TM 5-3805-254-14P-2 PART 8 IHC F-5070 DUMP TRUCK

8/14/2019 TM 5-3805-254-14P-2 PART 8 IHC F-5070 DUMP TRUCK

1/56

TM 5-3805-254-14&P-2

TRUCK SERVICE MANUAL TRANSMISSION

DISASSEMBLY Para 5-11/5-12

Fig. 5-41 Removing rear cover

Fig. 5-42. Low planetary carrier, ring gear and clutch

(2) Refer to paragraph 6-24 for rebuild of lowplanetary carrier assembly.

(3) Remove the low ring gear with two clutchplates (fig. 5-42).

Fig. 5-43. Removing low clutch plates.(4) Remove the remaining eleven clutch plates

(fig. 5-43).NOTE

Tie the low-clutch plates together, and identifythe pack. Identification is required at assembly.

(5) Remove the adapter housing and the adapterhousing gasket (fig. 5-43).

(6) Refer to paragraph 6-25 for rebuild of the

adapter housing assembly.

c. First Clutch and Ring Gear(1) Remove one internal-splined and one external-

tanged clutch plate (fig. 5-44).(2) Remove the ring gear (fig. 5-44).(3) Remove the remaining eleven clutch plates

(fig. 5-44).NOTE

Tie the first-clutch plates together, and identifythe pack. Identification is required at assembly.

733


2/56


Para 5-13 HT 700D SERIES TRANSMISSION

Fig. 5.44. Removing first clutch plates .

5-13. REMOVING CENTER SUPPORT, GEAR UNIT,SECOND CLUTCH.

a. Supporting Gear Unit(1) With the output end of the transmission

upward, install the adapter housing (less piston) andgasket.

(2) Place center support compressor bar 8 (fig. 4-2) across the rear of the adapter housing so that thecenter hole in the bar will engage the mainshaft (fig. 5-45).

(3) Install two bolts to retain the tool and theadapter housing to the transmission housing.

b. Removing Components(1) Invert the transmission housing, converter end

upward. Remove the center support anchor bolt andwasher (figure 5-33).

(2) Remove the snapring that retains the centersupport assembly (fig. 5-34). This is a selectivethickness snapring.

Fig. 5-45. Removing gear unit assembly

(3) Install center support lifting bracket 5 (fig. 4-2)into the recess between the step-joint sealrings on thecenter support hub (fig. 5-35).

(4) Lift carefully, straight upward, on the liftingbracket to remove the center support assembly.

CAUTION

The center support is fitted to the transmissioncase with very little clearance. It may bind in thecase if the case is cold. Heat the case slightly, ifnecessary. Do not use a torch to heat the case.A heat lamp, or a current of warm air, issufficient. If the support assembly starts upwardand then binds, tap it downward and lift again.

734


3/56


Para 5-13 DISASSEMBLY

(5) Refer to paragraph 6-19 for rebuild of thecenter support assembly.

(6) Attach lifting bracket 16 (fig. 4-2) to the mainshaft of the gear unit assembly (fig. 5-45).

(7) Attach a hoist to the lifting bracket eyebolt andremove the gear unit and shaft assembly from thetransmission housing (fig. 5-45).

(8) Refer to paragraph 6-26 for rebuild of the gearunit and shaft assembly.

(9) Remove the snapring that retains the second-clutch plates (fig. 5-37). Remove the 13 second-clutchplates.

NOTE

Tie the second-clutch plates together, andidentify the pack. Identification is required atassembly.

(10) Remove the two bolts retaining the tool 8 (fig.4-2), adapter housing and gasket to the transmissionhousing (fig. 5-45). Remove the tool, housing andgasket.

(11) Refer to paragraph 6-23 for rebuild of thetransmission housing.

735


4/56


Para 6-1/6-3Section 6. INSPECTION AND REBUILD OF SUBASSEMBLIES

6-1. SCOPE OF SECTION 6

This section describes the disassembly and assembly ofsubassemblies that were removed in Section 5. Forrebuild procedures, refer to the exploded views (foldouts7 through 17) located at the end of this manual.Reference is also made to line drawings andphotographs in this section.

6-2. GENERAL INFORMATION FOR SUBASSEMBLYREBUILD

a. Tools, Parts, Methods. Refer to paragraphs 4-2,4-3 and 4-4.

b. Cleaning, Inspection. Refer to paragraph 4-5 forcleaning and inspection procedures.

c. Torque Specifications. The specific torque valuefor each threaded fastener is stated at each assemblystep. Torque values are also presented in paragraph 4-9.

d. Wear Limits, Spring Data. Refer to Section 8 forwear limits and spring data.

e. Plugs and Fittings. Prior to installation, apply asmall amount of nonhardening sealant (or Teflon tape)into the threads of each plug. Tighten the plugssufficiently to prevent leakage.

f. Clutch Pack Procedure. Soak the friction-facedclutch plates in transmission fluid for a minimum of 2minutes prior to assembly.

6-3. FLYWHEEL, LOCKUP CLUTCH, CONVERTERTURBINE

a. Disassembly (foldout 7)(1) Position the flywheel assembly, front

downward, on the work table (fig. 6-1).(2) Using two large screwdrivers or (prybars)

cushioned to prevent scratching(components)pry thetorque converter turbine free of the flywheel and lockupclutch (fig. 6-1).

Fig. 6-1. Removing converter turbine 6 from flywheel.

(3) Remove ball bearing 6 (B, foldout 7) fromtorque converter turbine 7, if parts replacement isnecessary.

(4) Re move the lockup clutch back plate from theflywheel (fig. 6-2). Remove the key from the recess inthe flywheel bore.

(5) Remove the lockup clutch plate (fig. 6-2).(6) Remove the lockup clutch piston (fig. 6-3).

Remove the sealring from the piston outer groove.(7) Remove the sealring from the inner hub of the

flywheel (fig. 6-3).(8) If replacement is necessary, remove the

starter ring gear from the flywheel after noting whetherthe gear chamfers are toward the front or rear of theflywheel.

(9) If the sealring surface of the flywheel bore isworn beyond 1. 007 inches diameter, rework the boreand install a sleeve (P/N 6881519) as shown in figure 6-4.

(10) Cool the sleeve in dry ice for at least thirtyminutes before installing. Proper alinement duringinstallation is necessary to prevent damaging the boreand sleeve.

(11) Press the sleeve flush with surface X (fig. 6-4).Be sure the internal chamfer is toward the rear side ofthe flywheel.

NOTE

Refer to paragraph 6-2, above.

736


5/56


Para 6-3 HT 700D SERIES TRANSMISSIONS

Fig. 6.2. Removing (or installing) lockup clutch back plate .

Fig. 6.3. Installing lockup clutch piston.

Fig. 6-4. Rework of flywheel-cross section view.

Fig. 6-5. Components of control valve assembly

b. Assembly(1) If the starter ring gear was removed, install a

new gear, as follows.

(2) Install the starter ring gear after heating ituniformly to 4000F (2040C) maximum temperature. Besure the chamfers of the teeth are facing the properdirection for starter pinion engagement. The ring gearmust seat firmly against the shoulder on the flywheel.

(3) Lay the flywheel on the assembly table, withthe cavity side upward, and install the sealring onto thehub (fig. 6-3).

(4) Install a sealring on the outside diameter of thelockup clutch piston and lubricate both sealrings.

(5) Place a pencil mark on the edge of the lockupclutch piston opposite a dowel pin hole. Also place apencil mark in the flywheel bore, opposite a dowel pin.

(6) Install the lockup clutch piston into theflywheel, alining the pencil marks, to engage therecesses in the piston with the dowel pins (fig. 6-3). Becertain the dowel pins are engaged.

(7) Install the lock key in the lock key groove ofthe flywheel (fig. 6-2). Use oil soluble grease to retain it.

(8) Install the lockup clutch plate (fig. 6-2)

(9) Install the lockup clutch back plate, flat sidefirst, engaging the notch in the plate with the key in theflywheel (fig. 6-2).

737


6/56


INSPECTION AND REBUILD Para 6-3/6-4

Fig. 6-6. Ball locations for control valve.

(10) If ball bearing 6 (B, foldout 7) was removed,press it onto the hub of turbine 7.

(11) Carefully center the lockup clutch plate in theflywheel. Install the torque converter turbine, engagingits hub splines with the internal splines of the lockupclutch plate. Seat the ball bearing in its bore.

6-4. CONTROL VALVE BODY ASSEMBLY

CAUTION

The valve body assembly contains a number ofsprings, some of which are similar and can bemistakenly interchanged. Also, springs vary invalve bodies used on different models. Ifsprings are not reinstalled in the same locationsfrom which removed, the calibration of valvebody functions will be lost. For these reasons, itis recommended that each spring, at removal, betagged with its item number in B, foldout 16.This will simplify correct reassembly of the valvebody components.

a. Disassembly (B, foldout 16)

(1) If not removed previously, remove manualselector valve 72. Stop bolt 62 must be removed beforevalve 72 can be removed.

(2) Position the valve assembly, modulatorupward (fig. 6-5). Remove three bolts that retain themodulator valve body, while holding the oil transfer plateand separator plate together.

(3) Lift off the modulator valve body and set itaside, while retaining a grasp on the oil transfer andseparator plates.

(4) Invert the oil transfer and separator plateswhile holding them firmly together. Lay them on the worktable.

(5) Lift the separator plate off the oil transfer plate.Compare check ball locations in the transfer plate tothose in the chart (shown in fig. 6-6), Make a sketch orlist that will identify the ball sizes and locations (for

reassembly). Remove the balls.(6) Remove the lubrication pressure regulator

valve from the oil transfer plate as

738


7/56


Para 6-4 HT 700D SERIES

Fig. 6-7. Control valve assembly - with components installed.

follows. Compress cup washer 4 (B, foldout 16) andremove pin 5. Release washer 4 and remove it.Remove spring 3 and valve 2. Remove lubrication valvepin 6 from the oil transfer plate.

