CTM308 - Tecnico Componentes - Transmision DF180

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

021505
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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):
OVERALL, how would you rate the quality of this publication? (Check one)
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THANK YOU!
TX,TM,FAX –19–03JUL01–1/1

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Introduction

021505
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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
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

021505
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Contents
01
02
03
04
05
06
INDX
CTM308 (15FEB05) ii DF180 Series Powershift Transmission

021505
PN=2
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

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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

021505
PN=9
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

021505
PN=10
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

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PN=11
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

021505
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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

021505
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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

021505
PN=14
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

021505
PN=15
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

021505
PN=16
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

021505
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Safety
01
005
10

021505
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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

021505
PN=19
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

021505
PN=20
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)
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)
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

021505
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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
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

021505
PN=22
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

021505
PN=23
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

021505
PN=24
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

021505
PN=25
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

021505
PN=26
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

021505
PN=27
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

021505
PN=28
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

021505
PN=29
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

021505
PN=30
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

021505
PN=31
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

021505
PN=32
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

021505
PN=33
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

021505
PN=34
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

021505
PN=35
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

021505
PN=36
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

021505
PN=37
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

021505
PN=38
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

021505
PN=39
01
015
22

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
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
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

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

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

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
Remote Mount Torque Converter Drive . . .02-043-60
Assemble Clutch Piston and Spring -
Assemble Clutch Pack - Remote Mount
Torque Converter Drive . . . . . . . . . . . . . . .02-043-70
Assemble Clutch Gear and Bearing -
Seventh Stage (Output Gear) - Remote
Mount Torque Converter Drive. . . . . . . . . .02-043-79
Seventh Stage (Output Gear) Repair -
Group 045—Drive Plate and Torque Converter

Assembly
Remove and Install Torque Converter
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-045-1
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

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

021505
PN=43
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

021505
PN=44
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.

021505
PN=45
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)

021505
PN=46
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

021505
PN=47
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: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.
YZ5703
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

021505
PN=48
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

021505
PN=49
02
025
8

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

021505
PN=51
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

021505
PN=52
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

021505
PN=53
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

021505
PN=54
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

021505
PN=55
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

021505
PN=56
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)

021505
PN=57
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

021505
PN=58
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

021505
PN=59
02
027
10

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

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

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
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

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

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

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

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

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

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

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

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

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

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

021505
PN=73
Output Seals

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

C—JDG1737A Grease Seal Driver
–UN–24JAN05
YZ7125
YZ03225,0000036 –19–01OCT04–3/4

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

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
12. Remove Seal Protector (B).

–UN–24JAN05
A—Grease Seal (Outer)

B—JDG1519 Seal Protector
YZ7126
YZ03225,0000036 –19–01OCT04–4/4

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)
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

021505
PN=75
Output Seals
2. Position JDG1519 Seal Protector (A) over output shaft

Spline.

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

B—Oil Seal
YZ7127
C—JDG1736A Oil Seal Driver
YZ03225,0000037 –19–01OCT04–2/4

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

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
–UN–24JAN05

YZ7128

021505
PN=76
Output Seals

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

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
12. Remove Seal Protector (A).
–UN–24JAN05
B—Grease Seal (Outer)
YZ7129
YZ03225,0000037 –19–01OCT04–4/4

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
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

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

021505
PN=79
Output Seals
02
031
8

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

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

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)

B—O-ring
C—O-ring
–UN–09SEP04
YZ5492A

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
–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

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

021505
PN=85
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

021505
PN=86
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

021505
PN=87
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

021505
PN=88
NOTE: Optimal white paste reduces spline wear.
3. Apply OPTIMOL PASTE WHITE T on charge pump

shaft spline before installing charge pump onto
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

021505
PN=89
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

021505
PN=90
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

021505
PN=91
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

021505
PN=92
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

021505
PN=93
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)

021505
PN=94
18. Install Drive Gear (A) into Front Housing.
A—Drive Gear Assembly
02
035
11
–UN–28DEC04
YZ7073
YZ03225,00000E6 –19–28DEC04–11/11

021505
PN=95
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

021505
PN=96
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

021505
PN=97
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

021505
PN=98
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

021505
PN=99
Remove and Install Idler Shaft — Remote

Mount Torque Converter Drive

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

021505
PN=100
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

021505
PN=101

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

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

021505
PN=103
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
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

021505
PN=104
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

2. Install new O-ring (A).
A—O-ring
B—Charge Pump
–UN–28DEC04
YZ7002

021505
PN=105
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)
–UN–03NOV04
YZ7003
YZ03225,0000059 –19–03FEB05–5/5

021505
PN=106
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

021505
PN=107
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

021505
PN=108
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

021505
PN=109
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

021505
PN=110
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

021505
PN=111
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

021505
PN=112
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
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

021505
PN=113
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

021505
PN=114
Assemble and Install Charge Pump Idler

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

021505
PN=115

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
–UN–08NOV04
YZ5349
YZ03225,00000BC –19–08NOV04–3/3

021505
PN=116
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

021505
PN=117
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

021505
PN=118
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

021505
PN=119

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

021505
PN=120
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

021505
PN=121
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).

B—Bearing with Snap Ring
C—Auxiliary Pump Output Gear
–UN–28DEC04
YZ7010A
Continued on next page YZ03225,000005D –19–03FEB05–1/5

021505
PN=122
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).

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

021505
PN=123
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

021505
PN=124

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

021505
PN=125
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

021505
PN=126
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

–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

021505
PN=127
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

021505
PN=128
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

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

021505
PN=129
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

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

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
2
6F/6R (1 used); 6F/3R (2 used)
YZ03225,0000002 –19–25AUG04–1/1

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
2
6F/6R (1 used); 6F/3R (2 used)
YZ03225,0000003 –19–25AUG04–1/1

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
Transmission Control Valve —Specification

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

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

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

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)

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

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).

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

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).

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

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

021505
PN=141
Control Valve
5. Install and tighten Cooler Relief Valve (A).

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

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).
–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.

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
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

021505
PN=144
Control Valve
3. Inspect for contamination and damage.
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
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).
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).

Plug-to-Valve Housing—Torque ........................................... 9.8-14.1 N•m
(7.2-10.4 lb-ft)
YZ03225,000001C –19–03SEP04–1/1

021505
PN=145
Control Valve
02
037
16

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

021505
PN=147
Remove and Install Input Yoke - Remote

Mount Transmission

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

021505
PN=148
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

021505
PN=149
02
039
4

021505
PN=150
Group 040
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

021505
PN=151
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

021505
PN=152
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

021505
PN=153
02
040
4

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

021505
PN=155
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: 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

021505
PN=156
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

021505
PN=157
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

021505
PN=158
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

021505
PN=159
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)
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)

–UN–15NOV04
YZ5280
–UN–15NOV04
YZ5363

021505
PN=160
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
Rear Housing—Engine Mount—Specification

(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

021505
PN=161
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

021505
PN=162
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

021505
PN=163
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

021505
PN=164
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

021505
PN=165
Gear Ratio Group - 8 Forward / 8 Reverse - Remote Mount Direct Drive
02
041
12
–UN–19NOV04
YZ5502
(High and Low Reverse) D—Sixth Stage Shaft Stage) (Second Stage)
(Third Stage) Assembly
YZ03225,0000007 –19–25AUG04–1/1

021505
PN=166
Gear Ratio Group - 6 Forward / 6 Reverse - Remote Mount Torque Converter Drive
02
041
13
–UN–23NOV04
YZ5503
(High and Low Reverse) D—Sixth Stage Gear (Idler Stage) (Second Stage)
(Third Stage) Gear)
YZ03225,0000008 –19–25AUG04–1/1

021505
PN=167
Gear Ratio Group - 6 Forward / 3 Reverse - Remote Mount Torque Converter Drive
02
041
14
–UN–23NOV04
YZ5422
(High and Low Reverse) D—Sixth Stage Gear (Idler Stage) (Second Stage)
(Third Stage) Gear)
YZ03225,0000009 –19–25AUG04–1/1

021505
PN=168
Remove Gear Ratio Group - Remote Mount

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: 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

021505
PN=169
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
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

021505
PN=170
14. Remove Sixth Stage Shaft Assembly (C) from rear

housing.
02
041
–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

021505
PN=171
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
2. Remove Input Drive Hub (See Input Drive Hub -
Engine Mount Transmission)
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

021505
PN=172
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

021505
PN=173
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
–UN–23NOV04
YZ7044
YZ03225,00000C6 –19–16NOV04–5/5

021505
PN=174
Install Gear Ratio Group - Remote Mount

02
1. Install Sixth Stage Shaft Assembly (C). 041
–UN–23DEC97
21
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)

(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

021505
PN=175
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
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.

Gear Ratio Group (Second—Fifth
–UN–25JAN05
Stage) With Input Shaft
Assembly—Weight ................................................. approximate 157.4 kg
(347.0 lb)
YZ7134
A—Bearing Cone

021505
PN=176
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

021505
PN=177
Install Gear Ratio Group - Engine Mount

02
041 1. Install Seventh Stage Output Assembly (B) into
24 housing.

(68.0 lb)
2. Remove Eyebolt M16 (A).
A—Eyebolt M16
–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

021505
PN=178
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.

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

021505
PN=179
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

021505
PN=180
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

021505
PN=181
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
excessive bearing end play, extend cure
0.25 mm (0.01 inch) thick. Do not use
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.

021505
PN=182
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
Front and Rear Housing Assemble—Specification

(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).
C—Rear Housing
6. Install Cap Screws (B) into housings

021505
PN=183
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

021505
PN=184
Install 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

excessive bearing end play, extend cure
0.25 mm (0.01 inch) thick. Do not use –UN–07JAN05
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.

021505
PN=185
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

021505
PN=186
8.
Install Cap Screws (A).
9. Install Cap Screw (B).

02
041
10. Install remaining Cap Screws (C) 33
11. Install Cap Screw (D)

C—Cap Screw M12 x 130 (18 Used)
D—Cap Screw M12 x 65
–UN–10JAN05
YZ7086
–UN–10JAN05
YZ7087

021505
PN=187
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

021505
PN=188
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

YZ5370

021505
PN=189
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
B—O-ring
YZ5372
C—Shims
YZ03225,0000063 –19–03FEB05–3/3

021505
PN=190
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)

021505
PN=191
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
B—Feeler Gauge

021505
PN=192
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

021505
PN=193
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

021505
PN=194
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

021505
PN=195
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

021505
PN=196
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

021505
PN=197
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

021505
PN=198
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

021505
PN=199
4. Tighten the expander.
02
041
46
–UN–12JAN05
YZ6166
YZ03225,0000024 –19–13JAN05–3/7
5. Install the Sleeve.
–UN–12JAN05
YZ6168

021505
PN=200
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

021505
PN=201
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

021505
PN=202
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

021505
PN=203
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

021505
PN=204
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

021505
PN=205
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

021505
PN=206
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

021505
PN=207
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

021505
PN=208
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

021505
PN=209
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

021505
PN=210
Rear Housing - Engine Mount
02
041
57
–UN–11JAN05
YZ7096
A—Ball B—Pluget C—Lube Relief Valve

021505
PN=211
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

021505
PN=212
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)

021505
PN=213
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).
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)

021505
PN=214
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

021505
PN=215
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

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

021505
PN=217
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

021505
PN=218
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

021505
PN=219
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
YZ03225,000000C –19–25AUG04–1/1

021505
PN=220

(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

021505
PN=221
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

021505
PN=222
02
043
7

021505
PN=223
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

021505
PN=224
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

021505
PN=225
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

021505
PN=226
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

021505
PN=227
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

021505
PN=228
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)
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

021505
PN=229
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

021505
PN=230
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)
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

021505
PN=231
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

021505
PN=232
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

021505
PN=233
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

021505
PN=234
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

021505
PN=235
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

021505
PN=236
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

021505
PN=237
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

021505
PN=238
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

021505
PN=239
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

021505
PN=240

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

installing or removing retaining rings.
6. Remove Retaining Ring (A). Inspect and discard.
A—Retaining Ring
–UN–02NOV96
YZ403

021505
PN=241

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

021505
PN=242
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

removing snap ring (high tension snap ring).
11. Remove Snap Ring (B).
B—Snap Ring
–UN–25MAR97
YZ407

021505
PN=243
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

021505
PN=244

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

021505
PN=245
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

021505
PN=246
Assemble Clutch Piston and Spring - Direct

Drive

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
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).
–UN–21AUG96
YZ413

021505
PN=247
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.

YZ418
C—Retaining Ring

021505
PN=248

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

021505
PN=249
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

021505
PN=250
4. Install Clutch Plate Retainer (A).

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

021505
PN=251
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.)

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).

021505
PN=252
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

021505
PN=253
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
–UN–22SEP04
YZ6023
–UN–22SEP04
YZ6024

021505
PN=254
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

021505
PN=255
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

021505
PN=256
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

021505
PN=257
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

021505
PN=258
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

021505
PN=259
Seventh Stage (Output) Shaft Repair - Direct

Drive

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

021505
PN=260
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
B—JDG1110 Input Shaft Seal Installer Driver
D—Bearing Cone
–UN–20SEP04
YZ1136A
YZ03225,0000060 –19–04OCT04–2/2

021505
PN=261
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

021505
PN=262
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
YZ03225,000000D –19–25AUG04–1/1

021505
PN=263

(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

021505
PN=264
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.

B—JDG1105 Bearing Replacer
C—Bearing Cone
–UN–20SEP04
YZ1134A
YZ03225,0000061 –19–04OCT04–2/2

021505
PN=265
Second Stage (High / Low Forward) Clutch Assembly Cross-Section - Remote Mounted
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

021505
PN=266
Second Stage (High / Low Forward) Clutch Assembly Exploded View - Remote Mounted
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

021505
PN=267
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

021505
PN=268
Third Stage (High / Low Reverse) Clutch Assembly Exploded View - Remote Mount
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

021505
PN=269
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

021505
PN=270
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

021505
PN=271
Fourth Stage (First / Second Speed) Clutch Assembly Cross-Section - Remote Mounted
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

021505
PN=272
Fourth Stage (First / Second Speed) Clutch Assembly Exploded View - Remote Mounted
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

021505
PN=273
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

021505
PN=274
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

021505
PN=275
Disassemble and Assemble Clutch - Remote


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)

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

021505
PN=276
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

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

021505
PN=277
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
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

021505
PN=278
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

021505
PN=279
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

removing snap ring (high tension snap ring).
11. Remove Snap Ring (B).
B—Snap Ring
–UN–25MAR97
YZ407

021505
PN=280
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

021505
PN=281

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
C—Clutch Return Springs (6)
YZ463
YZ03225,000003D –19–01OCT04–2/5
7. Remove Lube Shutoff Washer (D).

–UN–21AUG96
YZ464
Continued on next page YZ03225,000003D –19–01OCT04–3/5

021505
PN=282

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
YZ415
C—O-ring
YZ03225,000003D –19–01OCT04–5/5

021505
PN=283
Assemble Clutch Piston and Spring - Remote


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
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).

–UN–21AUG96
YZ413

021505
PN=284
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

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
C—Retaining Ring

021505
PN=285

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

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

021505
PN=286
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

021505
PN=287
4. Install Clutch Plate Retainer (A).

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

021505
PN=288
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
Clearance ......................................................................... 2.31—4.47 mm
(0.091—0.176 in.)
Clutch Plate (Fourth and Fifth
Clearance ......................................................................... 2.79—5.59 mm
(0.110—0.220 in.)

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).

021505
PN=289
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

021505
PN=290
Assemble Clutch Gear and Bearing - Remote

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
–UN–22SEP04
YZ6023
–UN–22SEP04
YZ6024

021505
PN=291
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

021505
PN=292
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
(0.010 in.)
D—Bearing
E—Retaining Ring
F—JDG1108 Bearing Driver
–UN–29MAR01
YZ4173

021505
PN=293
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
(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
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
YZ4167

021505
PN=294
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

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

021505
PN=295
Seventh Stage (Output Gear) Repair -

1. Use a bearing puller to remove Bearing Cones (A).

02 Discard bearing cones.
043
80
A—Bearing Cones
–UN–12JAN98
YZ1135

021505
PN=296
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
B—JDG1110 Input Shaft Seal Driver
D—Bearing Cone
–UN–20SEP04
YZ1136A
YZ03225,0000067 –19–04OCT04–2/2

021505
PN=297
02
043
82

021505
PN=298
Group 045
Drive Plate and Torque Converter Assembly
Assembly

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

021505
PN=299
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

021505
PN=300
Torque Converter —Specification

Torque Converter and Drive
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

021505
PN=301
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
Torque Converter Drive Plate—Specification

Torque Converter and Drive
(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

021505
PN=302
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

021505
PN=303
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

021505
PN=304
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.

021505
PN=305
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

021505
PN=306
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

021505
PN=307
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

021505
PN=308
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

021505
PN=309
8. Remove turbine (C) and inspect for wear or damage.
C—Turbine
02
045
12
–UN–27FEB01
YZ4023

021505
PN=310
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

021505
PN=311
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

021505
PN=312
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

021505
PN=313
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

021505
PN=314
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

021505
PN=315
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

021505
PN=316
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

021505
PN=317
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

021505
PN=318
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
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)

021505
PN=319
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

021505
PN=320
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).

021505
PN=321
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

021505
PN=322
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
–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

021505
PN=323
02
045
26

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

021505
PN=325
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

021505
PN=326
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

021505
PN=327
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

021505
PN=328
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

021505
PN=329
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

021505
PN=330
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

021505
PN=331
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

021505
PN=332
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

021505
PN=333
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

021505
PN=334
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

021505
PN=335
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).

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

021505
PN=336
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

021505
PN=337
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

021505
PN=338
10. Install and tighten Cap Screws (F) to Idler Shafts.
11. Install and tighten Cap Screws (E). Tighten Cap

Screw (D).
02
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
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.

Converter Housing Plug—Torque ............................................ 189.8 N•m
(140.0 lb-ft)
H—Plug (2 used)
–UN–10MAR01
YZ4064A

021505
PN=339
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
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

021505
PN=340
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

021505
PN=341
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

021505
PN=342
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

021505
PN=343
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

021505
PN=344
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

021505
PN=345
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

021505
PN=346
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

021505
PN=347
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

021505
PN=348
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).

Hydraulic Pump Adapter Plate
(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

021505
PN=349
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

021505
PN=350
22. Rotate idler gear (A) to align teeth with driven gear
(B).
A—Idler Gear
B—Driven Gear 02
047
27
–UN–14MAR98
YZ579

021505
PN=351
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

021505
PN=352
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).
–UN–04SEP03
Hydraulic Pump Adapter Plate
(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

021505
PN=353
02
047
30

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 . . . . . . . . . . . . . . .03-100-8 First Forward - Engine Mount Direct Drive
Transmission Diagram - Direct Drive 8F/8R Transmission. . . . . . . . . . . . . . . . . .03-100-50
Transmission . . . . . . . . . . . . . . . . . . . . . . . .03-100-9 First Reverse - Engine Mount Direct Drive
Transmission Diagram - Torque Converter 8F/8R Transmission. . . . . . . . . . . . . . . . . .03-100-52
Drive Transmission . . . . . . . . . . . . . . . . . .03-100-10 Gear Selection - Remote Mount Torque
Torque Converter PTO Assembly . . . . . . . . .03-100-11 Converter Drive 6F/6R Transmission . . . . .03-100-54
Hydraulic System Operation - Direct Drive Clutch and Gear Component Location -
Transmission . . . . . . . . . . . . . . . . . . . . . . .03-100-13 Remote Mount Torque Converter Drive 6F/6R
Hydraulic System Operation - Torque Transmission . . . . . . . . . . . . . . . . . . . . . . .03-100-56
Converter Drive Transmission . . . . . . . . . .03-100-16 First Forward - Remote Mount Torque
Transmission Charge Pump Operation . . . . .03-100-18 Converter Drive 6F/6R Transmission . . . . .03-100-58
Transmission Filter Bypass Valve . . . . . . . . .03-100-19 First Reverse - Remote Mount Torque
Transmission Control Valve Port Identification Converter Drive 6F/6R Transmission . . . . .03-100-60
(Remote Mount). . . . . . . . . . . . . . . . . . . . .03-100-20 Gear Selection - Remote Mount Torque
Transmission Control Valve Port Identification Converter Drive 6F/3R Transmission . . . . .03-100-62
(Engine Mount) . . . . . . . . . . . . . . . . . . . . .03-100-21 Clutch and Gear Component Location -
Transmission Proportional Solenoid Remote Mount Torque Converter Drive 6F/3R
Valves Identification (Remote Mount). . . . .03-100-22 Transmission . . . . . . . . . . . . . . . . . . . . . . .03-100-64
Transmission Proportional Solenoid First Forward - Remote Mount Torque
Valves Identification (Engine Mount) . . . . .03-100-23 Converter Drive Transmission . . . . . . . . . .03-100-66
Transmission Control Valve Operation First Reverse - Remote Mount Torque
(Remote Mount). . . . . . . . . . . . . . . . . . . . .03-100-24 Converter Drive Transmission . . . . . . . . . .03-100-68
Transmission Control Valve Operation Park Brake Operation . . . . . . . . . . . . . . . . . .03-100-70
(Engine Mount) . . . . . . . . . . . . . . . . . . . . .03-100-26 Park Brake Manual Release Operation . . . . .03-100-74
Control Valve-to-Front Housing Oil
Passage Identification (Remote Mount) . . .03-100-28
Control Valve-to-Front Housing Oil
Passage Identification (Engine Mount) . . . .03-100-29
Proportional Solenoid Valve Operation -
De-Energized. . . . . . . . . . . . . . . . . . . . . . .03-100-30
Main Pressure Regulator Valve Operation. . .03-100-32
Clutch Actuation . . . . . . . . . . . . . . . . . . . . . .03-100-33
Directional Clutch Operation . . . . . . . . . . . . .03-100-34

021505
PN=1
Contents
03

021505
PN=2
Group 100
Transmission Operation
Power Train Component Overview
The power train consists of the following major

components:
Torque Converter—Torque Converter Drive Transmission

See Torque Converter PTO Assembly in this group.
• Turbine
• Stator
• Impeller 03
100
1
Transmission
• Case, Gears, Bearings, and Clutches

See Clutch and Gear Component Location - Remote
Mount Direct Drive 8F/8R Transmission or Clutch And
Gear Component Location - Engine Mount Direct Drive
8F/8R Transmission or Clutch and Gear Component
Location - Remote Mount Torque Converter Drive 6F/6R
Transmission or Clutch and Gear Component Location -
Remote Mount Torque Converter Drive 6F/3R
Transmission in this group.
• Transmission Charge Pump
See Transmission Charge Pump Operation in this group.
• Transmission Control Valve
See Transmission Control Valve Operation (Remote
Mount) or Transmission Control Valve Operation (Engine
Mount) in this group.
• Park Brake
See Park Brake Operation in this group.
YZ03225,0000070 –19–04OCT04–1/1

021505
PN=357
Transmission Operation—Direct Drive Transmission
For the Remote Mount transmission the engine is

connected to the input shaft of the transmission by a drive
shaft. For the Engine Mount transmission the engine is
connected by a splined hub mounted to the engine
flywheel and transmission input shaft.
03 When the transmission is engaged into gear, the engine

100 power is connected to the output shaft of the transmission
2
at different speed ratios depending on which directional
and speed clutches are engaged. Each clutch is engaged
hydraulically and controlled by an individual proportional
solenoid valve. The rate of pressure rise behind each
clutch piston is determined by the Transmission Control
Unit (TCU) providing the current to each valve. The
engine power may be disconnected from the transmission
output shaft by depressing the inching pedal or by shifting
the transmission to the neutral or park position.
The transmission charge pump, main hydraulic pump and

differential lock pump are always connected to the engine
power via a constant mesh gear train located on the input
side of the transmission.
A torsional damper (isolator) is used between the engine

and transmission input shaft to protect transmission from
torsional vibrations produced by the engine.
The engine driveline is direct-coupled to the torsional

damper, unless the optional cold weather disconnect is
installed and put in the disengaged position. In that
condition, all power is disconnected from the engine
driveline. The transmission, pumps, and winch all remain
rotation free.

021505
PN=358
Transmission Operation—Torque Converter Drive

Transmission
The engine is connected to the torque converter, which is

connected to the input shaft of the transmission by a drive
shaft. When the transmission is engaged into gear, the
engine power is connected to the output shaft of the
transmission at different speed ratios depending on which
directional and speed clutches are engaged. Each clutch
is engaged hydraulically and controlled by an individual
proportional solenoid valve. The rate of pressure rise 03
behind each clutch piston is determined by the 100
3
Transmission Control Unit (TCU) providing the current to
each valve. The engine power may be disconnected from
the transmission output shaft by either shifting the
transmission to neutral or engaging the de-clutch switch
and then depressing the brake pedal enough to produce
241.3 kPa (2.41 bar) (35.0 psi) in the brake circuit. This
will send the transmission to neutral until the brake pedal
has been released.
The transmission charge pump, main hydraulic pump and

differential lock pump are always connected to the engine
power via a constant mesh gear train located on the
torque converter housing.
YZ03225,0000071 –19–04OCT04–2/2

021505
PN=359
Transmission Component Identification - Remote Mount Direct Drive 8 Forward / 8

Reverse
03
100
4
–UN–01FEB05
YZ5411A

021505
PN=360
A—Transmission Drain Fitting F—Suction Tube L—Dipstick Port S—Differential Lock Pump
B—Front Housing G—Front Output M—Park Brake Assembly Drive
C—Transmission Control H—Winch PTO Yoke N—Rear Housing T—Winch PTO Cover
Valve I—Magnetic Pickup Sensor O—Winch PTO U—Fill Tube Port
D—Input Yoke (Input Speed) P—Rear Output V—Identification Plate
E—Charge Pump with J—Dipstick Pressure Q—Park Brake Pressure Port
Auxiliary Drive for Equalization Port R—Magnetic Pickup Sensor
Hydraulic Pump K—Magnetic Pickup Sensor (Output Speed)
(Cylinder Speed)
03
100
YZ03225,0000072 –19–04OCT04–2/2 5

021505
PN=361
Component Identification - Remote Mount Torque Converter Drive Transmission 6

Forward / 6 Reverse
03
100
6
–UN–01FEB05
YZ5496A
A—Transmission Drain Fitting F—Front Output J—Dipstick Port P—Magnetic Pickup Sensor
B—Front Housing G—Winch PTO Yoke K—Park Brake Assembly (Output Speed)
C—Transmission Control H—Dipstick Pressure L—Rear Housing Q—Winch PTO Cover
Valve Equalization Port M—Winch PTO R—Fill Tube Port/Breather Port
D—Input Yoke I—Magnetic Pickup Sensor N—Rear Output S—Identification Plate
E—Suction Tube (Cylinder Speed) O—Park Brake Pressure Port
YZ03225,0000012 –19–27AUG04–1/1

021505
PN=362
Component Identification - Remote Mount Torque Converter Drive Transmission 6

Forward / 3 Reverse
03
100
7
–UN–01FEB05
YZ5412A
A—Transmission Drain Fitting F—Front Output J—Dipstick Port P—Magnetic Pickup Sensor
B—Front Housing G—Winch PTO Yoke K—Park Brake Assembly (Output Speed)
C—Transmission Control H—Dipstick Pressure L—Rear Housing Q—Winch PTO Cover
Valve Equalization Port M—Winch PTO R—Fill Tube Port/Breather Port
D—Input Yoke I—Magnetic Pickup Sensor N—Rear Output S—Identification Plate
E—Suction Tube (Cylinder Speed) O—Park Brake Pressure Port
YZ03225,0000013 –19–27AUG04–1/1

021505
PN=363
Component Identification- Engine Mount Direct Drive 8 Forward / 8 Reverse
03
100
8
–UN–08APR97
YZ262
A—Front Housing F—Oil Drain Plug L—Magnetic Pickup Sensor Q—Bearing Retainer
B—Transmission Charge G—Oil Fill/Dipstick Tube (Cylinder Speed) R—Suction Screen
Pump H—Suction Tube M—Park Brake S—Identification Plate
C—Magnetic Pickup Sensor I—HFWD Pump Drive N—Brake Pressure Port T—Fan Drive Output
(Input Speed) J—Hydraulic Pump Drive O—Brake Pressure Sensor U—Rear Housing
D—Oil Accumulator K—Transmission Control (Bleed) Port V—Lifting Hole
E—Magnetic Pickup Sensor Valve Housing P—Drive Hub W—Output Yoke
(Output Speed)
YZ03225,0000066 –19–03FEB05–1/1

021505
PN=364
Transmission Diagram - Direct Drive Transmission
F
H
E K
I
03
100
J 9
C
L
R
B
Q M
A
N
P
O
Q
–19–01FEB05
T
U
YZ6076A
Transmission Diagram Direct Drive (Remote Mount Shown)
A—Transmission Output Shaft G—Transmission Pressure L—Suction Screen Q—Transmission Oil Cooler
B—Park Brake Assembly Regulator Valve M—Main Case Front Housing R—Auxiliary Pressure Port
(Disengaged) H—Control Valve Body N—Lubrication Relief Valve S—System Pressure Oil
C—Park Brake Solenoid I—Temperature Sensor O—Proportional Solenoid T—Lubrication Oil
D—Check Valve J—Transmission Oil Filter Control Valve (8 used) U—Pressure-Free Oil
E—Park Brake Valve K—Transmission Charge P—Clutch Assembly
F—Cooler Relief Valve Pump (Engaged) (8 used)
YZ03225,0000073 –19–04OCT04–1/1

021505
PN=365
Transmission Diagram - Torque Converter Drive Transmission
F
H
E K
I
03
100
10 A J
C
L
R
M
B
V
W N
P
O
Q
S
T
–19–01FEB05
U
YZ6077A
Transmission Diagram Converter Drive
A—Torque Converter H—Control Valve Body O—Proportional Solenoid Q—Oil From Cooler
B—Park Brake Assembly I—Temperature Sensor Control Valve (7 Used for R—Auxiliary Pressure Port
(Disengaged) J—Transmission Oil Filter 6F/6R and 6 Used for S—System Pressure Oil
C—Park Brake Solenoid K—Transmission Charge 6F/3R) T—Lubrication Oil
D—Check Valve Pump P—Clutch Assembly (7 Used U—Pressure-Free Oil
E—Park Brake Valve L—Suction Screen for 6F/6R and 6 Used for V— Oil To Cooler
F—Converter Relief Valve M—Main Case Front Housing 6F/3R) W—Transmission Output Shaft
G—Transmission Pressure N—Lubrication Relief Valve
Regulator Valve
YZ03225,0000014 –19–27AUG04–1/1

021505
PN=366
Torque Converter PTO Assembly
D
B E
A
C
F 03
100
11
J
O
K P –19–04FEB05
Q
M L
N
YZ6180
A—Turbine F—Idler Gear (2 used) K—Stator Carrier O—Inlet Pressure

B—Stator G—Accessory Drive Gear L—Fixed Stator Hub P—Outlet Pressure
C—Impeller H—Lubrication Orifice M—Housing Q—Lubrication Oil
D—Lubrication Line I—Output N—Flex Plate Adapter R—Torque Converter
E—Pump Drive Gear (2 used) J—Manifold
The torque converter assembly is made up of the three-element type with a stator freewheel clutch. The
torque converter (R), and the gears (E, F, and G) to housing (M) is mounted to the engine flywheel
drive the transmission and hydraulic pumps. The housing. The flex plate adapter (N) connects to the
torque converter is a single-stage, rotating housing, flywheel and impeller.

