SECTION 6001 – POWER TRAIN 1

SECTION 6001

SEMI–POWERSHIFT TRANSMISSION
CONTENT

Description Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Section 4000 Electrical
Removal – Installation – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SPECIFICATIONS – TIGHTENING TORQUES – SPECIAL TOOLS

– SECTIONAL VIEWS – DESCRIPTION AND OPERATION

SPECIFICATIONS – SEMI–POWERSHIFT TRANSMISSION AND RANGE GEARS

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 forward and 6 reverse speeds.
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical toothed
Range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 forward ranges and 1 reverse range
for a total of 18 forward and 6 reverse
speeds on 40kph models.
17 forward and 6 reverse speeds for
30kph models
– Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical toothed
– Reduction ratios:
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 15) : (46 x 55) = 1 : 7.03
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 25) : (46 x 37) = 1 : 2.84
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Speed and range shift controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by button and rocker switch located on
the control lever
Shift and range gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced–fed by a gear pump (same as
the power steering circuit pump)
Number of driven discs–Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– Thickness of driven discs – Clutch A . . . . . . . . . . . . . . . . . mm 2.65 to 2.75
Number of drive discs – Clutch A 7
– Thickness of drive discs – Clutch A . . . . . . . . . . . . . . . . . . mm 1.80 – 2.00
Multi–pack clutch A thickness under a load of
163 kg (1600 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 32.7 to 32.9
Number of Belleville springs – Clutch A . . . . . . . . . . . . . . . . . mm 9
– Free spring length – Clutch A . . . . . . . . . . . . . . . . . . . . . . . mm 4.2
– Compressed spring length under a load of
215 kg (2108 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.28

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2 SECTION 6001 – POWER TRAIN

SPECIFICATIONS – SEMI–POWERSHIFT TRANSMISSION AND RANGE GEARS

Number of driven discs–Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– Thickness of driven discs – Clutch B . . . . . . . . . . . . . . . . . . . mm 2.65 to 2.75
Number of drive discs – Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– Thickness of drive discs – Clutch B . . . . . . . . . . . . . . . . . . . . mm 1.80 – 2.00
Multi–pack clutch B thickness under a load of 163 kg (1600 N) mm 32.7 to 32.9
Number of Belleville springs – Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . 9
– Free spring length – Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.2
– Compressed spring length under a load of 215 kg (2108 N) mm 3.28
Number of driven discs–Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– Thickness of driven discs – Clutch C . . . . . . . . . . . . . . . . . . . mm 2.70 to 2.80
Number of drive discs – Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– Thickness of drive discs – Clutch C . . . . . . . . . . . . . . . . . . . . mm 1.5
Multi–pack clutch C thickness under a load of 163 kg (1600 N) mm 26.2 to 26.4
Number of Belleville springs – Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . 6
– Free spring length – Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.1
– Compressed spring length under a load of 182 kg (1784 N) mm 3.22
Number of driven discs–Clutches D–E . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– Thickness of driven discs – Clutches D–E . . . . . . . . . . . . . . . mm 2.70 to 2.80
Number of drive discs – Clutches D–E . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– Thickness of drive discs – Clutches D–E . . . . . . . . . . . . . . . . mm 1.5
Multi–pack clutches D–E thickness under a load of
163 kg (1600 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 26.2 to 26.4
Number of Belleville springs – Clutches D–E . . . . . . . . . . . . . . . . . . . . . 6
– Free spring length – Clutches D–E . . . . . . . . . . . . . . . . . . . . . mm 4.1
– Compressed spring length under a load of 182 kg (1784 N) mm 3.22
PTO drive shaft (7) diameter at the bushing . . . . . . . . . . . . . . . . . mm 31.950 to 31.975
Press–fit bush inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 31.990 to 32.085 ( ° )
PTO drive shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . mm 0.015 to 0.135
Transmission input shaft adjust shim (6) . . . . . . . . . . . . . . . . . . . . mm 3.80 – 3.85 – 3.90 –3.95 – 4.00 –
4.05 – 4.10 – 4.15 – 4.20 – 4.25 –
4.30 – 4.35 – 4.40 – 4.45 – 4.50 –
4.55 – 4.60 – 4.65 – 4.70 – 4.75 –
4.80
Transmission input shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . see page 49
Transmission output shaft adjust shim (26) . . . . . . . . . . . . . . . . . mm 9.80 – 9.825 – 9.85 – 9.875 – 9.90 –
9.925 – 9.95 – 9.975 – 10.00 –
10.025 – 10.05 – 10.075 – 10.10 –
10.125 – 10.15 – 10.175 – 10.20 –
10.225 – 10.25 – 10.275 – 10.30 –
10.325 – 10.35 – 10.375 – 10.40 –
10.425 – 10.45 – 10.475 – 10.50 –
10.525 – 10.55 – 10.575 – 10.60 –
10.625 – 10.65 – 10.675 – 10.70
Transmission output shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . see page 49
Transmission output shaft thrust washer mm . . . . . . . . . . . . . . . . . . . . . 3.95 to 4.00
(°) Final dimension to be obtained without grinding

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 SECTION 6001 – POWER TRAIN 3

SPECIFICATIONS – SEMI–POWERSHIFT TRANSMISSION AND RANGE GEARS

(continued)
Range gear input shaft bearing adjustment see pag. 49
Range gear input shaft bearing adjust shims (12, Fig. 10) . . . . . . . . . 1.70 – 1.75 – 1.80 –1.85 – 1.90
mm –1.95 – 2.00 – 2.05 – 2.10 – 2.15 –
2.20 – 2.25 – 2.30 –2.35 – 2.40 –
2.45 – 2.50 – 2.55 – 2.60 – 2.65 –
2.70 – 2.75 – 2.80 – 2.85 – 2.90 –
2.95 – 3.00 – 3.10 – 3.20 – 3.30
Range gear output shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . see pag. 49
Range gear output shaft adjust shims (14, Fig. 10) . . . . . . . . . . mm 1.70 –1.75 – 1.80 –1.85 – 1.90
–1.95 – 2.00 – 2.05 – 2.10 – 2.15 –
2.20 – 2.25 – 2.30 –2.35 – 2.40 –
2.45 – 2.50 – 2.55 – 2.60 – 2.65 –
2.70 – 2.75 – 2.80 – 2.85 – 2.90 –
2.95 – 3.00 – 3.10 – 3.20 – 3.30
Low pressure regulation valve spring (9, Fig. 11):
– Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 127
– Compressed spring length under a load of 278 to 304
N (28.4 to 31 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 102.5
Low pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 16.7 to 17.6 (17 to 18)
Lubrication pressure regulation valve spring (32, Fig. 10):
– Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35.5
– Compressed spring length under a load of 37 to 41 N 25.5
(3.8 to 4.2 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 2.7 to 3.4 (2.8 to 3.5)

