Bearings,
Group 029—Park Brake and Shafts - Engine Mount . . . . . . . . . . . . .02-036-5
Park Brake - Remote Mount Transmission . . .02-029-1 Charge Pump Drive Cross-Section -
Park Brake - Engine Mount Transmission . . . .02-029-2 Engine Mount . . . . . . . . . . . . . . . . . . . . . . .02-036-6
Remove Park Brake . . . . . . . . . . . . . . . . . . . .02-029-3 Pump Output Gear Assembly
Install Park Brake . . . . . . . . . . . . . . . . . . . . . .02-029-7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . .02-036-7
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . .02-036-8
Group 031—Output Seals Remove and Disassemble Charge Pump
Remove and Install Output Seals (Brake Idler Gear and Shaft - Engine Mount . . . . .02-036-10
Side) - Remote Mount Transmission . . . . . .02-031-1 Assemble and Install Charge Pump Idler
Remove and Install Output Seals Gear and Shaft - Engine Mount . . . . . . . . .02-036-13
(Opposite Brake Side) - Remote Mount Auxiliary Pump Drive Idler Shaft - Engine
Transmission . . . . . . . . . . . . . . . . . . . . . . . .02-031-3 Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-036-15
Remove and Install Output Oil Seal - Engine Auxiliary Pump Drive Idler Gears,
Mount Transmission. . . . . . . . . . . . . . . . . . .02-031-6 Bearings, and Shafts - Engine Mount . . . .02-036-16
Auxiliary Pump Drive Cross-Section -
Group 033—Suction Tube Engine Mount . . . . . . . . . . . . . . . . . . . . . .02-036-17
Remove and Install Suction Tube . . . . . . . . . .02-033-1 Pump Output Gear Assembly
Remove and Install Suction Tube - Torque Disassemble . . . . . . . . . . . . . . . . . . . . . . .02-036-18
Converter Drive . . . . . . . . . . . . . . . . . . . . . .02-033-4 Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-036-20
Remove and Disassemble Auxiliary Pump
Idler Shaft and Gear - Engine Mount . . . . .02-036-23
Group 035—Charge Pump and Idler Gears/Shaft -
Assemble and Install Auxiliary Pump Idler
Remote Mount Gear and Shaft - Engine Mount . . . . . . . . .02-036-25
Charge Pump and Auxiliary Pump Drive
Train - Exploded View - Remote Mount Direct Group 037—Control Valve
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-035-1 Control Valve 8 Forward / 8 Reverse - Direct
Charge Pump and Auxiliary Pump Gear Drive Transmission . . . . . . . . . . . . . . . . . . .02-037-1
Train - Cross-Section - Remote Mount Direct
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-035-2 Continued on next page

CTM308 (15FEB05) 02-1 DF180 Series Powershift Transmission


021505
PN=1
Contents

Page Page

Control Valve 6 Forward / 6 Reverse - Gear Ratio Group - 6 Forward / 6 Reverse


Remote Mount Torque Converter Drive . . . .02-037-2 - Remote Mount Torque Converter
02 Control Valve 6 Forward / 3 Reverse - Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-13
Remote Mount Torque Converter Drive . . . .02-037-3 Gear Ratio Group - 6 Forward / 3 Reverse
Remove Transmission Control Valve. . . . . . . .02-037-4 - Remote Mount Torque Converter
Install Transmission Control Valve. . . . . . . . . .02-037-5 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-14
Remove and Install Proportional Solenoid Remove Gear Ratio Group - Remote
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-037-8 Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-15
Remove and Install Cooler Relief Valve . . . .02-037-11 Remove Gear Ratio Group - Engine
Remove and Install Main Pressure Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-18
Regulator Valve . . . . . . . . . . . . . . . . . . . . .02-037-12 Install Gear Ratio Group - Remote Mount . . .02-041-21
Remove and Install Proportional Solenoid Install Gear Ratio Group - Engine Mount. . . .02-041-24
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-037-13 Seal Rings
Remove and Install Temperature Sensor . . .02-037-14 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-27
Remove and Install Clutch Pressure Check Assemble Front and Rear Housing —
Port Plug . . . . . . . . . . . . . . . . . . . . . . . . . .02-037-15 Remote Mount . . . . . . . . . . . . . . . . . . . . . .02-041-28
Seal Rings
Group 039—Input Yoke - Remote Mount Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-31
Transmission Rear Housing
Input Yoke Group - Remote Mount Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-31
Transmission . . . . . . . . . . . . . . . . . . . . . . . .02-039-1 Housing Tightening Sequence - Engine
Remove and Install Input Yoke - Remote Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-35
Mount Transmission. . . . . . . . . . . . . . . . . . .02-039-2 Remove Sixth Stage Bearing Retainer —
Engine Mount . . . . . . . . . . . . . . . . . . . . . .02-041-35
Bearing Adjustment of Sixth Stage
Group 040—Input Drive Hub - Engine Mount Assembly — Engine Mount . . . . . . . . . . . .02-041-37
Transmission Remove and Install PTO Oil Seal - Engine
Input Drive Hub - Engine Mount Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-40
Transmission . . . . . . . . . . . . . . . . . . . . . . . .02-040-1 Front Housing - Remote Mount Direct
Drive Hub Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-41
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-2 Front Housing - Remote Mount Torque
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-2 Converter Drive . . . . . . . . . . . . . . . . . . . . .02-041-43
Front Housing Repair . . . . . . . . . . . . . . . . . .02-041-45
Group 041—Front and Rear Housing and Clutch Remove and Install Housing Bore
Assembly Group Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-45
Front and Rear Housing Bolts - Remote Remove and Install Front Housing Bearing
Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-1 Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-49
Disassemble Front and Rear Housing - Remove and Install Lube Relief Valve. . . . . .02-041-50
Remote Mount . . . . . . . . . . . . . . . . . . . . . . .02-041-2 Remove and Install Sump Drain Valve -
Sixth Stage Lube Line - Engine Mount . . . . . .02-041-3 Remote Mount . . . . . . . . . . . . . . . . . . . . . .02-041-52
Remove and Install Sixth Stage Lube Line . . .02-041-4 Rear Housing - Remote Mount Direct
Front and Rear Housing Bolts - Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-53
Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-5 Rear Housing - Remote Mount Torque
Disassemble Front and Rear Housing - Converter Drive . . . . . . . . . . . . . . . . . . . . .02-041-54
Engine Mount . . . . . . . . . . . . . . . . . . . . . . .02-041-6 Rear Housing - Remote Mount . . . . . . . . . . .02-041-55
Front Housing Screen and Plugs. . . . . . . . . . .02-041-8 Rear Housing - Engine Mount . . . . . . . . . . . .02-041-56
Remove and Install Front Housing Screen - Rear Housing Repair - Engine Mount . . . . . .02-041-59
Engine Mount . . . . . . . . . . . . . . . . . . . . . . .02-041-9 Remove and Install Rear Housing Bearing
Remove and Install Front Housing Plugs. . . .02-041-10 Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-59
Gear Ratio Group - 8 Forward / 8 Reverse Remove and Install Magnetic Sensor
- Engine Mount Direct Drive. . . . . . . . . . . .02-041-11 Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-60
Gear Ratio Group - 8 Forward / 8 Reverse
- Remote Mount Direct Drive . . . . . . . . . . .02-041-12 Continued on next page

CTM308 (15FEB05) 02-2 DF180 Series Powershift Transmission


021505
PN=2
Contents

Page Page

Install Pluget Orifice - Engine Mount . . . . . . .02-041-61 Fourth Stage (First / Third Speed) Clutch
Identification Plate . . . . . . . . . . . . . . . . . . . . .02-041-62 Assembly Cross-Section — Engine Mount Direct
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-20 02
Group 043—Gears, Bearings, and Shafts Fourth Stage (First / Third Speed) Clutch
Gear Ratio Group Repair - Direct Drive . . . . .02-043-1 Assembly Exploded View — Engine Mount Direct
First Stage Shaft Assembly - 8 Forward / Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-21
8 Reverse - Remote Mount Direct Drive . . .02-043-1 Fifth Stage (Second / Fourth Speed) Clutch
First Stage Shaft Assembly - 8 Forward / Assembly Cross-Section — Engine Mount Direct
8 Reverse - Engine Mount Direct Drive . . .02-043-2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-22
Sixth Stage Assembly 8 Forward / 8 Fifth Stage (Second / Fourth Speed) Clutch
Assembly Exploded View — Engine Mount Direct
Reverse - Remote Mount Direct Drive . . . .02-043-3
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-23
Sixth Stage Assembly 8 Forward / 8
Disassemble and Assemble Clutch -
Reverse - Engine Mount Direct Drive . . . . .02-043-4
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-24
Input Shaft (First Stage) and Sixth Stage
Disassemble Clutch Gear and Bearing -
(Idler Gear) Repair - Direct Drive . . . . . . . . .02-043-5
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-25
Second Stage (High / Low Forward) Clutch
Disassemble Clutch Piston and Spring -
Assembly Cross-Section - Remote Mount Direct
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-29
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-8
Assemble Clutch Piston and Spring -
Second Stage (High / Low Forward) Clutch
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-31
Assembly Exploded View - Remote Mount Direct
Assemble Clutch Pack - Direct Drive. . . . . . .02-043-33
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-9 Assemble Clutch Gear and Bearing -
Third Stage (High / Low Reverse) Clutch Direct Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-38
Assembly Cross-Section - Remote Mount Direct Seventh Stage (Output) Shaft - Remote
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-10 Mount Direct Drive. . . . . . . . . . . . . . . . . . .02-043-42
Third Stage (High / Low Reverse) Clutch Seventh Stage (Output) Shaft - Engine Mount
Assembly Exploded View - Remote Mount Direct Direct Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-43
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-11 Seventh Stage (Output) Shaft Repair -
Fourth Stage (First / Third Speed) Clutch Direct Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-44
Assembly Cross-Section - Remote Mount Direct Gear Ratio Group Repair - Remote
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-12 Mounted Torque Converter Drive . . . . . . .02-043-46
Fourth Stage (First / Third Speed) Clutch Input Shaft Assembly - 6 Forward / 6
Assembly Exploded View - Remote Mount Direct Reverse and 6 Forward / 3 Reverse -
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-13 Remote Mounted Torque Converter Drive
Fifth Stage (Second / Fourth Speed) Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-46
Assembly Cross-Section - Remote Mount Direct Sixth Stage Assembly 6 Forward / 6 Reverse
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-14 and 6 Forward / 3 Reverse - Remote
Fifth Stage (Second / Fourth Speed) Clutch Mounted Torque Converter Drive . . . . . . .02-043-47
Assembly Exploded View - Remote Mount Direct Input Shaft (First Stage) and Sixth Stage
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-15 (Idler Gear) Repair - Torque Converter
Second Stage (High / Low Forward) Clutch Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-48
Assembly Cross-Section - Engine Mount Direct Second Stage (High / Low Forward) Clutch
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-16 Assembly Cross-Section - Remote
Second Stage (High / Low Forward) Clutch Mounted Torque Converter Drive. . . . . . . .02-043-50
Assembly Exploded View - Engine Mount Direct Second Stage (High / Low Forward) Clutch
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-17 Assembly Exploded View - Remote
Third Stage (High / Low Reverse) Clutch Mounted Torque Converter Drive. . . . . . . .02-043-51
Assembly Cross-Section — Engine Mount Direct Third Stage (High / Low Reverse) Clutch
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-18 Assembly Cross-Section - Remote
Third Stage (High / Low Reverse) Clutch Mount Torque Converter Drive. . . . . . . . . .02-043-52
Assembly Exploded View — Engine Mount Direct
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-19 Continued on next page

CTM308 (15FEB05) 02-3 DF180 Series Powershift Transmission


021505
PN=3
Contents

Page Page

Third Stage (High / Low Reverse) Clutch Remove and Install Hydraulic Lube Hose
Assembly Exploded View - Remote Auxiliary Pump Port . . . . . . . . . . . . . . . . . . .02-047-2
02 Mount Torque Converter Drive. . . . . . . . . .02-043-53 Torque Converter PTO Component
Third Stage (Low Reverse) Clutch Assembly Identification . . . . . . . . . . . . . . . . . . . . . . . .02-047-4
Cross-Section - Remote Mount Torque Converter Torque Converter Exploded View . . . . . . . . . .02-047-5
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-54 Disassemble Torque Converter PTO . . . . . . . .02-047-6
Third Stage (Low Reverse) Clutch Assembly Assemble Torque Converter PTO . . . . . . . . .02-047-12
Exploded View - Remote Mounted Torque Converter Disassemble Converter PTO Pump Drive . . .02-047-18
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-55 Assemble Converter PTO Pump Drive . . . . .02-047-22
Fourth Stage (First / Second Speed) Clutch
Assembly Cross-Section - Remote
Mounted Torque Converter Drive. . . . . . . .02-043-56
Fourth Stage (First / Second Speed) Clutch
Assembly Exploded View - Remote
Mounted Torque Converter Drive. . . . . . . .02-043-57
Fifth Stage (Third Speed) Clutch Assembly
Cross-Section - Remote Mounted Torque Converter
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-58
Fifth Stage (Third Speed) Clutch Assembly
Exploded View - Remote Mounted Torque Converter
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-043-59
Disassemble and Assemble Clutch -
Remote Mount Torque Converter Drive . . .02-043-60
Disassemble Clutch Gear and Bearing -
Remote Mount Torque Converter Drive . . .02-043-61
Disassemble Clutch Piston and Spring -
Remote Mount Torque Converter Drive . . .02-043-66
Assemble Clutch Piston and Spring -
Remote Mount Torque Converter Drive . . .02-043-68
Assemble Clutch Pack - Remote Mount
Torque Converter Drive . . . . . . . . . . . . . . .02-043-70
Assemble Clutch Gear and Bearing -
Remote Mount Torque Converter Drive . . .02-043-75
Seventh Stage (Output Gear) - Remote
Mount Torque Converter Drive. . . . . . . . . .02-043-79
Seventh Stage (Output Gear) Repair -
Remote Mount Torque Converter Drive . . .02-043-80

Group 045—Drive Plate and Torque Converter


Assembly
Remove and Install Torque Converter
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-045-1
Remove and Install Torque Converter
Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . .02-045-4
Torque Converter Cover, Drive Plate and
Impeller Hub Tightening Sequence . . . . . . .02-045-7
Torque Converter Exploded View . . . . . . . . . .02-045-9
Disassemble Torque Converter . . . . . . . . . . .02-045-10
Assemble Torque Converter . . . . . . . . . . . . .02-045-20

Group 047—Torque Converter PTO Housing


Remove and Install Magnetic Speed
Sensor, Converter PTO Assembly . . . . . . . .02-047-1

CTM308 (15FEB05) 02-4 DF180 Series Powershift Transmission


021505
PN=4
Group 025
Repair Procedures and Repair Stand
Transmission Repair Procedures

NOTE: There are three transmission configurations


shown in the manual. There are many
components and procedures common for all three
02
transmission configurations, for those components 025
and procedures that differ for a transmission 1
configuration the different configuration will be
noted.

Before beginning repair:

• Drain transmission oil.


• Thoroughly clean the outside of the transmission before
disassembly to reduce the possibility of contamination.

Disassembly:

• Clean all parts and flush any debris from oil passages.
• Use moisture-free compressed air to dry parts (except
bearings) and to clean out oil passages.

IMPORTANT: DO NOT use solvent to clean the clutch


and brake disks; use a lint-free cloth.

• Lightly oil all bearings with clean hydraulic oil after


cleaning.

IMPORTANT: Spinning a bearing with compressed air


can damage the bearing.

• Inspect bearings for discoloration, roughness of rotation,


and excessive wear of rollers or balls.
• Inspect bushings, remove burrs and sharp edges.
Replace bushings if out-of-round, scored or excessively
worn.
• Inspect control valve bores for contamination.
• Inspect clutch and brake plates for facing material
condition, wear to teeth, and flatness of the plate.
• Inspect clutch and brake separator plates for
discoloration, tooth wear, scoring, and flatness.
• Inspect all thrust surfaces for scoring.
• Inspect all gear and spline teeth for excessive wear or
damage.
• Inspect all gasket and sealing surfaces for damage.

Continued on next page YZ03225,0000044 –19–04OCT04–1/2

CTM308 (15FEB05) 02-025-1 DF180 Series Powershift Transmission


021505
PN=43
Repair Procedures and Repair Stand

IMPORTANT: Replace all bearings, oil seals, O-rings,


ring seals, and gaskets.

02
025 Assembly:
2
• Lightly oil all bearings.
• Use new O-rings, seal rings, oil seals and gaskets.
• Lubricate oil seals and O-rings.
• Clean and prepare all gasket and sealing surfaces.

YZ03225,0000044 –19–04OCT04–2/2

CTM308 (15FEB05) 02-025-2 DF180 Series Powershift Transmission


021505
PN=44
Repair Procedures and Repair Stand

Transmission Lifting and Mounting on Repair


Stand

Lifting heavy components incorrectly can cause severe


injury or machine damage. 02
025

–UN–23AUG88
Follow recommended procedure for removal and 3
installation of components in the manual.

Safety Precautions

TS226
CAUTION: Do not allow any part of the body to
be under the transmission while it is being
lifted or after it is suspended on the repair
stand. Do not exceed maximum capacities for
the repair stand. Use only high grade fasteners
in good condition. Personal injury could result.

The transmission repair stands shown and suggested in


this manual should be used at every tear down and only
by a qualified, experienced technician familiar with this
equipment.

Use class 10.9 (SAE Grade 8) or better cap screws to


attach mounting plates to transmission.

Make sure threaded holes in adapters and transmission


are clean and not damaged.

Minimum cap screw thread engagement should be equal


to 1-1/2 times the diameter of the screw.

Do not exceed the maximum capacity rating of the stand.

Be sure transmission is solidly mounted before releasing


from lifting device.

Never permit any part of the body to be positioned under


a load being lifted or suspended. Accidental slippage may
result in personal injury.

Continued on next page YZ03225,0000045 –19–04OCT04–1/3

CTM308 (15FEB05) 02-025-3 DF180 Series Powershift Transmission


021505
PN=45
Repair Procedures and Repair Stand

CAUTION: Heavy component; use a hoist.

Transmission Lifting and Mounting on Repair Stand—Specification


Remote Mount Transmission—
02 Weight..................................................................... approximate 521.6 kg
025 (1150.0 lb)

–UN–09DEC97
4 Engine Mount Transmission—
Weight..................................................................... approximate 567.0 kg
(1250.0 lb)

Install lifting device into rear housing.

YZ1032
Lifting Device attached to Remote Mount Transmission Rear
Housing (Shown)

Continued on next page YZ03225,0000045 –19–04OCT04–2/3

CTM308 (15FEB05) 02-025-4 DF180 Series Powershift Transmission


021505
PN=46
Repair Procedures and Repair Stand

IMPORTANT: When any other stand is used, consult


the manufacturer’s instructions for
mounting.

• Use Repair Stand (A) or equivalent.


02
025
A—D01003AA Repair Stand 5

–UN–23SEP04
YZ6025
Remote Mount Transmission on Repair Stand

–UN–12NOV04
YZ7028

Engine Mount Transmission on Repair Stand

YZ03225,0000045 –19–04OCT04–3/3

CTM308 (15FEB05) 02-025-5 DF180 Series Powershift Transmission


021505
PN=47
Repair Procedures and Repair Stand

Repair Stand Mounting - Remote Mount

NOTE: The JDG1111 Bottom Mounting Bracket (A) is


used on transmission lower than the following
Serial Numbers.
02
025
6 S/N:YZTF18C021027 for Spec YZ18836
S/N:YZTF18C021597 for Spec YZ18837
S/N:YZTF18C020207 for Spec YZ18999
S/N:YZTF18C020202 for Spec YZ19000.

1. Install mounting bracket (Bottom Mount) (A) to


transmission repair stand and transmission.

NOTE: The JDG1111-2 Bottom Mounting Bracket (B) is

–UN–23SEP04
used on transmission with the following Serial
Numbers and higher.

S/N:YZTF18C021027 for Spec YZ18836

YZ5703
S/N:YZTF18C021597 for Spec YZ18837
S/N:YZTF18C020207 for Spec YZ18999
Left Mounting Bracket of JDG1111 - Two Bolt Mounting
S/N:YZTF18C020202 for Spec YZ19000 Design

2. Install Bottom Mounting Bracket (B) to transmission


repair stand and transmission.

A—JDG1111 Mounting Bracket (Bottom Mount)


B—JDG1111-2 Bottom Mounting Bracket

–UN–04FEB05
YZ7122
JDG1111-2 Bottom Mount Bracket - One Bolt Mounting
Design
Continued on next page YZ03225,00000C3 –19–12NOV04–1/2

CTM308 (15FEB05) 02-025-6 DF180 Series Powershift Transmission


021505
PN=48
Repair Procedures and Repair Stand

3. Install JDG1111Mounting Bracket (Top) (A) and


JDG1111-4 Spacer (A) to transmission repair stand
and transmission.

A—JDG1111-3 Spacer 02
B—JDG1111 Mounting Bracket (Top) and Mounting 025
Adapter 7

–UN–25JAN05
YZ7136
YZ03225,00000C3 –19–12NOV04–2/2

Repair Stand Mounting - Engine Mount

1. Install mounting bracket (A) to transmission repair


stand and transmission.

2. Install mounting bracket (B) to transmission repair


stand and transmission.

A—JDG1100 Mounting Bracket (Crank Side)


B—JDG1100 Mounting Bracket

–UN–12NOV04
YZ7029
YZ03225,00000C4 –19–12NOV04–1/1

CTM308 (15FEB05) 02-025-7 DF180 Series Powershift Transmission


021505
PN=49
Repair Procedures and Repair Stand

02
025
8

CTM308 (15FEB05) 02-025-8 DF180 Series Powershift Transmission


021505
PN=50
Group 027
Winch Drive - Remote Mount
Winch Drive with 5C Yoke - Remote Mount

02
027
1

–UN–28DEC04
YZ6014

Winch Drive With 5C Yoke - Cap Screw Tightening Sequence

A—Winch Drive Cover E—Cap Screw I—Dowel Pin M—Ball Bearing (2 used)
B—Cap Screw (11 used) F—Yoke Washer J—Ball Bearing N—Gear
C—Oil Seal G—Yoke K—Output Shaft O—Gear
D—V-Ring Seal H—Dowel Pin L—Ball Bearing P—Snap Ring

YZ03225,00000D0 –19–01DEC04–1/1

CTM308 (15FEB05) 02-027-1 DF180 Series Powershift Transmission


021505
PN=51
Winch Drive - Remote Mount

Winch Drive with Universal Joint Yoke - Remote Mount

02
027
2

–UN–28DEC04
YZ6013

Winch Drive With Universal Joint Yoke - Cap Screw Tightening Sequence

A—Winch Drive Cover E—Yoke I—Ball Bearing M—Gear


B—Cap Screw (11 used) F—Yoke Washer J—Output Shaft N—Snap Ring
C—Oil Seal G—Cap Screw K—Ball Bearing O—Dowel Pin (2 used)
D—V-Ring Seal H—Ball Bearing (2 used) L—Gear

YZ03225,00000E4 –19–22DEC04–1/1

CTM308 (15FEB05) 02-027-2 DF180 Series Powershift Transmission


021505
PN=52
Winch Drive - Remote Mount

Winch Drive without Gears - Remote Mount

02
027
3

–UN–22DEC04
YZ7072

Transmission without Winch Drive - Remote Mount

A—Dowel Pin (2 Used) C—Snap Ring E—O-ring F—Plug (Winch Output)


B—PTO Cover D—Cap Screw M8 x 60 (11
Used)

YZ03225,00000E3 –19–22DEC04–1/1

CTM308 (15FEB05) 02-027-3 DF180 Series Powershift Transmission


021505
PN=53
Winch Drive - Remote Mount

Remove Winch Drive - Remote Mount


Transmission

1. Remove cap screw (B) and washer (A).


02 2. Remove yoke (C).
027 3. Remove V-Ring seal (D) and discard.

–UN–20SEP04
4 4. Remove seal (E) and discard.

A—Washer
B—Cap Screw

YZ6011
C—Yoke
D—V-Ring Seal
E—Seal Winch with 5C Yoke (Shown)

–UN–20SEP04
YZ6012
YZ03225,0000046 –19–04OCT04–1/5

5. Remove cap screws (A) from winch cover.

A—Winch Cover Cap Screws (11 Used)

–UN–17FEB98
YZ1045

Winch Cover Removing Cap Screws

Continued on next page YZ03225,0000046 –19–04OCT04–2/5

CTM308 (15FEB05) 02-027-4 DF180 Series Powershift Transmission


021505
PN=54
Winch Drive - Remote Mount

CAUTION: Output shaft assembly may or may


not stay in transmission housing. If output shaft
assembly stays in winch housing, output shaft
assembly could fall out during removal of PTO
02
housing. 027

–UN–17FEB98
5
6. Remove winch cover.
7. Remove output shaft Assembly (A).
8. Remove bearings from output shaft Assembly (A) and

YZ1046A
discard.

A—Winch Output Shaft Assembly

YZ03225,0000046 –19–04OCT04–3/5

9. Remove idler gear Assembly (A).


10. Remove bearings from idler gear Assembly (A) and
discard.

A—Idler Gear Assembly

–UN–20SEP04
YZ6015
YZ03225,0000046 –19–04OCT04–4/5

11. Remove snap ring (B).


12. Remove drive gear (A).
13. Inspect all gears and replace as need.

A—Drive Gear
B—Snap Ring
–UN–20SEP04
YZ6019

YZ03225,0000046 –19–04OCT04–5/5

CTM308 (15FEB05) 02-027-5 DF180 Series Powershift Transmission


021505
PN=55
Winch Drive - Remote Mount

Install Winch Drive - Remote Mount

1. Install new bearings on winch output shaft (A).


2. Install winch output shaft Assembly (A).
3. Install new bearings on idler gear (B).
02
027 4. Install idler gear Assembly (B).

–UN–17FEB98
6 5. Install drive gear (C).
6. Install snap ring (D).

A—Winch Output Shaft

YZ1047
B—Idler Gear
C—Drive Gear
D—Snap Ring Winch Drive Gears for 8 Forward / 8 Reverse Transmission
(Shown)

Continued on next page YZ03225,00000D2 –19–01DEC04–1/4

CTM308 (15FEB05) 02-027-6 DF180 Series Powershift Transmission


021505
PN=56
Winch Drive - Remote Mount

IMPORTANT: Both Rear housing and winch drive


housing sealing surfaces must be clean
and free of all dirt, grease, oil, and old
flexible form-in-place gasket material.
02
027

–UN–17FEB98
7. Clean mating surfaces of housings with isopropyl 7
alcohol or equivalent.

IMPORTANT: Excessive amounts of flexible

YZ1044D
form-in-place gasket may cause
incorrect bearing endplay, extend cure
time and cause runoff of material. Apply
with ink roll (rubber roller with a handle)
a thin and even layer approximately
0.25 mm (0.01 inch) thick. Do not use
Loctite cure primers when applying
flexible form-in-place gasket.

8. Apply form-in-place sealant to rear housing mounting


surface, using care to apply a thin layer over the entire
surface. Excess gasket material should be wiped from

–UN–20MAR01
joint. Installation should occur within three minutes of
application. Allow a minimum of one hour of cure time
before adding oil.
9. Make sure two dowel pins are installed in rear housing.

YZ4114
10. Install winch drive cover (A).
11. Install and tighten cap screws (B) in sequence shown.
Repeat sequence again to check cap screw torques. A—Winch Drive Cover
B—Cap Screw (11 Used)
Winch Drive—Specification
Winch Cover-to-Rear Housing—
Torque ......................................................................................... 24.4 N•m
(18.0 lb-ft)

Continued on next page YZ03225,00000D2 –19–01DEC04–2/4

CTM308 (15FEB05) 02-027-7 DF180 Series Powershift Transmission


021505
PN=57
Winch Drive - Remote Mount

12. Apply medium strength thread lock and sealer to


outside diameter of oil seal and petroleum jelly to
inside diameter of oil seal between seal lips.

NOTE: Wipe off excess thread lock and sealer after


02
027 installation.
8

NOTE: Oil shaft seal journal with clean hydraulic oil to

–UN–18FEB98
help from damaging oil seal during installation.

13. Install new output oil seal (A) using JDG1110 Input
Shaft Seal Installation Tool (B) and JDG1108 Clutch

YZ1043
Bearing Driver (C).

A—Output Oil Seal


B—JDG1110 Input Shaft Seal Installation Tool
C—JDG1108 Clutch Bearing Driver

Continued on next page YZ03225,00000D2 –19–01DEC04–3/4

CTM308 (15FEB05) 02-027-8 DF180 Series Powershift Transmission


021505
PN=58
Winch Drive - Remote Mount

14.
15. Lubricate and install V-Ring seal (D).

NOTE: Optimol Paste White T reduces spline wear.


02
16. Apply OPTIMOL PASTE WHITE T on output shaft 027

–UN–20SEP04
spline before installing yoke. 9
17. Install yoke (C).
18. Apply high strength thread lock and sealer to cap
screw.

YZ6012
19. Install washer (A) and cap screw (B). Tighten to
specification.

Winch Drive—Specification
Yoke Cap Screw—Torque........................................................ 215.6 N•m
(159.0 lb-ft)

A—Washer
B—Cap Screw

–UN–20SEP04
C—Yoke
D—V-Ring Seal
E—Seal

YZ6011
OPTIMOL PASTE WHITE T is a trademark of Castrol Industries GmbH YZ03225,00000D2 –19–01DEC04–4/4

CTM308 (15FEB05) 02-027-9 DF180 Series Powershift Transmission


021505
PN=59
Winch Drive - Remote Mount

02
027
10

CTM308 (15FEB05) 02-027-10 DF180 Series Powershift Transmission


021505
PN=60
Group 029
Park Brake
Park Brake - Remote Mount Transmission

02
029
1

–UN–16SEP04
YZ5700
Park Brake for Remote Mount Transmission

A—Gasket F—Clutch Disks (8 used) K—Belleville Spring P—Oil Seal


B—Brake Hub G—Inner Piston Seal L—Park Brake Cover Q—Grease Seal (2 used)
C—Retaining Ring H—Piston M—Cap Screw (10 used) R—Grease Fitting
D—Park Brake Housing J—Outer Piston Seal N—Cap Screw (4 used) S—Separator Plates (9 used)
E—O-ring

YZ03225,00000B0 –19–25OCT04–1/1

CTM308 (15FEB05) 02-029-1 DF180 Series Powershift Transmission


021505
PN=61
Park Brake

Park Brake - Engine Mount Transmission

02
029
2

–UN–25OCT04
YZ6035

Park Brake for Engine Mount Transmission

A—Gasket F—O-ring K—Piston, Brake P—Cap Screw (M12 x 110) (4


B—Hub, Brake G—Plate, Separator (9 Used) L—Seal, Piston Outer Used)
C—Washer H—Disk, Clutch (8 Used) M—Spring, Belleville Q—Cap Screw (M12 x 140) (10
D—Cap Screw (M16 x 35) J—Seal, Piston Inner N—Cover Used)
E—Housing, Brake

YZ03225,00000B1 –19–25OCT04–1/1

CTM308 (15FEB05) 02-029-2 DF180 Series Powershift Transmission


021505
PN=62
Park Brake

Remove Park Brake

1. Remote mount transmission remove yoke.

NOTE: Belleville spring under tension between brake


02
housing and brake cover. 029
3
IMPORTANT: Four of the fourteen cap screws are
shorter and are located at the recessed
areas in the housing. These screws

–UN–05SEP03
keep the park brake cover and brake
housing together.

2. Remove only two park brake cover cap screws (A) (at

YZ4121B
recessed casting area) and attach JT01748 Lifting
Brackets (B) with two 12 mm x 140 mm cap screws.

3. Remove only park brake cap screws (C). A—Park Brake Cover Cap Screw—Short (4 Used)
B—JT01748 Lifting Bracket (2 used)
C—Park Brake Cap Screw—Long (10 Used)

YZ03225,0000047 –19–04OCT04–1/8

CAUTION: Heavy component; use a hoist.

Park Brake Assembly—Specification


Park Brake Assembly—Weight ................................ approximate 43.1 kg
(95.0 lb)

4. Lift park brake assembly from rear housing.

–UN–16JAN03
T163608B

Continued on next page YZ03225,0000047 –19–04OCT04–2/8

CTM308 (15FEB05) 02-029-3 DF180 Series Powershift Transmission


021505
PN=63
Park Brake

5. Remote Mount Transmission

Remove snap ring (A).

6. Remove brake hub (B) and inspect for wear or


02
029 damage.
4
7. Remove gasket (C) and discard.

A—Snap Ring
B—Brake Hub

–UN–10APR01
C—Gasket

YZ4189
YZ03225,0000047 –19–04OCT04–3/8

8. Engine Mount Transmission

Remove Cap Screw (B) and Washer (C).

9. Remove Brake Hub (A) and inspect for wear or


damage.

–UN–21OCT04
10. Remove Gasket (D) and discard.

A—Brake Hub
B—Cap Screw

YZ6036
C—Washer
D—Gasket
Engine Mount Hub Removal

Continued on next page YZ03225,0000047 –19–04OCT04–4/8

CTM308 (15FEB05) 02-029-4 DF180 Series Powershift Transmission


021505
PN=64
Park Brake

11. Remove lifting brackets (A).

CAUTION: Park brake cover is spring loaded.


Loosen each cap screw only 2—3 turns at a
time. Alternate between cap screws several 02
times until spring force has been released. 029
5

12. Remove remaining cap screws (B).

–UN–05SEP03
13. Remove park brake cover (D) from park brake
housing (C).

YZ4120B
NOTE: Inspect grease fitting (E). Remove, clean or
replace as needed.

14. Remove and discard grease seals (F) and oil seal (G)
from park brake cover.

A—JT01748 Lifting Brackets (2 Used)


B—Park Brake Cover Cap Screws (4 Used)
C—Park Brake Housing
D—Park Brake Cover
E—Grease Fitting
F—Grease Seals (2 Used)
G—Oil Seal

–UN–05SEP03
YZ4120C
YZ03225,0000047 –19–04OCT04–5/8

15. Remove Belleville spring (A).

16. Remove brake piston (B).

A—Belleville Spring
B—Brake Piston
–UN–13MAR01
YZ1062A

Continued on next page YZ03225,0000047 –19–04OCT04–6/8

CTM308 (15FEB05) 02-029-5 DF180 Series Powershift Transmission


021505
PN=65
Park Brake

17. Remove and discard outer piston seal (C) and inner
piston seal (D) from piston (E).

C—Outer Piston Seal


02 D—Inner Piston Seal
029 E—Piston
6

–UN–13MAR01
YZ1063A
YZ03225,0000047 –19–04OCT04–7/8

18. Remove separator plates (A) and clutch disks (B).

19. Discard clutch disks (B).

20. Inspect separator plates (A) for wear or damage.

21. Remove and discard O-ring (C).

A—Separator Plates

–UN–13MAR01
B—Clutch Disks
C—O-ring

YZ1064A

YZ03225,0000047 –19–04OCT04–8/8

CTM308 (15FEB05) 02-029-6 DF180 Series Powershift Transmission


021505
PN=66
Park Brake

Install Park Brake

NOTE: Use guide pins during assembly to guide the


brake housing onto the rear housing.
02
1. Remote Mount Transmission 029
7
Install gasket (A) on rear housing.

A—Gasket

–UN–10APR01
YZ4196
–UN–29JUN04
YZ5249
Wet Park Brake Gasket - Engine Mount

YZ03225,00000B2 –19–25OCT04–1/9

2. Install brake hub (B) onto output shaft with small


diameter of hub down.

3. Install snap ring (A).

A—Snap Ring
B—Brake Hub
–UN–25OCT04
YZ6037

Wet Park Brake Hub - Remote Mount

Continued on next page YZ03225,00000B2 –19–25OCT04–2/9

CTM308 (15FEB05) 02-029-7 DF180 Series Powershift Transmission


021505
PN=67
Park Brake

4. Engine Mount Transmission

Install Brake Hub (C) onto output shaft with small


diameter of hub down.
02
029 5. Install Washer (B) and Cap Screw (A). Used Loctite
8 262 on cap screw threads.