021505
PN=367
The impeller is driven at engine speed and becomes a set of pump drive gears drives the hydraulic pump and
centrifugal pump forcing oil to flow out of the impeller transmission pump and the other set drives the
and into the turbine (A), causing it to turn in the same differential lock pump and hydraulic cooling pump. The
direction as the impeller. pump drive gears turn slightly faster than the
accessory drive gear.
The turbine is connected to the output shaft (I) which
drives the transmission input shaft. Inlet pressure (O) oil comes from the transmission
control oil valve cooler circuit. Oil flows through the
Oil from the turbine is flowing in the opposite direction manifold (J), through the passage formed by the stator
of the oil entering the impeller. To change the direction carrier (K) and impeller hub, through the thrust bearing
03 of oil flow, the stator (B), redirects the oil from the and into the impeller side of the torque converter.
100 turbine to flow in the same direction as the oil entering Outlet pressure (P) oil flows from the turbine side,
12
the impeller. This improves the efficiency of the torque through the thrust bearing, through the passage
converter. formed by the stator carrier and output shaft, into the
manifold and then out to the oil cooler.
Torque multiplication occurs when the velocity of the
turbine oil flow flowing through the stator is added to Lubrication oil for the drive gears is through a
the impeller oil flow to drive the turbine at a higher lubrication line (D) and orifice (H) which are connected
speed than what the impeller alone can produce. The to the converter inlet oil passage.
increased turbine speed is converted into additional
torque for the transmission to use. Converter leakage and drive gear lube oil drains back
to the transmission case through a drain line located in
The accessory drive gear (G) is driven by the engine the bottom of the accessory drive housing. The
through the impeller hub. The drive gear turns the idler transmission case is vented to ensure proper oil
gears (F) which drive the pump drive gears (E). One drainage.
YZ03225,0000074 –19–04OCT04–2/2

021505
PN=368
Hydraulic System Operation - Direct Drive Transmission
TRANSMISSION 6 TRANSMISSION
3 OIL COOLER FILTER
TRANSMISSION
2 PRESSURE
REGULATOR
COOLER RELIEF LUBE RELIEF 03

VALVE 5 TRANSMISSION 7 100
1 PARK VALVE 4 13
BRAKE CHARGE PUMP
LUBE
SUCTION
8 SCREEN
TRANSMISSION
13 PROPORTIONAL
MANUAL PARK 9 SOLENOID
CONTROL VALVE
BRAKE RELEASE
PORT
12
RELIEF
VALVE 1 23 4A BC D
P 10 DIRECTION CLUTCHES SPEED CLUTCHES
Park Brake PARK BRAKE
Solenoid PRESSURE SWITCH
Valve
11 PARK BRAKE
–19–01FEB05
VALVE
14 SYSTEM PRESSURE
OIL
15 LUBRICATION OIL
YZ6176
17 TRANSMISSION HYDRAULIC SCHEMATIC 16 PRESSURE FREE OIL
1—Park Brake (Applied) 6—Transmission Filter 11—Park Brake Valve 15—Lubrication Oil
2—Transmission Pressure 7—Transmission Charge Pump 12—Relief Valve 16—Pressure-Free Oil
Regulator 8—Suction Screen 13—Manual Park Brake 17—Transmission Hydraulic
3—Transmission Oil Cooler 9—Transmission Proportional Release Port Schematic
4—Cooler Relief Valve Solenoid Control Valve 14—System Pressure Oil
5—Lube Relief Valve 10—Park Brake Pressure
Switch

021505
PN=369
Hydraulic System Operation - Direct Drive dumped by the transmission pressure regulator valve
Transmission to the transmission oil cooler (3) and lube circuits.
Oil is picked up by the transmission charge pump (7) The charge pump also provides the flow for winch (10)
from the transmission sump through a suction screen operation (if equipped). A constant flow is fed to the
(8). It travels through an external suction tube to the winch circuit to keep the temperature of the oil in the
inlet side of the charge pump. The charge pump is an lines at a level where the operation will be smooth.
external gear pump with fixed clearance end plates
and the gear shafts supported by bushings. The pump The pressure in the transmission oil cooler circuit is
has a pressure balanced side plate for low-speed controlled by the flow restrictions in the oil cooler. If
03 efficiency. The pump is driven by the transmission the restriction in the circuit is excessive, the cooler
100 input gear train which is directly coupled to the engine relief valve (4) opens and dumps the excess flow to
14
driveline. the lube circuit, bypassing the oil cooler. If lube
pressure becomes excessive, it dumps to sump.
From the pump, the oil is directed to the transmission
oil filter assembly (6). The filter head has an internal The cooled oil returning to the valve body from the
bypass valve that bypasses oil to an alternate port transmission oil cooler is directed to the lube circuit.
when the pressure drop across the filter element Internal passages and manifolds located in the
exceeds bypass pressure. Bypassed oil is directed to transmission front cover direct the lube oil to the ends
the lubrication system and back to the transmission of each of the clutch shafts. This oil flow passes
sump. The filter head contains a pressure switch that through the lube shutoff washers on the engaged
is used to alert the operator of nearing bypass clutches and provides the cooling for the clutches.
conditions. There is also leakage flow to the disengaged clutches
to lubricate and cool them, and many orifices provide
Filtered oil from the filter assembly is directed to the flow to lubricate the bearings on these shafts. After
transmission control valve body located on the front of exiting the clutches and bearings on these shafts the
transmission. The pressure in the system is controlled oil returns to the transmission sump where it is again
by the transmission pressure regulator valve (2). The picked up by the charge pump. If the pressure in the
flow of oil is available for the transmission proportional lube circuit is excessive, the lube relief valve (5) opens
solenoid control valves (9) and clutch engagement. A and dumps the excess flow to the transmission sump.
small amount of this flow leaks through the pilot This condition is normal when the transmission is in
orifices in the transmission proportional solenoid neutral with all lube shutoff washers closed and the
control valves and past the seal rings in the shafts engine is at high idle or when the oil is cold.
when a clutch is engaged. The balance of the flow is
YZ03225,0000075 –19–04OCT04–2/2

021505
PN=370
03
100
15

021505
PN=371
Hydraulic System Operation - Torque Converter Drive Transmission
TRANSMISSION
2
OIL COOLER
1 TORQUE 3 THERMAL BYPASS

VALVE
CONVERTER
03
100
16
4 TRANSMISSION
FILTER
TRANSMISSION
16 PRESSURE
REGULATOR
CONVERTER LUBE RELIEF

5 VALVE 6
15 PARK RELIEF TRANSMISSION 7
BRAKE VALVE CHARGE PUMP
LUBE
SUCTION
8
SCREEN
TRANSMISSION
14 PROPORTIONAL
9 SOLENOID
MANUAL PARK CONTROL VALVE
BRAKE RELEASE
PORT
13
RELIEF
VALVE 1 23 4A B D
P 11 DIRECTION CLUTCHES SPEED CLUTCHES
Park Brake PARK BRAKE
Solenoid Valve PRESSURE SWITCH
17 SYSTEM PRESSURE
–19–01FEB05
12 PARK BRAKE
OIL
VALVE
18 LUBRICATION OIL
20 TRANSMISSION HYDRAULIC SCHEMATIC 19 PRESSURE FREE OIL
YZ6175

021505
PN=372
1—Torque Converter 7—Transmission Charge Pump 12—Park Brake Valve 17—System Pressure Oil
2—Transmission Oil Cooler 8—Suction Screen 13—Relief Valve 18—Lubrication Oil
3—Thermal Bypass Valve 9—Transmission Proportional 14—Manual Park Brake 19—Pressure-Free Oil
4—Transmission Filter Solenoid Control Valve Release Port 20—Transmission Hydraulic
5—Converter Relief Valve 11—Park Brake Pressure 15—Park Brake (Applied) Schematic
6—Lube Relief Valve Switch 16—Transmission Pressure
Regulator
Hydraulic System Operation—Torque Converter flowing through the thermal bypass valve is directed
Drive Transmission back to transmission sump and at higher temperatures,
oil flowing through the thermal bypass valve is directed
Oil is picked up by the transmission charge pump (7) through the transmission oil cooler (2). The cooled oil 03
from the transmission sump through a suction screen returning to the valve body from the transmission oil 100
(8). It travels through an external suction tube to the cooler is directed to the lube circuit. 17
inlet side of the charge pump. The charge pump is an
external gear pump with fixed clearance end plates The pressure in the transmission oil cooler circuit is
and the gear shafts supported by bushings. The pump controlled by the flow restrictions in the oil cooler. If
has a pressure balanced side plate for low-speed the restriction in the oil cooler is excessive, a
efficiency. The pump is driven by the torque converter spring-loaded seat in the thermal bypass valve opens
gear train which is directly coupled to the engine. and dumps the excess flow to the lube circuit,
bypassing the oil cooler. If lube pressure becomes
From the pump, the oil is directed to the transmission excessive, it dumps to sump.
oil filter assembly (4). The filter head has an internal
bypass valve that bypasses oil to an alternate port Internal passages and manifolds located in the
when the pressure drop across the filter element transmission front cover direct the lube oil to the ends
exceeds bypass pressure. Bypassed oil is directed to of each of the clutch shafts. This oil flow passes
the lubrication system and back to the transmission through the lube shutoff washers on the engaged
sump. The filter head contains a pressure switch that clutches and provides the cooling for the clutches.
is used to alert the operator of nearing bypass There is also leakage flow to the disengaged clutches
conditions. to lubricate and cool them, and many orifices provide
flow to lubricate the bearings on these shafts. After
Filtered oil from the filter assembly is directed to the exiting the clutches and bearings on these shafts the
transmission control valve body located on the front of oil returns to the transmission sump where it is again
transmission. The pressure in the system is controlled picked up by the charge pump. If the pressure in the
by the transmission pressure regulator valve (16). The lube circuit is excessive, the lube relief valve (6) opens
flow of oil is available for the transmission proportional and dumps the excess flow to the transmission sump.
solenoid control valves (9) and clutch engagement. A This condition is normal when the transmission is in
small amount of this flow leaks through the pilot neutral with all lube shutoff washers closed and the
orifices in the transmission proportional solenoid engine is at high idle or when the oil is cold.
control valves and past the seal rings in the shafts
when a clutch is engaged. The charge pump also provides the flow for winch (10)
operation (if equipped). A constant flow is fed to the
The balance of the flow is sent to the torque converter winch circuit to keep the temperature of the oil in the
(1). Oil coming out of the torque converter is sent to lines at a level where the operation will be smooth.
the thermal bypass valve (3). At low temperatures, oil
YZ03225,0000015 –19–27AUG04–2/2

021505
PN=373
Transmission Charge Pump Operation
B
A
03
100
18
–19–01FEB05
D
YZ1023B
C
Direct Drive Machine Shown
A—To Transmission Oil Filter C—From Transmission Oil D—System Pressure Oil F—Transmission Charge
Assembly Sump E—Pressure-Free Oil Pump
B—Transmission Charge
Pump
The transmission charge pump (B) is mounted external tube to the inlet side of the pump. From the
externally on the transmission case. It is driven by a pump, oil is directed to a filter assembly (A).
gear train engaged with the transmission input shaft,
which is driven by the engine. If equipped with torque As the pump drive gear turns the idler gear, gear teeth
converter, transmission charge pump is mounted on come out of mesh and oil from the sump flows into
torque converter housing. It is driven by a gear train cavity between the gear teeth. As gears continue to
engaged with the torque converter, which is driven by rotate, oil becomes trapped between gear teeth and
the engine. This is a gear-type pump with the shafts housing. Trapped oil is then carried to the pump outlet
supported by bushings. port. As gears mesh, they form a seal to prevent oil
from flowing between gears and back to the inlet port.
The pump draws oil from the transmission oil sump (C) Oil is forced out the outlet port to supply the
through a suction screen. The oil moves through an transmission with pressure oil.
YZ03225,0000076 –19–04OCT04–1/1

021505
PN=374
Transmission Filter Bypass Valve
E F
D
C
03
C 100
19
G
B
–19–01FEB05
H
A
I
YZ6177
J
A—Transmission Filter C—Relief Operation F—Filter Bypass Valve J—Lube Pressure Oil
Element D—Indicator Switch G—To Lube Circuit K—Transmission Filter Bypass
B—Inlet from Transmission E—To Pressure Regulating H—Transmission Pressure Oil Valve
Charge Pump Valve I—Restricted Pressure Oil
The spin-on type transmission filter element (A) is During normal operation, the inlet pressure and outlet
mounted to the bottom left of the hydraulic reservoir. pressure are nearly equal and the valve and indicator
The filter is protected by a pressure differential type remain seated. If the filter becomes plugged, or the oil
bypass valve (F) and an indicator switch (D). is very cold, the inlet pressure becomes higher than
the outlet pressure and spring force.
Inlet oil from the transmission charge pump (B) is
sensed on the bottom side of both the bypass valve During relief operation (C), the indicator switch piston
and the indicator switch. The oil goes through the filter moves upward, contacting the terminal and providing a
element and is sensed on the spring side of both the ground for the filter light in the monitor. The bypass
bypass valve and the indicator switch as it goes to the valve also opens and routes the unfiltered oil to the
pressure regulating valve (E). lube circuit (G).
YZ03225,0000077 –19–04OCT04–1/1

021505
PN=375
Transmission Control Valve Port Identification (Remote Mount)
03
100
20
–UN–01FEB05
YZ1018A
A—Clutch 3 Pressure Check G—Clutch A Pressure Check L—Clutch C Pressure Check N—Oil Cooler Out Pressure
Port Port Port Check Port
B—Clutch 1 Pressure Check H—Pressure to Park Brake M—Oil Flow Out-to-Oil O—Temperature Sensor Oil
Port I—Oil Flow into Lube Circuit Cooler—Direct Drive Sump—Direct Drive
C—Clutch 2 Pressure Check from Oil Cooler and Filter Machine Transmission
Port Bypass M—Oil Flow Out-to-Torque P—Clutch 4 Pressure Check
D—Lube Pressure Check Port J—Pressure to Winch Control Converter—Torque Port
E—Oil Flow in from Charge K—Clutch D Pressure Check Converter Drive Q—Pump Pressure Check Port
Pump Port Transmission
F—Clutch B Pressure Check
Port
YZ03225,0000078 –19–04OCT04–1/1

021505
PN=376
Transmission Control Valve Port Identification (Engine Mount)
03
100
21
–UN–01FEB05
YZ1018A
A—Clutch 2 Pressure Check F—Clutch C Pressure Check K—Clutch A Pressure Check O—Temperature Sensor Oil
Port Port Port Sump—Direct Drive
B—Clutch 4 Pressure Check G—Clutch D Pressure Check L—Clutch B Pressure Check Transmission
Port Port Port P—Clutch 1 Pressure Check
C—Clutch 3 Pressure Check H—Pressure to Park Brake M—Oil Flow Out-to-Oil Port
Port I—Oil Flow into Lube Circuit Cooler—Direct Drive Q—Pump Pressure Check Port
D—Lube Pressure Check Port from Oil Cooler and Filter Machine
E—Oil Flow in from Charge Bypass N—Oil Cooler Out Pressure
Pump Check Port
YZ03225,0000078 –19–04OCT04–1/1

021505
PN=377
Transmission Proportional Solenoid Valves Identification (Remote Mount)
03
100
22
–UN–25AUG04
YZ5427
Direct Drive Vehicle Shown
A—Transmission Solenoid D—Transmission Solenoid G—Transmission Solenoid H—Transmission Solenoid

Valve “1” Valve “A” Valve “4” (Not used on Valve “3”
B—Transmission Solenoid E—Transmission Solenoid 6F/6R or 6F/3R
Valve “2” Valve “D” transmissions)
C—Transmission Solenoid F—Transmission Solenoid
Valve “B” Valve “C” (Not used on
6F/3R transmissions)
YZ03225,0000079 –19–04OCT04–1/1

021505
PN=378
Transmission Proportional Solenoid Valves Identification (Engine Mount)
03
100
23
–UN–25AUG04
YZ5427
Direct Drive Vehicle - Engine Mount
A—Transmission Solenoid C—Transmission Solenoid E—Transmission Solenoid G—Transmission Solenoid

Valve “2” Valve “C” Valve “A” Valve “1”
B—Transmission Solenoid D—Transmission Solenoid F—Transmission Solenoid H—Transmission Solenoid
Valve “4” Valve “D” Valve “B” Valve “2”
YZ03225,0000079 –19–04OCT04–1/1

021505
PN=379
Transmission Control Valve Operation (Remote Mount)
B C
03
100
24
K
D
–19–01FEB05
L
I F
M
H G
YZ5401B
N
8 Froward / 8 Reverse Direct Drive Shown
A—Valve Housing C—O-ring — Direct Drive D—Converter Relief Valve - 90 K—Temperature Sensor
B—12V Proportional Solenoid Machine (24 used) PSI Torque Converter Drive K—Temperature Sensor (Not
Valve—Direct Drive C—O-ring — Torque Converter Transmission used for Converter Drive
Transmission (8 used) Machine (21 used) E—Main Regulator Valve Transmissions)
B—12V Proportional Solenoid C—O-ring — Torque Converter F—Pump Pressure Port L—Main Regulator Pressured
Valve—Torque Converter Machine (18 used) G—Lubrication In Port Oil
Drive 6F/6R Transmission D—Cooler Relief Valve - 120 H—Clutch Pressure M—Cooler Relief Pressured Oil
(7 used) PSI Direct Drive I—Sump Passage N—Return to Sump Oil
B—12V Proportional Solenoid Transmission J—Oil to Cooler Port
Valve—Torque Converter
Drive 6F/3R Transmission
(6 used)
Filtered oil from the filter assembly is directed to the regulated by the main regulator valve (E) which dumps
valve housing (A) through the charge pump pressure excess flow to the cooler pressure oil circuit (M).
port (F). The pressure in the system is controlled and

021505
PN=380
Main regulator valve oil (L) flows through oil passages oil to cooler port (J) and lube circuits. The pressure in
in the control valve and is made available to each 12V the transmission oil cooler circuit is controlled by the
proportional solenoid valve (B) to be used to control flow restrictions in the cooler assembly. For Direct
clutch engagement. Drive Transmissions, if the restriction exceeds 827.4
kPa (8.27 bar) (120.0 psi), the Converter relief valve
NOTE: The Transmission Control Valve Housing opens and dumps the excess flow to the lube circuits.
drawing and the Control Valve-to-Front For Converter Drive Transmissions, if the restriction
Housing Oil Passage Identification drawing exceeds 620.5 kPa (6.21 bar) (90.0 psi), the Converter
show the oil flow when machine is in Forward relief valve opens and dumps the excess flow to the
Seventh or direction clutch “1” and speed lube circuits. If the pressure in the lube circuit exceeds
clutch “D” are engaged. 310.3 kPa (3.10 bar) (45.0 psi), the lube relief valve 03
opens and dumps lube flow to the sump. 100
25
Cooler/Converter Relief Valve oil (M) is dumped by the
main pressure regulator valve (E) to the transmission
YZ03225,000007A –19–04OCT04–2/2

021505
PN=381
Transmission Control Valve Operation (Engine Mount)
B C
03
100
26
K
D
–19–01FEB05
L
I F
M
H G
YZ5401B
N
8 Froward / 8 Reverse Direct Drive Shown
A—Valve Housing D—Cooler Relief Valve - 120 G—Lubrication In Port L—Main Regulator Pressured
B—24V Proportional Solenoid PSI Direct Drive H—Clutch Pressure Oil
Valve—Direct Drive Transmission I—Sump Passage M—Cooler Relief Pressured Oil
Transmission (8 used) E—Main Regulator Valve J—Oil to Cooler Port N—Return to Sump Oil
C—O-ring — Direct Drive F—Pump Pressure Port K—Temperature Sensor
Machine (24 used)
Filtered oil from the filter assembly is directed to the Main regulator valve oil (L) flows through oil passages
valve housing (A) through the charge pump pressure in the control valve and is made available to each 24V
port (F). The pressure in the system is controlled and proportional solenoid valve (B) to be used to control
regulated by the main regulator valve (E) which dumps clutch engagement.
excess flow to the cooler pressure oil circuit (M).

021505
PN=382
NOTE: The Transmission Control Valve Housing cooler port (J) and lube circuits. The pressure in the
drawing and the Control Valve-to-Front transmission oil cooler circuit is controlled by the flow
Housing Oil Passage Identification drawing restrictions in the cooler assembly. If the restriction
show the oil flow when machine is in Reverse exceeds 827.4 kPa (8.27 bar) (120.0 psi), the cooler
Second or direction clutch “4” and speed relief valve opens and dumps the excess flow to the
clutch “A” are engaged. lube circuits. If the pressure in the lube circuit exceeds
310.3 kPa (3.10 bar) (45.0 psi), the lube relief valve
Cooler relief valve oil (M) is dumped by the main opens and dumps lube flow to the sump.
pressure regulator valve (E) to the transmission oil to
03
100
YZ03225,000007A –19–04OCT04–2/2 27

021505
PN=383
Control Valve-to-Front Housing Oil Passage Identification (Remote Mount)
2
1
10 3
03
100
28
9 4
8 6
–UN–11DEC02
11
7 12
13
T162712
T162712
Control Valve-to-Front Housing Oil Passage Identification
1—Clutch “3” 5—Clutch “A” 9—Front Housing 12—Lube Pressure Oil

2—Clutch “1” 6—Clutch “B” 10—Clutch “4” 13—Sump Pressure Oil
3—Clutch “2” 7—Clutch “D” 11—Main Regulator Pressure
4—Lube Relief Valve 8—Clutch “C” — Direct Drive Oil
Machine
YZ03225,000007B –19–04OCT04–1/1

021505
PN=384
Control Valve-to-Front Housing Oil Passage Identification (Engine Mount)
2
1
10 3
03
100
29
9 4
8 6
–UN–11DEC02
11
7 12
13
T162712
T162712
Control Valve-to-Front Housing Oil Passage Identification
1—Clutch “2” 5—Clutch “C” 9—Rear Housing 12—Lube Pressure Oil

2—Clutch “4” 6—Clutch “D” 10—Clutch “1” 13—Sump Pressure Oil
3—Clutch “3” 7—Clutch “A” 11—Main Regulator Pressure
4—Lube Relief Valve 8—Clutch “B” — Direct Drive Oil
Machine
YZ03225,000007B –19–04OCT04–1/1

021505
PN=385
Proportional Solenoid Valve Operation - De-Energized
B D F G
E
C
03
100
30
K J
L I H
Q
M
P N
–19–01FEB05
O
YZ5402B
A—Solenoid Coil F—Clutch Port K—Orifice O—Sump Pressure Oil
B—Push Pin G—Inlet Supply L—Pilot Cavity P—Proportional Solenoid
C—Seat H—Spring M—Ball Valve
D—Sump Port I—Feedback Passage N—System Pressure Oil Q—Armature
E—Spool J—Screen
The proportional solenoid valve (P) is a pilot operated, the spool position, to maintain a pressure source to the
pressure reducing cartridge valve. Its function is to pilot cavity.
provide a regulated pressure to the clutch port that can
be controlled by the TCU to a pressure less than the Pilot cavity operation enables the valve to work at a
supply pressure. Variations in inlet pressure will not current level that the TCU is capable of controlling.
affect the regulated pressure setting as long as the The armature (Q), push pin (B), and ball (M)
inlet pressure remains higher than the desired configuration controls the pilot cavity pressure, which
regulated pressure. in turn provides the force required to move the main
spool.
In operation, supply pressure enters the inlet supply
(G) port where it is blocked by the main spool (E) With the solenoid valve de-energized, flow is free to
which prevents the flow from going to the clutch port travel from the clutch port (F) to the sump port (D).
(F). The inlet supply (G) must past through a filter The orifice (K) is used to meter the flow into the pilot
screen (J) before reaching the orifice (K). The filter cavity (L). Flow coming into the pilot cavity then
screen is used to trap large particles from passes through the seat (C) and past the ball (M),
contaminating the orifice and preventing the valve from which is in the open position when the solenoid coil (A)
shifting. The orifice is used to meter the inlet flow into is de-energized. This flow then travels out through
the pilot cavity (L). The passage from the inlet supply slots on the outside threads of the valve to connect to
port is always open to the pilot cavity, regardless of the sump port (D).