NOTE

Before the modulator valve is disassembled (in(7), below), the grooves in adjusting ring 22 inwhich retainer pin 16 seats must be marked toinsure correct reassembly. Adjusting ring 22also must be identified for installation into thesame bore from which removed.

(7) Disassemble the modulator valve body, removedin (3), above. Press adjusting ring 22 inward andremove retainer pin 16. Release the adjusting ring andremove it. Remove valve stop 21, washer 20, spring 19,and valve 18.

(8) Remove priority valve 46 (fig. 6-7) spring 44, andvalve stop 45 from the control valve assembly.

(9) Position valve body 24 (B, foldout 16), flat sidedownward, on the work table. Remove plug 58 andscreen assembly 59.

739


8/56


INSPECTION AND REBUILD Para 6-4

LEGEND FOR FIGURE 6-7.A.

2-3 RELAY VALVE BORE

1 -- Relay valve*2 -- SpringB.

3-4 RELAY VALVE BORE3 -- Relay valve4 -- Valve stop

*5 -- SpringC. FOURTH-CLUTCH TRIMMER

VALVE BORE6 -- Fourth-clutch trimmer valve7 -- Trimmer plug

*8 -- Spring9 -- Valve stop

D. SECOND-CLUTCH TRIMMERVALVE BORE

10 -- Second-clutch trimmer valve11 -- Trimmer plug*12 -- Spring13 -- Valve stop

E. THIRD-CLUTCH TRIMMERVALVE BORE

14 -- Third-clutch trimmer valve15 -- Trimmer plug


F. FIRST-CLUTCH TRIMMERVALVE BORE

18 -- First-clutch trimmer valve19 -- Trimmer plug

*20 -- Spring -- outer

*21 -- Spring -- inner22 -- Valve stopG. TRIMMER REGULATOR VALVE BORE

23 -- Trimmer regulator valve*24 -- Spring25 -- Valve stop

H.4-5 RELAY VALVE BORE

26 -- Relay valve*27 -- Spring28 -- Valve stop

I.4-5 SHIFT VALVE BORE

29 -- Shift signal valve30 -- Shift modulator valve


J.

3-4 SHIFT VALVE BORE33 -- Shift signal valve34 -- Signal modulator valve


K.2-3 SHIFT VALVE BORE

37 -- Shift signal valve38 -- Signal modulator valve

*39- Spring40- Valve stop

L. HOLD REGULATOR VALVE BORE41 -- Hold regulator valve


M. PRIORITY VALVE BORE*44 -- Spring45 -- Valve stop46 -- Priority valve

N. MODULATOR VALVE BORE47 -- Modulator valve

*48- Spring49 -- Spring washer50 -- Adjusting ring51 -- Valve stop52 -- Retainer pin

0. MANUAL SELECTOR VALVE BORE53 -- Manual selector valve

P. LUBRICATION PRESSUREREGULATOR VALVE BORE

54 -- Valve guide pin55 -- Lubrication valve

*56 -- Spring57 -- Washer58 -- Retainer pin

Q. GOVERNOR SCREEN59 -- Screen60 -- Pipe plug

R. GOVERNOR ACCUMULATOR61 -- Accumulator valve

*62 -- Accumulator spring63 -- Accumulator stop64 -- Accumulator pin

S. TRIMMER BOOST ACCUMULATOR*65 -- Trim boost accum. spring66 -- Trim boost accum. stop67 -- Trim boost accum. valve

* Before installing, refer to spring chart (Section 8) for positive identification.

740


9/56



(10) Remove eight bolts 44while holding trimmercover 43 against spring pressure. Relieve pressure andremove cover 41.

(11) Remove springs 27 and 28, valve stop 29,trimmer plug 26, and trimmer valve 25.

(12) Remove springs 32 and 33, stop 34, plug 31,and valve 30.

(13) Remove springs 37 and 38, stop 39, plug 36,and valve 35.

(14) Remove valve 42, spring 41 and stop 40.(15) Remove springs 47 and 48, stop 49, plug 46

and valve 45.NOTE

In operations (16) through (24), below, the

components i n each bore are spring-loaded,and must be restrained while removing theretainer pins. Also, before removing retainerpins in operations (20), (21) and (22), theadjusting rings must be marked, and eachidentified with its bore, so they can bereassembled into the same bores and at thesame positions in the bores.

(16) Remove retainer pin 50, valve stop 54, spring53, and valve 52.

NOTE

In earlier models, valve stop 54 consisted of twoseparate pieces.

(17) Remove retainer pin 51, spring spacer 57,spring 56, and valve 55.

(18) Remove retainer pin 63, spring 61, stop 62and valve 60.

(19) Remove retainer pin 72, valve plug 71, spring69, valve stop 70, and valve 68.

(20) Remove retainer pin 75, adjusting ring 80,spring 78, valve stop 79, and valves 77 and 76.



(23) Remove retainer pin 96, valve stop 95, spring94, and valve 93.

NOTE


(24) Remove retainer pin 100, spring 98, valve stop99, and valve 97.

NOTE


b. Assembly (B, foldout 16)

NOTE

Check the position of all valve assemblycomponents, the configuration of all valves andplugs, and the identification of all springs beforeinstallation. Refer to figure 6-7 for position andconfiguration of components. Refer to thespring chart in Section 8 for identification ofsprings.

(1) Install components into bores A and B (fig. 6-7), in the sequence indicated by numbers 1 through 5.

NOTE

All valves must move by their own weight (dry)when installed.

(2) Install spring spacer 57 and valve stop 54 (B,foldout 16) into bores A and B (fig. 6-7). Depress thesprings and install retainer pins 51 and 50 (B, foldout 16)to retain spacer 57 and valve stop 54.

NOTE


(3) Install components into bores C, D and E (fig.6-7), in the sequence indicated by numbers 6 through 17.

(4) Install components into bore F, in thesequence indicated by numbers 18 through 22.

(5) Install components into bore S (fig. 6-7), insequence indicated by numbers 65, 66 and 67.

(6) Install trimmer cover 43 (B, foldout 16).Compress the springs, and retain the cover with eight1/4-20 x 5/8-inch bolts.

741


10/56


INSPECTION AND REBUILD Para 6-4 44

44. Tighten the bolts to 9 to 11 pound feet (12 to 15 Nm)torque.

(7) Install the components into bore G (fig. 6-7), inthe sequence indicated by numbers 23, 24 and 25.Install pin 100 (B, foldout 16) to retain stop 25 (fig. 6-7).

(8) Install the components into bore H (fig. 6-7), inthe sequence indicated by numbers 26, 27 and 28.

(9) Install valve stop 95 (B, foldout 16). Compressthe spring, and install retainer pin 96 into valve body 24to retain valve stop 95.

NOTE

In earlier models valve stop 95 consisted of twoseparate pieces.

(10) Install the components into bore I (fig. 6-7), inthe sequence indicated by numbers 29 through 32. Alinethe pin hole in valve stop 32 with the pin holes in thevalve body.

(11) Install adjusting ring 91 (B, foldout 16), flat sidefirst and at same position as before removal. Compressthe spring, and install retainer pin 92 into the valve bodyto retain adjusting ring 91 and valve stop 99. Be surethat pin 92 seats in the same grooves in ring 91 it wasseated in prior to removal.

(12) Install the components into bore J (fig. 6-7), inthe sequence indicated by numbers 33 through 36.

(13) Install adjusting ring 85 (B, foldout 16), flat sidefirst and at the same position as before removal.Compress the spring, and install retainer pin 86 into thevalve body to retain adjusting ring 85 and valve stop 84.Be sure that the retainer pin is seated in the samegrooves in the adjusting ring as before removal.

(14) Install the components into bore K (fig. 6-7), inthe sequence indicated by numbers 37 through 40.

(15) Install adjusting ring 80 (B, foldout 16), flat sidefirst and at the same position as before removal.Compress the spring, and install retainer pin 75 into thevalve body to retain adjusting ring 80 and valve stop 79.Be sure that the retainer pin is seated in the samegrooves in the adjusting ring as before removal.

(16) Install the components into bore L (fig. 6-7), inthe sequence indicated by numbers 41, 42 and 43.

(17) Install valve plug 71 (B, foldout 16). Compressthe spring, and install retainer pin 72 into the valve bodyto retain valve plug 71.

(18) Install components into bore M (fig. 6-6), in thesequence indicated by numbers 44, 45 and 46.

(19) Install components into bore N (fig. 6-7) of themodulator valve body, in the sequence indicated bynumbers 47 through 52. Adjusting ring 50 must beinstalled flat side first and at the same position as beforeremoval. Retainer pin 52 must pass through the hole invalve stop 51, and seat in the same grooves in adjustingring 50 as before removal.

(20) Install the components into bore R (fig. 6-7) in

proper sequence. Install valve 61, spring 62, stop 63and retainer pin 64. Aline stop 63 and the valve body forcorrect retainer pin installation.

(21) Install governor screen assembly 59 (fig. 6-7),open end first, into bore Q. Retain the screen assemblywith plug 60, tightened to 50 to 60 inch pounds (5. 6 to6.8 Nm) torque.

(22) Install components into bore P (fig. 6-7) of theoil transfer plate, in the sequence indicated by numbers54 through 58.

(23) Position the oil transfer plate, channeled sideupward, on the work table.

(24) Using the chart in figure 6-6 as a guide, installthe correct number of check valve balls in their properpositions. Retain each ball with a small quantity of oilsoluble grease.

NOTE

Failure to retain the balls with oil soluble greasemay result in balls being accidentally misplacedduring subsequent assembly steps.

(25) Lay separator plate 23 (B, foldout 16)onto theoil transfer plate so that their bolt holes aline. Grasp thetwo plates together, invert them, and position them onthe assembled control valve body so that priority valve 67

is compressed against spring 66 and into valve body 24.

742


11/56


HT 700D SERIES TRANSMISSIONS Para 6-4/6-6

NOTE

Use extreme care that the separator plate and oiltransfer plate do not separate. A slightseparation could dislocate the check valve ballsand cause malfunction of the transmission.