–UN–29JUN04
Wet Park Brake - Engine Mount—Specification
Wet Park Brake Cap Screw and
Washer—Torque ....................................................................... 215.6 N•m

YZ5248
(159.0 lb-ft)

A—Cap Screw Wet Park Brake - Engine Mount


B—Washer
C—Brake Hub

Continued on next page YZ03225,00000B2 –19–25OCT04–3/9

CTM308 (15FEB05) 02-029-8 DF180 Series Powershift Transmission


021505
PN=68
Park Brake

CAUTION: Be careful not to pinch fingers when


installing brake housing.

6. Install park brake housing (A) on rear housing.


02
NOTE: Lubricate O-ring to prevent damage during 029
9
assembly.

7. Lubricate and install new O-ring (B) on brake housing.

A—Park Brake Housing

–UN–10APR01
B—O-ring

YZ4198
–UN–10APR01
YZ4199
Continued on next page YZ03225,00000B2 –19–25OCT04–4/9

CTM308 (15FEB05) 02-029-9 DF180 Series Powershift Transmission


021505
PN=69
Park Brake

8. Starting with a separator plate (A), install alternately


separator plates and clutch disks (A and B) into brake
housing. Must end with separator plate (C).

NOTE: Separator plate (C) must be last plate installed.


02
029
10 A—Separator Plate (9 Used)
B—Clutch Disk (8 Used)

–UN–24AUG01
YZ4202
–UN–24AUG01
YZ4200

Continued on next page YZ03225,00000B2 –19–25OCT04–5/9

CTM308 (15FEB05) 02-029-10 DF180 Series Powershift Transmission


021505
PN=70
Park Brake

9. Lubricate and install new inner piston seal (A) and


outer piston seal (B) on piston (C).

NOTE: Lubricate brake housing piston seal surfaces with


clean hydraulic oil before installing brake piston.
02
029
10. Install piston onto brake housing. 11

A—Inner Piston Seal


B—Outer Piston Seal
C—Piston

–UN–24AUG01
YZ4201
YZ03225,00000B2 –19–25OCT04–6/9

NOTE: Visually line up spring with bore of piston.

11. Install Belleville spring (A) with inner diameter of


Belleville spring contacting piston.

A—Belleville Spring

–UN–24AUG01
YZ4203

Continued on next page YZ03225,00000B2 –19–25OCT04–7/9

CTM308 (15FEB05) 02-029-11 DF180 Series Powershift Transmission


021505
PN=71
Park Brake

CAUTION: Carefully lower park brake cover on


park brake housing watching for pinch points.

12. Position park brake cover (A) on park brake housing


02 (B).
029
12
IMPORTANT: Install the two cap screws in recessed
holes in park brake cover.

–UN–05SEP03
13. Install and alternately tighten two cap screws (C) to
compress Belleville spring.

YZ4123B
14. Remove guide pins and install the other two short cap
screws (C).
A—Park Brake Cover
B—Park Brake Housing
C—Park Brake Cover Cap Screws–Short (4)

YZ03225,00000B2 –19–25OCT04–8/9

NOTE: Use a typical criss-cross tightening sequence.

15. Install and tighten all cap screws to proper


specification.

Park Brake—Specification

–UN–20SEP04
Park Brake-to-Rear Housing Cap
Screw—Torque ........................................................................... 86.8 N•m
(64.0 lb-ft)

YZ6017
Cap Screws Torque - Remote Mount

–UN–22DEC04
YZ5252

Cap Screw Torque - Engine Mount

YZ03225,00000B2 –19–25OCT04–9/9

CTM308 (15FEB05) 02-029-12 DF180 Series Powershift Transmission


021505
PN=72
Group 031
Output Seals
Remove and Install Output Seals (Brake
Side) - Remote Mount Transmission

IMPORTANT: The drawing shows proper location of


Oil Seal (A) and Grease Seals (B) and 02
(C) for the output shaft assembly in the 031
brake housing assembly. The same oil 1
seal and grease seal installation applies
for the output shaft assembly on the
front housing side of the transmission.

Output (Brake Side) Grease procedure—Specification


Apply grease to grease fitting (D)
until 45.88 ml (2.8 oz) have been
applied or until grease starts to
extrude through grease seal (C)
(Outer).—Hours ............................................. Repeated every 100 hours.

–UN–19AUG04
1. Remove output grease seal (Outer) (C), grease seal
(Inner) (B), and oil seal (A) and discard.

A—Oil Seal

YZ5383
B—Grease Seal (Inner)
C—Grease Seal (Outer)
D—Grease Fitting

YZ03225,0000036 –19–01OCT04–1/4

2. Position JDG1519 Seal Protector (B) over output shaft.

3. Apply thread lock and sealer (medium strength) to


outside diameter of Oil Seal (A) .

4. Apply thin layer of petroleum jelly to inner seal lip of Oil


Seal (A).

5. Use JDG1736A Oil Seal Driver (C) and JDB1108


Bearing Driver (D) to install Oil Seal (A) until flush with
shoulder in transmission housing.

A—Oil Seal
–UN–24JAN05

B—JDG1519 Seal Protector


C—JDG1736A Oil Seal Driver
D—JDG1108 Bearing Driver
YZ7124

Continued on next page YZ03225,0000036 –19–01OCT04–2/4

CTM308 (15FEB05) 02-031-1 DF180 Series Powershift Transmission


021505
PN=73
Output Seals

6. Apply thread lock and sealer (medium strength) to


outside diameter of Grease Seal (Inner) (B).

7. Apply thin layer of petroleum jelly to inner seal lip of


Grease Seal (B).
02
031
2 8. Use JDG1737A Grease Seal Driver (C) and JDG1108
Bearing Driver (D) to install first Grease Seal (Inner)
(B), with inner seal lip up, to bottom of seal bore in
transmission housing.

A—JDG1519 Seal Protector


B—Grease Seal (Inner)
C—JDG1737A Grease Seal Driver
D—JDG1108 Bearing Driver

–UN–24JAN05
YZ7125
YZ03225,0000036 –19–01OCT04–3/4

9. Apply thread lock and sealer (medium strength) to


outside diameter of Grease Seal (Outer) (A).

10. Apply thin layer of petroleum jelly to inner seal lip of


Grease Seal (Outer) (A).

11. Use JDG1738A Grease Seal Driver (C) and JDG1108


Bearing Driver (D) to install second Grease Seal
(Outer) (B), with inner seal lip up, until flush with
shoulder in transmission housing.

12. Remove Seal Protector (B).


–UN–24JAN05

A—Grease Seal (Outer)


B—JDG1519 Seal Protector
C—JDG1738A Grease Seal Driver
D—JDG1108 Bearing Driver
YZ7126

YZ03225,0000036 –19–01OCT04–4/4

CTM308 (15FEB05) 02-031-2 DF180 Series Powershift Transmission


021505
PN=74
Output Seals

Remove and Install Output Seals (Opposite


Brake Side) - Remote Mount Transmission

IMPORTANT: The drawing shows proper location of


Oil Seal (C) and Grease Seals (B) and 02
(A) for the output shaft assembly on the 031
front housing side of the transmission. 3
The same oil seal installation applies
for the output shaft assembly on the
brake housing assembly.

Output (Opposite Brake Side) Grease procedure—Specification


Apply grease to grease fitting (D)
until 29.50 ml (1.0 oz) have been
applied or until grease starts to
extrude through grease seal
(Outer) (A).—Hours ....................................... Repeated every 100 hours.

1. Remove output grease seal (Outer) (A), grease seal


(Inner) (B), and oil seal (C) and discard.

–UN–25JUN04
A—Grease Seal
B—Grease Seal
C—Oil Seal

YZ5202
D—Grease Fitting

Continued on next page YZ03225,0000037 –19–01OCT04–1/4

CTM308 (15FEB05) 02-031-3 DF180 Series Powershift Transmission


021505
PN=75
Output Seals

2. Position JDG1519 Seal Protector (A) over output shaft


Spline.

3. Apply thread lock and sealer (medium strength) to


outside diameter of Oil Seal (B).
02
031
4 4. Apply thin layer of petroleum jelly to inner seal lip of Oil
Seal (B).

5. Use JDG1736A Oil Seal Driver (C) and JDG1108


Bearing Driver (D) to install Oil Seal (B) until flush with

–UN–24JAN05
shoulder in transmission housing.

A—JDG1519 Seal Protector


B—Oil Seal

YZ7127
C—JDG1736A Oil Seal Driver
D—JDG1108 Bearing Driver

YZ03225,0000037 –19–01OCT04–2/4

6. Apply thread lock and sealer (medium strength) to


outside diameter of Grease Seal (Inner) (B).

7. Apply thin layer of petroleum jelly to inner seal lip of


Grease Seal (Inner) (B).

8. Use JDG1737A Grease Seal Driver (C) and JDG1108


Bearing Driver (D) to install first Grease Seal (Inner)
(B), with inner seal lip up, to bottom of seal bore in
transmission housing.
–UN–24JAN05

A—JDG1519 Seal Protector


B—Grease Seal (Inner)
C—JDG1737A Grease Seal Driver
D—JDG1108 Bearing Driver
YZ7128

Continued on next page YZ03225,0000037 –19–01OCT04–3/4

CTM308 (15FEB05) 02-031-4 DF180 Series Powershift Transmission


021505
PN=76
Output Seals

9. Apply thread lock and sealer (medium strength) to


outside diameter of Grease Seal (Outer) (B).

10. Apply thin layer of petroleum jelly to inner seal lip of


Grease Seal (Outer) (B).
02
031
11. Use JDG1738A Grease Seal Driver (C) and JDG1108 5
Bearing Driver (D) to install second Grease Seal
(Outer) (B), with inner seal lip up, until flush with
shoulder in transmission housing.

12. Remove Seal Protector (A).

–UN–24JAN05
A—JDG1519 Seal Protector
B—Grease Seal (Outer)
C—JDG1738A Grease Seal Driver
D—JDG1108 Bearing Driver

YZ7129
YZ03225,0000037 –19–01OCT04–4/4

CTM308 (15FEB05) 02-031-5 DF180 Series Powershift Transmission


021505
PN=77
Output Seals

Remove and Install Output Oil Seal - Engine


Mount Transmission

1. Remove Oil Seals and discard.


02 YZ03225,00000B3 –19–25OCT04–1/3
031
6
2. Apply thread lock and sealer (medium strength) to
outside diameter of Oil Seal (A).
3. Install Oil Seal (A) using JDG1973 Seal Driver (B) and
JDG1108 Bearing Driver (C).

A—Oil Seal
B—JDG1973 Oil Seal Driver
C—JDG1108 Bearing Driver

–UN–26OCT04
YZ6038
–UN–26OCT04
YZ6040

Continued on next page YZ03225,00000B3 –19–25OCT04–2/3

CTM308 (15FEB05) 02-031-6 DF180 Series Powershift Transmission


021505
PN=78
Output Seals

4. Install Oil Seal (A) using JDG1973 Seal Driver (B) and
JDG1108 Bearing Driver (C).

A—Oil Seal
B—JDG1973 Oil Seal Driver 02
C—JDG1108 Bearing Driver 031
7

–UN–26OCT04
YZ6039
–UN–26OCT04
YZ6041
YZ03225,00000B3 –19–25OCT04–3/3

CTM308 (15FEB05) 02-031-7 DF180 Series Powershift Transmission


021505
PN=79
Output Seals

02
031
8

CTM308 (15FEB05) 02-031-8 DF180 Series Powershift Transmission


021505
PN=80
Group 033
Suction Tube
Remove and Install Suction Tube

1.

Loosen nut (C) before removing cap screws (A).


02
033
2. Remove cap screws (A). 1

–UN–21JUN04
3. Remove nut (C) to remove suction tube (B).

A—Cap Screws
B—Suction Tube

YZ5189
C—Nut

Suction Tube - Remote Mount Direct Drive

–UN–28OCT04
YZ6042
Suction Tube - Engine Mount Direct Drive

–UN–28OCT04
YZ6043

Continued on next page YZ03225,0000048 –19–04OCT04–1/6

CTM308 (15FEB05) 02-033-1 DF180 Series Powershift Transmission


021505
PN=81
Suction Tube

4. Remove flat face fitting (A). Discard O-rings (B) and


(C).

A—Flat Face Fitting


02 B—O-ring
033 C—O-ring
2

–UN–09SEP04
YZ5491A
–UN–16SEP04
YZ5709
YZ03225,0000048 –19–04OCT04–2/6

5. Remove suction screen (B).

6. Remove and discard O-ring (A).

A—O-ring
B—Suction Screen
–UN–19AUG04
YZ5403

Continued on next page YZ03225,0000048 –19–04OCT04–3/6

CTM308 (15FEB05) 02-033-2 DF180 Series Powershift Transmission


021505
PN=82
Suction Tube

7. Install suction screen (B) and new O-ring (A).

A—O-ring
B—Suction Screen
02
033

–UN–19AUG04
3

YZ5403
–UN–28OCT04
YZ6045
YZ03225,0000048 –19–04OCT04–4/6

8. Install flat face fitting (A) with new O-rings (B) and (C).

Charge Pump—Specification
Flat Face Fitting-to-Charge
Pump—Torque ......................................................................... 189.8 N•m
(140.0 lb-ft)

A—Flat Face Fitting


B—O-ring
C—O-ring
–UN–09SEP04
YZ5492A

Continued on next page YZ03225,0000048 –19–04OCT04–5/6

CTM308 (15FEB05) 02-033-3 DF180 Series Powershift Transmission


021505
PN=83
Suction Tube

9. Install suction tube (B).

10. Install cap screws (A), do not tighten.

11. Install suction tube nut (C), do not tighten.


02
033
4 12. Tighten cap screws (A)

–UN–21JUN04
Suction Tube to Housing—Specification
Suction Tube-to-Front Housing
Cap Screws—Torque ................................................................. 24.4 N•m
(18.0 lb-ft)

YZ5189
13. Tighten suction tube nut (C)

Suction Tube Fitting—Specification


Flat Face Fitting Nut—Torque ................................................... 189.8 N•m A—Cap Screws
(140.0 lb-ft) B—Suction Tube
C—Suction Tube Nut

YZ03225,0000048 –19–04OCT04–6/6

Remove and Install Suction Tube - Torque


Converter Drive

1. Remove cap screws (A).

2. Remove suction tube (B).

–UN–14SEP04
3. If necessary, remove suction screen (D).

4. Remove and discard O-ring (E).

YZ5704
5. Install suction screen (D) and new O-ring (E).

6. Install suction tube (B).

7. Install and tighten cap screws (A).

Transmission Suction Tube—Specification


Suction Tube-to-Front Housing
Cap Screws—Torque ................................................................. 24.4 N•m
–UN–21MAR01

(18.0 lb-ft)

A—Cap Screws
B—Suction Tube
YZ4125

C—Suction Tube Baffle


D—Suction Screen
E—O-ring

YZ03225,0000049 –19–04OCT04–1/1

CTM308 (15FEB05) 02-033-4 DF180 Series Powershift Transmission


021505
PN=84
Group 035
Charge Pump and Idler Gears/Shaft - Remote Mount
Charge Pump and Auxiliary Pump Drive Train - Exploded View - Remote Mount Direct
Drive

02
035
1

–UN–28DEC04
YZ5086
Direct Drive Application

A—O-ring D—Seal Side Bearing1 G—Cap Screw J—Ball Bearing (2 Used)


B—Bearing E—Transmission Charge H—O-ring K—Idler Gear
C—Drive Gear Pump I—Idler Shaft L—O-ring
F—Cap Screw (4 used)

1
Install bearing (D) with seal positioned next to pump
YZ03225,00000C8 –19–18NOV04–1/1

CTM308 (15FEB05) 02-035-1 DF180 Series Powershift Transmission


021505
PN=85
Charge Pump and Idler Gears/Shaft - Remote Mount

Charge Pump and Auxiliary Pump Gear Train - Cross-Section - Remote Mount Direct
Drive

02
035
2

–UN–19NOV04
YZ7037

A—Bearing D—Bearing (Seal towards G—Cap Screw L—O-ring


B—Front Cover Charge Pump) H—O-ring M—Bearing (with Snap Ring)
C—Charge Pump Output Drive E—Charge Pump J—Idler Gear (2 Used)
Gear F—O-ring K—Idler Shaft

YZ03225,00000C9 –19–18NOV04–1/1

CTM308 (15FEB05) 02-035-2 DF180 Series Powershift Transmission


021505
PN=86
Charge Pump and Idler Gears/Shaft - Remote Mount

Remove and Install Charge pump - Remote


Mount Direct Drive

1. Remove cap screws (A).


02
A—Cap Screw (4) 035
3

–UN–08SEP04
YZ5493
Continued on next page YZ03225,000004A –19–04OCT04–1/4

CTM308 (15FEB05) 02-035-3 DF180 Series Powershift Transmission


021505
PN=87
Charge Pump and Idler Gears/Shaft - Remote Mount

IMPORTANT: Drive gear (B) bearings are slip-fit in


charge pump (A) housing and front
cover housing. Use care when removing
charge pump (A), in case drive gear
stays with charge pump, so not to drop
02
035 and damage drive gear and bearings.
4
2. Remove charge pump (A) from front housing.

A—Charge Pump
B—Drive Gear Assembly

–UN–03JAN05
YZ7074
–UN–28DEC04
YZ5188

Continued on next page YZ03225,000004A –19–04OCT04–2/4

CTM308 (15FEB05) 02-035-4 DF180 Series Powershift Transmission


021505
PN=88
Charge Pump and Idler Gears/Shaft - Remote Mount

NOTE: Optimal white paste reduces spline wear.

3. Apply OPTIMOL PASTE WHITE T on charge pump


shaft spline before installing charge pump onto
transmission housing.
02
035
4. Lubricate O-ring (B) with Petroleum Jelly and install in 5
housing groove (C).

IMPORTANT: Direct drive transmission have a sealed


bearing (D). When installing the drive
gear assembly into the charge pump
port the sealed side of bearing (D) will

–UN–27AUG04
be toward the transmission charge
pump.

5. Install charge pump (A).

YZ5488
A—Charge Pump
B—O-ring
C—Housing Groove
D—Bearing (Sealed)

OPTIMOL PASTE WHITE T is a trademark of Castrol Industries GmbH Continued on next page YZ03225,000004A –19–04OCT04–3/4

CTM308 (15FEB05) 02-035-5 DF180 Series Powershift Transmission


021505
PN=89
Charge Pump and Idler Gears/Shaft - Remote Mount

6. Install and tighten cap screws (1-4) in the sequence


shown.

Charge Pump—Specification
Transmission Charge
02 Pump-to-Transmission Housing—
035 Torque ........................................................................................ 74.6 N•m
6 (55.0 lb-ft)

1—Bottom Right Cap Screw


2—Top Left Cap Screw
3—Bottom Left Cap Screw
4—Top Right Cap Screw

–UN–23DEC97
YZ1156
–UN–21SEP04
YZ6016
YZ03225,000004A –19–04OCT04–4/4

CTM308 (15FEB05) 02-035-6 DF180 Series Powershift Transmission


021505
PN=90
Charge Pump and Idler Gears/Shaft - Remote Mount

Remove and Install Charge and Auxiliary


Pump Gear Train - Remote Mount Direct
Drive

1. Remove Drive Gear (A) from Front Housing. 02


035
7
A—Drive Gear Assembly

–UN–28DEC04
YZ7073
YZ03225,00000E6 –19–28DEC04–1/11

2. Remove bearing (A) and bearing (with seal) (C) and


discard.

A—Bearing
B—Drive Gear
C—Bearing (with Seal)

–UN–15SEP04
YZ5705
YZ03225,00000E6 –19–28DEC04–2/11

3. Remove cap screw (A).

A—Cap Screw
–UN–17DEC97
YZ1070

Continued on next page YZ03225,00000E6 –19–28DEC04–3/11

CTM308 (15FEB05) 02-035-7 DF180 Series Powershift Transmission


021505
PN=91
Charge Pump and Idler Gears/Shaft - Remote Mount

4. Install an M8 x 35 mm cap screw (B) in tapped hole.

B—Cap Screw M8 x 35 mm

02
035

–UN–17DEC97
8

YZ1071
YZ03225,00000E6 –19–28DEC04–4/11

5. Use cap screw (A) to remove idler shaft (C).

IMPORTANT: There are two O-rings (B) and (D), (B) at


large end of idler shaft (C) and (D) at
small end of idler shaft (C). The O-ring
(D) located on the small end of the idler
shaft (C) may slip off at removal of idler
shaft (C) and stay in the housing idler
shaft bottom bore.

–UN–14SEP04
6. Remove O-rings (B) and (D) and discard.

A—Cap Screw (Used for shaft removal only)


B—O-ring

YZ5190
C—Idler Shaft
D—O-ring

YZ03225,00000E6 –19–28DEC04–5/11

7. Remove idler gear (B).

8. Remove bearings (A) in idler gear (B) and discard.

A—Bearings (2)
B—Idler Gear
–UN–14SEP04
YZ5706

Continued on next page YZ03225,00000E6 –19–28DEC04–6/11

CTM308 (15FEB05) 02-035-8 DF180 Series Powershift Transmission


021505
PN=92
Charge Pump and Idler Gears/Shaft - Remote Mount

9. Install bearings (A) into idler gear (B).

10. Install idler gear (B) into front housing.

A—Bearings (2) 02
B—Idler Gear 035
9

–UN–14SEP04
YZ5707
YZ03225,00000E6 –19–28DEC04–7/11

NOTE: Lubricate O-rings with Petroleum Jelly to avoid


damage during assembly.

11. Install new O-ring (A) on large end of idler shaft (B).

12. Install O-ring (C) for small end of idler shaft (B) into
the bottom bore of the housing idler shaft bore.

13. Install idler shaft (B) through idler shaft housing bore
and through idler gear assembly into idler shaft
housing bottom bore.

–UN–14SEP04
A—O-ring
B—Idler Shaft
C—O-ring

YZ5708
Continued on next page YZ03225,00000E6 –19–28DEC04–8/11

CTM308 (15FEB05) 02-035-9 DF180 Series Powershift Transmission


021505
PN=93
Charge Pump and Idler Gears/Shaft - Remote Mount

NOTE: Using cap screw (A) turn idler shaft to align holes
in shaft and housing.

14. Install cap screw (A) through idler shaft and into front
housing.
02
035
10 15. Use cap screw (A) to align idler shaft with front
housing hole.

–UN–31AUG04
16. Tighten cap screw (A) for idler shaft in front housing.

Charge Pump —Specification


Idler Gear Shaft-to-Front Housing

YZ5499
Cap Screw—Torque ................................................................... 86.8 N•m
(64.0 lb-ft)

A—Cap Screw

YZ03225,00000E6 –19–28DEC04–9/11

IMPORTANT: Direct drive remote mount


transmissions will have a sealed
bearing (C) on the drive gear (B)
assembly. Bearing (C) to be on charge
pump side sealed bearing (C) facing
charge pump. Failure to install sealed
bearing (C) correctly will shorten the life
of the bearing. Refer to Charge Pump
and Auxiliary Pump Gear Train -
Cross-Section - Remote Mount Direct
Drive drawing.

17. Install bearing (A) and (C) onto drive gear (B).

–UN–15SEP04
A—Bearing
B—Drive Gear

YZ5705
C—Bearing (Sealed)

Continued on next page YZ03225,00000E6 –19–28DEC04–10/11

CTM308 (15FEB05) 02-035-10 DF180 Series Powershift Transmission


021505
PN=94
Charge Pump and Idler Gears/Shaft - Remote Mount

18. Install Drive Gear (A) into Front Housing.

A—Drive Gear Assembly

02
035
11

–UN–28DEC04
YZ7073
YZ03225,00000E6 –19–28DEC04–11/11

CTM308 (15FEB05) 02-035-11 DF180 Series Powershift Transmission


021505
PN=95
Charge Pump and Idler Gears/Shaft - Remote Mount

Pump Pad Covers and Idler Shaft - Remote Mount Converter Drive

02
035
12

–UN–17NOV04
YZ7036

A—Cover Plate (4 Bolt) D—O-ring G—Cap Screw M10 x 16 (4 H—Cover Plate


B—O-ring E—Idler Shaft Used) J—O-ring
C—Cap Screw F—O-ring
YZ03225,00000C7 –19–17NOV04–1/1

CTM308 (15FEB05) 02-035-12 DF180 Series Powershift Transmission


021505
PN=96
Charge Pump and Idler Gears/Shaft - Remote Mount

Remove and Install Cover Plates to Front


Housing - Remote Mount Torque Converter
Drive

Transmission Cover Plate Remove and Install—Front 02


Housing (Front View) 035
13

–UN–21MAR01
1. Remove Cap Screws (A) and Washers (B).

2. Remove Cover Plate (C).

YZ4126
3. Remove and discard O-ring (D).

A—Cap Screw (4)


B—Washer (4)
C—Cover Plate
D—O-ring

–UN–21MAR01
YZ4127
Continued on next page YZ03225,000004B –19–04OCT04–1/3

CTM308 (15FEB05) 02-035-13 DF180 Series Powershift Transmission


021505
PN=97
Charge Pump and Idler Gears/Shaft - Remote Mount

1. Install new O-ring (A) into Front Housing groove.

2. Install Cover Plate (B).

3. Install Washers (C) and Cap Screws (D). Tighten Cap


02
035 Screws to proper specification.
14
Transmission Cover Plate—Specification
Cover Plate-to-Transmission
Housing Cap Screws—Torque ................................................... 50.2 N•m
(37.0 lb-ft)

A—O-ring
B—Cover Plate
C—Washer (4 used)
D—Cap Screw (4 used)

–UN–21MAR01
YZ4129
–UN–21MAR01
YZ4130

Continued on next page YZ03225,000004B –19–04OCT04–2/3

CTM308 (15FEB05) 02-035-14 DF180 Series Powershift Transmission


021505
PN=98
Charge Pump and Idler Gears/Shaft - Remote Mount

Transmission Cover Plate Remove and Install—Front


Housing (Rear View)

1. Remove Cap Screws (A).


02
2. Remove Cover Plate (B). 035
15
3. Remove and discard O-ring (C).

1. Install O-ring (C) on Cover Plate (B).

–UN–29MAR01
2. Install Cover Plate to housing.

3. Install and tighten Cap Screws (A).

YZ4178
Transmission Cover Plate —Specification
Cover Plate-to-Transmission
A—Cap Screw (2 used)
Housing Cap Screws—Torque ................................................... 50.2 N•m
B—Cover Plate
(37.0 lb-ft)
C—O-ring

YZ03225,000004B –19–04OCT04–3/3

CTM308 (15FEB05) 02-035-15 DF180 Series Powershift Transmission


021505
PN=99
Charge Pump and Idler Gears/Shaft - Remote Mount

Remove and Install Idler Shaft — Remote


Mount Torque Converter Drive

1. Remove cap screw (A).


02
035

–UN–06APR01
A—Cap Screw
16

YZ1070E
YZ03225,000004C –19–04OCT04–1/5

2. Install an M8 x 35 mm cap screw (B) in tapped hole.

B—M8 x 35 Cap Screw

–UN–06APR01
YZ1071E
Continued on next page YZ03225,000004C –19–04OCT04–2/5

CTM308 (15FEB05) 02-035-16 DF180 Series Powershift Transmission


021505
PN=100
Charge Pump and Idler Gears/Shaft - Remote Mount

3. Use cap screw (A) to remove idler shaft (C).

IMPORTANT: There are two O-rings (B) and (D),


O-ring (B) at large end of idler shaft (C)
and O-ring (D) at the small end of idler
02
shaft (C). The O-ring (D) located on the 035
small end of the idler shaft (C) may slip 17
off at removal of shaft and stay in the
housing idler shaft bottom bore.

4. Remove O-rings (B) and (D) and discard.

A—Idler Shaft
B—O-ring
C—Cap Screw
D—O-ring

–UN–31AUG04
YZ5504
Continued on next page YZ03225,000004C –19–04OCT04–3/5

CTM308 (15FEB05) 02-035-17 DF180 Series Powershift Transmission


021505
PN=101
Charge Pump and Idler Gears/Shaft - Remote Mount

NOTE: Lubricate O-rings with Petroleum Jelly to avoid


damage during assembly.

5. Install new O-ring (A) on large end of Idler Shaft (B).


02
035 6. Install new O-ring (D) for small end of Idler Shaft (B)
18 into the bottom bore of the housing idler shaft bore.

7. Install Idler Shaft (B) through Idler Shaft housing bore


and through Idler Gear assembly into idler shaft
housing bottom bore.

–UN–28DEC04
8. Install Cap Screw (C) into Idler Shaft (B).

NOTE: Use Cap Screw (C) to turn the idler shaft (B) to

YZ5193A
help align the shaft hole with the housing holes,
during Idler Shaft installation.

9. Install Idler Shaft (B) using Cap Screw (C) to align A—O-ring
B—Idler Shaft
holes in Idler Shaft (B) and housing.
C—Cap Screw
D—O-ring

YZ03225,000004C –19–04OCT04–4/5

10. Install and tighten cap screw in idler shaft.

Transmission Idler Shaft—Torque Converter Drive Transmissions—


Specification
Idler Shaft-to-Front Housing Cap
Screw—Torque ........................................................................... 86.8 N•m
(64.0 lb-ft)

–UN–16SEP04
A—Cap Screw

YZ5452

YZ03225,000004C –19–04OCT04–5/5

CTM308 (15FEB05) 02-035-18 DF180 Series Powershift Transmission


021505
PN=102
Group 036
Charge Pump and Idler Gears/Shaft - Engine Mount
Charge Pump For Engine Mount

02
036
1

–UN–03NOV04
YZ6046

A—Cap Screw M16 x 75 (3 B—O-ring D—O-ring F—O-ring


Used) C—Fitting, Flat Face E—Charge Pump 50 cc

YZ03225,00000B6 –19–03NOV04–1/1

CTM308 (15FEB05) 02-036-1 DF180 Series Powershift Transmission


021505
PN=103
Charge Pump and Idler Gears/Shaft - Engine Mount

Remove and Install Charge Pump - Engine


Mount

Remove
02

–UN–24JUN98
036
2 NOTE: Refer to “Remove and Install Suction Tube and/or
see Remove and Install Suction Tube - Torque
Converter Drive” for removing suction tube.

YZ1556
1. Remove flat face fitting (A).
2. Remove O-rings (B) and (C) and Discard.

NOTE: Lubricate O-rings (B) and (C) with Petroleum Jelly


to avoid damage during assemble.

3. Install new O-rings (B) and (C).


4. Install flat face fitting (A).

Remove and Install Charge Pump—Specification


Flat Face Fitting-to-Charge Pump
Cap Screw—Torque ................................................................. 189.8 N•m
(140.0 lb-ft)

–UN–29JUN04
A—Flat Face Fitting
B—O-ring (Suction Tube Side)
C—O-ring (Charge Pump Side)

YZ5222
YZ03225,0000059 –19–03FEB05–1/5

5. Remove three Cap Screws (B).

CAUTION: Drive gear bearings are slip-fit in


charge pump housing and front cover housing.
Use care when removing charge pump, in case
drive gear stays with charge pump, so not to
drop and damage drive gear and bearings.

6. Remove Pump (A).


7. Remove O-ring (C) and discard.
–UN–03NOV04

Install

A—Charge Pump
YZ7001

B—Cap Screw (3 used)


C—O-ring

Continued on next page YZ03225,0000059 –19–03FEB05–2/5

CTM308 (15FEB05) 02-036-2 DF180 Series Powershift Transmission


021505
PN=104
Charge Pump and Idler Gears/Shaft - Engine Mount

IMPORTANT: Be sure charge pump drive gear is


install correctly. Sealed bearing (A) is to
be towards charge pump.
02
A—Sealed Bearing 036
3

–UN–03NOV04
YZ7000
YZ03225,0000059 –19–03FEB05–3/5

NOTE: Lubricate O-ring (A) with Petroleum Jelly to avoid


damage during assembly.

2. Install new O-ring (A).

A—O-ring
B—Charge Pump

–UN–28DEC04
YZ7002
Continued on next page YZ03225,0000059 –19–03FEB05–4/5

CTM308 (15FEB05) 02-036-3 DF180 Series Powershift Transmission


021505
PN=105
Charge Pump and Idler Gears/Shaft - Engine Mount

3. Install charge pump.


4. Install Cap Screws (A).
5. Tighten Cap Screws (A) to 173 N•m (128 lb-ft).

Specification
02 Charge Pump-to-Front Housing
036 Cap Screws—Torque ............................................................... 100.3 N•m
4 (74.0 lb-ft)

A—Cap Screw (3 used)

–UN–03NOV04
YZ7003
YZ03225,0000059 –19–03FEB05–5/5

CTM308 (15FEB05) 02-036-4 DF180 Series Powershift Transmission


021505
PN=106
Charge Pump and Idler Gears/Shaft - Engine Mount

Charge Pump Drive Idler Gears, Bearings, and Shafts - Engine Mount

02
036
5

–UN–03JAN05
YZ7020
A—Housing Front D—Idler Shaft G—Bearing (with Seal) J—Pump Output Gear
B—O-ring E—Packing O-ring H—Pump Idler Gear K—Bearing
C—Cap Screw M12 x 90 F—Bearing (2 Used)

YZ03225,00000B8 –19–04NOV04–1/1

CTM308 (15FEB05) 02-036-5 DF180 Series Powershift Transmission


021505
PN=107
Charge Pump and Idler Gears/Shaft - Engine Mount

Charge Pump Drive Cross-Section - Engine Mount

02
036
6

–UN–04NOV04
YZ6049

A—Bearing D—Bearing (2 Used) G—Packing O-ring J—O-ring


B—Pump Output Gear E—Idler Shaft H—Idler Gear K—Front Housing
C—Bearing, with seal (Seal F—Cap Screw M12 x 90
toward large bore)

YZ03225,00000B9 –19–04NOV04–1/1

CTM308 (15FEB05) 02-036-6 DF180 Series Powershift Transmission


021505
PN=108
Charge Pump and Idler Gears/Shaft - Engine Mount

Remove and Disassemble Charge Pump


Output Gear Assembly - Engine Mount

1. Remove transmission control valve. See Remove


Transmission Control Valve. 02
036
2. Remove park brake. See Remove Park Brake. 7

3. Disassemble front and rear housing engine mount.


SeeDisassemble Front and Rear Housing - Engine
Mount.

4. Remove gear ratio group - engine mount. See Remove


Gear Ratio Group - Engine Mount

5. Remove Charge Pump - Engine Mount. See Remove


and Install Charge Pump - Engine Mount.

YZ03225,000005A –19–03FEB05–1/3

6. Remove charge pump drive gear assembly (A) from


front housing.

A—Charge Pump Drive Gear Assembly

–UN–05NOV04
YZ7005

Continued on next page YZ03225,000005A –19–03FEB05–2/3

CTM308 (15FEB05) 02-036-7 DF180 Series Powershift Transmission


021505
PN=109
Charge Pump and Idler Gears/Shaft - Engine Mount

7. Use puller to remove bearings (A) from pump output


gear (B) and discard.

8. Remove ball bearing (C) and discard.


02
036 9. Inspect for pump output gear for wear or damage.
8
A—Bearing with Seal
B—Pump Output Gear
C—Ball Bearing

–UN–29DEC04
YZ5310
YZ03225,000005A –19–03FEB05–3/3

Assemble and Install Charge Pump Output


Gear Assembly - Engine Mount

IMPORTANT: Press on inner race of the bearing.

