Вы находитесь на странице: 1из 84

Chapter 6 POWERSHIFT TRANSMISSION

1. Structure and Functions......................................................................... 6-1


1.1 Transmission ........................................................................................................... 6-1
1.2 Torque Converter .................................................................................................... 6-2
1.3 Control System for Powershift Transmission........................................................... 6-2
1.4 Hydraulic System Schematic of Powershift Transmission....................................... 6-3
2. Removal and Installation........................................................................ 6-4
2.1 Removal .................................................................................................................. 6-4
2.2 Installation ............................................................................................................... 6-4
3. Outline...................................................................................................... 6-5
3.1 Overall View of Powershift Transmission ................................................................ 6-5
3.2 Overall View of Control Valve.................................................................................. 6-6
4. Powershift Transmission, Disassembly ............................................... 6-7
4.1 Preparation .............................................................................................................. 6-7
4.2 Transmission External Parts, Removal ................................................................... 6-7
4.3 Oil Pump Assembly, Removal ............................................................................... 6-10
4.4 Transmission Housing, Removal........................................................................... 6-11
4.5 Input Shaft, Idler Shaft and Output Gear, Removal............................................... 6-14
4.6
4.7
Transmission Housing, Disassembly..................................................................... 6-17
Torque Converter Housing, Disassembly.............................................................. 6-18
6
4.8 Idler Shaft, Disassembly........................................................................................ 6-18
4.9 Output Gear, Disassembly .................................................................................... 6-19
4.10 Forward Input Shaft Gear Assembly, Disassembly ............................................... 6-20
4.11 Reverse Input Shaft Gear Assembly, Disassembly............................................... 6-25
4.12 Oil Pump Body, Disassembly ................................................................................ 6-26
5. Powershift Transmission, Reassembly .............................................. 6-28
5.1 Transmission Housing, Reassembly ..................................................................... 6-28
5.2 Torque Converter Housing, Reassembly 1 ........................................................... 6-29
5.3 Idler Shaft Assembly, Reassembly........................................................................ 6-29
5.4 Output Gear Assembly, Reassembly .................................................................... 6-30
5.5 Input Shaft Gear Assembly, Inspection ................................................................. 6-30
5.6 Forward Input Shaft Gear Assembly, Reassembly................................................ 6-32
5.7 Reverse Input Shaft Gear Assembly, Reassembly ............................................... 6-38
5.8 Oil Pump Assembly, Reassembly and Installation ................................................ 6-39
5.9 Torque Converter Housing, Reassembly 2 ........................................................... 6-44
5.10 Transmission Housing, Installation........................................................................ 6-46
5.11 Servo Case Assembly, Installation ........................................................................ 6-47
5.12 Transmission External Parts, Installation .............................................................. 6-49
6. Control Valve, Disassembly ................................................................. 6-54
6.1 Control Valve External Parts, Removal ................................................................. 6-54
6.2 Valve Body Plate, Removal ................................................................................... 6-54
6.3 Plugs, Removal ..................................................................................................... 6-55
6.4 Strainer, Removal.................................................................................................. 6-56
6.5 Regulator Valve Section, Removal........................................................................ 6-56
6.6 Accumulator Valve Section, Removal ................................................................... 6-57
6.7 Inching Valve Section, Removal............................................................................ 6-58
6.8 Oil Seal and Plug, Removal................................................................................... 6-59
7. Control Valve, Reassembly .................................................................. 6-61
7.1 Control Valve .........................................................................................................6-61
7.2 Washing and Inspection ........................................................................................6-62
7.3 Valve Plug and Oil Seal, Installation......................................................................6-63
7.4 Inching Valve Section, Reassembly ......................................................................6-64
7.5 Accumulator Valve Section, Reassembly.............................................................. 6-65
7.6 Regulator Valve Section, Reassembly ..................................................................6-66
7.7 Strainer, Installation...............................................................................................6-68
7.8 Plugs, Installation ..................................................................................................6-68
7.9 Valve Body Plate, Breather Cover, Installation......................................................6-69
7.10 Control Valve External Parts, Removal .................................................................6-70
8. Inspection and Adjustment .................................................................. 6-71
8.1 Oil Pressure Measurement ....................................................................................6-71
8.2 Brake (Inching) Pedal, Adjustment ........................................................................6-73
8.3 Inching Cable, Adjustment.....................................................................................6-74
9. Troubleshooting .................................................................................... 6-76
10. Service Data........................................................................................... 6-79
POWERSHIFT TRANSMISSION

Chapter 6 POWERSHIFT TRANSMISSION

1. Structure and Functions


1.1 Transmission

b
4 (30) 3

a
(33) 2
5

6
1

c
(32) No. 2 shaft
7
d No. 1 shaft
(30)
No. 3 shaft

e
(61)

The figure in parentheses shows the number of gear teeth.


213641

1 Flexible plate 3 Oil pump assembly 5 Input shaft (No.1 shaft)


2 Torque converter assembly 4 Control valve 6 Idler shaft (No. 2 shaft)
7 Output shaft (No. 3 shaft)

Truck type
This transmission consists of one forward gear and
one reverse gear. The forward-reverse changeover is Item 2 ton class
1 ton class
accomplished by a powershift mechanism that uses 3 ton class
hydraulically controlled multiple-disc clutches. Three-element, single-stage,
Type
The transmission housing and torque converter hous- two-phase
ing can be separated from each other. Range Power path
The torque converter shell is constructed of steel- F (Forward) a→cd→e
plates welded in one body. For this reason, torque R (Reverse) b→e
converter parts can be replaced as an assembled unit
only.
Transmission reduction ratio
32 61
F (Forward) × = 1.972
33 30
61
R (Reverse) = 2.033
30

6-1
POWERSHIFT TRANSMISSION

1.2 Torque Converter

4 3
1
7

5
8
9

213642

1 Turbine runner 4 Pump impeller 7 Drive cover


2 Stator assembly 5 Pump boss 8 Turbine boss
3 Flexible plate 6 Clutch hub 9 Pilot boss

1.3 Control System for Powershift Transmission

3
F
N
R

213643

1 Forward-reverse shift lever 3 Cable (inching)


2 Clutch (inching) pedal 4 Control valve assembly

6-2
POWERSHIFT TRANSMISSION

1.4 Hydraulic System Schematic of Powershift Transmission

Engine speed at : 1600 min-1 (rpm)

Torque
converter
Torque converter inlet pressure relief valve
0.10 to 0.50 MPa
Oil cooler (1.02 to 5.1 kgf/cm2)
PL PO [14.5 to 72.53 psi]
(Valve top surface marked with "M")

Torque converter bypass


Φ6.0 mm (0.24 in.) PM Main orifice
Lubricating Low capacity T/C:Φ1.6 mm (0.063 in.)
circuit High capacity T/C:Φ1.8 mm (0.071 in.)
M
Hydraulic (gear) pump
Logic capacity:
18.6 cc/rev Main regulator valve
(11.35 cu.in.) 1.00 to 1.30 MPa
(10.20 to 13.26 kgf/cm2)
[145.05 to 188.57 psi]
Suction strainer
with magnet
100 mesh Accumulator valve
Installing pressure:
0.06 MPa (0.612 kgf/cm2)
[8.70 psi]
Complete filling pressure:
0.57 MPa (5.812 kgf/cm2)
Orifice bypass [82.68 psi]
Φ1.7 mm (0.07 in.)
Inching valve
0 to 0.44 MPa
(0 to 4.49 kgf/cm2)
[63.82 psi]
D
(Valve top surface
marked with "D")
Strainer

Selector valve

CF CR
Forward clutch Reverse clutch

213644

6-3
POWERSHIFT TRANSMISSION

2. Removal and Installation


2.1 Removal
(1) Remove the engine and transmission as an
assembly from the truck.
Note: For removal and installation procedures for the
engine and transmission as an assembled unit,
refer to "Removal and Installation" in "Chapter 5
POWER TRAIN." Drain oil out of the transmis-
sion housing when removing the engine and
transmission.
(2) Remove the bolts securing the flexible plate
through the access hole in the torque converter
housing.
(3) Separate the torque converter and transmission
assembly from the engine.

2.2 Installation
(1) Couple the torque converter and transmission to
the engine.
To do this, push the torque converter toward the
transmission as far as it goes so that the distance
between the end surface of the torque converter
housing and the flywheel connecting face of the
flexible plate is 50 mm (1.97 in.).
When the assembly is coupled with the engine,
the clearance between the flywheel and flexible
plate should be 1 to 5 mm (0.039 to 0.197 in.).
A zero clearance indicates that the torque con-
verter is in improperly engaged with the oil pump
gear or any of the splines. In this case, reassem-
ble the torque converter and oil pump properly.
(2) Connect the flexible plate to the flywheel with the
bolts through the access hole in the torque con-
verter housing.
Note: Tighten the bolts evenly and progressively.
Avoid giving strain to the flexible plate.
Unit: N·m (kgf·m) [lbf·ft]
24 ± 2.4
Tightening torque (2.45 ± 0.24)
[17.7 to 1.77]

(3) Refilling transmission with oil


(a) Refill the transmission with oil only after the
transmission is installed in the truck and the
engine is ready to be started.
(b) Check the oil level using the level gauge.
(c) Start and run the engine at an idling speed, and
then stop the engine.
(d) Wait for 1 minute or more after stopping the
engine, and check the level.
(e) The checking procedure must be completed
within 15 minutes after the engine has stopped.

6-4
POWERSHIFT TRANSMISSION

3. Outline
3.1 Overall View of Powershift Transmission

Serial No.

Control valve Cooler inlet pipe


Hanger Torque convertor

Cooler outlet pipe

Servo case Engine side

Oil strainer assembly


Oil drain plug

214910
Left side of lift truck

Oil lever gauge

Speed sensor

Engine side

Output flange

Oil temperature switch

214911
Right side of lift truck

6-5
POWERSHIFT TRANSMISSION

3.2 Overall View of Control Valve

Control valve

215210
Overall view of control valve

6-6
POWERSHIFT TRANSMISSION

4. Powershift Transmission, Disassembly


4.1 Preparation
4.1.1 Draining transmission oil
(1) Before removing the transmission from the lift
truck, attach a wire to the torque converter assem-
bly to prevent it from slipping out.
(2) Remove the oil drain plug and drain transmission
oil.
Transmission oil capacity 8 liter (all models)

Oil drain plug

214912
4.1.2 Transmission, setting on the stand
Place the transmission on the special tool (stand,
91A68-03500). Special tool
(Stand,91A68-03500)
Part name Part number
Stand 91A68-03500

214913

4.2 Transmission External Parts, Removal


4.2.1 Oil level gauge, Removal
4.2.2 Cooler pipe, Removal
Remove the oil cooler inlet and outlet pipes together
with eye bolt and gaskets. Oil level gauge Cooler inlet pipe

Control valve

Cooler outlet pipe


214914
4.2.3 Control valve, Removal
Remove control valve together with gasket and O-ring.