021505
PN=386
Because the ball has no restriction to the flow of fluid cavity (L) and applies a force on the end of the main
exiting the pilot cavity, no pressure is built up in the spool (E) causing it to move and compress the bias
pilot cavity to act against the spool end. A bias spring spring (H). As the main spool (E) moves, it closes the
(H) is located on the opposite end of the spool to passage from the clutch port (F) to the sump port (D)
maintain spool position and prevents any slight and begins to open the inlet supply (G) pressure port
pressure buildup from actuating the clutch. The bias slightly. The flow of oil causes the pressure in the
spring requires a nominal pressure of 34.4—55.2 kPa clutch to rise.
(0.34—0.55 bar) (5.0—8.0 psi) to start spool
movement. The clutch port pressure is fed to the spring end of the
main spool via the feedback passage (I), causing the
To provide proportional control, the solenoid coil (A) is main spool to close as the clutch pressure and spring 03
energized by the use of a pulse width modulated force become equal to the pilot cavity pressure. The 100
31
(PWM) signal by a varying duty cycle of 0% to 100%. output pressure from the valve is zero at zero current
The increased duty cycle acts to increase the effective and increases to within 103.4 kPa (1.00 bar) (15.0 psi)
current in the solenoid coil windings causing an of the inlet pressure as the current to the coil is
increase in the magnetic force. As the duty cycle increased. At 100% duty cycle, the ball (M) rests fully
increases, the magnetic force on the armature (Q) against the seat (C); the flow past the seat is
increases, causing the push pin (B) to push against essentially stopped and the pressure in the pilot cavity
the ball (M) to restrict flow exiting the pilot cavity (L). (L) is the same as the supply pressure at the inlet
This restriction causes a rise in pressure in the pilot supply (G) port.
YZ03225,000007C –19–04OCT04–2/2

021505
PN=387
Main Pressure Regulator Valve Operation
C
B
03
100
32
H
D
F
–19–31JAN05
G I E
J
K
YZ5400
A—Spool D—Shims G—Pressure Regulator Valve J—Cooler Pressure Oil
B—Cooler Pressure Port E—Spring H—Inlet Port K—Sump Pressure Oil
C—Sump Port F—Spring I—System Pressure Oil
System pressure oil (I) flows from the transmission pressure for the system pressure oil (I). The system
charge pump to the main regulator inlet port (H) as the pressure oil (I) is set by adjusting springs (E) and (F)
pressure increases the main regulator spool (A) is height by adding or subtracting the number of shims
forced back until it opens the cooler pressure oil port (D) behind springs (E) and (F).
(B) and dump oil. This allows the oil to dump to the
cooler circuit until the pressure drops to the required The cooler pressure oil that leaks by the main
pressure for the transmission system pressure oil (I). regulator spool (A) is dumped to sump through main
This allows the main regulator to maintain the required regulator sump port (C).
YZ03225,000007D –19–04OCT04–1/1

021505
PN=388
Clutch Actuation
Hydraulic oil pressure is directed from the proportional

valve, through passages in the transmission control valve
housing, to drilled passages and manifolds located in the
transmission front covers that directs the oil pressure to
the seal rings on the end of the clutch shaft. The oil
pressure is transferred from the stationary manifold to the
rotating shaft in the area between the shaft seal rings.
The oil pressure then travels down a hole in the shaft until
it enters the area enclosed by clutch cylinder, the clutch 03
apply piston and the piston seals. Here it acts on the 100
33
piston area causing it to move toward the clutch pack,
compressing the belleville piston return springs and
removing the free clearance in the clutch. The piston also
moves the lube shutoff washer, trapped between the
piston and the belleville springs, causing it to uncover the
lube holes that provide cooling oil flow to the clutch. Once
the free clearance in the clutch is eliminated, the piston
applies pressure to the clutch plates causing the clutch to
transmit torque in proportion to the oil pressure applied.
YZ03225,000007E –19–04OCT04–1/1

021505
PN=389
Directional Clutch Operation
B
D F
H
E
03
100 C G
34
–19–01FEB05
L K
M
N
I
YZ1024A
J
A—Seal Ring D—Piston H—Clutch Hub Gear Assembly L—Main Regulator Pressure
B—Clutch and Separator E—Additional Separator Plate I—Clutch Engaged Oil
Plates F—Clutch Cylinder J—Clutch Disengaged M—Lubrication Oil
C—Lubrication Shut-Off G—Return Springs K—Sealing Ring N—Pressure-Free Oil
Washer
Direction clutches are numbered 1 through 4. Clutches have clutch and separator plates (B) with larger
1 and 2 engage forward gears, clutches 3 and 4 outside diameters than those used in the speed
engage reverse gears. Direction clutches are located clutches. The larger plates provide more friction area
in the upper part of the transmission. These clutches and higher thermal capacity.
are used for modulation during shifting and inching
pedal operations. Direction clutches have an additional separator plate
(E) next to the piston (D). The additional plate helps to
Direction clutches have a second lube passage in the evenly distribute the force applied by the piston to the
shaft to provide additional flow for cooling. They also larger plates.

021505
PN=390
Each direction clutch has a sealing ring (K) that helps Main Regulator pressure oil (L) is used to engage the
to contain lubrication oil in the clutch assemblies. The clutches (I). Lubrication oil (M) comes from the control
lubrication oil, once through the holes in the clutch hub valve through oil passages in the transmission front
(H), is forced to flow through the clutch disks and housing. The oil pressure for each clutch and the
separator plates (B) and out the holes in the clutch lubrication oil enter the clutch shaft at one end and are
cylinder (F) back to sump. kept separated by the clutch shaft seal rings (A).
All clutches have a lubrication shutoff washer (C) that Once the free clearance between the clutch and
restricts lubrication oil flow to the clutch when it is not separator plates is eliminated, the piston applies
engaged. When the clutch is engaged (I), the piston pressure to the clutch and separator plates, causing
(D) moves to apply pressure to the clutch plates and at the clutch to transmit torque in proportion to the oil 03
the same time moves the lubrication shutoff washer pressure applied. 100
35
and uncovers the oil passage, allowing more
lubrication to the clutch pack. The extra oil flow When the clutch is disengaged (J), main regulator
provides additional lubrication and takes away heat pressure oil becomes pressure-free oil (N) and
generated during shift modulation and inching pedal remains in the passages ready to be pressurized
operation. again.
YZ03225,000007F –19–04OCT04–2/2

021505
PN=391
Speed Clutch Operation
G
B D
C
E F
03
100
36
G
A
–19–31JAN05
J I H
K
YZ1025A
L
A—Seal Ring E—Piston H—Clutch Engaged K—Lubrication Oil

B—Clutch Hub Gear Assembly F—Lubrication Shut-Off I—Clutch Disengaged L—Pressure-Free Oil
C—Return Springs Washer J—Main Regulator Pressure
D—Clutch Cylinder G—Clutch and Separator Oil
Plates
Speed clutches are lettered A, B, C and D. These pack and the lubrication oil enter the clutch shaft at
clutches work in conjunction with the direction clutches one end and are kept separated by the three clutch
to provide eight speeds forward and seven speeds shaft seal rings (A).
reverse. If equipped with torque converter, speed
clutches are lettered A, B, and D. These clutches work All clutches have a lubrication shutoff washer (F) that
in conjunction with the direction clutches to provide six restricts lubrication oil flow to the clutch when it is not
speeds forward and six speeds reverse. Speed engaged. When the clutch is engaged (H), the piston
clutches are located in the lower part of the (E) moves to apply pressure to the clutch plates (G)
transmission. and at the same time moves the lube shutoff washer
(F) and uncovers the oil passage, allowing more
Main regulator pressure oil (J) is used to engage the lubrication to the clutch pack . The extra oil flow
speed clutches. Lubrication oil (K) comes from the provides additional lubrication and takes away heat
control valve through oil passages in the transmission generated during shift modulation.
front housing. The oil pressure for each speed clutch

021505
PN=392
Once the free clearance between the clutch and When the clutch is disengaged (I), main regulator
separator plates is eliminated, the piston applies pressure oil becomes pressure-free oil (L) and remains
pressure to the clutch and separator plates (G), in the passages ready to be pressurized again.
causing the clutch to transmit torque in proportion to
the oil pressure applied.
03
100
YZ03225,0000080 –19–04OCT04–2/2 37
Cylinder Speed Sensor Operation
The cylinder speed sensor (A) is located on the right-hand

side of the transmission rear housing. The sensor
provides a signal to the Transmission Control Unit (TCU)
that represents cylinder rpm. The cylinder rpm is
calculated by pulses per minute divided by the number of
teeth on the cylinder gear. The cylinder rpm is used in the
self-calibration routine of transmission shift times.
A—Cylinder Speed Sensor
–UN–30JUL04
YZ5399
YZ03225,0000082 –19–04OCT04–1/1

021505
PN=393
Gear Selection - Remote Mount Direct Drive

8F/8R Transmission
Two clutches must be engaged in order to transmit torque

from the transmission input to the transmission output
shaft. In NEUTRAL all clutches are in the released
condition.
Clutches 1—4 are referred to as directional clutches.

Clutches 1 and 2 engage forward gears and clutches 3
03 and 4 engage reverse gears. These clutches have two
100
passages through the shaft in order to maximize the lube
38
flow to cool the clutches. These clutches have more
friction surface area and a higher thermal capacity than
the speed clutches. The directional clutches are used for
modulation during shifting and when using the inching
pedal. The directional clutches connect the input shaft of
the transmission through various ratios to the cylinder
gear train and are located in the upper part of the
transmission.
–UN–18SEP97
Clutches lettered A, B, C, and D are referred to as speed
clutches. The speed clutches connect the cylinder gear
train to the output shaft of the transmission at various
T111308
ratios. Working in conjunction with the directional clutches
up to eight speed ranges in forward and seven speed
ranges in reverse directions are possible. The speed Remote Mount Shown
clutches are located in the lower part of the transmission.
A—Input Shaft
B—3rd Stage High and Low Reverse Directional
The following table shows which clutches are engaged for Clutch Packs
each gear. C—5th Stage “C” and “D” Speed Clutch Packs
D—Output Shaft
FORWARD E—6th Stage Gear (Idler Gear)
F—4th Stage “A” and “B” Speed Clutch Packs
Gear Range Directional Clutch Speed Clutch G—2nd Stage High and Low Forward Directional
1st 1 (Low) A Clutch Packs
2nd 2 (High) A
3rd 1 (Low) C
4th 2 (High) C
5th 1 (Low) B
6th 2 (High) B
7th 1 (Low) D
8th 2 (High) D

021505
PN=394
REVERSE
Gear Range Directional Clutch Speed Clutch
1st 3 (Low) A
2nd 4 (High) A
3rd 3 (Low) C
4th 4 (High) C
5th 3 (Low) B
6th 4 (High) B
7th 3 (Low) D
8th 4 (High) D
03
CLUTCH STAGE CLUTCH PACKS 100
ASSEMBLY 39
2nd Direction (1 and 2)

3rd Direction (3 and 4)
4th Speed (A and B)
5th Speed (C and D)
YZ03225,0000083 –19–04OCT04–2/2

021505
PN=395
Clutch and Gear Component Location - Remote Mount Direct Drive 8F/8R Transmission
03
100
40
–UN–29AUG03
YZ1001C
Direct Drive Transmission - 8 Forward / 8 Reverse

021505
PN=396
A—1st Stage Gear (Back) E—5th Stage Speed Clutch C J—6th Stage Gear (Middle) O—3rd Stage Direction Clutch
B—3rd Stage Direction Clutch F—6th Stage Gear (Back) (Idler K—6th Stage Gear (Front) 4 (High-Reverse)
3 (Low-Reverse) Assembly) L—5th Stage Speed Clutch D P—Input
C—2nd Stage Direction Clutch G—7th Stage Output Gear M—4th Stage Speed Clutch B Q—1st Stage Gear (Front)
1 (Low-Forward) H—Rear Output N—2nd Stage Direction Clutch
D—4th Stage Speed Clutch A I—Front Output 2 (High-Forward)
The transmission Shown is a remote mount full Each clutch is individually controlled by a proportional
powershift transmission. The power is controlled and hydraulic solenoid valve which receives current from
transmitted by hydraulically engaged clutch packs the Transmission Control Unit (TCU) to determine the
working together with a countershaft-type gear train. rate of the pressure rise behind each clutch piston
(See Proportional Solenoid Valve Operation - 03
The clutch packs provide up to eight forward and eight De-Energized in this group. When the transmission is 100
41
reverse speeds. Two clutch packs, one directional and engaged into gear, the engine power is connected to
one speed, have to be engaged for movement. The the output shaft of the transmission at different
directional clutch packs and speed clutch packs are direction and speed ratios, depending on which
identified as: direction and speed clutches are engaged.
Direction Clutches
2nd Stage Clutch Assembly (C) Clutch 1 or Low-Forward
(N) Clutch 2 or High-Forward
3rd Stage Clutch Assembly (B) Clutch 3 or Low-Reverse
(O) Clutch 4 or High-Reverse
Speed Clutches
4th Stage Clutch Assembly (D) Clutch A
(M) Clutch B
5th Stage Clutch Assembly (E) Clutch C
(L) Clutch D
YZ03225,0000084 –19–04OCT04–2/2

021505
PN=397
First Forward - Remote Mount Direct Drive 8F/8R Transmission
03
100
42
F
I
J
G K
H
–19–29AUG03
YZ1002C
Direct Drive Transmission - First Forward - 8 Forward / 8 Reverse

021505
PN=398
A—Input D—4th Stage Speed Clutch A F—6th Stage Gear (Middle) I—System Pressure Oil
B—1st Stage Gear (Back) E—6th Stage Gear (Back) G—7th Stage Output Gear J—Lubrication Oil
C—2nd Stage Direction Clutch (Idler Assembly) H—Output K—Pressure-Free Oil
1 (Low-Forward)
When the transmission control lever is in 1st Forward clutch packs for lubrication. Pressure free oil (K) is
(M), clutches 1 (C) and A (D) are engaged. The present in the clutches that are disengaged.
solenoids controlling the transmission clutches
(solenoids 1 and A) are driven by a signal that Engine power comes into the input shaft (A) to the 1st
produces proportional pressure and flow changes. stage gear (back) (B). Power flow is directed to the
2nd stage direction clutch 1 (C) and 4th stage speed
03
When system pressure oil (I) is applied to clutches 1 clutch A (D) and then travels through the transmission
100
and A, the piston moves to apply pressure to the to the 6th stage gear (back) (E) and (middle) (F). 43
clutch plates and at the same time, moves the Power then flows to the 7th stage output gear (G), and
lubrication shutoff washer to open the oil passage out the output shaft (H).
which allows lubrication oil (J) to flow through the
YZ03225,0000085 –19–04OCT04–2/2

021505
PN=399
First Reverse - Remote Mount Direct Drive 8F/8R Transmission
03
100 C
44
G
J
K
H L
I
–19–29AUG03
YZ1010C
Direct Drive Transmission - First Reverse - 8 Forward / 8 Reverse

021505
PN=400
A—Input D—2nd Stage Cylinder Gear G—6th Stage Gear (Middle) J—System Pressure Oil
B—1st Stage Gear (Back) E—4th Stage Speed Clutch A H—7th Stage Output Gear K—Lubrication Oil
C—3rd Stage Direction Clutch F—6th Stage Gear (Back) (Idler I—Output L—Pressure-Free Oil
3 (Low-Reverse) Assembly)
When the transmission control lever is in 1st Reverse clutch packs for lubrication. Pressure free oil (L) is
(N), Clutches 3 (C) and A (E) are engaged. The present in the clutches that are disengaged.
produces proportional pressure and flow changes. stage gear (back) (B). Power flow is directed to the 3rd
stage direction clutch 3 (C) through the 2nd stage
03
When system pressure oil (J) is applied to clutches 3 cylinder gear (D) to the 4th stage speed clutch A (E)
100
and A, the piston moves to apply pressure to the and travels through the transmission to the 6th stage 45
clutch plates and at the same time, moves the gear (back) (F) and (middle) (G). Power then flows to
lubrication shutoff washer to open the oil passage the 7th stage output gear (H), and out the output shaft
which allows lubrication oil (K) to flow through the (I).
YZ03225,0000086 –19–04OCT04–2/2

021505
PN=401
Gear Selection - Engine Mount Direct Drive

8F/8R Transmission

shaft. In Neutral all clutches are in the released condition.
Clutches numbered 1 through 4 are referred to as

directional clutches. Clutches 1 and 2 engage forward
gears and clutches 3 and 4 engage reverse gears. These
03 clutches have two passages through the shaft in order to
100
maximize the lube flow to cool the clutches. These
46
clutches have more friction surface area and a higher
thermal capacity than the speed clutches. The directional
clutches are used for modulation during shifting and when
using the inching pedal. The directional clutches connect
the input shaft of the transmission through various ratios
to the cylinder gear train and are located in the upper part
of the transmission.
Clutches lettered A, B, C, and D are referred to as speed

ratios. Working in conjunction with the directional clutches
–UN–31JAN05
up to 8 speed ranges in both forward and reverse
directions are possible. The speed clutches are located in
the lower part of the transmission.
YZ7141
The following table shows which clutches are engaged for
each gear.
A—Input Shaft
FORWARD B—3rd Stage High and Low Reverse Directional
Clutch Assembly
C—5th Stage “C” and “D” Speed Clutch
1st 1 (Low) A Assembly
2nd 2 (High) A D—Output Shaft
3rd 1 (Low) C E—6th Stage Shaft (Idler Gears)
4th 2 (High) C F—4th Stage “A” and “B” Speed Clutch Assembly
G—2nd Stage High and Low Froward Directional
5th 1 (Low) B Clutch Assembly
6th 2 (High) B
7th 1 (Low) D
8th 2 (High) D
Continued on next page YZ,CTM114,10,21 –19–16JUN98–1/2

021505
PN=402
REVERSE
Gear Directional Clutch Speed Clutch
1st 3 (Low) A
2nd 4 (High) A
3rd 3 (Low) C
4th 4 (High) C
5th 3 (Low) B
6th 4 (High) B
7th 3 (Low) D
8th 4 (High) D
03
100
CLUTCH STAGE CLUTCH PACKS 47
ASSEMBLY
4th Speed (A and B)
5th Speed (C and D)
YZ,CTM114,10,21 –19–16JUN98–2/2

021505
PN=403
Clutch And Gear Component Location - Engine Mount Direct Drive 8F/8R Transmission
B C
03
100 D E
48
H
G
K
E
L
E
M
Q
P
–19–01FEB05
YZ6174A
Direct Drive Transmission - 8 Forward / 8 Reverse


021505
PN=404
A—Input F—2nd Stage Direction Clutch I—4th Stage Speed Clutch “A” N—6th Stage Gear (Back)
B—1st Stage Gear (Front) “2” J—4th Stage Speed Clutch “D” O—7th Stage Output Gear
C—1st Stage Gear (Back) G—2nd Stage Direction Clutch K—5th Stage Speed Clutch P—Output
D—3rd Stage Direction Clutch “1” “C” Q—Park Brake
“4” H—4th Stage Speed Clutch L—6th Stage Gear (Middle) R—Clutch And Gear
E—3rd Stage Direction Clutch “B” M—6th Stage Gear (Front) Component Location
“3”
The transmission is a direct drive, remote mount full Each clutch is individually controlled by a proportional
powershift transmission. The power is controlled and hydraulic solenoid valve which receives current from
transmitted by hydraulically engaged clutch packs the Transmission Electronic Control Unit (TCU) to
working together with a countershaft-type gear train. determine the rate of the pressure rise behind each 03
clutch piston (Refer to "Transmission Control Unit 100
The clutch packs provide eight forward and seven Operation" and "Proportional Valves Operation" in this 49
reverse speeds. Two clutch packs, one directional and group). When the transmission is engaged into gear,
one speed, have to be engaged for movement. The the engine power is connected to the output shaft of
directional clutch packs and speed clutch packs are the transmission at different direction and speed ratios,
identified as: depending on which direction and speed clutches are
engaged.
Direction Clutches
(N) Clutch 2 or High-Forward
(O) Clutch 4 or High-Reverse
Speed Clutches
(M) Clutch B
5th Stage Clutch Assembly (E) Clutch C
(L) Clutch D
YZ03225,0000067 –19–03FEB05–2/2

021505
PN=405
First Forward - Engine Mount Direct Drive 8F/8R Transmission
03
100
50
J
D
K
E
F
L
H
A B
C D
E F
–19–01FEB05
G H
YZ6178
Direct Drive Transmission - First Forward - 8 Forward / 8 Reverse


021505
PN=406
A—Input D—4th Stage Speed Clutch G—7th Stage Output Gear K—Pressure Free Oil
B—1st Stage Gear (Back) “A” H—Output L—Power Flow Through
C—2nd Stage Direction Clutch E—6th Stage Gear (Back) I—System Pressure Oil Transmission
“1” F—6th Stage Gear (Middle) J—Lubrication Oil M—1st Forward
When the transmission control lever is in 1st Forward clutch packs for lubrication. Pressure free oil (K) is
(M), Clutches 1 (C) and A (D) are engaged. The present in the clutches that are disengaged.
produces proportional pressure/flow changes. stage gear (back) (B). Power flow is directed to the
2nd stage direction clutch "1" (C) and 4th stage speed
03
When system pressure oil (I) is applied to clutches 1 clutch "A" (D) and then travels through the
100
and A, the piston moves to apply pressure to the transmission to the 6th stage gear (back) (E) and 51
clutch plates and at the same time, moves the middle (F). Power then flows to the 7th stage output
lubrication shut-off washer to open the oil passage gear (G), and out the output shaft (H).
YZ03225,0000068 –19–03FEB05–2/2

021505
PN=407
First Reverse - Engine Mount Direct Drive 8F/8R Transmission
03
100
52 C
K
E
L
F
G
M
I
A B
C D
E F
–19–01FEB05
G H
I
YZ6179
Direct Drive Transmission - First Reverse - 8 Forward / 8 Reverse

021505
PN=408
A—Input E—4th Stage Speed Clutch H—7th Stage Output Gear L—Pressure Free Oil
B—1st Stage Gear (Back) “A” I—Output M—Power Flow Through
C—3rd Stage Direction Clutch F—6th Stage Gear (Back) J—System Pressure Oil Transmission
“3” G—6th Stage Gear (Middle) K—Lubrication Oil N—1st Reverse
D—2nd Stage Cylinder Gear
When the transmission control lever is in 1st Reverse clutch packs for lubrication. Pressure free oil (L) is
(N), Clutches 3 (C) and A (E) are engaged. The present in the clutches that are disengaged.
produces proportional pressure/flow changes. stage gear (back) (B). Power flow is directed to the 3rd
stage direction clutch "3" (C) through the 2nd stage 03
100
When system pressure oil (J) is applied to clutches 3 cylinder gear (D) to the 4th stage speed clutch "A" (E)
53
and A, the piston moves to apply pressure to the and travels through the transmission to the 6th stage
clutch plates and at the same time, moves the gear (back) (F) and middle (G). Power then flows to
lubrication shut-off washer to open the oil passage the 7th stage output gear (H), and out the output shaft
which allows lubrication oil (K) to flow through the (I).
YZ03225,0000069 –19–03FEB05–2/2

021505
PN=409
Gear Selection - Remote Mount Torque

Converter Drive 6F/6R Transmission A
B
Gear Selection - Torque Converter Drive Transmission
- 6 Forward and 6 Reverse

shaft. In NEUTRAL all clutches are in the released
condition.
03
100 C
Clutches 1—4 are referred to as directional clutches. G
54
Clutches 1 and 2 engage forward gears and clutches 3
and 4 engage reverse gears. These clutches have two
passages through the shaft in order to maximize the lube
flow to cool the clutches. These clutches have more F
friction surface area and a higher thermal capacity than D
the speed clutches. The directional clutches are used for
modulation during shifting and when using the inching
–UN–09MAR01
pedal. The directional clutches connect the input shaft of
the transmission through various ratios to the cylinder E
gear train and are located in the upper part of the
transmission.
T138531
T138531
Clutches lettered A, B, and D are referred to as speed
A—Input Shaft
train to the output shaft of the transmission at various B—3rd Stage High and Low Reverse Directional
ratios. Working in conjunction with the directional clutches Clutch Packs
up to six speed ranges in forward and six speed ranges in C—5th Stage “D” Speed Clutch Pack
reverse directions are possible. The speed clutches are D—Output Shaft
E—6th Stage Gear (Idler Gear)
located in the lower part of the transmission.
F—4th Stage “A” and “B” Speed Clutch Packs
G—2nd Stage High and Low Forward Directional
The following table shows which clutches are engaged for Clutch Packs
each gear.
FORWARD
1st 1 (Low) A
2nd 2 (High) A
3rd 1 (Low) B
4th 2 (High) B
5th 1 (Low) D
6th 2 (High) D

021505
PN=410
REVERSE
1st 3 (Low) A
2nd 4 (High) A
3rd 3 (Low) B
4th 4 (High) B
5th 3 (Low) D
6th 4 (High) D
CLUTCH STAGE CLUTCH PACKS

ASSEMBLY 03
2nd Direction (1 and 2) 100
55
4th Speed (A and B)
5th Speed (D)
YZ03225,0000087 –19–04OCT04–2/2

021505
PN=411
Clutch and Gear Component Location - Remote Mount Torque Converter Drive 6F/6R
Transmission
03
100
56
–UN–28AUG03
YZ1001A
Torque Converter Drive Transmission - 6 Forward

Continued / 6 Reverse
on next page YZ03225,0000088 –19–04OCT04–1/2

021505
PN=412
A—1st Stage Gear (Back) C—2nd Stage Direction Clutch G—Rear Output M—2nd Stage Direction Clutch
B—3rd Stage Direction Clutch 1 (Low-Forward) H—Front Output 2 (High-Forward)
3 (Low-Reverse) D—4th Stage Speed Clutch A I—6th Stage Gear (Middle) N—3rd Stage Direction Clutch
E—6th Stage Gear (Back) J—6th Stage Gear (Front) 4 (High-Reverse)1
(Idler Assembly) K—5th Stage Speed Clutch D O—Input
F—7th Stage Output Gear L—4th Stage Speed Clutch B P—1st Stage Gear (Front)
The transmission is a remote mount full powershift Each clutch is individually controlled by a proportional
transmission. The power is controlled and transmitted hydraulic solenoid valve which receives current from
by hydraulically engaged clutch packs working together the Transmission Control Unit (TCU) to determine the
with a countershaft-type gear train. rate of the pressure rise behind each clutch piston
(See Transmission Control Valve Operation (Remote 03
The clutch packs provide six forward and six reverse 2
Mount) or Transmission Control Valve Operation 100
57
speeds. Two clutch packs, one directional and one (Engine Mount) and see Proportional Solenoid Valve
speed, have to be engaged for movement. The Operation - De-Energized in this group). When the
directional clutch packs and speed clutch packs are transmission is engaged into gear, the engine power is
identified as: connected to the output shaft of the transmission at
different direction and speed ratios, depending on
Direction Clutches which direction and speed clutches are engaged.
(M) Clutch 2 or High-Forward
(N) Clutch 4 or High-Reversea
a
Not included in 6/3 TC transmission.
Speed Clutches
(L) Clutch B
5th Stage Clutch Assembly (K) Clutch D
1
Not Included in 6/3 Torque Converter Drive Transmission.
2
6/3 Torque Converter Drive Transmission has three reverse speeds.
YZ03225,0000088 –19–04OCT04–2/2

021505
PN=413
First Forward - Remote Mount Torque Converter Drive 6F/6R Transmission
03
100
58
J
G
K
H
–19–29AUG03
YZ1002A
Torque Converter Drive Transmission - First Forward - 6 Forward / 6 Reverse


021505
PN=414
1 (Low-Forward)
When the transmission control lever is in 1st Forward Engine power comes into the input shaft (A) to the 1st
(M), clutches 1 (C) and A (D) are engaged. The stage gear (back) (B). Power flow is directed to the
solenoids controlling the transmission clutches 2nd stage direction clutch 1 (C) and 4th stage speed
(solenoids 1 and A) are driven by a signal that clutch A (D) and then travels through the transmission
produces proportional pressure and flow changes. to the 6th stage gear (back) (E) and (middle) (F).
Power then flows to the 7th stage output gear (G), and
03
When system pressure oil (I) is applied to clutches 1 out the output shaft (H). See Clutch and Gear
100
and A, the piston moves to apply pressure to the Component Location - Remote Mount Torque 59
clutch plates and at the same time, moves the Converter Drive 6F/6R Transmission for other speed
lubrication shutoff washer to open the oil passage clutch locations.
clutch packs for lubrication. Pressure free oil (K) is
present in the clutches that are disengaged.
YZ03225,0000089 –19–04OCT04–2/2