(26) Install the assembled modulator valve onto theoil transfer plate as shown in figure 6-5. Install three 1/4-20 x 2 1/2-inch bolts to retain the modulator body, oiltransfer plate, separator plate and control valveassembly as a unit. Do not tighten the bolts at this time.

(27) Aline the bolt holes in the control valveassembly with those in the separator plate and oiltransfer plate. When all bolt holes are alined, tighten thebolts installed in (26), above, to 9 to 11 pound feet (12 to15 Nm) torque.

(28) Install manual selector valve 53 (fig. 6-7) intobore O of the control valve body.

(29) Valve 53 must be positioned so that its flatside is upward (when assembly is positioned as in fig. 6-8).

(30) Install stop bolt 64 (B, foldout 16) intocontrol valve assembly. The flat end of the bolt mustaline with the flat side of the selector valve (fig. 6-8).Tighten the stop bolt to 36 to 43 pound feet (49 to 58Nm) torque.

NOTE

Refer to paragraph 3-11 for adjustment of shiftspeed points.

(31) To prevent dust or dirt from contaminating thevalve assembly, place it in a plastic bag until ready forinstallation onto the transmission.

6-5. LOW TRIMMER VALVE BODY ASSEMBLYa. Disassembly (A, foldout 17)

(1) Press inward on retainer plug 26, and removeretainer pin 20.

(2) Release pressure, and remove plug 26,springs 23and 24, valve stop 25, plug 22 and valve 21.

Fig. 6-8 Tightening selector valve stop bolt .

NOTE


b. Assembly (A, foldout 17)

(1) Install low clutch trimmer valve 21, recessedend first, into valve body 19.

NOTE

Valves, when installed dry, should move by theirown weight.

(2) Install trimmer plug 22.

(3) Install springs 23 and 24, valve stop 25, andretainer plug 26.

(4) Compress springs 23 and 24, and installretainer pin 20 to secure plug 26.

6-6. LOW SHIFT VALVE BODY ASSEMBLY

a. Disassembly (A, foldout 17)

(1) While holding inward against valve stop 9,remove retainer pin 5.

NOTE


(2) Release spring pressure, and remove valvestop 9, spring 8, and relay valve 7.

NOTE

Mark adjusting ring 15 and valve body 3 so thatring 15 can be reinstalled at the same position asbefore removal.

743


12/56



(3) While holding inward against adjusting ring 15,remove retainer pin 6. Relieve the spring pressure.

(4) Remove adjusting ring 15, washer 14, valvestop 13, spring 12, and valve ll.

(5) Remove retainer pin 4 and plug valve 16.

NOTERefer to paragraph 6-2, above.

b. Assembly (A, foldout 17)(1) Install, plug valve 16, and retainer pin 4.

NOTE

Valves, when installed dry, should move by theirown weight.

(2) Install valve 11 into valve body 3.

(3) Install spring 12, valve stop 13, washer 14, andadjusting ring 15. Aline the hole in valve stop 13 with thepin hole in valve body 3. Position adjusting ring 15 asbefore removal.

(4) Press inward against adjusting ring 15 untilretainer pin 6 can be installed.

(5) Install relay valve 7, spring 8, valve stop 9.

NOTE


(6) Press inward against valve stop 9, and installretainer pin 5.

6-8. TORQUE CONVERTER STATOR ASSEMBLY

a. Disassembly (B, foldout 7)(1) Rotate stator freewheel roller race 14 in a

clockwise direction so the race may be removed.

(2) Remove race 14, thrust bearing 13, thrustbearing race 12, ten stator rollers 11 and ten freewheelroller springs 10 from stator 9.

NOTE



(1) Place stator 9 on the work table, rear upward,and install thrust bearing race 12 into the stator.

Fig. 6-9. Installing stator freewheel roller

744


13/56


Para 6-8/6-9 HT 700D SERIES TRANSMISSIONS

(2) Coat the pockets of stator 9, stator springs 10and rollers 11 with oil-soluble grease.

(3) Install stator roller holder 17 (fig. 4-2) into thestator against the thrust bearing race installed in (1),above (fig. 6-9).

(4) Install ten freewheel roller springs into thestator cam pockets. The springs must be positioned asshown in figure 6-10 (5) Install ten freewheel rollers (fig.6-9).

(6) Install the thrust bearing onto the freewheelroller race (fig. 6-11).

(7) Start the freewheel roller race the roller holder(fig. 6-11). Rotate the race clockwise to install it.

Fig. 6-10. Spring and roller in stator cam.

Fig. 6-11. Installing freewheel roller race.

(8) Remove the roller holder by pulling on thethong attached to it. Push the roller race inward (rotatingclockwise) until the thrust bearing seats.

(9) Rotate the freewheel roller racecounterclockwise to lock it in place. Place the statorassembly, roller race upward until ready for installation.Cover or wrap the assembly to keep out dust and dirt.

6-9. TORQUE CONVERTER PUMP ASSEMBLY


(1) Flatten the corners of the lockstrips, andremove twelve bolts from the converter pump (fig. 6-12).

(2) Remove the bearing retainers. Remove pumphub 27 (B, foldout 7), pump hub gasket 26, and sealring28 from hub 27.

(4) If necessary for parts replacement, removebearing 25 or 31. Remove sealring 20 from theconverter pump.

(5) Replacement of any converter balance weights23, requires re-balancing of the converter pump.

NOTE


Fig. 6.12. Torque converter pump components.

745


14/56




(1) If bearing 25 was removed, install a newbearing, ungrooved end first, into pump hub 27. Installgasket 26.

(2) Install a 3/8-24 headless guide bolt intoconverter pump hub 27 or gear 32. Install sealring 20onto the outside diameter of converter pump assembly21.

(3) Install converter pump hub 27 onto theconverter pump. Remove the guide bolt. Install twobearing retainers 19 and retain them with twelve 3/8-24x 1 1/4-inch bolts (pump hub 27) and six new lockstrips.Tighten the bolts to 33 to 40 pound feet (45 to 54 Nm)torque. Bend one lockstrip corner against each bolt

head (fig. 6-12).

6-10. CONVERTER HOUSING WITH 2-BOLT TOPCOVER, FRONT SUPPORT, OIL PUMP.

a. Disassembly

(1) Place the converter housing front downward(fig. 6-13). Remove two sealrings, needle bearing andrace from the front support hub.

Fig. 6.13 Converter housing components (2.bolt cover,no retarder).

(2) Place a wood 2 x 4 (51 x 102 mm) through theconverter housing access opening, about 14 inches (356mm) into the housing (fig. 6-14). Remove four of the sixbolts retaining the oil pump assembly. Loosen theremaining two bolts, leaving about four turns of threadengaged.

(3) Press on the wood 2 x 4 (51 x 102 mm), andtap alternately on the two loose bolts (fig. 6-14). This willdislodge the oil pump. Remove the bolts, and allow thepump to drop onto the wood support. Remove the pumpassembly. Remove the sealring (if present) from theouter circumference of the pump.

(4) Remove the screw retaining the oil pumpcover (fig. 6-15). Remove the cover, sealring, drive gear,and driven gear assembly.

(5) Remove the roller bearing from the drivengear, and the oil seal from the pump assembly. Removethe sealring (if present) from the outer circumference ofthe pump.

(6) Using the spring compressor (item 23, fig. 4-2)depress the main pressure regulator valve spring (fig.6-16). Remove the snapring.

NOTE

The spring compressor may be used whetherthe front support assembly is attached to orremoved from the torque converter housing.

Fig. 6.14. Supporting oil pump during removal.

746


15/56


Para 6-10 HT 700D SERIES TRANSMISS IONS

Fig. 6-15. Oil pump and torque converter housing .

(7) Remove the spring compressor, and removewasher 6 (B, foldout 10), valve stop 5, spring 4, and mainpressure regulator valve 3.

(8) Using the spring compressor, remove snapring12, washer 11, valve stop 10, spring 9, and lockup shift

valve 8.(9) The spring compressor is not required for the

remaining valve components. Push inward against valvesupport assembly 16, and remove snapring 19. Removesupport assembly 16, seat 15, converter bypass valve14, and spring 13.

(10) Remove the 19 bolts remaining in the frontsupport assembly (fig. 6-13). Lift off the front supportassembly and gasket.

(11) If replacement is necessary, remove theneedle bearing from the bore of the support hub (fig. 6-16).

(12) If parts replacement is necessary, remove testplugs 18 (A, foldout 8) from housing 16.

Fig. 6-16. Removing (or installing) main pressure regulator snapring.

(13) Do not remove the ground sleeve (fig. 6-15)from the front support. If there is evidence of movement,or damage, replace front support and ground sleeveassembly 2 (B, foldout 10).

NOTE


b. Assembly (A, foldout 8).(1) If the needle bearing was removed from the

front support (fig. 6-17), install a new bearing. Installer30 (fig. 4-3) may be used with handle 46 for driving thebearing, or without the handle when press-installing thebearing.

NOTE

When no installer is available, the depth ofinstallation must be measured. Proper depth,from rear of hub to rear of bearing is 1.26 to 1.28inches (32-32.5 mm)

(2) Install the main-pressure regulator and lockupshift valves, as described in (3) through (6), below.

Install the converter regulator valve, as described in (7)through (9), below.

(3) Install main-pressure regulator valve 3, smallend first, into the bore indicated in B, foldout 10. Be surethe valve will move freely of its own weight in its bore.

747


16/56



Fig. 6-17. Tool for installing front support needle bearing.

(4) Install spring 4 and valve stop 5. Place washer6 on spring 4 and compress the spring into the valvebore until the snapring groove is clear (fig. 6-16). Installsnapring 7.

(5) Install lockup shift valve 8, small end first, intothe bore indicated in B, foldout 10. Be sure the valve willmove freely of its own weight in its bore.

(6) Install spring 9 and valve stop 10. Placewasher 11 on spring 9 and compress the spring into thevalve bore until the snapring groove is clear (use springcompressor). Install snapring 12.