6-7
POWERSHIFT TRANSMISSION

4.2.4 Speed sensor and oil temperature switch, Removal


(1) Remove speed sensor together with O-ring.
(2) Remove oil temperature switch.

Speed sensor

Output flange
Oil temperature
switch
214915
4.2.5 Output flange, Removal
4.2.6 Oil strainer, Removal
Remove oil strainer together with O-ring.
Oil strainer assembly

214916

6-8
POWERSHIFT TRANSMISSION

4.2.7 Torque converter assembly, Removal


(1) Install the eye bolts.
Eye bolt

214917

Eye bolt

Bolt
214918

(2) Attach a wire to eye bolt, lift the transmission, and


install on the special tool (stand kit, 91A68-0020) Special tool
using 2 bolts. (Stand kit 91A68-00020)

Part name Part number


Stand kit 91A68-00020

214919

Eye bolt

Bolt
214920

6-9
POWERSHIFT TRANSMISSION

(3) Lift the transmission and stand kit together and


place the transmission on the stand kit so that the
transmission housing side faces upward.

214921

214922

(4) Remove two bolts from flexible plate and install


two eye bolts.
(5) Remove the wire that was attached to the torque
convertor assembly to prevent it from slipping out.
(6) Hoist the torque converter assembly.
Note: 1. The torque converter assembly cannot be
disassembled.
2. Prepare an oil pan to receive oil that is flowing
out when removing the torque converter as-
sembly.
214923

4.3 Oil Pump Assembly, Removal


4.3.1 Oil pump mounting bolts, Removal
Remove the eight mounting bolts from the oil pump.
Special tool
(Bolt,67281-15400)

Oil pump
214924

6-10
POWERSHIFT TRANSMISSION

4.3.2 Oil pump, Removal


Install special tool (Bolts, 67281-15400) at the loca-
tions indicated by the arrows (pictured) and remove oil
pump.

Part name Part number


Bolt 67281-15400

4.3.3 O-ring, relief valve and torque converter spring, Removal


Remove O-ring, relief valve and torque converter
spring.
Bolt

O-ring

Relief valve and


torque converter spring
214925

4.4 Transmission Housing, Removal


4.4.1 Transmission housing mounting bolts, Removal 1
Remove three bolts from the inside of torque converter
housing.
4.4.2 Servo case, Removal
(1) Lift the transmission, and remove the special tool
(stand kit, 91A68-00020), and place the transmis-
sion so that torque converter housing faces down-
ward.

214926

214927

6-11
POWERSHIFT TRANSMISSION

(2) Remove servo case together with O-ring and


shims.
Servo case assembly
(3) Remove seal rings from input shaft.

214928

O-ring

Seal ring

Shim
214929

4.4.3 Transmission housing mounting bolts, Removal 2


Remove twelve bolts that hold the torque converter
housing.

214930

214931

6-12
POWERSHIFT TRANSMISSION

4.4.4 Transmission housing, Removal


(1) Place a wooden block under the torque converter
housing, and hoist the transmission housing.
(2) Remove the transmission housing by tapping the
torque converter housing and output gear bearing.
(3) Remove the transmission gasket.
(4) Remove O-rings.

214932

Output gear bearing


214933

Transmission
gasket

O-ring
214934

6-13
POWERSHIFT TRANSMISSION

4.5 Input Shaft, Idler Shaft and Output Gear, Removal


4.5.1 Input shaft and idler shaft, Removal
(1) Install guide bolts at two places at the bottom of
torque converter housing to raise the housing.
Guide bolt

214935

Guide bolt
214936
(2) Wrap wire around input shaft and idler shaft, and
lift the housing slightly.

Idler shaft
assembly Input shaft
assembly
214937

6-14
POWERSHIFT TRANSMISSION

(3) Alternately tap the input shaft fitting portion with


the torque converter and the idler shaft gear to Input shaft assembly
separate the input shaft and idler shaft.

214938

Idler shaft
assembly

214939

214940

6-15
POWERSHIFT TRANSMISSION

4.5.2 Output gear, Removal


(1) Place torque converter housing so that torque
converter housing faces downward as shown in
the figure. Bearing puller

(2) Sling a bearing puller and install the bearing puller


to the output gear.
Output gear
(3) With a plastic hammer placed on the torque con-
verter housing, tap the plastic hammer to remove
output gear.
Note: When removing output gear, do not tap the
mating face with transmission housing. This
can cause oil leaks. 214941

214942

214943

6-16
POWERSHIFT TRANSMISSION

4.6 Transmission Housing, Disassembly


4.6.1 Output gear oil seal, Removal
(1) Install transmission housing to special tool (stand
kit, 91A68-00020).
Transmission
Output gear oil seal housing
Part name Part number
Stand kit 91A68-00020

(2) Remove the output gear oil seal. Special tool


(Stand kit, 91A68-00020)

214944

4.6.2 Input shaft bearing outer race, Removal


(1) Remove transmission housing from special tool
(stand kit, 91A68-00020), and place transmission
housing so that the mounting surface of servo
case faces upward on a wooden block.
(2) Special tool (Installer and Remover, 91A68-
02300).

Part name Part number


Installer & Remover 91A68-02300
Special tool (Installer &
Remove, 91A68-02300) 214945

4.6.3 Idler gear bearing outer race, Removal


(1) Remove two drain plugs together with gasket.
(2) Tighten special tool (bolts, 67281-15400), and
remove idler gear bearing outer race.

Part name Part number


Bolt 67281-15400

Drain plug

214946

Special tool
(Bolt, 67281-15400)

214947

6-17
POWERSHIFT TRANSMISSION

4.7 Torque Converter Housing, Disassembly


4.7.1 Baffle plate, Removal
4.7.2 Torque converter relief plate and cover, Removal
Remove the torque converter relief plate and relief
cover.

Baffle plate

Torque converter
relief cover
Torque converter
relief plate

214948

4.8 Idler Shaft, Disassembly


4.8.1 Forward gear side, Disassembly
(1) Place idler shaft assembly on the special tool
(stand,91A68-01300) and the stand (91A68- Special tool
02100, special tool). (Stand, 91A68-02100)

Part name Part number


Idler shaft assembly
Stand 91A68-01300
Stand 91A68-02100

Special tool
(2) Using a screw driver, remove bearing. (Stand, 91A68-01300)

214949

4.8.2 Output gear side, Disassembly


Disassemble the same way as above forward gear
side.

6-18
POWERSHIFT TRANSMISSION

4.9 Output Gear, Disassembly


4.9.1 Transmission housing side, Disassembly
(1) Place the output gear assembly on the special
tool (stand, 91A68-01300).
(2) Using a claw bar, slightly raise the bearing. Output gear assembly

(3) Using the special tool (puller, 91A68-01800),


remove bearing.

Part name Part number


Puller 91A68-01800

Special tool
(Stand, 91A68-01300) 214950

Special tool
(Puller, 91A68-01800)
214951

4.9.2 Torque converter housing side, Disassembly


Disassemble the torque converter housing using the
same process as for the transmission housing.

6-19
POWERSHIFT TRANSMISSION

4.10 Forward Input Shaft Gear Assembly, Disassembly


4.10.1 Forward gear assembly, Removal
(1) With forward gear facing up, place input shaft
assembly on the clutch pack special tool (stand
kit, 91A68-00010).
Forward gear
Part name Part number
Clutch pack stand kit 91A68-00010
Stand 91A68-01300
Plate 1 91A68-01400
Plate 2 91A68-01500
Special tool
(Stand, 91A68-01300) 214952
(2) Using a screw driver, raise bearing together with
input spacer.
Note: When using a screw driver, be sure to insert the
screw driver beneath the input spacer to raise
bearing. Otherwise, the bearing case will be
damaged.

Input spacer
214953
(3) Using the special tool (puller, 91A68-01800),
remove bearing together with input spacer.
Special tool
Part name Part number (Puller,91A68-01800)
Puller 91A68-01800

Input spacer
214954

6-20
POWERSHIFT TRANSMISSION

(4) Remove snap ring.

Snap ring

214955
(5) Using a screw driver, raise forward gear assem-
bly.

Forward gear
assembly
214956
(6) Using the special tool (puller, 91A68-01800),
remove forward gear assembly.

Special tool
(puller, 91A68-01800)
214957

6-21
POWERSHIFT TRANSMISSION

4.10.2 Forward gear assembly, Disassembly


(1) Remove snap ring.
(2) With gear faced downward, place forward gear
assembly on the special tool (stand, 91A68-
01700 ).
(3) Remove angular bearing using special tool
(installer, 91268-04100).

Part name Part number Snap ring


Installer 91268-04100

214958

Special tool
(Installer, 91268-04100)

Special tool
(Stand, 91A68-01700) 214959

4.10.3 Forward side gear input shaft, Disassembly


(1) Remove snap ring.
Special tool
(2) Remove one pressure plate, one Belleville spring, Snap ring
(Stand, 91A68-01300)
six mating plates, and five friction plates.

Note: When disassembling plates, record the position


of each plate so that they can be reassembled
as they were.

214960

Friction plate

Mating plate
214961

6-22
POWERSHIFT TRANSMISSION

(3) Remove spacer.

Note: On old models, no spacer is used. Pay attention Spacer


to the presence of spacer when removing.

Input shaft

214962
(4) Using clutch pack special tool (stand kit, 91A68-
00010), retract clutch spring together with spring
retainer, and remove snap ring.

Part name Part number


Clutch pack stand kit 91A68-00010
60
Stand 91A68-01300 214963
Plate 1 91A68-01400
Plate 2 91A68-01500

Clutch piston
Spring retainer
CAUTION
Exposed thread of the bolt under the nut should be
60 mm or more.