SPECIFICATIONS – CREEPER GEARS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . epicyclic spur gear set
– Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 : (20+100) = 1:6
Control type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through a lever on LH side of the
driver’s seat
Creeper housing and driven gear thrust washer thickness . . mm 1.465 to1.535

TIGHTENING TORQUES
Tightening Torques
Thread Torque
size
Bolts and nuts, clutch/transm housing to engine . . . . . . . . . . . . . . . (see C3 and C4, page 2, Sec. 18)
Bolts, clutch/transm housing to rear axle housing . . . . . . . . . . . . . . M14 x 1.5 176 18

Bolts, clutch front cover (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2,4

Bolts, transmission housing cover (C2) . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Screws, range rear bearing retaining plate (C3) . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Nut, range output shaft (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M47.5 x 1.5 294 30
Nut, transmission output shaft (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . M45 x 1.5 490 50

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4 SECTION 6001 – POWER TRAIN

Screws, damper to flywheel(C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 60to74 6.1to7.5

Screws, range drive piston housing(C7) . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Screw, solenoid valve(C8) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 5.4to81 0.55to0.83
Screw, solenoid valve pin(C9) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 47to54 4.8to5.5
Screws, range rear bearing support plate . . . . . . . . . . . . . . . . . . . . . M14 x 1.5 142 14.5
Screws, transmission input shaft cover plate . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4

(*) Apply a couple of drops of Loctite Thread Seal 542

67

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 SECTION 6001 – POWER TRAIN 5

SPECIAL TOOLS
CAUTION
Operations described in this Section of the Manual
must be performed using the following ESSENTIAL
tools marked with the identification code (X).
To work safely and achieve the best technical results
with additional savings of time and effort, these
mandatory tools should be used in conjunction with
the suggested special tools listed below and
integrated with the self–made ones for which you will
find the necessary construction drawings and
specifications directly on this Manual.

Description Tool
Number
Overhaul rotary stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000301
Tractor Splitting Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS.300009A
Transmission overhaul front bracket . . . . . . . . . . . . . . . . . . 380000271
(use with tool no. 380000301).
Transmission overhaul rear bracket . . . . . . . . . . . . . . . . . . 380000272
(use with tool no.380000301).
Output shaft spanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000459
Input shaft bearing puller (use with tool no. 50062). . . . . . 380000465 (X)
Output shaft tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000466 (X)
Range input and output shaft end play test tool . . . . . . . . 380000458
(use with tools nos. 380000568).
Output shaft bearing installer (use with tool no. 50108). . 380000460
Medium and Clutch C bearing adjustment tool. . . . . . . . . . 380000497 (X)
Clutch spring compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000291
Diagnostic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000488 (X)
Limp Home Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000489
Range gear output shaft retaining tool. . . . . . . . . . . . . . . . . 380000491
Range input and output shaft bearing adjustment tool. . . 380000568 (X)

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 6 SECTION 6001 – POWER TRAIN

2
Tool to be fabricated for range input shaft taper bearing assembly (Mark tool with no. 50013 –
Dimensions in mm).
Fabricate tool using UNI C40 material. – Use only part (a).

25844
3 4
Tool to be fabricated for clutch B circlip assembly Tool to be fabricated for range output shaft bearing
(Mark tool with no. 50115 – assembly (Mark tool with no. 50061 –
( Dimensions in mm). (Dimensions in mm).
Fabricate tool using UNI C40 material. Make 3. Fabricate tool using C30 material.

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 SECTION 6001 – POWER TRAIN 7

Tool to be fabricated for range input shaft

bearing assembly (Mark tool with no. 50060 –
Dimensions in mm.)
Fabricate tool using C30 material.

107
53

60

5
Bracket to be fabricated to fix the transmission on
the rotary stand. Use with bracket tool no. 293971
(Mark tool with no. 50110 – Dimensions in mm).
Fabricate tool using Fe 42 C material.

25290

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8 SECTION 6001 – POWER TRAIN

Tool to be fabricated for input and output shaft

bearing assembly (Mark tool with no. 50108 –
Dimensions in mm).
Fabricate tool using UNI C40 material.

25291

7
Alignment pins to be fabricated for engine and
speed clutch/transmission housing
removal/installation (Mark tool with no. 50117 –
Dimensions in mm).
Fabricate tool using UNI C40 material.

25292

8
Adapter to be fabricated for reverse idler gear pin
removal (Mark tool with no. 50143 –
Dimensions in mm).
Fabricate tool using UNI C40 material.

25280

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 SECTION 6001 – POWER TRAIN 9

10
Transmission Longitudinal and Cross Sections
1. Damper coupler. 17. Clutch E driven discs.
2. Clutch housing. 18. Clutch E housing.
3. Clutch A drive discs. 19. Clutch E drive discs.
4. Clutch A driven discs. 20. Belleville springs, clutches D and E.
5. Cover plate. 21. Clutch D housing.
6. Transmission input shaft adjust shim 22. Clutch C driven discs.
7. Transmission input shaft. 23. Clutch C drive discs.
8. Clutch D driven discs. 24. Clutch C housing.
9. Clutch D drive discs. 25. Clutch C Belleville springs.
10. Range gear input shaft. 26. Transmission driven gear end play adjust shim
11. Reverse idler gear. 27. Transmission driven shaft.
12. Range input shaft adjust shim. 28. Clutch B Belleville springs.
13. Range output shaft. 29. Clutch A Belleville springs.
14. Range output shaft adjust shim. 30. Range gear and transmission lubrication control line.
15. Medium range and reverse control synchroniser. 31. Valve spring (32).
16. Low and high range control synchroniser. 32. Lubrication pressure regulation valve

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10 SECTION 6001 – POWER TRAIN

a
b

11
Range Control Valve Assembly Sections and Views
A. Top view. 8. Low pressure regulation valve.
B. Bottom view. 9. Valve (8) spring.
1. Reverse solenoid valve. 10. Pressure sensor.
2. High range solenoid valve. 11. PTO brake solenoid valve.
3. Low range solenoid valve. 12. FWD solenoid valve.
4. Medium range solenoid valve. 13. Circlips.
5. Diff lock solenoid valve. 14. Piston housing.
6. PTO solenoid valve. 15. Range drive pistons.
7. Valve. 16. By–pass valve.

NOTE: During installation apply liquid gasket, Loctite 574 on surfaces marked with an X as detailed on page
46.