(7) Install spring 13 into the converter regulatorvalve bore indicated in B, foldout 10. Install converterbypass valve 14 and valve seat 15. Spring compressoris not required for this spring.

(8) Install support assembly 16 and snapring 19into the valve bore.

(9) Place converter housing 16 (A, foldout 8) onthe work table, front side down.

(10) Place front support gasket 17 onto theconverter housing. Aline holes in the gasket with thosein the converter housing.

(11) Install front support assembly I (B, foldout 10)onto converter housing 16 (B, foldout 8).

(12) Install three 3/8-16 x 2 1/2-inch bolts into thefront support (fig. 6-13). Tighten the bolts to 36 to 43pound feet (49 to 58 Nm) torque.

(13) Install one 3/8-16 x 1 1/2-inch bolt into the holebetween the two valve bores that are closer to eachother (fig. 6-13). Tighten it to 36 to 43 pound feet (49 to58 Nm) torque.

(14) Install fifteen 3/8-16x 11/2-inch bolts into theouter bolt circle of the front support (fig. 6-13). Tightenthe bolts to 36 to 43 pound feet (49 to 58 Nm) torque.

748


17/56

TRUCK SERVICE MANUALTRANSMISSION

HT 700D SERIES TRANSMISSIONS

Para 6-10

Fig. 6-19 Checking oil pump driven gear end clearance

(15) Install the bearing race, flat side first, onto the frontsupport hub (fig. 6-13).Install the needle bearing onto therace.

NOTE

Grease both the race and bearing,before installing, with sufficient oil-soluble grease to retain them.

(16) If the oil seal was removed from the oil pump body,install a new seal (fig. 6-18). Use seal installer 27 anddriver handle 28 (fig. 4-3) for driving or pressing the seal.The lip of the seal must face inward (toward rear oftransmission). If no installer is available, press the seallightly until it is flush with the front of the housing.

NOTE

The installer 27, (fig. 4-3) can be usedwith the transmission assembled exceptfor the flywheel and torque converter.

(17) If the needle bearing (fig. 6-15) wasremoved from the oil pump driven gear, install a newbearing. Center it in the gear.

(18) Install the driven gear and the drive gear intothe oil pump body (fig. 6-15).

Fig. 6-20 Checking oil pump drive gear end clearance

(19) Install the cover, and retain it with the 1/4-20 x 5/8-inch flat-head screw (fig. 6-15).

(20) Check the oil pump driven gear end clearance as

shown in figure 6-19. Check the oil pump drive gearclearance as shown in figure 6-20. The gear endclearance should not exceed 0. 006 inch (0.15 mm).

(21) Install the sealring around the cover outercircumference (fig. 6-21). Install two 3/8-16 guide screwsinto the pump at the locations shown.

(22) Lubricate the seal ring (if used) and oil pump cavityin the housing (fig. 6-21).

Install the pump assembly, guiding the screws throughthe holes indicated.

(23) While holding the pump assembly in place, install six3/8-16 x 4-inch bolts to retain it (remove guide screws toinstall last two bolts). Tighten the bolts to 36 to 43 poundfeet (49 to 58 Nm) torque.

(24) Lubricate the two step-joint seal rings with oil-solubleg r e a s e, and install them into the grooves in the frontsupport hub (fig. 6-13).

(25) If removed, install plugs 18 (A, foldout 8). Usenonhardening sealer on the plug threads, and tightenthem to 50 to 60 inch-pounds (5. 64 to 6.78 Nm) torque.

749


18/56


INSPECTION AND REBUILDPara 6-16/6-17

Fig. 6-21 Installation position of oil pump assembly (housing with 2-bolt cover)

Fig. 6-29 Forward clutch components

Figure 6-30 Removing (or installing) forward clutch spring retainer snapping

6-17. FORWARD CLUTCH AND TURBINE SHAFT


(1) Remove hook-type sealring 1 from the frontof the turbine shaft.

(2) Remove bearing race 2 from the hub offorward clutch housing assembly 3.

(3) Remove two hook-type sealrings 4 from theturbine shaft.

(4) Position forward clutch assembly 3 on a worktable, turbine shaft down.

(5) Remove bearing race 25and bearing 26 fromforward clutch hub 20.

(6) Remove snapring 24 and fourth-clutch drivinghub 23.

(7) Remove five each of clutch plates 21 and 22.

(8) Re move forward clutch hub 20.

(9) Remove bearing race 19 and needle bearing18 from the inner hub of the forward clutch hub (fig. 6-29).

(10) Remove bearing race 17 from the inner hub

of the forward clutch housing (fig. 6-29).

(11) Using spring compressor 4 (fig. Fig. 6.29) 4-2), compress the spring retainer. Remove the snapring(fig. 6-30).

(12) Carefully remove pressure from at thespring retainer. Remove the spring retainer.

750


19/56


HT 700D SERIES TRANSMISSIONSPara 6-17

Fig. 6-31 Removing PTO gear from forward clutch

(13) Remove twenty piston return springs 14 (A,foldout 11).

(14) Remove forward clutch piston 13 andsealrings 10, 11 and 12. If the piston is replaced, be surethe identification (A, B or C) for the new piston is identical

to that of the piston replaced.(15) Remove the PTO gear by compressing the

snapring, located within the gear, sufficiently to allow thegear to slip easily from the clutch housing.

(16) To compress the snapring, insert 10 piecesof 3/32 x 0.020 x 3-inch (2.38 x 0. 50x 76. 2-mm) steelshim stock between the snapring and the PTO gear (fig.6-31). To accomplish this, locate the snapring gap, andat the cutout nearest the gap, press the snapring into thegroove in the housing. Slip a piece of shim stockbetween the snapring and the inner ends of the splines ofthe PTO gear. Repeat the operation at the other side ofthe snapring gap.

(17) Then, working at each opening (missingspline) to compress the snapring, insert the remaining

pieces of shim stock at approximately 3-inch (76.2 mm)increments. Push the gear from the housing. Remove the

Fig. 6-32 Forward clutch housing-partial cross-section view

Fig. 6-33 Installing pivot collector ring

snapring. If the gear does not slip easily, check for abreak in the light that can be seen between the gear andhousing; work to depress the snapring in that area.

(18) Unless replacement is necessary, do not removecollector ring 6. If damage has occurred, support theinner circumference of the ring and press the forwardhousing and input shaft assembly free.

(19) Do not remove balls 7 from the forward clutchhousing unless replacement is necessary.

751


20/56


INSPECTION AND REBUILDPara 6-17

Fig. 6-34 Staking pivot collector ring to forward clutch housing



(1) If collector ring 6 was removed, replaceit with a new ring. Apply Loctite Retaining Compound 40to the joint and install the ring (fig. 6-33)Use installer 12(fig. 4-2)to drive the collector ring onto the clutch housing(fig. 6-33)Use light hammer blows, and work around theentire installer circumference.

(2) Using staking tool 11 (fig. 4-2), bend theedge of the ring into the groove in the clutch housing (fig.6-34)Check the four steel balls in the housing (fig. 6-32)They must be free to move, unobstructed, andsecurely staked.

(3) Position the forward clutch housing and shaftassembly 5 (A, foldout 11), turbine shaft down, on a worktable.

(4) Grease and install sealring 12 into thesealring groove in the forward clutch housing. Be surethe lip of the seal faces upward (rearward) (fig. 6-35).

CAUTION

If sealring 12 is installed incorrectly, rough shifts inforward gears will occur.

Fig. 6-35 Forward clutch assembly cross section

(5) A clutch plate running clearance check isessential before completing the assembly rebuild. Items(6) through (13), below, explain the procedure. Items (14)through (20), below, complete the rebuild of thesubassembly.

NOTEIf the forward clutch housing is replaced,selection of a proper piston (A, B or C) isimperative before sealring installation. Ifthe forward clutch housing is notreplaced and a new piston is required,make sure the identification letterstamped on the new piston is identical tothat on the old piston.

(6) Usingfigure6-35as a guide, place forwardpiston A on the work table with the return spring bossesup. Grease and install lip-type sealring B and C, lips ofthe seals facing downward.

(7) Install piston A into forward clutch housing G.Make sure the lips of sealrings B and C are facing thebottom of the piston cavity. Install seal protector 15 (fig.4-2) onto the clutch housing hub before installing thepiston (fig. 6-36).

(8) Beginning with an external-tangled plate,

alternately install five external-tangled plates D (fig. 6-35)and five internal-splined plates E into forward clutchhousing G.

(9) Install fourth-clutch driving hub F into housingG.

(10) Install snapring H.752


21/56



Fig. 6-36 Installing forward clutch piston

Fig. 6-37 Checking forward clutch plate running clearance

Fig. 6-38 Removing (or installing) fourth clutch front bearing race

(11) While holding hub F firmly against snapringH, measure. the clutch clearance with gage 42 (fig. 4-3)at the location shown CLUTCH in figure 6-35. Whenclearance is satisfactory, the thinner step of the gage willenter between the driving hub and clutch plates; the

thicker step will not (fig. 6-37). The prescribed clearanceis 0.080 to 0. 120 inch (2.03 to 3.05 mm). Any clearancemeasurement within this range is satisfactory, but thenearer to 0.080 inch that can be attained, the longer theclutch will maintain satisfactory clearance.

(12) If the clutch running clearance is not withinthe specified limits, remove snapring H, fourth-clutchdriving hub F and clutch plates D and E. Replace clutchplates, as required, to obtain the desired runningclearance. Refer to wear limits in Section 8, to determinethe plate thickness.

(13) Repeat items (9), (10) and (11), above.When the clutch running clearance is within the specifiedlimits of 0. 080 to 0. 120 (2.03 to 3.05 mm), removesnapring H and hub F.

(14) Install 20 piston return springs 14 (A, foldout11) onto the spring guide bosses of piston 13. Placespring retainer 15 on top of the 20 springs, recessed side(outer lip) of the retainer facing down.

(15) Compress spring retainer 15 until thesnapring groove on the clutch housing hub is exposed(fig. 6-30). Install the snapring.