021505
PN=415
First Reverse - Remote Mount Torque Converter Drive 6F/6R Transmission
03
100 C
60
G
J
K
H L
I
–19–29AUG03
YZ1010A
Torque Converter Drive Transmission - First Reverse - 6 Forward / 6 Reverse


021505
PN=416
C—3rd Stage Direction Clutch F—6th Stage Gear (Back) I—Output L—Pressure-Free Oil
3 (Low-Reverse)
When the transmission control lever is in 1st Reverse Engine power comes into the input shaft (A) to the 1st
(N), Clutches 3 (C) and A (E) are engaged. The stage gear (back) (B). Power flow is directed to the 3rd
solenoids controlling the transmission clutches stage direction clutch 3 (C) through the 2nd stage
(solenoids 3 and A) are driven by a signal that cylinder gear (D) to the 4th stage speed clutch A (E)
produces proportional pressure and flow changes. and travels through the transmission to the 6th stage
gear (back) (F) and (middle) (G). Power then flows to
03
When system pressure oil (J) is applied to clutches 3 the 7th stage output gear (H), and out the output shaft
100
and A, the piston moves to apply pressure to the (I). SeeClutch and Gear Component Location - 61
clutch plates and at the same time, moves the Remote Mount Torque Converter Drive 6F/6R
lubrication shutoff washer to open the oil passage Transmission for other speed clutch locations.
which allows lubrication oil (K) to flow through the
clutch packs for lubrication. Pressure free oil (L) is
YZ03225,000008A –19–04OCT04–2/2

021505
PN=417
Gear Selection - Remote Mount Torque Converter Drive 6F/3R Transmission
03
100
62
–UN–26AUG03
YZ105919
A—Input Shaft C—3rd Stage Low Reverse E—5th Stage “D” Speed F—6th Stage Gear (Idler Gear)
B—2nd Stage High and Low Directional Clutch Pack Clutch Pack
Forward Directional Clutch D—4th Stage “A” and “B”
Packs Speed Clutch Packs
Gear Selection - Torque Converter Drive Clutches lettered A, B, and D are referred to as speed
Transmission - 6 Forward and 3 Reverse clutches. The speed clutches connect the cylinder gear
Two clutches must be engaged in order to transmit ratios. Working in conjunction with the directional
torque from the transmission input to the transmission clutches up to six speed ranges in forward and three
output shaft. In NEUTRAL all clutches are in the speed ranges in reverse directions are possible. The
released condition. speed clutches are located in the lower part of the
transmission.
Clutches 1—3 are referred to as directional clutches.
Clutches 1 and 2 engage forward gears and clutch 3 The following table shows which clutches are engaged
engages reverse gears. These clutches have two for each gear.
passages through the shaft in order to maximize the
lube flow to cool the clutches. These clutches have FORWARD
more friction surface area and a higher thermal Gear Range Directional Clutch Speed Clutch
capacity than the speed clutches. The directional 1st 1 (Low) A
clutches are used for modulation during shifting and 2nd 2 (High) A
when using the inching pedal. The directional clutches 3rd 1 (Low) B
connect the input shaft of the transmission through 4th 2 (High) B
various ratios to the cylinder gear train and are located 5th 1 (Low) D
in the upper part of the transmission. 6th 2 (High) D

021505
PN=418
REVERSE
1st 3 (Low) A
2nd 3 (Low) B
3rd 3 (Low) D
CLUTCH STAGE CLUTCH PACKS

ASSEMBLY
3rd Direction (3) 03
4th Speed (A and B) 100
63
5th Speed (D)
YZ03225,0000087 –19–04OCT04–2/2

021505
PN=419
Clutch and Gear Component Location - Remote Mount Torque Converter Drive 6F/3R
Transmission
03
100
64
–UN–04FEB05
YZ7142
Torque Converter Drive Transmission - 6 Forward

Continued / 3 Reverse
on next page YZ03225,0000088 –19–04OCT04–1/2

021505
PN=420
A—1st Stage Gear (Back) D—4th Stage Speed Clutch A H—Front Output M—2nd Stage Direction Clutch
B—3rd Stage Direction Clutch E—6th Stage Gear (Back) I—6th Stage Gear (Middle) 2 (High-Forward)
3 (Low-Reverse) (Idler Assembly) J—6th Stage Gear (Front) O—Input
C—2nd Stage Direction Clutch F—7th Stage Output Gear K—5th Stage Speed Clutch D P—1st Stage Gear (Front)
1 (Low-Forward) G—Rear Output L—4th Stage Speed Clutch B
The transmission is a remote mount full powershift Each clutch is individually controlled by a proportional
transmission. The power is controlled and transmitted hydraulic solenoid valve which receives current from
by hydraulically engaged clutch packs working together the Transmission Control Unit (TCU) to determine the
with a countershaft-type gear train. rate of the pressure rise behind each clutch piston
(See Transmission Control Valve Operation (Remote
The clutch packs provide six forward and six1 reverse Mount) or Transmission Control Valve Operation 03
100
speeds. Two clutch packs, one directional and one (Engine Mount) and see Proportional Solenoid Valve
65
speed, have to be engaged for movement. The Operation - De-Energized in this group). When the
directional clutch packs and speed clutch packs are transmission is engaged into gear, the engine power is
identified as: connected to the output shaft of the transmission at
different direction and speed ratios, depending on
Direction Clutches which direction and speed clutches are engaged.
(M) Clutch 2 or High-Forward
Speed Clutches
(L) Clutch B
5th Stage Clutch Assembly (K) Clutch D
1
6/3 Torque Converter Drive Transmission has three reverse speeds.
YZ03225,0000088 –19–04OCT04–2/2

021505
PN=421
First Forward - Remote Mount Torque Converter Drive Transmission
03
100
66
J
G
K
H
–UN–14FEB05
YZ7143
Torque Converter Drive Transmission - First Forward - 6 Forward / 3 Reverse


021505
PN=422
1 (Low-Forward)
When the transmission control lever is in 1st Forward Engine power comes into the input shaft (A) to the 1st
(M), clutches 1 (C) and A (D) are engaged. The stage gear (back) (B). Power flow is directed to the
solenoids controlling the transmission clutches 2nd stage direction clutch 1 (C) and 4th stage speed
(solenoids 1 and A) are driven by a signal that clutch A (D) and then travels through the transmission
produces proportional pressure and flow changes. to the 6th stage gear (back) (E) and (middle) (F).
Power then flows to the 7th stage output gear (G), and
03
When system pressure oil (I) is applied to clutches 1 out the output shaft (H). See Clutch and Gear
100
and A, the piston moves to apply pressure to the Component Location - Remote Mount Torque 67
clutch plates and at the same time, moves the Converter Drive 6F/3R Transmission for other speed
lubrication shutoff washer to open the oil passage clutch locations.
clutch packs for lubrication. Pressure free oil (K) is
YZ03225,0000089 –19–04OCT04–2/2

021505
PN=423
First Reverse - Remote Mount Torque Converter Drive Transmission
03
100 C
68
G
J
K
H L
I
–UN–04FEB05
YZ7144
Torque Converter Drive Transmission - First Reverse - 6 Forward / 3 Reverse


021505
PN=424
C—3rd Stage Direction Clutch F—6th Stage Gear (Back) I—Output L—Pressure-Free Oil
3 (Low-Reverse)
When the transmission control lever is in 1st Reverse Engine power comes into the input shaft (A) to the 1st
(N), Clutches 3 (C) and A (E) are engaged. The stage gear (back) (B). Power flow is directed to the 3rd
solenoids controlling the transmission clutches stage direction clutch 3 (C) through the 2nd stage
(solenoids 3 and A) are driven by a signal that cylinder gear (D) to the 4th stage speed clutch A (E)
produces proportional pressure and flow changes. and travels through the transmission to the 6th stage
gear (back) (F) and (middle) (G). Power then flows to
03
When system pressure oil (J) is applied to clutches 3 the 7th stage output gear (H), and out the output shaft
100
and A, the piston moves to apply pressure to the (I). See Clutch and Gear Component Location - 69
clutch plates and at the same time, moves the Remote Mount Torque Converter Drive 6F/3R
lubrication shutoff washer to open the oil passage Transmission for other speed clutch locations.
which allows lubrication oil (K) to flow through the
clutch packs for lubrication. Pressure free oil (L) is
YZ03225,000008A –19–04OCT04–2/2

021505
PN=425
Park Brake Operation
4 5 6
7
3
2
03
100
70
11
–UN–18DEC02
1 8
12
13
T162767
T162767
10 9
Park Brake Operation (Remote Mount Shown)
1—Transmission Housing 5—Piston 8—Separator Plates 11—Oil Passage

2—Transmission Output Shaft 6—Return Spring 9—Cover 12—System Pressure Oil
3—Brake Disks 7—Pressure Applied—Brake 10—Brake Housing 13—Pressure-Free Oil
4—Pressure Released—Brake OFF
ON
The park brake is located on the rear end of Park brake components are cooled and lubricated by
transmission output shaft (2). The brake disks (3) are transmission oil moving through oil passages (11) in
splined to a hub on the output shaft and separator brake housing (10) and transmission housing (1).
plates (8) are tabbed to brake housing (10).
The park brake assembly is spring applied and
The park brake is ON (4) when there is no hydraulic hydraulically released. This multi-plate brake is
pressure applied to piston (5). Spring (6) applies immersed in an oil filled chamber located on
pressure to piston forcing brake disks and separator transmission. It is connected to and holds transmission
plates together. This locks transmission output shaft output shaft (2) stationary to prevent drive train rotation
(2) to brake housing (10), which is fixed to when applied. The park brake is applied manually by
transmission housing (1). placing the transmission control and park brake lever
in P (park). The park brake is applied automatically
The park brake is OFF (7) when system pressure oil when ignition key switch is in OFF position or when
(12), from parking brake valve, moves piston (5) service brake valve inlet switch closes due to low
against spring (6) and releases disks (3) and plates pressure.
(8).

021505
PN=426
After engine startup when both transmission control When transmission control and the machine are out of
and the machine are taken out of P (park), P (park), power from park brake reset relay is directed
transmission charge pump pressure is directed to park to PARK/NEUTRAL switch. This energizes park brake
brake. This pressure supplies release force against solenoid and releases park brake.
spring (6) to disengage park brake and allow
transmission output shaft (2) to rotate. The engine will start only when machine is in P (park).
If machine is bypass started out of P (park), park
When transmission control and machine in P (park) brake will remain applied until machine is switched
with ignition key ON, power is applied through back to P (park) then shifted into gear.
PARK/NEUTRAL switch to park/start relay, and then to
park brake reset relay. The park brake relay is 03
energized through the engine start circuit. 100
71

021505
PN=427
TRANSMISSION F TRANSMISSION
C
OIL COOLER FILTER
B
TRANSMISSION
PRESSURE
REGULATOR
COOLER LUBE RELIEF

03
RELIEF D VALVE
100 PARK
A BRAKE VALVE
E G TRANSMISSION
72 CHARGE PUMP
LUBE
SUCTION
H
TRANSMISSION SCREEN
PROPORTIONAL
M I SOLENOID
MANUAL PARK CONTROL VALVE
BRAKE RELEASE
PORT
L RELIEF 1 23 4 A BC D
VALVE
P DIRECTION CLUTCHES SPEED CLUTCHES
–19–01FEB05
PARK BRAKE
J
SECTION
PARK BRAKE
PRESSURE SWITCH N SYSTEM PRESSURE
OIL
YZ1027A
K PARK BRAKE VALVE
O PRESSURE FREE OIL
A—Park Brake E—Lube Relief Valve I—Transmission Proportional L—Relief Valve

B—Transmission Pressure F—Transmission Filter Solenoid Control Valve M—Manual Park Brake
Regulator G—Transmission Charge J—Park Brake Pressure Release Port
C—Transmission Oil Cooler Pump Switch N—System Pressure Oil
D—Cooler Relief Valve H—Suction Screen K—Park Brake Valve O—Pressure-Free Oil
Park Brake—Released to the park brake solenoid valve. The park brake
solenoid valve is energized by the park/neutral brake
NOTE: Transmission proportional solenoid control switch (K). Oil is then directed to the park brake to
valve “C” only used on direct drive release the brake.
Transmission.
The park brake is released when system pressure oil

(O) from the transmission charge pump (G) is routed

021505
PN=428
TRANSMISSION F TRANSMISSION
C
OIL COOLER FILTER
B TRANSMISSION
PRESSURE
REGULATOR
COOLER RELIEF LUBE RELIEF

VALVE
A
PARK VALVE D E G TRANSMISSION 03
BRAKE CHARGE PUMP 100
73
LUBE
SUCTION
TRANSMISSION H
SCREEN
PROPORTIONAL
M SOLENOID
I CONTROL VALVE
MANUAL PARK
BRAKE RELEASE
PORT
L 1 23 4A BC D
RELIEF VALVE P DIRECTION CLUTCHES SPEED CLUTCHES
J
–19–01FEB05
PARK BRAKE
SECTION PARK BRAKE
PRESSURE SWITCH
K N SYSTEM PRESSURE OIL
YZ1028A
PARK BRAKE VALVE
O PRESSURE FREE OIL
A—Park Brake E—Lube Relief Valve I—Transmission Proportional L—Relief Valve

B—Transmission Pressure F—Transmission Filter Solenoid Control Valve M—Manual Park Brake
Regulator G—Transmission Charge J—Park Brake Pressure Release Port
C—Transmission Oil Cooler Pump Switch N—System Pressure Oil
D—Cooler Relief Valve H—Suction Screen K—Park Brake Valve O—Pressure-Free Oil
Park Brake—Engaged or automatically when the ignition key switch is in the

OFF position.
NOTE: Transmission proportional solenoid central
valve “C” only used on direct drive The service brake pressure switch senses hydraulic
Transmission. pressure at the brake valve. If hydraulic pressure
drops below 2068.4 kPa (20.68 bar) (300.0 psi) the
The park brake is spring applied by placing the park brake release solenoid de-energizes, applying the
transmission control and park brake lever in P (park) spring applied brake.
YZ03225,000008B –19–04OCT04–4/4

021505
PN=429
Park Brake Manual Release Operation
F
G
E
D H
03
100
74
B
A
I
K
–19–01FEB05
L
YZ1029A
M
Manual Park Brake Release Diagram - Engine/Trans Non-Operational (Remote Mount Shown)
A—Hose F—Park Brake Housing K—Porta-Power Source N—Park Brake Released—

B—Transmission Housing G—Return Spring L—Manual Park Brake Engine/Transmission
C—Transmission Output Shaft H—Park Brake Valve Pressure Oil Non-Operational Diagram
D—Separator Plates I—Piston M—Manual Park Brake
E—Brake Disks J—Pressure Relief Pressure-Free Oil
The park brake is spring applied and hydraulically park brake. A direct connection between porta-power
released. It is located on the rear end of the source (K) and the park brake is required to supply
transmission output shaft (C). pressure to release the park brake. This connection is
attained by disconnecting the park brake hose from the
The park brake is engaged where there is no hydraulic park brake control valve and connecting it to the
pressure applied to the piston (I). The brake disks (E) pressure relief valve connection located under the cab
are splined to a hub on the output shaft and the and connecting a porta-power source.
separator plates (D) are tabbed to the brake housing
(F). The spring (G) applies pressure to the piston, The porta-power source (K) is connected at the fitting
forcing the brake disks and separator plates together. located on the rear kick panel on the left side of the
This locks the transmission output shaft (C) to the operator’s cab. Approximately 1379.0 kPa (13.78 bar)
brake housing (F), which is fixed to the transmission (200.0 psi) is required to release brake.
housing (B).
When the engine is not running or transmission is not

functioning, there is no system pressure to release the
YZ03225,000008C –19–04OCT04–1/1

021505
PN=430
Section 04
Diagnostics
Contents
Page
Group 200—Transmission Diagnostics and Tests

Diagnose Powershift Transmission and
Hydraulic Related Malfunctions . . . . . . . . . .04-200-2
Diagnose Park Brake Malfunctions . . . . . . . .04-200-11
Group 225—Transmission Tests

Transmission Oil Warm-Up Procedure . . . . . .04-225-1
04
Transmission Pump Flow Test . . . . . . . . . . . .04-225-2
Transmission System Pressure Test . . . . . . . .04-225-4
Lube Pressure Test. . . . . . . . . . . . . . . . . . . . .04-225-6
Transmission Clutch Pressure Test . . . . . . . . .04-225-8
Transmission Cooler Relief Valve
Pressure Test - Direct Drive
Transmission . . . . . . . . . . . . . . . . . . . . . . .04-225-12
Converter-In Pressure Test - Torque
Converter Drive Transmission . . . . . . . . . .04-225-14
Converter-Out Pressure Test - Torque
Converter Drive Transmission . . . . . . . . . .04-225-16
Torque Converter Pressure Relief Test -
Torque Converter Drive Transmission . . . .04-225-18
Converter-Out Flow Test - Torque Converter
Drive Transmission . . . . . . . . . . . . . . . . . .04-225-21
Torque Converter Stall Speed Test - Torque
Converter Drive . . . . . . . . . . . . . . . . . . . . .04-225-23
Transmission Oil Cooler Thermal Bypass
Valve Test - Torque Converter Drive
Transmission . . . . . . . . . . . . . . . . . . . . . . .04-225-25
Relief Valve Test - Torque Converter Drive
Transmission . . . . . . . . . . . . . . . . . . . . . . .04-225-27
Park Brake Pressure Test . . . . . . . . . . . . . . .04-225-30

021505
PN=1
Contents
04

021505
PN=2
Group 200
Transmission Diagnostics and Tests
04
200
1

021505
PN=433
Diagnose Powershift Transmission and

Hydraulic Related Malfunctions
Symptom Problem Solution
Transmission Overfills with Oil Hydraulic pump mounted to Inspect hydraulic pump shaft seal.
transmission seal leaking
Transmission Slippage Low oil level Check and add oil.
Transmission oil aerated Fill transmission with oil to

specifications. If problem is
unresolved, suction tube O-rings are
damaged. See Remove and Install
Suction Tube and/or see Remove
04 and Install Suction Tube - Torque
200 Converter Drive.
2
O-ring on suction tube failed Replace O-rings. (See Remove and
Install Suction Tube) and/or (See
Remove and Install Suction Tube -
Torque Converter Drive)
suction tube fitting loose Tighten Fittings. (See Remove and

Install Suction Tube) and/or (See
Torque Converter Drive)
suction screen plugged Unplug suction screen. (See

Remove and Install Suction Tube)
and/or (See Remove and Install
Suction Tube - Torque Converter
Drive)
Broken main pressure regulator Repair or replace main regulator

valve spring or main pressure valve. (See Remove and Install Main
regulator valve stuck open Pressure Regulator Valve)
Low transmission charge pump flow Replace charge pump. (See Remove
due to worn transmission charge and Install Charge pump - Remote
pump Mount Direct Drive or Remove and
Install Charge Pump - Engine Mount.
Transmission filter is bypassing oil to Change filter element. If oil still

lube (cooler). Bypass indicator on bypasses filter after new element
monitor is ON has been installed, replace filter
head.

021505
PN=434
Excessive clutch leakage See Disassemble and Assemble

Clutch - Direct Drive and/or See
Remote Mount Torque Converter
Drive.
Vehicle Lacks Power or Moves Low oil level Adjust to correct level.
Slow
Restricted filter, indicator should be Change filter.

ON
Transmission pump suction screen Remove and clean screen. (See

restricted Remove and Install Suction Tube)
04
and/or (See Remove and Install 200
Suction Tube - Torque Converter 3
Drive)
Transmission Clutch slipping Repair Clutch Assembly. See

Direct Drive and/or See Disassemble
and Assemble Clutch - Remote
Mount Torque Converter Drive.
Converter relief valve stuck open— Replace Converter Relief Valve See
Torque Converter Drive Remove and Install Cooler Relief
Transmission Valve and See Torque Converter
Pressure Relief Test - Torque
Converter Drive Transmission.
Failed torque converter—Torque Repair or replace Converter. See

Converter Drive Transmission Torque Converter Stall Speed Test -
Torque Converter Drive.
Relief valve stuck open Replace relief valve.
Torque Converter Stall RPM Too Aerated oil Put clear hose on thermal bypass
High—Torque Converter Drive outlet port. Run machine to check for
Transmission bubbles in oil.
Stuck open Converter relief valve See Converter-Out Pressure Test -

Transmission.

021505
PN=435
Leakage in torque converter seal See Converter-Out Pressure Test -

Transmissionn.
Torque converter not transferring Replace torque converter. See

power (bent fins, broken stator) Remove and Install Torque
Converter.
Torque Converter Stall RPM Too Mechanical malfunction See Remove and Install Torque
Low - Torque Converter Drive Converter.
Transmission
Transmission Shifts Too Slow Low oil level (aeration of oil) Check and add oil.
(Vehicle Stops When Changing
04
200 Gears Under Load)
4
Restricted transmission filter, Change filter.
indicator should be ON
Sticking transmission solenoid valve See Transmission System Pressure

Test, Transmission Clutch Pressure
Test.
Low transmission pump flow or See Transmission Pump Flow Test.

pump problem
Low transmission system pressure See Transmission System Pressure

Test.
Oil passaged restricted between Remove control valve and inspect oil
control valve and clutch passages.
Transmission Shifts Too Quickly High system pressure See Transmission System Pressure
Test.
Vehicle Will Not Move in Any Low transmission oil level Adjust to correct level.
Gear and Park Brake Disengaged
Air leakage in transmission pump Inspect and install suction tube

suction tube properly. See Remove and Install
Suction Tube and/or see Remove
and Install Suction Tube - Torque
Converter Drive.

021505
PN=436
Transmission filter is bypassing oil to Change transmission oil filter

lubrication (transmission oil cooler) element. If oil still bypasses filter
circuit. Bypass indicator on monitor after new element has been
should be ON installed, replace filter head.
Transmission input shaft or input See Input Shaft (First Stage) and
drive shaft broken Sixth Stage (Idler Gear) Repair -
Direct Drive or Input Shaft (First
Stage) and Sixth Stage (Idler Gear)
Repair - Torque Converter Drive
Failed torque converter—Torque See Torque Converter Stall Speed

Converter Drive Transmission Test - Torque Converter Drive.
04
Vehicle Will Not Move (Load Put Park brake dragging See Park Brake Pressure Test. 200
on Engine or Engine Stalls when 5
Shifted into Gear)
Proportional solenoid valve stuck See Transmission Clutch Pressure

open Test. See Remove and Install
Proportional Solenoid Valve.
Suction Screen Blocked Remove, inspect transmission

suction screen for metal particles.
Clean and reinstall Suction Screen.
Low Pressure in Different Gears Proportional solenoid valve stuck Identify affected valve. See
Using Same Proportional Transmission Clutch Pressure Test.
Solenoid Valve See Control Valve 8 Forward / 8
Reverse - Direct Drive Transmission,
and See Remove and Install Suction
Tube and/or see Remove and Install
Drive. Replace transmission oil filter.
Vehicle Creeps with transmission Warped disks and plates in one Replace warped disks and plates.
in NEUTRAL (Load Put on directional clutch pack and one
Engine when Service Brakes Are speed clutch pack in transmission
Applied)
Vehicle Creeps Excessively in Warped disks and plates in one Replace warped disks and plates.
Gear with Inching Pedal Fully directional clutch pack in
Depressed—Direct Drive transmission
Transmission

021505
PN=437
Transmission System Overheats Transmission overfilled with oil Check oil level. Correct.
(Transmission Slippage May
Occur)
Transmission filter restricted Remove. Inspect. Replace.
Low air flow through oil cooler Clean debris from radiator and oil
restricted cooler fins. Check serpentine belt.
Check fan to ensure fan installed
correctly. Check shroud and baffles
to ensure baffles are in correct
position.
Oil cooler plugged Clean core.

04
200
6 Pinched line to cooler Inspect line. Repair.
Clutch pack disk and plates worn Replace worn disks and plates. (See
(See Disassemble and Assemble
Clutch - Direct Drive and/or See
Drive).
Low transmission pump output See Transmission Pump Flow Test.
Extended high operation in 8TH Lower transport speed.

FORWARD
Excessive torque converter Reduce load or see Torque

slippage—Torque Converter Drive Converter Stall Speed Test - Torque
Transmission Converter Drive.
Malfunction in Converter relief See Converter-Out Pressure Test -

valve—Torque Converter Drive Torque Converter Drive
Transmission Transmission.
Lube Pressure Low, Lube relief valve stuck open, broken Inspect lube relief valve spring.
Transmission Charge Pressure spring Replace lube relief valve. See
Normal Remove and Install Lube Relief
Valve in Front Housing Repair
Low transmission pump flow or See Transmission Pump Flow Test.

pump problem

021505
PN=438
Excessive Transmission Noise Transmission oil level low Adjust to correct level.
(Under Load or No Load)
Low or no lube See Converter-Out Pressure Test -

Transmission. See Lube Pressure
Test.
See Transmission Pump Flow Test.)
Parts worn or damaged in Repair as necessary. (See

transmission Disassemble and Assemble Clutch -
Direct Drive and/or See Disassemble
and Assemble Clutch - Remote
04
Mount Torque Converter Drive). 200
7
Vehicle Makes Excessive Noise Transmission oil level low Adjust to correct level.
when Moving
Transmission mechanical problem Inspect and repair transmission.
Erratic Transmission Oil Low oil level Add oil to proper level.
Pressure
Air leak in transmission pump Inspect and replace O-ring as

suction tube: O-ring on suction tube necessary. See Remove and Install
failed, suction tube fitting loose or Suction Tube and/or see Remove
suction screen plugged and Install Suction Tube - Torque
Converter Drive. Tighten fittings.
Foreign object in suction port Remove object and check for other
contamination. See Remove and
Install Suction Tube and/or see
Excessive Torque Converter Converter bearings failed See Remove and Install Torque
Noise (Under Load or No Load) - Converter.)
Transmission
Excessive Oil Pressure Sticking main regulator valve Replace main regulator valve. See
Remove and Install Main Pressure
Regulator Valve.

021505
PN=439
Faulty spring in Main Regulator See Remove and Install Main

Pressure Regulator Valve.
Low Oil Pressure in All Gears Sticking main regulator valve See Remove and Install Main
Leakage between valve housing and Inspect gaskets and replace if

transmission case necessary. See Remove
Transmission Control Valve and
Install Transmission Control Valve.
Charge pump problem, low oil flow Replace charge pump. See Remove
and Install Charge pump - Remote
Mount Direct Drive or Remove and
04
200 Install Charge Pump - Engine Mount.
8
Transmission filter is bypassing oil to Change filter element. If oil still
lubrication (transmission oil cooler) bypasses filter after new element
circuit. Bypass indicator on monitor has been installed, replace filter
should be ON head.
Main regulator valve problem See Remove and Install Main

Control valve body cracked See Remove and Install Charge

pump - Remote Mount Direct Drive
or Remove and Install Charge Pump
- Engine Mount.
Low Pressure in One Gear but Sticking proportional solenoid control See Remove and Install Proportional
Correct in Other Gears valve Solenoid Valve. See Remove and
Install Suction Tube and/or see
Broken wire to one solenoid, or dirty Repair wire.

connection
Broken seal ring on input end of Replace seal ring. See Disassemble
clutch assembly Front and Rear Housing - Engine
Mount or Disassemble Front and
Rear Housing - Remote Mount. See
Install Seal Rings.