NOTE: Press bearing onto gear hub with seal side away
from gear

1. Press Bearing with Seal (B) onto Charge Pump Output


Gear (C) using JDG1108 Bearing Driver (A).
–UN–29DEC04

A—JDG1108 Bearing Driver


B—Bearing with Seal
C—Charge Pump Output Gear
YZ5314A

Continued on next page YZ03225,000005B –19–03FEB05–1/3

CTM308 (15FEB05) 02-036-8 DF180 Series Powershift Transmission


021505
PN=110
Charge Pump and Idler Gears/Shaft - Engine Mount

2. Turn gear over and press Bearing (B) onto Charge


Pump Output Gear (C) using JDG1108 Bearing Driver
(A).

A—JDG1108 Bearing Driver 02


B—Bearing without Seal 036
C—Charge Pump Output Gear 9

–UN–29DEC04
YZ5313A
YZ03225,000005B –19–03FEB05–2/3

3. Install Charge Pump Output Gear Assembly (A) into


front cover.

A— Charge Pump Output Gear Assembly

–UN–05NOV04
YZ7005
YZ03225,000005B –19–03FEB05–3/3

CTM308 (15FEB05) 02-036-9 DF180 Series Powershift Transmission


021505
PN=111
Charge Pump and Idler Gears/Shaft - Engine Mount

Remove and Disassemble Charge Pump Idler


Gear and Shaft - Engine Mount

1. Remove Cap Screw (A).


02
036 A—Cap Screw M12 x 90
10

–UN–08NOV04
YZ7016
YZ03225,00000BB –19–08NOV04–1/4

2. Install Cap Screw M8 x 35 (A).


3. Remove Idler Shaft (C) using Cap Screw M8 x 35 (A).

A—Cap Screw M8 x 35

–UN–08NOV04
YZ7017

Continued on next page YZ03225,00000BB –19–08NOV04–2/4

CTM308 (15FEB05) 02-036-10 DF180 Series Powershift Transmission


021505
PN=112
Charge Pump and Idler Gears/Shaft - Engine Mount

NOTE: O-ring (D) may stay in bottom of housing bore


when Idler Shaft is removed.

4. Remove O-ring (B) and (D) and discard.


02
5. Remove Idler Gear (E) from front housing. 036
11
A—Cap Screw M8 x 35
B—O-ring
C—Idler Shaft
D—O-ring
E—Idler Gear

–UN–08NOV04
YZ7018
Continued on next page YZ03225,00000BB –19–08NOV04–3/4

CTM308 (15FEB05) 02-036-11 DF180 Series Powershift Transmission


021505
PN=113
Charge Pump and Idler Gears/Shaft - Engine Mount

6. Remove Bearings (B) from Idler Gear (A) and discard.


7. Inspect Idler Gear for wear or damage.

A—Idler Gear
02 B—Bearing (2)
036 C—Prybars
12

–UN–08NOV04
YZ5336
–UN–08NOV04
YZ5335
YZ03225,00000BB –19–08NOV04–4/4

CTM308 (15FEB05) 02-036-12 DF180 Series Powershift Transmission


021505
PN=114
Charge Pump and Idler Gears/Shaft - Engine Mount

Assemble and Install Charge Pump Idler


Gear and Shaft - Engine Mount

NOTE: Be should to only press on outer race of bearing 02


during bearing installation. 036

–UN–08NOV04
13
1. Install Bearings (B) into Idler Gear (A) using Bearing
Drivers (C) and (D).

YZ5334
A—Idler Gear
B—Bearings (2 Used)
C—JDG1108 Bearing Driver
D—JDG1110 Bearing Driver

–UN–08NOV04
YZ7019
Continued on next page YZ03225,00000BC –19–08NOV04–1/3

CTM308 (15FEB05) 02-036-13 DF180 Series Powershift Transmission


021505
PN=115
Charge Pump and Idler Gears/Shaft - Engine Mount

NOTE: Lubricate O-rings with Petroleum Jelly to avoid


damage during assembly.

2. Install idler gear (A) into front housing.


02
036 3. Install O-ring (small) (E) for small end of Idler Shaft (D)

–UN–08NOV04
14 in bottom bore of front housing idler shaft bore.
4. Install O-ring (large) (C) onto large end of Idler Shaft
(D).

YZ5348
A—Idler Gear Assembly
B—Cap Screw M12 x 90
C—O-ring (Large)
D—Idler Shaft
E—O-ring (Small)

–UN–08NOV04
YZ5347
YZ03225,00000BC –19–08NOV04–2/3

5. Install idler shaft (D) into front housing.


6. Install Cap Screw (B) into Idler Shaft (A) and front
housing. Use Cap Screw (B) to align Idler Shaft (A)
hole with housing holes.
7. Tighten Cap Screw (B).

Specification

–UN–08NOV04
Charge Pump Idler Shaft Cap
Screw—Torque ............................................................................ 86.8 N•m
(64.0 lb-ft)

YZ5346
A—Idler Shaft
B—Cap Screw M12 x 90
–UN–08NOV04
YZ5349

YZ03225,00000BC –19–08NOV04–3/3

CTM308 (15FEB05) 02-036-14 DF180 Series Powershift Transmission


021505
PN=116
Charge Pump and Idler Gears/Shaft - Engine Mount

Auxiliary Pump Drive Idler Shaft - Engine Mount

02
036
15

–UN–05NOV04
YZ7004

A—Idler Shaft B—O-ring C—O-ring

YZ03225,00000B7 –19–04NOV04–1/1

CTM308 (15FEB05) 02-036-15 DF180 Series Powershift Transmission


021505
PN=117
Charge Pump and Idler Gears/Shaft - Engine Mount

Auxiliary Pump Drive Idler Gears, Bearings, and Shafts - Engine Mount

02
036
16

–UN–28DEC04
YZ7021
A—Housing Front D—Auxiliary Pump Output F—Bearing H—Snap Ring
B—Bearing (2 Used) Gear G—Bearing Spacer J—Auxiliary Pump Idler Gear
C—Bearing (with Seal) E—Snap Ring

YZ03225,00000BD –19–08NOV04–1/1

CTM308 (15FEB05) 02-036-16 DF180 Series Powershift Transmission


021505
PN=118
Charge Pump and Idler Gears/Shaft - Engine Mount

Auxiliary Pump Drive Cross-Section - Engine Mount

02
036
17

–UN–12NOV04
YZ6048

A—Bearing (with Seal) D—Snap Ring H—Bearing (2 Used) L—Packing O-ring


B—Auxiliary Pump Output E—Bearing Spacer J—Snap Ring M—Idler Shaft
Gear F—Bearing (with Snap Ring) K—Auxiliary Pump Idler Gear N—Cap Screw M12 x 110
C—Front Housing G—O-ring

YZ03225,00000BA –19–04NOV04–1/1

CTM308 (15FEB05) 02-036-17 DF180 Series Powershift Transmission


021505
PN=119
Charge Pump and Idler Gears/Shaft - Engine Mount

Remove and Disassemble Auxiliary Pump


Output Gear - Engine Mount

1. Remove Transmission Control Valve. See Remove


02 Transmission Control Valve.
036
18 2. Remove Park Brake (See Remove Park Brake.)

3. Disassemble Front and Rear Housing - Engine Mount.


(See Disassemble Front and Rear Housing - Engine
Mount.)

4. Remove Gear Ratio Group - Engine Mount (See


Remove Gear Ratio Group - Engine Mount.)

YZ03225,000005C –19–03FEB05–1/5

5. Remove Snap Ring (A).

A—Snap Ring

–UN–08NOV04
YZ7015
–UN–28DEC04
YZ5307A

Continued on next page YZ03225,000005C –19–03FEB05–2/5

CTM308 (15FEB05) 02-036-18 DF180 Series Powershift Transmission


021505
PN=120
Charge Pump and Idler Gears/Shaft - Engine Mount

6. Remove Bearing Spacer (A) and Auxiliary Pump Drive


Gear Assembly (B) from front housing.

A—Spacer
B—Auxiliary Pump Drive Gear Assembly 02
036
19

–UN–28DEC04
YZ7075
YZ03225,000005C –19–03FEB05–3/5

7. Use puller to remove Bearings with Snap Ring (A) from


Auxiliary Pump Output Gear (B) and discard.

A—Bearing with Snap Ring


B—Auxiliary Pump Output Gear

–UN–28DEC04
YZ7008A
Continued on next page YZ03225,000005C –19–03FEB05–4/5

CTM308 (15FEB05) 02-036-19 DF180 Series Powershift Transmission


021505
PN=121
Charge Pump and Idler Gears/Shaft - Engine Mount

8. Remove Bearing with Seal (A) and discard.

9. Inspect for Auxiliary Pump Output Gear (B) for wear or


damage.
02
036 A—Bearing with Seal
20 B—Auxiliary Pump Output Gear

–UN–28DEC04
YZ7009A
YZ03225,000005C –19–03FEB05–5/5

Assemble and Install Auxiliary Pump Output


Gear - Engine Mount

IMPORTANT: Press on inner race of the bearing.

NOTE: Auxiliary pump output gear assembly will use one


bearing with a snap ring on the outside diameter.
Install bearing with snap ring next to gear.

1. Press Bearing with Snap Ring (B) onto Auxiliary Pump


Output Gear (C) using JDG1108 Bearing Driver (A).

A—JDG1108 Bearing Driver


B—Bearing with Snap Ring
C—Auxiliary Pump Output Gear

–UN–28DEC04
YZ7010A

Continued on next page YZ03225,000005D –19–03FEB05–1/5

CTM308 (15FEB05) 02-036-20 DF180 Series Powershift Transmission


021505
PN=122
Charge Pump and Idler Gears/Shaft - Engine Mount

NOTE: Auxiliary pump output gear assembly will use one


bearing with a seal on one side. Install bearing
with seal on the side of the gear with the internal
counterbore with the seal away from gear.
02
2. Turn gear over and press Bearing with Seal (D) onto 036
Auxiliary Pump Output Gear (C) using JDG1108 21
Bearing Driver (A).

A—JDG1108 Bearing Driver


B—Bearing with Seal
C—Auxiliary Pump Output Gear

–UN–28DEC04
YZ7011A
YZ03225,000005D –19–03FEB05–2/5

3. Install Auxiliary Pump Output Gear Assembly (A) into


front housing.

A—Auxiliary Pump Output Gear Assembly

–UN–09NOV04
YZ7007

Continued on next page YZ03225,000005D –19–03FEB05–3/5

CTM308 (15FEB05) 02-036-21 DF180 Series Powershift Transmission


021505
PN=123
Charge Pump and Idler Gears/Shaft - Engine Mount

4. Install Bearing Spacer (A) into front housing.

A—Bearing Spacer

02
036
22

–UN–08NOV04
YZ7014
YZ03225,000005D –19–03FEB05–4/5

5. Install Snap Ring (A) into front housing.

A—Snap Ring

–UN–08NOV04
YZ7015

YZ03225,000005D –19–03FEB05–5/5

CTM308 (15FEB05) 02-036-22 DF180 Series Powershift Transmission


021505
PN=124
Charge Pump and Idler Gears/Shaft - Engine Mount

Remove and Disassemble Auxiliary Pump


Idler Shaft and Gear - Engine Mount

1. Remove Cap Screw (A).


02
A—Cap Screw M12 x 110 mm 036
23

–UN–29DEC04
YZ7022A
YZ03225,00000BE –19–08NOV04–1/6

2. Install Cap Screw (A) into Auxiliary Pump Idler Shaft


(B).
3. Remove auxiliary pump idler shaft (B).

A—Cap Screw M8 x 35 mm

–UN–09NOV04
YZ7023

Continued on next page YZ03225,00000BE –19–08NOV04–2/6

CTM308 (15FEB05) 02-036-23 DF180 Series Powershift Transmission


021505
PN=125
Charge Pump and Idler Gears/Shaft - Engine Mount

4. Remove O-rings (A) and (C) and discard.

A—O-ring
B—Idler Shaft
C—O-ring
02
036
24

–UN–09NOV04
YZ7024
YZ03225,00000BE –19–08NOV04–3/6

5. Remove Auxiliary Pump Idler Gear Assembly (A) from


front housing.

A—Auxiliary Pump Idler Gear Assembly

–UN–28DEC04
YZ5321

Continued on next page YZ03225,00000BE –19–08NOV04–4/6

CTM308 (15FEB05) 02-036-24 DF180 Series Powershift Transmission


021505
PN=126
Charge Pump and Idler Gears/Shaft - Engine Mount

6. Remove Bearings (B) from Auxiliary Pump Idler Gear


(A) and discard.

A—Auxiliary Pump Idler Gear


B—Bearing (2) 02

–UN–28DEC04
036
25

YZ5326A
YZ03225,00000BE –19–08NOV04–5/6

7. Remove Snap Ring (A) from Auxiliary Pump Idler Gear


(B).

–UN–28DEC04
A—Snap Ring
B—Auxiliary Pump Idler Gear

YZ5328A
YZ03225,00000BE –19–08NOV04–6/6

Assemble and Install Auxiliary Pump Idler


Gear and Shaft - Engine Mount

–UN–28DEC04
1. Install Snap Ring (A) into Auxiliary Pump Idler Gear
(B).

YZ5328A
A—Snap Ring
B—Auxiliary Pump Idler Gear

–UN–29DEC04
YZ5327A

Continued on next page YZ03225,00000BF –19–08NOV04–1/6

CTM308 (15FEB05) 02-036-25 DF180 Series Powershift Transmission


021505
PN=127
Charge Pump and Idler Gears/Shaft - Engine Mount

2. Install Bearings (C) into Auxiliary Pump Idler Gear (D)


using JDG1110 Bearing Driver (B) and JDG1108
Bearing Driver (A).

02 A—JDG1108 Bearing Driver


036 B—JDG1110 Bearing Driver
26 C—Bearing (2 Used)
D—Auxiliary Pump Idler Gear

–UN–29DEC04
YZ5325A
YZ03225,00000BF –19–08NOV04–2/6

IMPORTANT: Install Bearing Inner Races with


shoulder to the outside on both
bearings.

3. Install Bearing Inner Race (B) into Bearing (A).

A—Bearing (2 Used)
B—Bearing Inner Race (2 Used)

–UN–19JUL04
YZ5322

Continued on next page YZ03225,00000BF –19–08NOV04–3/6

CTM308 (15FEB05) 02-036-26 DF180 Series Powershift Transmission


021505
PN=128
Charge Pump and Idler Gears/Shaft - Engine Mount

4. Install Auxiliary Pump Idler Gear (A) into front housing.

A—Auxiliary Pump Idler Gear

02
036
27

–UN–28DEC04
YZ5321
YZ03225,00000BF –19–08NOV04–4/6

NOTE: Lubricate O-rings with Petroleum Jelly to avoid


damage during assembly.

5. Install O-ring (small) (A) into bottom of front housing


auxiliary pump idler shaft bore.
6. Install O-ring (large) (C) onto Auxiliary Pump Idler
Shaft (B) large end.
7. Install Auxiliary Pump Idler Shaft (B) into front housing
auxiliary pump idler shaft bore.

A—O-ring –UN–09NOV04
B—Auxiliary Pump Idler Shaft
C—O-ring
YZ5318

Continued on next page YZ03225,00000BF –19–08NOV04–5/6

CTM308 (15FEB05) 02-036-27 DF180 Series Powershift Transmission


021505
PN=129
Charge Pump and Idler Gears/Shaft - Engine Mount

IMPORTANT: Cap screw (A) assembles into rear


housing. This cap screw to be installed
when rear housing is assembled to
front housing.
02
036
28 8. Install Cap Screw (A) into Auxiliary Pump Idler Shaft
(B) and rear housing.

Specification
Cap Screw to retain Auxiliary
Pump Idler Shaft—Torque........................................................... 86.6 N•m
(64.0 lb-ft)

–UN–09NOV04
A—Cap Screw M12 x 110mm
B—Auxiliary Pump Idler Shaft

YZ7022
YZ03225,00000BF –19–08NOV04–6/6

CTM308 (15FEB05) 02-036-28 DF180 Series Powershift Transmission


021505
PN=130
Group 037
Control Valve
Control Valve 8 Forward / 8 Reverse - Direct Drive Transmission

02
037
1

–UN–25JAN05
YZ5413B
A—Proportional Solenoid1 D—Main Pressure Valve G—Plug (2 used) K—O-ring
B—Valve Housing E—O-ring (12 Used) H—O-ring (2 Used)
C—Cooler Pressure Relief F—Plug (12 used) J—Temperature Sensor—
Valve Direct Drive Only

1
Torque Converter Drive Transmission 6F/6R (7 used); Torque
Converter Drive Transmission 6F/3R (6 used); Direct Drive
Transmission (8 used)
YZ03225,0000001 –19–25AUG04–1/1

CTM308 (15FEB05) 02-037-1 DF180 Series Powershift Transmission


021505
PN=131
Control Valve

Control Valve 6 Forward / 6 Reverse - Remote Mount Torque Converter Drive

02
037
2

–UN–25JAN05
YZ5449
A—Proportional Solenoid1 D—Main Pressure Valve I—Proportional Solenoid Plug– K— Plug–Torque Converter
B—Valve Housing E—O-ring (12 Used) Torque Converter Drive Drive Transmission Only
C—Converter Pressure Relief F—Plug (12 used) Transmission Only2 L—O-ring
Valve G—Plug (2 used) J—O-ring – Torque Converter M—O-ring – Torque Converter
H—O-ring (2 Used) Drive Transmission Only2 Drive Transmission Only2

1
Torque Converter Drive Transmission 6F/6R (7 used); Torque
Converter Drive Transmission 6F/3R (6 used); Direct Drive
Transmission (8 used)

2
6F/6R (1 used); 6F/3R (2 used)

YZ03225,0000002 –19–25AUG04–1/1

CTM308 (15FEB05) 02-037-2 DF180 Series Powershift Transmission


021505
PN=132
Control Valve

Control Valve 6 Forward / 3 Reverse - Remote Mount Torque Converter Drive

02
037
3

–UN–25JAN05
YZ5414
A—Proportional Solenoid1 D—Main Pressure Valve I—O-ring L—O-ring – Torque Converter
B—Valve Housing E—O-ring (12 Used) J—Plug–Torque Converter Drive Transmission Only2
C—Converter Pressure Relief F—Plug (12 used) Drive Transmission Only M—O-ring – Torque Converter
Valve G—Plug (2 used) K—Proportional Solenoid Drive Transmission Only2
H—O-ring (2 Used) Plug–Torque Converter
Drive Transmission Only2

1
Torque Converter Drive Transmission 6F/6R (7 used); Torque
Converter Drive Transmission 6F/3R (6 used); Direct Drive
Transmission (8 used)

2
6F/6R (1 used); 6F/3R (2 used)

YZ03225,0000003 –19–25AUG04–1/1

CTM308 (15FEB05) 02-037-3 DF180 Series Powershift Transmission


021505
PN=133
Control Valve

Remove Transmission Control Valve

Direct drive machine shown throughout. Procedures for


torque converter drive and engine drive transmission are
the same except where noted.
02
037
4 NOTE: During the disassembly and assembly check and
clean oil passages of contamination.

1. Remove Cap Screws (B) from Control Valve (A).

–UN–15SEP04
2. Install Control Valve Lifting Bracket JDG1938 (C).

YZ5486
CAUTION: Heavy component; use a hoist.

Transmission Control Valve —Specification


Control Valve—Weight ............................................. approximate 27.7 kg
(61.0 lb)

3. Remove Control Valve (A).

A—Control Valve
B—Cap Screw (27 Used)
C—JDG1138 Control Valve Lift Bracket

–UN–21JUN04
YZ5195
YZ03225,000004D –19–04OCT04–1/2

4. Remove Gasket (A), Plate (B), and Gasket (C) from


front housing and discard gaskets.

A—Gasket
B—Plate
–UN–03SEP04

C—Gasket
YZ5485

YZ03225,000004D –19–04OCT04–2/2

CTM308 (15FEB05) 02-037-4 DF180 Series Powershift Transmission


021505
PN=134
Control Valve

Install Transmission Control Valve

02
037
5

–UN–25JAN05
YZ5498
Gasket and Valve Plate Alignment

A—Gasket B—Plate C—Gasket

Continued on next page YZ03225,00000E7 –19–29DEC04–1/5

CTM308 (15FEB05) 02-037-5 DF180 Series Powershift Transmission


021505
PN=135
Control Valve

IMPORTANT: Gaskets (A and C) and plate (B) must


be in correct order and correct side up.
Gasket (A) is cut to the shape of the
front housing. Gasket (C) is cut to the
shape of the control valve. In most

–UN–03SEP04
02
037 cases printed side of gasket must be
6 towards the control valve. Be sure slot
shape at the bottom of the gaskets and
plate match the rear housing.

YZ5485
1. Install Gasket (A), Plate (B) and Gasket (C) on front
housing .

2. Install two Guide Pins (D) in the front housing. Use


Guide Pins (D) as alignment guide.

NOTE: The guide pins (D) help align the gaskets by


holding them in place and ease valve assembly

–UN–24SEP04
installation.

A—Gasket

YZ6027
B—Plate
C—Gasket
D—Guide Pins

YZ03225,00000E7 –19–29DEC04–2/5

3. Install control valve (D) on front housing.

4. Remove guide pins.

NOTE: Start all cap screws by hand before tightening,


–UN–29DEC04

there are three different lengths of cap screws.

Remove guide pins as control valve cap screws


are installed
YZ7077

5. Install Cap Screws (A), (B), and (C) per numerical


sequence drawing. A—Cap Screws (9)
B—Cap Screws (13)
C—Cap Screws (5)
D—Control Valve

Continued on next page YZ03225,00000E7 –19–29DEC04–3/5

CTM308 (15FEB05) 02-037-6 DF180 Series Powershift Transmission


021505
PN=136
Control Valve

02
037
7

–UN–25JAN05
YZ5416

Cap Screw Tightening Sequence - Direct Drive Control Valve Shown

A—Cap Screw, 45 mm (1.77 in) B—Cap Screw, 90 mm (3.54 in) C—Cap Screw, 75 mm (2.95 in)
long (5 used) long (9 used) long (13 used)

Continued on next page YZ03225,00000E7 –19–29DEC04–4/5

CTM308 (15FEB05) 02-037-7 DF180 Series Powershift Transmission


021505
PN=137
Control Valve

6. Tighten cap screws (A, B, and C) in sequence shown


in tightening sequence.

Transmission Control Valve—Specification


Control Valve-to-Front Housing
02 Cap Screws—Torque ................................................................. 39.3 N•m
037 (29.0 lb-ft)
8
7. Repeat tightening sequence.

IMPORTANT: After repeating sequence step 7, the

–UN–14SEP04
torque value can change due to heating
of the transmission and oil saturation of
valve gaskets. This can occur after
testing transmission or after warming

YZ5201
up transmission in vehicle for the first
time. Repeat tightening sequence.

A—Cap Screws (5)


B—Cap Screws (9)
C—Cap Screws (13)
D—Control Valve

YZ03225,00000E7 –19–29DEC04–5/5

Remove and Install Proportional Solenoid


Valve

NOTE: Direct drive 8 Forward / 8 Reverse transmission


has eight proportional solenoids in the valve
housing; torque converter drive transmission has
seven solenoids in 6 Forward / 6 Reverse and six
solenoids in 6 Forward / 3 Reverse. All valves can
be removed without removing the control valve
from the transmission.
–UN–19AUG04

1. Remove Nut (A), O-rings (B) and Solenoid Valve Coil


(C) from Proportional Cartridge Valve (D) and discard
O-rings (B).
YZ5196

A—Nut
B—O-rings (two used)
C—Solenoid Valve Coil
D—Proportional Cartridge Valve

Continued on next page YZ03225,000004E –19–04OCT04–1/5

CTM308 (15FEB05) 02-037-8 DF180 Series Powershift Transmission


021505
PN=138
Control Valve

2. Remove Proportional Cartridge Valve (A).

3. Remove O-rings (B), (C), and (D) and discard

A—Proportional Cartridge Valve 02


B—O-ring 037
C—O-ring 9
D—O-ring

–UN–19AUG04
YZ5197
YZ03225,000004E –19–04OCT04–2/5

4. Inspect Proportional Cartridge Valve for contamination.

5. install new O-rings (B), (C), and (D) on Proportional


Cartridge Valve.

6. Lubricate New O-rings (B), (C), and (D) with clean


hydraulic oil.

7. Install Proportional Cartridge Valve (A) into valve


housing.

–UN–19AUG04
8. Tighten Proportional Cartridge Valve (A).

Transmission Control Valve—Specification


Proportional Cartridge
Valve-to-Valve Housing—Torque .................................... 16.3—20.3 N•m

YZ5197
(12.0—15.0 lb-ft)

A—Proportional Cartridge Valve


B—O-ring
C—O-ring
D—O-ring

Continued on next page YZ03225,000004E –19–04OCT04–3/5

CTM308 (15FEB05) 02-037-9 DF180 Series Powershift Transmission


021505
PN=139
Control Valve

NOTE: If a new Nut (A) skip steps 2 and 3, new nut has
locking sealant in threads. Clean proportional
valve cartridge valve threads of all grease and oil
before installing new nut (A).
02
037 9. Install O-rings (B) and Solenoid Valve Coil (C) on
10 Proportional Cartridge Valve (D).

NOTE: Make sure nut threads and proportional cartridge


valve threads are free of grease and oil before

–UN–19AUG04
applying sealer to ensure sealer will set up
properly.

10. Clean threads on Proportional Cartridge Valve (D)

YZ5196
and Nut (A). Apply cure primer.

11. Apply high strength thread lock and sealer to


Proportional Cartridge Valve (D) threads. A—Nut
B—O-rings (two used)
C—Solenoid Valve Coil
12. Install Nut (A) on Proportional Cartridge Valve (D). D—Proportional Cartridge Valve

13. Tighten Nut (A).

Transmission Control Valve—Specification


Nut-to-Proportional Cartridge
Valve—Torque ..................................................................... 4.5—6.8 N•m
(40.0—60.0 lb-in.)

14. Repeat steps to install remaining Solenoid Valve Coils


(C) and Proportional Cartridge Valves (D).

YZ03225,000004E –19–04OCT04–4/5

NOTE: Solenoid coils above cooler relief valve to be


rotated as shown only on direct drive remote
mounted transmissions.

15. Two Solenoid Coils (A) above the lube relief valve to
be rotated as shown.

A —Solenoid Coil
–UN–31AUG04
YZ5495

Direct Drive Remote Mounted Transmission Solenoid Coil rotation

YZ03225,000004E –19–04OCT04–5/5

CTM308 (15FEB05) 02-037-10 DF180 Series Powershift Transmission


021505
PN=140
Control Valve

Remove and Install Cooler Relief Valve

1. Remove Cooler Relief Valve (A).

A—Cooler Relief Valve 02


037
11

–UN–25JUN04
YZ5199
YZ03225,000004F –19–04OCT04–1/3

2. Remove O-rings (A), Back-up Rings (B), and O-ring


(C) and discard.

3. Inspect Cooler Relief Valve (D) for wear or


contamination.

–UN–19AUG04
NOTE: Lubricate with clean hydraulic oil before installing.

4. Install new O-rings (A), Back-up Rings (B), and O-ring


(C).

A—O-rings YZ5316
B—Back-up Rings
C—O-ring
D—Cooler Relief Valve

Continued on next page YZ03225,000004F –19–04OCT04–2/3

CTM308 (15FEB05) 02-037-11 DF180 Series Powershift Transmission


021505
PN=141
Control Valve

NOTE: Lubricate with clean hydraulic oil before installing.

5. Install and tighten Cooler Relief Valve (A).

Transmission Control Valve—Specification


02 Cooler Relief Valve
037 Assembly-to-Valve Housing—
12 Torque ............................................................................. 40.7—54.2 N•m
(30.0—40.0 lb-ft)

A—Cooler Relief Valve

–UN–25JUN04
YZ5199
YZ03225,000004F –19–04OCT04–3/3

Remove and Install Main Pressure Regulator


Valve

1. Remove main pressure regulator (D).

2. Remove O-rings (A), (B), and (C) and discard

A—O-ring
B—O-ring
C—O-ring
D—Main Pressure Regulator –UN–19AUG04
YZ5200

Continued on next page YZ03225,0000050 –19–04OCT04–1/2

CTM308 (15FEB05) 02-037-12 DF180 Series Powershift Transmission


021505
PN=142
Control Valve

3. Inspect Main Pressure Regulator (D) for wear or


contamination.

4. Lubricate with oil and install new O-rings (A), (B), and
(C).
02
037
NOTE: Lubricate with clean hydraulic oil before installing. 13

5. Install and tighten Main Pressure Regulator (D).

Transmission Control Valve—Specification

–UN–19AUG04
Main Regulator
Assembly-to-Valve Housing—
Torque ............................................................................. 40.7—54.2 N•m
(30.0—40.0 lb-ft)

YZ5200
A—O-ring
B—O-ring
C—O-ring
D—Main Pressure Regulator

YZ03225,0000050 –19–04OCT04–2/2

Remove and Install Proportional Solenoid


Plug

NOTE: The Proportional Solenoid Plug (B) is used when


a Proportional Solenoid Valve is not used in a

–UN–25JUN04
valve port. Torque converter Drive Transmission 6
Forward / 6 Reverse uses one Proportional
Solenoid Plug (B) and the 6 Forward / 3 Reverse
uses two Proportional Solenoid Plugs (B). Refer to

YZ5198
Control Valve 6 Forward / 6 Reverse - Remote
Mount Torque Converter Drive or Control Valve 6
Forward / 3 Reverse - Remote Mount Torque A—O-ring
Converter Drive. B—Proportional Solenoid Plug
C—O-ring
1. Remove Proportional Solenoid Plugs (B) on torque
converter drive transmission. Direct drive machine will
have a Proportional Solenoid Valve Assembly.

2. Remove O-rings (A) and (C) and discard.

Continued on next page YZ03225,0000051 –19–04OCT04–1/2

CTM308 (15FEB05) 02-037-13 DF180 Series Powershift Transmission


021505
PN=143
Control Valve

3. Inspect Proportional Solenoid Plug (B) for


contamination.

4. Lubricate with clean hydraulic oil and install O-rings (A)


and (C) on Proportional Solenoid Plug (B).
02

–UN–25JUN04
037
14 NOTE: Lubricate with clean hydraulic oil before installing.

5. Install and tighten proportional solenoid plug (B).

YZ5198
Transmission Control Valve—Specification
Proportional Solenoid
Plug-to-Valve Housing—Torque ...................................... 16.3—20.3 N•m A—O-ring
(12.0—15.0 lb-ft) B—Proportional Solenoid Plug
C—O-ring

YZ03225,0000051 –19–04OCT04–2/2

Remove and Install Temperature Sensor

NOTE: Direct drive has temperature sensor. Torque


converter Drive Transmission has plug. Refer to
Control Valve 6 Forward / 6 Reverse - Remote
Mount Torque Converter Drive or Control Valve 6
Forward / 3 Reverse - Remote Mount Torque
Converter Drive.

1. Remove Temperature Sensor or Plug (A). Direct drive


has temperature sensor. Torque converter drive

–UN–03SEP04
transmission has a plug.

2. Remove O-ring (B) and discard.

YZ5480
A—Temperature Sensor—Direct Drive Machine
B—O-ring

Continued on next page YZ03225,0000052 –19–04OCT04–1/2

CTM308 (15FEB05) 02-037-14 DF180 Series Powershift Transmission


021505
PN=144
Control Valve

3. Inspect for contamination and damage.

NOTE: Lubricate with clean hydraulic oil before installing.

4. Install new O-Ring (B).


02
037
5. Install Temperature Sensor (A). Torque converter drive 15
transmission will have plug.

6. Tighten Temperature Sensor or Plug (A).

–UN–03SEP04
Transmission Control Valve—Specification
Temperature Sensor or
Plug-to-Valve Housing—Torque ........................................... 9.8-14.1 N•m
(7.2-10.4.0 lb-ft)

YZ5480
A—Temperature Sensor—Direct Drive Machine
B—O-ring

YZ03225,0000052 –19–04OCT04–2/2

Remove and Install Clutch Pressure Check


Port Plug

1. Remove twelve plugs (A).

2. Remove O-ring (B) and discard.

3. Inspect for contamination in control valve passages.

–UN–07SEP04
NOTE: Apply Petroleum Jelly to all O-rings prior to
installing into valve housing.
YZ5482
4. Install new O-ring (B) (12 used).

5. Install plugs (A) into valve housing.


A—Plugs (12 used)
B—O-ring (12 used)
6. Tighten plugs (A).

Transmission Control Valve—Specification


Plug-to-Valve Housing—Torque ........................................... 9.8-14.1 N•m
(7.2-10.4 lb-ft)

YZ03225,000001C –19–03SEP04–1/1

CTM308 (15FEB05) 02-037-15 DF180 Series Powershift Transmission


021505
PN=145
Control Valve

02
037
16

CTM308 (15FEB05) 02-037-16 DF180 Series Powershift Transmission


021505
PN=146
Group 039
Input Yoke - Remote Mount Transmission
Input Yoke Group - Remote Mount Transmission

02
039
1

–UN–31AUG04
YZ5505
A—Cap Screw C—O-ring D—Yoke E—Oil Seal
B—Washer

YZ03225,0000004 –19–25AUG04–1/1

CTM308 (15FEB05) 02-039-1 DF180 Series Powershift Transmission


021505
PN=147
Input Yoke - Remote Mount Transmission

Remove and Install Input Yoke - Remote


Mount Transmission

1. Remove cap screw (A).


02
039 2. Remove Washer (B).

–UN–20DEC97
2
3. Remove O-ring (C) and discard.

4. Remove Yoke (D).

YZ1091
5. Remove Oil Seal (E) and discard.

6. Apply medium strength thread lock and sealer to


outside diameter of new Oil Seal (E) and petroleum
jelly to inside diameter of new Oil Seal (E). Install using
JDG1108 and JDG1110 driver.

NOTE: Optimol Paste White T reduces spline wear.

–UN–20DEC97
7. Apply OPTIMOL PASTE WHITE T on input shaft
spline before installing Yoke (D).

YZ1092
IMPORTANT: The yoke may need to be moved up and
down until the seal lip is pointing out
over the full circumference. Seal lip of
oil seal must not be rolled when yoke is A—Cap Screw
B—Washer
installed. C—O-ring
D—Yoke
NOTE: Apply Petroleum Jelly to yoke oil seal surface E—Oil Seal
before assembly.

8. Install Yoke (D).

NOTE: Apply Petroleum Jelly to O-ring (C) before


installing.

9. Install O-ring (C).

10. Install Washer (B).

NOTE: Cap Screw threads and Input Shaft threads must


be free of grease and oil before applying high
strength thread lock and sealer.

11. Apply high strength thread lock and sealer to Cap


Screw (A).

OPTIMOL PASTE WHITE T is a trademark of Castrol Industries GmbH Continued on next page YZ03225,0000053 –19–04OCT04–1/2

CTM308 (15FEB05) 02-039-2 DF180 Series Powershift Transmission


021505
PN=148
Input Yoke - Remote Mount Transmission

12. Install and tighten Cap Screw (A) to specification.

Input Yoke —Specification


Yoke Cap Screw—Torque........................................................ 215.6 N•m
(159.0 lb-ft)
02
039
3

–UN–03JAN05
YZ1153A
YZ03225,0000053 –19–04OCT04–2/2

CTM308 (15FEB05) 02-039-3 DF180 Series Powershift Transmission


021505
PN=149
Input Yoke - Remote Mount Transmission

02
039
4

CTM308 (15FEB05) 02-039-4 DF180 Series Powershift Transmission


021505
PN=150
Group 040
Input Drive Hub - Engine Mount Transmission
Input Drive Hub - Engine Mount Transmission

02
040
1

–UN–12NOV04
YZ7027

A—Snap Ring B—Drive Hub C—O-ring

YZ03225,00000C1 –19–11NOV04–1/1

CTM308 (15FEB05) 02-040-1 DF180 Series Powershift Transmission


021505
PN=151
Input Drive Hub - Engine Mount Transmission

Remove Drive Hub

CAUTION: Wear proper eye protection when


removing Snap-Ring.
02
040 1. Remove Snap Ring (A) from first stage shaft assembly.
2

–UN–29JUN04
A—Snap-Ring
B—Drive Hub

YZ5217
YZ03225,000005E –19–03FEB05–1/2

2.