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 SECTION 6001 – POWER TRAIN 11

12
SEMI–POWERSHIFT Transmission Control Valve Assembly Sections and Views
C1. Semi–powershift control valve retaining screw, 3. Pressure test port – Clutch C.
24.5 Nm (2.5 kgm). 4. Pressure test port – Clutch A.
C2. Solenoid valve pin retaining screw, 14.9 to 20.3 Nm 5. Pressure test port – Clutch B.
(1.520 to 2.071 kgm). 6. Clutch A control solenoid valve.
C3. Solenoid valve retaining screw, 1.72 to 2.79 Nm 7. Clutch B control solenoid valve.
(0.175 to 0.285 kgm). 8. Clutch C control solenoid valve.
1. Pressure test port – Clutch E. 9. Clutch D control solenoid valve.
2. Pressure test port – Clutch D. 10. Clutch E control solenoid valve.

NOTE: Apply a couple of drops of Thread Seal, Loctite 542 to screws C2 and C3 .

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12 SECTION 6001 – POWER TRAIN

DESCRIPTION AND OPERATION

A
B H

C D E R M
L

BSD2247A
1 2

The SEMI–POWERSHIFT transmission is
subdiviced into a speed (1) and range (2) sections
providing 6 speed gears in each of 3 ranges:–
18 forward X 6 reverse ratios on the 40kph option
or
17 forward X 6 reverse ratios on the 30kph option
where the18 gear is electronically blocked.
The mechanical components within these
transmissions do not differ and the number of gears
and therefore the maximum speed of the tractor is
controlled by the electronic transmission control
module (TCM)
When the optional creeper gear is fitted their are:–
31 forward and 12 reverse ratios on the 40kph
option.
30 forward and 12 reverse ratios on the 30kph
option.
The speed section of the semi powershift
transmission is actuated by 5 multiplate hydraulic
clutch packs A, B, C, D and E which provide the 6
speeds for each of three ranges
13
CLUTCH C D E
A 1 3 5
B 2 4 6
The range section consists of 3 forward and 1
reverse set of constant mesh gears each
electro–hydraulically selected giving low (L) medium
(M) and high (H) ranges as well as reverse (R)
Clutch design allows shifting from one speed into
another when the tractor is moving. Clutches are
operated by the control oil from the respective
solenoid valves located into the control valve
assembly attached to the right side of the
transmission housing.
The range gears are operated by two hydraulic
cylinders acting on two synchronisers. Hydraulic
cylinders are actuated by control oil from the
respective solenoid valves located into the control
valve assembly attached to the right side of the
transmission housing.

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 SECTION 6001 – POWER TRAIN 13

When driving the tractor the speed gears and ranges

are selected using the controls (1) and (2) on the right
side of the operator’s seat and displayed in the panel
(3).
There is one switch and one button on the lever. The
upshift/downshift switch (2) located on the left side of
the lever and are used for shifting through all the
speed gears (ratios) within the same range.
When pressing the upshift/downshift switch a signal
is sent to the transmission control module which
analyses the signal and responds by energising and
de–energising the relevant pulse width modulation
solenoid valve (PWM) which supply oil to the speed
clutches. 14
Signals concerning range changes are also acted on
by the transmission control module which powers the
relevant solenoid valve located on the transmission
side cover sending oil to the control piston attached
to the range selector fork.
To shift from one range into another, press and hold
the range button (1) while pressing upshift/downshift
switch (2) as required. The range can only be
changed when either the lowest or highest speed in
that range has been selected. The operator is
warned that a range change is required by an audible
signal generated by the transmission control unit.
Neutral, forward or reverse direction is selected
using the lever (1) on the left hand side of the steering
column.
1
The SEMI–POWERSHIFT transmission is not fitted
with a central clutch on the engine flywheel.
Consequently, the clutch pedal should not be
pressed for speed or range shifting.
However the clutch pedal must be used when
changing a range, when under a draft load.
The clutch pedal should be used to stop the tractor,
connect implements and operate the tractor in
restricted areas.
25805

15
Typical examples for oil flow during engagement of
clutches, lubrication of transmission components
and power flows through both the speed and range
gears are shown on the following pages:–

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14 SECTION 6001 – POWER TRAIN
1 2
A
B
BSD2261A
Pressure oil
Lubrication pressure oil
SEMI–POWERSHIFT Transmission Oil Flow with 1st Gear Forward Engaged
When the 1st gear or ratio is selected using the
upshift/downshift switch (2, Fig. 14), the solenoid
valves (6 and 8, Fig. 12) direct oil from the hydraulic
pump to clutches A and C, respectively.
Oil reaches the pistons (1 and 3), moves them
against the force of the Belleville springs (2 and 4,
respectively) and compresses the two clutches A
and C. The 1st gear or ratio is engaged.
6–66000 – 06 – 2002
C D E
4 3
16
Trapped oil
Pressure oil lubrication is fed to all the
SEMI–POWERSHIFT transmission components. Oil
pressure is regulated by the valve (32, Fig. 10).
If the clutch pedal is pressed, the solenoid valves (6
and 8) stop sending oil to the clutches A and C and
consequently pistons (1 and 3) are pushed away
from the clutch discs by the action of the Belleville
springs (2 and 4). Clutches are then released.
 SECTION 6001 – POWER TRAIN 15

1 2

A
B

C D E
4 3
BSD2261B

17

Pressure oil Trapped oil

Lubrication pressure oil

SEMI–POWERSHIFT Transmission Oil Flow with 6th Gear Forward Engaged

When the 6th gear or ratio is selected using the
upshift/downshift switch (2, Fig. 14), the solenoid
valves (7 and 10, Fig. 12) direct oil from the hydraulic
pump to clutches B and E, respectively.
Oil reaches the pistons (2 and 4), moves them
against the force of the Belleville springs (1 and 3,
respectively) and compresses the two clutches B
and E. The 6th gear or ratio is engaged.
Pressure oil lubrication is fed to all the
SEMI–POWERSHIFT transmission components. Oil
pressure is regulated by the valve (32, Fig. 10).
If the clutch pedal is pressed, the solenoid valves (7
and 10, Fig. 12) stop sending oil to the clutches B and
E and consequently pistons (2 and 4) are pushed
away from the clutch discs by the action of the
Belleville springs (1 and 3). Clutches are then
released.

6–66000 – 06 – 2002
16 SECTION 6001 – POWER TRAIN

A
B H

C D E R M
L

BSD2247B

18
Power Flow 1st Gear Medium Range–Forward
A and C Clutches Engaged
1. A Clutch 6. High Range
2. B Clutch 7. Low Range
3. C Clutch 8. Reverse Range
4. D Clutch 9. Medium Range
5. E Clutch

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 17

A
B H

C D E R M
L

BSD2247C

19
Power Flow 2nd Gear Medium Range–Forward
B and C Clutches Engaged
1. A Clutch 6. High Range
2. B Clutch 7. Low Range
3. C Clutch 8. Reverse Range
4. D Clutch 9. Medium Range
5. E Clutch

6–66000 – 06 – 2002
18 SECTION 6001 – POWER TRAIN

A
B H

C D E R M
L

BSD2247D

20
Power Flow 2nd Gear Medium Range–Reverse
B and C Clutches Engaged
1. A Clutch 6. High Range
2. B Clutch 7. Low Range
3. C Clutch 8. Reverse Range
4. D Clutch 9. Medium Range
5. E Clutch
NOTE: Reverse gears are only available in Medium
Range.