021505
PN=440
Bore sleeve on valve end of clutch Replace bore sleeves. See

shaft worn Disassemble Front and Rear
Housing - Engine Mount or
Disassemble Front and Rear
Housing - Remote Mount. See Front
Housing Repair or Rear Housing
Repair - Engine Mount. See Remove
and Install Housing Bore Sleeves.
Outer or inner piston seal leaking Replace seals. See Disassemble

and Assemble Clutch - Direct Drive
and/or See Disassemble and
Assemble Clutch - Remote Mount
04
200
Transmission Breather Oil Transmission overfilled with oil Check oil level. Correct. 9
Leakage
Charge pump suction tube damaged Inspect tube. Tighten fittings. See
or loose Remove and Install Suction Tube
and/or see Remove and Install
Drive.
Charge pump suction tube O-rings Inspect and replace.

damaged or missing
Filter or Filter Oil Lines Blow Out Hoses bend too sharply or are Reroute hoses.
kinked
Defective hose Replace hose.
Main regulator valve Change valve and change filter and

oil.
Problem of filter bypass valve Replace oil filter head.
System plumbing incorrect Correct plumbing.
Filter O-ring Replace filter.

021505
PN=441
With Engine at Low Idle, Low Leakage in clutch circuits for gear Repair gear stage with low pressure.
Lube Pressure in Some Gears with low lube See Disassemble and Assemble
but Correct in Other Gears Clutch - Direct Drive and/or See
Drive
Excessive Lube Pressure in Leakage past seal ring on input end Repair seal ring. See Disassemble
Some Gears but Correct in Other of clutch assembly Front and Rear Housing - Engine
Gears Mount or Disassemble Front and
Rear Housing - Remote Mount. See
Install Seal Rings.
Low Transmission Cooler Inlet Transmission filter is bypassing oil to Change filter element. If oil still
04
200 Pressure. Lube Pressure Is lubrication (transmission oil cooler) bypasses filter after new element
10 Correct circuit. Bypass indicator on monitor has been installed, replace filter
should be ON head.
Low Transmission Cooler Inlet Low pump flow See Transmission Pump Flow Test.
Pressure and Lube Pressure Replace pump. See Remove and
Install Charge pump - Remote Mount
Direct Drive and/or see Remove and
Install Charge Pump - Engine Mount.
Leakage between valve housing and Replace gaskets. See Remove

rear transmission case Transmission Control Valve and .
Leakage past proportional solenoid Replace proportional solenoid valve

valve O-rings O-rings. See Remove and Install
Proportional Solenoid Valve
YZ03225,000008D –19–04OCT04–9/9

021505
PN=442
Diagnose Park Brake Malfunctions
Park Brake Engages While Transmission oil level low Inspect oil level and fill.
Vehicle Is Moving
Low park brake pressure See Park Brake Pressure Test.
Park Brake Will Not Release Low park brake pressure See Park Brake Pressure Test.
Park Brake Will Not Hold Park Brake piston hanging up in Repair park brake.
bore
Broken park brake spring or Replace park brake spring.

assembled wrong
04
200
Excessively worn park brake disks Replace park brake disks and plates. 11
and plates
Park Brake Overheats Low park brake pressure See Park Brake Pressure Test.
Warped brake disks and plates Replace warped disks and plates.
Brake piston hanging up in bore Repair park brake piston.
Brake stack height incorrect (too Repair park brake piston.

many plates)
Park Brake Noisy Brake dragging See Park Brake Pressure Test.
YZ07927,00003CA –19–20DEC04–1/1

021505
PN=443
04
200
12

021505
PN=444
Group 225
Transmission Tests
Transmission Oil Warm-Up Procedure
SPECIFICATIONS
Transmission Oil Temperature 48.9°C ± 5.6°C
(120.0°F ± 10.0°F)
Direct Drive Transmission:
1. Operate machine at fast idle in 8TH FORWARD, or

under a load, until oil temperature is within specified
range.
Transmission Oil Warm-Up Procedure—Specification

Transmission Oil—Temperature........................................ 48.9°C ± 5.6°C
(120.0°F ± 10.0°F)
04
Torque Converter Drive Transmission: 225
1
1. Release park brake.
2. Apply service brake.
3. Shift to 3rd Forward.
IMPORTANT: Do not exceed 30 seconds of stall

without shifting to neutral for 15
seconds. Failure to do so will cause
excessive internal heat and
transmission damage.
4. Run engine at fast idle until test specification is met or

for 30 seconds (whichever comes first).
5. Reduce speed, shift to neutral, and run for 15 seconds.
6. Repeat steps 2—5 until oil is to test specification.
Transmission Oil Warm-Up Procedure—Specification

(120.0°F ± 10.0°F)
YZ03225,0000091 –19–04OCT04–1/1

021505
PN=445
Transmission Tests
Transmission Pump Flow Test
SPECIFICATIONS
(120.0°F ± 10.0°F)
Transmission Pressure 1861.6 ± 103.4 kPa
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
Engine Speed 2000 ± 5 rpm
New Pump Flow 98.4 L/min
(typical) (26.0 gpm)
Pump Allowable Flow 75.7 L/min
(minimum) (20.0 gpm)
TOOLS
Digital Thermometer
04
225 Electronic Tachometer
2 1 5/16 ORB x -12 M ORFS Adapter
Flow Meter
–UN–27OCT97
Hose
Gauge 0.0—4136.9 kPa
(0.0—41.37 bar)
(0.0—600.0 psi)
T111961B
1. Connect Digital Thermometer.
NOTE: Monitor tachometer in the vehicle can be used.

A—Hose
B—Hose
2. Use display monitor tachometer or install Clamp-On C—Flow Meter
Electronic Tachometer Installation. D—Adapter (2 used)
3. Install adapters (D) into flow meter (C).
4. Disconnect filter hose (B) from transmission oil filter

and install in flow meter.
5. Connect a hose (A) from flow meter to transmission

filter.
IMPORTANT: Flow meter loading valve must be open

before starting the engine and during
the test to prevent damage to the
transmission pump.
6. Open flow meter loading valve.

021505
PN=446
Transmission Tests
7. Check and correct transmission oil level. (See

Operator’s Manual for fill procedure.)
8. Heat transmission oil to test specifications.
Transmission Pump Flow Test—Specification

(120.0°F ± 10.0°F)
9. Put transmission and park brake control lever in PARK.
10. Check transmission pressure with 0.0—4136.9 kPa

(0.0—41.4 bar) (0.0—600.0 psi) gauge.

Transmission Oil—Pressure ...................................... 1861.6 ± 103.4 kPa
(18.62 ± 1.03 bar)
04
(270.0 ± 15.0 psi)
225
3
If pressure is not within specification, adjust pressure. See
Transmission System Pressure Test in this group.
11. Run engine at specified speed and record flow.

Engine—Speed .................................................................... 2000 ± 5 rpm
If flow is not within specification, remove and clean

transmission suction screen and test flow again.

New Pump—Flow .......................................................... typical 98.4 L/min
(26.0 gpm)
Pump Allowable—Flow............................................. minimum 75.7 L/min
(20.0 gpm)
If still low, replace pump and/or transmission filter.
YZ03225,0000092 –19–04OCT04–2/2

021505
PN=447
Transmission Tests
Transmission System Pressure Test
SPECIFICATIONS
(120.0°F ± 10.0°F)
Transmission Oil Pressure 1861.6 ± 103.4 kPa
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
TOOLS
Digital Thermometer
Electronic Tachometer
(0.0—41.37 bar)
(0.0—600.0 psi)
04
225
4 NOTE: Isolate the transmission circuit from the winch
circuit by disconnecting the winch pressure line
inlet to the winch control valve. Close all lines and
fittings using caps and plugs.
–UN–25JAN05
1. Connect Digital Thermometer..
NOTE: Monitor tachometer in the Vehicle can be used.
YZ5393
2. Use monitor tachometer or install Clamp-On Electronic
Tachometer Installation. A—Fitting
B—Gauge
3. Install 0.0—4136.9 kPa (0.0—41.4 bar) (0.0—600.0 C—Pressure Regulating Valve
psi) gauge (B) on quick coupler and fitting (A).
4. Heat transmission oil to specification.
Transmission System Pressure Test—Specification

(120.0°F ± 10.0°F)
See Transmission Oil Warm-Up Procedure in this group.
6. Run engine at specified speed and record pressure.

Engine—Speed .................................................................... 2000 ± 5 rpm

021505
PN=448
Transmission Tests
If pressure is not to specification, adjust pressure

regulating valve (C) by adding or removing shims as
required to obtain correct pressure.

Transmission Oil—Pressure ......................................... 1861.6 ± 103 kPa
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
YZ03225,0000093 –19–04OCT04–2/2
04
225
5

021505
PN=449
Transmission Tests
Lube Pressure Test
SPECIFICATIONS
(120.0°F ± 10.0°F)
Lube Relief Pressure 137.9 kPa
(Minimum) (1.38 bar)
(20.0 psi)
Lube Relief Pressure 310.3 kPa
(Maximum) (3.10 bar)
(45.0 psi)
TOOLS
Digital Thermometer
04
225 7/16 -20 Female Flare Quick Coupler
6 7/16 -20 37° x 7/16 -20 M ORB Connector
(0.0—4.14 bar)
(0.0—60.0 psi)
–UN–25JAN05
NOTE: Isolate the transmission circuit from the winch
circuit by disconnecting the winch pressure line at
YZ5392
the transmission control valve.

A—Test Port

Tachometer Installation.
3. Install 0.0—413.7 kPa (0.0—4.14 bar) (0.0—60.0 psi)

gauge, quick coupler, and Connector to test port (A).
Lube Pressure Test—Specification

(120.0°F ± 10.0°F)
6. Run engine at specified speed and record lube

pressure.

021505
PN=450
Transmission Tests

Engine—Speed .................................................................... 2000 ± 5 rpm
If lube pressure is below specification, block off cooler

line. If pressure increases, check cooler relief.

Lube Relief—Pressure .............................................. Minimum 137.9 kPa
(1.38 bar)
(20.0 psi)
Lube Relief—Pressure ............................................. Maximum 310.3 kPa
(3.10 bar)
(45.0 psi)
If pressure is still below specification, check main system

pressure. If OK, check lubrication relief valve.
04
225
7
YZ03225,0000094 –19–04OCT04–2/2

021505
PN=451
Transmission Tests
Transmission Clutch Pressure Test
04
225
–UN–25JAN05
8
YZ5394
A—Direction Clutch 3 D—Speed Clutch B (3rd G—Speed Clutch D (4th I—Direction Clutch 4
(Low-Reverse) Speed) Speed) (High-Reverse)
B—Direction Clutch 1 E—Speed Clutch A (1st Speed) H—Speed Clutch C (2nd
(Low-Forward) F—Pressure Regulating Valve Speed)
C—Direction Clutch 2 (System Pressure)
(High-Forward)
Transmission Clutch Pressure Test—Direct Drive TOOLS

Transmission Digital Thermometer
Gauge (3 used) 0.0—4136.9
SPECIFICATIONS (0.0—41.37 bar)
Transmission Oil Temperature 48.9°C ± 5.6°C (0.0—600.0 psi)
(120.0°F ± 10.0°F) 7/16 -20 Female Flare Quick Coupler (2 used)
Engine Speed 2000 ± 5 rpm 7/16 -20 37° x 7/16 -20 M ORB Connector (2 used)
Transmission Oil Pressure 1861.6 ± 103.4 kPa JT05801 Electronic Tachometer
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
Main Pressure and Each Clutch 103.4 kPa
Pressure Difference (1.03 bar)
(maximum) (15.0 psi)

021505
PN=452
Transmission Tests
NOTE: For an eight-gauge method, Powershift 5. Heat transmission oil to test specifications.
Transmission Test Kit can be converted by
using eight 4136.9 kPa (41.37 bar) (600.0 psi) Transmission Clutch Pressure Test—Direct Drive
gauges and eight Connectors. Transmission—Specification
Transmission Oil—Temperature ................................. 48.9°C ± 5.6°C
(120.0°F ± 1.00°F)
FORWARD
Gear Range Directional Clutch Speed Clutch See Transmission Oil Warm-Up Procedure in this
1st 1 (Low) A (1st) group.
2nd 2 (High) A (1st)
3rd 1 (Low) C (2nd) 6. Run engine at specified speed.
4th 2 (High) C (2nd)
5th 1 (Low) B (3rd) Transmission Control Clutch Pressure Test—Direct Drive
6th 2 (High) B (3rd) Transmission—Specification
Engine—Speed .............................................................. 2000 ± 5 rpm
7th 1 (Low) D (4th)
8th 2 (High) D (4th)
REVERSE
7. Shift to each gear and record the following:
04
Gear Range Directional Clutch Speed Clutch 225
• Engagement of proper clutches. Refer to Gear 9
1st 3 (Low) A (1st) Selection - Remote Mount Direct Drive 8F/8R
Transmission and/or Gear Selection - Engine
3rd 3 (Low) C (2nd) Mount Direct Drive 8F/8R Transmission and/or
4th 4 (High) C (2nd)
5th 3 (Low) B (3rd) Converter Drive 6F/6R Transmission and/or Gear
6th 4 (High) B (3rd)
Selection - Remote Mount Torque Converter
7th 3 (Low) D (4th) Drive 6F/6R Transmission.
• Clutch pressure.
CLUTCH STAGE ASSEMBLY CLUTCH PACKS
2nd Direction (1 and 2) Transmission Clutch Pressure Test—Direct Drive
3rd Direction (3 and 4) Transmission—Specification
Transmission Oil—Pressure ............................... 1861.6 ± 103.4 kPa
4th Speed (A and B) (18.62 ± 1.03 bar)
5th Speed (C and D) (270 ± 15 psi)
Main Pressure and Each Clutch
Pressure—Difference......................................... maximum 103.4 kPa
1. Connect Digital Thermometer. (1.03 bar)
(15.0 psi)
2. Use monitor tachometer or Install Clamp-On

Electronic Tachometer Installation
If clutch engagement is not correct for a certain
3. Install frame locking bar. gear, the proportional solenoid valve for that gear
should be replaced.
4. Disconnect rear drive shafts from the transmission
output shaft. Raise front axle off ground using the
blade and support with stands.

021505
PN=453
Transmission Tests
–UN–25JAN05
04
225
10
YZ5395
A—Direction Clutch 3 C—Direction Clutch 2 E—Speed Clutch A (1st Speed) H—Direction Clutch 4
(Low-Reverse) (High-Forward) F—Pressure Regulating Valve (High-Reverse)
B—Direction Clutch 1 D—Speed Clutch B (3rd (System Pressure)
(Low-Forward) Speed) G—Speed Clutch D (4th
Speed)
Transmission Clutch Pressure Test—Torque NOTE: For an eight-gauge method, Powershift

Converter Drive Transmission Transmission Test Kit can be converted by
using eight 4136.9 kPa (41.37 bar) (600 psi)
SPECIFICATIONS gauges and eight Connectors.
(120.0°F ± 10.0°F) FORWARD
Engine Speed 2000 ± 5 rpm Gear Range Directional Clutch Speed Clutch
Transmission Oil Pressure 1861.6 ± 103.4 kPa 1st 1 (Low) A (1st)
(18.62 ± 1.03 bar) 2nd 2 (High) A (1st)
(270.0 ± 15.0 psi) 3rd 1 (Low) B (2nd)
Main Pressure and Each Clutch 103.4 kPa 4th 2 (High) B (2nd)
Pressure Difference (1.03 bar) 5th 1 (Low) D (3rd)
(Maximum) (15.0 psi)
6th 2 (High) D (3rd)
REVERSE
TOOLS
Digital Thermometer
1st 3 (Low) A (1st)
Gauge (3 used) 0.0—4136.9
(0.0—41.37 bar)
(0.0—600.0 psi) 3rd 3 (Low) B (2nd)
4th 4 (High) B (2nd)
7/16 -20 Female Flare Quick Coupler (2 used)
5th 3 (Low) D (3rd)
7/16 -20 37° x 7/16 -20 M ORB Connector (2 used) 6th 4 (High) D (3rd)

021505
PN=454
Transmission Tests
CLUTCH STAGE ASSEMBLY CLUTCH PACKS 7. Shift to each gear and record the following:
3rd Direction (3 and 4) • Engagement of proper clutches. Refer to Gear
4th Speed (A and B) Selection - Remote Mount Direct Drive 8F/8R
Transmission and/or Gear Selection - Engine
5th Speed (D)
Mount Direct Drive 8F/8R Transmission and/or
1. Connect Digital Thermometer in this group. Converter Drive 6F/6R Transmission and/or Gear
Selection - Remote Mount Torque Converter
NOTE: Monitor tachometer in the vehicle can be used. Drive 6F/6R Transmission.
• Clutch pressure.
2. Use monitor tachometer or install Clamp-On
Electronic Tachometer Installation. Transmission Clutch Pressure Test—Torque Converter Drive
3. Install frame locking bar. Transmission Oil—Pressure ............................... 1861.6 ± 103.4 kPa
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi) 04
4. Disconnect rear drive shafts from the transmission Main Pressure and Each Clutch 225
output shaft. Raise front axle off ground using the Pressure—Difference......................................... Maximum 103.4 kPa 11
blade and support with stands. (1.03 bar)
(15.0 psi)
Transmission Clutch Pressure Test—Torque Converter Drive

Transmission Oil—Temperature ................................. 48.9°C ± 5.6°C If clutch engagement is not correct for a certain
(120.0°F ± 10.0°F)
gear, the proportional solenoid valve for that gear
should be replaced.
See Transmission Oil Warm-Up Procedure in this
group.
6. Run engine at specified speed.
Transmission Clutch Pressure Test—Torque Converter Drive

Engine—Speed .............................................................. 2000 ± 5 rpm
YZ03225,0000095 –19–04OCT04–4/4

021505
PN=455
Transmission Tests
Transmission Cooler Relief Valve Pressure

Test - Direct Drive Transmission
SPECIFICATIONS
(120.0°F ± 10.0°F)
Cooler Relief Valve Pressure 827.4 kPa
(8.27 bar)
(120.0 psi)
TOOLS
Digital Thermometer
7/16 -20 Female Flare Quick Coupler
04 7/16 -20 37° x 7/16 -20 M ORB Connector
225
12 Gauge 0.0—1103.2 kPa
(0.0—11.03 bar)
(0.0—160.0 psi)
–UN–25JAN05
1. Connect Digital Thermometer in this group.
YZ5391
A—Test Port
3. Install Connector, 7/16 -20 Female Flare Quick
B—Cooler Relief Valve
Coupler, and 0.0—1103.2 kPa (0.0—11.03 bar) (0.0—
160.0 psi) gauge to test port (A).
Transmission Cooler Relief Valve Pressure Test—Direct Drive

(12.0°F ± 10.0°F)
5. Stop the oil flow through transmission oil cooler by

removing cooler inlet hose from cooler, plugging hose,
and capping fitting on cooler.

021505
PN=456
Transmission Tests

Engine—Speed .................................................................... 2000 ± 5 rpm
If relief pressure is not within specification, replace cooler

relief valve (B).

Cooler Relief Valve—Pressure.................................................. 827.4 kPa
(8.27 bar)
(120.0 psi)
04
225
13
YZ03225,0000096 –19–04OCT04–2/2

021505
PN=457
Transmission Tests
Converter-In Pressure Test - Torque

Converter Drive Transmission
SPECIFICATIONS
(120.0°F ± 10.0°F)
Converter-In Pressure 655.0 kPa
(at 48.9°C (120.0°F) min.) (6.55 bar)
(95.0 psi)
TOOLS
Digital Thermometer
04 (0.0—11.03 bar)
225 (0.0—150.0 psi)
7/16 -20 37° x 7/16 -20 M ORB Connector
–UN–25JAN05
YZ5396
B—Gauge
3. Install 7/16 -20 37° x 7/16 -20 M ORB Connector, 7/16
-20 Female Flare Quick Coupler, and 0.0—1103.2 kPa
(0.0—11.03 bar) (0.0—150.0 psi) gauge (B) to test port
(A).
Converter-In Pressure Test—Torque Converter Drive

(120.0°F ± 10.0°F)
Converter-In Pressure Test—Torque Converter Drive

Engine—Speed .................................................................... 2000 ± 5 rpm

021505
PN=458
Transmission Tests
Converter-In—Pressure
(at 48.9°C (120.0°F) min.) ............................................................ 655 kPa
(6.55 bar)
(95.0 psi)
Low converter-in pressure can be caused by:
• Converter minimum pressure regulator valve set too

low, stuck open, or spring broken or weak.
• Transmission pump worn. See Transmission Pump
Flow Test in this group.
• Control valve or valve gasket leakage. Remove and
inspect.
• Converter relief valve set too low, stuck open, or spring
broken or weak. See Torque Converter Pressure Relief
Test - Torque Converter Drive Transmission in this
group. 04
225
15
YZ03225,0000097 –19–04OCT04–2/2

021505
PN=459
Transmission Tests
Converter-Out Pressure Test - Torque

SPECIFICATIONS
(120.0°F ± 10.0°F)
Converter-Out Pressure 655 kPa
(at 48.9°C (120.0°F) min) (6.55 bar)
(95.0 psi)
TOOLS
Digital Thermometer
Gauge 0—2068.4 kPa
04 (0.0—20.68 bar)
225 (0.0—300.0 psi)
7/16 -20 37° x 7/16 -20 M ORB Connector
–UN–25JAN05
YZ5397
B—Gauge
3. Install 0.0—2068.4 kPa (0.0—220.68 bar) (0.0—300.0
psi) gauge (B) to test port (A).
Converter-Out Pressure Test - Torque Converter Drive

(120.0°F ± 10.0°F)
Converter-Out Pressure Test - Torque Converter Drive

Engine—Speed .................................................................... 2000 ± 5 rpm

021505
PN=460
Transmission Tests
Converter-Out—Pressure
(at 48.9°C (120.0°F) min.) .......................................................... 655 kPa
(6.55 bar)
(95.0 psi)
Low converter-out pressure can be caused by:
• Transmission pump worn. See Torque Converter

Pressure Relief Test - Torque Converter Drive
Transmission in this group.
• Control valve or valve gasket leakage. Remove and
inspect.
• Torque converter leakage. Disassemble and inspect.
• Converter relief valve set too low, stuck open, or spring
broken or weak. See Torque Converter Pressure Relief
Test - Torque Converter Drive Transmission in this
group. 04
• Plugged suction screen. Disassemble transmission to 225
inspect suction screen. 17
High Converter-out pressure can be caused by:
• Pinched or restricted hose. Check

converter-out-to-thermal bypass inlet and return hoses.
• Thermal bypass valve restriction. Disassemble and
inspect components.
YZ03225,0000098 –19–04OCT04–2/2

021505
PN=461
Transmission Tests
Torque Converter Pressure Relief Test -

Torque Converter Drive Transmission
SPECIFICATIONS
(12.0°F ± 10.0°F)
Engine Speed Slow idle
Converter Relief Valve Pressure 620.5 kPa
(6.21 bar)
(90.0 psi)
TOOLS
Digital Thermometer
04 7/16 -20 37° x 7/16 -20 M ORB Connector
225
18 Gauge 2068.4 kPa
(20.68 bar)
(300.0 psi)

021505
PN=462
Transmission Tests
04
225
19
–UN–30MAR01
A
T139649
T139649
1. Disconnect hose from thermal bypass valve. Install NOTE: Monitor tachometer in the vehicle can be used.
union (A) and flowmeter.
3. Use monitor tachometer or install Clamp-On
2. Connect Digital Thermometer. Electronic Tachometer Installation.

021505
PN=463
Transmission Tests
4. Install 7/16 -20 37° x 7/16 -20 M ORB Connector, 7/16

-20 Female Flare Quick Coupler, and 2068 kPa (21
bar) (300 psi) gauge to test port (A).
Torque Converter Pressure Relief Test - Torque Converter Drive

Transmission Oil—Temperature......................................... 48.9°C ±5.6°C
(120.0°F ± 10.0°F)
7. Run engine at specified speed.

04
225 Torque Converter Pressure Relief Test - Torque Converter Drive
20 Transmission—Specification
Engine—Speed ............................................................................ Slow idle
–UN–26JAN05
8. Close flow-meter restriction valve and record pressure.
If relief pressure is not within specification, replace

Converter Relief Valve (B).
YZ5398
Torque Converter Pressure Relief Test - Torque Converter Drive
A—Test Port
Converter Relief Valve—Pressure .......................................... 620.5 kPa
B—Converter Relief Valve
(6.21 bar)
(90.0 psi)
YZ03225,0000099 –19–04OCT04–3/3

021505
PN=464
Transmission Tests
Converter-Out Flow Test - Torque Converter Drive Transmission
04
225
21
–UN–30MAR01
A
T139649
T139649
A—Union
SPECIFICATIONS TOOLS
Transmission Oil Temperature 48.9°C ± 5.6°C Flow-meter 1.9 - 283.9 l/min (0.5 - 75 gpm)
(120.0°F ± 10.0° F) Digital Thermometer
Converter-Out Flow Rate 98 L/min 1. Disconnect hose from thermal bypass valve. Install
(at 48.9°C (120.0°F) min) (26 gpm) union (A) and flow-meter.
ESSENTIAL TOOLS
38H1281 Union (-16 M ORFS X -16 M ORFS)
Parker No. 16HLO-S Union (-16 M ORFS X -16 M ORFS)

021505
PN=465
Transmission Tests
NOTE: Monitor tachometer in the vehicle can be used. • Cold transmission oil.
• Plugged suction screen.
3. Use monitor tachometer or install Clamp-On • Air leak in pump suction tube.
Electronic Tachometer Installation. • Plugged thermal bypass valve or lube passage.
See Lube Pressure Test in this group.
4. Heat transmission oil to test specification. See • Low transmission pump flow. See Transmission
Transmission Oil Warm-Up Procedure in this group. Pump Flow Test in this group.
• Transmission control valve gasket leakage.
Converter-Out Flow Test—Torque Converter Drive Remove and inspect gasket.
Transmission—Specification • Torque Converter Relief Valve stuck open, spring
Transmission Oil—Temperature ................................. 48.9°C ± 5.6°C
(120.0°F ± 10.0°F) weak or broken. See Torque Converter Pressure
Relief Test - Torque Converter Drive
NOTE: If Converter-out flow is low in one gear, check Transmission in this group.
for piston or sealing ring leakage in the • Torque converter leakage. See Disassemble
elements for that gear. Torque Converterand see Assemble Torque
Converter.
04
225 6. Run engine at test speed.
22 Test Results
Converter-Out Flow Test—Torque Converter Drive Gear Flow (gpm) at 48.9°C (120.0°F)
Transmission—Specification 1st Forward 26
Engine—Speed .............................................................. 2000 ± 5 rpm
2nd Forward 26
Record converter-out flow in each gear. Compare to 3rd Forward 26
specification. 4th Forward 27

5th Forward 26
Converter-Out Flow Test—Torque Converter Drive 6th Forward 27
Converter-Out—Flow Rate 1st Reverse 27
(at 48.9°C (120.0°F) min.) ................................................ 98.4 L/min 2nd Reverse 27
(26.0 gpm)
3rd Reverse 27
If Converter-out flow is low in all gears, check the 4th Reverse 28
following: 5th Reverse 27

6th Reverse 27
• Low oil level in transmission.
YZ03225,000009A –19–04OCT04–2/2

021505
PN=466
Transmission Tests
Torque Converter Stall Speed Test - Torque

Converter Drive
SPECIFICATIONS
(180.0°F ± 20.0°F)
Hydraulic Oil Temperature 65.6°C ± 5.6°C
(150.0°F ± 10.0°F)
Engine Speed Fast Idle
Engine at Converter Stall Speed 1795 rpm
TOOLS
Digital Thermometer
04
225
23
2. Use monitor tachometer or JT05801 Clamp-On

Electronic Tachometer Installation.
3. Determine whether your machine has No.1 or No.2

fuel. Engine speed will be different for each grade of
fuel.
4. Auto and clutch cutoff (Neutral) switches must be in

the “OFF” position. Apply service brakes and release
Park brake.
5. Warm transmission until temperature is at test

specification.
Torque Converter Stall Speed Test—Specification

Transmission Oil—Temperature...................................... 82.2°C ± 11.1°C
(180.0°F ± 20.0°F)
6. Warm Hydraulic system to test specification.