Note: Make sure to tighten bolts (special tool) evenly.


(5) Remove the special tool, and remove spring Clutch spring
retainer and clutch spring.
214964
Note: Make sure to loosen bolts (special tool) evenly.

Special tool
(Plate2, 91A68-01500)

Special tool
(Stand kit,91A68-01300) 214965

Special tool
(Plate1,91A68-01400)

Bolt

Snap ring

214966

6-23
POWERSHIFT TRANSMISSION

4.10.4 Forward clutch piston, Removal


(1) Apply air through oil hole of input shaft on the
servo case side, and remove forward clutch pis-
ton. Forward side oil hole

(2) Remove piston ring from forward clutch piston.

Reverse side oil hole

214967

Clutch piston

Piston ring
214968

6-24
POWERSHIFT TRANSMISSION

4.11 Reverse Input Shaft Gear Assembly, Disassembly


Note: Disassembly procedure for reverse side and
forward side is the same. Observe the instruc-
tions, cautions, and special tools to be used in
the instructions for forward side.
4.11.1 Reverse gear assembly, Removal
(1) With reverse gear facing up, place input shaft
assembly on the clutch pack special tool (stand
kit, 91A68-00010).

Part name Part number


Clutch pack stand kit 91A68-00010
Stand 91A68-01300
Plate 1 91A68-01400
Plate 2 91A68-01500

(2) Using a screw driver, raise bearing together with


input spacer.
(3) Using the special tool (puller, 91A68-01800),
remove bearing together with input spacer.

Part name Part number


Puller 91A68-01800

(4) Remove snap ring.


(5) Using a screw driver, raise reverse gear assem-
bly.
(6) Using the special tool (puller, 91A68-01800),
remove reverse gear assembly.
4.11.2 Reverse gear assembly, Disassembly
(1) Remove snap ring.
(2) With gear faced downward, place reverse gear
assembly on the special tool
(stand, 91A68-01700 ).

Part name Part number


Installer 91268-04100

(3) Remove angular bearing using special tool


(installer, 91268-04100).

6-25
POWERSHIFT TRANSMISSION

4.11.3 Reverse gear input shaft, Disassembly


(1) Remove snap ring.
(2) Remove one pressure plate, one Belleville spring,
six mating plates, and five friction plates.
(3) Remove spacer.
(4) Using clutch pack stand kit (91A68-00010, special
tool), retract clutch spring together with spring
retainer, and remove snap ring.
(5) Remove the special tool, and remove spring
retainer and clutch spring.
Note: Make sure to loosen bolts (special tool) evenly.

Part name Part number


Clutch pack stand kit 91A68-00010
Stand 91A68-01300
Plate 1 91A68-01400
Plate 2 91A68-01500

4.11.4 Reverse clutch piston, Removal


(1) Apply air through oil hole of input shaft on the
servo case side, and remove reverse clutch pis-
ton.
(2) Remove piston ring from forward clutch piston.

4.12 Oil Pump Body, Disassembly


4.12.1 Stator shaft, Removal
(1) Set oil pump assembly on the special tool (stand,
91A68-01700).

Part name Part number


Stand 91A68-01700

(2) Loosen hexagon cap bolt, and remove stator


shaft.

6-26
POWERSHIFT TRANSMISSION

4.12.2 Oil pump body, Disassembly


(1) Remove pump drive gear, internal gear and O-
ring from oil pump body. Oil pump assembly
Hexagon cap bolt

Special tool
(Stand, 91A68-01700) 214969

Stator shaft

Internal gear
Pump drive gear
O-ring

Oil pump body


214970
(2) Remove oil seal from oil pump body.
(3) Using the special tool (remover, 91A68-01900),
remove bushing from oil pump body. Oil pump body

Part name Part number


Remover 91A68-01900

Note: Before removing bushing, inspect bushing for


damage, wear, etc. If abnormality is found, re-
place oil pump assembly. When bushing is re-
placed, surface finish of inner bushing is
required.
214971

Special tool
(Remover, 91A68-01900) 214972

6-27
POWERSHIFT TRANSMISSION

5. Powershift Transmission, Reassembly


5.1 Transmission Housing, Reassembly
5.1.1 Output gear oil seal, Installation
(1) With Servo case mounting surface facing upward,
place transmission housing on wooden blocks.
(2) Using the special tool (installer, 91268-05500),
install output gear oil seal.

Part name Part number Quantity


Oil seal 91A24-08600 1
Special tool
(Installer,
Part name Part number
91268-05500)
Installer 91268-05500
214973

5.1.2 Idle gear bearing outer race, Installation


(1) Install two drain plugs together with gasket.

Part name Part number Quantity


Gasket F4202-08000 2

Unit: N·m (kgf·m) [lbf·ft]


39.2 ± 3.9
Drain plug (4.0 ± 0.4)
[28.9 ± 2.9] Drain plugs

(2) Install transmission housing to special tool (stand 214974


kit, 91A68-00020).
(3) Using the special tool (installer & remover, Special tool
91A68-02300), install idler gear assembly bearing (Installer &
outer race. Remover,
91A68-02300)
Part name Part number
Stand kit 91A68-00020
Installer & Remover 91A68-02300 Special tool
(Stand kit,
91A68-00020)

214975

6-28
POWERSHIFT TRANSMISSION

5.2 Torque Converter Housing, Reassembly 1


5.2.1 Torque converter relief plate and relief cover, Installation
Install torque converter relief plate and relief cover.
Torque converter
relief cover

Torque converter
relief plate

214976

5.2.2 Baffle plate, Installation


Install baffle plate using 2 bolts.

Baffle plate

214977

5.3 Idler Shaft Assembly, Reassembly


5.3.1 Forward gear side, Reassembly
(1) Place idler shaft on the special tool (stand, 91A68-
01700). Special tool
(Remover, 91A68-01900)
(2) Using the special tool (remover, 91A68-01900),
install the bearing of torque converter housing Bearing
side.

Part name Part number


Stand 91A68-01700
Remover 91A68-01900 Idler shaft
Special tool
(Stand, 91A68-01700) 214978

5.3.2 Output gear side, Reassembly


Reassembly procedure for output gear side and for-
ward gear side is the same. See above.

6-29
POWERSHIFT TRANSMISSION

5.4 Output Gear Assembly, Reassembly


5.4.1 Transmission housing side, Reassembly
(1) Place the output gear on the special tool (stand,
91A68-01300). Special tool
(Installer & Remover,
(2) Using the special tool (installer & remover,
91A68-02300)
91A68-02300), install bearing of transmission
housing side.
Output gear
Part name Part number Bearing
Stand 91A68-01300
Special tool
Installer & Remover 91A68-02300 (Stand, 91A68-01300)

214979

5.4.2 Torque converter housing, Reassembly


Reassembly procedure for torque converter housing
side and transmission housing side is the same. See
above "Transmission housing side, Reassembly."

5.5 Input Shaft Gear Assembly, Inspection


5.5.1 Clutch piston
Inspect sliding area for wear and damage.
If any scratches are found, polish the surface using
fine grit sandpaper. If scratches are really bad, replace
the clutch piston.

Clutch piston
214980

5.5.2 Input shaft


(1) Inspect spline for wear and damage.
(2) Inspect grooves A and B for wear and damage. Set screw Input
Measure the width of grooves A and B. shaft
C
(3) Inspect oil passage C for clogging. C C
If clogging is found, remove set screw, and clean
the oil passage using compressed air.
Note: 1. If set screw is removed, apply LOCTITE 242
C B C C
to the set screw when reinstalling.
A
2. Be sure to use clean compressed air which is
filtered through an air-filter. Clutch drum
214981
Input shaft groove Input shaft cross-section
Unit: mm (in.)
- A B
Standard Value 2.5 (0.098) 2.8 (0.110)
Repair limit 3.0 (0.118) 3.0 (0.118)

(4) Inspect looseness between clutch drum and input


shaft.

6-30
POWERSHIFT TRANSMISSION

5.5.3 Gear
Inspect gear and spline for wear and damage.
5.5.4 Drum
Inspect sliding area of clutch piston for wear and dam-
age.

5.5.5 Friction plates and mating plates


(1) Inspect plates for seizure, local contact, deforma-
tion and damage.
(2) Inspect spline for wear and damage.
(3) Measure the thickness of each plate.
Note: If any of above abnormalities is found, replace
all plates.
Unit: mm (in.)
2.6 ± 0.1
A
(0.12 ± 0.004)
Friction plate
2.2 214982
B
(0.087) Friction plates and mating plates
1.6 ± 0.1
A
(0.063 ± 0.004)
Mating plate
1.4
B
(0.055)
A: Standard value B: Repair or service limit

Part name Part number Quantity


Friction plate 91B24-00800 10
Mating plate 91324-12601 12

6-31
POWERSHIFT TRANSMISSION

5.6 Forward Input Shaft Gear Assembly, Reassembly


5.6.1 Forward clutch piston, Reassembly
(1) Place the input shaft on the special tool (stand,
91A68-01300).
Input shaft Seal ring
Part name Part number
Stand 91A68-01300

(2) Install seal ring to input shaft.

Part name Part number Quantity


Seal ring 65425-03300 1 Special tool
(Stand, 91A68-01300)
214983
(3) Install piston ring to forward clutch piston.

Part name Part number Quantity Clutch piston ring


Clutch piston 91A24-21500 1
Piston ring 65425-13000 1

Clutch piston
214984
(4) Apply oil to piston ring and sliding area of clutch
piston.
(5) Install input shaft to clutch piston.

(6) Using a wooden bar, install clutch piston.


Note: When installing the clutch piston with a wood Boss
bar, be sure to tap on the boss of clutch piston.

(7) Install clutch spring and spring retainer.


Clutch piston
Input shaft
214985

Wood bar

214986

6-32
POWERSHIFT TRANSMISSION

(8) Using special tools; Stand, 91A68-01300, Plate 1,


91A68-01400 and Plate 2, 91A68-01500, com-
Clutch piston Spring retainer
press the spring retainer together with clutch
spring.
(9) Install snap ring, and loosen the bolt of special
tool.
Note: Be sure to install new snap ring. Do not reuse
once it is removed.