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 19

LIMP HOME
1
WARNING
Care should be taken when operating the tractor with
the limp home harness connected. Clutch
engagement will be harsher than normal. Do not
leave the limp home harness connected when the
operation has been completed.
2
In the unlikely event of an electrical fault developing
within the transmission that renders the tractor
immobile, for example, failure of the supply voltage
to the PWM valves, the emergency ‘Limp Home
Harness’, Special Tool No. 380000489 for
21
Semi–Powershift transmissions, is available to
enable the tractor to be driven onto a transporter or
hard standing, in order that the repair can be carried
out in a suitable location. The Limp Home device is
not and must not be used as a means to continue
operating the tractor in its work environment.
To engage and operate the ‘Limp Home Harness’
proceed as follows:–

1.Apply the parking brake.

2.Stop the engine and turn keystart off.

3.Remove the electronic draft control panel.

4.Locate and disconnect the rear main harness

access connector.

22
5.Connect the limp home harness connector,
marked with ‘HARNESS’, into the rear main
harness of the tractor.

6.Connect the other connector of the Limp Home

harness marked ‘DIAGNOSTIC’, to the ‘WHITE’
diagnostic plug.

7.Start the vehicle.

8.Select forward or reverse by operating

forward/reverse switch, (2) Figure 21, for 2
seconds on the Limp home harness control box.
Return the switch to the centre position.

9.Operate the momentary switch, (1) Figure 21, of 23

the Limp Home Harness to move the vehicle. If
necessary, depress the foot throttle to increase
engine speed.

10.When the tractor has been delivered to the repair

area, disconnect the Limp Home Harness and
reconnect the limp home access connector of the
rear main harness and proceed with diagnosing
and repairing the fault.

6–66000 – 06 – 2002
20 SECTION 6001 – POWER TRAIN

PRESSURE TESTING
Transmission Clutches, A,B,C,D and E

1. Prepare the tractor for pressure testing:

(i) Ensure the handbrake is fully applied and wheels

chocked.

(ii) Install diagnostic switch, Tool No.380000488,

Figure 24, into the white diagnostic plug of the
tractor harness under the electronic draft control
panel, Figure 25.

24
(iii)Start and run the tractor to warm the transmission
oil to a minimum operating temperature of 50°C
(122°F).

25
2. Install suitable pressure gauges (0–40bar,
0–600 lbf.in2), five if available, into each of the E D C
A B

clutch pressure test points, located in the raised

horizontal manifold, under the right hand foot
step.

TA6021003
26
1. Pressure gauge with adaptor
2. Adaptor (10–1.00 mm x 7/16 JIC)
3. Hose

27

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 21

3. Start the engine and enter HJ mode using the

diagnostic switch. Depress the clutch pedal and
move the shuttle lever into forward. Release the
clutch. The upper character on the display will
show ‘A’, indicating that clutch ‘A’ solenoid will be
energised. To energise the solenoid press and
hold the downshift control switch and observe
the pressure reading on the gauge which should
be 17±1 bar.

28
4. To select other clutches, B, C ,D or E, repeatedly
press the upshift switch and then depress the
downshift control to energise the solenoid.

5. The pressure can be controlled with the clutch

pedal. When the pedal is depressed the lower
two digits will change to a number 0–16
indicating the approximate pressure in bars, as
long as the clutch pedal is correctly calibrated.
With the pedal fully released ‘FP’ will be
displayed indicating Full Pressure.

29

6–66000 – 06 – 2002
22 SECTION 6001 – POWER TRAIN

Low, Medium, High and Reverse Synchroniser

Pressure testing
2
1
Figure 30 –1. Reverse synchroniser test point
2. High synchroniser test point

TIA35159

30
Figure 31 –1. Low synchroniser test point
2. Medium synchroniser test point
2

Due to the operating characteristics of the

transmisson it is not possible to pressure test the
1
synchroniser circuits during normal tractor
operation.

To check the pressure within the synchroniser

circuits it is recommended that the clutch calibration
procedure using, H1, mode ‘N’ is used.

TIA355160
31
1. Prepare the tractor for pressure testing:

(i) Ensure the handbrake is fully applied and wheels

chocked.

(ii) Install diagnostic switch, Tool No.380000488 into

the white diagnostic plug of the tractor harness.
refer to Figure 25.

(iii)Start and run the tractor to warm the transmission

oil to a minimum temperature of 50°C (122°F).

32
2. Install suitable (0–40bar, 0–600 lbf.in2) pressure
gauges, four if available, into each of the
synchroniser pressure test points, located in the
transmission side cover, Figure 33.
1. Pressure gauge with adaptor
2. Adaptor (10–1.25 mm x 7/16 JIC)
3. Hose

TA6021013
33

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 23

3. Start the engine and enter mode H1.

4. Depress the clutch pedal and position the shuttle

lever in forward.

5. Set engine speed to 1100 rev/min.

6. Cycle through H1 to ‘N’, using the upshift switch.

34
7. Depress the downshift control to activate all of
the synchroniser solenoids.

35
8. Each gauge should indicate 17±1 bar when the
solenoids are activated and zero when
de–activated.

9. If all gauges read low, suspect a fault in the low

pressure hydraulic system, refer to the hydraulic
section of this Repair Maual for further details.

10. If one or more gauges read correct and the other

gauges are low this indicates that the hydraulic
system is okay and that the fault lies within the
transmission assembly. Remove and inspect the
solenoid valve assembly, if no fault is found
remove the transmission side cover and inspect TA6021004
the operating piston and seals.
36

6–66000 – 06 – 2002
24 SECTION 6001 – POWER TRAIN

CLUTCH AND SYNCHRONISER CALIBRATION

The Semi–powershift transmission has 5 clutch

packs and 2 synchronisers that require periodic
calibration to compensate for wear. Calibration
should only be necessary only if a deterioration in
gear shift quality is noted.
NOTE: During the calibration procedure the
electronic management system detects precisely the
point at which the clutches start to engage . The
engagement is detected by a reduction in engine
speed. During calibration it is essential that no action
is taken to to cause the engine speed to vary. Be sure
that the air conditioner and all electrical equipment is 37
switched off. Do not operate the PTO or any
hydraulic lever or move the hand or foot throttle.
There are two methods to enter the calibration mode:
Through the white diagnostic connector, using
special tool No. 380000488 and menu mode H1
or,
With the operator in the seat, depress and hold down
the clutch pedal. With key start in the off position
depress and hold the transmission upshift control
(1). Start the engine and, within two seconds,
depress and release the downshift control (2), to
enter the calibration mode. Release the clutch pedal.
38
Tractor Preparation

NOTE: The clutches should be adjusted when the

transmission oil temperature is between 20°C (68°F)
and 50°C (122°F).
Park the tractor on level ground, away from
obstacles (in case of unexpected tractor movement).