Remove Drive Hub (B).

3. Remove O-ring (A) and discard.

4. Inspect Drive Hub (B) for abnormal wear and damage.

–UN–29JUN04
A—O-ring
B—Drive Hub

YZ5220
YZ03225,000005E –19–03FEB05–2/2

Install Drive Hub

1. Install O-ring (B).

2. Install Drive Hub (A).

A—Drive Hub
B—O-ring

–UN–29JUN04
YZ5219

Continued on next page YZ03225,000005F –19–03FEB05–1/3

CTM308 (15FEB05) 02-040-2 DF180 Series Powershift Transmission


021505
PN=152
Input Drive Hub - Engine Mount Transmission

CAUTION: Use eye protection when removing


or installing Snap Ring (A).

3. Install Snap Ring (A).


02
040
A—Snap Ring 3

–UN–29JUN04
YZ5218
YZ03225,000005F –19–03FEB05–2/3

NOTE: Inspect Snap Ring (A) to insure Snap Ring (A) is


properly seated into snap ring gloove.

4. Use a driver to ensure Snap Ring (C) is seat into snap


ring groove.

C—Snap Ring

–UN–14MAR97
YZ299
YZ03225,000005F –19–03FEB05–3/3

CTM308 (15FEB05) 02-040-3 DF180 Series Powershift Transmission


021505
PN=153
Input Drive Hub - Engine Mount Transmission

02
040
4

CTM308 (15FEB05) 02-040-4 DF180 Series Powershift Transmission


021505
PN=154
Group 041
Front and Rear Housing and Clutch Assembly Group
Front and Rear Housing Bolts - Remote Mount

02
041
1

–UN–19NOV04
YZ7038

A—Cap Screw M12 x 120 (19 B—Front Housing C—Rear Housing D—Cap Screw M12 x 120
Used) (Listed in Charge Pump
Group)
YZ03225,00000CA –19–18NOV04–1/1

CTM308 (15FEB05) 02-041-1 DF180 Series Powershift Transmission


021505
PN=155
Front and Rear Housing and Clutch Assembly Group

Disassemble Front and Rear Housing -


Remote Mount

Remove Front Housing — Remote Mount


02
041 1. Remove Transmission Control Valve (See Remove

–UN–27AUG04
2 Transmission Control Valve)
2. Remove Park Brake (See Remove Park Brake)
3. Remove Charge Pump (See Remove and Install
Charge pump - Remote Mount Direct Drive)

YZ5404
NOTE: Install Eye-Bolt into 5/8 - 11 tapped hole marked
“DF180 Remote Mount” on Lift Bracket JDG1937. A—JDG1937 Lifting Bracket
B—Cap Screws (19)
4. Install JDG1937 Lifting Bracket (A) in control valve
mounting holes.

IMPORTANT: Be sure to remove cap screw that


retains the pump idler shaft. See
Remove and Install Charge pump -
Remote Mount Direct Drive or see
Remove and Install Charge and
Auxiliary Pump Gear Train - Remote
Mount Direct Drive or see Remove and
Install Cover Plates to Front Housing -
Remote Mount Torque Converter Drive.

5. Remove Cap Screws (B).

YZ03225,00000CB –19–18NOV04–1/2

CAUTION: Heavy component; use a hoist.

CAUTION: Slowly raise transmission front


cover. Clutches may bind and stick in cover.
–UN–01SEP04

6. Lift Front Housing (A) from Rear Housing (C) using


JDG1937 Lifting Bracket (B).
YZ5472

Remove Front Housing—Remote Mount—Specification


Front Housing—Weight ............................................ approximate 93.9 kg
(207.0 lb)
A—Front Housing
B—JDG1937 Lifting Bracket
C—Rear Housing

YZ03225,00000CB –19–18NOV04–2/2

CTM308 (15FEB05) 02-041-2 DF180 Series Powershift Transmission


021505
PN=156
Front and Rear Housing and Clutch Assembly Group

Sixth Stage Lube Line - Engine Mount

02
041
3

–UN–10JAN05
YZ7091

A—O-ring (2 Used) B—Elbow with Orifice Fitting C—O-ring (2 Used) D—Lube Hose Assembly
(2 Used)

YZ03225,0000005 –19–10JAN05–1/1

CTM308 (15FEB05) 02-041-3 DF180 Series Powershift Transmission


021505
PN=157
Front and Rear Housing and Clutch Assembly Group

Remove and Install Sixth Stage Lube Line

1. Remove Lube Line (A) and discard O-rings.

2. Remove Elbow Fitting (C) from Sixth Stage Bearing


02
041 Retainer (B) and discard O-ring.
4
3. Remove Elbow Fitting (C) from Control Valve (D) and
discard O-ring.

4. Install Elbow Fitting (C) into Control Valve (D) with new
O-ring

–UN–10JAN05
Specification
Elbow Fittings into Sixth Stage
Bearing Retainer—Torque........................................................... 12.2 N•m

YZ7092
(9.0 lb-ft)

5. Install Elbow fitting (C) into Sixth Stage Bearing


Retainer (B) with new O-ring.

Specification
Elbow Fittings into Control
Valve—Torque ............................................................................. 12.2 N•m
(9.0 lb-ft)

6. Install Lube Hose (A) to Elbow Fittings (C) with new


O-rings

–UN–10JAN05
Specification
Lube Hose Nut to Elbow Fitting—
Torque ......................................................................................... 16.3 N•m
(12.0 lb-ft)

YZ7093
.
A—Lube Line
B—Sixth Stage Bearing Retainer
C—Elbow Fitting
D—Control Valve

YZ03225,0000002 –19–13AUG04–1/1

CTM308 (15FEB05) 02-041-4 DF180 Series Powershift Transmission


021505
PN=158
Front and Rear Housing and Clutch Assembly Group

Front and Rear Housing Bolts - Engine Mount

02
041
5

–UN–19NOV04
YZ7039

A—Front Housing C—Cap Screw M12 x 65 E—Cap Screw M12 x 120 F—Cap Screw M12 x 110
B—Rear Housing D—Cap Screw M12 x 130 (18
Used)
YZ03225,00000CC –19–18NOV04–1/1

CTM308 (15FEB05) 02-041-5 DF180 Series Powershift Transmission


021505
PN=159
Front and Rear Housing and Clutch Assembly Group

Disassemble Front and Rear Housing -


Engine Mount

Remove Rear Housing — Engine Mount


02
041 1. Remove Transmission Control Valve (See Remove
6 Transmission Control Valve)
2. Remove Park Brake (See Remove Park Brake)
3. See Remove and Install Charge pump - Remote Mount
Direct Drive and/or see Remove and Install Charge
Pump - Engine Mount.

NOTE: Leave Cap Screws (C) and (B) in until


transmission has been rotated to where the valve
mounting face is on top.

4. Remove Cap Screws (A) and Cap Screws (C).

–UN–06JAN05
A—Cap Screw M12 x 120 (1 Used)
B—Cap Screw M12 x 130 (2)
C—Cap Screw M12 x 130 (14 used)
D—Cap Screw M12 x 130 (2)

YZ7033
YZ03225,0000054 –19–04OCT04–1/4

5. Rotate Transmission on repair stand until valve


mounting face is on top.
6. Remove Cap Screws (A) and (B).

A—Cap Screw M12 x 130 (4)


B—Cap Screw M12 x 65

–UN–15NOV04
YZ5280
–UN–15NOV04
YZ5363

Continued on next page YZ03225,0000054 –19–04OCT04–2/4

CTM308 (15FEB05) 02-041-6 DF180 Series Powershift Transmission


021505
PN=160
Front and Rear Housing and Clutch Assembly Group

7. Install JDG1102 Transmission Housing Lifting Bracket


(B) in control valve mounting holes. Using Cap Screws
(B).

A—JDG1102 Transmission Housing Lifting Bracket 02


B—Cap Screw 8M x 32 (2 Used) 041
7

–UN–12NOV04
YZ7030
YZ03225,0000054 –19–04OCT04–3/4

CAUTION: Heavy component; use a hoist.

Rear Housing—Engine Mount—Specification


Front Housing—Weight ............................................ approximate 93.9 kg
(207.0 lb)

CAUTION: Slowly raise transmission rear


housing. Clutches may bind and stick in cover.

–UN–15NOV04
Lift Rear Housing (A) from Front Housing (C) using
JDG1102 Lifting Bracket (B).

YZ7031
A—Rear Housing
B—JDG1102 Lifting Bracket
C—Front Housing

YZ03225,0000054 –19–04OCT04–4/4

CTM308 (15FEB05) 02-041-7 DF180 Series Powershift Transmission


021505
PN=161
Front and Rear Housing and Clutch Assembly Group

Front Housing Screen and Plugs

02
041
8

–UN–10JAN05
YZ7089

A—Washer (2 Used) C—Plug, 1-5/8 with O-ring E—Plug (2 Used) G—Cap Screw M6 X 12 (2
B—Magnet D—O-rings (2 Used) F—Screen Used)

YZ03225,0000003 –19–10JAN05–1/1

CTM308 (15FEB05) 02-041-8 DF180 Series Powershift Transmission


021505
PN=162
Front and Rear Housing and Clutch Assembly Group

Remove and Install Front Housing Screen -


Engine Mount

1. Remove two Cap Screws (B).


2. Remove Front Housing Screen (A). 02
3. Remove Magnet (C) from Front Housing Screen (A). 041
4. Clean Front Housing Screen (A) and Magnet (C). 9
5. Check for Damage.

IMPORTANT: If ordering the DF180 series

–UN–10JAN05
transmission front housing (service
item) will be shipped with the front
housing screen in-place and should not

YZ7088
require removal, if service is required to
the front housing screen. Clean the
holes, primer, and use loctite 262 on
cap screws to assemble the screen to A—Front Housing Screen
the front housing. B—Cap Screw
C—Magnet

6. Place magnetic (C) on Front Housing Screen.


7. Place Front Housing Screen (A).
8. Install Cap Screws (B).
9. Tighten Cap Screws (B).

Specification
Input Housing Screen-to-Front
Housing Cap Screw—Torque...................................................... 10.4 N•m
(7.7 lb-ft)

YZ03225,0000060 –19–03FEB05–1/1

CTM308 (15FEB05) 02-041-9 DF180 Series Powershift Transmission


021505
PN=163
Front and Rear Housing and Clutch Assembly Group

Remove and Install Front Housing Plugs

1. Remove Plugs and O-rings (A) and discard O-rings.


2. Remove Plug 1-5/8 with O-ring (B) and discard O-ring.
3. Install Plug (A) with new O-rings.
02
041
10 Specification
Plug with O-ring to Front
Housing—Torque......................................................................... 11.7 N•m
(8.8 lb-ft)

–UN–10JAN05
4. Install Plug 1-5/8 (B) with new O-ring

Specification

YZ7090
Plug 1-5/8 O-ring to Front
Housing—Torque....................................................................... 185.7 N•m
(137 lb-ft)
A—Plug and O-ring (2 Used)
. B—Plug 1-5/8 with O-ring

YZ03225,0000004 –19–10JAN05–1/1

CTM308 (15FEB05) 02-041-10 DF180 Series Powershift Transmission


021505
PN=164
Front and Rear Housing and Clutch Assembly Group

Gear Ratio Group - 8 Forward / 8 Reverse - Engine Mount Direct Drive

02
041
11

–UN–19NOV04
YZ7040

A—Input Shaft (First Stage) C—Second and Fourth Speed E—First and Third Speed F—Direction Clutch Packs
B—Direction Clutch Packs Clutch Packs (Fifth Stage) Clutch Packs (Fourth (High and Low Forward)
(High and Low Reverse) D—Sixth Stage Shaft Stage) (Second Stage)
(Third Stage) Assembly

YZ03225,0000007 –19–25AUG04–1/1

CTM308 (15FEB05) 02-041-11 DF180 Series Powershift Transmission


021505
PN=165
Front and Rear Housing and Clutch Assembly Group

Gear Ratio Group - 8 Forward / 8 Reverse - Remote Mount Direct Drive

02
041
12

–UN–19NOV04
YZ5502

A—Input Shaft (First Stage) C—Second and Fourth Speed E—First and Third Speed F—Direction Clutch Packs
B—Direction Clutch Packs Clutch Packs (Fifth Stage) Clutch Packs (Fourth (High and Low Forward)
(High and Low Reverse) D—Sixth Stage Shaft Stage) (Second Stage)
(Third Stage) Assembly

YZ03225,0000007 –19–25AUG04–1/1

CTM308 (15FEB05) 02-041-12 DF180 Series Powershift Transmission


021505
PN=166
Front and Rear Housing and Clutch Assembly Group

Gear Ratio Group - 6 Forward / 6 Reverse - Remote Mount Torque Converter Drive

02
041
13

–UN–23NOV04
YZ5503

A—Input Shaft (First Stage) C—Second and Fourth Speed E—First and Third Speed F—Direction Clutch Packs
B—Direction Clutch Packs Clutch Packs (Fifth Stage) Clutch Packs (Fourth (High and Low Forward)
(High and Low Reverse) D—Sixth Stage Gear (Idler Stage) (Second Stage)
(Third Stage) Gear)

YZ03225,0000008 –19–25AUG04–1/1

CTM308 (15FEB05) 02-041-13 DF180 Series Powershift Transmission


021505
PN=167
Front and Rear Housing and Clutch Assembly Group

Gear Ratio Group - 6 Forward / 3 Reverse - Remote Mount Torque Converter Drive

02
041
14

–UN–23NOV04
YZ5422

A—Input Shaft (First Stage) C—Second and Fourth Speed E—First and Third Speed F—Direction Clutch Packs
B—Direction Clutch Packs Clutch Packs (Fifth Stage) Clutch Packs (Fourth (High and Low Forward)
(High and Low Reverse) D—Sixth Stage Gear (Idler Stage) (Second Stage)
(Third Stage) Gear)

YZ03225,0000009 –19–25AUG04–1/1

CTM308 (15FEB05) 02-041-14 DF180 Series Powershift Transmission


021505
PN=168
Front and Rear Housing and Clutch Assembly Group

Remove Gear Ratio Group - Remote Mount

1. Remove Charge Pump (See Remove and Install


Charge pump - Remote Mount Direct Drive)
2. Remove Input Yoke (See Remove and Install Input
02
Yoke - Remote Mount Transmission) 041
3. Remove Park Brake (See Remove Park Brake) 15
4. Remove Winch Drive (See Remove Winch Drive -
Remote Mount Transmission)
5. Remove Transmission Control Valve (See Remove
Transmission Control Valve)
6. Remove Front Housing (See Disassemble Front and
Rear Housing - Remote Mount)

YZ03225,0000055 –19–04OCT04–1/5

CAUTION: Heavy component; use a hoist.

CAUTION: Make sure Gear Ratio Group lifting


plate is fastened to Gear Ratio Group and input
shaft to avoid personal injury.

7. Install JDG1101A Gear Ratio Group Lifting Plate (B).


8. Attach transmission Input Shaft Holder (A) to input
shaft using a M8 x 38 mm cap screw.

–UN–24JAN05
CAUTION: Carefully lift Gear Ratio Group out of
housing and away from 6th stage idler gear, so
as to not damage 6th stage bearing Cone (C).

YZ7130
9. Remove Gear Ratio Group from rear housing.

A—Input Shaft Holder


B—JDG1101A Gear Ratio Group Lifting Plate
C—Bearing Sixth Stage Assembly

Continued on next page YZ03225,0000055 –19–04OCT04–2/5

CTM308 (15FEB05) 02-041-15 DF180 Series Powershift Transmission


021505
PN=169
Front and Rear Housing and Clutch Assembly Group

CAUTION: Heavy component; use a hoist.

NOTE: Set nesting plate with the note “DF180 Remote


02
041 Mount This Side Up” to the up position.
16
10. Set on JDG1104 Gear Ratio Group Nesting Plate (B).

Transmission Gear Ratio Group—Specification


Gear Ratio Group (Second—Fifth
Stage) and Input Shaft - Remote
Mount—Weight ....................................................... approximate 157.4 kg

–UN–24JAN05
(377.0 lb)

11. Remove JDG1101A Gear Ratio Group Lifting Plate


(A).

YZ7131
A—JDG1101A Gear Ratio Group Lifting Plaate
B—JDG1104 Gear Ratio Group Nesting Plate

YZ03225,0000055 –19–04OCT04–3/5

CAUTION: Heavy component; use a hoist.

12. Use a hoist and JT05548 Eyebolt M8 (A) to remove


Seventh Stage Output Assembly (B) and Oil Trough
(D).

Transmission Gear Ratio Group Repair—Remote Mount—


Specification
Seventh Stage Output Assembly
(Output Gear)—Weight............................................. approximate 29.5 kg
(65.0 lb)

13. Remove Oil Trough (D) from Output Assembly (B).


–UN–24JAN05

A—JT05548 Eyebolt M8
B—Seventh Stage Output Assembly
YZ7132

C—Sixth Stage Assembly


D—Oil Trough

Continued on next page YZ03225,0000055 –19–04OCT04–4/5

CTM308 (15FEB05) 02-041-16 DF180 Series Powershift Transmission


021505
PN=170
Front and Rear Housing and Clutch Assembly Group

CAUTION: Heavy component; use a hoist.

14. Remove Sixth Stage Shaft Assembly (C) from rear


housing.
02
041
Transmission Gear Ratio Group—Specification

–UN–23DEC97
17
Sixth Stage Shaft Assembly (Idler
Gear)—Weight .......................................................... approximate 13.6 kg
(30.0 lb)

YZ1144
15. Clean and inspect Rear Housing for wear or damage.

C—Sixth Stage Shaft Assembly (Idler Gear)

YZ03225,0000055 –19–04OCT04–5/5

CTM308 (15FEB05) 02-041-17 DF180 Series Powershift Transmission


021505
PN=171
Front and Rear Housing and Clutch Assembly Group

Remove Gear Ratio Group - Engine Mount

For Remote Mount Configuration must first remove


transmission charge pump, input drive hub, park brake,
winch drive, and rear housing before gear ratio group can
02
041 be removed.
18
1. Remove Charge Pump (See Remove and Install
Charge pump - Remote Mount Direct Drive)
2. Remove Input Drive Hub (See Input Drive Hub -
Engine Mount Transmission)
3. Remove Park Brake (See Remove Park Brake)
4. Remove Winch Drive (See Remove Winch Drive -
Remote Mount Transmission)
5. Remove Transmission Control Valve (See Remove
Transmission Control Valve)
6. Remove Rear Housing (See Disassemble Front and
Rear Housing - Engine Mount)

YZ03225,00000C6 –19–16NOV04–1/5

7. Remove Oil Trough (B) from Seventh Stage Output


Assembly gear.

A—Seventh Stage Output Assembly


B—Oil Trough

–UN–29NOV04
YZ5284

Continued on next page YZ03225,00000C6 –19–16NOV04–2/5

CTM308 (15FEB05) 02-041-18 DF180 Series Powershift Transmission


021505
PN=172
Front and Rear Housing and Clutch Assembly Group

CAUTION: Approximate weight of all stage


assemblies is 196.0 kg (432 lb).

02
IMPORTANT: Lift all stage assemblies at one time 041
with JDG1101A Clutch Stack Nest Lift 19

–UN–15JUL04
Plate.

8. Install JDG1101A Gear Ratio Group Nest Lift Plate (A).

YZ5285
Specification
Gear Ratio Group—Weight .................................... approximate 196.0 kg
(432 lb)
A—Gear Ratio Group Nest Lift Plate
B—Holders
9. Lock Holders (B) into place.
C—Cap Screw
10. Install cap screw (C) into Sixth Stage Assembly.
11. Lift Gear Ratio Group from front housing.

YZ03225,00000C6 –19–16NOV04–3/5

NOTE: Set nesting plate with the note “DF180 Engine


Mount This Side Up” to the up position.

12. Set Gear Ratio Group into JDG1104 Gear Ratio


Group Nesting Plate.
13. Loosen Cap Screw (B).
14. Unlock Holders (C) on lift Plate.
15. Remove JDG1101A Gear Ratio Group Lift Plate (D)
from Gear Ratio Group.

A—JDG1104 Gear Ratio Group Nest Lift Plate –UN–15JUL04


B—Cap Screw
C—Holders
D—JDG1101A Gear Ratio GroupLifting Plate
YZ5286

Continued on next page YZ03225,00000C6 –19–16NOV04–4/5

CTM308 (15FEB05) 02-041-19 DF180 Series Powershift Transmission


021505
PN=173
Front and Rear Housing and Clutch Assembly Group

16. Install Eyebolt M16 (A) into end of Seventh Stage


Output Assembly (B).
17. Remove Seventh Stage Output Assembly (B) from
front housing.
18. Clean and inspect front housing for wear or damage.
02
041
20 A—Eyebolt M16
B—Seventh Stage Output Assembly

–UN–23NOV04
YZ7044
YZ03225,00000C6 –19–16NOV04–5/5

CTM308 (15FEB05) 02-041-20 DF180 Series Powershift Transmission


021505
PN=174
Front and Rear Housing and Clutch Assembly Group

Install Gear Ratio Group - Remote Mount

CAUTION: Heavy component; use a hoist.


02
1. Install Sixth Stage Shaft Assembly (C). 041

–UN–23DEC97
21
Transmission Gear Ratio Group—Specification
Sixth Stage Shaft Assembly (Idler
Gear)—Weight .......................................................... approximate 13.6 kg
(30.0 lb)

YZ1144
YZ03225,00000CD –19–22NOV04–1/5

2. Install JT05548 Eyebolt 8M (A) into end of Output


Shaft Assembly (B).
3. Lift Output Shaft Assembly (B)

Transmission Gear Ratio Group—Specification


Seventh Stage Output Assembly
(Output Gear)—Weight............................................. approximate 29.5 kg
(65.0 lb)

4. Install Oil Trough (D) onto Gear of Output Shaft


Assembly (B). Sixth Stage Clearance Slot (E) must be
towards brake side of transmission.
5. Install Output Shaft Assembly into Housing.

–UN–24JAN05
A—JT05548 Eyebolt 8M
B—Output Shaft Assembly
C—Sixth Stage Shaft Assembly

YZ7132
D—Oil Trough
E—Sixth Stage Clearance Slot

–UN–24NOV04
YZ6029

Continued on next page YZ03225,00000CD –19–22NOV04–2/5

CTM308 (15FEB05) 02-041-21 DF180 Series Powershift Transmission


021505
PN=175
Front and Rear Housing and Clutch Assembly Group

CAUTION: Make sure lift plate is fastened to


clutch pack to avoid personal injury.

6. Install JDG1101A Gear Ratio Group Lifting Plate (A) on


02
041 Gear Ratio Group. Lock holders onto the four Gear
22 Ratio Group.

NOTE: Prelubing bearing bores in housing aids Gear


Ratio Group installation.

A—JDG1101A Gear Ratio Group Lifting Plate

–UN–24JAN05
YZ7133
YZ03225,00000CD –19–22NOV04–3/5

CAUTION: Heavy component; use a hoist.

IMPORTANT: Carefully lower Gear Ratio Group into


position to avoid damage to Sixth Stage
Shaft Assembly Bearing Cone (A).

7. Carefully install Gear Ratio Group in rear housing.

Transmission Gear Ratio Group—Specification


Gear Ratio Group (Second—Fifth

–UN–25JAN05
Stage) With Input Shaft
Assembly—Weight ................................................. approximate 157.4 kg
(347.0 lb)

YZ7134
A—Bearing Cone

Continued on next page YZ03225,00000CD –19–22NOV04–4/5

CTM308 (15FEB05) 02-041-22 DF180 Series Powershift Transmission


021505
PN=176
Front and Rear Housing and Clutch Assembly Group

8. Remove JDG1101B Input Shaft Retainer (B).


9. Remove JDG1101A Gear Ratio Group Lifting Plate (A).
10. Use JT05548 Metric Lifting Eyebolt (B) to install
Seventh Stage Output Assembly (Output Gear) (C)
with Oil Trough (D) into rear housing.
02
041
A—JDG1101A Gear Ratio Group Lifting Plate 23
B—JDG1101B Input Shaft Retainer

–UN–25JAN05
YZ7135
YZ03225,00000CD –19–22NOV04–5/5

CTM308 (15FEB05) 02-041-23 DF180 Series Powershift Transmission


021505
PN=177
Front and Rear Housing and Clutch Assembly Group

Install Gear Ratio Group - Engine Mount

CAUTION: Heavy component; use a hoist.


02
041 1. Install Seventh Stage Output Assembly (B) into
24 housing.

Transmission Gear Ratio Group—Specification


Seventh Stage Output Assembly
(Output Gear)—Weight............................................. approximate 30.8 kg
(68.0 lb)

2. Remove Eyebolt M16 (A).

A—Eyebolt M16
B—Seventh Stage Output Assembly

–UN–23NOV04
YZ7044
YZ03225,00000CD –19–22NOV04–1/5

CAUTION: Make sure lift plate is fastened to


clutch pack to avoid personal injury.

3. Install JDG1101A Gear Ratio Group Lifting Plate (C)


on Gear Ratio Group. Fasten Shaft Lock Holders (B)
onto the Gear Ratio Group shafts.

NOTE: Prelubing bearing bores in housing aids Gear


Ratio Group installation.

A—Cap Screw
B—Shaft Lock Holder
C—JDG1101A Gear Ratio Group Lifting Plate
–UN–29NOV04
YZ7047

Continued on next page YZ03225,00000CD –19–22NOV04–2/5

CTM308 (15FEB05) 02-041-24 DF180 Series Powershift Transmission


021505
PN=178
Front and Rear Housing and Clutch Assembly Group

CAUTION: Heavy component; use a hoist.

IMPORTANT: Carefully lower Gear Ratio Group into


02
position to avoid damage to Sixth Stage 041
Shaft Assembly Bearing Cone (A). 25

4. Carefully install Gear Ratio Group in rear housing.

Transmission Gear Ratio Group—Specification


Gear Ratio Group (First Stage—
Sixth Stage)—Weight ............................................. approximate 157.4 kg
(347.0 lb)

–UN–29NOV04
YZ7048
YZ03225,00000CD –19–22NOV04–3/5

5. Remove JDG1101A Gear Ratio Group Lifting Plate (A).

A—JDG1101A Gear Ratio Group Lifting Plate

–UN–29NOV04
YZ7049

Continued on next page YZ03225,00000CD –19–22NOV04–4/5

CTM308 (15FEB05) 02-041-25 DF180 Series Powershift Transmission


021505
PN=179
Front and Rear Housing and Clutch Assembly Group

6. Put Oil Trough (B) on large gear of Seventh Stage


Output Assembly (Output Gear) (A). Sixth Stage Gear
Clearance Slot (C) must be towards brake side of
transmission.
02
041 A—Seventh Stage Output Assembly (Output Gear)
26 B—Oil Trough
C—Sixth Stage Gear Clearance Slot

–UN–29NOV04
YZ5284
–UN–29NOV04
YZ7050
YZ03225,00000CD –19–22NOV04–5/5

CTM308 (15FEB05) 02-041-26 DF180 Series Powershift Transmission


021505
PN=180
Front and Rear Housing and Clutch Assembly Group

Install Seal Rings

IMPORTANT: Always use new seal rings.

1. Install three Seal Rings into ring grooves in all shaft


02
assemblies. 041

–UN–20MAR98
27

YZ671
–UN–19JUL04
YZ5360
YZ03225,0000061 –19–03FEB05–1/1

CTM308 (15FEB05) 02-041-27 DF180 Series Powershift Transmission


021505
PN=181
Front and Rear Housing and Clutch Assembly Group

Assemble Front and Rear Housing —


Remote Mount

IMPORTANT: Both Front housing (A) and Rear


02 housing (C) gasket surfaces must be
041 clean and free of all dirt, grease, oil,

–UN–01SEP04
28 and old form-in-place gasket material.

1. Clean gasket surfaces on Front Housing (A) and Rear


Housing (C) with isopropyl alcohol or equivalent.

YZ5472
2. Attach JDG1937 Front Cover Lifting Bracket (B) to
front housing (A). A—Front Housing
B—JDG1937 Front Cover Lifting Bracket
IMPORTANT: Excessive amounts of flexible C—Rear Housing
form-in-place gasket may cause
excessive bearing end play, extend cure
time and cause runoff of material. Apply
with ink roll (rubber roller with a handle)
a thin and even layer approximately
0.25 mm (0.01 inch) thick. Do not use
Loctite cure primers when applying
flexible form-in-place gasket.

3. Apply high flexible form-in-place gasket to Rear


Housing (C) gasket surface. Using a small roller will
help to apply a thin, even layer of adhesive. Excess
gasket material should be wiped from joint. Installation
should occur within three minutes of application. Allow
a minimum of 30 minutes of cure time before adding
oil.

Continued on next page YZ03225,0000057 –19–04OCT04–1/4

CTM308 (15FEB05) 02-041-28 DF180 Series Powershift Transmission


021505
PN=182
Front and Rear Housing and Clutch Assembly Group

4. Install Dowel Pins (A) into Rear Housing.

A—Dowel Pins (2 Used)

02
041
29

–UN–07JAN05
YZ7080
YZ03225,0000057 –19–04OCT04–2/4

CAUTION: Heavy component; use a hoist.

Front and Rear Housing Assemble—Specification


Front Housing—Weight ............................................ approximate 93.9 kg
(207.0 lb)

–UN–06JAN05
IMPORTANT: Be sure to line up Front Housing (A)
seal ring bores with clutch shaft
assemblies seal rings and be sure to
keep the Front Housing (A) is level

YZ6028A
while lowering slowly on to Rear
Housing (C).
A—Front Housing
5. Lower Front Housing (A) slowly onto Rear Housing (C).
B—Cap Screw (19 Used)
C—Rear Housing
6. Install Cap Screws (B) into housings

Continued on next page YZ03225,0000057 –19–04OCT04–3/4

CTM308 (15FEB05) 02-041-29 DF180 Series Powershift Transmission


021505
PN=183
Front and Rear Housing and Clutch Assembly Group

02
041
30

–UN–09SEP03
YZ4147A

7. Tighten cap screws to specification in sequence 8. Remove lifting bracket.


shown. Repeat tightening sequence a second time.

Front and Rear Housing Assembly—Specification


Front Housing-to-Rear Housing
Cap Screw—Torque ............................................................ 86.8 N•m
(64.0 lb-ft)

YZ03225,0000057 –19–04OCT04–4/4

CTM308 (15FEB05) 02-041-30 DF180 Series Powershift Transmission


021505
PN=184
Front and Rear Housing and Clutch Assembly Group

Install Seal Rings

IMPORTANT: Always use new seal rings.

1. Install three Seal Rings into ring grooves in all shaft


02
assemblies. 041

–UN–20MAR98
31

YZ671
–UN–19JUL04
YZ5360
YZ03225,00000CE –19–24NOV04–1/1

Assemble Front and Rear Housing — Engine


Mount

1. Install Lifting Tool (A).

IMPORTANT: Excessive amounts of flexible


form-in-place gasket may cause
excessive bearing end play, extend cure
time and cause runoff of material. Apply
with ink roll (rubber roller with a handle)
a thin and even layer approximately
0.25 mm (0.01 inch) thick. Do not use –UN–07JAN05
Loctite cure primers when applying
flexible form-in-place gasket.
YZ5264A

2. Apply high flexible form-in-place gasket to Front


Housing (C) gasket surface. Using a small roller will
help to apply a thin, even layer of adhesive. Excess A—Lifting Tool
gasket material should be wiped from joint. Installation B—Rear Housing
should occur within three minutes of application. Allow C—Front Housing
a minimum of 30 minutes of cure time before adding
oil.

Continued on next page YZ03225,0000062 –19–03FEB05–1/5

CTM308 (15FEB05) 02-041-31 DF180 Series Powershift Transmission


021505
PN=185
Front and Rear Housing and Clutch Assembly Group

3. Install Dowel Pins (A) into Front Housing.

4. Lower Rear Housing (B) onto Front Housing (C).

02 A—Dowel Pin (2 Used)


041
32

–UN–07JAN05
YZ7081
YZ03225,0000062 –19–03FEB05–2/5

5. Install four Cap Screws (D) through Front Housing (C)


into Rear Housing (B). Two on both sides of housings.

6. Remove housing Lifting Tool (A).

7. Rotate transmission to vertical position in repair stand.

A—Housing Lift Tool


B—Rear Housing
C—Front Housing
D—Cap Screw –UN–10JAN05
YZ7085

Continued on next page YZ03225,0000062 –19–03FEB05–3/5

CTM308 (15FEB05) 02-041-32 DF180 Series Powershift Transmission


021505
PN=186
Front and Rear Housing and Clutch Assembly Group

8.

Install Cap Screws (A).

9. Install Cap Screw (B).


02
041
10. Install remaining Cap Screws (C) 33

11. Install Cap Screw (D)

A—Cap Screw M12 x 110


B—Cap Screw M12 x 120
C—Cap Screw M12 x 130 (18 Used)
D—Cap Screw M12 x 65

–UN–10JAN05
YZ7086
–UN–10JAN05
YZ7087
Continued on next page YZ03225,0000062 –19–03FEB05–4/5

CTM308 (15FEB05) 02-041-33 DF180 Series Powershift Transmission


021505
PN=187
Front and Rear Housing and Clutch Assembly Group

12. Tighten Cap Screws to 86.8 N•m (64 lb-ft) per


tightening sequence.

Specification
Front Housing-to-Rear Housing
02 Cap Screw—Torque ................................................................... 86.8 N•m
041 (64.0 lb-ft)
34

–UN–10JAN05
YZ5362A
YZ03225,0000062 –19–03FEB05–5/5

CTM308 (15FEB05) 02-041-34 DF180 Series Powershift Transmission


021505
PN=188
Front and Rear Housing and Clutch Assembly Group

Housing Tightening Sequence - Engine Mount

02
041
35

–UN–10JAN05
YZ7082
YZ03225,0000007 –19–11JAN05–1/1

Remove Sixth Stage Bearing Retainer —


Engine Mount

1. Remove Cap Screws (A).


–UN–19JUL04

A—Cap Screw (6 used)


YZ5370

Continued on next page YZ03225,0000063 –19–03FEB05–1/3

CTM308 (15FEB05) 02-041-35 DF180 Series Powershift Transmission


021505
PN=189
Front and Rear Housing and Clutch Assembly Group

2. Remove Bearing Retainer (A).

A—Bearing Retainer

02
041
36

–UN–19JUL04
YZ5371
YZ03225,0000063 –19–03FEB05–2/3

3. Remove shims (C).

4. Remove O-ring (B) from Bearing Retainer (A).

5. Discard O-ring (B).

6. Inspect Bearing Retainer (A) for wear and damage.

–UN–10JAN05
A—Bearing Retainer
B—O-ring

YZ5372
C—Shims

YZ03225,0000063 –19–03FEB05–3/3

CTM308 (15FEB05) 02-041-36 DF180 Series Powershift Transmission


021505
PN=190
Front and Rear Housing and Clutch Assembly Group

Bearing Adjustment of Sixth Stage


Assembly — Engine Mount

1. Install Washer (A) and Cap Screw (B) to output shaft.


02
NOTE: Do not install O-ring onto bearing retainer. 041
37
2. Place Bearing Retainer (C) into front housing without

–UN–06JAN05
Shims.

A—Washer
B—Cap Screw

YZ5375A
C—Bearing Retainer

YZ03225,0000064 –19–03FEB05–1/6

3. Install two Cap Screws (A) in the positions shown


(180° apart).

4. Tighten Cap Screws (A) to 2.8 N•m (25 lb-in.).

Specification

–UN–06JAN05
Bearing Retainer-to-Front
Housing Cap Screws—Torque ..................................................... 2.8 N•m
(25.0 lb-in.)

YZ5377A
A—Cap Screw (2)

Continued on next page YZ03225,0000064 –19–03FEB05–2/6

CTM308 (15FEB05) 02-041-37 DF180 Series Powershift Transmission


021505
PN=191
Front and Rear Housing and Clutch Assembly Group

NOTE: Make sure Cap Screws (B) are tightened evenly


to prevent the bearing retainer from slanting.