Part name Part number Clutch spring


Clutch pack stand kit 91A68-00010 214987

Stand 91A68-01300
Plate 1 91A68-01400 Special tool
(Plate 2, 91A68-01500)
Plate 2 91A68-01500

Special tool
(Stand, 91A68-01300) 214988

Special tool
(Plate 1,
91A68-01400)

Snap ring
214989

6-33
POWERSHIFT TRANSMISSION

5.6.2 Forward side friction plates and mating plates, Reassembly


(1) Install friction plates and mating plates in the order
they were removed. Friction plate
(2) Install Belleville spring and pressure plate.
Note: a) Make sure to install Belleville spring so that its
inner side comes into contact with mating
plate. (See figure.)
b) Apply ATF to each friction plate and mating
plate before installing them into the drum.

Mating plate 214990

Mating plate Friction plate


Pressure plate (6 pieces) (5 pieces)
(1 piece) Drum
Belleville spring

214991
(3) Install snap ring.

Part name Part number Quantity Friction plate


Snap ring 58622-03001 1

Mating plate
214992

Snap ring

Special tool
(Stand, 91A68-01300)
214993

6-34
POWERSHIFT TRANSMISSION

5.6.3 Forward clutch piston, Motion check


Check that the clutch piston is moving normally by
applying compressed air through the gear oil hole on Forward side oil hole
the forward side.
Note: Be sure to use clean compressed air which is
filtered through an air-filter.

Reverse side oil hole


Set screw
214994

5.6.4 Forward gear assembly, Installation


(1) Install forward gear.
(2) Install spacer.

Forward gear

214995

Spacer

Input shaft
214996

6-35
POWERSHIFT TRANSMISSION

(3) Install angular bearing using special tool (installer,


91268-04100).
Angular bearing
Part name Part number
Installer 91268-04100

214997

Special tool
(Installer, 91268-04100)

214998

(4) Install snap ring.

Part name Part number Quantity


Snap ring 91A24-6900 1

Note: Be sure to install new snap ring. Do not reuse


once it is removed.
(5) Using a screw driver, raise forward gear assem-
bly.
(6) Install snap ring.
Snap ring
214999
Part name Part number Quantity
Snap ring F3202-06200 1

Forward gear
215000

6-36
POWERSHIFT TRANSMISSION

Snap ring

215001

5.6.5 Forward input spacer and bearing, Installation


(1) Install input spacer using the special tool (installer,
91268-04100). Input spacer Oil groove

Part name Part number


Installer 91268-04100

Note: 1. Install the spacer with the oil grooves facing


the ball bearing.
2. Once input spacer is installed, snap ring is
not visible.

215002

Special tool
(Installer, 91268-04100)

215003

Angular bearing
Input spacer

215004

6-37
POWERSHIFT TRANSMISSION

(2) Install bearing using the special tool (installer,


91268-04100).

Part name Part number Special tool


(Installer, 91268-04100)
Installer 91268-04100

Bearing

215005

(3) Install seal ring.


Seal ring
Bearing
Part name Part number Quantity
Seal ring 58321-05000 3

Forward gear
215006

5.7 Reverse Input Shaft Gear Assembly, Reassembly


Note: Reassembly procedure for reverse side and for-
ward side is the same.
Observe the instructions, cautions, and special
tools to be used in the instructions for forward
side.
5.7.1 Reverse clutch piston, Reassembly
The same as the forward side.
5.7.2 Reverse side friction plates and mating plates, Reassembly
The same as the forward side.
5.7.3 Reverse clutch piston, Motion check
The same as the procedure for the forward side.
5.7.4 Reverse gear assembly, Installation
The same as the forward side.
5.7.5 Reverse side input spacer and bearing, Installation
The same as the forward side.

6-38
POWERSHIFT TRANSMISSION

5.8 Oil Pump Assembly, Reassembly and Installation


5.8.1 Inspection
(1) Set pump body on the stand (91A68-01700, spe-
cial tool), and install internal gear and drive gear.
Internal gear
Part name Part number
Stand 91A68-01700 Pump body

Special tool Pump drive gear


(Stand, 91A68-01700)
215007
(2) Measure the clearance between pump body and
internal gear, and the clearance between pump
body and drive gear using a feeler gauge.

Clearance (for pump body)


Unit: mm (in.)
0.04 to 0.07
Internal gear
(0.002 to 0.003)
A
0.30 to 0.33
Drive gear
(0.012 to 0.013)
A: Standard value
215008

(3) Measure the clearance between torque converter


housing (pump body) and drive gear using a
feeler gauge.
Unit: mm (in.)
0.040 to 0.083
A
Internal gear and Drive (0.002 to 0.003)
gear 0.15
B
(0.006)
A: Standard value B: Repair or service limit

215009

6-39
POWERSHIFT TRANSMISSION

5.8.2 Bushing, Installation


Note: If bushing is badly damaged or worn, replace oil
pump assembly. If bushing is replaced, an inner Special tool
(Installer, 91A68-01600)
bore surface finishing process is required for
bushing after the installation. For the finishing
process, see the drawing on the next page.
Failure to conduct the inner bore surface finish-
ing results in serious damage to oil pump as-
sembly and transmission.
(1) Remove internal gear and drive gear from pump Special tool
(Stand, 91A68-01700)
body, and set the pump body on the stand
(91A68-01700, special tool). 215010
(2) Using special tool (installer, 91A68-01600), install
bushing.

Part name Part number


Stand 91A68-01700
Installer 91A68-01600

(3) Conduct the inner bore surface finishing of bush-


ing.

6-40
POWERSHIFT TRANSMISSION

Unit: mm (in.)
UUu

44 (1.7)
9
22 (0.9) (0.4)
0
21 -0.5
0
(0.8 -0.02) 0 to 1.0 (0 to 0.04) POSITION OF BUSHING

PUMP BODY

BUSHING

ø0.025 S X
ø0.025 S Y

)
+0.025 )

ø60H7 (+0.030
ø42F7 (+0.050

+0
5
5

0.
0.
C

BUFFING
*
*

3.2S

SYMBOL
(SEE NOTE(2)) X

215011

6-41
POWERSHIFT TRANSMISSION

5.8.3 Oil seal, Installation


(1) Using special tool (installer, 91A68-01600), install
oil seal. Special tool
(Installer,91A68-01600)
Part name Part number Quantity Bushing
Oil seal 91A24-07900 1

Oil seal
(2) Apply grease to lip portions.

215012

5.8.4 Oil pump assembly, Reassembly


(1) With internal and drive gears mounting side facing
upward, place the pump body on the special tool Pump body
(stand, 91A68-01700).
(2) Install internal gear and drive gear to pump body Drive gear
and apply oil to the gears.
(3) Rotate drive gear with your fingers and make sure
the drive gear rotates freely. Special tool
(Stand, 91A68-01700)
(4) Install O-ring.

Part name Part number Quantity Internal gear


215013
O-ring 91A24-08300 1

(5) Install guide bolt, and then install stator shaft. Stator shaft

Guide bolt

O-ring 215014
(6) Tentatively install the oil pump assembly mounting
bolts from stator shaft side, and remove guide
Oil pump assembly bolt
bolt.
(7) Tighten the hexagon cap bolt. Hexagon
cap bolt
(8) Remove the oil pump assembly mounting bolts
that were tentatively installed.

215015

6-42
POWERSHIFT TRANSMISSION

5.8.5 Oil pump assembly, Installation


(1) Install O-rings to transmission housing.

Part name Part number Qty


91A24-08300 1
O-ring 05500-24022 1
05500-24012 3

(2) Install relief valve and torque converter spring.


Guide bolts
(3) Install guide bolts.
(4) Place oil pump assembly in the transmission
housing.
(5) Tentatively tighten the bolts to the oil pump
assembly.
Note: The bolt indicated with arrow must be replaced O-ring
O-ring
with new one.
Relief valve and
Torque converter spring 215016
Part name Part number Qty
Flange bolt 91524-04200 1
Guide bolt

215017

215018

6-43
POWERSHIFT TRANSMISSION

(6) Tap the oil pump assembly with a copper bar so


that it will fit snugly.
Note: When tapping with a copper bar, tap on the bolt
mounting surface or ribs of oil pump assembly.

(7) Tighten bolts to the specified torque.


Unit: N·m (kgf·m) [lbf·ft]
16.7 ± 1.7 Copper bar
Oil pump assembly (1.70 ± 0.17)
[12.3 ± 1.25] 215019

5.9 Torque Converter Housing, Reassembly 2


5.9.1 Output gear assembly, Installation
(1) Place torque converter housing so that the mount-
ing surface of torque converter assembly faces
downward. Output gear assembly
(2) Install output gear assembly to the torque con-
verter housing.
Note: The side with the larger protrusion should face
(downward) to torque converter housing.

215020

5.9.2 Input shaft gear assembly and idler gear assembly, Installation
(1) Tentatively install input shaft gear assembly.
(2) Tentatively install idler gear assembly. Input shaft gear
assembly
Note: The gear having 30 teeth should be on the
torque converter housing side, and the gear
having 32 teeth should be on the transmission
housing side.

215021

Idler gear
assembly

Z=30
215022

6-44
POWERSHIFT TRANSMISSION

(3) Alternately tap the input shaft gear assembly and


the idler gear assembly through the plastic ham- Plastic hammer
mer to install. When input shaft gear assembly
and idler gear assembly are seated in place,
rotate the input shaft gear assembly and make
sure that gears are correctly meshed.

215023

(4) Apply oil to each bearing thoroughly.

215024

(5) Install guide bolts.

Guide bolt Guide bolt

215025

(6) Install oil seal, O-rings and transmission gasket.

Transmission gasket

O-ring

Oil seal

215026

6-45
POWERSHIFT TRANSMISSION

5.10 Transmission Housing, Installation


5.10.1 Transmission housing, Installation
(1) Align the dowel holes of transmission housing
with the dowels of torque converter housing. Transmission
housing
(2) Tentatively install transmission housing.
Note: When installing the transmission housing, make
sure that the bearing of idler gear assembly is
correctly fitted in the outer race by checking it
from the control valve attaching portion.

215027

Control valve
attaching point

Idler gear assembly


Idler gear assembly bearing outer race
bearing
215028
(3) Lightly tap transmission housing into place with a
copper bar.
Copper bar

215029

6-46
POWERSHIFT TRANSMISSION

5.10.2 Transmission housing bolts, Tightening


(1) Insert transmission housing bolts to the holes and
tighten them to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
39.2 ± 3.9
Transmission housing (4.00 ± 0.40)
[28.9 ± 2.88]

215030

(2) Install transmission to stand kit (91A68-00020,


special tool).