(16) Grease (with oil-soluble grease) and installthe thrust bearing race onto the retainer hub of forwardclutch housing (fig. A

(17) Grease (with oil-soluble grease) and installthe bearing race and needle bearing onto the inner hubof the forward clutch hub). (fig. 6-29).Install the forward clutch hub, outer splines first, into theforward clutch housing (fig. 6-29).

(19) Install the fourth- clutch driving hub 23 (A,foldout 11) and retain it with snapring 24.

(20) Place the forward clutch housing on a worktable, turbine shaft upward. Install PTO gear snapring 8(A, foldout 11) on

753


22/56


INSPECTION AND REBUILDPara 6-17/ 6-18

to the forward-clutch housing. Install the PTO gear,chamfered end of internal splines first, from the rear ofthe clutch housing. Slide the gear onto the housing untilthe snapring engages its mating groove in the gear.

(21) Grease and install two hook-type sealrings4 (A, foldout 11). Install hook-type sealring 1 on the frontof the turbine shaft. Install thrust bearing race 2, cuppedside first, onto the front of the forward clutch housing.

(22) Grease (with oil-soluble grease) and installbearing race 25, flat side first, and needle bearing 26onto the rear of forward clutch hub 20.

6-18. FOURTH CLUTCH ASSEMBLY


(1) Remove the bearing race from the front hubof the fourth-clutch housing (fig. 6-38).

(2) Remove the bearing race from the rear hubof the fourth-clutch housing (fig. 6-39).

(3) Place the fourth-clutch assembly, snapringup, on the work table.

(4) Remove the large snapring and the backplate (fig. 6-40).

Fig. 6-39 Removing (or installing) fourth clutch rear bearing race

(5) Remove five external-tangled clutch plates and fiveinternal-splined clutch plates.

(6) Using items 3 and 4 (fig. 4-2), compress the springretainer until it is clear of the snapring (fig. 6-41).Remove the snapring.

(7) Carefully release the pressure from the springretainer. Remove the retainer and 20 piston returnsprings.

(8) Remove the piston from the clutch housing (fig. 6-41).

Fig. 6-40 Removing (or installing) fourth clutch plates

754


23/56



Fig. 6-41 Removing (or installing) fourth clutch spring retainer snapring

(9) Remove sealrings 10 (B, foldout 11) and 11.

(10) Check balls 13, as outlined in paragraph 6-17b(2), above.



(1) Place fourth-clutch housing assembly 12 (B,foldout 11) on the work table, flat (rear) side downward.

(2) Grease (oil-soluble grease) and installsealring 11 into the clutch housing. Be sure the lip of thesealring is facing the bottom of the piston cavity.

(3) Place fourth-clutch piston 9 on the work table,spring bosses side up. Grease and install sealring 10, lipdownward, into the groove on the outside circumferenceof the piston. A sealring for the inside groove in piston 9

is not required. Install the piston into the clutch housing,using inner seal protector 13 (fig. 4-2) to center andguide the piston, although no seal contacts the tool (fig.6-42).

Fig. 6-12 Installing fourth clutch piston

NOTE

If the forward clutch housing is replaced,selection of a proper piston (A, B or C) isimperative before sealring installation. Ifthe forward clutch housing is notreplaced and a new piston is required,make sure the identification letterstamped on the new piston is identical tothat on the old piston.

(4) A clutch plate running clearance check isessential before completing the assembly. Items (5)through (7), below, explain the procedure. Items (8)through (12), below, complete the rebuild of theassembly.

(5) Beginning with an external-tangled plate,alternately install five external-tangled plates and fiveinternal-splined plates into the fourth-clutch housing (fig.6-40).

(6) Install the back plate and snapring (fig. 6-30).

(7) Hold the back plate firmly against thesnapring. Insert gage 42 (fig. 4-3) and check theclearance at the location shown in figure 6-43. Whenclearance is satisfactory, the thinner step of the gage willenter between the back plate and clutch plates; thethicker

755


24/56


INSPECTION AND REBUILD

Fig. 6-13 Fourth clutch assembly-cross-section view

step will not (fig. 6-44). The prescribed clearance is 0.080 to 0.120 inch(2.03 to 3.05 mm). Any clearancemeasurement within this range is satisfactory, but thenearer to 0. 080 inch that can be attained, the longer theclutch will maintain satisfactory clearance.

(8) Install 20 piston release springs, one each onthe 20 cast bosses on the fourth clutch piston (fig. 6-40).

(9) Install the spring retainer, recessed side

(outer lip) down, on the 20 piston return springs (fig. 6-40).

(10) Compress the spring retainer until thesnapring groove on the clutch hub is clear (fig. 6-41).Install the snapring.

(11) Grease (with oil-soluble grease) and installthe bearing race onto the rear hub of the fourth-clutchhousing (fig. 6-39).

(12) Grease (with oil-soluble grease) and installthe bearing race onto the front hub of the fourth-clutchhousing assembly (fig. 6-38).

6-19. CENTER SUPPORT ASSEMBLY


Fig. 6-4. Checking fourth clutch running clearance

Fig. 6-45 Installing retainer rings onto second clutch piston

(1) Place center support housing assembly 16(A, foldout 12), vertically (upright), on the work table.

(2) Remove pistons 10 and 21with attachedparts.

(3) Remove the inner and outer sealrings from

each piston. If replacement is necessary, disassemblethe two piston assemblies. Cut the

756


25/56


HT 700D SERIES TRANSMI SSIONSPara 6-19/6-20

retainer rings to prevent damaging the piston projections.Remove four retainer rings, a retainer, and twentysprings from each piston.

(5) Remove two step-joint sealrings 13 (A,foldout 12) from the hub of support housing 18.

(6) Remove thrust bearing race 15 and needlebearing 14.

NOTE



(1) Temporarily place piston 10 in the front pistoncavity of center support housing 18. Install springs 9 intothe pockets of the piston. Aline spring retainer 8 on thefour ejector pin bosses of the piston. Compress thesprings by forcing the retainer into the recess at the outeredge of the center support w hen the retainer rings areinstalled (fig. 6-45). Install a new self-locking retainer ring7 on the ejector pins of each piston, using installer 58(fig. 4-4). Remove the piston from the center support.

(2) Repeat the procedures in (1), above, toassemble items 21 through 24 (A, foldout 12) into therear cavity of support housing 18.

NOTE

If the pistons are not forced to thebottom of their cavities during installationof self-locking retainer rings 7 and 24,proper clutch clearance cannot beestablished.

(3) Grease (with oil-soluble grease) and installinner sealrings 11 and 20, and outer sealrings 12 and 19onto pistons 10 and 21. The lips of all sealrings must betoward the piston cavities of the center support.

(4) Inspect the piston cavities in center supporthousing 18 for any obstruction or

foreign material. Install piston 21 into the rear of thecenter support. Be sure the lips of both the inner andouter sealrings face the bottom of the piston cavity.Leave the assembled third clutch piston (10) out of thecenter support until final installation of the center supportassembly in Section 7.

(5) Lubricate needle roller bearing 14 andbearing race 15 with oil-soluble grease. Install the race,flat side first, onto the front hub of the center support. Tofacilitate assembly, keep the race square with thesupport housing hub during installation. Forcing maydamage the race. Install the needle roller bearing ontothe race.

(6) Carefully install two step-joint sealrings 13into the sealring grooves of the support housing hub.Retain them with oil-soluble grease.

Fig. 6-17 Installing orifice plug into main shaft


26/56



Fig. 6-49 Removing dust shield from rear cover

6-22. REAR COVER ASSEMBLY


(1) Using remover 24 (fig. 4-3), remove the dust shieldfrom the rear cover (fig. 6-49).

(2) Using remover 24 (fig. 4-3), remove the output shaftoil seal from the rear cover (fig. 6-50).

(3) Re move the speedometer drive components fromthe rear cover (fig. 6-50).

(4) Remove the snapring that retains the rear outputshaft bearing (fig. 6-51).

(5) Remove the rear output shaft, and its attached parts,from the rear cover (fig. 6-52).

(6)

Fig. 6-50 Removing output shaft rear oil seal

Fig. 6-51 Removing (or installing) output shaft bearing snapring

758


27/56


Para 6-22 HT 700D SERIES TRANSMISS IONS

Fig. 6-52. Removing (or Installing) output shaft

(6) Support the front of the speedometer drivegear, and press the output shaft from the gear, spacersleeve and bearing (Fig. 6-52).

(7) If orifice plug 20 (A, foldout 16) or bushing 22requires replacement remove either or both as required.

(8) Using compressor components 2 and 3 (Fig.

4-2), compress the spring retainer and springs (Fig. 6-53). Remove the snapring, and remove the compressor.

Fig.6-53. Removing (or iInstalling) snap ring that retains piston in rear cover

(9) Remove the spring retainer and30 springs(Fig. 6-53).

(10) Remove the clutch piston (fig 6-53).Remove the inner and outer sealrings from the piston.

(11) If the speedometer driven gear bushingrequires replacement, remove it. Thread remover 22(Fig. 4-2).into the bushing (Fig. 6-54). Attach slidehammer 19 (fig.4-2) to remover 22 and remove thebushing.

(12) Remove any remaining parts (dowel pins,snapring, governor support pin, plugs) that requirereplacement, from the rear cover (Fig. 6-54).



(1) If removed, replace the dowelpins in the mountingface of the rear cover (fig.6-55). The dowel pins project0. 360 to 0.400 inch (9.15 to 10.16 mm) above the faceof the cover.

759


28/56


INSPECTION AND REBUILD Para6-22

Fig. 6-54. Removing speedometer driven gear bushing

Fig. 6-56. Governor support pin location

(2) If removed, install the bearing front snapringinto the rear cover (Fig. 6-55) Install plugs, if removed,into the rear cover.

(3) If removed, install the governor support pin tothe dimension shown in figure 6-56. Accuracy oflocation and concentricity with the governor bore is ofthe utmost importance when installing the pin.

(4) If removed, install a new speedometer drivengear bushing (Fig. 6-55). Use installer 21 (Fig. 4-2) toseat the bushing in the rear cover.