5. Rotate Output Shaft (A) two complete turns clockwise;


then rotate two complete turns counterclockwise.
02
041
38 6. Retighten Cap Screws (B) to 2.8 N•m (25 lb-in.).

–UN–10JAN05
Specification
Bearing Retainer-to-Front
Housing Cap Screws—Torque ..................................................... 2.8 N•m
(25.0 lb-in.)

YZ5376
A—Output Shaft
B—Cap Screws

YZ03225,0000064 –19–03FEB05–3/6

NOTE: There are two slots milled into the front housing.
A gap measurement must be taken from both
slots to obtain an average reading.

7. Use feeler gauge (B) to check gap between front


housing and Bearing Retainer (A).

–UN–10JAN05
8. Remove Cap Screws (C).

9. Remove Bearing Retainer (A).

YZ5378
A—Bearing Retainer
B—Feeler Gauge

Continued on next page YZ03225,0000064 –19–03FEB05–4/6

CTM308 (15FEB05) 02-041-38 DF180 Series Powershift Transmission


021505
PN=192
Front and Rear Housing and Clutch Assembly Group

NOTE: To obtain shim thickness for shimming sixth


stage, add 0.127 mm (0.005 in.) to the average
gap measurement. Due to housing deflection
during measuring procedure shims need to be
added to compensate for the housing deflection.
02

–UN–06JAN05
041
Specification 39
Sixth Stage Assembly—Preload ................................... 0.101 ±0.051 mm
(0.004 ±0.002 in.)

YZ5380
10. Install correct amount of Shims (A).

A—Shims

YZ03225,0000064 –19–03FEB05–5/6

11. Install new O-ring (A) onto bearing retainer.

12. Install five cap screws.

13. TIGHTENING SEQUENCE

Tighten in crossing patterns to 12 N•m (9 lb-ft).

–UN–06JAN05
Specification
Transmission Bearing Retainer
Cap Screw—Torque ........................................................ Initial: 12.2 N•m

YZ5381
(9.0 lb-ft)

14. Tighten in crossing pattern to 24 N•m (18 lb-ft).


A—O-ring
Specification
Transmission Bearing Retainer
Cap Screw—Torque ......................................................... Final: 24.4 N•m
(18.0 lb-ft)

YZ03225,0000064 –19–03FEB05–6/6

CTM308 (15FEB05) 02-041-39 DF180 Series Powershift Transmission


021505
PN=193
Front and Rear Housing and Clutch Assembly Group

Remove and Install PTO Oil Seal - Engine


Mount

1.
02
041 Remove Oil Seal (C).
40
2. Discard Oil Seal (C).

3. Install JDG1972-2 Seal Protector (B) onto first stage


PTO spline.

–UN–27JAN05
4. Apply Thread Lock and sealer (medium strength) to
outside Diameter of new Oil Seal (C).

YZ7137
5. Install new Oil Seal (C) onto JDG1972-2 Seal Protector
(B).
A—JDG1972-1 Seal Driver
6. Install new Oil Seal (C) flush with shoulder using B—JDG1972-2 Seal Protector
JDG1972-1 Seal Driver (A). C—Oil Seal

YZ03225,000002E –19–26JAN05–1/1

CTM308 (15FEB05) 02-041-40 DF180 Series Powershift Transmission


021505
PN=194
Front and Rear Housing and Clutch Assembly Group

Front Housing - Remote Mount Direct Drive

02
041
41

–UN–16SEP04
YZ5701

A—Front Housing G—Drain Valve M—Suction Tube S—Suction Tube Baffle


B—Cap Screw (19 used) H—Plug and O-ring (3 used) N—Grease Seal (2 used) T—Grease Fitting
C—O-ring J—O-ring P—Oil Seal U—Plug
D—Flat Face Fitting K—Plug Q—O-ring V—Ball
E—O-ring L—Cap Screw (2 used) R—Suction Screen W—Oil Trough
F—Lube Relief Valve

Continued on next page YZ03225,0000005 –19–25AUG04–1/2

CTM308 (15FEB05) 02-041-41 DF180 Series Powershift Transmission


021505
PN=195
Front and Rear Housing and Clutch Assembly Group

02
041
42

–UN–24NOV04
YZ7045

A—Dowel Pin (2 used) C—Bearing Cup D—Bearing Cup (2 Used) E—Bore Sleeve (4 used)
B—Front Housing

YZ03225,0000005 –19–25AUG04–2/2

CTM308 (15FEB05) 02-041-42 DF180 Series Powershift Transmission


021505
PN=196
Front and Rear Housing and Clutch Assembly Group

Front Housing - Remote Mount Torque Converter Drive

02
041
43

–UN–11JAN05
YZ5702

A—Front Housing G—O-ring N—Oil Seal U—Ball


B—Cap Screw (19 used) H—Cover Plate P—O-ring V—Oil Trough
C—O-ring J—Washer (4 used) Q—Suction Screen W—Drain Valve
D—Idler Shaft K—Cap Screw (4 used) R—Suction Tube Baffle X—Plug
E—O-ring L—Plug (3 Used) S—Grease Fitting Y—O-ring
F—Lube Relief Valve M—Grease Seal (2 used) T—Plug

Continued on next page YZ03225,0000006 –19–25AUG04–1/2

CTM308 (15FEB05) 02-041-43 DF180 Series Powershift Transmission


021505
PN=197
Front and Rear Housing and Clutch Assembly Group

02
041
44

–UN–02DEC04
YZ7046

A—Cap Screw (2 Used) D—Dowel Pin (2 used) F—Bearing Cup H—Bore Sleeve (4 used)
B—Cover E—Front Housing G—Bearing Cup J—Bearing Cup
C—O-ring

YZ03225,0000006 –19–25AUG04–2/2

CTM308 (15FEB05) 02-041-44 DF180 Series Powershift Transmission


021505
PN=198
Front and Rear Housing and Clutch Assembly Group

Front Housing Repair

Direct drive machine shown throughout. Procedures for


torque converter drive transmission are the same except
where noted.
02
041
1. Disassemble of Front and Rear Housing for Remote 45
Mount Transmissions (See Disassemble Front and
Rear Housing - Remote Mount)

YZ03225,0000023 –19–13JAN05–1/1

Remove and Install Housing Bore Sleeves

IMPORTANT: Disassemble only if parts are damaged


and must be replaced. Sleeves are
pressed into housing.

1. Inspect bore sleeves (A), if damage remove and


discard.

–UN–20DEC97
A—Bore Sleeves

YZ1099
YZ03225,0000024 –19–13JAN05–1/7

NOTE: The Bore Sleeve Blind Hole Puller Kit JDG1974

–UN–12JAN05
consists of several parts, To use the blind hole
puller kit remove the nut (A) and sleeve (B) adjust
the nut to expand the holder to a diameter big
enough to cover the face of the bore sleeve but
YZ6165

not to tight against the bore sleeve hole. Then


assemble the sleeve (B) and nut (A) back onto
the blind hole puller.
A—Nut
B—Sleeve
2. Remove Nut (A).
3. Remove Sleeve (B)

Continued on next page YZ03225,0000024 –19–13JAN05–2/7

CTM308 (15FEB05) 02-041-45 DF180 Series Powershift Transmission


021505
PN=199
Front and Rear Housing and Clutch Assembly Group

4. Tighten the expander.

02
041
46

–UN–12JAN05
YZ6166
YZ03225,0000024 –19–13JAN05–3/7

5. Install the Sleeve.

–UN–12JAN05
YZ6168

Continued on next page YZ03225,0000024 –19–13JAN05–4/7

CTM308 (15FEB05) 02-041-46 DF180 Series Powershift Transmission


021505
PN=200
Front and Rear Housing and Clutch Assembly Group

6. Install Nut.

02
041
47

–UN–12JAN05
YZ6167
YZ03225,0000024 –19–13JAN05–5/7

7. Remove the Bore Sleeve


8. Inspect and discard Bore Sleeve.

–UN–12JAN05
YZ7099

Continued on next page YZ03225,0000024 –19–13JAN05–6/7

CTM308 (15FEB05) 02-041-47 DF180 Series Powershift Transmission


021505
PN=201
Front and Rear Housing and Clutch Assembly Group

IMPORTANT: Install bore sleeves (A) with the Internal


Chamfer (B) toward clutch stack
assembly side of housing.
02
041 9. Position front housing with Housing Bore (D) side up.
48 10. Use JDG1109 Bushing Driver (C) to install Bore
Sleeves (A) .
11. Install Bore Sleeves (A) into Housing Bore (D) until
JDG1109 Bushing Driver (C) is against casting.
A—Bore Sleeves
B—Internal Chamfer
C—JDG1109 Bushing Driver
D—Housing Bore

–UN–31AUG04
YZ5468
–UN–31AUG04
YZ5467
–UN–26AUG04
YZ5465

YZ03225,0000024 –19–13JAN05–7/7

CTM308 (15FEB05) 02-041-48 DF180 Series Powershift Transmission


021505
PN=202
Front and Rear Housing and Clutch Assembly Group

Remove and Install Front Housing Bearing


Cup

1. Inspect for wear and damage.


2. Remove Bearing Cups (A) and discard. 02

–UN–23DEC97
041
49
A—Bearing Cups

YZ1103
YZ03225,0000025 –19–13JAN05–1/2

IMPORTANT: Use a bearing cup driver to install


bearing cups. Bearing cups must be
installed tight against shoulders.

–UN–25JUN04
3. Install new Bearing Cups (A, B, and C) with bearing
driver.

A—Bearing Cup

YZ1104A
B—Bearing Cup
C—Bearing Cup

YZ03225,0000025 –19–13JAN05–2/2

CTM308 (15FEB05) 02-041-49 DF180 Series Powershift Transmission


021505
PN=203
Front and Rear Housing and Clutch Assembly Group

Remove and Install Lube Relief Valve

1. Position front housing with control valve mounting


surface up.
2. Remove Lube Relief Valve (A) using 3/4-10 Bolt (C)
02
041 and Prybars (B) and discard.
50
A—Lube Relief Valve
B—Prybars
C—3/4-10 Bolt

–UN–27AUG04
YZ5497
–UN–31AUG04
YZ5478
Continued on next page YZ03225,0000026 –19–13JAN05–1/2

CTM308 (15FEB05) 02-041-50 DF180 Series Powershift Transmission


021505
PN=204
Front and Rear Housing and Clutch Assembly Group

IMPORTANT: Use care installing Lube Relief Valve


(A). The valve seat shoulder on the
Lube Relief Valve (A) and the inside
housing shoulder can be damaged if
02
too much force is applied. 041
51
3. Install new Lube Relief Valve (B) into lube relief valve
bore with 3/4-10 Bolt (A) until the Lube Relief Valve (A)
shoulder is flush with the bore shoulder.

A—3/4-10 Bolt

–UN–01SEP04
B—Lube Relief Valve

YZ5477
–UN–26AUG04
YZ5476
YZ03225,0000026 –19–13JAN05–2/2

CTM308 (15FEB05) 02-041-51 DF180 Series Powershift Transmission


021505
PN=205
Front and Rear Housing and Clutch Assembly Group

Remove and Install Sump Drain Valve -


Remote Mount

1. Remove and replace Drain Valve (A), if damaged.


02
041 NOTE: Bottom of open end of Drain Valve (A) should line
52 up with top side of Cap Screw (B).

2. Install Drain Valve (A) with open end of Drain Valve (A)
approximately 5 degrees below horizontal (as shown).

–UN–08SEP04
Specification
Sump Drain Valve—Torque ....................................................... 62.4 N•m
(46 lb-ft)

YZ5453
Specification
Sump Drain Valve—Angle............................................... Approximately 5°

A—Drain Valve
B—Cap Screw

YZ03225,0000029 –19–13JAN05–1/1

CTM308 (15FEB05) 02-041-52 DF180 Series Powershift Transmission


021505
PN=206
Front and Rear Housing and Clutch Assembly Group

Rear Housing - Remote Mount Direct Drive

02
041
53

–UN–22SEP04
YZ6020
A—Rear Housing D—Retaining Washer G—Magnetic Pickup Cover (2 J—Cap Screw (4 used)
B—O-ring (2 used) E—Snap Ring used) K—Drive Screw (2 Used)
C—Input and Output Speed F—Cylinder Speed Pickup H—Washer (4 Used) L—Identification Plate
Pickup Sensor Sensor I—Lock Washer (4 used)

YZ03225,000001E –19–16SEP04–1/1

CTM308 (15FEB05) 02-041-53 DF180 Series Powershift Transmission


021505
PN=207
Front and Rear Housing and Clutch Assembly Group

Rear Housing - Remote Mount Torque Converter Drive

02
041
54

–UN–23MAR01
YZ4145
Torque Converter Drive Transmission Rear Housing

A—Rear Housing D—Magnetic Pickup Cover (2 F—Lock Washer (4 used) I—Identification Plate
B—O-ring (2 used) used) G—Cap Screw (4 used) J—Drive Screw (2 Used)
C—Cylinder Speed Pickup E—Washer (4 Used) H—Output Shaft Pickup
Sensor Sensor

YZ03225,000001D –19–16SEP04–1/1

CTM308 (15FEB05) 02-041-54 DF180 Series Powershift Transmission


021505
PN=208
Front and Rear Housing and Clutch Assembly Group

Rear Housing - Remote Mount

02
041
55

–UN–13JAN05
YZ7100

A—Rear Housing B—Bearing Cup C—Bearing Cup D—Bearing Cup

YZ03225,000002D –19–13JAN05–1/1

CTM308 (15FEB05) 02-041-55 DF180 Series Powershift Transmission


021505
PN=209
Front and Rear Housing and Clutch Assembly Group

Rear Housing - Engine Mount

02
041
56

–UN–07JAN05
YZ7084

A—Washer (4 Used) D—Cover, Magnetic Pick-Up (2 F—O-ring (3 Used) J—Snap Ring


B—Cap Screw M6 x 120 (4 Used) G—Sensor, Magnetic Pick-Up K—Identification Plate
Used) E—Sensor, Magnetic Pick-Up H—Washer, Retaining L—Drive Screw (2 Used)
C—Washer, Helical Spring (2 Used
Lock (4 Used)

YZ03225,0000002 –19–07JAN05–1/1

CTM308 (15FEB05) 02-041-56 DF180 Series Powershift Transmission


021505
PN=210
Front and Rear Housing and Clutch Assembly Group

Rear Housing - Engine Mount

02
041
57

–UN–11JAN05
YZ7096

A—Ball B—Pluget C—Lube Relief Valve

Continued on next page YZ03225,0000009 –19–11JAN05–1/2

CTM308 (15FEB05) 02-041-57 DF180 Series Powershift Transmission


021505
PN=211
Front and Rear Housing and Clutch Assembly Group

02
041
58

–UN–11JAN05
YZ7097

A—Bearing Cup C—Rear Housing E—Bearing Cup G—Bore Sleeve (4 Used)


B—Bore Sleeve D—Plug (Drain) F—Bearing Cup

YZ03225,0000009 –19–11JAN05–2/2

CTM308 (15FEB05) 02-041-58 DF180 Series Powershift Transmission


021505
PN=212
Front and Rear Housing and Clutch Assembly Group

Rear Housing Repair - Engine Mount

Remove and Install Housing Bore Sleeves. See Remove


and Install Housing Bore Sleeves.
02
Remove and Install Lube Relief Valve. See Remove and 041
Install Lube Relief Valve. 59

YZ03225,000002A –19–13JAN05–1/1

Remove and Install Rear Housing Bearing


Cup

1. Remove and discard Bearing Cups (A), clean and


inspect housing for wear or damage.

A—Bearing Cups

–UN–23DEC97
YZ1142
Remove Bearing Cups (Remote Mount Shown)

Continued on next page YZ03225,0000059 –19–04OCT04–1/2

CTM308 (15FEB05) 02-041-59 DF180 Series Powershift Transmission


021505
PN=213
Front and Rear Housing and Clutch Assembly Group

2. Install new Bearing Cups (A), (B), and (C) into rear
housing with bearing drivers.

A—Bearing Cup
02 B—Bearing Cup
041 C—Bearing Cup
60

–UN–25JUN04
YZ1142A
Install Bearing Cups (Remote Mount Shown)

YZ03225,0000059 –19–04OCT04–2/2

Remove and Install Magnetic Sensor Pickup

Magnetic Pickup Sensor Cover Retained

1. Remove Cap Screw (D), Lock Washer (E), and Flat


Washer (F).

–UN–10JAN05
2. Remove Cover Retainer (C).
3. Remove Magnetic Pickup Sensor (A).
4. Remove O-ring (B) and discard.
5. Install New O-ring (B) onto Magnetic Pickup Sensor
(A). YZ7095

6. Install Magnetic Pickup Sensor (A) into Housing.


7. Install Flat Washer (F), Washers (E), and Cap Screws
A—Magnetic Pickup Sensor (2 Used)
(D). B—O-ring (2 Used)
C—Cover Retainer (2 Used)
Specification D—Cap Screw M6 x 20 (4 Used)
Cap Screws for Magnetic Pickup E—Lock Washer (4 Used)
Sensor Cover—Torque................................................................ 10.8 N•m F—Flat Washer (4 Used)
(8.0 lb-ft)

Continued on next page YZ03225,0000006 –19–10JAN05–1/2

CTM308 (15FEB05) 02-041-60 DF180 Series Powershift Transmission


021505
PN=214
Front and Rear Housing and Clutch Assembly Group

Magnetic Pickup Sensor Snap Ring Retained

1. Remove Snap Ring (A).


2. Remove Retaining Washer (C).
3. Remove Magnetic Pickup Sensor (B) and discard
02
O-ring. 041
4. Install New O-ring onto Magnetic Pickup Sensor (B). 61
5. Install Magnetic Pickup Sensor (B) into Housing
6. Install Retaining Washer (C).
7. Install Snap Ring (A).

–UN–10JAN05
A—Snap Ring
B—Magnetic Pickup Sensor
C—Retaining Washer

YZ7094
YZ03225,0000006 –19–10JAN05–2/2

Install Pluget Orifice - Engine Mount

A—Pluget
B—JDG1745 Pluget Driver

–UN–11JAN05
YZ6163
YZ03225,0000027 –19–13JAN05–1/2

IMPORTANT: Use JDG1745 Pluget driver to install


pluget (A).

Install

Install new pluget (A).


–UN–11JAN05

A—Pluget
B—JDG1745 Pluget Driver
YZ6164

YZ03225,0000027 –19–13JAN05–2/2

CTM308 (15FEB05) 02-041-61 DF180 Series Powershift Transmission


021505
PN=215
Front and Rear Housing and Clutch Assembly Group

Identification Plate

–UN–24APR98
The identification plate for the Engine Mount transmission
is located in the lower left side on the rear housing. The
identification plate for the Remote Mount transmission is
02
041 located on the left side on the rear side of the rear

YZ1502
62 housing. Should repair parts be required, please specify
the model, specification, and serial number of your
transmission.

YZ03225,0000065 –19–03FEB05–1/1

CTM308 (15FEB05) 02-041-62 DF180 Series Powershift Transmission


021505
PN=216
Group 043
Gears, Bearings, and Shafts
Gear Ratio Group Repair - Direct Drive

YZ03225,000001A –19–03SEP04–1/1 02
043
1
First Stage Shaft Assembly - 8 Forward / 8 Reverse - Remote Mount Direct Drive

–UN–31AUG04
YZ5500
First Stage Shaft Assemble 8 Forward / 8 Reverse Remote Mount

A—Bearing Cone (2) B—First Stage Shaft

YZ03225,000000A –19–25AUG04–1/1

CTM308 (15FEB05) 02-043-1 DF180 Series Powershift Transmission


021505
PN=217
Gears, Bearings, and Shafts

First Stage Shaft Assembly - 8 Forward / 8 Reverse - Engine Mount Direct Drive

02
043
2

–UN–02DEC04
YZ7051

First Stage Shaft Assemble 8 Forward / 8 Reverse Engine Mount

A—Bearing Cone B—First Stage Shaft C—Bearing Cone D—Seal Ring (2 Used)

YZ03225,000000A –19–25AUG04–1/1

CTM308 (15FEB05) 02-043-2 DF180 Series Powershift Transmission


021505
PN=218
Gears, Bearings, and Shafts

Sixth Stage Assembly 8 Forward / 8 Reverse - Remote Mount Direct Drive

02
043
3

–UN–25JUN04
YZ5210
Sixth Stage Assembly 8 Forward / 8 Reverse Remote Mount

A—Bearing Cone (2) B—Sixth Stage Assembly

Sixth Stage Shaft Assembly stage shaft assembly. Refer to Input Shaft (First
Stage) and Sixth Stage (Idler Gear) Repair - Direct
The procedure for assembly and disassembly of the Drive or Input Shaft (First Stage) and Sixth Stage (Idler
sixth stage shaft assembly is the same as for the first Gear) Repair - Torque Converter Drive.

YZ03225,000000C –19–25AUG04–1/1

CTM308 (15FEB05) 02-043-3 DF180 Series Powershift Transmission


021505
PN=219
Gears, Bearings, and Shafts

Sixth Stage Assembly 8 Forward / 8 Reverse - Engine Mount Direct Drive

02
043
4

–UN–02DEC04
YZ7052

Sixth Stage Assembly 8 Forward / 8 Reverse Engine Mount

A—Bearing Cone B—Sixth Stage Assembly C—Bearing Cone

Sixth Stage Shaft Assembly stage shaft assembly. Refer to Input Shaft (First
Stage) and Sixth Stage (Idler Gear) Repair - Direct
The procedure for assembly and disassembly of the Drive or Input Shaft (First Stage) and Sixth Stage (Idler
sixth stage shaft assembly is the same as for the first Gear) Repair - Torque Converter Drive.

YZ03225,000000C –19–25AUG04–1/1

CTM308 (15FEB05) 02-043-4 DF180 Series Powershift Transmission


021505
PN=220
Gears, Bearings, and Shafts

Input Shaft (First Stage) and Sixth Stage


(Idler Gear) Repair - Direct Drive

First Stage Shaft Assembly


YZ03225,000005A –19–04OCT04–1/3 02
043
5

CAUTION: When pulling bearing, pullers could


slip off.

1. Use bearing Puller to remove Bearing Cones (A) and


(B). Discard Bearing Cones (A) and (B).

A—Bearing Cone
B—Bearing Cone

–UN–23DEC97
YZ1133
Continued on next page YZ03225,000005A –19–04OCT04–2/3

CTM308 (15FEB05) 02-043-5 DF180 Series Powershift Transmission


021505
PN=221
Gears, Bearings, and Shafts

IMPORTANT: Press only on the inner race of bearing


cone. Do not reuse bearing cones if
removed.

NOTE: Gear and shaft assemblies are serviced as an


02
043 assembly. If either the gear or shaft is damaged
6 or worn, entire assembly must be replaced.

2. Use JDG1105 Bearing Driver (B) and JDG1108 Clutch


Bearing Driver (A) to install new Bearing Cones (C) on
both ends of shaft. Push bearing tight against shoulder
of shaft.

A—JDG1108 Clutch Bearing Driver


B—JDG1105 Bearing Driver
C—Bearing Cone

–UN–20SEP04
YZ1134A
YZ03225,000005A –19–04OCT04–3/3

CTM308 (15FEB05) 02-043-6 DF180 Series Powershift Transmission


021505
PN=222
Gears, Bearings, and Shafts

02
043
7

CTM308 (15FEB05) 02-043-7 DF180 Series Powershift Transmission


021505
PN=223
Gears, Bearings, and Shafts

Second Stage (High / Low Forward) Clutch Assembly Cross-Section - Remote Mount
Direct Drive

02
043
8

–UN–08DEC04
YZ7062

Second Stage (High / Low Forward Clutch) Remote Mount - Cross-Section

A—Seal Ring (3 used) H—Piston Outer Seal (2 used) N—Bearing T—Clutch Return Spring (12
B—Ball Bearing (2 used) J—Second Stage Shaft P—Retaining Ring (2 used) used)
C—Bearing Assembly Q—Gear U—Lube Shut-Off Washer (2
D—Bearing with Seal (2 used) K—Clutch Piston (2 used) R—Retaining Ring (2 used) used)
E—O-ring (2 used) L—Clutch Plate Retainer (2 S—Snap Ring Retainer (2 V—O-ring (2 used)
F—Clutch Plate (18 used) used) used) W—Gear
G—Clutch Separator Plate (20 M—Internal Snap Ring (2
used) used)

YZ03225,000005B –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-8 DF180 Series Powershift Transmission


021505
PN=224
Gears, Bearings, and Shafts

Second Stage (High / Low Forward) Clutch Assembly Exploded View - Remote Mount
Direct Drive

02
043
9

–UN–22JAN03
T163664
Second Stage (High / Low Forward Clutch) Remote Mount - Exploded View

1—Seal Ring (3 used) 8—Internal Snap Ring (2 used) 13—Snap Ring Retainer (2 16—Oaring (2 used)
2—Ball Bearing (2 used) 9—Clutch Plate Retainer (2 used) 17—Clutch Piston (2 used)
3—Retaining Ring (2 used) used) 14—Clutch Return Spring (12 18—Piston Outer Seal (2 used)
4—Bearing 10—Clutch Plate (18 used) used) 19—Second Stage Shaft
5—Gear 11—Clutch Separator Plate (20 15—Lube Shut-Off Washer (2 20—Gear
6—O-Ring (2 used) used) used) 21—Bearing
7—Bearing with Seal (2 used) 12—Retaining Ring (2 used)

YZ03225,000005B –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-9 DF180 Series Powershift Transmission


021505
PN=225
Gears, Bearings, and Shafts

Third Stage (High / Low Reverse) Clutch Assembly Cross-Section - Remote Mount Direct
Drive

02
043
10

–UN–08DEC04
YZ7063

Third Stage (High / Low Reverse Clutch) Remote Mount - Cross-Section

A—Seal Ring (3 used) G—Internal Snap Ring (2 L—Lube Shut-Off Washer (2 Q—Gear
B—Ball Bearing (2 used) used) used) R—Bearing (2 used)
C—Bearing (2 Used) H—Clutch Plate Retainer (2 M—Third Stage Shaft S—Snap Ring (2 Used)
D—Snap Ring Retainer (2 used) Assembly T—Piston Outer Seal (2 used)
used) J—Clutch Plate (18 used) N—O-ring (2 used) U—Clutch Piston (2 used)
E—O-ring (2 used) K—Clutch Separator Plate (20 P—Retaining Ring (2 used) V—Gear
F—Clutch Return Spring (12 used)
used)

YZ03225,000005B –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-10 DF180 Series Powershift Transmission


021505
PN=226
Gears, Bearings, and Shafts

Third Stage (High / Low Reverse) Clutch Assembly Exploded View - Remote Mount Direct
Drive

02
043
11

–UN–15JAN03
T163679
Third Stage (High / Low Reverse Clutch) Remote Mount - Exploded View

1—Seal Ring (3 used) 8—Internal Snap Ring (2 used) 12—Retaining Ring (2 used) 16—O-ring (2 used)
2—Ball Bearing (2 used) 9—Clutch Plate Retainer (2 13—Snap Ring Retainer (2 17—Clutch Piston (2 used)
3—Retaining Ring (2 used) used) used) 18—Piston Outer Seal (2 used)
4—Bearing (2 used) 10—Clutch Plate (18 used) 14—Clutch Return Spring (12 19—Third Stage Shaft
5—Gear 11—Clutch Separator Plate (20 used) 20—Gear
6—O-ring (2 used) used) 15—Lube Shut-Off Washer (2
7—Bearing with Seal (2 used) used)

YZ03225,000005C –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-11 DF180 Series Powershift Transmission


021505
PN=227
Gears, Bearings, and Shafts

Fourth Stage (First / Third Speed) Clutch Assembly Cross-Section - Remote Mount Direct
Drive

02
043
12

–UN–08DEC04
YZ7064

Fourth Stage (First / Third Speed Clutch) Remote Mount - Cross-Section

A—Ball Bearing (2 used) G—Lube Shut-Off Washer (2 L—Clutch Plate Retainer (2 R—Clutch Separator Plate (20
B—Retaining Ring (2 used) used) used) used)
C—Gear H—Fourth Stage Shaft M—Snap Ring (2 Used) S—Piston Outer Seal (2 used)
D—Bearing (2 Used) Assembly N—Bearing (2 used) T—Clutch Piston (2 used)
E—Snap Ring Retainer (2 J—O-ring (2 used) P—Gear U—Seal Ring (3 used)
used) K—Internal Snap Ring (2 Q—Clutch Plate (18 used)
F—Clutch Return Spring (12 used)
used)

YZ03225,000005B –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-12 DF180 Series Powershift Transmission


021505
PN=228
Gears, Bearings, and Shafts

Fourth Stage (First / Third Speed) Clutch Assembly Exploded View - Remote Mount Direct
Drive

02
043
13

–UN–15JAN03
T163680
Fourth Stage (First / Third Speed Clutch) Remote Mount - Exploded View

1—Seal Ring (3 used) 7—Snap Ring (2 used) 11—Retaining Ring (2 used) 15—O-ring (2 used)
2—Bearing (2 used) 8—Clutch Plate Retainer (2 12—Snap Ring Retainer (2 16—Clutch Piston (2 used)
3—Retaining Ring (2 used) used) used) 17—Piston Outer Seal (2 used)
4—Ball Bearing (2 used) 9—Clutch Plate (20 used) 13—Clutch Return Spring (12 18—Fourth Stage Shaft
5—Clutch Gear 10—Clutch Separator Plate (20 used) 19—Clutch Gear
6—Ball Bearing (2 used) used) 14—Lube Shut-Off Washer (2
used)

YZ03225,000005D –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-13 DF180 Series Powershift Transmission


021505
PN=229
Gears, Bearings, and Shafts

Fifth Stage (Second / Fourth Speed) Clutch Assembly Cross-Section - Remote Mount
Direct Drive

02
043
14

–UN–09DEC04
YZ7065

Fifth Stage (Second / Fourth Speed Clutch) Remote Mount - Cross-Section

A—Seal Ring (3 used) F—Lube Shut-Off Washer (2 L—Snap Ring (2 Used) R—Clutch Separator Plate (20
B—Ball Bearing (2 used) used) M—Gear used)
C—Bearing (2 Used) G—Fifth Stage Shaft Assembly N—Bearing (2 used) S—Piston Outer Seal (2 used)
D—Snap Ring Retainer (2 H—O-ring (2 used) P—Retaining Ring (2 used) T—Clutch Piston (2 used)
used) J—Internal Snap Ring (2 used) Q—Clutch Plate (20 used) U—Gear
E—Clutch Return Spring (12 K—Clutch Plate Retainer (2
used) used)

YZ03225,000005B –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-14 DF180 Series Powershift Transmission


021505
PN=230
Gears, Bearings, and Shafts

Fifth Stage (Second / Fourth Speed) Clutch Assembly Exploded View - Remote Mount
Direct Drive

02
043
15

–UN–15JAN03
T163681
Fifth Stage (Second / Fourth Speed Clutch) Remote Mount - Exploded View

1—Seal Ring (3 used) 7—Snap Ring (2 used) 11—Retaining Ring (2 used) 15—O-ring (2 used)
2—Bearing (2 used) 8—Clutch Plate Retainer (2 12—Snap Ring Retainer (2 16—Clutch Piston (2 used)
3—Retaining Ring (2 used) used) used) 17—Piston Outer Seal (2 used)
4—Ball Bearing (2 used) 9—Clutch Plate (20 used) 13—Clutch Return Spring (12 18—Fifth Stage Shaft
5—Clutch Gear 10—Clutch Separator Plate (20 used) 19—Clutch Gear
6—Ball Bearing (2 used) used) 14—Lube Shut-Off Washer (2
used)

YZ03225,000005E –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-15 DF180 Series Powershift Transmission


021505
PN=231
Gears, Bearings, and Shafts

Second Stage (High / Low Forward) Clutch Assembly Cross-Section - Engine Mount
Direct Drive

02
043
16

–UN–06DEC04
YZ7054

Second Stage (High / Low Forward Clutch) Engine Mount - Cross-Section

A—Seal Ring (3 Used) G—Clutch Separator Plate (20 M—O-ring T—Snap Ring Retainer (2
B—Bearing (2 Used) Used) N—Clutch Gear Used)
C—Clutch Gear H—O-ring (2 Used) P—Retaining Ring (2 Used) U—Clutch Return Spring (12
D—Clutch Plate Retainer (2 J—Clutch Piston (2 Used) Q—Bearing (2 Used) Used)
Used) K—Piston Outer Seal (2 Used) R—Bearing (2 Used) V—Lube Shutoff Washer (2
E—Snap Ring (2 Used) L—Second Stage Shaft S—Retaining Ring (2 Used) Used)
F—Clutch Plate (18 Used) Assembly

YZ03225,00000D9 –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-16 DF180 Series Powershift Transmission


021505
PN=232
Gears, Bearings, and Shafts

Second Stage (High / Low Forward) Clutch Assembly Exploded View - Engine Mount
Direct Drive

02
043
17

–UN–06DEC04
YZ7055

Second Stage (High / Low Forward Clutch) Engine Mount - Exploded View

A—Clutch Separator Plate (20 F—O-ring (2 Used) N—Clutch Return Spring (12 S—Piston Outer Seal (2 Used)
Used) G—Clutch Gear Used) T—Second Stage Shaft
B—Clutch Plate (18 Used) H—Bearing (2 Used) P—Lube Shutoff Washer (2 Assembly
C—Clutch Plate Retainer (2 J—Retaining Ring (2 Used) Used) U—Clutch Gear
Used) K—Bearing (2 Used) Q—O-ring (2 Used) V—Seal Ring (3 Used)
D—Snap Ring (2 Used) L—Retaining Ring (2 Used) R—Clutch Piston (2 Used)
E—Bearing (2 Used) M—Snap Ring Retainer (2
Used)

YZ03225,00000D9 –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-17 DF180 Series Powershift Transmission


021505
PN=233
Gears, Bearings, and Shafts

Third Stage (High / Low Reverse) Clutch Assembly Cross-Section — Engine Mount Direct
Drive

02
043
18

–UN–06DEC04
YZ7056

Third Stage (High / Low Reverse Clutch) Engine Mount - Cross-Section

A—Seal Ring (3 Used) G—Clutch Separator Plate (20 M—O-ring T—Snap Ring Retainer (2
B—Bearing (2 Used) Used) N—Clutch Gear Used)
C—Clutch Gear H—O-ring (2 Used) P—Retaining Ring (2 Used) U—Clutch Return Spring (12
D—Clutch Plate Retainer (2 J—Clutch Piston (2 Used) Q—Bearing (2 Used) Used)
Used) K—Third Stage Shaft R—Bearing (2 Used) V—Lube Shutoff Washer (2
E—Snap Ring (2 Used) Assembly S—Retaining Ring (2 Used) Used)
F—Clutch Plate (18 Used) L—Piston Outer Seal (2 Used)

YZ03225,00000DA –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-18 DF180 Series Powershift Transmission


021505
PN=234
Gears, Bearings, and Shafts

Third Stage (High / Low Reverse) Clutch Assembly Exploded View — Engine Mount
Direct Drive

02
043
19

–UN–07DEC04
YZ7057

Third Stage (High / Low Reverse Clutch) Engine Mount - Exploded View

A—Clutch Separator Plate (20 F—O-ring (2 Used) N—Clutch Return Spring (12 S—Piston Outer Seal (2 Used)
Used) G—Clutch Gear Used) T—Third Stage Shaft
B—Clutch Plate (18 Used) H—Bearing (2 Used) P—Lube Shutoff Washer (2 Assembly
C—Clutch Plate Retainer (2 J—Retaining Ring (2 Used) Used) U—Clutch Gear
Used) K—Bearing (2 Used) Q—O-ring (2 Used) V—Seal Ring (3 Used)
D—Snap Ring (2 Used) L—Retaining Ring (2 Used) R—Clutch Piston (2 Used)
E—Bearing (2 Used) M—Snap Ring Retainer (2
Used)

YZ03225,00000DA –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-19 DF180 Series Powershift Transmission


021505
PN=235
Gears, Bearings, and Shafts

Fourth Stage (First / Third Speed) Clutch Assembly Cross-Section — Engine Mount Direct
Drive

02
043
20

–UN–07DEC04
YZ7058

Fourth Stage (First / Third Speed Clutch) Engine Mount - Cross-Section

A—Seal Ring (3 Used) G—Clutch Plate (20 Used) N—Retaining Ring (2 Used) T—Clutch Return Spring (12
B—Bearing (2 Used) H—O-ring (2 Used) P—Bearing (2 Used) Used)
C—Clutch Gear J—Clutch Piston (2 Used) Q—Bearing (2 Used) U—Lube Shutoff Washer (2
D—Clutch Plate Retainer (2 K—Piston Outer Seal (2 Used) R—Retaining Ring (2 Used) Used)
Used) L—Fourth Stage Shaft S—Snap Ring Retainer (2 V—Bearing Bronze Cage (2
E—Snap Ring (2 Used) Assembly Used) Used)
F—Clutch Separator Plate (20 M—Clutch Gear
Used)

YZ03225,00000DA –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-20 DF180 Series Powershift Transmission


021505
PN=236
Gears, Bearings, and Shafts

Fourth Stage (First / Third Speed) Clutch Assembly Exploded View — Engine Mount
Direct Drive

02
043
21

–UN–11JAN05
YZ7059

Fourth Stage (First / Third Speed Clutch) Engine Mount - Exploded View

A—Clutch Plate (20 Used) F—Clutch Gear M—Clutch Return Spring (12 S—Fourth Stage Shaft
B—Clutch Separator Plate (20 G—Bearing (2 Used) Used) Assembly
Used) H—Retaining Ring (2 Used) N—Lube Shutoff Washer (2 T—Bearing Bronze Cage (2
C—Clutch Plate Retainer (2 J—Bearing (2 Used) Used) Used)
Used) K—Retaining Ring (2 Used) P—O-ring (2 Used) U—Clutch Gear
D—Snap Ring (2 Used) L—Snap Ring Retainer (2 Q—Clutch Piston (2 Used) V—Seal Ring (3 Used)
E—Bearing (2 Used) Used) R—Piston Outer Seal (2 Used)

YZ03225,00000DA –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-21 DF180 Series Powershift Transmission


021505
PN=237
Gears, Bearings, and Shafts

Fifth Stage (Second / Fourth Speed) Clutch Assembly Cross-Section — Engine Mount
Direct Drive

02
043
22

–UN–07DEC04
YZ7060

Fifth Stage (Second / Fourth Speed Clutch) Engine Mount - Cross-Section

A—Seal Ring (3 Used) F—Clutch Separator Plate (20 L—Fifth Stage Shaft Assembly S—Snap Ring Retainer (2
B—Bearing (2 Used) Used) M—Clutch Gear Used)
C—Clutch Gear G—Clutch Plate (20 Used) N—Retaining Ring (2 Used) T—Clutch Return Spring (12
D—Clutch Plate Retainer (2 H—O-ring (2 Used) P—Bearing (2 Used) Used)
Used) J—Clutch Piston (2 Used) Q—Bearing (2 Used) U—Lube Shutoff Washer (2
E—Snap Ring (2 Used) K—Piston Outer Seal (2 Used) R—Retaining Ring (2 Used) Used)

YZ03225,00000DA –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-22 DF180 Series Powershift Transmission


021505
PN=238
Gears, Bearings, and Shafts

Fifth Stage (Second / Fourth Speed) Clutch Assembly Exploded View — Engine Mount
Direct Drive

02
043
23

–UN–07DEC04
YZ7061

Fifth Stage (Second / Fourth Speed Clutch) Engine Mount - Exploded View

A—Clutch Plate (20 Used) E—Bearing (2 Used) L—Snap Ring Retainer (2 P—O-ring (2 Used)
B—Clutch Separator Plate (20 F—Clutch Gear Used) Q—Clutch Piston (2 Used)
Used) G—Bearing (2 Used) M—Clutch Return Spring (12 R—Piston Outer Seal (2 Used)
C—Clutch Plate Retainer (2 H—Retaining Ring (2 Used) Used) S—Fifth Stage Shaft Assembly
Used) J—Bearing (2 Used) N—Lube Shutoff Washer (2 T—Clutch Gear
D—Snap Ring (2 Used) K—Retaining Ring (2 Used) Used) U—Seal Ring (3 Used)

YZ03225,00000DA –19–07DEC04–1/1

CTM308 (15FEB05) 02-043-23 DF180 Series Powershift Transmission


021505
PN=239
Gears, Bearings, and Shafts

Disassemble and Assemble Clutch - Direct


Drive

CAUTION: Heavy components; use a hoist.