Part name Part number


Stand kit 91A68-00020

(3) From toque converter mounting side, tighten three


transmission housing bolts to the specified torque.
Unit: N·m (kgf·m) [lbf·ft] Transmission
39.2 ± 3.9 housing bolts
Transmission housing (4.00 ± 0.40)
215031
[28.9 ± 2.88]

5.11 Servo Case Assembly, Installation


5.11.1 Bearing outer race, Installation
(1) Remove transmission with special tool (stand kit,
91A68-00200), and with torque converter housing Input shaft gear assembly
side face down so that the case can be separated,
lay the transmission.
(2) Apply oil to outer race of input shaft gear assem-
bly.
(3) Using special tool (installer, 91A68-02200), install
outer race. Input shaft gear assembly
bearing outer race
Part name Part number
Installer 91A68-02200 215032

Special tool
(Installer, 91A68-02200)

215033

6-47
POWERSHIFT TRANSMISSION

5.11.2 Input shaft gear assembly bearing, Clearance adjustment


(1) Using a depth micro gauge, measure the depth of
bearing outer race from top of transmission hous- Input shaft gear
Depth micro gauge
ing. (The measured value = A) assembly bearing
outer race

215034
(2) Using a depth micro gauge, measure the height
of fitting protrusion on servo case assembly.
(The measured value = B)
Depth micro gauge

Servo case
assembly
B

215035
(3) Use the following formula to obtain the play in the
thrusting direction of input shaft gear assembly.
C (play) = A - B Input shaft gear assembly
Install shims on the top of outer race so that the
play meets the standard.
Unit: mm (in.) Shims
Play in the thrusting 0.3 to 0.4
direction (0.012 to 0.016)

215036

6-48
POWERSHIFT TRANSMISSION

5.11.3 Servo case assembly, Installation


(1) Install O-rings.
O-ring

O-rings
215037
(2) Apply oil to seal ring of input shaft gear assembly,
and install servo case assembly with bolts tighten-
ing to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
39.2 ± 3.9
Servo case assembly (4.00 ± 0.40)
Servo case assembly
[28.9 ± 2.88]

(3) Insert output flange, and make sure it rotates


smoothly by hand.

215038

5.12 Transmission External Parts, Installation


5.12.1 Torque converter assembly, Installation
(1) Install special tool (stand kit, 91A68-00200) to
transmission. Special tool
(Stand kit, 91A68-00020)

Part name Part number


Stand kit 91A68-00020

215039

215040

6-49
POWERSHIFT TRANSMISSION

(2) Hoist the transmission and lay it so that torque


converter housing side faces upward.
(3) Remove two bolts from flexible plate, install two
eye bolts in the bolt holes, and hoist the torque
converter assembly.

Eye bolts

215041
(4) As you rotate idler gear with a screwdriver from
control valve attaching portion, install torque con-
verter assembly.
Note: Be careful when installing so that your hands
will not be caught between transmission hous-
ing and flexible plate or torque converter.

Idler gear

215042

Note: 1. When installing, slowly and carefully install


the torque converter assembly. If torque con-
verter assembly is brought into contact with
the oil pump assembly in a rough manner, it
may cause damage to the oil pump assembly.
2. There are three parts to align when installing
torque converter assembly.

Torque converter
Oil pump
Stator shaft

Oil pump
Pump drive gear

Input shaft

215043

6-50
POWERSHIFT TRANSMISSION

(5) After torque converter is installed in place, make


sure that the distance between the top surface of
torque converter housing and the flywheel mount-
ing surface of flexible plate meets the specified
value.
Unit: mm (in.)
Distance between torque converter
housing end surface and flywheel 50 (1.97)
fitting surface of flexible plate

215044

50 mm
(2.0 in.)

215045

(6) Remove two eye bolts, and apply LOCTITE 242 to


the two flexible plate bolts, and tighten them to the
specified torque.
Unit: N·m (kgf·m) [lbf·ft]
34.0 ± 4.0
Flexible plate (3.47 ± 0.41)
[25.1 ± 2.95]

(7) Attach a wire that prevents torque converter from


slipping out.

215046
5.12.2 Control valve, Installation
(1) Remove special tool (stand kit, 91A68-00200)
from transmission, and set the transmission in the Guide bolts
special tool (stand, 91A68-03500).

Part name Part number


Stand 91A68-03500

(2) Install guide bolts to the control valve attaching


portion. Special tool
(Stand, 91A68-03500)
215047

6-51
POWERSHIFT TRANSMISSION

(3) Install gasket and O-rings.


Gasket O-rings
Part name Part number Quantity
Gasket 91A28-11101 1
O-ring 05500-24015 4

O-rings

215048

(4) Install control valve and tighten the bolts to the


specified torque.
Control valve
Unit: N·m (kgf·m) [lbf·ft]
39.2 ± 3.9
Control valve (4.00 ± 0.40)
[28.9 ± 2.88]

215049

5.12.3 Oil strainer assembly, Installation


(1) Install O-ring to oil strainer assembly and install
the oil strainer assembly to the transmission.
Note: If strainer is clogging, do not reuse the strainer.
Replace with a new one.

(2) Install bolts and tighten them to the specified


torque.
Unit: N·m (kgf·m) [lbf·ft]
16.7 ± 1.7
Oil strainer assembly (1.70 ± 0.17)
[12.3 ± 1.25]

Oil strainer assembly O-ring


215050

5.12.4 Output flange, Installation


(1) Apply grease to the lip portions of oil seals of out-
put gear assembly.
(2) Install output flange.
(3) Install stopper to output flange.
Output flange

Stopper
215051

6-52
POWERSHIFT TRANSMISSION

5.12.5 Speed sensor and oil temperature switch, Installation


(1) Install speed sensor together with O-ring, and
tighten it to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
29.4 ± 2.9
Speed sensor (3.00 ± 0.30)
[21.7 ± 2.14]

(2) Install oil temperature switch, and tighten it to the


specified torque.
Unit: N·m (kgf·m) [lbf·ft]
39.3 ± 7.9
Speed sensor
Speed sensor (4.01 ± 0.81)
[29.0 ± 5.83]
Oil temperature
switch

215052

5.12.6 Cooler pipes, Installation


(1) Install eyebolt and gasket to the cooler inlet pipe,
and tighten the eyebolt to the specified torque.
Cooler inlet pipe
(2) Install eyebolt and gasket to the cooler outlet pipe Control valve
and tighten the eyebolt to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
44.1 ± 4.9
Eyebolt (4.50 ± 0.50)
[32.5 ± 3.61]

Cooler outlet pipe


215053

5.12.7 Level gauge, Installation


Install level gauge.

6-53
POWERSHIFT TRANSMISSION

6. Control Valve, Disassembly


6.1 Control Valve External Parts, Removal
6.1.1 Solenoid valve, Removal
(1) Hold control valve body in a vise.
Control valve body
Note: When holding in a vise, use an aluminum plate
to prevent direct contact with the vise. Solenoid valve

(2) Remove solenoid valve together with O-ring.

Vise
215054

6.1.2 Breather, Removal


Remove breather.

6.1.3 Inching lever, Removal


Remove inching lever together with retainer and bush-
ing. Inching lever

Breather
215055

6.2 Valve Body Plate, Removal


6.2.1 Breather cover, Removal
Remove breather cover.

6.2.2 Valve body plate, Removal


Remove valve body plate together with gasket.
Valve body plate

Breather cover
215056

6-54
POWERSHIFT TRANSMISSION

6.3 Plugs, Removal


Remove each plug.
Note: Before loosening the plugs, be sure to lightly Main orifice plug
tap the head of the plug. Failure to do so may
cause damage to hexagon socket.
Plugs
Plugs

Plugs
215057

Plug

215058

6.3.1 Main orifice, Removal


Using a flat-blade screwdriver, remove main orifice.

Flat tip
screwdriver

215059

Main orifice

215060

6-55
POWERSHIFT TRANSMISSION

6.4 Strainer, Removal


(1) Hold valve body in a vise so that inching rod pro-
trusion side faces downward. Strainer
(2) Remove strainer together with O-ring.

Vise Inching rod

215061

6.5 Regulator Valve Section, Removal


6.5.1 Main spring seat, Removal
(1) Remove snap ring from main spring seat.
Note: When removing snap ring, slowly remove the
snap ring by pressing it against the main spring Snap ring
seat. Otherwise the main spring seat will pop
out.

Main spring seat

Regulator valve section

215062
(2) Remove main spring seat together with O-ring.

Main spring seat

215063

6-56
POWERSHIFT TRANSMISSION

6.5.2 Regulator valve, Removal


(1) Remove inner and outer main relief springs.
(2) Remove regulator valve together with slug. Regulator valve

Slug
215064

Regulator valve Main relief spring,


outer

Slug

Main relief spring,


Inner
215065

6.6 Accumulator Valve Section, Removal


6.6.1 Accumulator spring seat, Removal
(1) Remove snap ring from accumulator spring seat.
Note: When removing snap ring, slowly remove the
snap ring by pressing it against the accumulator
spring seat. Otherwise the accumulator spring
seat will pop out.
(2) Remove accumulator spring seat together with O-
ring. Snap ring

Accumulator valve section


215066

Accumulator
spring seat

215067

6-57
POWERSHIFT TRANSMISSION

6.6.2 Accumulator piston, Removal


(1) Remove inner and outer springs.
(2) Remove accumulator piston.
Accumulator piston Outer spring

Inner spring
215068

6.7 Inching Valve Section, Removal


6.7.1 Inching rod plate, Removal
(1) Remove valve body from the vice, and lay the
valve body on a wooden board.
(2) With the inching rod plate placed on the special
tool (stand, 91A68-02701), remove spring pin and
remove two inching rod plates.

Part name Part number


Stand 91A68-02701

Note: When removing spring pin, be sure to use spe-


cial tool. If not, it can result in damage to the
inching rod and valve body.

Special tool
(Stand, 91A68-02801)
Pin remover

Inching rod plate


Valve body
215069

(3) With inching rod plate attaching portion faced


downward, hold it in a vise.
6.7.2 Valve, Removal
(1) Remove inching plug together with O-ring.
Note: When removing inching plug, slowly remove the Inching stopper 1 Inching plug
inching plug while pressing it with a tool. Other-
wise inching spring will pop out.
(2) Remove inching spring, inching stopper 1, inching Inching spring
rod, inching valve spring, inching valve and return
spring.