(5) Lubricate sealrings 5 and 6 (A, foldout 16) withtransmission fluid, and install them into the grooves ofpiston 4. The lip of each sealring must face the rear ofthe piston (toward piston cavity in rear cover).

(6) Using inner seal protector 12 (fig.4-2), carefullyinstall the piston into the rear cover (Fig. 6-57). Useextreme care to prevent the lip of either seal foldingback over itself. If installation is difficult, remove thepiston and check the seal and cover bore before againattempting installation.

Fig. 6-55. Installing speedometer driven gear bushing.

760


29/56



Fig. 6-57. Installing piston into rear cover

Fig. 6-58 Installing output shaft orifice plug

Figure 6-58. Installing output shaft orifice plug.

(7) Remove the seal protector. Install 30 springs(Fig. 6-53). Install the spring retainer, cupped side first,onto the springs.

(8) Using compressor components 2 and 3 (Fig. 4-2), compress the retainer and springs (Fig. 6-53). Installthe snapring, and remove the compressor.

(9) If the orifice plug was removed f r o m the outputshaft, install a new plug, orificed side first (Fig. 6-58).Use installer 34 (Fig. 4-3) to properly position the plug inthe shaft. In each model, the plug must clear thechamfer at the front of the plug bore in the output shaft.

(10) If the bushing was removed from the front of theoutput shaft, install a new bushing (Fig. 6-59).

Locate the bushing in the shaft with installer 31(Fig. 4-3). The bushing is 0. 145 to 0. 165 inch (3. 68to 4.19 mm) from the front of the shaft.

(11) Press the speedometer drive gear, spacersleeve, and bearing onto the rear output shaft (Fig. 6-52). Install the assembled shaft.Fig. 6-58 Installing output shaft orifice plug

(12) On assemblies before S/N 5660, install thebevelled snapring (bevel toward rear of transmission) asshown inf igure 6-51 On later transmissions, the snapringis not bevelled. Be certain that the proper snapring isused to match the groove in the housing. Be sure thesnapring is expanded fully into the groove.

(13) Coat the outer circumference of the output shaftoil seal with nonhardening sealer. Install the oil seal,spring-loaded lip first. Use installer 26 and driver handle28 (Fig. 4-3) to locate the rear of the seal 0. 60 to 0.70inch (15. 2 to 17.8 mm) in front of the parking brakemounting surface plane (fig..

761


30/56


INSPECTION AND REBUILD Para 6-2216-23

Fig. 6-61. Manual shaft components

Fig. 6-59. Installing output shaft bushing (14) Coat the outer circumference of dust shield 32

(A, foldout 16) with nonhardening sealer. Install theshield, flat side first, into the rear cover. The rear edge ofthe shield must be flush with, to 0.040 inch (1. 01 mm)

below, the rear surface of the cover.(15) If available, install the output flange after coatingthe oil sealinner circumference with high-temperaturegrease.

Tighten the flange retaining nut 31 (A, foldout 16)to750 to 1000 pound feet (1017 to 1356 Nm) torque.

(16) Install the speedometer drive components (Fig.6-50).

6-23. TRANSMISSION HOUSINGa. Disassembly (A, foldout 14)

(1) To remove the manual detent lever, use thefollowing procedure. Remove the retainer pin andlocknut (Fig. 6-61).

(2) Hold the detent lever in one hand and remove themanual shaft by carefully pulling the shaft through the oilseal in the housing. Remove the detent lever.

CAUTIONIf the shaft is burred or rough, smooth it withcrocus cloth or a honing stone, beforeremoval, to avoid scratching the housing bore.

762


31/56


Para 6-2316-24 HT 700D SERIES TRANSMI SS IONS

(3) Remove oil seal 42 (A, foldout 14) from thetransmission housing.

4) If replacement of breather 1 is necessary, removeit from the housing.

(5) Inspect neutral safety switch plug 41, washer 40,and reverse signal plug 4 for damage. If damaged,replace with new parts.

(6) If it is necessary to replace nameplate 6, removeone drive screw 5.

NOTE

All replacement parts ordered refer to the

information both nameplate Therefore it isimperative that the new nameplate be stampedwith identical information.

NOTE



(1) Coat the inside diameter of oil seal 42 (A,foldout 14) with a seal lubricant, and the outside diameterwith a nonhardening sealant. Install the oil seal, lip first,

into the transmission housing (Fig. 6-62). Use installer32 (Fig. 4-3) to properly locate the seal in the housing.The seal must clear the chamfer in the housing bore.

(2) Hold detent lever 34 (A, foldout 14) so that theselector valve pin extends toward the inside of thehousing (Fig. 6-61).Slide the manual shaft through theopening in the housing, oil seal, and slot in the detentlever. Install the locknut and retainer pin. Tighten thelocknut to 15 to 20 pound feet (20 to 27 Nm) torque.

(3) If breather 1 (A, foldout 14) was removed,install the breather.

(4) If removed, install nameplate 6 and drive screw5 (refer to a(6), and note, above).

6-24. LOW PLANETARY CARRIER ASSEMBLY

NOTE

Disassemble the planetary assembly only ifthere is evidence of undue wear or damage.Failure of one pinion requires replacement ofthe entire set, because the pinions areselectively matched.

a. Disassembly (A, foldout 15) (1) Using a 31/32-inchdrill, centered accurately, drill into one end of each pinionpin 20 until the swaged end is sufficiently weakened.

CAUTION

Do not drill into metal of carrier 19.

(2) Place carrier assembly 18 in a press, andpress four pins 20 from carrier 19, shearing the drilledends of pins 20.

Fig. 6-62. Installing manual shaft oil seal

763


32/56


INSPECTION AND REBUILD Para 6-24//6-25

Fig. 6-63. Components of low planetary carrier assembly

(3) Remove as a unit, each of the four piniongroups consisting of pinions 23, thrust washers 21 and24, and needle roller bearings 22. Remove bearings

from pinion bores. NOTE



NOTE

To facilitate assembly, it is permissible tofreeze pinion pin 20 or heat carrier 19 beforepinion pin installation.

(1) Install bearings 22 into the bore of each pinion23. Place a steel thrust washer 24 (first), and a bronzewasher 21 (last) onto each face of pinions 23.

(2) Position carrier 19 in a press, and place a piniongroup (as assembled in (1), above) into the carrier. Aline

the parts of the pinion group with the pinion pin holes inthe carrier.

(3) Install pinion pin 20 and press it through thecarrier and pinion group to the dimension shown in figure6-63.

NOTEPins must be a tight, to moderately tight, pressfit (when parts are at normal temperatures).

(4) Install the remaining pinion groups and pins inthe manner described above.

(5) Support each pinion pin on an 0. 812-inch (20.62 mm) (approx) anvil. Using a suitable punch, swage

the pin firmly against the carrier to form the patternshown in figure 6-63. After swaging, each pinion mustrotate freely with 0. 008 to 0. 031 inch (0. 203 to 0. 787mm) end play.

6-25. ADAPTER HOUSING ASSEMBLY


(1) Position the assembly, piston assembly upward. Liftout the piston assembly (includes items 3 through 8).

(2) Remove the inner and outer sealrings from the piston(Fig. 6-64).

Fig. 6-64. Removing (or installing) first clutch piston seal ring

764


33/56


HT 700D SERIES TRANSMISSIONS Para 6-25/6-26

(3) Turn the piston assembly over, and cut the ourretainer rings while depressing the retainer (Fig. 6-65).

NOTEAny method of removal except cutting maydamage the risers on the piston. Damage willlessen the holding power of retainer ringsinstalled thereafter.

(4) Remove the spring retainer and 28 springsfrom the piston (Fig. 6-55).

(5) If replacement is necessary, remove dowel pins11 and 12, and orifice plug 13 (A, foldout 15) fromadapter housing 10.



(1) If removed, install new dowelpins 11 and 12into housing 10. They must project 0. 360 to 0.400(9.15 to 10.16 mm) above the front face of the adapterhousing. Install orifice plug 13 (if removed) flush with, orto 0. 060 inch below the front face of the housing.

(2) Place piston 6 in the piston cavity of housing10. Be sure it is firmly bottomed in the cavity.

(3) Install 28 springs 5 into their recesses in thepiston. Install retainer 4, so that its offset tangs areupward, onto the piston and springs.

(4) Using installer 58 (Fig. 4-4), install four retainerrings 3 (A, foldout 15).Press each ring into place until theadjacent retainer tang bottoms in the counterbore of theadapter housing.

CAUTIONFailure to install the retainer rings properly canresult in transmission damage or malfunction.If installed too far onto the risers, proper clutch

clearance cannot be obtained .If not installedfar enough, the retainers may fall off.

Fig. 6.65. Removing retainer rings from first clutch piston

(5) When all four retainer rings are properly installed,remove the piston assembly from the adapter housing.

(6) Lubricate sealrings 7 and 8 with transmission fluid.Install the sealrings, with the lip of each sealring facingrearward, away from the spring side of the piston (Fig. 6-64).

(7) Do not install the piston assembly into the adapterhousing until the housing is installed, as outlined inSection 7, for gear unit installation.

6-26. GEAR UNIT AND MAIN SHAFT ASSEMBLY


(1) Remove thrust washer 1 (fig.6-66) from sungear 2. Remove sun gear 2 and thrust washer 3.

(2) Remove front planetary carrier assembly 4, andthrust washer 5. Refer to paragraph 6-30 for rebuild ofthe carrier assembly.

765


34/56



Fig. 6-66. Components of gear unit and main shaft assembly (HT750CRD)

(3) Remove sun gear and shaft assembly 6, andthrust washer 7. If the bushings in gear and shaftassembly 6 require replacement, replace entire shaftassembly 6.

(4) Remove snapring 8 and ring gear 9 from thefront of planetary connecting drum 17.

(5) Lift out center planetary carrier assembly 10.Refer to paragraph 6-31 for rebuild of the carrierassembly.

(6) Remove snapring 23. Remove low sun gear24.

(7) Remove bearing race 20, bearing 21, andbearing race 22.