02
043 Transmission Clutch Packs Disassembly and Assembly—Direct
24 Drive Transmission—Specification
Second Stage Assembly—Weight ........................... approximate 43.1 kg
(95.0 lb)
Third Stage Assembly—Weight ............................... approximate 40.8 kg
(90.0 lb)
Fourth Stage Assembly—Weight ............................. approximate 34.5 kg
(76.0 lb)
Fifth Stage Assembly—Weight ................................ approximate 39.0 kg
(86.0 lb)

IMPORTANT: DO NOT mix components of individual


shaft assemblies. Keep all clutch pack
components together as a set.

NOTE: The disassembly and assembly of clutch packs


are similar. Second Stage Clutch Pack is shown
unless otherwise indicated.

1. Use JDG1106 Clutch Lifting tool to lift clutch assembly.

–UN–25JUN04
YZ5208
Direct Drive 8F/8R Second Stage Clutch Assembly Shown

YZ03225,000005F –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-24 DF180 Series Powershift Transmission


021505
PN=240
Gears, Bearings, and Shafts

Disassemble Clutch Gear and Bearing -


Direct Drive

1. Remove Seal Rings (A) and discard.


02
2. Inspect clutch shaft seal ring grooves for wear or 043
damage. 25

A—Seal Rings (3 used)

–UN–01SEP04
YZ5459
YZ03225,0000043 –19–01OCT04–1/9

CAUTION: When using gear or bearing pullers,


puller could slip off.

3. Install Bearing Puller (B).

4. Install Gear Puller (A) on bearing puller (B).

–UN–13AUG96
5. Remove Ball Bearing (C). Inspect and discard.

A—Gear Puller

YZ402
B—Bearing Puller
C—Ball Bearing

YZ03225,0000043 –19–01OCT04–2/9

CAUTION: Wear proper eye protection when


installing or removing retaining rings.

6. Remove Retaining Ring (A). Inspect and discard.

A—Retaining Ring
–UN–02NOV96
YZ403

Continued on next page YZ03225,0000043 –19–01OCT04–3/9

CTM308 (15FEB05) 02-043-25 DF180 Series Powershift Transmission


021505
PN=241
Gears, Bearings, and Shafts

CAUTION: When using gear or bearing pullers,


puller could slip off.

7. Use gear puller to remove Clutch Gear (B).


02
043
26 B—Clutch Gear

–UN–12MAR97
YZ404
YZ03225,0000043 –19–01OCT04–4/9

8. Remove Ball Bearing (A). Inspect and discard.

A—Ball Bearing
–UN–12MAR97
YZ849A

Continued on next page YZ03225,0000043 –19–01OCT04–5/9

CTM308 (15FEB05) 02-043-26 DF180 Series Powershift Transmission


021505
PN=242
Gears, Bearings, and Shafts

9. On direction clutch pack (second and third stage)


assemblies only, remove O-ring (A) and discard.

10. Inspect gear assembly for wear or damage.


02
A—O-ring 043
27

–UN–19APR97
YZ429
YZ03225,0000043 –19–01OCT04–6/9

CAUTION: Wear proper eye protection when


removing snap ring (high tension snap ring).

11. Remove Snap Ring (B).

B—Snap Ring

–UN–25MAR97
YZ407

Continued on next page YZ03225,0000043 –19–01OCT04–7/9

CTM308 (15FEB05) 02-043-27 DF180 Series Powershift Transmission


021505
PN=243
Gears, Bearings, and Shafts

12. Turn shaft assembly over.

13. Remove Clutch Plate Retainer (C).

14. Remove Clutch Plates (B) and Separator Plates (A).


02
043
28 15. Discard Clutch Plates (B).

16. Inspect Clutch Plate Retainer (C) and Separator


Plates (A) for wear, damage, or heat.

A—Separator Plate
B—Clutch Plate
C—Clutch Plate Retainer

–UN–09SEP04
YZ5630A
YZ03225,0000043 –19–01OCT04–8/9

CAUTION: When using bearing pullers, puller


could slip off.

17. Install bearing puller.

18. Remove Ball Bearing (A). Inspect and discard .

A—Ball Bearing

–UN–19APR97
YZ406

YZ03225,0000043 –19–01OCT04–9/9

CTM308 (15FEB05) 02-043-28 DF180 Series Powershift Transmission


021505
PN=244
Gears, Bearings, and Shafts

Disassemble Clutch Piston and Spring -


Direct Drive

CAUTION: Clutch piston return springs are


under pressure. 02
043
29
1. Place shaft assembly on press.

IMPORTANT: Compress springs only enough to


facilitate removal of retaining ring. Over
compressing springs can damage
piston.

2. Use JDG1103 Clutch Pack Spring Compressor (A) to


compress clutch return springs.

–UN–29APR97
3. Remove Retaining Ring (B) from shaft groove.

4. Relieve pressure on JDG1103 Clutch Pack Spring


Compressor.

YZ410
A—JDG1103 Clutch Pack Spring Compressor
B—Retaining Ring

YZ03225,0000042 –19–01OCT04–1/5

5. Lift out Retaining Ring (A), Snap Ring Retainer (B) and
Clutch Return Springs (C). Inspect for wear or damage.

A—Retaining Ring
B—Snap Ring Retainer
C—Clutch Return Springs (6)

–UN–21AUG96
YZ463
YZ03225,0000042 –19–01OCT04–2/5

6. Remove Lube Shutoff Washer (D). Inspect for wear or


damage.

D—Lube Shutoff Washer


–UN–21AUG96
YZ464

Continued on next page YZ03225,0000042 –19–01OCT04–3/5

CTM308 (15FEB05) 02-043-29 DF180 Series Powershift Transmission


021505
PN=245
Gears, Bearings, and Shafts

CAUTION: Prevent possible injury from


unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
02 piston or flying debris. Wear personal
043 protection equipment, including eye protection.
30
Use only regulated, compressed air of 68.9 kPa
(0.69 bar) (10 psi) maximum to remove piston.

–UN–20AUG96
7. Apply 68.9 kPa (0.69 bar) (10.0 psi) maximum,
regulated air pressure through oil passage to force
clutch piston from shaft assembly.

YZ414
Transmission Clutch Packs Disassembly—Direct Drive
Transmission—Specification
Maximum Regulated Air—
Pressure ...................................................................................... 68.9 kPa
(0.69 bar)
(10.0 psi)

YZ03225,0000042 –19–01OCT04–4/5

8. Remove clutch piston (A).

9. Remove Piston Outer Seal (B) and O-ring (C) from


clutch piston (A). Inspect and discard.

10. Inspect clutch piston (A) for wear or damage.

11. For complete disassembly of this shaft, repeat


disassembly steps for clutch pack assembly on
opposite end of this shaft.
–UN–20AUG96

A—Clutch Piston
B—Piston Outer Seal
YZ415

C—O-ring

YZ03225,0000042 –19–01OCT04–5/5

CTM308 (15FEB05) 02-043-30 DF180 Series Powershift Transmission


021505
PN=246
Gears, Bearings, and Shafts

Assemble Clutch Piston and Spring - Direct


Drive

IMPORTANT: DO NOT mix components of individual


shaft assemblies. Keep all clutch pack 02
components together as a set. 043
31
Inspect inside of cylinder for sharp
edges, burrs, or wear. Use care not to
damage seals on pistons during

–UN–20AUG96
installation.

1. Install new O-ring (A).

YZ416
2. Install new Piston Outer Seal (B).

3. Lubricate O-ring (A) and Piston Outer Seal (B).


A—O-ring
B—Piston Outer Seal
4. Install Clutch Piston (C) with raised center boss up. C—Clutch Piston

YZ03225,0000041 –19–01OCT04–1/5

5. Install Lube Shutoff Washer (D).

D—Lube Shutoff Washer

–UN–21AUG96
YZ413
Continued on next page YZ03225,0000041 –19–01OCT04–2/5

CTM308 (15FEB05) 02-043-31 DF180 Series Powershift Transmission


021505
PN=247
Gears, Bearings, and Shafts

IMPORTANT: Install clutch piston return springs as


shown for proper spring force. Also, if a
new spring is required in a clutch pack,

–UN–20MAR97
then all six springs for that clutch pack
will have to be replaced.
02
043
32 6. Install Clutch Return Springs (A) as three pairs with

YZ853
outer diameters contacting for each pair.

A—Clutch Return Springs (6)

–UN–14AUG96
YZ417
YZ03225,0000041 –19–01OCT04–3/5

IMPORTANT: Wear proper eye protection when


installing retaining rings.

7. Put Snap Ring Retainer (B) and Retaining Ring (C) on


shaft.

8. Compress clutch return springs using JDG1103 Clutch

–UN–19APR97
Pack Spring Compressor.

B—Snap Ring Retainer


YZ418
C—Retaining Ring

Continued on next page YZ03225,0000041 –19–01OCT04–4/5

CTM308 (15FEB05) 02-043-32 DF180 Series Powershift Transmission


021505
PN=248
Gears, Bearings, and Shafts

CAUTION: Wear proper eye protection when


installing retaining rings.

9. Install Retaining Ring (C) in groove.


02
10. Release pressure on clutch return springs slowly. Be 043
33
sure snap ring retainer is properly positioned.

–UN–19APR97
C—Retaining Ring

YZ410A
YZ03225,0000041 –19–01OCT04–5/5

Assemble Clutch Pack - Direct Drive

IMPORTANT: For direction clutch packs (second and


third stage), install two Clutch
Separator Plates (A) first. For speed
clutch packs (fourth and fifth stage),
install one Clutch Separator Plate (A).

NOTE: Clutch Separator Plates (A) are steel with external


spline teeth. Clutch plates have a lining material
on the face and internal spline teeth.

1. Install two Clutch Separator Plates (A) on directional


clutch pack assemblies (second and third stage). Install

–UN–05APR01
one Clutch Separator Plate (A) on speed clutch pack
assemblies (fourth and fifth stage).

YZ4182
A—Clutch Separator Plates

Continued on next page YZ03225,0000040 –19–01OCT04–1/6

CTM308 (15FEB05) 02-043-33 DF180 Series Powershift Transmission


021505
PN=249
Gears, Bearings, and Shafts

2. Install one Clutch Plate (B).

B—Clutch Plate

02
043
34

–UN–05APR01
YZ4183
YZ03225,0000040 –19–01OCT04–2/6

3. Install remaining plates alternately and end with clutch


plate.

NOTE: Last plate is always a clutch plate.

C—Clutch Separator Plate

–UN–05APR01
YZ4186

Continued on next page YZ03225,0000040 –19–01OCT04–3/6

CTM308 (15FEB05) 02-043-34 DF180 Series Powershift Transmission


021505
PN=250
Gears, Bearings, and Shafts

4. Install Clutch Plate Retainer (A).

CAUTION: Wear proper eye protection when


installing snap ring (high tension snap ring).
02
5. Install Retaining Ring (B). 043
35

A—Clutch Plate Retainer


B—Retaining Ring

–UN–25JUN04
YZ4181A
Continued on next page YZ03225,0000040 –19–01OCT04–4/6

CTM308 (15FEB05) 02-043-35 DF180 Series Powershift Transmission


021505
PN=251
Gears, Bearings, and Shafts

6. Procedure For Checking Clutch Plate Clearance At


Full Piston Travel.

IMPORTANT: Make sure Clutch Retainer (F) is in


place and the Retaining Ring (E) is
02
043 seated.
36
Check that clutch and separator plates
do not bind. If clutch and separator
plates bind either during installation or
during actuation they must be replaced.

–UN–29SEP04
Plates can not bind at all for correct
clutch operation.

Check clutch plates for clearance to

YZ6030
allow for piston travel after assembly.

Replace clutch plates as necessary to


A—Air Nozzle
obtain proper clearance.
B—Dial Indicator
C—Bottom Clutch Oil Pressure Passage
Clutch Stage Assembly — Direct Drive Transmission—Specification D—Top Clutch Oil Pressure Passage
Clutch Plate (Second and Third E—Retaining Ring
Stage Clutch Assemblies)— F—Clutch Retainer
Clearance ......................................................................... 2.31—4.47 mm
(0.091—0.176 in.)
Clutch Plate (Fourth and Fifth
Stage Clutch Assemblies)—
Clearance ......................................................................... 2.79—5.59 mm
(0.110—0.220 in.)

CAUTION: Prevent possible injury from


unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
piston or flying debris. Wear personal
protection equipment, including eye protection.
Use only regulated compressed air.

a. Position stem of a long-stem Dial Indicator (B)


against one tooth of top clutch plate, in axial
direction of shaft.

b. Zero Dial Indicator (B).

Continued on next page YZ03225,0000040 –19–01OCT04–5/6

CTM308 (15FEB05) 02-043-36 DF180 Series Powershift Transmission


021505
PN=252
Gears, Bearings, and Shafts

IMPORTANT: There are two cross-drilled holes in the


seal ring end of the shaft. The hole
located between the first and second
Seal Ring Groove (C) applies to the
bottom clutch pack and the hole located
02
between the second and third Seal Ring 043
Groove (D) applies to the top clutch 37
pack. In case the wrong hole is
pressurized, make sure that the other
clutch on the shaft is either completely
built with Clutch Plate Retainer (F) in

–UN–29SEP04
place and Snap Ring (E) seated, or that
there are no parts installed which may
be expelled by the air pressure.

YZ6030
c.

Apply regulated air pressure with air nozzle (A) to


A—Air Nozzle
piston, maximum of 620.5 kPa (6.21 bar) (90 psi) to
B—Dial Indicator
appropriate hole (C or D), depending on which C—Bottom Clutch Oil Pressure Passage
clutch pack you are checking. D—Top Clutch Oil Pressure Passage
E—Retaining Ring
d. Read the Dial Indicator (B). This measurement is F—Clutch Plate Retainer
clutch pack clearance.

IMPORTANT: Clutch plate splines must be


pre-aligned before installing bearings
on the shaft assembly to avoid clutch
plate damage.

7. Use clutch gear without O-ring to align clutch plates


and separator plates.

8. Move clutch gear clockwise, then counterclockwise,


working clutch gear spline through clutch and separator
plates. Remove clutch gear.

YZ03225,0000040 –19–01OCT04–6/6

CTM308 (15FEB05) 02-043-37 DF180 Series Powershift Transmission


021505
PN=253
Gears, Bearings, and Shafts

Assemble Clutch Gear and Bearing - Direct


Drive

IMPORTANT: Seal side of bearing must be toward


02 clutch return springs. Lubricate bearing
043 to prevent dry start up of transmission.
38 Press only on inner race of ball bearing.

1. Install Ball Bearing (A), with seal side down. Install Ball
Bearing (A) until bearing inner race contacts shoulder
of shaft, using JDG1108 Bearing Driver (B).

A—Ball Bearing
B—JDG1108 Bearing Driver

–UN–22SEP04
YZ6023
–UN–22SEP04
YZ6024

Continued on next page YZ03225,000003F –19–01OCT04–1/5

CTM308 (15FEB05) 02-043-38 DF180 Series Powershift Transmission


021505
PN=254
Gears, Bearings, and Shafts

2. On second and third stage clutch assemblies only,


install new O-ring (B) on clutch gear .

B—O-ring
02
043
39

–UN–19APR97
YZ429A
Continued on next page YZ03225,000003F –19–01OCT04–2/5

CTM308 (15FEB05) 02-043-39 DF180 Series Powershift Transmission


021505
PN=255
Gears, Bearings, and Shafts

IMPORTANT: Forcing clutch gear through clutch


plates can damage clutch plates if
plates are not properly aligned. Use
care not to damage O-ring (A).
02
043 3. Move clutch gear clockwise; then counterclockwise,
40 working the clutch gear spline through the clutch and
separator plates.

4. Install clutch gear. O-ring (A) must fit into bore of

–UN–12MAR97
clutch plate retainer.

IMPORTANT: Start Bearing (B) into clutch gear. DO


NOT press Bearing (B) below ring

YZ425
groove in shaft. Pressing Bearing (B) all
the way into the gear will preload the
bearings . Preloading bearings will
shorten the life of the bearings.

5. Put new Bearing (B) onto clutch gear. Start Bearing (B)
into bore only.

A—O-ring
B—Bearing

–UN–20AUG96
YZ432

Continued on next page YZ03225,000003F –19–01OCT04–3/5

CTM308 (15FEB05) 02-043-40 DF180 Series Powershift Transmission


021505
PN=256
Gears, Bearings, and Shafts

6. Install Retaining Ring (A) on shaft assembly.

IMPORTANT: Press only on retaining ring. DO NOT

–UN–02NOV96
preload bearing.
02
7. Using a press and Bearing Driver JDG1108, push 043
slowly on retaining ring until retaining ring snaps into 41

YZ433
groove of shaft assembly.

8. Lubricate and install Ball Bearing (B). Press bearing


onto shaft until bearing contacts retaining ring, using
bearing driver JDG1108.

NOTE: To disassemble bottom half of directional clutch


assemblies following the steps outlined above.

–UN–20AUG96
IMPORTANT: If endplay is not present then bearings
are pre-loaded and clutch will
prematurely fail.

YZ434
9. Clutch gear must turn and have end play. Check for
0.25 mm (0.010 in.) min end play of gear using a dial
indicator.

Transmission Clutch Packs Assemble—Direct Drive Transmission—


Specification
Clutch Gear—End Play ............................................................... 0.25 mm

–UN–02NOV96
(0.010 in.)

10. Assemble opposite end of shaft by repeating steps.

YZ435
A—Retaining Ring
B—Ball Bearing

Continued on next page YZ03225,000003F –19–01OCT04–4/5

CTM308 (15FEB05) 02-043-41 DF180 Series Powershift Transmission


021505
PN=257
Gears, Bearings, and Shafts

IMPORTANT: Always use new seal rings.

NOTE: Clutch shaft seal rings are normally installed after


clutch stacks have been installed into housing.
02
043 NOTE: The seal rings need to rotate freely after
42 installation.

11. Install three Seal Rings (A) into ring grooves.

A—Seal Ring (3 used)

–UN–01SEP04
YZ5459
YZ03225,000003F –19–01OCT04–5/5

Seventh Stage (Output) Shaft - Remote Mount Direct Drive

–UN–31AUG04
YZ5501

Output Shaft Assembly Seventh Stage (Output) Shaft Assembly Remote Mount Direct Drive

A—Bearing Cone (2 Used) B—Output Shaft Assembly

YZ03225,000000F –19–26AUG04–1/1

CTM308 (15FEB05) 02-043-42 DF180 Series Powershift Transmission


021505
PN=258
Gears, Bearings, and Shafts

Seventh Stage (Output) Shaft - Engine Mount Direct Drive

02
043
43

–UN–03DEC04
YZ7053

Seventh Stage (Output) Shaft Assembly Engine Mount Direct Drive

A—Bearing Cone (2 Used) B—Output Shaft Assembly

YZ03225,000000F –19–26AUG04–1/1

CTM308 (15FEB05) 02-043-43 DF180 Series Powershift Transmission


021505
PN=259
Gears, Bearings, and Shafts

Seventh Stage (Output) Shaft Repair - Direct


Drive

CAUTION: When using gear or bearing pullers,


02 puller could slip off.
043
44
1. Use a bearing puller to remove Bearing Cones (A).
Discard bearing cones.

A—Bearing Cone

–UN–12JAN98
YZ1135
Continued on next page YZ03225,0000060 –19–04OCT04–1/2

CTM308 (15FEB05) 02-043-44 DF180 Series Powershift Transmission


021505
PN=260
Gears, Bearings, and Shafts

IMPORTANT: Push on inner race of bearing only.

2. Install new Bearing Cones (D) on both ends of gear


and shaft assembly using a press and Bearing Drivers
(A), (B), and (C). Push bearings tight against shoulder
02
of shaft. 043
45
A—JDG1108 Clutch Bearing Driver
B—JDG1110 Input Shaft Seal Installer Driver
C—JDG1107 Bearing Driver
D—Bearing Cone

–UN–20SEP04
YZ1136A
YZ03225,0000060 –19–04OCT04–2/2

CTM308 (15FEB05) 02-043-45 DF180 Series Powershift Transmission


021505
PN=261
Gears, Bearings, and Shafts

Gear Ratio Group Repair - Remote Mounted


Torque Converter Drive

02 YZ03225,000001B –19–03SEP04–1/1
043
46
Input Shaft Assembly - 6 Forward / 6 Reverse and 6 Forward / 3 Reverse - Remote
Mounted Torque Converter Drive

–UN–31AUG04
YZ5424
Input Shaft Assembly - (6 Forward / 6 Reverse) and (6 Forward / 3 Reverse) - Remote Mount Converter Drive

A—Bearing Cone (2) B—Input Shaft

YZ03225,000000B –19–25AUG04–1/1

CTM308 (15FEB05) 02-043-46 DF180 Series Powershift Transmission


021505
PN=262
Gears, Bearings, and Shafts

Sixth Stage Assembly 6 Forward / 6 Reverse and 6 Forward / 3 Reverse - Remote


Mounted Torque Converter Drive

02
043
47

–UN–22SEP03
YZ5089
Sixth Stage Assembly - (6 Forward / 6 Reverse) and (6 Forward / 3 Reverse) - Remote Mount Converter Drive

A—Bearing Cone (2) B—Sixth Stage Assembly

Sixth Stage Shaft Assembly stage shaft assembly. Refer to Input Shaft (First
Stage) and Sixth Stage (Idler Gear) Repair - Direct
The procedure for assembly and disassembly of the Drive or Input Shaft (First Stage) and Sixth Stage (Idler
sixth stage shaft assembly is the same as for the first Gear) Repair - Torque Converter Drive.

YZ03225,000000D –19–25AUG04–1/1

CTM308 (15FEB05) 02-043-47 DF180 Series Powershift Transmission


021505
PN=263
Gears, Bearings, and Shafts

Input Shaft (First Stage) and Sixth Stage


(Idler Gear) Repair - Torque Converter Drive

CAUTION: When pulling bearing, pullers could


02 slip off.
043
48
1. Remove and discard Bearing Cones (A and B).

A—Bearing Cone
B—Bearing Cone

–UN–28MAR01
YZ4160
–UN–28MAR01
YZ4161
Input Shaft (First Stage) Shown
Continued on next page YZ03225,0000061 –19–04OCT04–1/2

CTM308 (15FEB05) 02-043-48 DF180 Series Powershift Transmission


021505
PN=264
Gears, Bearings, and Shafts

IMPORTANT: Press only on the inner race of bearing


cone. Do not reuse bearing cones if
removed.

NOTE: Gear and shaft assemblies are serviced as an


02
assembly. If either the gear or shaft is damaged 043
or worn, entire assembly must be replaced. 49

2. Use JDG1108 Clutch Bearing Driver (A) and JDG1105


Bearing Replacer (B) to install new Bearing Cones (C)
on both ends of shaft. Push bearings tight against shaft
shoulder.

A—JDG1108 Clutch Bearing Driver


B—JDG1105 Bearing Replacer
C—Bearing Cone

–UN–20SEP04
YZ1134A
YZ03225,0000061 –19–04OCT04–2/2

CTM308 (15FEB05) 02-043-49 DF180 Series Powershift Transmission


021505
PN=265
Gears, Bearings, and Shafts

Second Stage (High / Low Forward) Clutch Assembly Cross-Section - Remote Mounted
Torque Converter Drive

02
043
50

–UN–13DEC04
YZ7066

Second Stage (High / Forward Clutch) - Cross-Section - (6 Forward / 6 Reverse) and (6 Forward / 3 Reverse)

A—Seal Ring (3 used) G—Clutch Separator Plate (20 M—Internal Snap Ring (2 S—Clutch Return Spring (12
B—Ball Bearing (2 used) used) used) used)
C—Ball Bearing (2 used) H—Piston Outer Seal (2 used) N—Retaining Ring (2 used) T—Lube Shut-Off Washer (2
D—Ball Bearing with Seal (2 J—Second Stage Shaft P—Gear & Hub used)
used) K—Clutch Piston (2 used) Q—Retaining Ring (2 used) U—O-ring (2 used)
E—O-ring (2 used) L—Clutch Plate Retainer (2 R—Snap Ring Retainer (2 V—Gear & Hub
F—Clutch Plate (18 used) used) used)

YZ03225,00000DC –19–13DEC04–1/1

CTM308 (15FEB05) 02-043-50 DF180 Series Powershift Transmission


021505
PN=266
Gears, Bearings, and Shafts

Second Stage (High / Low Forward) Clutch Assembly Exploded View - Remote Mounted
Torque Converter Drive

02
043
51

–UN–26MAR01
YZ4152
Second Stage (High / Low Forward Clutch) - Exploded View - (6 Forward / 6 Reverse) and (6 Forward / 3 Reverse)

A—Seal Ring (3 used) H—Internal Snap Ring (2 used) M—Snap Ring Retainer (2 P—O-ring (2 used)
B—Ball Bearing (2 used) I—Clutch Plate Retainer (2 used) Q—Clutch Piston (2 used)
C—Retaining Ring (2 used) used) N—Clutch Return Spring (12 R—Piston Outer Seal (2 used)
D—Ball Bearing (2 used) J—Clutch Plate (18 used) used) S—Second Stage Shaft
E—Gear & Hub K—Clutch Separator Plate (20 O—Lube Shut-Off Washer (2 Assembly
F—O-ring (2 used) used) used) T—Gear & Hub
G—Ball Bearing with Seal (2 L—Retaining Ring (2 used)
used)

YZ03225,0000062 –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-51 DF180 Series Powershift Transmission


021505
PN=267
Gears, Bearings, and Shafts

Third Stage (High / Low Reverse) Clutch Assembly Cross-Section - Remote Mount Torque
Converter Drive

02
043
52

–UN–14DEC04
YZ7071

Third Stage (High / Low Reverse Clutch) - Cross-Section – (6 Forward / 6 Reverse)

A—Seal Ring (3 used) F—Clutch Return Spring (12 K—Third Stage Shaft R—Clutch Separator Plate (20
B—Ball Bearing (2 used) used) Assembly used)
C—Ball Bearing with Seal (2 G—Internal Snap Ring (2 used) L—O-ring (2 used) S—Clutch Plate (18 used)
used) H—Clutch Plate Retainer (2 M—Retaining Ring (2 used) T—Piston Outer Seal (2 used)
D—Snap Ring Retainer (2 used) N—Gear & Hub U—Clutch Piston (2 used)
used) J—Lube Shut-Off Washer (2 P—Ball Bearing (2 used) V—Gear & Hub
E—O-ring (2 used) used) Q—Retaining Ring (2 used)

YZ03225,0000063 –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-52 DF180 Series Powershift Transmission


021505
PN=268
Gears, Bearings, and Shafts

Third Stage (High / Low Reverse) Clutch Assembly Exploded View - Remote Mount
Torque Converter Drive

02
043
53

–UN–26MAR01
YZ4153
Third Stage (High / Low Reverse Clutch) - Exploded View –(6 Forward / 6 Reverse)

A—Seal Ring (3 used) H—Internal Snap Ring (2 used) L—Retaining Ring (2 used) P—O-ring (2 used)
B—Ball Bearing (2 used) I—Clutch Plate Retainer (2 M—Snap Ring Retainer (2 Q—Clutch Piston (2 used)
C—Retaining Ring (2 used) used) used) R—Piston Outer Seal (2 used)
D—Bearing (2 used) J—Clutch Plate (18 used) N—Clutch Return Spring (12 S—Third Stage Shaft
E—Gear K—Clutch Separator Plate (20 used) T—Gear
F—O-ring (2 used) used) O—Lube Shut-Off Washer (2
G—Bearing with Seal (2 used) used)

YZ03225,0000063 –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-53 DF180 Series Powershift Transmission


021505
PN=269
Gears, Bearings, and Shafts

Third Stage (Low Reverse) Clutch Assembly Cross-Section - Remote Mount Torque
Converter Drive

02
043
54

–UN–13DEC04
YZ7067

Third Stage (High / Low Reverse Clutch) - Cross-Section – (6 Forward / 3 Reverse)

A—Seal Rings (2 used) G—Retaining Ring M—Ball Bearing S—Clutch Return Springs (6
B—Ball Bearing (2 used) H—O-ring N—Snap Ring Retainer used)
C—3rd Stage Shaft Assembly J—Gear & Hub P—Internal Snap Ring T—Clutch Piston
D—O-ring K—Ball Bearing Q—Clutch Plate Retainer U—Piston Outer Seal
E—Lube Shutoff Washer L— Retaining Ring R—Clutch Plates (9 used)
F—Clutch Separator Plates (10
used)

YZ03225,00000DD –19–13DEC04–1/1

CTM308 (15FEB05) 02-043-54 DF180 Series Powershift Transmission


021505
PN=270
Gears, Bearings, and Shafts

Third Stage (Low Reverse) Clutch Assembly Exploded View - Remote Mounted Torque
Converter Drive

02
043
55

–UN–14DEC04
YZ7070

Third Stage (Low Reverse Clutch) - Exploded View – (6 Forward / 3 Reverse)

A—Clutch Plates (9 used) F—O-ring L—Retaining Ring Q—O-ring


B—Clutch Separator Plates (10 G—Gear & Hub M—Snap Ring Retainer R—Clutch Piston
used) H—Ball Bearing N—Clutch Return Springs (6 S—Piston Outer Seal
C—Clutch Plate Retainer J—Retaining Ring used) T—3rd Stage Shaft Assembly
D—Internal Snap Ring K—Ball Bearing (2 used) P—Lube Shutoff Washer U—Seal Rings (2 used)
E—Ball Bearing

YZ03225,000001F –19–20SEP04–1/1

CTM308 (15FEB05) 02-043-55 DF180 Series Powershift Transmission


021505
PN=271
Gears, Bearings, and Shafts

Fourth Stage (First / Second Speed) Clutch Assembly Cross-Section - Remote Mounted
Torque Converter Drive

02
043
56

–UN–13DEC04
YZ7068

Fourth Stage (First / Second Speed Clutch) - Cross-Section - ( 6 Forward / 6 Reverse) and (6 Forward / 3 Reverse)

A—Ball Bearing (2 used) F—Clutch Separator Plate (20 K—O-ring (2 used) Q—Internal Snap Ring (2 used)
B—Retaining Ring (2 used) used) L—Ball Bearing (2 used) R—Clutch Return Spring (12
C—Gear & Hub G—Clutch Plate (20 used) M—Gear & Hub used)
D—Ball Bearing (2 used) H—Lube Shut-Off Washer (2 N—Retaining Ring (2 used) S—Piston Outer Seal (2 used)
E—Snap Ring Retainer (2 used) P—Clutch Plate Retainer (2 T—Clutch Piston (2 used)
used) J—Fourth Stage Shaft used) U—Seal Ring (3 used)

YZ03225,00000DE –19–13DEC04–1/1

CTM308 (15FEB05) 02-043-56 DF180 Series Powershift Transmission


021505
PN=272
Gears, Bearings, and Shafts

Fourth Stage (First / Second Speed) Clutch Assembly Exploded View - Remote Mounted
Torque Converter Drive

02
043
57

–UN–26MAR01
YZ4154
Fourth Stage (First / Second Speed Clutch) - Exploded View - (6 Forward / 6 Reverse) and (6 Forward / 3 Reverse)

A—Seal Ring (3 used) G—Internal Snap Ring (2 used) K—Retaining Ring (2 used) O—O-ring (2 used)
B—Ball Bearing (2 used) H—Clutch Plate Retainer (2 L—Snap Ring Retainer (2 P—Clutch Piston (2 used)
C—Retaining Ring (2 used) used) used) Q—Piston Outer Seal (2 used)
D—Ball Bearing (2 used) I—Clutch Plate (20 used) M—Clutch Return Spring (12 R—Fourth Stage Shaft
E—Clutch Gear J—Clutch Separator Plate (20 used) S—Clutch Gear
F—Ball Bearing (2 used) used) N—Lube Shut-Off Washer (2
used)

YZ03225,0000064 –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-57 DF180 Series Powershift Transmission


021505
PN=273
Gears, Bearings, and Shafts

Fifth Stage (Third Speed) Clutch Assembly Cross-Section - Remote Mounted Torque
Converter Drive

02
043
58

–UN–13DEC04
YZ7069

Fifth Stage (Third Speed Clutch) - Cross-Section - (6 Forward / 6 Reverse) and (6 Forward / 3 Reverse)

A—Seal Ring (2 used) G—Lube Shut-Off Washer M—Clutch Piston R—Retaining Ring
B—Ball Bearing (2 used) H—O-ring N—Clutch Plate (10 used) S—Gear & Hub
C—Ball Bearing J—Fifth Stage Shaft Assembly P—Clutch Separator Plate (10 T—Ball Bearing
D—Snap Ring Retainer K—Retaining Ring used) U—Retaining Ring
E—Internal Snap Ring L—Piston Outer Seal Q—Clutch Plate Retainer
F—Clutch Return Spring (6
used)

YZ03225,00000DF –19–13DEC04–1/1

CTM308 (15FEB05) 02-043-58 DF180 Series Powershift Transmission


021505
PN=274
Gears, Bearings, and Shafts

Fifth Stage (Third Speed) Clutch Assembly Exploded View - Remote Mounted Torque
Converter Drive

02
043
59

–UN–24MAR01
YZ4151
Fifth Stage (Third Speed Clutch) - Exploded View - (6 Forward / 6 Reverse) and (6 Forward / 3 Reverse)

A—Seal Ring (2 used) G—Internal Snap Ring K—Retaining Ring O—O-ring


B—Ball Bearing (2 used) H—Clutch Plate Retainer L—Snap Ring Retainer P—Clutch Piston
C—Retaining Ring I—Clutch Plate (10 used) M—Clutch Return Spring (6 Q—Piston Outer Seal
D—Ball Bearing J—Clutch Separator Plate (10 used) R—Fifth Stage Shaft Assembly
E—Gear & Hub used) N—Lube Shut-Off Washer S—Retaining Ring
F—Ball Bearing

YZ03225,0000065 –19–04OCT04–1/1

CTM308 (15FEB05) 02-043-59 DF180 Series Powershift Transmission


021505
PN=275
Gears, Bearings, and Shafts

Disassemble and Assemble Clutch - Remote


Mount Torque Converter Drive

CAUTION: Heavy component; use a hoist.