Hydraulic Oil—Temperature .............................................. 65.6°C ± 5.6°C
(150.0°F ± 10.0°F)
7. Release park brake and hold machine with service

brakes.
Shift transmission to 6th forward.

021505
PN=467
Transmission Tests
Run engine at test specification.

Engine—Speed ............................................................................ Fast Idle
8. Record engine speed and compare to specification.

Engine at Converter Stall—Speed ..................................... See Table rpm
Stall rpm per Applicationa

John Deere 460/640/648 Skidders 1759 rpm
a
Application Specific
04
225 If Engine RPM is Excessively Low:
24
• Engine horsepower or an incorrect torque converter is
indicated.
If Engine RPM is Excessively High:
• Clutch slippage or incorrect torque converter is

indicated. See Diagnose Powershift Transmission and
Hydraulic Related Malfunctions.
Engine is Overpowered:
• Remove and replace torque converter. See Remove

and Install Torque Converter Assembly.
YZ03225,000009B –19–04OCT04–2/2

021505
PN=468
Transmission Tests

Valve Test - Torque Converter Drive
Transmission
SPECIFICATIONS
Transmission Oil Temperature 82.2°C± 11.1°C
(180.0°F ± 20.0°F)
Thermal Bypass Valve Flow (Starting 82.2°C ± 11.1°C
to Open) Temperature (180.0°F ± 20.0°F)
Thermal Bypass Valve Flow (Full 96.1°C
Open) Temperature (205.0°F)
Flow Rate 94.6 L/min
(Maximum) (25 gpm)
TOOLS 04
Union (-16 M ORFS X -16 M ORFS) 225
25
Parker No. 16HLO-S Union (-16 M ORFS X -16 M ORFS)
SERVICE EQUIPMENT AND TOOLS

D01074AA Flow-meter 1.9 — 283.9 l/min
(0.5—75 gpm)
Temperature Reader

021505
PN=469
Transmission Tests
04
225
26
–UN–30MAR01
A
T140523
T140523
A—Union
1. Disconnect hose from cooler at thermal bypass 6. Heat transmission oil temperature to test
valve. Install union (A) and flow-meter. specification. See Transmission Oil Warm-Up
Procedure in this group.
2. Install temperature reader at flow-meter.
Transmission Oil Cooler Thermal Bypass Valve Test—Torque
Converter Drive Transmission—Specification
3. Open restriction valve on flow-meter.
Transmission Oil—Temperature ............................... 82.2°C ± 11.1°C
(180.0°F ± 20.0°F)
7. Run engine at test speed.
Transmission Oil Cooler Thermal Bypass Valve Test—Torque
5. Use monitor tachometer or install Clamp-On Converter Drive Transmission—Specification
Electronic Tachometer Installation. Engine—Speed .............................................................. 2000 ± 5 rpm

021505
PN=470
Transmission Tests
8. Flow-meter reading must start to increase at Transmission Oil Cooler Thermal Bypass Valve Test—Torque
specified temperature. Converter Drive Transmission—Specification
Thermal Bypass Valve Flow
(Full Open)—Temperature....................................................... 96.1°C
Transmission Oil Cooler Thermal Bypass Valve Test—Torque (205°F)
Converter Drive Transmission—Specification Maximum—Flow Rate ....................................................... 94.6 L/min
Thermal Bypass Valve Flow (25 gpm)
(Starting to Open)—
Temperature ............................................................. 82.2°C ± 11.1°C
(180.0°F ± 20.0°F) 10. If valve does not meet specifications, inspect valve
and repair.
9. Flow meter reading must be at maximum flow at
specified temperature. 11. Repeat test after repair.
04
225
27
YZ03225,000009C –19–04OCT04–3/3

Relief Valve Test - Torque Converter Drive
Transmission
SPECIFICATIONS
(180.0°F ± 20.0°F)
Engine Speed Slow Idle
Cooler Bypass Pressure 620.5 kPa
(6.21 bar)
(90.0 psi)
TOOLS
Plug (-16 M ORFS)
Tee (-16 M ORFS x -16 F ORFS x -16 M ORFS)
Adapter (7/16 M 37° x -16 F ORFS) (2 used)
Hydraulic Switch Box or Differential Pressure Gauge
ERVICE EQUIPMENT AND TOOLS

Digital Thermometer
Gauge 1034.2 kPa
(10.34 bar)
(150.0 psi)

021505
PN=471
Transmission Tests
04
225
28
B B
–UN–30MAR01
A
T140524
T140524
A—Tee B—Adapter C—Cap
1. Disconnect hose from oil cooler at thermal bypass 4. Heat transmission oil to test specification.
valve and install plug in hose.
Transmission Oil Cooler Thermal Bypass Relief Valve Test—
Install tee, union, and adapter in hose to torque Torque Converter Drive Transmission—Specification
Transmission Oil—Temperature ................................ 82.2°C± 11.1°C
converter. (180.0°F ± 20.0°F)
Connect differential pressure gauge or hydraulic 5. Observe pressure gauges during warm-up.
switch box to tees.
Pressure differential below 79.4°C—85.0°C
NOTE: Monitor tachometer in the vehicle can be used. (175.0°F—185.0°F) should be low to no pressure.
2. Use monitor tachometer or install Clamp-On When thermal bypass valve opens at 79.4°C—
Electronic Tachometer Installation. 85.0°C (175.0°F—185.0°F), pressure differential will
increase.

021505
PN=472
Transmission Tests
6. With transmission in neutral, run engine at test Transmission Oil Cooler Thermal Bypass Relief Valve Test—
speed. Torque Converter Drive Transmission—Specification
Cooler Bypass Differential—
Pressure.............................................................................. 620.5 kPa
Transmission Oil Cooler Thermal Bypass Relief Valve Test— (6.21 bar)
Torque Converter Drive Transmission—Specification (90.0 psi)
Engine—Speed ...................................................................... Slow Idle
7. Record differential pressure and compare to

specification.
YZ03225,000009D –19–04OCT04–3/3
04
225
29

021505
PN=473
Transmission Tests
Park Brake Pressure Test
SPECIFICATIONS
(120.0°F ± 10.0°F)
Park Brake Pressure 1861.6 ± 103.4 kPa
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
TOOLS
Digital Thermometer
7/16 -20 37° x 7/16 -20 M ORB Connector
04 Gauge 0.0—4136.9 kPa
225 (0.0—41.37 bar)
30 (0.0—600.0 psi)
–UN–18DEC97
T112000
3. Remove plug (B) and install 7/16 -20 37° x 7/16 -20 M
A—Gauge
ORB Connector, 7/16 -20 Female Flare Quick Coupler,
B—Plug
and 0.0—4136.9 kPa (0.0—41.37 bar) (0.0—600.0 psi)
gauge (A) to park brake valve test port.
Park Brake Pressure Test—Specification

(120.0°F ± 10.0°F)
5. Put transmission and park brake control lever in

NEUTRAL.

Engine—Speed .................................................................... 2000 ± 5 rpm
7. If pressure is not within specification, disconnect park

brake valve line to park brake.

021505
PN=474
Transmission Tests

Park Brake—Pressure ............................................... 1861.6 ± 103.4 kPa
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
Check pressure again. If pressure is OK, leak is indicated

in the park brake.
YZ03225,000009E –19–04OCT04–2/2
04
225
31

021505
PN=475
Transmission Tests
04
225
32

021505
PN=476
Section 05
Tools and Other Materials
Contents
Page
Group 300—Essential Tools

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . .05-300-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .05-300-8
Group 325—Dealer Fabricated Service Tools

Pry Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-325-1
Pry Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-325-2
05

021505
PN=1
Contents
05

021505
PN=2
Group 300
Essential Tools
Essential Tools
NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company YZ03225,000009F –19–04OCT04–1/29
Repair Stand . . . . . . . . . . . . . . . . . . . . . . D01003AA
Used to support transmission. For Remote Mount and

Engine Mount Transmissions.
05
300
1
–UN–24JAN05
YZ7121
YZ03225,000009F –19–04OCT04–2/29
Left and Right Mounting Plates . . . . . . . . . . . JDG1111
Used to mount the Remote Mount transmission in repair
–UN–24JAN05
stand.For Remote Mount Transmissions.
YZ7109
YZ03225,000009F –19–04OCT04–3/29
Bottom Mounting Bracket . . . . . . . . . . . . . . JDG1111-2

stand.For Remote Mount Transmissions.

021505
PN=479
Essential Tools
Bottom Mounting Bracket Spacer . . . . . . . . . JDG1111-3
Used to mount the older two bolt mounting design Remote
–UN–14FEB05
Mount transmission in repair stand with New JDG1111-2
Bottom Mounting Bracket.For Remote Mount
Transmissions.
YZ7145
YZ03225,000009F –19–04OCT04–5/29
Top Mounting Bracket Spacer . . . . . . . . . . . JDG1111-4

stand with the JDG1111 Top Mounting Adaptor. For
Remote Mount Transmissions.
05
300
2
YZ03225,000009F –19–04OCT04–6/29
Transmission Mounting Adapters . . . . . . . . . . JDG1100
Used to mount the Engine Mount transmission in repair

stand.For Engine Mount Transmissions.
–UN–31MAR99
T120873
YZ03225,000009F –19–04OCT04–7/29
Input Shaft Seal Driver . . . . . . . . . . . . . . . . . JDG1110
Used JDG1110 with JDG1108 to install input shaft seal on

–UN–20JAN05
Remote Mount transmission. For Remote Mount

Transmissions.
YZ7119

021505
PN=480
Essential Tools
Clutch Bearing Driver . . . . . . . . . . . . . . . . . . JDG1108
Used to install clutch bearings on Engine and Remote
–UN–20JAN05
Mounted transmissions. For Remote Mount and Engine
Mount Transmissions.
YZ7117
YZ03225,000009F –19–04OCT04–9/29
Bearing Driver . . . . . . . . . . . . . . . . . . . . . . JDG1105
Used Use JDG1105 with JDG1108 to install bearings on
–UN–20JAN05
input shaft on Remote and Engine Mounted
transmissions. For Remote Mount and Engine Mount
Transmissions.
YZ7114
05
300
3
YZ03225,000009F –19–04OCT04–10/29
Bore Sleeve Driver . . . . . . . . . . . . . . . . . . . JDG1109
Used to install sleeve on the Remote and Engine Mount
–UN–20JAN05
transmissions. For Remote Mount and Engine Mount
Transmissions.
YZ7118
YZ03225,000009F –19–04OCT04–11/29
Clutch Stack Lift Plate . . . . . . . . . . . . . . . . JDG1101A
Used to lift clutch gear ratio group from transmission

–UN–26JAN05
housing on the Remote and Engine Mount transmissions.

For Remote Mount and Engine Mount Transmissions.
YZ7110

021505
PN=481
Essential Tools
Input Shaft Retainer. . . . . . . . . . . . . . . . . . JDG1101B
Used for Remote Mount transmission in conjunction with
–UN–20JAN05
JDG1101A Clutch Stack Lifting Plate. For Remote Mount
Transmissions.
YZ7108
YZ03225,000009F –19–04OCT04–13/29
Clutch Stack Nesting Plate . . . . . . . . . . . . . JDG1104A
Used to set gear ratio group on after removing group from
–UN–20JAN05
transmission housing. For Remote Mount and Engine
Mount Transmissions.
YZ7113
05
300
4
YZ03225,000009F –19–04OCT04–14/29
Single Clutch Lifting Tool . . . . . . . . . . . . . . . JDG1106
Used to remove and install clutch assemblies. For
–UN–20JAN05
Remote Mount and Engine Mount Transmissions.
YZ7115
YZ03225,000009F –19–04OCT04–15/29
Control Valve Lifting Tool . . . . . . . . . . . . . . . JDG1938
Used to lift control valve from transmission housing. For

–UN–20JAN05
Remote Mount and Engine Mount Transmissions.

YZ7106

021505
PN=482
Essential Tools
Clutch Spring Compressor . . . . . . . . . . . . . . JDG1103
Used to remove and install clutch spring. For Remote
–UN–20JAN05
Mount and Engine Mount Transmissions.
YZ7112
YZ03225,000009F –19–04OCT04–17/29
Bearing Driver . . . . . . . . . . . . . . . . . . . . . . JDG1107
Used JDG1104, JDG1110, and JDG1108 to install
–UN–20JAN05
bearings output shaft assembly. For Remote Mount and
Engine Mount Transmissions.
YZ7116
05
300
5
YZ03225,000009F –19–04OCT04–18/29
Output Seal Drive Engine Mount

Transmission . . . . . . . . . . . . . . . . . . . . . . . JDG1973
–UN–20JAN05
Used to install output seals on Engine Mount transmission
output shaft. For Engine Mount Transmissions.
YZ7101
YZ03225,000009F –19–04OCT04–19/29
Oil Seal Protector . . . . . . . . . . . . . . . . . . . . JDG1519
Used to install output shaft oil seals on Remote Mount

–UN–20JAN05
transmission output shaft. For Remote Mount

Transmissions.
YZ7107

021505
PN=483
Essential Tools
Oil Seal driver . . . . . . . . . . . . . . . . . . . . . JDG1736A
Used to install output shaft oil seals on Remote Mount
–UN–20JAN05
transmission output shaft. For Remote Mount
Transmissions.
YZ7102
YZ03225,000009F –19–04OCT04–21/29
Grease Seal Driver (Inner) . . . . . . . . . . . . . JDG1737A
Used to install output shaft inner grease seals on Remote
–UN–20JAN05
Mount transmission output shaft. For Remote Mount
Transmissions.
YZ7103
05
300
6
YZ03225,000009F –19–04OCT04–22/29
Grease Seal Driver (Outer) . . . . . . . . . . . . . JDG1738A
Used to install output shaft outer grease seals on Remote
–UN–20JAN05
Mount transmission output shaft. For Remote Mount
Transmissions.
YZ7104
YZ03225,000009F –19–04OCT04–23/29
Lifting Brackets . . . . . . . . . . . . . . . . . . . . . . . JT01748
Used to remove park brake cover. For Remote Mount

–UN–24JAN05
and Engine Mount Transmissions.

YZ7120

021505
PN=484
Essential Tools
Remote Mount Transmission Housing Lifting

Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1937
–UN–20JAN05
Used to remove Remote Mount front housing from rear
housing. For Remote Mount Transmissions.
YZ7105
YZ03225,000009F –19–04OCT04–25/29
Engine Mount Transmission Housing Lifting

Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1102
–UN–20JAN05
Used to remove Engine Mount transmission rear housing
from front housing. For Engine Mount Transmissions.
YZ7111
05
300
7
YZ03225,000009F –19–04OCT04–26/29
Bore Sleeve Blind Hole Puller Kit . . . . . . . . . . JDG1974
Used to remove Bore Sleeves from transmission
–UN–28JAN05
housings. For Remote Mount and Engine Mount
Transmissions. Kit consist of JDG1490, JT017 Collet,
JT01722 Actuator Pin, Ball, JT01716 Forcing Screw, and
JT01717 Forcing Screw Nut.
YZ7138
YZ03225,000009F –19–04OCT04–27/29
Pluget Driver . . . . . . . . . . . . . . . . . . . . . . . JDG1745
Used to install pluget in the Engine Mount transmission

–UN–28JAN05
rear housing.For Engine Mount Transmissions.

YZ7139

021505
PN=485
Essential Tools
Seal Driver. . . . . . . . . . . . . . . . . . . . . . . . . JDG1972
Used to install PTO Oil Seal on the Engine Mount

transmission rear housing. Consist of JDG1972-1 Seal
Driver and JDG1972-2 Seal Protector.For Engine Mount
Transmissions.
YZ03225,000009F –19–04OCT04–29/29
Other Material
Number Name Use
TY6304 (U.S.) Flexible Sealant LOCTITE Products Applied to rear housing mounting
TY9484 (Canadian) surfaces.
518 (LOCTITE)
05
300
8 T43512 (U.S.) Thread Lock and Sealer (Medium Applied to outside diameter of new
TY9473 (Canadian) Strength) oil seal. Apply to OD of park brake
242 (LOCTITE) seal.
TY16021 (U.S.) High Flex Form-In-Place Gasket Applied to rear housing mounting
TY9484 (Canadian) LOCTITE Products surface.
17430 (LOCTITE)
LOCTITE is a registered trademark of Loctite Corp. YZ03225,00000A1 –19–04OCT04–1/1

021505
PN=486
Group 325
Dealer Fabricated Service Tools
Pry Tool
–UN–19NOV04
05
325
1
YZ6099
A—99 mm (3.90 in) C—50.8 mm (2.00 in) E—20.6 mm (0.81 in) G—137 mm (5.39 in)
B—1x10.3 drill Thru D—25.4 mm (1.00 in) F—88 mm (3.46 in) H—21 mm (0.83 in)
Pry tool to be used when checking endplay on input

and output shaft.
YZ03225,000006B –19–04FEB05–1/1

021505
PN=487
Dealer Fabricated Service Tools
Pry Bar
–UN–19NOV04
YZ6100
A—19 mm (0.75 in) C—121 mm (4.76 in) D—2x1.5 mmx45° (2x0.06x45° E—1x9.5 mm drill thru
B—400 mm (15.75 in) in) (1x0.374 in drill thru)
05
325
2 Used with Pry Tool. Use a 1/4 in x 2 1/4 in cap screw
and nut to assemble pry bar and pry tool.
YZ03225,000006A –19–04FEB05–1/1

021505
PN=488
Section 06
Specifications
Contents
Page
Group 400—Bolt and Cap Screw Specification

Metric Bolt and Screw Torque Values . . . . . . .06-400-1
Unified Inch Bolt and Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-400-2
Group 415—Transmission Specification

Specifications for Transmission
Identifications and General Procedures . . . .06-415-1
Specifications for Repair Procedures and
Repair Stand . . . . . . . . . . . . . . . . . . . . . . . .06-415-3
Specifications for Winch Drive - Remote
Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-415-3
Specifications for Park Brake . . . . . . . . . . . . .06-415-4
Specifications for Output Seals . . . . . . . . . . . .06-415-5
Specifications for Suction Tube . . . . . . . . . . . .06-415-6
Specifications for Charge Pump and Idler
Gears/Shaft - Remote Mount . . . . . . . . . . . .06-415-7
06
Gears/Shaft - Engine Mount . . . . . . . . . . . .06-415-8
Specifications for Control Valve. . . . . . . . . . . .06-415-9
Specifications for Input Yoke - Remote Mount
Transmission . . . . . . . . . . . . . . . . . . . . . . .06-415-10
Specifications for Front and Rear Housing
and Clutch Assembly Group . . . . . . . . . . .06-415-11
Specifications for Gears, Bearings, and
Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-415-14
Group 425—Specifications for Drive Plate and

Torque Converter Assembly
Specifications for Drive Plate and Torque
Converter Assembly. . . . . . . . . . . . . . . . . . .06-425-1
Group 435—Specifications for Torque Converter

PTO Housing
Specifications for Torque Converter PTO
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-435-1
Group 445—Specifications for Transmission Tests

Specifications for Transmission Tests . . . . . . .06-445-1

021505
PN=1
Contents
06

021505
PN=2
Group 400
Bolt and Cap Screw Specification
Metric Bolt and Screw Torque Values
–UN–01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
TS1670
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N•m lb-ft N•m lb-ft N•m lb-ft
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N•m lb-ft
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800 06
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000 400
1
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. instructions are given for the specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
YZ03225,000006C –19–04FEB05–1/1

021505
PN=491
Bolt and Cap Screw Specification
Unified Inch Bolt and Screw Torque Values

TS1671 –UN–01MAY03
Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c b c b c
Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N•m lb-ft N•m lb-ft
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N•m lb-ft N•m lb-ft
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N•m lb-ft N•m lb-ft N•m lb-ft
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N•m lb-ft
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
06
400 1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
2 1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
YZ03225,000006D –19–04FEB05–1/1

021505
PN=492
Group 415
Transmission Specification
Specifications for Transmission
Identifications and General Procedures
Specifications
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)
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)
2600 rpm
Turbine torque (maximum) - 1355.8 06
N•m (1000 lb-ft) 415
1
DF180 Engine Mount Direct Drive Rating (Depending on application) Input power (maximum) - 149.1 kW
(200 SAE hp)
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.
Continued on next page YZ03225,000002F –19–03FEB05–1/2

021505
PN=493
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
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
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)
06
415 Pressures and Flows at Control Pump Pressure 1758—1965 kPa (255—285 psi)
2 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)
YZ03225,000002F –19–03FEB05–2/2

021505
PN=494
Specifications for Repair Procedures and

Repair Stand
Specifications
Transmission Lifting and Mounting

on Repair Stand
Remote Mount Transmission Weight approximate 521.6 kg

(1150.0 lb)
Engine Mount Transmission Weight approximate 567.0 kg

(1250.0 lb)
YZ03225,0000030 –19–03FEB05–1/1
Specifications for Winch Drive - Remote

Mount
Specifications
Item Measurement Specification 06

415
3
Winch Drive
Winch Cover-to-Rear Housing Torque 24.4 N•m

(18.0 lb-ft)
Winch Drive
Yoke Cap Screw Torque 215.6 N•m

(159.0 lb-ft)
YZ03225,0000031 –19–03FEB05–1/1

021505
PN=495
Specifications for Park Brake
Specifications
Park Brake Assembly
Park Brake Assembly Weight approximate 43.1 kg

(95.0 lb)
Wet Park Brake - Engine Mount
Wet Park Brake Cap Screw and Torque 215.6 N•m

Washer (159.0 lb-ft)
Park Brake
Park Brake-to-Rear Housing Cap Torque 86.8 N•m

Screw (64.0 lb-ft)
YZ03225,0000032 –19–03FEB05–1/1
06
415
4

021505
PN=496
Specifications for Output Seals
Specifications
Output (Brake Side) Grease

procedure
Apply grease to grease fitting (D) Hours Repeated every 100 hours.
extrude through grease seal (C)
(Outer).
Output (Opposite Brake Side)

Grease procedure
Apply grease to grease fitting (D) Hours Repeated every 100 hours.
extrude through grease seal
(Outer) (A).
06
415
5
YZ03225,0000033 –19–03FEB05–1/1

021505
PN=497
Specifications for Suction Tube
Specifications
Charge Pump
Flat Face Fitting-to-Charge Pump Torque 189.8 N•m

(140.0 lb-ft)
Suction Tube to Housing
Suction Tube-to-Front Housing Torque 24.4 N•m

Cap Screws (18.0 lb-ft)
Suction Tube Fitting
Flat Face Fitting Nut Torque 189.8 N•m

(140.0 lb-ft)
Transmission Suction Tube
Suction Tube-to-Front Housing Torque 24.4 N•m

06
415 Cap Screws (18.0 lb-ft)
6
YZ03225,0000034 –19–03FEB05–1/1

021505
PN=498

Gears/Shaft - Remote Mount
Specifications
Charge Pump
Transmission Charge Torque 74.6 N•m

Pump-to-Transmission Housing (55.0 lb-ft)
Charge Pump
Idler Gear Shaft-to-Front Housing Torque 86.8 N•m

Cap Screw (64.0 lb-ft)
Transmission Cover Plate
Cover Plate-to-Transmission Torque 50.2 N•m

Housing Cap Screws (37.0 lb-ft)
Transmission Cover Plate

06
Cover Plate-to-Transmission Torque 50.2 N•m 415
Housing Cap Screws (37.0 lb-ft) 7
Transmission Idler Shaft—Torque

Converter Drive Transmissions
Idler Shaft-to-Front Housing Cap Torque 86.8 N•m

Screw (64.0 lb-ft)
YZ03225,0000035 –19–03FEB05–1/1

021505
PN=499

Gears/Shaft - Engine Mount
Specifications
Remove and Install Charge Pump
Flat Face Fitting-to-Charge Pump Torque 189.8 N•m

Charge Pump-to-Front Housing Cap Torque 100.3 N•m

Screws (74.0 lb-ft)
Charge Pump Idler Shaft Cap Screw Torque 86.8 N•m

(64.0 lb-ft)
Cap Screw to retain Auxiliary Pump Torque 86.6 N•m

Idler Shaft (64.0 lb-ft)
YZ03225,0000036 –19–03FEB05–1/1
06
415
8

021505
PN=500
Specifications for Control Valve
Specifications
Transmission Control Valve
Control Valve Weight approximate 27.7 kg

(61.0 lb)
Control Valve-to-Front Housing Torque 39.3 N•m

Cap Screws (29.0 lb-ft)
Proportional Cartridge Torque 16.3—20.3 N•m

Valve-to-Valve Housing (12.0—15.0 lb-ft)
Nut-to-Proportional Cartridge Valve Torque 4.5—6.8 N•m

06
(40.0—60.0 lb-in.) 415
9
Cooler Relief Valve Torque 40.7—54.2 N•m

Assembly-to-Valve Housing (30.0—40.0 lb-ft)
Main Regulator Assembly-to-Valve Torque 40.7—54.2 N•m

Housing (30.0—40.0 lb-ft)
Proportional Solenoid Torque 16.3—20.3 N•m

Plug-to-Valve Housing (12.0—15.0 lb-ft)

021505
PN=501
Temperature Sensor or Torque 9.8-14.1 N•m

Plug-to-Valve Housing (7.2-10.4.0 lb-ft)
Plug-to-Valve Housing Torque 9.8-14.1 N•m

(7.2-10.4 lb-ft)
YZ03225,0000037 –19–03FEB05–2/2
Specifications for Input Yoke - Remote

Mount Transmission
Specifications
06 Item Measurement Specification

415
10
Input Yoke
Yoke Cap Screw Torque 215.6 N•m

(159.0 lb-ft)
YZ03225,0000038 –19–03FEB05–1/1

021505
PN=502
Specifications for Front and Rear Housing

and Clutch Assembly Group
Specifications
Remove Front Housing—Remote

Mount
Front Housing Weight approximate 93.9 kg

(207.0 lb)
Elbow Fittings into Sixth Stage Torque 12.2 N•m

Bearing Retainer (9.0 lb-ft)
Elbow Fittings into Control Valve Torque 12.2 N•m

(9.0 lb-ft)
Lube Hose Nut to Elbow Fitting Torque 16.3 N•m

(12.0 lb-ft)
Rear Housing—Engine Mount

(207.0 lb) 06
415
11
Input Housing Screen-to-Front Torque 10.4 N•m
Housing Cap Screw (7.7 lb-ft)
Plug with O-ring to Front Housing Torque 11.7 N•m

(8.8 lb-ft)
Plug 1-5/8 O-ring to Front Housing Torque 185.7 N•m

(137 lb-ft)
Transmission Gear Ratio Group
Gear Ratio Group (Second—Fifth Weight approximate 157.4 kg

Stage) and Input Shaft - Remote (377.0 lb)
Mount

021505
PN=503

Repair—Remote Mount
Seventh Stage Output Assembly Weight approximate 29.5 kg

(Output Gear) (65.0 lb)
Sixth Stage Shaft Assembly (Idler Weight approximate 13.6 kg

Gear) (30.0 lb)
Gear Ratio Group Weight approximate 196.0 kg

(432 lb)
Sixth Stage Shaft Assembly (Idler Weight approximate 13.6 kg

Gear) (30.0 lb)

06
415 (Output Gear) (65.0 lb)
12
Gear Ratio Group (Second—Fifth Weight approximate 157.4 kg

Stage) With Input Shaft Assembly (347.0 lb)

(Output Gear) (68.0 lb)
Gear Ratio Group (First Stage— Weight approximate 157.4 kg

Sixth Stage) (347.0 lb)

021505
PN=504
Front and Rear Housing Assemble

(207.0 lb)
Front and Rear Housing Assembly
Front Housing-to-Rear Housing Torque 86.8 N•m

Front Housing-to-Rear Housing Cap Torque 86.8 N•m

Screw (64.0 lb-ft)
Bearing Retainer-to-Front Housing Torque 2.8 N•m

Cap Screws (25.0 lb-in.)
Bearing Retainer-to-Front Housing Torque 2.8 N•m

Cap Screws (25.0 lb-in.)
Sixth Stage Assembly Preload 0.101 ±0.051 mm

(0.004 ±0.002 in.)
Transmission Bearing Retainer Cap Torque Initial: 12.2 N•m

06
Screw (9.0 lb-ft) 415
13
Transmission Bearing Retainer Cap Torque Final: 24.4 N•m
Screw (18.0 lb-ft)
Sump Drain Valve Torque 62.4 N•m

(46 lb-ft)
Sump Drain Valve Angle Approximately 5°
Cap Screws for Magnetic Pickup Torque 10.8 N•m

Sensor Cover (8.0 lb-ft)
YZ03225,000003B –19–03FEB05–3/3

021505
PN=505
Specifications for Gears, Bearings, and

Shafts
Specifications
Transmission Clutch Packs

Disassembly and Assembly—Direct
Drive Transmission
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)

Disassembly—Direct Drive
06 Transmission
415
14 Maximum Regulated Air Pressure 68.9 kPa
(0.69 bar)
(10.0 psi)
Clutch Stage Assembly — Direct

Drive Transmission
Clutch Plate (Second and Third Clearance 2.31—4.47 mm

Stage Clutch Assemblies) (0.091—0.176 in.)
Clutch Plate (Fourth and Fifth Clearance 2.79—5.59 mm


021505
PN=506

Assemble—Direct Drive
Transmission
Clutch Gear End Play 0.25 mm

(0.010 in.)