(8) Remove main shaft 11. Remove centerplanetary ring gear 12 and its attached parts (items 13,14, 15, 16, 19).

(9) Remove snapring 13. Lift gear 12 from gear16. Remove race 14, bearing 15, and race 19.

(10) Remove snapring 18, and lift rear planetarycarrier assembly 25 from drum 17. Refer to paragraph6-34 for rebuild of carrier assembly.

NOTE



(1) If the bushings were unserviceable or removedfrom sun gear and shaft assembly 6 (Fig. 6-66), replacethe entire shaft assembly.

(2) If orifice plug 36 (A, foldout 13) was removedfrom shaft 35, install a new plug. If orifice plug 35 (B,foldout 12) was removed from main shaft 36, install anew plug. Be sure the plug is pressed deep enough intothe bore to clear the chamfer of the shaft. Use installer34 (Fig. 4-3) to position the orifice plug properly (Fig. 6-47).

(3) Position planetary connecting drum 17 (Fig. 6-66), front (longer internal splines) downward. Install r earplanetary carrier assembly 25, larger carrier bore first,into drum 17. Retain the carrier with snapring 18.

(4) Install bearing race 14, flat side first, onto the

rear of center planetary ring gear 12. Retain it with oil-soluble grease. Install needle roller bearing 15 onto race14.Retain it with oil-soluble grease.

(5) Install thick, flat bearing race 19 onto bearing15. Retain it with oil-soluble grease.

(6) Install rear planetary sun gear 16 into the rear ofcenter planetary ring gear 12. Retain it with snapring 13.

(7) Install main shaft 11, smaller end first, throughthe parts (12, 13, 14, 15, 16, 19) assembled above.Install shaft 11 and its assembled parts into drum 17 untilbearing race 19 seats in the front counterbore of rearplanetary carrier assembly 25.

(8) Install bearing race 22, flat side first, onto therear hub of rear planetary carrier assembly 25. Retain itwith oil-soluble grease. Install bearing 21, and thick,

766


35/56


Para 6-26 /6-30 HT 700D SERIES TRANSMI SS IONS

flat race 20 onto bearing 21, retaining each with oil-soluble grease.

(9) At the rear of carrier assembly 25, install low sungear 24, extended hub first, over the rear end of shaft 11.Retain it with snapring 23.

(10) Position the assembly, front upward, andsupport the rear of carrier assembly 25.

(11) Install center planetary carrier assembly 10,outer splines upward, into drum 17. Install frontplanetary ring gear 9, outer splines first, into drum 17.Retain gear 9 with snapring 8.

(12) Install thrust washer 7 onto shaft 11. Install

sun gear and shaft assembly 6, larger diameter first, ontoshaft 11.

(13) Install thrust washer 5 onto the rear hub offront planetary carrier assembly 4. Install carrierassembly 4 so that thrust washer 5 seats on the front ofcenter planetary carrier assembly 10.

(14) Install thrust washer 3, sun gear 2, and thrustwasher 1 into the front of front planetary carrier assembly4.

6-29. FLEX DISK ASSEMBLY


(1) If flex disk assembly 2 has not been removedfrom the engine crankshaft, remove it.

(2) Remove twelve self-locking bolts 9 andseparate plate 8, flex disks 6 and 7, and hub assembly 3.

NOTE



(1) Install flex disk6 onto hub assembly 3, aliningthe dowel pin hole in the disk with pin 5. Washersattached to disk 6 must face toward hub assembly 3.

(2) Install flex disks 7 in the same manner.

(3) Install plate 8, alining the plate with dowel pin 5.

(4) Install twelve self-locking, 1/2-20 x 3/4-inchbolts 9 through plate 8, disks 6 and 7, and into hubassembly 3. Tighten the bolts to 96 to 115 pound feet(130 to 156 Nm) torque.

(5) Install flex disk assembly 2 onto the enginecrankshaft. Refer to the vehicle service manual for bolttorque-value.

6-30. FRONT PLANETARY CARRIER ASSEMBLY

NOTE

Refer to paragraph 6-26 for removal from gearunit. Disassemble the planetary only if there isevidence of undue wear or damage. Failure ofone pinion requires replacement of the entireset because the pinions are selectivelymatched.

767


36/56


Para 6-30 INSPECTION AND REBUILD

a. Disassembly ( A foldout 13)

(1) Using a 5/8-inch drill, centered accurately, drillinto one end of each pinion pin 12, until the swaged endis sufficiently weakened.

CAUTION

Do not drill into metal of carrier assembly 6.

(2) Place carrier assembly 5 on a press bed.Support the carrier in a manner such that no stress willbe placed on the swaged pins (smaller diameter) that donot retain the pinions. Press six pinion pins 12 fromcarrier assembly 5, shearing the drilled ends of pins 12.

(3) Remove as a unit, each of the six pinion groupsconsisting of pinions 10, thrust washers 8 and 11, andneedle roller bearing 9. Remove the bearings from thepinion bores.

(4) Inspect carrier assembly 6 for relativemovement bet w e e n the remaining parts. If loosenessis detected, replace the assembly.

NOTE


b. Assembly (A,foldoutl3)

NOTE

To facilitate assembly, it is permissibleto freeze pinion pin 12 or heat carrier 6before pinion installation.

(2) Install a needle roller bearing 9 (A, foldout 13)into the bore of each pinion 10. Place a steel thrustwasher 11(first) and a bronze thrust washer 8 (second)onto each face of pinion 10.

(3) Place the carrier assembly in a press. Supportthe carrier in such a manner that no stress will be placed

on the swaged pins when the pinion pins are installed.Place a pinion group (as assembled in (2), above) intothe carrier.

(4) Carefully aline the parts of the pinion groupwith the pinion pin holes in the carrier assembly, andinstall pinion pin 12 (A foldout 13). Press the pinion pinthrough the carrier and pinion group to the dimensionshown in figure 6-68.

Fig. 6-68. Components of front planetary carrier assembly

768


37/56


HT 700D SERIES TRANSMISSIONSPara 6-30/6-32

NOTEPins must be a tight, to moderately tight,

press fit (when parts are at normaltemperatures).


(6) Support each pinion pin on a 1/2inch (12. 7 mm)(approx.) anvil. Using a suitable punch, swagethe pins firmly against the carrier to form thepattern shown in figure 6-68. Pinions mustrotate freely after swaging.

6-31. CENTER PLANETARY CARRIER ASSEMBLY

NOTERefer to paragraph 6-26 for removalfrom gear unit. Disassemble theplanetary assembly only if there isevidence of undue wear or damage.Failure of one pinion requiresreplacement of the entire set becausethe pinions are selectively matched.

a. Disassembly (A foldout 13)

(1) Using a31/32-inch drill, centered accurately, drillinto one end of each pinion pin 17 until the swaged end

is sufficiently weakened.

CAUTIONDo not drill into metal of carrier 18.

(2) Place carrier assembly 16 in a press, and pressfour pins 17 from carrier 18, shearing the drilled ends ofpins 17.

(3) Remove as a unit, each of the four pinion groupsconsisting of pinions 20, thrust washers 19 and 22, andneedle roller bearings 21. Remove bearings from pinionbores.


b. Assembly ( A foldout 13)

NOTETo facilitate assembly, it is permissibleto freeze pinion pin 17 or heat carrier 18before pinion pin installation.

(1) Install two bearings 21 into the bore of eachpinion 20. Place a steel thrust washer 22 (first) and abronze thrust washer 19 (second) onto each face ofpinions 20.

(2) Position carrier 18 in a press, and place a piniongroup (as assembled in (1), above) into the carrier. Alignthe parts of the pinion group with the pinion pin holes inthe carrier.

(3) Install pinion pin 17 and press it through thecarrier and pinion group to the dimension shown in figure6-69.

NOTEPins must be a tight, to moderately tight,press fit (when parts a r e at normaltemperatures).


(5) Support each pinion pin on an 0.812-inch (20.62mm) (approx.) anvil. Using a suitable punch, swage thepin firmly against the carrier to form the pattern shown infigure 6-69. After swaging, each pinion must rotatefreely.

769


38/56


INSPECTION AND REBUILDPara 6-32 -34

Fig. 6.69 Components of center planetary carrier assembly

6-34. REAR PLANETARY CARRIERASSEMBLY

NOTEDisassemble the planetary assemblyonly if there is evidence of undue wearor damage. Failure of one pinionrequires the replacement of the entireset, because the pinions are selectivelymatched.


(1) If carrier 40 or bushing 41 is damaged orotherwise unserviceable, replace with a carrier andbushing assembly. Field replacement of the bushingalone is not recommended.

(2) Using a31/32-inch drill, centeredaccurately, drill into one end of each pinion

pin 46 until the swaged end is sufficiently weakened.

CAUTIONDo not drill into metal of carrier 40.

(3) Place carrier assembly 38 in a press, andpress four pins 46 from carrier 40, shearing the drilledends of pins 46.

(4) Remove, as a unit, each of the four piniongroups consisting of pinions 43, thrust washers 42 and45, and needle roller bearings 44.



NOTETo facilitate assembly, it is permissibleto freeze pinion pin 46 or heat carrier 40before pinion pin installation.

(1) Install a needle roller bearing 44 into thebore of each pinion 43. Place a steel thrust washer 45(first) and a bronze thrust washer 42 (second) onto eachface of pinions 43.

(2) Position carrier 40, front downward(bushing bore upward), in a press. Place a pinion group(as assembled in (1), above) into the carrier. Align thepinion group with the pinion pin bore in the carrier.

(3) Install a pinion pin 46, and press it throughthe carrier and pinion group, to the dimension shown infigure 6-72.

NOTEPins must be a tight, to moderately tight,press fit (when parts are at normal

temperatures).

770


39/56


HT 700D SERIES TRANSMISSIONSPara 6-34/6-35

(4) Install the remaining pinion groups andpins in the manner described above.