Inching valve assembly


215070

6-58
POWERSHIFT TRANSMISSION

6.7.3 Inching valve assembly, Disassembly


(1) Using special tool (stand, 91A68-02701), remove
spring pin from inching stopper 2. Special tool Pin remover
(Stand, 91A68-02701)

Inching valve assembly

Inching stopper 2 215071


(2) Remove inching stopper 2, inching valve spring
and inching valve from inching rod.
Inching valve spring Spring pin

Inching rod Inching


stopper 2
Inching valve
215072

6.8 Oil Seal and Plug, Removal


6.8.1 Regulator valve section
(1) With inching lever mounting portion faced upward,
hold the control valve body in a vice. Inching lever mounting portion
(2) Remove snap ring from regulator valve section,
and remove main relief plug together with O-ring.

Snap ring

Main relief plug


215073

6.8.2 Accumulator valve section


Remove snap ring from accumulator valve section,
and remove accumulator plug together with O-ring. Snap ring

Accumulator plug

215074

6-59
POWERSHIFT TRANSMISSION

6.8.3 Inching valve section


(1) Remove inching rod oil seal.
Inching rod oil seal

215075
(2) Remove snap ring from inching valve section.

Snap ring

215076

6-60
POWERSHIFT TRANSMISSION

7. Control Valve, Reassembly


7.1 Control Valve
7.1.1 Reassembly

2 1 3 4 6 5 7 8

11

12
10

14

9
15

13 23

24
16
22

25
F R

17 19 18 20 21
213654

Reassembly sequence
1 Main relief plug, O-ring 10 Snap ring 19 Inching valve
2 Snap ring 11 Accumulator piston 20 Inching valve spring
3 Slug 12 Outer spring 21 Inching stopper, Spring pin
4 Regulator valve 13 Inner spring 22 Inching spring
5 Main relief spring (thick) 14 Accumulator spring seat, O-ring 23 Inching stopper
6 Main relief spring (thin) 15 Snap ring 24 Inching plug, O-ring
7 Main spring seat, O-ring 16 Oil seal 25 Strainer, O-ring
8 Snap ring 17 Snap ring
9 Accumulator plug, O-ring 18 Inching rod

Suggestions for Reassembly


(1) Cleaning oil passages (2) Tightening torque
(a) Oil passages and components of the valve (a) Tighten the following parts to the specified
housing must be washed thoroughly. Make torques.
sure there is no clogging before reassembling.
Unit: N·m (kgf·m) [lbf·ft]
39.2 to 49
Inching plug 24 (4.00 to 5.00)
[28.9 to 36.14]
19.6 to 24.5
Strainer 25 (2.00 to 2.50)
[14.5 to 18.07]

6-61
POWERSHIFT TRANSMISSION

7.2 Washing and Inspection


7.2.1 Control valve body
(1) Thoroughly wash control valve body using wash
oil, and dry it using compressed air.
(2) Inspect inner control valve body for damage and
abnormal wear.

215077

215078

7.2.2 Valve, piston, spring, main orifice


(1) Wash valve, piston, spring, main orifice, etc. with
wash oil, and dry them using compressed air.
(2) After applying compressed air, inspect valve and
piston for abnormal wear and damage, and Hole
Slug
inspect springs for deformation and damage.
Also inspect regulator valve, accumulator piston
and main orifice for clogging.

Regulator valve
215079

6-62
POWERSHIFT TRANSMISSION

7.3 Valve Plug and Oil Seal, Installation


7.3.1 Plugs, Installation
(1) With inching lever mounting portion faced upward,
hold the control valve body in a vise.
Main relief plug
Note: 1. When holding in a vise, use aluminum plates
to prevent direct contact with the vise.
(2) Install O-ring to both main relief plug and accumu-
lator plug, and apply grease to the circumference
of O-rings, and install main relief plug and accu- Accumulator plug
mulator plug.
2. Do not reuse resin plugs and O-rings. Make
sure to use new ones.
215080
3. Grease should be applied in thin coats.

(3) Install snap ring to main relief plug and accumula-


tor plug respectively.

Part name Part number Quantity


Snap ring
F3202-02200 1
(Main relief plug)
Snap ring
F3202-03200 1
(Accumulator plug)

215081

7.3.2 Oil seal, Installation


(1) Install snap ring to inching valve section.

Snap ring

Inching valve section


215082
(2) Using special tool (installer, 91A68-02800), install
oil seal to inching valve section.
Special tool
Part name Part number (Installer, 91A68-02800)
Installer 91A68-02800

Oil seal

215083

6-63
POWERSHIFT TRANSMISSION

7.4 Inching Valve Section, Reassembly


7.4.1 Valve assembly, Reassembly
(1) Install inching valve, inching vale spring and inch-
ing stopper 2 to the inching. Spring pin
Inching valve spring

Inching rod Inching


stopper 2
Inching valve
215072

(2) Align spring pin holes of inching rod and inching


stopper 2, and install spring pin using special tool Pin remover
(stand, 91A68-02701).
Special tool
Part name Part number (Stand, 91A68-02701)
Stand 91A68-02701
Inching valve assembly
(3) Install inching valve assembly to inching valve
section.

Inching stopper 2 215084

7.4.2 Inching valve section, Reassembly


(1) Insert inching spring and inching stopper 1 into
the inching valve section.
Inching stopper 1 Inching spring
(2) Install O-ring to inching plug, and apply a thin coat
of grease to the O-ring.

Inching valve section


215085

(3) With inching spring holding down with a tool,


install inching plug tightening to the specified
Socket wrench
torque.
Unit: N·m (kgf·m) [lbf·ft]
44.1 ± 4.9
Inching plug (4.50 ± 0.50)
[32.5 ± 3.61]
Inching plug

215086

6-64
POWERSHIFT TRANSMISSION

Note: Protrusion "A" of inching rod when inching valve


assembly is fitted in the control valve body is Control valve body
shown below.
Inching rod

Length of inching rod when fitted: Protrusion of inching


rod from control valve
Unit: mm (in.)
A
New part 34 (1.34)

215087

7.5 Accumulator Valve Section, Reassembly


7.5.1 Accumulator piston, Installation
Install accumulator piston to accumulator valve sec-
tion. Accumulator spring seat

n
lever directio
Inching

Outer spring
Accumulator piston
Inner spring
215088

7.5.2 Accumulator spring seat, Installation


(1) Install inner and outer springs.
(2) Install O-ring to accumulator spring seat, and
apply a thin coat of grease to the O-ring.
(3) Install accumulator spring seat in the accumulator
valve section.
Note: Do not reuse accumulator spring seats and O-
rings. Make sure to use new ones.
(4) Using special tool (installer, 91A68-03100), install
the snap ring while holding down accumulator
spring seat. Special tool
(Installer, 91A68-03100)
Part name Part number
Installer 91A68-03100

Accumulator spring seat

Accumulator valve section


215089

6-65
POWERSHIFT TRANSMISSION

7.6 Regulator Valve Section, Reassembly


7.6.1 Regulator valve section, Reassembly
(1) Apply oil to slug, and install it to regulator valve.
Regulator valve
(2) Install the regulator valve with slug to the regulator
valve section. Slug
Note: When inserting the regulator valve, orient the

Lo
regulator valve so that the side to which slug is

ng
sid
fitted is facing to the lever side.

e
Regulator valve section

Inching lever side 215090

7.6.2 Main spring seat, Installation


(1) Install inner and outer main relief springs to the
regulator valve section. Regulator valve Main relief spring,
Slug Outer
(2) Install O-ring to main spring seat, and apply a thin
coat of grease to the O-ring. Main spring seat
(3) Install main spring seat to the regulator valve sec-
tion.

Direction of In
ching lever

Main relief spring, Inner 215091


Note: Do not reuse main spring seats and O-rings.
Make sure to use new ones.
Special tool
(4) Using special tool (installer, 91A68-03100), install (Installer, 91A68-03100)
the snap ring while holding down main spring
seat. Main spring seat

Part name Part number


Installer 91A68-03100

Regulator valve section 215092

6-66
POWERSHIFT TRANSMISSION

7.6.3 Inching rod plate, Installation


(1) Remove valve body from the vise, and lay the
valve body on a wooden board.
(2) Apply oil to the inching rod, and install two inching
rod plates to the rod.
(3) Place the special tool (stand, 91A68-02701) under
the outer inching rod plate, and install spring pin.

Valve body
215093

Special tool
(Stand, 91A68-02701)
Pin remover

Inching rod plate

215094
Note: 1. When installing spring pin, be sure to use the
special tool. If not, it can result in damage to
Spring pin Inching lever
the inching rod and valve body.
2. When installing spring pin, orient it so that its
notch faces to the end of inching rod.

Inching rod plate


The end of inching rod
215095

6-67
POWERSHIFT TRANSMISSION

7.7 Strainer, Installation


(1) Hold the control valve body in a vice so that inch-
ing rod protrusion side faces downward. Strainer

Note: When holding in a vise, use aluminum plates to


prevent direct contact.
(2) Install O-ring to strainer, and apply a thin coat of
grease to the O-ring.
Note: If strainer is clogging, do not reuse the strainer.
Replace with new one.
Vise
Inching rod

Part name Part number Quantity 215096


O-ring 05500-24014 1
Strainer 91A28-02500 1

(3) Install strainer to control valve body, and tighten it


to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
22.1 ± 2.4
Strainer (2.25 ± 0.24)
[16.3 ± 1.77]

7.8 Plugs, Installation


7.8.1 Main orifice, Installation
(1) With inching lever mounting portion faced upward,
hold the control valve body in a vise. Main orifice

(2) Using a flat-blade screwdriver, install main orifice.