02
043
Third stage weight specified is for 6 Forward / 6
60
Reverse torque converter transmission. Third
stage clutch pack weight on 6 Forward / 3
Reverse should be about half of weight
specified.

Transmission Clutch Packs Disassembly and Assembly—Torque


Converter Drive Transmission. —Specification
Second Stage—Weight ............................................ approximate 46.7 kg
(103.0 lb)
Third Stage—Weight ................................................ approximate 45.4 kg
(100.0 lb)
Fourth Stage—Weight .............................................. approximate 34.9 kg
(77.0 lb)
Fifth Stage—Weight ................................................. approximate 26.3 kg
(58.0 lb)

IMPORTANT: DO NOT mix components of individual


shaft assemblies. Keep all clutch pack
components together as a set.

1. Use JDG1106 Clutch Lifting tool to lift clutch.

–UN–25JUN04
YZ5208
Direct Drive 8F/8R Second Stage Clutch Assembly Shown

Continued on next page YZ03225,0000066 –19–04OCT04–1/2

CTM308 (15FEB05) 02-043-60 DF180 Series Powershift Transmission


021505
PN=276
Gears, Bearings, and Shafts

NOTE: The disassembly and assembly of clutch packs


are similar; therefore, procedures for
disassembling and assembling clutch packs are
outlined one time. Follow these procedures when
02
disassembling and assembling both direction and 043
speed clutch packs. Second stage clutch packs 61
are shown, unless otherwise indicated.

Fifth stage clutch pack assembly has 2 seal rings


instead of 3 and one clutch pack (D or Third
Speed Clutch Pack). Refer to Fifth Stage (Second
/ Fourth Speed) Clutch Assembly Exploded
View — Remote Mount Direct Drive drawing to
disassemble and/or Fifth Stage (Second / Fourth
Speed) Clutch Assembly Exploded View —
Engine Mount Direct Drive.

Third stage clutch pack assembly on 6 Forward /


3 Reverse Torque Converter Drive Transmission
models have 2 seal rings and one clutch pack
(Low Reverse). Refer to Third Stage (Low
Reverse) Clutch Assembly Exploded View —
Remote Mounted Torque Converter Drive drawing
to disassemble.

YZ03225,0000066 –19–04OCT04–2/2

Disassemble Clutch Gear and Bearing -


Remote Mount Torque Converter Drive

1. Remove Seal Rings (A), (B), and (C). Inspect and


discard.

NOTE: Fifth Stage Clutch Pack Assembly on 6 Forward /


6 Reverse and 6 Forward / 3 Reverse models
have 2 Seal Rings (B) and (C). Third stage Clutch
Pack Assembly on the 6 Forward / 3 Reverse
–UN–22SEP04

torque converter drive transmission also has 2


Seal Rings (A) and (B).
YZ6021

A—Seal Ring
B—Seal Ring
C—Seal Ring

Continued on next page YZ03225,000003E –19–01OCT04–1/8

CTM308 (15FEB05) 02-043-61 DF180 Series Powershift Transmission


021505
PN=277
Gears, Bearings, and Shafts

CAUTION: When pulling bearing, puller could


slip off.

2. Install Bearing Puller (B).


02
043 3. Install Gear Puller (A) on Bearing Puller (A).
62

4. Remove Ball Bearing (C). Inspect and discard.

–UN–28MAR01
CAUTION: Wear proper eye protection when
installing or removing retaining rings.

5. Remove Retaining Ring (D). Inspect and discard.

YZ4163
A—Gear Puller
B—Bearing Puller
C—Ball Bearing
D—Retaining Ring

–UN–28MAR01
YZ4166

Continued on next page YZ03225,000003E –19–01OCT04–2/8

CTM308 (15FEB05) 02-043-62 DF180 Series Powershift Transmission


021505
PN=278
Gears, Bearings, and Shafts

6. Install gear puller.

7. Remove Clutch Gear (A).

A—Clutch Gear 02
043
63

–UN–28MAR01
YZ4168
YZ03225,000003E –19–01OCT04–3/8

8. Remove Ball Bearing (A). Inspect and discard.

A—Ball Bearing

–UN–28MAR01
YZ4169

Continued on next page YZ03225,000003E –19–01OCT04–4/8

CTM308 (15FEB05) 02-043-63 DF180 Series Powershift Transmission


021505
PN=279
Gears, Bearings, and Shafts

9. On directional clutch pack assemblies only (second


and third stage), remove O-ring (A) and discard.

10. Inspect gear assembly for wear or damage.


02
043 A—O-ring
64

–UN–28MAR01
YZ4170
YZ03225,000003E –19–01OCT04–5/8

CAUTION: Wear proper eye protection when


removing snap ring (high tension snap ring).

11. Remove Snap Ring (B).

B—Snap Ring

–UN–25MAR97
YZ407

Continued on next page YZ03225,000003E –19–01OCT04–6/8

CTM308 (15FEB05) 02-043-64 DF180 Series Powershift Transmission


021505
PN=280
Gears, Bearings, and Shafts

12. Turn shaft assembly over.

13. Remove Clutch Plate Retainer (C).

14. Remove Clutch Plates (B) and Separator Plates (A).


02
043
15. Discard Clutch Plates (B). 65

16. Inspect Clutch Plate Retainer (C) and Separator


Plates (A) for wear, damage, or heat damage.

A—Separator Plate
B—Clutch Plate
C—Clutch Plate Retainer

–UN–09SEP04
YZ5630A
YZ03225,000003E –19–01OCT04–7/8

CAUTION: When pulling bearing, puller could


slip off.

17. Install bearing puller.

18. Remove Bearing (A). Inspect and discard.

A—Bearing

–UN–19APR97
YZ406

YZ03225,000003E –19–01OCT04–8/8

CTM308 (15FEB05) 02-043-65 DF180 Series Powershift Transmission


021505
PN=281
Gears, Bearings, and Shafts

Disassemble Clutch Piston and Spring -


Remote Mount Torque Converter Drive

CAUTION: Clutch piston return springs are


02 under pressure.
043
66
1. Place shaft assembly on press.

2. Use JDG1103 Clutch Pack Spring Compressor (A) to


compress clutch return springs.

3. Remove Retaining Ring (B) from shaft groove.

4. Relieve pressure on JDG1103 Clutch Pack Spring


Compressor tool.

–UN–29APR97
A—JDG1103 Clutch Pack Spring Compressor
B—Retaining Ring

YZ410
YZ03225,000003D –19–01OCT04–1/5

5. Lift out Retaining Ring (A), Snap Ring Retainer (B) and
Clutch Return Springs (C).

6. Inspect Retaining Ring (A), Snap Ring Retainer (B)


and Clutch Return Springs (C) for wear and damage.

–UN–21AUG96
A—Retaining Ring
B—Snap Ring Retainer
C—Clutch Return Springs (6)

YZ463

YZ03225,000003D –19–01OCT04–2/5

7. Remove Lube Shutoff Washer (D).

D—Lube Shutoff Washer


–UN–21AUG96
YZ464

Continued on next page YZ03225,000003D –19–01OCT04–3/5

CTM308 (15FEB05) 02-043-66 DF180 Series Powershift Transmission


021505
PN=282
Gears, Bearings, and Shafts

CAUTION: Prevent possible injury from


unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
piston or flying debris. Wear personal 02
protection equipment, including eye protection. 043
67
Use only regulated, compressed air of 68.9 kPa
(0.69 bar) (10 psi) maximum to remove piston.

–UN–20AUG96
8. Remove piston. If needed apply 68.9 kPa (0.69 bar)
(10 psi) maximum, regulated air pressure through oil
passage to force clutch piston from shaft assembly.

YZ414
Clutch Piston—Specification
Maximum Regulated Air—
Pressure ...................................................................................... 68.9 kPa
(0.69 bar)
(10.0 psi)

YZ03225,000003D –19–01OCT04–4/5

9. Remove Clutch Piston (A).

10. Remove Piston Outer Seal (B) and O-ring (C) from
Clutch Piston (A). Inspect and discard.

11. Inspect Clutch Piston (A) for wear or damage.

12. For complete disassembly of this shaft, repeat


disassembly steps for clutch pack assembly on
opposite end of this shaft.

–UN–20AUG96
A—Clutch Piston
B—Piston Outer Seal
YZ415

C—O-ring

YZ03225,000003D –19–01OCT04–5/5

CTM308 (15FEB05) 02-043-67 DF180 Series Powershift Transmission


021505
PN=283
Gears, Bearings, and Shafts

Assemble Clutch Piston and Spring - Remote


Mount Torque Converter Drive

IMPORTANT: DO NOT mix components of individual


02 shaft assemblies. Keep all clutch pack
043 components together as a set.
68
Inspect clutch piston bore for sharp
edges or wear. Use care not to damage
seals on pistons during installation.

–UN–20AUG96
NOTE: Fifth stage clutch pack assembly has 2 seal rings
instead of 3 and one clutch pack (D or Third
Speed Clutch Pack). Refer to Fifth Stage (Third

YZ416
Speed) Clutch Assembly Exploded View —
Remote Mounted Torque Converter Drive drawing
to assemble. A—O-ring
B—Piston Outer Seal
NOTE: Third stage clutch pack assembly on 6F/3R C—Clutch Piston
Torque Converter Drive Transmission models has
2 seal rings and one clutch pack (Low Reverse).
Refer to Third Stage (Low Reverse) Clutch
Assembly Exploded View — Remote Mounted
Torque Converter Drive drawing to assemble.

1. Iinstall new O-ring (A).

2. nstall new Piston Outer Seal (B).

3. Lubricate O-ring (A) and Piston Outer Seal (B) with


clean hydraulic Oil..

4. Install Clutch Piston (C) with raised center boss up.

YZ03225,000003B –19–01OCT04–1/5

5. Install Lube Shutoff Washer (D).

D—Lube Shutoff Washer


–UN–21AUG96
YZ413

Continued on next page YZ03225,000003B –19–01OCT04–2/5

CTM308 (15FEB05) 02-043-68 DF180 Series Powershift Transmission


021505
PN=284
Gears, Bearings, and Shafts

IMPORTANT: Install clutch piston return springs as


shown for proper spring force. Also, if a
new spring is required in a clutch pack,

–UN–20MAR97
then all six springs for that clutch pack
will have to be replaced.
02
043
6. Install Clutch Return Springs (A) as three pairs with 69

YZ853
outer diameters contacting for each pair.

A—Clutch Return Springs (6)

–UN–14AUG96
YZ417
YZ03225,000003B –19–01OCT04–3/5

IMPORTANT: Wear proper eye protection when


installing retaining rings.

7. Put Snap Ring Retainer (B) and Retaining Ring (C) on


shaft.

8. Compress clutch return springs using JDG1103 Clutch

–UN–19APR97
Pack Spring Compressor (A).

A— JDG1103 Clutch Pack Spring Compressor

YZ418
B—Snap Ring Retainer
C—Retaining Ring

Continued on next page YZ03225,000003B –19–01OCT04–4/5

CTM308 (15FEB05) 02-043-69 DF180 Series Powershift Transmission


021505
PN=285
Gears, Bearings, and Shafts

CAUTION: Wear proper eye protection when


installing retaining rings.

9. Install Retaining Ring (C) in groove.


02
043 10. Release pressure on clutch return springs slowly. Be
70
sure snap ring retainer is properly positioned.

–UN–19APR97
C—Retaining Ring

YZ410A
YZ03225,000003B –19–01OCT04–5/5

Assemble Clutch Pack - Remote Mount


Torque Converter Drive

IMPORTANT: For direction clutch (second and third


stage) ONLY, install two clutch
separator plates first.

NOTE: Clutch separator plates are steel with external


spline teeth. Clutch plates have a lining material
on the face and internal spline teeth.

1. On direction clutch pack (second and third stage)


assemblies, first install two Clutch Separator Plates
(A). On speed clutch pack (fourth and fifth stage)

–UN–05APR01
assemblies, first install one Clutch Separator Plate (A).

A—Clutch Separator Plates


YZ4182

Continued on next page YZ03225,000003A –19–01OCT04–1/6

CTM308 (15FEB05) 02-043-70 DF180 Series Powershift Transmission


021505
PN=286
Gears, Bearings, and Shafts

2. Install one Clutch Plate (B).

B—Clutch Plate

02
043
71

–UN–05APR01
YZ4183
YZ03225,000003A –19–01OCT04–2/6

3. Install remaining plates alternately and end with clutch


plate.

NOTE: Last plate is always a clutch plate.

C—Clutch Separator Plate

–UN–05APR01
YZ4186

Continued on next page YZ03225,000003A –19–01OCT04–3/6

CTM308 (15FEB05) 02-043-71 DF180 Series Powershift Transmission


021505
PN=287
Gears, Bearings, and Shafts

4. Install Clutch Plate Retainer (A).

CAUTION: Wear proper eye protection when


installing snap ring (high tension snap ring).
02
043 5. Install Retaining Ring (B).
72

A—Clutch Plate Retainer


B—Retaining Ring

–UN–25JUN04
YZ4181A
Continued on next page YZ03225,000003A –19–01OCT04–4/6

CTM308 (15FEB05) 02-043-72 DF180 Series Powershift Transmission


021505
PN=288
Gears, Bearings, and Shafts

6. Procedure For Checking Clutch Plate Clearance At


Full Piston Travel.

IMPORTANT: Make sure Clutch Plate Retainer (F) is in


place and the Retaining Ring (E) is
02
seated. 043
73
Check that clutch and separator plates
do not bind. If clutch and separator
plates bind either during installation or
during actuation they must be replaced.

–UN–29SEP04
Plates cannot bind at all for correct
clutch operation.

Check clutch plates for clearance to

YZ6030
allow for piston travel after assembly.

Replace clutch plates as necessary to


A—Air Nozzle
obtain proper clearance.
B—Dial Indicator
C—Clutch Oil Pressure Passage
Clutch Stage Assemblies —Direct Drive Transmission— D—Clutch Oil Pressure Passage
Specification E—Retaining Ring
Clutch Plate (Second and Third F—Clutch Plate Retainer
Stage Clutch Assemblies)—
Clearance ......................................................................... 2.31—4.47 mm
(0.091—0.176 in.)
Clutch Plate (Fourth and Fifth
Stage Clutch Assemblies)—
Clearance ......................................................................... 2.79—5.59 mm
(0.110—0.220 in.)

CAUTION: Prevent possible injury from


unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
piston or flying debris. Wear personal
protection equipment, including eye protection.
Use only regulated compressed air.

a. Position stem of a long-stem Dial Indicator (B)


against one tooth of top clutch plate, in axial
direction of shaft.

b. Zero Dial Indicator (B).

Continued on next page YZ03225,000003A –19–01OCT04–5/6

CTM308 (15FEB05) 02-043-73 DF180 Series Powershift Transmission


021505
PN=289
Gears, Bearings, and Shafts

IMPORTANT: There are two cross-drilled holes in the


seal ring end of the shaft. The hole
located between the first and second
Seal Ring Groove (C) applies to the
bottom clutch pack and the hole located
02
043 between the second and third Seal Ring
74 Groove (D) applies to the top clutch
pack. In case the wrong hole is
pressurized, make sure that the other
clutch on the shaft is either completely
built with Clutch Plate Retainer (F) in

–UN–29SEP04
place and Retaining Ring (E) seated, or
that there are no parts installed which
may be expelled by the air pressure.

YZ6030
c. Apply regulated air pressure to piston, maximum of
620.5 kPa (6.21 bar) (90 psi) to appropriate hole (C
or D), depending on which clutch pack you are
A—Air Nozzle
checking.
B—Dial Indicator
C—Bottom Clutch Oil Pressure Passage
d. Read the Dial Indicator (B). This measurement is D—Top Clutch Oil Pressure Passage
clutch pack clearance. E—Retaining Ring
F—Clutch Plate Retainer
IMPORTANT: Clutch plate splines must be aligned
before installing bearings on the shaft
assembly to avoid clutch plate damage.

7. Use clutch gear without O-ring to align clutch plates


and separator plates.

8. Move clutch gear clockwise, then counterclockwise,


working clutch gear spline through clutch and separator
plates. Remove clutch gear.

YZ03225,000003A –19–01OCT04–6/6

CTM308 (15FEB05) 02-043-74 DF180 Series Powershift Transmission


021505
PN=290
Gears, Bearings, and Shafts

Assemble Clutch Gear and Bearing - Remote


Mount Torque Converter Drive

IMPORTANT: Seal side of bearing must be toward


clutch return springs. Lubricate bearing 02
to prevent dry start-up of transmission. 043
Press only on inner race of ball bearing. 75

1. Install Ball Bearing (A), with seal side down. Install


bearing until bearing inner race contacts shoulder of
shaft. using JDG1108 Bearing Driver (B).

A—Ball Bearing
B—JDG1108 Bearing Driver

–UN–22SEP04
YZ6023
–UN–22SEP04
YZ6024

Continued on next page YZ03225,0000039 –19–01OCT04–1/7

CTM308 (15FEB05) 02-043-75 DF180 Series Powershift Transmission


021505
PN=291
Gears, Bearings, and Shafts

2. Install new O-ring (A). On second and third stage


clutch assemblies only.

A—O-ring
02
043
76

–UN–28MAR01
YZ4170
YZ03225,0000039 –19–01OCT04–2/7

IMPORTANT: Forcing clutch gear through clutch


plates can damage clutch plates if
plates are not properly aligned. Use
care not to damage O-ring (B).

3. Install clutch gear (A). O-ring (B) must fit into bore of
clutch plate retainer (C).

A—Clutch Gear
B—O-ring
C—Clutch Plate Retainer –UN–29MAR01
YZ4171

Continued on next page YZ03225,0000039 –19–01OCT04–3/7

CTM308 (15FEB05) 02-043-76 DF180 Series Powershift Transmission


021505
PN=292
Gears, Bearings, and Shafts

IMPORTANT: Start Bearing (D) into clutch gear. DO


NOT press bearing below ring groove in
shaft. Pressing Bearing (D) all the way
into the gear will preload the bearings.
Pre-loading bearings will shorten the
02
life of the bearings. 043
77
4. Put new Bearing (D) onto clutch shaft. Only start new
bearing into gear bore, do not install all the way.

5. Install Retaining Ring (E) on shaft assembly.

IMPORTANT: Press only on retaining ring. DO NOT


preload bearing. If endplay is not
present then bearings are pre-loaded

–UN–29MAR01
and clutch will prematurely fail.

6. Using a press and JDG1108 Bearing Driver (F), push


slowly on retaining ring until retaining ring snaps into

YZ4172
groove of shaft assembly.

Clutch gear must turn and have end play. Check for
0.25 mm (0.010 in.) min. end play of gear using a dial
indicator.

Clutch Pack Assemble — Torque Converter Drive Transmission—


Specification
Clutch Gear—End Play ............................................................... 0.25 mm
(0.010 in.)

D—Bearing
E—Retaining Ring
F—JDG1108 Bearing Driver

–UN–29MAR01
YZ4173

Continued on next page YZ03225,0000039 –19–01OCT04–4/7

CTM308 (15FEB05) 02-043-77 DF180 Series Powershift Transmission


021505
PN=293
Gears, Bearings, and Shafts

7. Lubricate and install Ball Bearing (G).

8. Press Ball Bearing (G) onto shaft until Ball Bearing (G)
contacts retaining ring, using JDG1108 Bearing Driver.
02
043 IMPORTANT: If endplay is not present then bearings
78 are pre-loaded and clutch will
prematurely fail.

9. Clutch gear must turn and have end play. Check for
0.25 mm (0.010 in.) min. end play of gear using a dial
indicator.

Clutch Pack Assemble —Torque Converter Drive Transmission—


Specification
Clutch Gear—End Play ............................................................... 0.25 mm
(0.010 in.)

10. Assemble opposite end of shaft by repeating these


assembly steps.

–UN–29MAR01
G—Ball Bearing

YZ4174
YZ03225,0000039 –19–01OCT04–5/7

IMPORTANT: Always use new seal rings.

NOTE: Clutch shaft Seal Rings (A) are normally installed


after clutch stacks have been installed into
housing.

11. Lubricate and install three Seal Rings (A) into ring
grooves.

–UN–28MAR01
A—Seal Rings (3 used)
YZ4167

Continued on next page YZ03225,0000039 –19–01OCT04–6/7

CTM308 (15FEB05) 02-043-78 DF180 Series Powershift Transmission


021505
PN=294
Gears, Bearings, and Shafts

NOTE: Fifth stage assembly has two Seal Rings (A) in


grooves closest to bearing.

NOTE: Third stage assembly for 6F/3R torque converter


drive transmission has two Seal Rings (A) in
02
grooves closest to end of shaft. 043
79
NOTE: Clutch shaft Seal Rings (A) are normally installed

–UN–28MAR01
after clutch stacks have been installed into
housing.

12. Lubricate and install two Seal Rings (A) into ring

YZ4164
grooves.

Fifth Stage Seal Rings


A—Seal Rings (2 used)

YZ03225,0000039 –19–01OCT04–7/7

Seventh Stage (Output Gear) - Remote Mount Torque Converter Drive

–UN–31AUG04
YZ5425

Seventh Stage (Output) Remote Mount Converter Drive

A—Bearing (2) B—Output Shaft Assembly

YZ03225,0000011 –19–27AUG04–1/1

CTM308 (15FEB05) 02-043-79 DF180 Series Powershift Transmission


021505
PN=295
Gears, Bearings, and Shafts

Seventh Stage (Output Gear) Repair -


Remote Mount Torque Converter Drive

1. Use a bearing puller to remove Bearing Cones (A).


02 Discard bearing cones.
043
80
A—Bearing Cones

–UN–12JAN98
YZ1135
Continued on next page YZ03225,0000067 –19–04OCT04–1/2

CTM308 (15FEB05) 02-043-80 DF180 Series Powershift Transmission


021505
PN=296
Gears, Bearings, and Shafts

IMPORTANT: Push on inner race of bearing only.

2. Install Bearing Cone (D) on both ends of gear and


shaft assembly using a press and Bearing Drivers (A),
(B), and (C) as shown. Push Bearing Cones (D) tight
02
against shoulder of shaft. 043
81
A—JDG1108 Clutch Bearing Driver
B—JDG1110 Input Shaft Seal Driver
C—JDG1107 Bearing Driver
D—Bearing Cone

–UN–20SEP04
YZ1136A
YZ03225,0000067 –19–04OCT04–2/2

CTM308 (15FEB05) 02-043-81 DF180 Series Powershift Transmission


021505
PN=297
Gears, Bearings, and Shafts

02
043
82

CTM308 (15FEB05) 02-043-82 DF180 Series Powershift Transmission


021505
PN=298
Group 045
Drive Plate and Torque Converter Assembly
Remove and Install Torque Converter
Assembly

CAUTION: Heavy component; use a hoist.


02
Torque Converter Housing—Specification 045
Torque Converter and Drive 1
Plate—Weight ........................................................... approximate 31.8 kg
(70.0 lb)

1. Remove torque converter (A).

A—Torque Converter
B—Torque Converter PTO Housing

–UN–10MAR01
YZ4097
YZ03225,0000069 –19–04OCT04–1/4

2. Remove seal ring (A). Inspect and discard.

A—Seal Ring
B—Impeller Hub

–UN–28FEB01
YZ4039

Continued on next page YZ03225,0000069 –19–04OCT04–2/4

CTM308 (15FEB05) 02-045-1 DF180 Series Powershift Transmission


021505
PN=299
Drive Plate and Torque Converter Assembly

IMPORTANT: Seal ring ends must be hooked


together.

3. Install seal ring (A) into groove on impeller hub (B).


Apply petroleum jelly to seal ring (A). Lock ends as
02
045 shown.

–UN–25OCT93
2
A—Seal Ring
B—Impeller Hub

YZ527
–UN–28FEB01
YZ4039
Continued on next page YZ03225,0000069 –19–04OCT04–3/4

CTM308 (15FEB05) 02-045-2 DF180 Series Powershift Transmission


021505
PN=300
Drive Plate and Torque Converter Assembly

CAUTION: Heavy component; use a hoist.

Torque Converter —Specification


Torque Converter and Drive
Plate—Weight ........................................................... approximate 31.8 kg
02
(70.0 lb)
045
3
4. Install torque converter (A) into converter cover (B).

IMPORTANT: Make sure torque converter turns freely


in clockwise rotation.

5. Apply anti-seize lubricant inside diameter of pilot


sleeve (C).

6. Install pilot sleeve (C) on torque converter.

–UN–10MAR01
A—Torque Converter
B—Converter PTO Housing
C—Pilot Sleeve

YZ4097
–UN–10MAR01
YZ4098

YZ03225,0000069 –19–04OCT04–4/4

CTM308 (15FEB05) 02-045-3 DF180 Series Powershift Transmission


021505
PN=301
Drive Plate and Torque Converter Assembly

Remove and Install Torque Converter Drive


Plate

A—Drive Plate Assembly


02 B—Ring
045 C—Cap Screw (12 used)
4

–UN–27FEB01
YZ4011
YZ03225,000006A –19–04OCT04–1/4

CAUTION: Heavy component; use a hoist.

Torque Converter Drive Plate—Specification


Torque Converter and Drive
Plate—Weight ........................................................... approximate 31.8 kg
(70.0 lb)

1. Remove torque converter and place on work surface.

NOTE: Oil cannot be drained completely until converter is


disassembled.

2. Drain oil through impeller hub, check for contaminants.

–UN–28FEB01
Dispose of oil properly.

YZ4004

Continued on next page YZ03225,000006A –19–04OCT04–2/4

CTM308 (15FEB05) 02-045-4 DF180 Series Powershift Transmission


021505
PN=302
Drive Plate and Torque Converter Assembly

3. Remove pilot sleeve (A) and cap screws (B).

4. Remove ring (C) and drive plate (D).

5. Inspect for wear or damage. Look closely at drive plate


02
(D) for signs of fatigue, cracks or elongated bolt holes. 045
5
A—Pilot Sleeve
B—Cap Screws (12 used)

–UN–27FEB01
C—Ring
D—Drive Plate

YZ4012
–UN–27FEB01
YZ4013
Continued on next page YZ03225,000006A –19–04OCT04–3/4

CTM308 (15FEB05) 02-045-5 DF180 Series Powershift Transmission


021505
PN=303
Drive Plate and Torque Converter Assembly

6. Install Drive Plate (A) and Ring (B).

NOTE: Converter threaded holes (12) must be oil free


and cleaned of all excess old Loctite.
02
045 7. Apply high strength thread lock to first three threads of
6 Cap Screws (C).

8. Install and tighten Cap Screws (C). See Torque


Converter Cover, Drive Plate and Impeller Hub

–UN–27FEB01
Tightening Sequence in this group.

Torque Converter Drive Plate—Specification


Drive Plate Ring Cap Screw—

YZ4014
Torque ........................................................................................ 50.2 N•m
(37.0 lb-ft)

9. Apply anti-seize lubricant to inside diameter of Pilot


Sleeve (D).

10. Install Pilot Sleeve (D).

A—Drive Plate
B—Ring
C—Cap Screw (12 used)

–UN–27FEB01
D—Pilot Sleeve

YZ4015
–UN–27FEB01
YZ4016

YZ03225,000006A –19–04OCT04–4/4

CTM308 (15FEB05) 02-045-6 DF180 Series Powershift Transmission


021505
PN=304
Drive Plate and Torque Converter Assembly

Torque Converter Cover, Drive Plate and Impeller Hub Tightening Sequence

02
045
7

–UN–06MAR01
YZ4057
Torque Procedure: Torque four cap screws at zero, 180, 90 and 270
degrees, in order. This pattern is designated in graphic
All torque values listed apply to non-lubricated plain or using numbers 1, 2, 3 and 4.
zinc plated cap screws which include only residual oil
of the manufacturer. Do Not Add additional lubricants Follow by a circular sequence starting at zero degrees,
unless otherwise specified. which is designated as number 5 in graphic. Continue
torquing in a circular pattern, tightening each cap
Preliminary Torque: screw in line back to zero degrees.

If an impact wrench is used, it must be set below the 1. Drive plate: apply high strength thread lock to drive
final torque required. plate cap screws and tighten to specification.

Final Torque: Torque Converter Cover, Drive Plate and Impeller Hub
Tightening Sequence—Specification
Drive Plate Ring Cap Screw—
Values listed must be obtained by a certified torque Torque.................................................................................. 50.2 N•m
wrench. (37.0 lb-ft)

Torque Sequence: 2. Torque converter cover: Tighten and torque cap


screws to specification.
Use this sequence: torque converter cover, drive plate
and impeller hub for preliminary and final torquing.

Continued on next page YZ03225,000006B –19–04OCT04–1/2

CTM308 (15FEB05) 02-045-7 DF180 Series Powershift Transmission


021505
PN=305
Drive Plate and Torque Converter Assembly

Torque Converter Cover, Drive Plate and Impeller Hub 3. Impeller hub: apply high strength thread lock to
Tightening Sequence—Specification impeller hub cap screws and tighten to
Torque Converter
Cover-to-Impeller Cap specification.
Screws—Torque .................................................................. 50.2 N•m
(37.0 lb-ft) Torque Converter Cover, Drive Plate and Impeller Hub
02 Tightening Sequence—Specification
045 Impeller-to-Hub Cap Screws—
8 NOTE: Impeller hub threaded holes must be oil free Torque.................................................................................. 24.4 N•m
and cleaned of all old loctite. Loctite primer is (18.0 lb-ft)
used to aid in setup of loctite.

YZ03225,000006B –19–04OCT04–2/2

CTM308 (15FEB05) 02-045-8 DF180 Series Powershift Transmission


021505
PN=306
Drive Plate and Torque Converter Assembly

Torque Converter Exploded View

02
045
9

–UN–26FEB01
YZ4008
A—Seal Ring H—Needle Thrust Bearing— M—Retainer Ring R—Turbine Hub
B—Impeller Hub Large Roller N—Thrust Washer—Thin S—Bearing
C—O-ring I—Thrust Washer—Thick O—Needle Thrust Bearing— T—O-ring
D—Impeller J—Retainer Ring Small Roller U—Front Cover
E—Flat Washer (12 used) K—Fixed Stator Hub P—Thrust Washer—Thin V—Flat Washers (24 used)
F—Cap Screws (12 used) L—Stator Q—Turbine W—Cap Screws (24 used)
G—Thrust Washer—Thick

YZ03225,00000D3 –19–02DEC04–1/1

CTM308 (15FEB05) 02-045-9 DF180 Series Powershift Transmission


021505
PN=307
Drive Plate and Torque Converter Assembly

Disassemble Torque Converter

1. Remove cap screws (B) and flat washers (A).

2. Thread two cap screws (D) three to four turns into front
02
045 cover to aid front cover removal.
10
3. Attach two JT05549 Lifting Eyebolts (C) to front cover.

IMPORTANT: Tap lightly on cap screws, with a rubber

–UN–27FEB01
mallet, until cover separates from the
impeller. Do not use pry bars to remove
front cover (E), damage to aluminum
impeller casting could result.

YZ4017
4. Lift front cover (E) and lightly tap cap screws (D) to
separate front cover and impeller.
A—Washer (24 used)
B—Cap Screw (24 used)
C—JT05549 Lifting Eyebolt (2 used)
D—Washer and Cap Screw (2 used)
E—Front Cover

–UN–27FEB01
YZ4018
–UN–27FEB01
YZ4019

Continued on next page YZ03225,000006C –19–04OCT04–1/11

CTM308 (15FEB05) 02-045-10 DF180 Series Powershift Transmission


021505
PN=308
Drive Plate and Torque Converter Assembly

5. Remove and discard O-ring (A).

A—O-Ring

02
045
11

–UN–27FEB01
YZ4020
YZ03225,000006C –19–04OCT04–2/11

6. Remove bearing (A). Inspect and discard.

7. Remove turbine hub (B). Inspect for wear or damage.

A—Bearing
B—Turbine Hub

–UN–27FEB01
YZ4021
–UN–27FEB01
YZ4022

Continued on next page YZ03225,000006C –19–04OCT04–3/11

CTM308 (15FEB05) 02-045-11 DF180 Series Powershift Transmission


021505
PN=309
Drive Plate and Torque Converter Assembly

8. Remove turbine (C) and inspect for wear or damage.

C—Turbine

02
045
12

–UN–27FEB01
YZ4023
Continued on next page YZ03225,000006C –19–04OCT04–4/11

CTM308 (15FEB05) 02-045-12 DF180 Series Powershift Transmission


021505
PN=310
Drive Plate and Torque Converter Assembly

9. Remove thrust washers (A) and needle thrust bearing


(B). Inspect and discard.

10. Remove stator assembly (C).


02
A—Thrust Washer—Thin (2 used) 045
B—Needle Thrust Bearing—Small Roller 13
C—Stator Assembly

–UN–27FEB01
YZ4024
–UN–27FEB01
YZ4025
Continued on next page YZ03225,000006C –19–04OCT04–5/11

CTM308 (15FEB05) 02-045-13 DF180 Series Powershift Transmission


021505
PN=311
Drive Plate and Torque Converter Assembly

11. Remove retainer ring (A).

12. Remove fixed stator hub (B).

13. Turn stator (C) over.


02
045
14 14. Remove retainer ring (D).