Disassembly and Assembly—Torque
Second Stage Weight approximate 46.7 kg

(103.0 lb)
Third Stage1 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)
06
Clutch Piston 415
15
Maximum Regulated Air Pressure 68.9 kPa
(0.69 bar)
(10.0 psi)
Clutch Stage Assemblies —Direct

Drive Transmission
Clutch Plate (Second and Third Clearance 2.31—4.47 mm

Clutch Plate (Fourth and Fifth Clearance 2.79—5.59 mm

1
Weight specified is for 6F/6R torque converter transmission. Third stage
clutch pack weight on 6F/3R should be about half of weight specified.

021505
PN=507
Clutch Pack Assemble — Torque


(0.010 in.)
Clutch Pack Assemble —Torque


(0.010 in.)
YZ03225,000003C –19–03FEB05–3/3
06
415
16

021505
PN=508
Group 425
Specifications for Drive Plate and Torque Converter Assembly
Specifications for Drive Plate and Torque
Converter Assembly
Specifications
Magnetic Speed Sensor
Magnetic Speed Sensor Cap Torque 10.8 N•m

Screw (8.0 lb-in.)
Torque Converter Housing
Torque Converter and Drive Plate Weight approximate 31.8 kg

(70.0 lb)
Torque Converter
Torque Converter and Drive Plate Weight approximate 31.8 kg

(70.0 lb)
Torque Converter Drive Plate

06
Torque Converter and Drive Plate Weight approximate 31.8 kg 425
(70.0 lb) 1
Torque Converter Drive Plate
Drive Plate Ring Cap Screw Torque 50.2 N•m

(37.0 lb-ft)
Torque Converter Cover, Drive Plate

and Impeller Hub Tightening
Sequence
Drive Plate Ring Cap Screw Torque 50.2 N•m

(37.0 lb-ft)

021505
PN=509
Specifications for Drive Plate and Torque Converter Assembly

Sequence
Torque Converter Torque 50.2 N•m

Cover-to-Impeller Cap Screws (37.0 lb-ft)

Sequence
Impeller-to-Hub Cap Screws Torque 24.4 N•m

(18.0 lb-ft)
Torque Converter
Impeller-to-Hub Cap Screws Torque 24.4 N•m

(18.0 lb-ft)
Torque Converter
Front Cover-to-Impeller Cap Screw Torque 50.2 N•m

06
425 (37.0 lb-ft)
2
YZ03225,000003D –19–03FEB05–2/2

021505
PN=510
Group 435
Specifications for Torque Converter PTO Housing
Specifications for Torque Converter PTO
Housing
Specifications
Hose Fitting-to-Converter Housing Torque 12.0 N•m

(106.0 lb-in.)
Hose Fitting with Orifice-to-Front Torque 12.0 N•m

Cover—Pump Adapter (106.0 lb-in.)
Hydraulic Lube Hose Fitting Torque 16.0 N•m

(142.0 lb-in.)
Stater Support Tube and Oil Torque 36.6 N•m

Deflector Cap Screw (27.0 lb-ft)

06
Converter Housing Cap Screw Torque 86.8 N•m 435
(64.0 lb-ft) 1
Converter Housing Allen Head Torque 86.8 N•m

Converter Housing Plug Torque 189.8 N•m

(140.0 lb-ft)
Output Yoke
Output Yoke Cap Screw Torque 215.6 N•m

(159.0 lb-ft)
Continued on next page YZ03225,000003E –19–03FEB05–1/2

021505
PN=511
Specifications for Torque Converter PTO Housing
Hydraulic Pump Adapter Plate Cap Torque 86.8 N•m

Screws (64.0 lb-ft)
Hydraulic Pump Adapter Plate Cap Torque 86.8 N•m

Screws (64.0 lb-ft)
YZ03225,000003E –19–03FEB05–2/2
06
435
2

021505
PN=512
Group 445
Specifications for Transmission Tests
Specifications
Transmission Oil Warm-Up

Procedure

(120.0°F ± 10.0°F)
Transmission Oil Warm-Up

Procedure

(120.0°F ± 10.0°F)

(120.0°F ± 10.0°F)

06
445
Transmission Oil Pressure 1861.6 ± 103.4 kPa 1
(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
New Pump Flow typical 98.4 L/min

(26.0 gpm)
Pump Allowable Flow minimum 75.7 L/min

(20.0 gpm)

021505
PN=513

(120.0°F ± 10.0°F)
Transmission Oil Pressure 1861.6 ± 103 kPa

(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
Lube Pressure Test

(120.0°F ± 10.0°F)
Lube Pressure Test

06
445
2 Engine Speed 2000 ± 5 rpm
Lube Pressure Test
Lube Relief Pressure Minimum 137.9 kPa

(1.38 bar)
(20.0 psi)
Lube Relief Pressure Maximum 310.3 kPa

(3.10 bar)
(45.0 psi)
Transmission Clutch Pressure Test—

Direct Drive Transmission

(120.0°F ± 1.00°F)

021505
PN=514
Transmission Control Clutch

Pressure Test—Direct Drive
Transmission


(18.62 ± 1.03 bar)
(270 ± 15 psi)
Main Pressure and Each Clutch Difference maximum 103.4 kPa

Pressure (1.03 bar)
(15.0 psi)

Transmission

(120.0°F ± 10.0°F)
06
445
3
Transmission

Transmission

(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
Main Pressure and Each Clutch Difference Maximum 103.4 kPa

Pressure (1.03 bar)
(15.0 psi)

021505
PN=515

Transmission

(12.0°F ± 10.0°F)

Transmission

Transmission
Cooler Relief Valve Pressure 827.4 kPa

(8.27 bar)
(120.0 psi)
Converter-In Pressure Test—Torque

06
445 Converter Drive Transmission
4
(120.0°F ± 10.0°F)
Converter-In Pressure Test—Torque

Converter-In Pressure 655 kPa

(at 48.9°C (120.0°F) min.) (6.55 bar)
(95.0 psi)

021505
PN=516
Converter-Out Pressure Test -

Transmission

(120.0°F ± 10.0°F)
Converter-Out Pressure Test -

Transmission
Converter-Out Pressure 655 kPa

(at 48.9°C (120.0°F) min.) (6.55 bar)
(95.0 psi)
Torque Converter Pressure Relief

Test - Torque Converter Drive
Transmission
Transmission Oil Temperature 48.9°C ±5.6°C

06
(120.0°F ± 10.0°F) 445
5

Transmission
Engine Speed Slow idle

Transmission
Converter Relief Valve Pressure 620.5 kPa

(6.21 bar)
(90.0 psi)

021505
PN=517
Converter-Out Flow Test—Torque


(120.0°F ± 10.0°F)


Converter-Out Flow Rate 98.4 L/min

(at 48.9°C (120.0°F) min.) (26.0 gpm)
Torque Converter Stall Speed Test

(180.0°F ± 20.0°F)
06
445
6
Hydraulic Oil Temperature 65.6°C ± 5.6°C

(150.0°F ± 10.0°F)
Engine Speed Fast Idle
Engine at Converter Stall Speed See Table rpm

021505
PN=518
Transmission Oil Cooler Thermal

Bypass Valve Test—Torque

(180.0°F ± 20.0°F)


Thermal Bypass Valve Flow Temperature 82.2°C ± 11.1°C

(Starting to Open) (180.0°F ± 20.0°F)

06
Converter Drive Transmission 445
7
Thermal Bypass Valve Flow (Full Temperature 96.1°C
Open) (205°F)
Maximum Flow Rate 94.6 L/min

(25 gpm)

Bypass Relief Valve Test—Torque
Transmission Oil Temperature 82.2°C± 11.1°C

(180.0°F ± 20.0°F)

Engine Speed Slow Idle

021505
PN=519

Cooler Bypass Differential Pressure 620.5 kPa

(6.21 bar)
(90.0 psi)

(120.0°F ± 10.0°F)
Park Brake Pressure 1861.6 ± 103.4 kPa

(18.62 ± 1.03 bar)
(270.0 ± 15.0 psi)
06
445
8
YZ03225,0000041 –19–03FEB05–8/8

021505
PN=520
Index
Page Page
A Remove and Disassemble . . . . . . . . . .02-036-10

Output Gear Assembly, Pump - Engine Mount
Adhesives and sealants . . . . . . . . . . . . . . . .01-015-7 Assemble and Install . . . . . . . . . . . . . . .02-036-8
Auxiliary Pump Remove and Disassemble . . . . . . . . . . .02-036-7
Gear Train - Remote Mount Remote Mount, Charge Pump
Remove and Install . . . . . . . . . . . . . . . .02-035-7 Remove and Install . . . . . . . . . . . . . . . .02-035-3
Lube Hose - Torque Converter PTO Assembly Theory of Operation . . . . . . . . . . . . . . . .03-100-18
Remove and Install . . . . . . . . . . . . . . . .02-047-2 Clutch
Output Gear - Engine Mount Clutch Actuation
Assemble and Install . . . . . . . . . . . . . .02-036-25 Theory of Operation. . . . . . . . . . . . . . .03-100-33
Remove and Disassemble . . . . . . . . . .02-036-23 Clutch Plate and Separator Plate - Direct Drive
Output Gear Assembly - Engine Mount Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-33
Assemble and Install . . . . . . . . . . . . . .02-036-20 Clutch Plate and Separator Plate - Remote Mount
Remove and Disassemble . . . . . . . . . .02-036-18 Torque Converter Drive
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-70
Clutch Pressure Test . . . . . . . . . . . . . . . .04-225-8
B Direct Drive, Clutch
Disassemble and Assemble. . . . . . . . .02-043-24
Bearing Adjustment Directional Clutch Operation
Sixth Stage Assembly - Engine Theory of Operation. . . . . . . . . . . . . . .03-100-34
Mount . . . . . . . . . . . . . . . . . . . . . . . . .02-041-37 Fifth Stage (Second Fourth Speed) Clutch
Bearing Cup Assembly
Front Housing Cross-Section - Remote Mount Direct
Remove and Install . . . . . . . . . . . . . . .02-041-49 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-14
Rear Housing - Remote Mount Exploded View - Remote Mount Direct
Remove and Install . . . . . . . . . . . . . . .02-041-59 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-15
Bearing Retainer Fifth Stage (Second/Fourth Speed) Clutch
Sixth Stage - Engine Mount Assembly
Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-35 Cross-Section - Engine Mount Direct
Bore Sleeves Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-22
Housing Exploded View - Engine Mount Direct Indx
Remove and Install . . . . . . . . . . . . . . .02-041-45 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-23 1
Brake, Park Fifth Stage (Third Speed) Clutch Assembly
Drawing - Engine Mount . . . . . . . . . . . . . .02-029-2 Cross-Section - Remote Mounted Torque
Drawing - Remote Mount . . . . . . . . . . . . .02-029-1 Converter Drive . . . . . . . . . . . . . . . .02-043-58
Install Park Brake . . . . . . . . . . . . . . . . . . .02-029-7 Exploded View - Remote Mounted Torque
Manual Release Operation Converter Drive . . . . . . . . . . . . . . . .02-043-59
Theory of Operation. . . . . . . . . . . . . . .03-100-74 Fourth Stage (First/Second Speed) Clutch
Release Pressure Test . . . . . . . . . . . . . .04-225-30 Assembly
Remove Park Brake . . . . . . . . . . . . . . . . .02-029-3 Cross-Section - Remote Mounted Torque
Theory of Operation . . . . . . . . . . . . . . . .03-100-70 Converter Drive . . . . . . . . . . . . . . . .02-043-56
Exploded View - Remote Mounted Torque
Converter Drive . . . . . . . . . . . . . . . .02-043-57
C Fourth Stage (First/Third Speed) Clutch Assembly
Cross-Section - Engine Mount Direct
Charge Pump Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-20
Auxiliary Pump Gear Train - Remote Mount Cross-Section - Remote Mount Direct
Remove and Install . . . . . . . . . . . . . . . .02-035-7 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-12
Engine Mount, Charge Pump Exploded View - Engine Mount Direct
Remove and Install . . . . . . . . . . . . . . . .02-036-2 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-21
Idler Gear - Engine Mount Exploded View - Remote Mount Direct
Assemble and Install . . . . . . . . . . . . . .02-036-13 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-13
CTM308 (15FEB05) Index-1 DF180 Series Powershift Transmission

021505
PN=1
Index
Page Page
Gear and Bearing, Clutch - Direct Drive Third Stage (Low Reverse) Clutch Assembly
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-38 Cross-Section - Remote Mounted Torque
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-25 Converter Drive . . . . . . . . . . . . . . . .02-043-54
Gear and Bearing, Clutch - Remote Mount Torque Exploded View - Remote Mounted Torque
Converter Drive Converter Drive . . . . . . . . . . . . . . . .02-043-55
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-75 Clutch and Gear Component Location
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-61 Engine Mount Direct Drive 8F/8R Transmission
Gear Ratio Group - Engine Mount Theory of Operation. . . . . . . . . . . . . . .03-100-48
Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-041-24 Remote Mount Direct Drive 8F/8R Transmission
Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-18 Theory of Operation. . . . . . . . . . . . . . .03-100-40
Gear Ratio Group - Remote Mount Remote Mount Torque Converter Drive 6F/3R
Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-041-21 Transmission
Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-15 Theory of Operation. . . . . . . . . . . . . . .03-100-64
Piston and Spring - Direct Drive Remote Mount Torque Converter Drive 6F/6R
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-31 Transmission
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-29 Theory of Operation. . . . . . . . . . . . . . .03-100-56
Piston and Spring - Remote Mount Torque Clutch Plate
Converter Drive Clutch - Direct Drive
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-68 Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-33
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-66 Clutch - Remote Mount Torque Converter Drive
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-70
Clutch Pressure Check Port Plug
Remove and Install . . . . . . . . . . . . . . . . .02-037-15
Second Stage (High/Low Forward) Clutch
Clutch Stack Assembly
Assembly
Direct Drive, Clutch
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-16
Drive . . . . . . . . . . . . . . . . . . . . . . . . .02-043-8
Clutch Stacks Group
Cross-Section - Remote Mounted Torque Engine Mount
Converter Drive . . . . . . . . . . . . . . . .02-043-50 Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-041-24
Indx
Exploded View - Engine Mount Direct Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-18
2
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-17 Remote Mount
Exploded View - Remote Mount Direct Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-041-21
Drive . . . . . . . . . . . . . . . . . . . . . . . . .02-043-9 Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-15
Exploded View - Remote Mounted Torque Cold Weather Operation . . . . . . . . . . . . . . .01-015-10
Converter Drive . . . . . . . . . . . . . . . .02-043-51 Component Identification
Speed Clutch Operation Converter PTO Assembly
Theory of Operation. . . . . . . . . . . . . . .03-100-36 Drawing . . . . . . . . . . . . . . . . . . . . . . . . .02-047-4
Third Stage (High/Low Reverse) Clutch Assembly Engine Mount Direct Drive
Cross-Section - Engine Mount Direct 8 Forward / 8 Reverse Transmission . . .03-100-8
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-18 Remote Mount Direct Drive
Cross-Section - Remote Mount Direct 8 Forward / 8 Reverse Transmission . . .03-100-4
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-10 Remote Mount Torque Converter Drive
Cross-Section - Remote Mounted Torque 6 Forward / 3 Reverse Transmission . . .03-100-7
Converter Drive . . . . . . . . . . . . . . . .02-043-52 6 Forward / 6 Reverse Transmission . . .03-100-6
Exploded View - Engine Mount Direct Component Overview
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-19 Power Train . . . . . . . . . . . . . . . . . . . . . . .03-100-1
Exploded View - Remote Mount Direct Configuration
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-11 Engine Mount Direct Drive . . . . . . . . . . . .01-015-2
Exploded View - Remote Mounted Torque Remote Mount Converter Drive. . . . . . . . .01-015-1
Converter Drive . . . . . . . . . . . . . . . .02-043-53 Remote Mount Direct Drive . . . . . . . . . . . .01-015-1

021505
PN=2
Index
Page Page
Control Valve Drive Hub

Control Valve Operation - Engine Mount Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-2
Theory of Operation. . . . . . . . . . . . . . .03-100-26 Drive hub
Control Valve Operation - Remote Mount Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-2
Theory of Operation. . . . . . . . . . . . . . .03-100-24 Drive Pate
Control Valve-to-Front Housing Oil Passage Tightening Sequence . . . . . . . . . . . . . . . .02-045-7
Identification Drive plate
Engine Mount . . . . . . . . . . . . . . . . . . .03-100-29 Torque Converter
Remote Mount. . . . . . . . . . . . . . . . . . .03-100-28 Remove and Install . . . . . . . . . . . . . . . .02-045-4
Install, Control Valve . . . . . . . . . . . . . . . . .02-037-5
Port Identification
Engine Mount . . . . . . . . . . . . . . . . . . .03-100-21
Remote Mount. . . . . . . . . . . . . . . . . . .03-100-20 E
Pressure and Flows . . . . . . . . . . . . . . . . .01-015-3
Proportional Solenoid Valves Identification - Engine Essential Tools . . . . . . . . . . . . . . . . . . . . . . .05-300-1
Mount . . . . . . . . . . . . . . . . . . . . . . . . .03-100-23
Proportional Solenoid Valves Identification -
Remote Mount. . . . . . . . . . . . . . . . . . .03-100-22
Remove Control Valve . . . . . . . . . . . . . . .02-037-4
Converter PTO Assembly
F
Pump Drive
Assemble . . . . . . . . . . . . . . . . . . . . . .02-047-22 Fifth Stage
Disassemble . . . . . . . . . . . . . . . . . . . .02-047-18 Second/Fourth Speed Clutch Assembly
Converter Relief Valve Cross-Section - Engine Mount Direct
Pressure Test - Torque Converter Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-22
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-18 Cross-Section - Remote Mount Direct
Converter-In Pressure Test Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-14
Torque Converter Drive. . . . . . . . . . . . . .04-225-14 Exploded View - Engine Mount Direct
Converter-Out Flow Test Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-23
Torque Converter Drive. . . . . . . . . . . . . .04-225-21 Exploded View - Remote Mount Direct
Converter-Out Pressure Test Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-15
Indx
Torque Converter Drive. . . . . . . . . . . . . .04-225-16 Third Speed Clutch Assembly 3
Cooler Relief Valve Cross-Section - Remote Mounted Torque
Pressure Test - Direct Drive . . . . . . . . . .04-225-12 Converter Drive . . . . . . . . . . . . . . . .02-043-58
Remove and Install . . . . . . . . . . . . . . . . .02-037-11 Exploded View - Remote Mounted Torque
Cover Plates - Remote Mounted Torque Converter Converter Drive . . . . . . . . . . . . . . . .02-043-59
Drive Filter Bypass Valve. . . . . . . . . . . . . . . . . . .03-100-19
Remove and Install . . . . . . . . . . . . . . . . .02-035-13 First Forward
Cylinder Engine Mount Direct Drive 8F/8R Transmission
Speed Sensor Theory of Operation. . . . . . . . . . . . . . .03-100-50
Theory of Operation. . . . . . . . . . . . . . .03-100-37 Remote Mount Direct Drive 8F/8R Transmission
Theory of Operation. . . . . . . . . . . . . . .03-100-42
Remote Mount Torque Converter Drive 6F/3R
Transmission
D Remote Mount Torque Converter Drive 6F/6R
Transmission
Diagnostics Theory of Operation. . . . . . . . . . . . . . .03-100-58
Diagnose Powershift Transmission First Reverse
Problems . . . . . . . . . . . . . . . . . . . . . . . .04-200-2 Engine Mount Direct Drive 8F/8R Transmission
Diagram, Transmission Theory of Operation. . . . . . . . . . . . . . .03-100-52
Direct Drive Transmission . . . . . . . . . . . . .03-100-9 Remote Mount Direct Drive 8F/8R Transmission
Torque Converter Drive Transmission . . .03-100-10 Theory of Operation. . . . . . . . . . . . . . .03-100-44

021505
PN=3
Index
Page Page
Remote Mount Torque Converter Drive 6F/3R Front Housing Cover Plates
Transmission Remote Mounted Torque Converter Drive
Theory of Operation. . . . . . . . . . . . . . .03-100-68 Remove and Install . . . . . . . . . . . . . . .02-035-13
Remote Mount Torque Converter Drive 6F/6R Front Housing Plugs
Transmission Remove and Install . . . . . . . . . . . . . . . . .02-041-10
Theory of Operation. . . . . . . . . . . . . . .03-100-60 Front Housing Screen - Engine Mount
Flat Face Fitting Remove and Install . . . . . . . . . . . . . . . . . .02-041-9
Engine Mount, Charge Pump
Remove and Install . . . . . . . . . . . . . . . .02-036-2
Remote Mount, Charge Pump
Remove and Install . . . . . . . . . . . . . . . .02-033-1 G
Flow
Pump Flow . . . . . . . . . . . . . . . . . . . . . . . .01-015-3 Gear
Flow Rate Output Seventh Stage - Direct Drive
Oil Cooler Thermal Bypass Valve Test - Torque Disassemble and Assemble. . . . . . . . .02-043-44
Converter Drive . . . . . . . . . . . . . . . . . .04-225-25 Output Seventh Stage - Engine Mount Direct Drive
Flow Test Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-43
Converter-Out Flow Test - Torque Converter Output Seventh Stage - Remote Mount Direct
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-21 Drive
Transmission Pump . . . . . . . . . . . . . . . . .04-225-2 Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-42
Fourth Stage Output Seventh Stage - Remote Mount Torque
First/Second Speed Clutch Assembly Converter Drive
Cross-Section - Remote Mounted Torque Disassemble and Assemble. . . . . . . . .02-043-80
Converter Drive . . . . . . . . . . . . . . . .02-043-56 Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-79
Exploded View - Remote Mounted Torque Gear and Bearing
Clutch - Direct Drive
Converter Drive . . . . . . . . . . . . . . . .02-043-57
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-38
First/Third Speed Clutch Assembly
Clutch - Remote Mount Torque Converter Drive
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-75
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-20
Clutch Gear and Bearing - Direct Drive
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-25
Indx Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-12
Clutch Gear and Bearing - Remote Mount Torque
4 Exploded View - Engine Mount Direct
Converter Drive
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-21
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-61
Exploded View - Remote Mount Direct
Gear Ratio Group
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-13
Engine Mount
Front and Rear Housing Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-041-24
Engine Mount Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-18
Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-31 Remote Mount
Remote Mount Install. . . . . . . . . . . . . . . . . . . . . . . . . .02-041-21
Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-28 Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-15
Front and Rear Housing - Engine Mount Gear Selection
Disassembly . . . . . . . . . . . . . . . . . . . . . . .02-041-6 Engine Mount Direct Drive 8F/8R Transmission
Front and Rear Housing - Remote Mount Theory of Operation. . . . . . . . . . . . . . .03-100-46
Disassembly . . . . . . . . . . . . . . . . . . . . . . .02-041-2 Remote Mount Direct Drive 8F/8R Transmission
Front Housing Theory of Operation. . . . . . . . . . . . . . .03-100-38
Bearing Cup Remote Mount Torque Converter Drive 6F/3R
Remove and Install . . . . . . . . . . . . . . .02-041-49 Transmission
Engine Mount Theory of Operation. . . . . . . . . . . . . . .03-100-62
Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-31 Remote Mount Torque Converter Drive 6F/6R
Remote Mount Transmission
Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-28 Theory of Operation. . . . . . . . . . . . . . .03-100-54
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-45 General repair procedures . . . . . . . . . . . . . .01-015-6

021505
PN=4
Index
Page Page
H Idler Gear
Sixth Stage Repair - Direct Drive
Housing Disassemble and Assemble. . . . . . . . . .02-043-5
Bearing Cup, Front Housing Sixth Stage Repair - Torque Converter Drive
Remove and Install . . . . . . . . . . . . . . .02-041-49 Disassemble and Assemble. . . . . . . . .02-043-48
Bearing Cup, Rear Housing Idler Gears and Bearing
Remove and Install . . . . . . . . . . . . . . .02-041-59 Charge and Auxiliary Pump - Remote Mount
Bore Sleeves Remove and Install . . . . . . . . . . . . . . . .02-035-7
Remove and Install . . . . . . . . . . . . . . .02-041-45 Idler Shaft
Front and Rear - Engine Mount Remote Mounted Torque Converter Drive
Disassemble . . . . . . . . . . . . . . . . . . . . .02-041-6 Remove and Install . . . . . . . . . . . . . . .02-035-16
Front and Rear - Remote Mount Impeller Hub
Disassemble . . . . . . . . . . . . . . . . . . . . .02-041-2 Tightening Sequence . . . . . . . . . . . . . . . .02-045-7
Front and Rear Housing - Engine Mount Input Shaft
Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-31 First Stage Repair - Direct Drive
Front and Rear Housing - Remote Mount Disassemble and Assemble. . . . . . . . . .02-043-5
Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-28 First Stage Repair - Torque Converter Drive
Front Housing Disassemble and Assemble. . . . . . . . .02-043-48
Repair . . . . . . . . . . . . . . . . . . . . . . . . .02-041-45 Input Yoke
Rear Housing Repair - Engine Mount . . .02-041-59 Remove and Install . . . . . . . . . . . . . . . . . .02-039-2
Hydraulic System Operation
Theory of Operation. . . . . . . . . . . . . . .03-100-13 L
Torque Converter Drive Transmission
Theory of Operation. . . . . . . . . . . . . . .03-100-16 Lube Line
Lube Hose Auxiliary Pump Port - Torque Converter
PTO Assembly
I Sixth Stage - Engine Mount
Identification Lube Pressure Test Indx
Transmission. . . . . . . . . . . . . . . . . . . . . . .04-225-6 5
Control Valve Port
Engine Mount . . . . . . . . . . . . . . . . . . .03-100-21 Lube Relief Valve
Remote Mount. . . . . . . . . . . . . . . . . . .03-100-20 Remove and Install . . . . . . . . . . . . . . . . .02-041-50
Control Valve-to-Front Housing Oil Passage Lubricant
Engine Mount . . . . . . . . . . . . . . . . . . .03-100-29 Alternative and Synthetic . . . . . . . . . . . .01-015-14
Remote Mount. . . . . . . . . . . . . . . . . . .03-100-28 Changing Oil and Filters . . . . . . . . . . . . .01-015-16
Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-015-5 Drain Transmission Oil . . . . . . . . . . . . . .01-015-17
Proportional Solenoid Valves - Engine Mixing of Lubricants . . . . . . . . . . . . . . . .01-015-13
Mount . . . . . . . . . . . . . . . . . . . . . . . . .03-100-23 Oil Analysis. . . . . . . . . . . . . . . . . . . . . . .01-015-14
Proportional Solenoid Valves - Remote Oil Fill of Transmission . . . . . . . . . . . . . .01-015-18
Recommended Storage . . . . . . . . . . . . .01-015-13
Mount . . . . . . . . . . . . . . . . . . . . . . . . .03-100-22
Lubricant, transmission. . . . . . . . . . . . . . . .01-015-12
Identification Plate
Transmission. . . . . . . . . . . . . . . . . . . . . .02-041-62
Identification, Component
Engine Mount Direct Drive M
8 Forward / 8 Reverse Transmission . . .03-100-8
Remote Mount Direct Drive Magnetic Sensor Pickup
8 Forward / 8 Reverse Transmission . . .03-100-4 Remove and Install . . . . . . . . . . . . . . . . .02-041-60
Remote Mount Torque Converter Drive Magnetic Speed Sensor
6 Forward / 3 Reverse Transmission . . .03-100-7 Converter PTO Assembly
6 Forward / 6 Reverse Transmission . . .03-100-6 Remove and Install . . . . . . . . . . . . . . . .02-047-1