(3) Install O-ring to main orifice plug, and install the
main orifice plug to the control valve body, and
tighten the plug to the specified torque.
Unit: N·m (kgf·m) [lbf·ft] Inching lever
7.0 ± 1.0 installation point
Main orifice plug (0.71 ± 0.10)
[5.2 ± 0.74]
Main orifice installation point 215097

Flat-blade

215098

6-68
POWERSHIFT TRANSMISSION

Main orifice plug

215099

7.8.2 Plugs, Installation


(1) Hold control valve body in a vise.
(2) Install O-ring to all seven plugs, and install the
seven plugs to the control valve body, and tighten
them to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
7.0 ± 1.0
Plug (0.71 ± 0.10)
[5.2 ± 0.74]

215100

Main orifice plug

Plugs Plugs

Plugs
215101

7.9 Valve Body Plate, Breather Cover, Installation


7.9.1 Valve body plate, Installation
Install valve body plate together with gasket and
tighten it to the specified torque. Valve body plate
Unit: N·m (kgf·m) [lbf·ft]
7.0 ± 1.0
Valve body plate (0.71 ± 0.10)
[5.2 ± 0.74]

Breather cover
215102

6-69
POWERSHIFT TRANSMISSION

7.9.2 Breather cover, Installation


Install breather cover and tighten it to the specified
torque.
Unit: N·m (kgf·m) [lbf·ft]
7.0 ± 1.0
Breather cover (0.71 ± 0.10)
[5.2 ± 0.74]

7.10 Control Valve External Parts, Removal


7.10.1 Inching lever, Installation
Install inching lever together with retainer and bushing,
and tighten it to the specified torque. Inching lever
Note: Do not reuse bushings. Make sure to use new
bushings.
Unit: N·m (kgf·m) [lbf·ft]
39.2 ± 3.9
Inching lever (4.00 ± 0.40)
[28.9 ± 2.88]

Breather
215103

7.10.2 Breather, Installation


Install breather.
7.10.3 Solenoid valve, Installation
Install solenoid valve together with O-ring, and tighten
it to the specified torque.
Note: Do not reuse the mounting bolts that secure the Solenoid valve
solenoid valve or O-rings. Make sure to use
new bolts.
Unit: N·m (kgf·m) [lbf·ft]
7.0 ± 1.0
Solenoid valve (0.71 ± 0.10)
[5.2 ± 0.74]

215104

215105

6-70
POWERSHIFT TRANSMISSION

8. Inspection and Adjustment


8.1 Oil Pressure Measurement
(1) Transmission oil level check
(a) Check the oil level using the level gauge.
(b) Start and run the engine at an idling speed, and
then stop the engine.
(c) Wait for 1 minute or more after stopping the
engine, and check the level.
(d) The checking procedure must be completed
within 15 minutes after the engine has stopped.
(2) Engine warm-up
(a) Warm up the engine to raise the temperature of
the transmission oil.
(3) Engine speed measurement
(a) After the engine is warmed up, measure the
idling speed and maximum no-load speed
according to the engine service manual.
Make the necessary adjustments if either or
both of the speeds do not meet the specifica-
tions.
(4) Preparation for oil pressure measurement
(a) Stop the engine after checking and adjusting
the engine speeds.
(b) Raise the front wheels completely clear of the
ground either by jacking up the front axle hous- b
ing or placing a wood block under the outer
mast and tilting the mast forward.
(c) Block the rear wheels.
Note: The front wheels start turning during the clutch
pressure measurement. Be careful and stay d
away from the wheels.
(d) Connect the oil pressure gauge to each of the
oil pressure taps indicated in the illustration.
a
a: Main oil pressure
b: Clutch oil pressure c
c: Torque converter inlet oil pressure
213671
d: Lubrication oil pressure
Note: To make the plugs of a, b, c and d easier to
loosen, tap the plug head once or twice.

6-71
POWERSHIFT TRANSMISSION

(e) Use the following tools for the oil pressure


measurements.

Oil pressure measurement tools

Torque con-
Special tool/ part Lubrication oil
Remark Main pressure Clutch pressure verter inlet pres-
number pressure
sure
Connector
M14 × 1.5 thread ٤ -— — —
91268-04400
*Connector
R (PT) 1/8 thread — ٤ ٤ ٤
64309-17733
Connector
M14 × 1.5 thread — — — ٤
91268-02300
*Gauge
600 (6) [87] — — ٤ ٤
64309-17714
*Gauge
2000 (20) [290] ٤ ٤ — —
64309-17713
*Hose
64309-17722
٤ ٤ ٤ ٤
*Connector For gauge
64309-17731 connection ٤ ٤ ٤ ٤

Note: Tools marked by * are included in the gauge kit 64309-17701.

(5) Oil Pressure Measurement


(a) Start the engine, shift the direction lever into
the neutral position and measure the main oil
pressure, torque converter inlet oil pressure,
and lubrication oil pressure.
(b) Measure the clutch oil pressure with the lever
shifted into the forward position, then measure
it again with the lever in the reverse position.

Unit: MPa (kgf/cm2) [psi]


Engine speed Oil pressure
600 ± 50 min-1 (rpm) A 1.12 ± 0.03 (11.42 ± 0.31) [162.5 ± 4.4]
a Main oil pressure Neutral
1600 ± 100 min-1 (rpm) A 1.26 ± 0.03 (12.85 ± 0.31) [182.8 ± 4.4]
Forward A 1.09 ± 0.03 (11.11 ± 0.31) [158.1 ± 4.4]
600 ± 50 min-1 (rpm)
Reverse A 1.06 ± 0.03 (10.81 ± 0.31) [153.8 ± 4.4]
b Clutch oil pressure
Forward A 1.21 ± 0.03 (12.34 ± 0.31) [175.5 ± 4.4]
1600 ± 100 min-1 (rpm)
Reverse A 1.18 ± 0.03 (12.03 ± 0.31) [171.2 ± 4.4]

Torque converter 600 ± 50 min-1 (rpm) A 0.16 ± 0.02 (1.63 ± 0.20) [23.2 ± 2.9]
c Neutral
inlet oil pressure 1600 ± 100 min-1 (rpm) A 0.40 ± 0.02 (4.08 ± 0.20) [58.0 ± 2.9]

Lubrication oil 600 ± 50 min-1 (rpm) A 0.02 ± 0.02 (0.20 ± 0.20) [2.9 ± 2.9]
d Neutral
pressure 1600 ± 100 min-1 (rpm) A 0.05 ± 0.02 (0.51 ± 0.20) [7.3 ± 2.9]
A: Standard value

6-72
POWERSHIFT TRANSMISSION

8.2 Brake (Inching) Pedal, Adjustment

Brake
ineffective Play
stroke

Top of floor plate


B C Detail B Detail C

2
213672

The clutch (inching) mechanism is linked to the brake


pedal. Depressing the inching pedal cuts the pressure
acting on the transmission before the brakes take
effect, bringing the transmission to a neutral condition.
A faulty inching pedal adjustment may create such
problems as failure in clutch disengagement and par-
tial clutch engagement. This in turn may cause an
abnormal increase in the transmission oil temperature,
as well as braking malfunctions and clutch plate sei-
zures. Be sure to make all the following adjustments
carefully so that these problems can be avoided.
(1) Brake pedal, adjustment
(a) Adjust the brake pedal height A from the floor
plate top surface to the brake pedal top surface
to the following standard value by turning the
stopper bolt 1 and then lock it with the lock nut.
Unit: mm (in.)
187.6 to 191.6
Brake pedal height A
(7.39 to 7.54)

(b) Adjust the clearance to 1.0 mm, between push


rod and piston of the brake master cylinder 2.
To do this, turn the push rod clockwise until it
contacts the piston, then turn it back counter-
clockwise for approx. 0.8 turns, and finally
secure the clevis with nut. After this adjust-
ment, check the brake pedal play.
Unit: mm (in.)
1.5 to 6.5
Brake pedal free play
(0.06 to 0.26)

6-73
POWERSHIFT TRANSMISSION

(2) Inching pedal, adjustment


(a) Adjust the height A of the inching pedal from
the floor plate top surface to the inching pedal
top surface to the following standard value with
the stopper bolt 3, and lock it when the stan-
dard value is obtained.
Unit: mm (in.)
187.6 to 191.6
Inching pedal height A
(7.39 to 7.54)

(b) Adjust the clearance b between the end of bolt


and the brake link in the portion B to the follow-
ing value and lock it firmly with the nut.
Unit: mm (in.)
2-3 ton
Item 1 ton class
classes
Clearance b between 10 11.6
bolt end and brake link (0.39) (0.46)

(3) Stop lamp switch, adjustment


(a) Adjust the stop lamp switch position so that the
stop lamp glows for sure when the brake pedal
is pressed, and mount the switch into position.
Unit: mm (in.)
Stop lamp switch mount- 0.5 to 1.0
ing position C (0.020 to 0.039)

8.3 Inching Cable, Adjustment


Start by
(a) Block the rear wheels, then raise the front
wheels observing the procedure described in
the preceding oil pressure measurement sec-
tion. Connect an oil pressure gauge to the oil
pressure tap (position D in the illustration).
(b) Make sure that the projection of the inching rod
is 33.5 to 34.5 mm (1.32 to 1.36 in.).
(c) Insert 0.5 mm (0.020 in.) thick shim between
inching pedal stopper and inching pedal stop-
per bolt 3 so that the play of inching cable is 0
mm.
(d) Tighten the inching cable lock nut 3.
(e) Remove the 0.5 mm (0.020 in.) thick shim.
(f) Make sure that the inching pedal stopper has
contact with the stopper bolt.
(g) Lightly press the inching pedal by your hand,
and make sure that the clearance A between
inching pedal stopper and stopper bolt is 0.4 to
1.1 mm (0.016 to 0.0039 in.) when the inching
lever is just about to move.

6-74
POWERSHIFT TRANSMISSION

If the play of inching cable is not properly adjusted, 3


the following failure will occur.
(a) When the play is less than 0.4 mm (0.016 in.):
Even if the inching pedal is not pressed, or Projection of inching rod
when the operator has put his/her foot on the
inching pedal lightly, the clutch oil pressure D
1
decreases, and the clutch slips. This results
in the premature wear or burnout of friction
plates.
(b) When the play is more than 1.1 mm(0.0039
in.):
Even if the inching pedal is fully pressed, the
clutch oil pressure will not decrease enough 2
to disengage the clutch completely. This
213673
results in premature wear or burnout of fric-
tion plates.

Adjusting procedure
(1) Run the engine at idle speed to raise the tempera-
ture of the transmission oil.
Inching pedal
(2) Shift the direction lever into the forward position.
Inching cable play stopper
(3) Gradually press the inching pedal to retract the
inching rod 2. Make sure that the oil pressure is 0
(zero) when the projection of the inching rod
Inching cable
becomes 26.9 mm (1.06 in.) or less.