15. Inspect parts for wear or damage.

A—Retainer Ring

–UN–27FEB01
B—Fixed Stator Hub
C—Stator
D—Retainer Ring

YZ4026
–UN–27FEB01
YZ4027

Continued on next page YZ03225,000006C –19–04OCT04–6/11

CTM308 (15FEB05) 02-045-14 DF180 Series Powershift Transmission


021505
PN=312
Drive Plate and Torque Converter Assembly

IMPORTANT: Do not assemble stator incorrectly. The


torque converter will not work properly
and damage to converter will occur.

NOTE: In assembly process of torque converter the stator


02
“FRONT” and “BACK” sides will be referred to. 045
The stator casting is not marked; it must be 15
identified by characteristics of the cast vanes.

–UN–27FEB01
16. The “FRONT” of stator casting is identified by the
vanes being thicker. The “BACK” of stator casting is
identified by the vanes being thinner.

YZ4028
–UN–27FEB01
YZ4029
Continued on next page YZ03225,000006C –19–04OCT04–7/11

CTM308 (15FEB05) 02-045-15 DF180 Series Powershift Transmission


021505
PN=313
Drive Plate and Torque Converter Assembly

CAUTION: Wear eye protection when installing


or removing retaining rings.

17. Position stator with back side up.


02
045 18. Install retaining ring (A) in groove.
16

A—Retaining Ring

–UN–10MAR98
YZ512
Continued on next page YZ03225,000006C –19–04OCT04–8/11

CTM308 (15FEB05) 02-045-16 DF180 Series Powershift Transmission


021505
PN=314
Drive Plate and Torque Converter Assembly

19. Turn stator over, with thick vanes up.

IMPORTANT: Stator hub (B) must be installed with


Front side up as shown.
02
20. Install fixed stator hub (B) (front side up). 045
17
21. Install retaining ring (D) into groove.

B—Fixed Stator Hub


C—Stator
D—Retaining Ring

–UN–13MAR01
YZ4104
–UN–28FEB01
YZ4031
Continued on next page YZ03225,000006C –19–04OCT04–9/11

CTM308 (15FEB05) 02-045-17 DF180 Series Powershift Transmission


021505
PN=315
Drive Plate and Torque Converter Assembly

22. Remove thrust washers (A) and needle thrust bearing


(B). Inspect and discard.

23. Remove cap screws (C) and washers (D). Inspect


and discard.
02
045
18 A—Thrust Washer—Thick (2 used)
B—Needle Thrust Bearing—Large Roller
C—Cap Screw (12 used)

–UN–24MAR01
D—Washer (12 used)

YZ4032
–UN–28FEB01
YZ4033
Continued on next page YZ03225,000006C –19–04OCT04–10/11

CTM308 (15FEB05) 02-045-18 DF180 Series Powershift Transmission


021505
PN=316
Drive Plate and Torque Converter Assembly

24. Lift impeller (A) off impeller hub (B).

25. Remove O-ring (C) and seal ring (D). Inspect and
discard.
02
26. Inspect splines, seal and bearing surfaces. Inspect for 045
wear or damage. 19

A—Impeller
B—Impeller Hub
C—O-ring
D—Seal Ring

–UN–28FEB01
YZ4034
–UN–28FEB01
YZ4035

YZ03225,000006C –19–04OCT04–11/11

CTM308 (15FEB05) 02-045-19 DF180 Series Powershift Transmission


021505
PN=317
Drive Plate and Torque Converter Assembly

Assemble Torque Converter

1. Lubricate new O-ring (A) with petroleum jelly and install


on Impeller Hub (B).
02
045 2. Install Impeller (C) on Impeller Hub (B).
20
3. Align holes in Impeller Hub (B) with holes in Impeller
(C).

–UN–28FEB01
A—O-ring
B—Impeller Hub
C—Impeller

YZ4036
–UN–28FEB01
YZ4034A

Continued on next page YZ03225,00000D4 –19–02DEC04–1/6

CTM308 (15FEB05) 02-045-20 DF180 Series Powershift Transmission


021505
PN=318
Drive Plate and Torque Converter Assembly

IMPORTANT: It is imperative that cap screws and


holes be cleaned and free of oil or dirt
when reassembling. If not, Loctite will
not adhere to cap screws and holes
causing the cap screws to break free or
02
leak. 045
21
4. Clean Cap Screws (C). Apply cure primer.

5. Apply high strength thread lock to first three threads of

–UN–28FEB01
Cap Screws (C).

6. Install Cap Screws (C) and Washers (B) and tighten in


correct sequence to specification. See Torque

YZ4038
Converter Cover, Drive Plate and Impeller Hub
Tightening Sequence in this group.

Torque Converter—Specification B—Washer (12 used)


Impeller-to-Hub Cap Screws— C—Cap Screw (12 used)
Torque ........................................................................................ 24.4 N•m
(18.0 lb-ft)

Continued on next page YZ03225,00000D4 –19–02DEC04–2/6

CTM308 (15FEB05) 02-045-21 DF180 Series Powershift Transmission


021505
PN=319
Drive Plate and Torque Converter Assembly

IMPORTANT: The thrust bearing and thrust washers


used between impeller hub and stator
hub are different from set used between
stator hub and turbine. These have a
smaller outside diameter and larger
02
045 diameter needle roller with thicker
22 thrust washers.

7. Lubricate Needle Thrust Bearing (B) and Thrust

–UN–26MAR01
Washers (A) and (C) with clean transmission fluid.

IMPORTANT: Always use new thrust washers and


thrust needle bearings.

YZ4032A
8. Install thrust washer (A).

9. Install Needle Thrust Bearing (B).

10. Install Thrust Washer (C).

11. Install Fixed Stator (D) with “Front” side up (thick


vanes as shown).

NOTE: If stator is installed improperly it will not turn freely


on thrust bearing.

12. Rotate stator several turns to be sure it is properly

–UN–09MAR01
seated on thrust bearing.

A—Thrust Washer—Thick
B—Needle Thrust Bearing—Large Roller

YZ4025A
C—Thrust Washer—Thick
D—Fixed Stator
E—Impeller

Continued on next page YZ03225,00000D4 –19–02DEC04–3/6

CTM308 (15FEB05) 02-045-22 DF180 Series Powershift Transmission


021505
PN=320
Drive Plate and Torque Converter Assembly

IMPORTANT: The thrust bearing and thrust washers


used between the stator hub and
turbine are different from set used
between impeller hub and stator hub.
These have a larger outside diameter
02
and smaller diameter needle roller with 045
thinner thrust washers. 23

–UN–09MAR01
13. Lubricate needle thrust bearing and thrust washers
with clean transmission fluid.

IMPORTANT: Always use new thrust washers and

YZ4024A
thrust needle bearings.

14. Install thrust washer (A). A—Thrust Washer—Thin


B—Needle Thrust Bearing—Small Roller
15. Install needle thrust bearing (B). C—Thrust Washer—Thin
D—Impeller
16. Install thrust washer (C).

Continued on next page YZ03225,00000D4 –19–02DEC04–4/6

CTM308 (15FEB05) 02-045-23 DF180 Series Powershift Transmission


021505
PN=321
Drive Plate and Torque Converter Assembly

17. Install turbine hub (A).

18. Install turbine (B).

19. Lubricate and install bearing (C).


02
045
24 NOTE: Bearing is a slip-fit bearing.

20. Rotate turbine several turns to be sure it is properly


seated on thrust bearing.

–UN–28FEB01
A—Turbine Hub
B—Turbine
C—Bearing

YZ4040
–UN–28FEB01
YZ4041
Continued on next page YZ03225,00000D4 –19–02DEC04–5/6

CTM308 (15FEB05) 02-045-24 DF180 Series Powershift Transmission


021505
PN=322
Drive Plate and Torque Converter Assembly

21. Lubricate O-ring (A) with petroleum jelly and install.

22. Install front cover (B). Align cap screw holes of front
cover and impeller.
02
23. Install cap screws (D) and washers (C) and tighten in 045
correct sequence to specification. See Torque 25
Converter Cover, Drive Plate and Impeller Hub
Tightening Sequence in this group.

–UN–27FEB01
Torque Converter—Specification
Front Cover-to-Impeller Cap
Screw—Torque ........................................................................... 50.2 N•m

YZ4020
(37.0 lb-ft)

24. Install drive plate. See Remove and Install Torque


Converter Drive Plate in this group.
A—O-Ring
B—Front Cover
C—Washer (24 used)
D—Cap Screw (24 used)

–UN–28FEB01
YZ4019A
–UN–28FEB01
YZ4017A

YZ03225,00000D4 –19–02DEC04–6/6

CTM308 (15FEB05) 02-045-25 DF180 Series Powershift Transmission


021505
PN=323
Drive Plate and Torque Converter Assembly

02
045
26

CTM308 (15FEB05) 02-045-26 DF180 Series Powershift Transmission


021505
PN=324
Group 047
Torque Converter PTO Housing
Remove and Install Magnetic Speed Sensor,
Converter PTO Assembly

1. Disconnect wiring connector.


02
2. Remove cap screws and washers (A). 047
1
3. Remove magnetic speed cover (B).

4. Remove magnetic speed sensor with O-ring (C).

–UN–10MAR01
5. Install new O-ring in groove on magnetic speed sensor
(C).

YZ4094A
NOTE: Install magnetic speed sensor only after installing
driven gears.

6. Lubricate O-ring with new petroleum jelly.

NOTE: May need to use a twisting motion while pushing


to keep from rolling O-ring. If O-ring is rolled
during installation it will leak.

7. Push magnetic speed sensor into converter cover.

8. Install magnetic speed cover (B).

–UN–10MAR01
9. Install cap screws, lock washer and flat washers (A).

10. Tighten cap screws.

YZ4096A
Magnetic Speed Sensor—Specification
Magnetic Speed Sensor Cap
Screw—Torque ........................................................................... 10.8 N•m
(8.0 lb-in.)
A—Cap Screws, Lock Washers, and Flat Washers
(2 used)
B—Magnetic Speed Cover
C—Magnetic Speed Sensor and O-ring

YZ03225,0000068 –19–04OCT04–1/1

CTM308 (15FEB05) 02-047-1 DF180 Series Powershift Transmission


021505
PN=325
Torque Converter PTO Housing

Remove and Install Hydraulic Lube Hose


Auxiliary Pump Port

1. Remove hose (A), if not removed.


02
047 A—Hose
2 B—Fitting-to-Converter Housing
C—Fitting-to-Converter Cover—Auxiliary Pump
Adapter

–UN–05MAR01
YZ4050
Continued on next page YZ03225,000006D –19–04OCT04–1/2

CTM308 (15FEB05) 02-047-2 DF180 Series Powershift Transmission


021505
PN=326
Torque Converter PTO Housing

2. Install fitting with orifice (C) to converter cover. (If


removed.)

3. Install fitting (B) to converter housing (if removed).


02
4. Install hydraulic lube hose (A) to fittings and tighten. 047
3
Torque Converter Housing—Specification
Hose Fitting-to-Converter
Housing—Torque........................................................................ 12.0 N•m
(106.0 lb-in.)
Hose Fitting with Orifice-to-Front
Cover—Pump Adapter—Torque ................................................ 12.0 N•m
(106.0 lb-in.)
Hydraulic Lube Hose Fitting—
Torque ........................................................................................ 16.0 N•m
(142.0 lb-in.)

–UN–05MAR01
A—Hydraulic Lube Hose
B—Elbow Fitting-to-Converter Housing
C—Elbow Fitting with Orifice-to-Converter Cover—
Auxiliary Pump Adapter

YZ4050
–UN–10MAR01
YZ4095
YZ03225,000006D –19–04OCT04–2/2

CTM308 (15FEB05) 02-047-3 DF180 Series Powershift Transmission


021505
PN=327
Torque Converter PTO Housing

Torque Converter PTO Component Identification

02
047
4

–UN–09MAR01
YZ4010

A—Charge Pump E—Converter Cover H—Hydraulic Hose K—Magnetic Speed Sensor


B—Output Yoke F—Oil Out-to-Cooler I—Torque Converter L—Pump Discharge Port
C—Oil In-to-Torque Converter G—Auxiliary Pump Adapter J—Drive Plate M—Pilot Sleeve
D—Drain-to-Sump

YZ03225,00000D5 –19–02DEC04–1/1

CTM308 (15FEB05) 02-047-4 DF180 Series Powershift Transmission


021505
PN=328
Torque Converter PTO Housing

Torque Converter Exploded View

02
047
5

–UN–03SEP03
YZ4007
1—Cap Screw 13—Idler Shaft (2 used) 25—O-ring 36—Cap Screw (7 used)
2—Yoke Washer 14—O-ring (2 used) 26—Hydraulic Pump Adapter 37—Thrust Race
3—O-ring 15—Snap Ring Ball Bearing (4 Plate 38—Needle Thrust Bearing
4—Yoke used) 27—Cap Screw (4 used) 39—Input Gear
5—Oil Seal 16—Idler Gear (2 used) 28—O-ring 40—Bearing
6—Snap Ring 17—Oil Seal 29—Elbow Fitting and 41—O-ring (2 used)
7—Bearing 18—O-ring (2 used) O-rings — With Orifice 42—Bearing (2 used)
8—Turbine Shaft 19—Converter Cover 30—Hydraulic Hose 43—Washer (2 used)
9—Seal Ring 20—Sealed Bearing 31—Elbow Fitting and O-rings 44—Cap Screw (2 used)
10—O-ring Plug (2 used) 21—Driven Gear (2 used) 32—Converter Housing 45—Lock Washer (2 used)
11—Socket Head Cap Screw (2 22—Snap Ring Bearing 33—O-ring 46—Magnetic Speed Cover
used) 23—Bearing Spacer 34—Stator Support Tube 47—Magnetic Speed Sensor
12—Cap Screw (5 used) 24—Snap Ring 35—Deflector 48—O-ring

YZ03225,00000D6 –19–02DEC04–1/1

CTM308 (15FEB05) 02-047-5 DF180 Series Powershift Transmission


021505
PN=329
Torque Converter PTO Housing

Disassemble Torque Converter PTO

1. Remove parts (A Thru D) and discard O-ring (C).

2. Inspect parts for wear or damage.


02
047
6 A—Cap Screw

–UN–05MAR01
B—Washer
C—O-ring
D—Yoke

YZ4049
YZ03225,00000D7 –19–02DEC04–1/9

NOTE: Oil seal must be removed before output shaft can


be removed from housing.

3. Remove Oil Seal (A) from housing. Inspect and discard


.

A—Oil Seal

–UN–05MAR01
YZ4051

Continued on next page YZ03225,00000D7 –19–02DEC04–2/9

CTM308 (15FEB05) 02-047-6 DF180 Series Powershift Transmission


021505
PN=330
Torque Converter PTO Housing

4. Remove Snap Ring (B). Inspect for wear and damage.

B—Snap Ring

02
047
7

–UN–05MAR01
YZ4052
YZ03225,00000D7 –19–02DEC04–3/9

5. Remove Turbine Shaft (C) and Bearing.

NOTE: Bearing will come out with shaft.

C—Turbine Shaft and Bearing

–UN–05MAR01
YZ4054
Continued on next page YZ03225,00000D7 –19–02DEC04–4/9

CTM308 (15FEB05) 02-047-7 DF180 Series Powershift Transmission


021505
PN=331
Torque Converter PTO Housing

6. Remove Seal Ring (B) from Input Shaft (A). Inspect


and discard Seal Ring (B).

7. Remove Bearing (C) from Input Shaft (A). Inspect and


discard Bearing (C).
02
047
8 A—Input Shaft
B—Seal Ring
C—Bearing

–UN–19AUG04
YZ5409
–UN–19AUG04
YZ5410

Continued on next page YZ03225,00000D7 –19–02DEC04–5/9

CTM308 (15FEB05) 02-047-8 DF180 Series Powershift Transmission


021505
PN=332
Torque Converter PTO Housing

8. Remove O-ring plugs (A) from converter side of


converter cover. Inspect and discard O-rings.

9. Remove socket head cap screws (B) from converter


cover.
02
047
10. Remove idler cap screws (C) and cap screws (D). 9

CAUTION: Remove cap screw (E) last. Hold


converter housing while removing cap screw

–UN–09MAR01
(E). Converter housing could fall or drop
unexpectedly and cause injury or damage to
converter housing.

YZ4064
A—Plugs and O-rings (2 used)
B—Socket Head Cap Screws (2 used)
C—Cap Screws (Idler Shaft)
D—Cap Screws
E—Cap Screw

–UN–07MAR01
YZ4065
Continued on next page YZ03225,00000D7 –19–02DEC04–6/9

CTM308 (15FEB05) 02-047-9 DF180 Series Powershift Transmission


021505
PN=333
Torque Converter PTO Housing

11. Remove cap screw (E) while holding onto converter


housing (F).

12. Remove converter housing.


02
047 E—Cap Screw-to-Front Cover
10 F—Converter Housing

–UN–12SEP03
YZ4066
–UN–12SEP03
YZ4055
YZ03225,00000D7 –19–02DEC04–7/9

13. Remove O-rings (G). Inspect and discard.

14. Remove Input Gear (H). Inspect for wear and damage

G—O-ring (2 used)
H—Input Gear
–UN–12SEP03
YZ4067

Continued on next page YZ03225,00000D7 –19–02DEC04–8/9

CTM308 (15FEB05) 02-047-10 DF180 Series Powershift Transmission


021505
PN=334
Torque Converter PTO Housing

15. Remove needle thrust bearing (A) and thrust race (B).
Inspect and discard.

16. Remove O-ring (C). Inspect and discard .


02
17. Remove Cap Screws (E) and Oil Deflector (F). 047
11
18. Remove Stator Support Tube (D) from Converter
Housing (G).

A—Needle Thrust Bearing


B—Thrust Race
C—O-ring
D—Stator Support Tube
E—Cap Screws (7 used)
F—Oil Deflector
G—Converter Housing

–UN–06MAR01
YZ4058
–UN–06MAR01
YZ4059
YZ03225,00000D7 –19–02DEC04–9/9

CTM308 (15FEB05) 02-047-11 DF180 Series Powershift Transmission


021505
PN=335
Torque Converter PTO Housing

Assemble Torque Converter PTO

1. Align Oil Passages (C) and install Stator Support Tube


(A) on Converter Housing (B).
02
047 IMPORTANT: Oil passages and oil deflector must be
12 installed correctly to properly direct oil
flow. Install oil deflector (F) with angle
cut flush with outer diameter of stator
support tube (A). Check oil deflector so
tab (E) is below the surface of thrust
race shoulder of stator tube.

2. Install Oil Deflector (F) and tighten Cap Screws (D).

Torque Converter Housing—Specification


Stater Support Tube and Oil
Deflector Cap Screw—Torque ................................................... 36.6 N•m
(27.0 lb-ft)

A—Stator Support Tube

–UN–04SEP03
B—Converter Housing
C—Oil Passage Alignment
D—Cap Screws (7 used)
E—Oil Deflector Tab

YZ4060
F—Oil Deflector

–UN–04SEP03
YZ4059A

Continued on next page YZ03225,000006E –19–04OCT04–1/11

CTM308 (15FEB05) 02-047-12 DF180 Series Powershift Transmission


021505
PN=336
Torque Converter PTO Housing

3. Apply petroleum jelly to new Thrust Race (A) and


Needle Thrust Bearing (B) and install on Stator
Support Tube.

NOTE: Applying petroleum jelly to thrust race and needle


02
thrust bearing holds them in place when installing 047
converter housing in front cover. 13

4. Lubricate and install new O-ring (C).

5. Set Converter Housing with Stator Support Tube aside.

A—Thrust Race
B—Needle Thrust Bearing
C—O-ring

–UN–06MAR01
YZ4058A
YZ03225,000006E –19–04OCT04–2/11

6. Lubricate and install new O-rings (A) to converter


cover.

7. Install Input Gear (B) in housing; mesh with Idler


Gears.

A—O-ring (2 Used)
B—Input Gear

–UN–10MAR01
YZ4090

Continued on next page YZ03225,000006E –19–04OCT04–3/11

CTM308 (15FEB05) 02-047-13 DF180 Series Powershift Transmission


021505
PN=337
Torque Converter PTO Housing

CAUTION: Hold on to converter housing (C)


while installing cap screw (D) to prevent
component damage.

02 IMPORTANT: Make sure thrust race and needle thrust


047 bearing are aligned and in place when
14
installing converter housing into
converter cover.

–UN–10MAR01
8. Install Converter Housing (C) in Converter PTO
Housing.

9. Install Cap Screw (D) while holding onto converter

YZ4055A
housing. Secure cap screw to hold housing. Do not
tighten at this time.

C—Converter Housing
D—Cap Screw

–UN–10MAR01
YZ4066A
Continued on next page YZ03225,000006E –19–04OCT04–4/11

CTM308 (15FEB05) 02-047-14 DF180 Series Powershift Transmission


021505
PN=338
Torque Converter PTO Housing

10. Install and tighten Cap Screws (F) to Idler Shafts.

11. Install and tighten Cap Screws (E). Tighten Cap


Screw (D).
02
Torque Converter Housing—Specification
047
Converter Housing Cap Screw—
15
Torque ........................................................................................ 86.8 N•m
(64.0 lb-ft)

–UN–10MAR01
12. Apply high strength thread lock to Allen Head Cap
Screws (G) and install (inside housing). Tighten cap
screws.

YZ4093
Torque Converter Housing—Specification
Converter Housing Allen Head
Cap Screw—Torque ................................................................... 86.8 N•m
(64.0 lb-ft)

D—Cap Screw
E—Cap Screw (2 used)
F—Cap Screw-to-Idler Shafts (2 used)
G—Allen Head Cap Screw (2 used)

YZ03225,000006E –19–04OCT04–5/11

13. Install new O-rings onto Plug (H)

14. Install and tighten O-ring Plugs (H) to housing.

Torque Converter Housing—Specification


Converter Housing Plug—Torque ............................................ 189.8 N•m
(140.0 lb-ft)

H—Plug (2 used)

–UN–10MAR01
YZ4064A

Continued on next page YZ03225,000006E –19–04OCT04–6/11

CTM308 (15FEB05) 02-047-15 DF180 Series Powershift Transmission


021505
PN=339
Torque Converter PTO Housing

15. Press on new Bearing (A) on Input Shaft until bearing


seats against shaft shoulder using JDG1108 Driver
(B).

IMPORTANT: Press only on inner race of bearing.


02
047
16 16. Lubricate and install new Seal Ring (C).

A—Bearing
B—JDG1108 Bearing Driver
C—Seal Ring

–UN–06MAR01
YZ4063
YZ03225,000006E –19–04OCT04–7/11

17. Lubricate housing bore and seal ring with petroleum


jelly.

18. Install turbine shaft (I) into converter housing.

I—Turbine Shaft

–UN–10MAR01
YZ4054A

Continued on next page YZ03225,000006E –19–04OCT04–8/11

CTM308 (15FEB05) 02-047-16 DF180 Series Powershift Transmission


021505
PN=340
Torque Converter PTO Housing

19. Install snap ring (J).

J—Snap Ring

02
047
17

–UN–10MAR01
YZ4092
YZ03225,000006E –19–04OCT04–9/11

20. Apply medium strength thread lock to outside


diameter of oil seal (K) and install oil seal to converter
housing.

K—Oil Seal

–UN–10MAR01
YZ4091
YZ03225,000006E –19–04OCT04–10/11

21. Apply petroleum jelly to seal inner lip and yoke seal
surface.

22. Install yoke (D).

23. Apply high strength thread lock and sealer to cap


screw.
–UN–05MAR01

24. Install O-ring (C), washer (B) and cap screw (A).

NOTE: Install washer with number side out.


YZ4049

25. Tighten cap screw to specification.

Output Yoke—Specification A—Cap Screw


Output Yoke Cap Screw—Torque............................................ 215.6 N•m B—Washer
(159.0 lb-ft)
C—O-ring
D—Yoke

YZ03225,000006E –19–04OCT04–11/11

CTM308 (15FEB05) 02-047-17 DF180 Series Powershift Transmission


021505
PN=341
Torque Converter PTO Housing

Disassemble Converter PTO Pump Drive

1. Position converter cover converter side up.

NOTE: Use cap screw (A) to pull idler shafts from front
02
047 cover bores. The shafts are a slip fit.
18
2. Install a cap screw (A) into threaded hole in idler shaft
(B).
3. Remove idler shafts (B).

–UN–07MAR01
4. Remove and discard O-rings (C and D). O-rings may
stick in idler shaft housing.
5. Inspect idler shafts for wear or damage.
6. Remove oil seal (E) and bearing (F).

YZ4068
A—Cap Screw
B—Idler Shaft (2 used)
C—O-ring (2 used)
D—O-ring (2 used)
E—Oil Seal
F—Bearing

Continued on next page YZ03225,00000D8 –19–02DEC04–1/6

CTM308 (15FEB05) 02-047-18 DF180 Series Powershift Transmission


021505
PN=342
Torque Converter PTO Housing

7. Position converter cover to have pump ports and


driven gear up.
8. Remove driven gear (A) from charge pump side.
9. Remove cap screws (C).
10. Remove hydraulic pump adapter plate (B) and O-ring
02
(D) from auxiliary pump side. 047
A—Driven Gear (Charge Pump Side) 19
B—Hydraulic Pump Adapter Plate
C—Cap Screws (4 used)
D—O-ring

–UN–07MAR01
YZ4069
–UN–04SEP03
YZ4070
–UN–07MAR01
YZ4071

Continued on next page YZ03225,00000D8 –19–02DEC04–2/6

CTM308 (15FEB05) 02-047-19 DF180 Series Powershift Transmission


021505
PN=343
Torque Converter PTO Housing

11. Remove snap ring (A).


12. Remove spacer and driven gear.

A—Snap Ring
02
047
20

–UN–04SEP03
YZ4072
YZ03225,00000D8 –19–02DEC04–3/6

13. Remove bearings (C and D) from gear (B) using


puller.
14. Inspect bearings and gear and replace as necessary.

B—Driven Gear (2 used)


C—Snap Ring Bearing
D—Sealed Bearing

–UN–09MAR01
YZ4075
Driven Gear—Auxiliary Pump Side
Continued on next page YZ03225,00000D8 –19–02DEC04–4/6

CTM308 (15FEB05) 02-047-20 DF180 Series Powershift Transmission


021505
PN=344
Torque Converter PTO Housing

15. Remove idler gear (A) from auxiliary pump port (B).
16. Remove idler gear (C) from charge pump port (D).

A—Idler Gear
B—Front Cover Auxiliary Pump Port 02
C—Idler Gear 047
D—Front Cover Charge Pump Port 21

–UN–09MAR01
YZ4076
Idler Gear–Auxiliary Pump Port

–UN–09MAR01
YZ4077
Idler Gear—Charge Pump Port

Continued on next page YZ03225,00000D8 –19–02DEC04–5/6

CTM308 (15FEB05) 02-047-21 DF180 Series Powershift Transmission


021505
PN=345
Torque Converter PTO Housing

17. Remove bearings (A) from both idler gears (B).


18. Inspect bearings and gears for wear or damage.

IMPORTANT: Use press to install bearings. Apply


pressure to outer race of bearing until
02

–UN–08MAR01
047 snap ring contacts outside of gear.
22
19. Use press to install bearing. Press on bearing outer
race until snap ring contacts outside of gear.

YZ4078
20. Turn gear over and press bearing into idler gear until
snap ring rests on outside of gear.
21. Repeat for each idler gear.
A—Bearing (2 used)
B—Idler Gear

YZ03225,00000D8 –19–02DEC04–6/6

Assemble Converter PTO Pump Drive

IMPORTANT: Use press to install bearings. Apply


pressure to bearing inner race only.

1. Use press to install bearing (A) onto driven gear (B).


Apply pressure to bearing inner race only.

–UN–14MAR98
2. Turn gear over and press bearing (C) onto gear.

IMPORTANT: Auxiliary pump port driven gear (E) will

YZ555
have one snap ring bearing (D) and one
sealed bearing (F). Install snap ring Driven Gear and Bearing–Charge Pump Side
bearing onto gear with snap ring down.
Install sealed bearing onto gear with
seal side away from driven gear.

3. Press snap ring bearing (D) onto driven gear (E) with
snap ring side toward gear.

4. Turn gear over and press sealed bearing (F) onto gear
with seal side away from gear.

A—Bearing (Charge Pump)


B—Driven Gear (Charge Pump)
C—Bearing (Charge Pump)
–UN–04SEP03

D—Snap Ring Bearing (Auxiliary Pump)


E—Driven Gear (Auxiliary Pump)
F—Sealed Bearing (Auxiliary Pump)
YZ4075A

Driven Gear and Snap Ring Bearing—Auxiliary Pump Side

Continued on next page YZ03225,000006F –19–04OCT04–1/10

CTM308 (15FEB05) 02-047-22 DF180 Series Powershift Transmission


021505
PN=346
Torque Converter PTO Housing

5. Position front cover with converter side up.

IMPORTANT: Make sure oil seal is flush with machine


surface of housing.
02
NOTE: If outside diameter of oil seal is not already 047
coated with a sealer, apply medium strength 23
thread lock.

6. Install oil seal (A) using suitable driver.

–UN–08MAR01
7. Position converter cover with converter side down.

8. Install bearing (B) into front cover using suitable driver.

YZ4082
A—Oil Seal
B—Bearing

–UN–08MAR01
YZ4083
Continued on next page YZ03225,000006F –19–04OCT04–2/10

CTM308 (15FEB05) 02-047-23 DF180 Series Powershift Transmission


021505
PN=347
Torque Converter PTO Housing

9. Position converter cover with converter side up and


turn housing so auxiliary pump port hangs over work
table.

10. Place idler gear (A) into auxiliary pump port (B).
02
047
24 11. Position idler gear.

12. Turn housing so charge pump port hangs over work

–UN–09MAR01
table.

13. Install idler gear (C) into charge pump port (D).

YZ4076
A—Idler Gear
B—Auxiliary Pump Port of Converter Cover Idler Gear–Auxiliary Pump Port
C—Idler Gear
D—Charge Pump Port of Converter Cover

–UN–09MAR01
YZ4077
Idler Gear–Charge Pump Port

Continued on next page YZ03225,000006F –19–04OCT04–3/10

CTM308 (15FEB05) 02-047-24 DF180 Series Powershift Transmission


021505
PN=348
Torque Converter PTO Housing

14. Align bearing bore of idler gear (A) with input housing
shaft bore.

15. Lubricate O-ring (C) with petroleum jelly and install in


groove on idler shaft.
02
047
16. Position O-ring (B) at bottom of the shaft bore in input 25
housing.

NOTE: Hole in idler shaft must line up with hole in front

–UN–08MAR01
cover (input housing). Use cap screw (E) to guide
the alignment while installing.

17. Align hole in idler shaft with hole in input housing

YZ4084
using cap screw (E) as a guide. Push idler shaft (D)
through idler gear into input housing.

18. Tighten Cap Screw (E).

Torque Converter Housing—Specification


Hydraulic Pump Adapter Plate
Cap Screws—Torque ................................................................. 86.8 N•m
(64.0 lb-ft)

19. Install the other idler shaft in same manner.

A—Idler Gear (2 used)


B—O-ring (2 used)

–UN–12SEP03
C—O-ring (2 used)
D—Idler Shaft (2 used)
E—Cap Screw (2 used)

YZ4068A
–UN–12SEP03
YZ4085

Continued on next page YZ03225,000006F –19–04OCT04–4/10

CTM308 (15FEB05) 02-047-25 DF180 Series Powershift Transmission


021505
PN=349
Torque Converter PTO Housing

20. Install driven gear (A) in charge pump port of front


cover.

A—Driven Gear
02
047
26

–UN–07MAR01
YZ4069
YZ03225,000006F –19–04OCT04–5/10

21. Install driven gear with snap ring bearing up and seal
side of bearing (A) down toward torque converter side
in Auxiliary pump port.

A—Bearing (Seal Side)

–UN–08MAR01
YZ4086

Snap Ring Bearing Up and Seal Side of Bearing Down Toward


Engine Side
–UN–24MAR01
YZ4148

Sealed side down

Continued on next page YZ03225,000006F –19–04OCT04–6/10

CTM308 (15FEB05) 02-047-26 DF180 Series Powershift Transmission


021505
PN=350
Torque Converter PTO Housing

22. Rotate idler gear (A) to align teeth with driven gear
(B).

A—Idler Gear
B—Driven Gear 02
047
27

–UN–14MAR98
YZ579
Continued on next page YZ03225,000006F –19–04OCT04–7/10

CTM308 (15FEB05) 02-047-27 DF180 Series Powershift Transmission


021505
PN=351
Torque Converter PTO Housing

23. Install bearing spacer (C) in Auxiliary pump port.

CAUTION: Wear eye protection when installing


snap rings.
02
047 24. Install snap ring (D) into groove.
28

C—Bearing Spacer
D—Snap Ring

–UN–14JAN03
T163729B
–UN–04SEP03
YZ4088

Continued on next page YZ03225,000006F –19–04OCT04–8/10

CTM308 (15FEB05) 02-047-28 DF180 Series Powershift Transmission


021505
PN=352
Torque Converter PTO Housing

25. Lubricate and install O-ring (E) to hydraulic pump


adapter plate (F).

E—O-ring
F—Hydraulic Pump Adapter Plate 02
047
29

–UN–08MAR01
YZ4071A
YZ03225,000006F –19–04OCT04–9/10

IMPORTANT: Install pump adapter plate to front cover


with screw holes (G) positioned so they
are adjacent to screw holes (H) on
housing.

26. Install hydraulic pump adapter plate on auxiliary pump


port.

27. Install and tighten cap screws (I).

Torque Converter Housing—Specification

–UN–04SEP03
Hydraulic Pump Adapter Plate
Cap Screws—Torque ................................................................. 86.8 N•m
(64.0 lb-ft)

YZ4089
G—Hydraulic Pump Adapter Plate Screw Holes
H—Front Cover—Auxiliary Pump Port Screw Holes
I—Hydraulic Pump Adapter Plate-to-Front Cover Cap
Screw (4 used)

YZ03225,000006F –19–04OCT04–10/10

CTM308 (15FEB05) 02-047-29 DF180 Series Powershift Transmission


021505
PN=353
Torque Converter PTO Housing

02
047
30

CTM308 (15FEB05) 02-047-30 DF180 Series Powershift Transmission


021505
PN=354
Section 03
Theory of Operation
Contents

Page Page

Group 100—Transmission Operation Speed Clutch Operation . . . . . . . . . . . . . . . .03-100-36


Power Train Component Overview . . . . . . . . .03-100-1 Cylinder Speed Sensor Operation . . . . . . . . .03-100-37 03
Transmission Operation . . . . . . . . . . . . . . . . .03-100-2 Gear Selection - Remote Mount Direct Drive
Transmission Component Identification - 8F/8R Transmission. . . . . . . . . . . . . . . . . .03-100-38
Remote Mount Direct Drive 8 Forward / 8 Clutch and Gear Component Location -
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-100-4 Remote Mount Direct Drive 8F/8R
Component Identification - Remote Mount Transmission . . . . . . . . . . . . . . . . . . . . . . .03-100-40
Torque Converter Drive Transmission 6 First Forward - Remote Mount Direct Drive
Forward / 6 Reverse . . . . . . . . . . . . . . . . . .03-100-6 8F/8R Transmission. . . . . . . . . . . . . . . . . .03-100-42
Component Identification - Remote Mount First Reverse - Remote Mount Direct Drive
Torque Converter Drive Transmission 6 8F/8R Transmission. . . . . . . . . . . . . . . . . .03-100-44
Forward / 3 Reverse . . . . . . . . . . . . . . . . . .03-100-7 Gear Selection . . . . . . . . . . . . . . . . . . . . . . .03-100-46
Transmission Clutch and Gear Component Location. . . . . .03-100-48
Component Identification .