Apply handbrake, switch off all electrical equipment

and air conditioning if fitted. Stop the engine and
place remote levers in neutral and lower hydraulic
equipment to the ground.
39
Place the shuttle in neutral. Block the wheels, front
and rear..

Install tool 380000488 into the white diagnostic plug,

Figure 39 and start the engine. Select H1 by
depressing the diagnostic switch once.
or
Enter calibration mode using upshift and downshift
switches.

40

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 25

The display will change to show transmission

temperature. Press the upshift/downshift switch to
proceed.

If the temperature is less than 10°C Error Code ‘U19’

will be displayed. If the temperature is between 10°C
and 20°C ‘‘CL” will be displayed. If the temperature is
to high, above 50°C, ‘‘CH” will be displayed.

If ‘U19’ is displayed calibration will not be possible

and the oil will have to be warmed before proceeding.

41
If ‘CL’ or ‘CH’ are displayed after 4 seconds the
display will return to oil temperature and the tractor
may be operated to obtain the correct transmission
oil temperature. If it is not practical to wait for the oil
temperature to change press either of the upshift or
down shift switch while ‘CL’ or ‘CH’ is being
displayed. The display will then show an ‘A’ and
calibration can proceed.

Move the shuttle lever to forward and release the

clutch pedal.

Set engine speed to 1200 ERPM ±100.

42
The transmission is now ready for calibration.

Press and hold the downshift switch to calibrate

clutch A.

If the start up procedure was incorrect a ‘‘U” code will

appear.

Hold the downshift switch until the engine speed

decreases by 50 RPM and the calibration number
stops increasing.

43
Release the downshift switch, the display will change
to ‘b’, indicating that clutch B is ready for calibration.

Hold the downshift switch until the engine speed

decreases by 50 RPM and the calibration number
stops increasing.

44

6–66000 – 06 – 2002
26 SECTION 6001 – POWER TRAIN

Repeat the above steps for clutches C, D and E. After

clutch E has been calibrated, release the downshift
switch and the display will change to F.

Press the downshift switch again. The synchronisers

will be shifted to neutral and synchroniser stroke
relationship will be checked. If satisfactory the
display will show ‘CF’.

45
Pressing the downshift switch again will select mode
‘N’. This mode engages clutches A and C with the
synchronisers in neutral. This can be used to ‘free’
transmission components that may be suspected of
sticking , i.e,synchronisers.
WARNING
It should be noted that if a synchroniser is not actually
in neutral, this mode can cause the tractor to move.

When the display alternates between ‘N’ and ‘750’

this indicates that the mode has completed.

46
Turn the key start switch off for at least 10 seconds to
store the calibration values.

NOTES: Transmission output speed and clutch

pedal position are constantly monitored. Calibration
cannot proceed unless the tractor is stationary and
the clutch pedal released.

Repeatedly depressing the upshift switch will cycle

through each clutch mode, enabling a particular
clutch to be calibrated several times if required.
47
During each clutch calibration the synchroniser
positions are also calibrated:–
• During Clutch A – Mid range synchroniser
calibrated
• During Clutch B – Reverse range synchroniser
calibrated
• During Clutch C and D – High range synchroniser
calibrated
• During Clutch E – Low range synchroniser
calibrated

48

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 27

SEMI–POWERSHIFT
TRANSMISSION HOUSING

Removal – Installation
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity.Ensure that units
or parts are supported by suitable slings or
hooks.Ensure that no–one is in the vicinity of the load
to be lifted.

Remove the transmission housing from the tractor as

follows:
1. Remove cab as described in Section 9001.
2. Drain fuel tanks. Remove electrical connector
(1), and fuel supply quick coupling (2). Remove
main tank

49
3. If the auxillary fuel tank is fitted, remove the clip
(1). Remove auxillary tank.

50
4. Remove engine as described in Section 10.
5. To drain the oil from the transmission. Remove
plug (1).

51

6–66000 – 06 – 2002
28 SECTION 6001 – POWER TRAIN

6. Detach and remove the accumulator tubes.

52

7. Detach all connectors from the range control

valve assembly, SEMI–POWERSHIFT clutch
control valve assembly and different sensors.
NOTE: Before detaching connectors from both
control valve housings, mark each connector and
respective solenoid valve to assist reassembly and
avoid reversal of connections.

53
8. Detach and remove the PTO and lift lubrication
tubes (3) and (4).

54
9. Detach and remove the power steering supply
and return lines (1 and 2).

55

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 29

10. Disconnect all accessory control lines from their

fittings located in the lower part of the range
control valve assembly (1).

56
11. Loosen two bolts from the transmission housing
top cover, attach lifting chains to the housing and
keep them tensioned using a hoist.
12. Place a stationary stand under the draft sensing
unit bracket. Place the trolley jack of stand tool
no. CAS.30009A under the rear axle housing.
13. Detach the transmission housing retaining bolts
and remove the housing.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

57
14. Fix the transmission housing on the rotary stand
tool no. 380000301 using front and rear
brackets, tools nos. 380000271 (1) and
380000272 (2), respectively.

58

6–66000 – 06 – 2002
30 SECTION 6001 – POWER TRAIN

20270

59
Pattern for application of sealant during installation of the speed clutch–transmission housing to rear axle
housing.
Installation
1. Reinstall the transmission housing to the rear
axle housing and engine observing the following:
– Reinstallation follows the removal procedure
in reverse.
– Before reassembling housings, supports
and covers, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown.
– Tighten to correct torques as detailed on
page 3.

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 31

SEMI–POWERSHIFT TRANSMISSION

Disassembly–Reassembly
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Prior to servicing the SEMI–POWERSHIFT

transmission, it is necessary to remove the
transmission housing following the procedure
detailed on pages 27 to 29.
1. Fix the transmission housing on the rotary stand
tool no. 380000301 using front and rear
brackets, tools nos. 380000271 (1) and
380000272 (2), respectively.
2. Perform steps 3 to 5 to remove the range and
transmission control valve assemblies, if not
previously removed.