021505
PN=5
Index
Page Page
Main Pressure Regaulator Valve Converter PTO Assembly

Theory of Operation . . . . . . . . . . . . . . . .03-100-32 Theory of Operation. . . . . . . . . . . . . . .03-100-11
Main Pressure Regulator Valve Cylinder Speed Sensor
Remove and Install . . . . . . . . . . . . . . . . .02-037-12 Theory of Operation. . . . . . . . . . . . . . .03-100-37
Main Regulator Valve Directional Clutch Operation
Pressure Test . . . . . . . . . . . . . . . . . . . . . .04-225-4 Theory of Operation. . . . . . . . . . . . . . .03-100-34
Mounting Transmission to Repair Stand Filter BypassValve
Engine Mount . . . . . . . . . . . . . . . . . . . . . .02-025-7 Theory of Operation. . . . . . . . . . . . . . .03-100-19
Remote Mount . . . . . . . . . . . . . . . . . . . . .02-025-6 First Forward for Engine Mount Direct Drive 8F/8R
Transmission
First Forward for Remote Mount Direct Drive
O 8F/8R Transmission
Oil First Forward for Remote Mount Torque Converter
Air temperature range . . . . . . . . . . . . . . .01-015-12 Drive 6F/3R Transmission
Alternative and Synthetic . . . . . . . . . . . .01-015-14 Theory of Operation. . . . . . . . . . . . . . .03-100-66
Analysis . . . . . . . . . . . . . . . . . . . . . . . . .01-015-14 First Forward for Remote Mount Torque Converter
Changing Oil and Filters . . . . . . . . . . . . .01-015-16 Drive 6F/6R Transmission
Drain Transmission Oil . . . . . . . . . . . . . .01-015-17 Theory of Operation. . . . . . . . . . . . . . .03-100-58
Mixing of Lubricants . . . . . . . . . . . . . . . .01-015-13 First Reverse for Engine Mount Direct Drive 8F/8R
Oil Fill of Transmission . . . . . . . . . . . . . .01-015-18 Transmission
Oil specifications . . . . . . . . . . . . . . . . . . .01-015-12 Theory of Operation. . . . . . . . . . . . . . .03-100-52
Operating Conditions . . . . . . . . . . . . . . . .01-015-3 First Reverse for Remote Mount Direct Drive
Pressure and Flows . . . . . . . . . . . . . . . . .01-015-3 8F/8R Transmission
Recommended Storage . . . . . . . . . . . . .01-015-13 Theory of Operation. . . . . . . . . . . . . . .03-100-44
Temperature Warning Signal. . . . . . . . . .01-015-11 First Reverse for Remote Mount Torque Converter
Oil Cooler Thermal Bypass Relief Valve Drive 6F/3R Transmission
Presseure Test - Torque Converter Theory of Operation. . . . . . . . . . . . . . .03-100-68
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-27 First Reverse for Remote Mount Torque Converter
Oil Cooler Thermal Bypass Valve Drive 6F/6R Transmission
Indx Flow Test - Torque Converter Drive . . . .04-225-25 Theory of Operation. . . . . . . . . . . . . . .03-100-60
6
Operation Gear Selection for Engine Mount Direct Drive
Charge Pump 8F/8R Transmission
Theory of Operation. . . . . . . . . . . . . . .03-100-18 Theory of Operation. . . . . . . . . . . . . . .03-100-46
Clutch and Gear Component Location for Engine Gear Selection for Remote Mount Direct Drive
Mount Direct Drive 8F/8RTransmission 8F/8R Transmission
Clutch and Gear Component Location for Remote Gear Selection for Remote Mount Torque
Mount Direct Drive 8F/8RTransmission Converter Drive 6F/3R Transmission
Clutch and Gear Component Location for Remote Gear Selection for Remote Mount Torque
Mount Torque Converter Drive 6F/3R Converter Drive 6F/6R Transmission
Transmission Theory of Operation. . . . . . . . . . . . . . .03-100-54
Theory of Operation. . . . . . . . . . . . . . .03-100-64 Hydraulic System Operation - Direct Drive
Clutch and Gear Component Location for Remote Theory of Operation. . . . . . . . . . . . . . .03-100-13
Mount Torque Converter Drive 6F/6R Hydraulic System Operation - Torque Converter
Transmission Drive
Control Valve - Engine Mount Main Pressure Regaulator Valve
Control Valve - Remote Mount Park Brake

021505
PN=6
Index
Page Page
Park Brake Manual Release Operation Disassemble . . . . . . . . . . . . . . . . . . . .02-043-66

Theory of Operation. . . . . . . . . . . . . . .03-100-74 Plug
Proportional Solenoid Valve Operation - Clutch Pressure Check Port Plug
De-energized Remove and Install . . . . . . . . . . . . . . .02-037-15
Theory of Operation. . . . . . . . . . . . . . .03-100-30 Front Housing Plugs
Speed Clutch Operation Remove and Install . . . . . . . . . . . . . . .02-041-10
Theory of Operation. . . . . . . . . . . . . . .03-100-36 Proportional Solenoid Plug
Transmission Operation . . . . . . . . . . . . . .03-100-2 Remove and Install . . . . . . . . . . . . . . .02-037-13
Orifice, Pluget - Engine Mount Pluget Orifice - Engine Mount
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-61 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-041-61
Output Seals Power Train
(Brake Side) - Remote Mount Component Overview . . . . . . . . . . . . . . . .03-100-1
Remove and Install . . . . . . . . . . . . . . . .02-031-1 Pressure
Engine Mount Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-015-3
Remove and Install . . . . . . . . . . . . . . . .02-031-6 Pressure Test
(Opposite Brake Side) - Remote Mount Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-8
Remove and Install . . . . . . . . . . . . . . . .02-031-3 Converter Relief Valve - Torque Converter
Output Shaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-18
Seventh Stage - Engine Mount Direct Drive Converter-In - Torque Converter
Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-43 Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-14
Seventh Stage - Remote Mount Direct Drive Converter-Out - Torque Converter
Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-42 Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-16
Seventh Stage - Remote Mount Torque Converter Cooler Relief Valve - Direct Drive . . . . . .04-225-12
Drive Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-6
Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-79 Oil Cooler Thermal Bypass Relief Valve - Torque
Seventh Stage Repair - Direct Drive
Converter Drive . . . . . . . . . . . . . . . . . .04-225-27
Park Brake Release Pressure Test . . . . .04-225-30
Seventh Stage Repair - Remote Mount Torque
System Pressure. . . . . . . . . . . . . . . . . . . .04-225-4
Converter Drive
Proportional Solenoid Plug
Remove and Install . . . . . . . . . . . . . . . . .02-037-13
Proportional Solenoid Valve Indx
Remove and Install . . . . . . . . . . . . . . . . . .02-037-8 7
P Proportional Solenoid Valve - De-energized

Theory of Operation . . . . . . . . . . . . . . . .03-100-30
Proportional Solenoid Valves Identification
Park Brake
Drawing - Engine Mount . . . . . . . . . . . . . .02-029-2 Engine Mount . . . . . . . . . . . . . . . . . . . . .03-100-23
Drawing - Remote Mount . . . . . . . . . . . . .02-029-1 Remote Mount . . . . . . . . . . . . . . . . . . . .03-100-22
Engaged Park Brake. . . . . . . . . . . . . . . .03-100-73 PTO Oil Seal - Engine Mount
Install Park Brake . . . . . . . . . . . . . . . . . . .02-029-7 Remove and Install . . . . . . . . . . . . . . . . .02-041-40
Manual Release Operation Pump
Theory of Operation. . . . . . . . . . . . . . .03-100-74 Flow Test . . . . . . . . . . . . . . . . . . . . . . . . .04-225-2
Release Pressure Test . . . . . . . . . . . . . .04-225-30 Pump Drive
Released Park Brake . . . . . . . . . . . . . . .03-100-72 Converter PTO Assembly
Remove Park Brake . . . . . . . . . . . . . . . . .02-029-3 Assemble . . . . . . . . . . . . . . . . . . . . . .02-047-22
Theory of Operation . . . . . . . . . . . . . . . .03-100-70 Disassemble . . . . . . . . . . . . . . . . . . . .02-047-18
Troubleshooting . . . . . . . . . . . . . . . . . . .04-200-11 Pump Pad Cover Plates
Piston and Spring Remote Mounted Torque Converter Drive
Clutch - Direct Drive Remove and Install . . . . . . . . . . . . . . .02-035-13
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-31 Pump, Auxiliary
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-29 Output Gear - Engine Mount
Clutch - Remote Mount Torque Converter Drive Assemble and Install . . . . . . . . . . . . . .02-036-25
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-68 Remove and Disassemble . . . . . . . . . .02-036-23

021505
PN=7
Index
Page Page
Output Gear Assembly - Engine Mount Seal Rngs

Assemble and Install . . . . . . . . . . . . . .02-036-20 Install - Remote Mount . . . . . . . . . . . . . .02-041-27
Remove and Disassemble . . . . . . . . . .02-036-18 Seal, Rings
Pump, Charge Install - Engine Mount . . . . . . . . . . . . . . .02-041-31
Auxiliary Pump Gear Train - Remote Mount Install - Remote Mount . . . . . . . . . . . . . .02-041-27
Remove and Install . . . . . . . . . . . . . . . .02-035-7 Sealants
Engine Mount, Charge Pump Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-300-8
Remove and Install . . . . . . . . . . . . . . . .02-036-2 Sealants and adhesives . . . . . . . . . . . . . . . .01-015-7
Idler Gear - Engine Mount Sealing instructions . . . . . . . . . . . . . . . . . . .01-015-8
Assemble and Install . . . . . . . . . . . . . .02-036-13 Second Stage
Remove and Disassemble . . . . . . . . . .02-036-10 High/Low Forward) Clutch Assembly
Output Gear Assembly, Pump - Engine Mount Cross-Section - Engine Mount Direct
Assemble and Install . . . . . . . . . . . . . . .02-036-8 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-16
Remove and Disassemble . . . . . . . . . . .02-036-7 High/Low Forward Clutch Assembly
Remote Mount, Charge Pump Cross-Section - Remote Mount Direct
Remove and Install . . . . . . . . . . . . . . . .02-035-3 Drive . . . . . . . . . . . . . . . . . . . . . . . . .02-043-8
Cross-Section - Remote Mounted Torque
Converter Drive . . . . . . . . . . . . . . . .02-043-50
R High/Low Forward) Clutch Assembly
Exploded View - Engine Mount Direct
Rear and Front Housing - Engine Mount Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-17
Disassemble . . . . . . . . . . . . . . . . . . . . . . .02-041-6 High/Low Forward Clutch Assembly
Rear and Front Housing - Remote Mount Exploded View - Remote Mount Direct
Disassemble . . . . . . . . . . . . . . . . . . . . . . .02-041-2 Drive . . . . . . . . . . . . . . . . . . . . . . . . .02-043-9
Rear Housing Exploded View - Remote Mounted Torque
Bearing Cup Converter Drive . . . . . . . . . . . . . . . .02-043-51
Remove and Install . . . . . . . . . . . . . . .02-041-59 Sensor
Engine Mount Cylinder Speed Sensor
Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-31 Theory of Operation. . . . . . . . . . . . . . .03-100-37
Remote Mount Magnetic Pickup Sensor,
Indx Assemble . . . . . . . . . . . . . . . . . . . . . .02-041-28 Remove and Install . . . . . . . . . . . . . . .02-041-60
8 Rear Housing Repair - Engine Mount . . . . .02-041-59 Magnetic Speed Sensor - Converter PTO
Repair Stand for Transmission Assembly
Lifting Transmission . . . . . . . . . . . . . . . . .02-025-3 Remove and Install . . . . . . . . . . . . . . . .02-047-1
Temperature Sensor
Remove and Install . . . . . . . . . . . . . . .02-037-14
S Separator Plate,
Screen Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-33
Front Housing - Engine Mount Clutch - Remote Mount Torque Converter Drive
Remove and Install . . . . . . . . . . . . . . . .02-041-9 Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-70
Seal Service Transmission . . . . . . . . . . . . . . . . .01-015-15
Output - Engine Mount Seventh Stage
Remove and Install . . . . . . . . . . . . . . . .02-031-6 Output Shaft - Engine Mount Direct Drive
Output (Brake Side) - Remote Mount Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-43
Remove and Install . . . . . . . . . . . . . . . .02-031-1 Output Shaft - Remote Mount Direct Drive
Output (Opposite Brake Side) - Remote Mount Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-42
Remove and Install . . . . . . . . . . . . . . . .02-031-3 Output Shaft - Remote Mount Torque Converter
PTO Oil Seal - Engine Mount Drive
Remove and Install . . . . . . . . . . . . . . .02-041-40 Drawing . . . . . . . . . . . . . . . . . . . . . . . .02-043-79
Seal Rings Output Shaft Repair - Direct Drive
Install - Engine Mount . . . . . . . . . . . . . . .02-041-31 Disassemble and Assemble. . . . . . . . .02-043-44

021505
PN=8
Index
Page Page
Output Shaft Repair - Remote Mount Torque Suction Tube

Converter Drive Remote Mount / Engine Mount Direct Drive
Disassemble and Assemble. . . . . . . . .02-043-80 Remove and Install . . . . . . . . . . . . . . . .02-033-1
Sixth Stage Remote Mount Torque Converter Drive
Bearing adjustment - Engine Mount . . . .02-041-37 Remove and Install . . . . . . . . . . . . . . . .02-033-4
Bearing Retainer - Engine Mount Sump Drain Valve - Remote Mount
Remove. . . . . . . . . . . . . . . . . . . . . . . .02-041-35 Remove and Install . . . . . . . . . . . . . . . . .02-041-52
Idler Gear Repair - Direct Drive
Disassemble and Assemble. . . . . . . . . .02-043-5
Idler Gear Repair - Torque Converter Drive
T
Lube Line - Engine Mount
Temperature
Maximum Operating . . . . . . . . . . . . . . . . .01-015-3
Specification
Minimum Operating. . . . . . . . . . . . . . . . . .01-015-3
Charge Pump and Idler Gears/Shaft - Engine
Normal Operating . . . . . . . . . . . . . . . . . . .01-015-3
Mount . . . . . . . . . . . . . . . . . . . . . . . . . .06-415-8
Temperature Sensor
Charge Pump and Idler Gears/Shaft - Remote Remove and Install . . . . . . . . . . . . . . . . .02-037-14
Mount . . . . . . . . . . . . . . . . . . . . . . . . . .06-415-7 Theory of Operation
Control Valve . . . . . . . . . . . . . . . . . . . . . .06-415-9 Charge Pump . . . . . . . . . . . . . . . . . . . . .03-100-18
Drive Plate and Torque Converter Clutch Actuation . . . . . . . . . . . . . . . . . . .03-100-33
Assembly. . . . . . . . . . . . . . . . . . . . . . . .06-425-1 Clutch and Gear Component Location for
Front and Rear Housing and Clutch Assembly Engine Mount Direct Drive
Group . . . . . . . . . . . . . . . . . . . . . . . . .06-415-11 8F/8RTransmission . . . . . . . . . . . . . . .03-100-48
Gears, Bearings, and Shafts . . . . . . . . . .06-415-14 Clutch and Gear Component Location for
Input Yoke - Remote Mount Remote Mount Direct Drive
Transmission . . . . . . . . . . . . . . . . . . . .06-415-10 8F/8RTransmission . . . . . . . . . . . . . . .03-100-40
Metric Bolt and Screw Torque Values . . . .06-400-1 Clutch and Gear Component Location for Remote
Output Seals . . . . . . . . . . . . . . . . . . . . . . .06-415-5 Mount Torque Converter Drive 6F/3R
Park Brake . . . . . . . . . . . . . . . . . . . . . . . .06-415-4 Transmission . . . . . . . . . . . . . . . . . . . .03-100-64
Repair Procedures and Repair Stand . . . .06-415-3 Clutch and Gear Component Location for Remote
Indx
Suction Tube. . . . . . . . . . . . . . . . . . . . . . .06-415-6 Mount Torque Converter Drive 6F/6R 9
Torque Converter PTO Housing . . . . . . . .06-435-1 Transmission . . . . . . . . . . . . . . . . . . . .03-100-56
Transmission Identifications and General Control Valve Operation - Engine
Procedures . . . . . . . . . . . . . . . . . . . . . .06-415-1 Mount . . . . . . . . . . . . . . . . . . . . . . . . .03-100-26
Transmission Tests . . . . . . . . . . . . . . . . . .06-445-1 Control Valve Operation - Remote
Unified Inch Bolt and Screw Torque Mount . . . . . . . . . . . . . . . . . . . . . . . . .03-100-24
Converter PTO Assembly . . . . . . . . . . . .03-100-11
Values . . . . . . . . . . . . . . . . . . . . . . . . . .06-400-2
Cylinder Speed Sensor . . . . . . . . . . . . . .03-100-37
Winch Drive - Remote Mount . . . . . . . . . .06-415-3
Directional Clutch Operation . . . . . . . . . .03-100-34
Spring and Piston
Filter BypassValve . . . . . . . . . . . . . . . . .03-100-19
First Forward for Engine Mount Direct Drive 8F/8R
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-31 Transmission . . . . . . . . . . . . . . . . . . . .03-100-50
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-29 First Forward for Remote Mount Direct Drive
Clutch - Remote Mount Torque Converter Drive 8F/8R Transmission. . . . . . . . . . . . . . .03-100-42
Assemble . . . . . . . . . . . . . . . . . . . . . .02-043-68 First Forward for Remote Mount Torque
Disassemble . . . . . . . . . . . . . . . . . . . .02-043-66 Converter Drive 6F/3R
Stall Speed Test Transmission . . . . . . . . . . . . . . . . . . . .03-100-66
Torque Converter - Torque Converter First Forward for Remote Mount Torque
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-23 Converter Drive 6F/6R
Storage Transmission . . . . . . . . . . . . . . . . . . . .03-100-58
Transmission. . . . . . . . . . . . . . . . . . . . . .01-015-20 First Reverse for Engine Mount Direct Drive 8F/8R
Transmission Removal From Storage . . .01-015-20 Transmission . . . . . . . . . . . . . . . . . . . .03-100-52

021505
PN=9
Index
Page Page
First Reverse for Remote Mount Direct Drive Torque Converter

8F/8R Transmission. . . . . . . . . . . . . . .03-100-44 Assembly
First Reverse for Remote Mount Torque Remove and Install . . . . . . . . . . . . . . . .02-045-1
Converter Drive 6F/3R Converter Front Cover
Transmission . . . . . . . . . . . . . . . . . . . .03-100-68 Tightening Sequence. . . . . . . . . . . . . . .02-045-7
First Reverse for Remote Mount Torque Converter PTO Assembly
Converter Drive 6F/6R Assemble . . . . . . . . . . . . . . . . . . . . . .02-047-12
Transmission . . . . . . . . . . . . . . . . . . . .03-100-60 Disassemble . . . . . . . . . . . . . . . . . . . . .02-047-6
Gear Selection for Engine Mount Direct Drive Theory of Operation. . . . . . . . . . . . . . .03-100-11
8F/8R Transmission. . . . . . . . . . . . . . .03-100-46 Converter PTO Assembly Component Identification
Gear Selection for Remote Mount Direct Drive Drawing . . . . . . . . . . . . . . . . . . . . . . . . .02-047-4
8F/8R Transmission. . . . . . . . . . . . . . .03-100-38 Torque converter
Gear Selection for Remote Mount Torque Disassemble Torque Converter. . . . . . . .02-045-10
Converter Drive 6F/3R Torque Converter
Transmission . . . . . . . . . . . . . . . . . . . .03-100-62 Drive Plate
Gear Selection for Remote Mount Torque Remove and Install . . . . . . . . . . . . . . . .02-045-4
Converter Drive 6F/6R Tightening Sequence. . . . . . . . . . . . . . .02-045-7
Transmission . . . . . . . . . . . . . . . . . . . .03-100-54 Exploded View - Converter PTO Assembly
Hydraulic System Operation - Direct Drawing . . . . . . . . . . . . . . . . . . . . . . . . .02-047-5
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .03-100-13 Exploded View, Converter
Main Pressure Regaulator Valve. . . . . . .03-100-32 Drawing . . . . . . . . . . . . . . . . . . . . . . . . .02-045-9
Park Brake . . . . . . . . . . . . . . . . . . . . . . .03-100-70 Impeller Hub, Converter
Park Brake Manual Release Tightening Sequence. . . . . . . . . . . . . . .02-045-7
Operation . . . . . . . . . . . . . . . . . . . . . .03-100-74 Lube Hose Auxiliary Pump - Converter PTO
Proportional Solenoid Valve Operation - Assembly
De-energized . . . . . . . . . . . . . . . . . . . .03-100-30 Remove and Install . . . . . . . . . . . . . . . .02-047-2
Speed Clutch Operation . . . . . . . . . . . . .03-100-36 Torque converter
Torque Converter Drive Transmission . . .03-100-16 Relief Valve Pressure Test . . . . . . . . . . .04-225-18
Third Stage Torque Converter
High/Low Reverse Clutch Assembly Stall Speed Test - Torque Converter
Indx Cross-Section - Engine Mount Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-23
10 Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-18 Torque Converter Stall Speed Test
Cross-Section - Remote Mount Direct Torque Converter Drive. . . . . . . . . . . . . .04-225-23
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-10 Towing The Vehicle . . . . . . . . . . . . . . . . . .01-015-21
Cross-Section - Remote Mounted Torque Transmission
Converter Drive . . . . . . . . . . . . . . . .02-043-52 Oil specifications . . . . . . . . . . . . . . . . . . .01-015-12
Exploded View - Engine Mount Direct Operation, direct drive vehicles . . . . . . . . .03-100-2
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-19 Operation, torque converter machines . . .03-100-3
Exploded View - Remote Mount Direct Transmission control circuit pressure test
Drive . . . . . . . . . . . . . . . . . . . . . . . .02-043-11 Direct drive machines . . . . . . . . . . . . . . . .04-225-8
Exploded View - Remote Mounted Torque Torque converter vehicles . . . . . . . . . . . .04-225-10
Converter Drive . . . . . . . . . . . . . . . .02-043-53 Transmission Diagram
Low Reverse Clutch Assembly Direct Drive Transmission . . . . . . . . . . . . .03-100-9
Cross-Section - Remote Mounted Torque Torque Converter Drive Transmission . . .03-100-10
Converter Drive . . . . . . . . . . . . . . . .02-043-54 Transmission System
Exploded View - Remote Mounted Torque Pressure Test . . . . . . . . . . . . . . . . . . . . . .04-225-4
Converter Drive . . . . . . . . . . . . . . . .02-043-55 Transmission Tests
Tools Clutch Pressure Test . . . . . . . . . . . . . . . .04-225-8
Dealer Fabricated . . . . . . . . . . . . . . . . . . .05-325-1 Converter Relief Valve Pressure Test - Torque
Essential . . . . . . . . . . . . . . . . . . . . . . . . . .05-300-1 Converter Drive . . . . . . . . . . . . . . . . . .04-225-18
Torque converter Converter-In Pressure Test - Torque Converter
Assemble Torque Converter . . . . . . . . . .02-045-20 Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-14

021505
PN=10
Index
Page Page
Converter-Out Flow Test - Torque Converter Proportional Solenoid Valve

Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-21 Remove and Install . . . . . . . . . . . . . . . .02-037-8
Converter-Out Pressure Test - Torque Converter Proportional Solenoid Valve Operation -
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-16 De-energized
Lube Pressure Test. . . . . . . . . . . . . . . . . .04-225-6 Theory of Operation. . . . . . . . . . . . . . .03-100-30
Oil Cooler Thermal Bypass Relief Valve Sump Drain Valve - Remote Mount
Pressure Test - Torque Converter Remove and Install . . . . . . . . . . . . . . .02-041-52
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-27 Transmission System Pressure Test . . . . .04-225-4
Oil Cooler Thermal Bypass Valve Flow Rate
Test - Torque Converter Drive . . . . . . .04-225-25
Oil Warm-Up Procedure . . . . . . . . . . . . . .04-225-1
W
Park Brake Release Pressure Test . . . . .04-225-30
Pump Flow Test . . . . . . . . . . . . . . . . . . . .04-225-2 Warm-Up Procedure
System Pressure Test. . . . . . . . . . . . . . . .04-225-4 Transmission Oil . . . . . . . . . . . . . . . . . . . .04-225-1
Torque Converter Stall Speed Test - Torque Weight
Converter Drive . . . . . . . . . . . . . . . . . .04-225-23 Transmission. . . . . . . . . . . . . . . . . . . . . . .01-015-3
Troubleshooting Winch Drive - Remote Mount
Diagnose Powershift Transmission Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-027-6
Problems . . . . . . . . . . . . . . . . . . . . . . . .04-200-2 Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-027-4
Park Brake . . . . . . . . . . . . . . . . . . . . . . .04-200-11
Tube, Suction
Remote Mount / Engine Mount Direct Drive
Remove and Install . . . . . . . . . . . . . . . .02-033-1 Y
Tube, suction
Remote Mounted Torque Converter Drive Yoke Input
Remove and Install . . . . . . . . . . . . . . . .02-033-4 Remove and Install . . . . . . . . . . . . . . . . . .02-039-2
V
Indx
11
Valve
Control Valve
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-037-5
Remove. . . . . . . . . . . . . . . . . . . . . . . . .02-037-4
Converter Relief Valve Pressure Test - Torque
Converter Drive . . . . . . . . . . . . . . . . . .04-225-18
Cooler Relief Valve
Filter Bypass
Lube Relief Valve
Main Pressure Regaulator Valve
Main Pressure Regulator Vlave
Oil Cooler Thermal Bypass Relief Valve
Pressure Test - Torque Converter
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .04-225-27
Oil Cooler Thermal Bypass Valve Test - Torque
Converter Drive . . . . . . . . . . . . . . . . . .04-225-25

021505
PN=11
Index
Indx
12

021505
PN=12

CTM308 - Tecnico Componentes - Transmision DF180

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DF180 Series

Funk Manufacturing Company

CTM308 (15FEB05) DF180 Series Powershift Transmission

Technical Information Feedback Form

We need your help to continually improve our technical

SEND TO: John Deere Dubuque Works

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

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CTM308 (15FEB05) DF180 Series Powershift Transmission

CTM308 (15FEB05) DF180 Series Powershift Transmission

SECTION 03—Theory of Operation

SECTION 05—Tools and Other Materials

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

CTM308 (15FEB05) i DF180 Series Powershift Transmission

CTM308 (15FEB05) ii DF180 Series Powershift Transmission

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

Group 015—Transmission Identifications and

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

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

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

Handle Fluids Safely—Avoid Fires

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

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

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

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

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

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

Direct exposure to hazardous chemicals can cause

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

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin

Avoid the hazard by relieving pressure before

Search for leaks with a piece of cardboard. Protect hands

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

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

Before working on the machine:

• Lower all equipment to the ground.

Support Machine Properly

Always lower the attachment or implement to the ground

When implements or attachments are used with a tractor,

Wear Protective Clothing

Wear close fitting clothing and safety equipment

Prolonged exposure to loud noise can cause impairment

Wear a suitable hearing protective device such as

Operating equipment safely requires the full attention of

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

Before starting a job:

• Clean work area and machine.

Service Machines Safely