(5) Support each pinion pin on a.0. 812inch(20. 62 mm) (approx.) anvil. Using a suitable punch,swage the ends of each pinion pin firmly against thecarrier, to form the pattern shown in figure 6-72. Afterswaging, each pinion must rotate freely, with 0. 008 to 0.031inch (0. 20 to 0.78 mm) end play.

6-35. GOVERNOR INSPECTION

a. Inspect the governor to determine that itsfunction has not been impaired. If dirt or other foreignmaterials are present, clean the governor in mineralspirits then check the governor as explained in c, below.If the governor function is still impaired, disassemble thegovernor as explained in b, below.

b. Remove pins A shown in figure 6-73 andcarefully remove the governor weights and springs.Slide the governor valve out of its housing and aftercleaning the valve and housing, check for wear. If wearis evident, replace the governor, otherwise assemble thegovernor by reversing the disassembly procedure above.Be sure the governor valve is installed as shown in figure6-73. New pins must be used at reassembly. Thesepins, with instructions, are available in kit form. See yourHT 700 Series parts catalog SA 1268 for detail partnumber.

c. Hold the governor assembly drive gear upward,as shown in figure 6-73. Hold one weight outwardagainst its stop. Check the opening at the governor feedport. This is the distance the governor valve land clearsthe bottom side of the port. Repeat this check whileholding the other weight outward against the stop. Theminimum opening should be 0.020 inch (0.51 mm). Ifthe opening is less, replace the governor.

Fig. 6-72. Components of rear planetary carrier assembly 771

Fig. 6-73. Governor assembly-showing port openings

771


40/56



6-36.TORQUE SPECIFICATIONS

A complete listing of torque specifications are in atable in paragraph 4-9. Figure 6-74

illustrates a majority of the fasteners and the torquerecommendations for each.

Fig. 6.74. Torque requirements for threaded fasteners

772


41/56


Para 7-1/7-3Section 7. ASSEMBLY OF TRANSMISSION

FROM SUBASSEMBLIES

7-1. SCOPE OF SECTION 7

This section covers the assembly of thetransmission. It is arranged in a continuous sequence tofacilitate assembly. Certain illustrations will not alwaysillustrate the model being assembled, but, when theoperation is identical, the illustration may be referencedand will correctly illustrate the procedure.

7-2. CLUTCH CLEARANCES

a. Preparation Procedure. Preparations arerequired to establish the proper running clearance foreach clutch pack. Follow the procedures in b, below.

b. Determine Plate Thickness

(1) Determine the original thickness of eachexternal-tanged plate with a micrometer. Because thetangs of the clutch plate are not subject to face wear, themicrometer reading at a tang will be the originalthickness. Note that each clutch pack must contain onethick plate next to the piston, and a basic number of thickand thin plates. The combination of thick and thin platesare selected to meet the prescribed clearance with theclutch released. Install all thick plates toward the pistonend of the pack.

(2) Determine the wear on both internal andexternal plates (refer to wear limits in Section 8).Replace worn plates. Note that the thicknesses ofexternal-tanged plates in the low, first, second, and thirdclutches in earlier models may be different

from the thicknesses of corresponding plates in latermodels. Wear limits started in Section 8 are for platespresently supplied.

(3) If it is necessary to replace an external-tanged plate, be sure the plate thickness is identical tothe original equipment. Refer to b(l) and (2), above.Keep the clutch plates separated; do not mix the platesof one clutch with the plates of another.

(4) Clearance for the third clutch isestablished during assembly. Clearances for the forwardand fourth clutches are established during rebuild ofthose subassemblies in Section 60

Fig. 7-3. Installing second clutch, external-tangled plate

Fig. 7-4. Installing second clutch snapring

77 3


42/56


ASSEMBLYPara 7-3

Fig. 7-5. Installing center support assembly

Fig. 7-6. Checking selective snapring clearance

Fig. 7-7. Checking second clutch plate clearance

Fig. 7-8. Installing first clutch plates

7-4. ESTABLISHING CLUTCH CLEARANCES,SELECTING CENTER SUPPORT SNAPRING

a. Low and First Clutch Clearances

(1) Place the transmission housing in avertical position, rear end upward (Fig. 7-8).

(2) Beginning with an external-tanged clutchplate, alternately installs even external-tanged, and sixinternal-splined first clutch plates (Fig. 7-8).

(3) Install the adapter housing assembly (asassembled in para 6-25) and gasket.

774


43/56


HT 700D SERIES TRANSM ISSIONPara 7-4

Fig. 7-9. Installing rear cover assembly

(4) Beginning with an external-tanged clutch plate, alternately install seven external-tanged and six internal-splined low clutch plates (refer toFig. 7-19).

(5) Install the rear cover assembly (asassembled in para 6-22) and gasket onto the rear of thetransmission housing and secure it with six 1/2-13 boltsand flatwashers, evenly spaced (Fig. 7-9). Tighten thebolts to approximately 30 pound feet (41 Nm) torque.

(6) Invert the transmission, front end upward.Using gage 44 (Fig. 4-3), check the clearance betweenthe low clutch plates (fig. 7-10). It is recommended thegage be placed between the adapter housing wall andthe first steelplate. The prescribed running clearance is0.095 to 0.145 inch (2. 41 to 3.68 mm) Any dimensionwithin 0.095 to 0.145 inch (2.41 to 3.68 mm) issatisfactory. However, the closer the clearance is to0.095 inch, the longer the interval between clutch platereplacements will be. Clearance must not be less than0.095 inch. Replace worn clutch plates with new platesto establish the desired clearance. Recheck theclearance as described above.

(7) Using gage 44 (Fig. 4-3), check theclearance between the first clutch plates (Fig. 7-11). It isrecommended the gage be placed between thetransmission housing and the first steel plate. Theprescribed running clearance is 0.095 to 0.145 inch (2.41

Fig. 7.10. Checking low clutch clearance

to 3.68 mm). Any dimension within 0.095 to 0.145 inch(2. 41 to 3.68 mm) is satisfactory. However, the closerthe clearance is to 0.095 inch, the longer the intervalbetween clutch plate replacements will be. Clearancemust not be less than 0.095 inch. Replace worn clutchplates with new plates to establish the desired clearance.Recheck the clearance as described above.

b. Selecting Center Support Slapring

(1) Install thirteen second clutch plate s,beginning with an external-tanged plate. Alternatelyinstall seven external tanged plates and six internal-splined plates (Fig. 7-3).

(2) Install the clutch plate retaining snapring(Fig. 7-4). Be sure the snapring gap is at the top of thetransmission housing.

(3) Remove the third-clutch piston from the

center support assembly (if not previously removed).Install bracket 5 (Fig. 4-2) into the recess between thestep-joint sealrings on the center, support hub (Fig. 7-5).

(4) Install the center support into thetransmission housing (Fig. 7-5). Be sure the

775


44/56


ASSEMBLY

Fig. 7-11. Checking first clutch clearance

tapped hole in the support is aligned with the anchor bolthole in the bottom of the housing.

(5) Remove lifting bracket 5 (Fig. 4-2) fromthe center support, Install the special 3/8-16 x 2 1/4-inchanchor bolt into the support through the anchor bolt holein the bottom of the housing (Fig. 7-5). Tighten the boltfinger tight.

(6) Place compressor sleeve 7 (Fig. 4-2) onthe hub of the center support. Place compressor 8 (Fig.4-2) across the transmission housing Retain thecompressor bar with two bolts (Fig. 7-6)

(7) Compress the center support with a forceof 5 pound feet (6. 78 Nm) torque. Use gage 9 (Fig. 4-2) to determine the width of the snapring opening whilethe support is loaded (Fig. 7-6). The lugs of the gage arecolor coded to match the snapring colors. Select one ofthe snaprings listed below. Select the thickest snapringthat can be put into the groove.

Snapring color code Snapring thickness

Blue 0.148-0.150 in. (3.76-3.81 mm)Yellow 0.152-0.154 in. (3.86-3.91 mm)Green 0.155-0.157 in. (3.94-3.99 mm)Red 0.158-0.160 in. (4.01-4.06 mm)

(8) Install the snapring to retain thecenter support (selected in b(7), above). Be sure the

snapring gap is at the top of the transmission housing.

(9) Remove compressor 8 (Fig. 4-2) andsleeve 7.

c. Second Clutch Clearance

(1) Invert the transmission housing, rear coverside up.

(2) Remove the six bolts and washers thattemporarily retained the rear cover to the transmissionhousing. Remove the rear cover and gasket. (Refer tofigure 7-9.)

(3) Remove the thirteen low clutch plates fromthe adapter housing. (Refer to figure 7-21.) Since theseplates are preset for the low clutch running clearance,they should be maintained in a package form so theycannot be intermixed with other plates.

(4) Remove the adapter housing and gasketfrom the transmission housing. (Refer to figure 7-28.)

(5) Remove the thirteen first clutch platesfrom the transmission housing. These plates are nowpreset for proper clearance and should be maintained asa package for final installation.

(6) Using gage 44 (Fig. 4-3), check thesecond-clutch plate clearance (Fig. 7-7). It isrecommended the gage be placed between thetransmission housing and the first steel plate. Theprescribed running clearance is 0.095 to 0.145 inch (2.41to 3.68 mm). Any dimension within .095 to 0. 145 inch issatisfactory. However, the closer the clearance is to0.095 inch, the longer the interval between clutch platereplacements will be. Clearance must not be less than0.095 inch. Replace worn plates with new plates toestablish the desired clearance. Recheck the clearance

as described above.NOTE

Leave the second clutch and the centersupport in the transmission housing untilthe housing is again positioned front endupward. Begin assembly of Model HT750CRD at paragraph 7-6.

776


45/56


HT 700D SERIES TRANSMISSIONPara 7-6

Fig. 7-12. Installing first clutch plates

7-6. INSTALLING FIRST CLUTCH, GEAR UNIT,SECOND CLUTCH, CENTER S

TM 5-3805-254-14P-2 PART 8 IHC F-5070 DUMP TRUCK

Documents

Transcript of TM 5-3805-254-14P-2 PART 8 IHC F-5070 DUMP TRUCK