60
3. Detach the line (3) from transmission control
valve assembly and transmission housing.

61
4. Loosen the transmission control valve housing
retaining screws (4) and remove housing

62

6–66000 – 06 – 2002
32 SECTION 6001 – POWER TRAIN

5. Withdraw control lines (3) of clutches B, C, D and

E and discharge fitting (1). Loosen and remove
clutch A control line (2).

63
6. Loosen retaining screws and remove the range
control valve assembly (1) using a 80 mm long
bolt as an alignment pin.

64
7. Remove retainer nuts and support plate and slide
out the potentiometers(1).

65
8. Loosen retaining bolts and remove sensors (1
and 2).

66

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 33

9. Loosen retaining bolts and detach cover (6).

67
10. Loosen the bolts attaching the clutch A cover (3)
to the transmission housing. Insert three bolts (4)
into the threaded holes and screw them in until
detaching the cover (3) along with clutch A from
the transmission housing.

68
11. Remove circlip (5) and retrieve clutch discs and
centering springs.

69
12. Assemble tool no. 380000291 (6) on clutch B
housing, turn the tool bolt to compress clutch B
release Belleville springs and remove spring
retaining ring. Remove tool from the bell housing
and retrieve Belleville springs.
13. Blow compressed air into the oil supply hole to
clutch B to expel the clutch drive piston.

70

6–66000 – 06 – 2002
34 SECTION 6001 – POWER TRAIN

14. Remove the retaining ring (1) and withdraw the

clutch B housing.

71
15. Loosen the cover (1) retaining screws. Using a
plastic hammer engage the Medium/reverse
synchroniser with the medium gear. Place tool
no. 380000491 (2) on the transmission housing,
loosen the output shaft locknut using spanner
tool no. 380000459 (3). Return the
Medium/reverse sychroniser to the neutral
position. Retrieve cover.

72
16. Remove retaining bolts and detach the range
gear output and input shaft bearing cap (1).

73
17. Using a puller tool no. 38000542 (1) and a
suitable insert, remove the medium range driven
gear, bearing and bush.

74

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 35

18. Using a puller (2) and suitable support insert,

remove the medium range drive gear, bearing
and bush.

75
19. Loosen the plugs (3) and retrieve springs and
actuating balls. Remove plug from the
transmission housing and withdraw the medium
and reverse control fork lock pin.

76
20. Slide out the range selector dog (4) retaining
spring pins and remove rails.

77
21. Remove the medium and reverse control fork (1)
along with the synchroniser (2).

78

6–66000 – 06 – 2002
36 SECTION 6001 – POWER TRAIN

22. Remove the reverse driven and drive gears (3

and 4, respectively).

79
23. Loosen the reverse idler gear shaft setscrew (5).

80
24. Using adapter m10x1.25 adaptor (7) and slide
puller (6) remove the reverse idler gear shaft (8).

81
25. Slide out the low range driven gear (1).

82

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 37

26. Remove the low and high range control fork (4),
synchroniser (3) and output shaft (2).

23476

83
27. Remove input shaft (5).

84
28. Remove the position sensor control forks (6).
Retrieve bushings and seals at the outside of the
transmission housing.

85
29. Loosen the retaining screws and remove the
front cover plate (1).

86

6–66000 – 06 – 2002
38 SECTION 6001 – POWER TRAIN

30. Slide out the drive gear (2) and bearing. (3).

87
31. Remove the ring (4) retaining the gears on the
input shaft.

88
32. Slide out the input shaft (5) with the bearing inner
races from the opposite side of the housing.
Retrieve gears, thrust washer and adjustment
shim.

89
33. Install tool no. 380000466 (1) on the output shaft,
insert a spanner (2) to hold the shaft in position,
screw tool no. 380000465 (3) to the housing and
tighten the tool screw to support the tool.

90

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 39

34. Unstake and loosen the nut, retrieve the bush

and Belleville spring.

91
35. Withdraw the manifold (4) and bearing thrust
washer from the output shaft. Detach tool no.
380000465 (3), spanner (2) and tool no.
380000466 (1) from rear side.

92
36. Remove the output shaft (5) seals and, using an
aluminium punch and a hammer, partially
remove the shaft.

93
37. Turn the transmission housing upright, withdraw
the output shaft (1) and retrieve the
clutch/gear/bearing assembly along with the
bearing.

94

6–66000 – 06 – 2002
40 SECTION 6001 – POWER TRAIN

38. Loosen the lubrication oil fitting (2) and retrieve

inner bush.

95
39. Detach the fitting from the housing and slide out
the lubrication line from the inside of the
transmission housing.

96
40. Dismantle the clutch C by removing the circlip (3)
and collecting the clutch driven and drive discs.

97
41. Fix tool no. 380000291 (1) to the clutch bell
housing, screw in the tool bolt until compressing
the Belleville springs, then remove the spring
retaining ring. Loosen tool bolt, retrieve Belleville
springs and detach tool from the clutch bell
housing.

98

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 41

42. Screw two bolts into the threaded holes in the

piston (2), then withdraw piston pulling it out
using the bolts.
43. Repeat steps 40 to 42 to disassemble clutches D
and E.

99
44. Remove the retaining ring (1), the bearing inner
lock ring and retrieve the hubs of the clutches A
and B along with the bearing and clutch A discs
and centering springs.

100
45. Remove seal (3).

101
46. Remove the outer (4) and inner circlips from the
outside of clutch A (5), withdraw clutch A from the
cover. Retrieve the bearing.

102

6–66000 – 06 – 2002
42 SECTION 6001 – POWER TRAIN

47. Position tool no. 380000291 (6) on clutch A (5),

turn the tool bolt to compress the clutch release
Belleville springs and remove the retaining ring.
Disassemble tool no. 380000291 (6) and retrieve
Belleville springs.

103
48. Place the clutch A housing on the cover (2), blow
compressed air into the control oil inlet hole and
remove the piston (1).

WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

49. Reinstall the SEMI–POWERSHIFT transmission

into the transmission housing observing the
following:
– Reinstallation follows the removal procedure
in reverse, from step 49 back to step 1.
104
– Refer to figures on pages 10, 11, and 12 for
correct orientation of the different parts.
– Ensure the housing is thoroughly cleaned
(especially inner compartments).
– Check seals and replace if damaged.
– Before reassembling housings, supports
and covers, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the
figure on page 46.
– Tighten to correct torques as detailed on
page 3.
– Carry out following operations and
adjustments as detailed on pages 47 to 50.

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 43

50. Assemble retaining tool no. 380000466 (1) on

the transmission output shaft, insert a spanner
(3) to hold it and support tool (1) by attaching tool
no. 380000465 (2) to the housing.