Inching pedal
stopper bolt

Stop lamp switch

213674

6-75
POWERSHIFT TRANSMISSION

9. Troubleshooting
Engine lacks power Tune up engine.
Engine
Poor performance of engine Tune up engine.
Oil level too low Refill.
Air being sucked in Retighten or replace O-ring.
Faulty action of spool in main regulator
Repair or replace.
valve
Settling of spring in main regulator valve Replace the spring.
Torque converter Worn gears in oil pump, resulting in Disassemble and inspect and if defect
reduced capacity is found, replace the defective parts.
Magnet strainer clogged Replace.
Worn seal rings or O-rings Inspect, and if defective, replace.
Seizure of stator freewheel Replace torque converter assembly.
Not
Damage or rubbing of impeller Replace torque converter assembly.
enough
output Air being sucked on suction side Retighten or replace.
power
Outlet pressure too low to suppress inter-
Readjust pressure.
nal foaming
Water in oil Change oil.
Oil level too low Refill.
Pedal linkage maladjusted (brake shift and
Transmission Adjust.
forward reverse)
Main oil pressure too low, resulting in slip-
Adjust.
ping clutches
Worn seal rings or O-rings Inspect, and if defective, replace.
Damaged clutch piston Replace.
Friction plate seized or dragging Replace.
High mechanical resistance in road
Road wheels Check and adjust brake system.
wheels
Flexible plate broken Replace.
Oil level too low Refill.
Oil pump drive defective Replace.
Torque converter
Turbine shaft broken Replace.
Check pump gears for wear or
Main pressure too low
replace.
Oil level too low Refill.
Inching pedal link maladjusted Adjust.
Seal ring worn in servo case Replace.
O-rings on input shaft worn Replace.
No power
Plug on input shaft loose or slipped off,
flow Repair.
resulting in oil leaks
Clutch seized Replace.
Transmission
Shafts broken Replace.
Clutch drum, particularly snap ring groove,
Replace.
defective
Snap ring fitted to clutch drum broken Replace.
Oil way for supplying oil pressure to clutch
Clean or replace.
piston clogged
Shaft splines worn Replace shafts.
Broken parts in reduction differential or
Power train Repair or replace.
front axle

6-76
POWERSHIFT TRANSMISSION

Flexible plate broken Replace.


Bearings damaged Replace.
Rubbing of impeller Replace.
Torque converter
Bolts loose Retighten or replace.
Splines worn Replace.
Worn oil pump Disassemble, check, or replace.
Clutch seized and dragging Replace clutch plate.
Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace bolts.
Splines worn Replace.
Oil strainer clogged Clean.
Abnormal
noise Main regulator valve defective Clean or replace.
Restriction in oil pipe Replace.
Loud noise
Oil too viscous in cold weather Change oil.
Instruments faulty Replace.
Wrong kind of oil used Change oil.
Oil strainer clogged Clean or replace.
Oil pump defective Replace.
Excessive oil leaks
(1) Broken or settling of main regulator
Low noise Replace.
valve spring
(2) Defective main regulator valve spool Repair or replace.
Air being sucked in Retighten or replace packing.
Oil level too low Refill.
Check lips and sliding surfaces for
Leaking oil seals
wear. Replace seals.
Leaking joint of case Retighten or replace packing.
Repair or replace pipe, gasket and O-
Leaking pipe connection or joint
rings.
Leaking drain plug Retighten and replace gasket.
Oil leaks Cracks or blowholes in case Replace.
Oil blowing out of transmission case
(1) Water in oil Change oil.
(2) Air being sucked in suction side Replace packing and retighten.
(3) Oil leaks from air breather Repair.
Oil level too high Lower oil level.

6-77
POWERSHIFT TRANSMISSION

Oil level too high or too low Refill or drain.


Oil strainer clogged Clean or replace.
Rubbing of impeller Repair or replace.
Stator freewheel defective Replace stator assembly.
Air being sucked in Retighten or replace O-ring.
Torque converter
Water in oil Change oil.
Restriction in oil pipe (resulting in reduced
Repair or replace.
circulation flow)
Oil temper- Bearings worn or seized Repair or replace.
ature is too
Instruments faulty Replace.
high
Clutches dragging Replace clutch plate.
Transmission Bearings worn or seized Repair or replace.
Control linkage defective Repair or replace.
Truck not operated properly Urge user to operate properly.
Others
Others (1) Cooling fan belt damaged Replace.
(2) Oil cooler clogged Clean or replace.
(3) Brakes grabbing Check and readjust.
Main regulator valve defective Repair or replace valve assembly.
Main oil pressure is too high Oil viscosity too high at low temperature Change oil.
Wrong kind of oil used Change oil.
Magnet strainer clogged Clean or replace.
Oil pump defective Replace.
Coil spring defective in main regulator
Replace the spring.
valve
Faulty movement of spool in main regula-
Main oil pressure is too low Repair or replace spool.
tor valve
Air being sucked in Retighten or replace packing.
Oil level too low Refill.
Control linkage defective Repair or replace.
Clutch valve defective Repair or replace.
Magnet strainer clogged Clean or replace.
Oil pump worn or failed Replace.
Coil spring defective in main regulator
Replace the spring.
valve
Faulty movement of spool in main regula-
Repair or replace.
tor valve
Clutch oil pressure is too low Air being sucked in Retighten or replace packing.
Oil level too low Refill.
Control linkage defective Repair or replace.
Clutch valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch seal rings broken Replace.
Lack of engine power when the speed is
slightly low in both forward and reverse Tune up engine.
drive
Stator and freewheel damaged when the
Stall speed not within specifications
speed is excessively low in both forward Replace stator assembly.
and reverse drive
Inching pedal linkage defective, or clutch
Repair or replace.
slipping when the speed is too high

6-78
POWERSHIFT TRANSMISSION

10.Service Data
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Main oil pressure,
MPa (kgf/cm2) [psi] A Forward: 1.25 ± 0.03 (12.75 ± 0.31) [181.3 ± 4.4]
Engine at 1600 ± 100 rpm
Clutch oil pressure, Forward: 1.21 ± 0.03 (12.34 ± 0.31) [175.5 ± 4.4]
MPa (kgf/cm2) [psi] A
Engine at 1600 ± 100 rpm Reverse: 1.18 ± 0.03 (12.03 ± 0.31) [171.2 ± 4.4]
Torque converter inlet oil pressure,
MPa (kgf/cm2) [psi] A Forward:0.39 ± 0.02 (3.98 ± 0.20) [56.6 ± 2.9]
Engine at 1600±100 rpm
Lubrication oil pressure,
MPa (kgf/cm2) [psi] A Forward:0.05 ± 0.02 (0.51 ± 0.20) [7.3 ± 2.9]
Engine at 1600 ± 100 rpm
Travel time for 10m starting acceleration
sec. A 5 seconds, maximum
(no load)
K21: 1930 ± 100 min-1
Stall speed in theory K25: 2008 ± 100 min-1
S4S: 2100 ± 100 min-1
Pump boss A -0.085 -0.0033
42 -0.035 (1.65 -0.0014)
Diameter of fitting surface in contact with oil
seal 1
B 41.85 (1.65)

1
213675

Pilot boss A -0.007 -0.00028


15-0.042 (0.590-0.00165)
Diameter of shank 1
B 14.95 (0.5878)

213676

A: Standard value B: Repair or service limit

6-79
POWERSHIFT TRANSMISSION

Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Oil pump A 0.040 to 0.083 (0.00157 to 0.00327)
Side clearance 1
B 0.15 (0.0059)
A 0.3 to 0.33 (0.0118 to 0.0130)
Top clearance 2
B 0.35 (0.0138)
Backlash A 0.1 to 0.18 (0.00394 to 0.00709)

213677

Flexible plate A 0.2 (0.0079)


Face runout of flexible plate 1 (in free state)
B 0.5 (0.0197)
Distance between end face of transmission
A 50 (1.97)
case and mating face of flexible plate 2

214081

A: Standard value B: Repair or service limit

6-80
POWERSHIFT TRANSMISSION

Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Clutch A 1.6 ± 0.1 (0.063 ± 0.0039)
Thickness of mating plate 1
B 1.3 (0.0512)
A 2.6 ± 0.1 (0.1024 ± 0.0039)
Thickness of friction plate 2
B 2.2 (0.0866)
A 0.1 to 0.3 (0.0039 to 0.0118)
Backlash of friction plate and gear 3
B 0.5 (0.0197)
A 2 ± 0.1 (0.0787 ± 0.0039)
Width of seal ring 4
B 1.5 (0.0591)
A 2.3 ± 0.05 (0.0906 ± 0.002)
Width of piston seal ring groove 5
B 2.5 (0.0984)
Free length of clutch return spring 6 56.3 (2.22)
A
(Spring constant: k = N/mm (kgf/mm) [lbf/in.]) K=38.3 (3.905) [218.7]

2 1 3

5 213679

A: Standard value B: Repair or service limit

6-81
POWERSHIFT TRANSMISSION

Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
Input shaft A 2.5 ± 0.05 (0.0984 ± 0.002)
Turbine shaft seal ring width 1
B 2.0 (0.0866)
+0.2 +0.0079
A 2.5 +0.1 (0.0984+0.0039)
Turbine shaft piston seal ring groove width 2
B 3.0 (0.1181)
+0.021 +0.0008
Stator shaft inside diameter contacting seal A 30 0 (1.1811 0 )
ring 3
B 30.2 (1.189)
A 2.5 ± 0.05 (0.0984 ± 0.002)
Clutch piston seal ring width 4
B 2.0 (0.0866)
A 2.8 ± 0.05 (0.1102 ± 0.002)
Clutch piston seal ring groove width 5
B 3.0 (0.1181)
A 2.5 ± 0.05 (0.0984 ± 0.002)
Clutch shaft seal ring width 6
B 2.0 (0.0866)
+0.2 +0.0079
A 2.5 +0.1 (0.0984 +0.0039)
Clutch shaft seal ring groove width 7
B 3.0 (0.1181)
+0.021 +0.0008
Servo case inside diameter contacting seal A 30 0 (1.1811 0 )
ring 8 B 30.2 (1.189)

1, 2

6, 7

㧲 㧾

8 3
4, 5
213680

A: Standard value B: Repair or service limit

6-82