105
51. While assembling clutches C, D, and E and their
shafts to the transmission housing, take care to
match reference marks (1).

106
52. Install front bearing (7) using tools no. 50108 (6)
and 380000460 (5).

107
53. After installing the components of the output
shaft, lock the shaft with the nut. Temporarily
install the front cover (9) and install the supply
tubes (8).

108

6–66000 – 06 – 2002
44 SECTION 6001 – POWER TRAIN

54. Blow compressed air into the lines (1) and check
for correct operation of the clutches C, D, and E.
After this test, remove lines (1) and detach front
cover. Install the input shaft complete with its
accessory parts. After installing the front cover
and tightening attaching bolts, perform again the
above test to check that there are no leaks from
the manifold.

109
55. Upon reassembly of the clutch A, install the
bearing (1), then raise the hub (8) using a 1
suitable tool and insert the circlip (10).

10
8

110
56. When reinstalling the circlip (1) on to the clutch
cover (8), check that the oil leak–off hole (7) is
exactly in the middle of the outer circlip ends.

111
57. To assist assembly of clutch B disc retaining ring,
insert two suitable dowels (1) into two oil
discharge holes to keep the clutch centering
springs compressed.

112

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 45

58. Using tool no. 380000291 position the clutch disc

retaining ring into its seat.

113
59. With the clutch A housing assembled to the
transmission housing, install the bearing (7)
using tool no. 380000460. Fix bearing with the
retaining rings and install the seal.

114
60. Heat and install the bearing (3) on to the input
shaft using tool no. 50060 (2) shown on page 8.
Using tool no. 50013 (1) (see page 7), keep the
bearing properly seated against the gear during
cooling.

115
61. Heat and install the bearing (1) on to the output
shaft using tool no. 50061 (2) shown on page 7.
Using tool no. 50018 (1) (see page 6), keep the
bearing properly seated against the gear during
cooling.
NOTE: Remove tools nos. 50060 (2, Fig. 115) and
50061 (2, Fig. 116) when the bearings (3 and 1) have
completely cooled down.

116

6–66000 – 06 – 2002
46 SECTION 6001 – POWER TRAIN

117
Pattern for application of sealant during installation of: range control valve housing, top cover, front cover of
clutches A and B.

6–66000 – 06 – 2002
 SECTION 6001 – POWER TRAIN 47

TRANSMISSION HOUSING

Transmission input shaft end play adjustment

WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

Proceed as follows:
62. Place the transmission input shaft (1) on a bench,
slide on the gear (6), spacer (5), a 3.5 mm test
shim (4), gear (3). Lock the assembly with a
circlip (2).
63. Settle the assembly. Using a feeler gauge (7),
measure the end play between the circlip (2) and
gear (3).
64. Shim to be assembled is given by the measured
dimension plus the test shim minus the specified
end play.

Example:

Gauge reading:= 0.90 mm 118

Test shim:= 3.50 mm
Specified end play= 0 to 0.15 mm
Shim to be assembled: = 0.90 + 3.50 – 0.10 =
4.30 mm.
NOTE: Available adjust shims are detailed on page
2.
65. Remove circlip (2), withdraw the gear (3) and test
shim (4). Add shim (8) as previously found, gear
(3) and lock the assembly with the circlip (2).
66. Settle the assembly. Using a feeler gauge (7)
check that end play is to specification.

119

6–66000 – 06 – 2002
48 SECTION 6001 – POWER TRAIN

TRANSMISSION HOUSING
Transmission driven gear bearing adjustment
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

Proceed as follows:
1. Assemble the ’C’ clutch hub to the special tool,
No 380000497, complete with bearings, spacer
and original shim. Tighten the bolt of the special
tool to 140 Nm.

120
2. Wrap a length of string around the smaller of the
two gears and attach to a suitable spring
balance. Measure the rolling resistance of the
bearings during rotation, not at the point where
rotation begins.
3. The rolling resistance should equate to
0.5–0.8Kg on the spring balance. If outside the
specification install a thinner shim to increase the
resistance or install a thicker shim to reduce the
resistance.

121

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 SECTION 6001 – POWER TRAIN 49

TRANSMISSION HOUSING

Range input and output shaft taper bearing

adjustment
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

Proceed as follows:
4. Install cover (2) without adjust shim. Install tool
no. 50013 (1) on to the input shaft (see page7).

122
5. Screw installer tool no. 380000458 (2) on tool no.
50013 (3). Place a dial indicator (1) with the
stylus touching the bearing inner race. Turn the
shafts to settle the bearing rollers, reset dial to
zero ensuring that the assembly is bottoming.
Through the lever of installer tool no. 380000458
(2). bring the assembly to touch the cover (4) and
read the travel (L) on the dial indicator.
Adjust shim to be added is given by:
S = L – (0 to 0.06 mm)
where:
S = Test shim.
L = Travel reading.
0 to 0.06 mm =Input shaft bearing end play.
123
NOTE: Available adjust shims for the range input
shaft bearings are listed on page 3.
6. Dismantle tools (2 and 3), remove cover (4),
assemble the shim as previously found, reinstall
cover (4) and tools (2 and 3). Repeat step 73 to
check that end play is to specification, 0 to 0.06
mm.
Remove tools (2 and 3).

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50 SECTION 6001 – POWER TRAIN

7. Install disc (1) with a test shim (Sp). Remove

output shaft lubrication plug.Assemble tool no.
380000568 (4), installer tool no. 380000458 (3)
and dial indicator (2). Ensure indicator stylus is
located on the bearing inner race.
Ensure indicator stylus is located on the bearing
inner race.Turn the shafts to settle the bearing
rollers and reset the indicator ensuring that the
assembly is bottoming.Using the lever of installer
tool no. 380000458 (3) bring assembly to touch
the disc (1) and read travel (H) on the dial
indicator.
Shim to be assembled is given by:

S1 = H + Sp – (0 to 0.06 mm) 124

where:
S1 = Adjust shim.
Sp = Test shim.
H = Travel reading.
0 to 0.06 mm = Output shaft bearing end play.
NOTE: Available adjust shims for the range output
shaft bearings are listed on page 3.
8. Dismantle tools (3 and 4), remove disc (1),
replace test shim (Sp) with adjust shim (S1),
reinstall disc (1) and tools (3 and 4). Repeat step
75 to check that end play is to specification, 0 to
0.06 mm. Remove tools (3 and 4) and screw in
the output shaft lubrication plug.

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 SECTION 6001 – POWER TRAIN 51

SEMI–POWERSHIFT RANGE CONTROL

VALVE ASSEMBLY

Removal – Installation
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity.
Ensure that units or parts are supported by suitable
slings or hooks.
Ensure that no–one is in the vicinity of the load to be
lifted.

Remove the SEMI–POWERSHIFT range control

valve assembly as follows:
1. Remove battery cover.
2. Detach the negative cable (1) from the battery
and insulate.

125
3. Detach and remove the accumulator (2) tubes.

126
4. Loosen the retaining screws and remove
accumulator (shown with auxillary tank removed
for clarity).

127

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52 SECTION 6001 – POWER TRAIN

5. Detach all connectors from the range control

valve assembly and sensors.
NOTE: Before detaching connectors from the control
valve housing, mark each connector and respective
solenoid valve to assist reassembly and avoid
reversal of connections.

128
6. Disconnect all accessory control lines from their
fittings located in the lower part of the range
control valve housing (1).

129
7. Remove PTO and lift lubrication line fittings (3
and 4), loosen retaining screws and remove the
SEMI–POWERSHIFT range control valve
assembly (3) using two alignment pins.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

130
8. Reinstall the SEMI–POWERSHIFT range
control valve assembly to the transmission
housing observing the following:
– Installation follows the removal procedure in
reverse.
– Before reassembling the
SEMI–POWERSHIFT range control valve
assembly thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the
figure on page 46.
– Tighten to correct torques as detailed on
page 3.

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 SECTION 6001 – POWER TRAIN 53

SEMI–POWERSHIFT RANGE CONTROL

VALVE ASSEMBLY

Disassembly–Reassembly
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

To overhaul the SEMI–POWERSHIFT range control

assembly it is necessary to remove it from the
transmission housing following the
removal–installation procedure described on pages
51 to 52.
1. Loosen the screw (1) and remove the diff lock
solenoid valve (2).

131
2. Remove the fitting (1).

132
3. Remove the regulated low pressure sensor.

133

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54 SECTION 6001 – POWER TRAIN

4. Remove the retaining plug (3) and retrieve the

low pressure regulating valve (1) and spring (2).

134
5. Remove the FWD pressure sensor (1), and the
differential lock sensor pressure (2).

135
6. Remove the hydraulic fitting (1) and retrieve the
coller bypass valve, and spring.

136
7. Loosen retaining bolts and remove the range
synchroniser drive pistons (1).

137

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 SECTION 6001 – POWER TRAIN 55

8. Loosen the oil suction valve for the power

steering circuit (1) (for when the engine is
shut–off) and all solenoid valves.

138
9. Remove the retaining ring (1). Remove the
sliding guide cover, inner ring and piston.

139
10. Using a suitable punch, drive out the inner
retaining ring (2) and retrieve inner ring.

140

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56 SECTION 6001 – POWER TRAIN

11. Range synchroniser drive piston components.

NOTE: If it is necessary to replace the seals (3) and

back–up rings, insert them in as fast as possible to
prevent bending. Wait 15 minutes before installing
the piston into the bore.
12. Reassemble the SEMI–POWERSHIFT range
control valve assembly observing the following:
– Reassembly follows the disassembly
procedure in reverse.
– Refer to figures on page10 for correct
orientation of different components.
– Ensure all components are thoroughly 141
cleaned.
– Check seals and replace if damaged.
– Tighten to correct torques as detailed on
page 3.

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 SECTION 6001 – POWER TRAIN 57

SEMI–POWERSHIFT RANGE CONTROL

SOLENOID VALVE

Replacement
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Replace one of the solenoid valves from the

SEMI–POWERSHIFT range control valve assembly
as follows:
1. Remove battery cover.
2. Detach the negative cable (1) from the battery
and insulate.

142
3. Detach connector (1) from the solenoid valve.

143
4. Loosen the retaining nut (2) and remove the
solenoid (3).

144

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58 SECTION 6001 – POWER TRAIN

5. Unscrew the pin (1) and remove.

WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

6. Reinstall the solenoid valve into the

SEMI–POWERSHIFT range control valve
assembly observing the following:
– Reinstallation follows the removal procedure
in reverse, from step 5 back to step 1.
– Check seals and replace if damaged.
– Tighten to correct torques as detailed on
page 3. 145

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 SECTION 6001 – POWER TRAIN 59

SEMI–POWERSHIFT TRANSMISSION
CONTROL VALVE ASSEMBLY

Removal–Installation(Op. 21 133 40)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the SEMI–POWERSHIFT

TRANSMISSION control valve assembly as
follows:
1. Remove battery cover.
2. Detach the negative cable (1) from the battery
and insulate.

146
3. Loosen the bolt attaching the steps (6) to the
bracket.

147
4. Loosen the bolt and nut attaching the steps (1) to
the cab platform.

148

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60 SECTION 6001 – POWER TRAIN

5. Drain fuel tanks, then loosen the clamp (1)

retaining the fuel lines between the main and
auxiliary tanks.

149
6. Loosen the clamp and detach the tube (3)
between the main and auxiliary tanks.
7. Detach the fuel return line (2) from the pump to
the auxiliary tank. Remove the auxiliary tank.

150
8. Detach all connectors (4) from the
SEMI–POWERSHIFT clutch control solenoid
valve assembly.
NOTE: Before detaching connectors from the control
valve housing, mark each connector and respective
solenoid valve to assist reassembly and avoid
reversal of connections.

151
9. Disconnect lines (5 and 6), loosen retaining
screws and remove the control valve housing.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

10. Reinstall the SEMI–POWERSHIFT control valve

assembly observing the following:
– Reinstallation follows the removal procedure
in reverse, from step 9 back to step 1.
– Tighten to correct torques as detailed on
page 11.
152

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 SECTION 6001 – POWER TRAIN 61

SEMI–POWERSHIFT TRANSMISSION
SOLENOID VALVE

Replacement
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Replace one of the solenoid valves from the

SEMI–POWERSHIFT transmission control valve
assembly as follows:
1. Remove battery cover.
2. Detach the negative cable (1) from the battery
and insulate.

153
3. Loosen the screw attaching the steps (6) to the
bracket.

154
4. Loosen the screw attaching the steps (1) to the
cab platform.

155

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62 SECTION 6001 – POWER TRAIN

5. Drain fuel tanks, then loosen the clamp (1)

retaining the fuel line between the main and
auxiliary tanks.

156
6. Detach the fuel return line (2) from the pump to
the auxiliary tank. Remove the auxiliary tank.

157
7. Detach connector (4) from the solenoid valve to
be replaced.

158
8. Unscrew the locknut (1), remove washer (2) and
solenoid coil (3). Then unscrew the solenoid (4).
9. Reinstall the solenoid valve into the
SEMI–POWERSHIFT transmission control
valve assembly observing the following:
– Reinstallation follows the removal procedure
in reverse, from step 10 back to step 1.
– Check seals and replace if damaged.
– Tighten to correct torques as detailed on
page 11.

159

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