SECTION 6001 Semi-Powershift Transmission
SECTION 6001 Semi-Powershift Transmission
SECTION 6001 Semi-Powershift Transmission
SECTION 6001
SEMI–POWERSHIFT TRANSMISSION
CONTENT
Description Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Section 4000 Electrical
Removal – Installation – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2 SECTION 6001 – POWER TRAIN
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 3
TIGHTENING TORQUES
Tightening Torques
Thread Torque
size
Bolts and nuts, clutch/transm housing to engine . . . . . . . . . . . . . . . (see C3 and C4, page 2, Sec. 18)
Bolts, clutch/transm housing to rear axle housing . . . . . . . . . . . . . . M14 x 1.5 176 18
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4 SECTION 6001 – POWER TRAIN
67
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SECTION 6001 – POWER TRAIN 5
SPECIAL TOOLS
CAUTION
Operations described in this Section of the Manual
must be performed using the following ESSENTIAL
tools marked with the identification code (X).
To work safely and achieve the best technical results
with additional savings of time and effort, these
mandatory tools should be used in conjunction with
the suggested special tools listed below and
integrated with the self–made ones for which you will
find the necessary construction drawings and
specifications directly on this Manual.
Description Tool
Number
Overhaul rotary stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000301
Tractor Splitting Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAS.300009A
Transmission overhaul front bracket . . . . . . . . . . . . . . . . . . 380000271
(use with tool no. 380000301).
Transmission overhaul rear bracket . . . . . . . . . . . . . . . . . . 380000272
(use with tool no.380000301).
Output shaft spanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000459
Input shaft bearing puller (use with tool no. 50062). . . . . . 380000465 (X)
Output shaft tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000466 (X)
Range input and output shaft end play test tool . . . . . . . . 380000458
(use with tools nos. 380000568).
Output shaft bearing installer (use with tool no. 50108). . 380000460
Medium and Clutch C bearing adjustment tool. . . . . . . . . . 380000497 (X)
Clutch spring compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000291
Diagnostic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000488 (X)
Limp Home Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000489
Range gear output shaft retaining tool. . . . . . . . . . . . . . . . . 380000491
Range input and output shaft bearing adjustment tool. . . 380000568 (X)
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6 SECTION 6001 – POWER TRAIN
2
Tool to be fabricated for range input shaft taper bearing assembly (Mark tool with no. 50013 –
Dimensions in mm).
Fabricate tool using UNI C40 material. – Use only part (a).
25844
3 4
Tool to be fabricated for clutch B circlip assembly Tool to be fabricated for range output shaft bearing
(Mark tool with no. 50115 – assembly (Mark tool with no. 50061 –
( Dimensions in mm). (Dimensions in mm).
Fabricate tool using UNI C40 material. Make 3. Fabricate tool using C30 material.
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 7
107
53
60
5
Bracket to be fabricated to fix the transmission on
the rotary stand. Use with bracket tool no. 293971
(Mark tool with no. 50110 – Dimensions in mm).
Fabricate tool using Fe 42 C material.
25290
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8 SECTION 6001 – POWER TRAIN
25291
7
Alignment pins to be fabricated for engine and
speed clutch/transmission housing
removal/installation (Mark tool with no. 50117 –
Dimensions in mm).
Fabricate tool using UNI C40 material.
25292
8
Adapter to be fabricated for reverse idler gear pin
removal (Mark tool with no. 50143 –
Dimensions in mm).
Fabricate tool using UNI C40 material.
25280
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 9
10
Transmission Longitudinal and Cross Sections
1. Damper coupler. 17. Clutch E driven discs.
2. Clutch housing. 18. Clutch E housing.
3. Clutch A drive discs. 19. Clutch E drive discs.
4. Clutch A driven discs. 20. Belleville springs, clutches D and E.
5. Cover plate. 21. Clutch D housing.
6. Transmission input shaft adjust shim 22. Clutch C driven discs.
7. Transmission input shaft. 23. Clutch C drive discs.
8. Clutch D driven discs. 24. Clutch C housing.
9. Clutch D drive discs. 25. Clutch C Belleville springs.
10. Range gear input shaft. 26. Transmission driven gear end play adjust shim
11. Reverse idler gear. 27. Transmission driven shaft.
12. Range input shaft adjust shim. 28. Clutch B Belleville springs.
13. Range output shaft. 29. Clutch A Belleville springs.
14. Range output shaft adjust shim. 30. Range gear and transmission lubrication control line.
15. Medium range and reverse control synchroniser. 31. Valve spring (32).
16. Low and high range control synchroniser. 32. Lubrication pressure regulation valve
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10 SECTION 6001 – POWER TRAIN
a
b
11
Range Control Valve Assembly Sections and Views
A. Top view. 8. Low pressure regulation valve.
B. Bottom view. 9. Valve (8) spring.
1. Reverse solenoid valve. 10. Pressure sensor.
2. High range solenoid valve. 11. PTO brake solenoid valve.
3. Low range solenoid valve. 12. FWD solenoid valve.
4. Medium range solenoid valve. 13. Circlips.
5. Diff lock solenoid valve. 14. Piston housing.
6. PTO solenoid valve. 15. Range drive pistons.
7. Valve. 16. By–pass valve.
NOTE: During installation apply liquid gasket, Loctite 574 on surfaces marked with an X as detailed on page
46.
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 11
12
SEMI–POWERSHIFT Transmission Control Valve Assembly Sections and Views
C1. Semi–powershift control valve retaining screw, 3. Pressure test port – Clutch C.
24.5 Nm (2.5 kgm). 4. Pressure test port – Clutch A.
C2. Solenoid valve pin retaining screw, 14.9 to 20.3 Nm 5. Pressure test port – Clutch B.
(1.520 to 2.071 kgm). 6. Clutch A control solenoid valve.
C3. Solenoid valve retaining screw, 1.72 to 2.79 Nm 7. Clutch B control solenoid valve.
(0.175 to 0.285 kgm). 8. Clutch C control solenoid valve.
1. Pressure test port – Clutch E. 9. Clutch D control solenoid valve.
2. Pressure test port – Clutch D. 10. Clutch E control solenoid valve.
NOTE: Apply a couple of drops of Thread Seal, Loctite 542 to screws C2 and C3 .
6–66000 – 06 – 2002
12 SECTION 6001 – POWER TRAIN
A
B H
C D E R M
L
BSD2247A
1 2
13
The SEMI–POWERSHIFT transmission is CLUTCH C D E
subdiviced into a speed (1) and range (2) sections
providing 6 speed gears in each of 3 ranges:– A 1 3 5
18 forward X 6 reverse ratios on the 40kph option B 2 4 6
or
The range section consists of 3 forward and 1
17 forward X 6 reverse ratios on the 30kph option reverse set of constant mesh gears each
where the18 gear is electronically blocked. electro–hydraulically selected giving low (L) medium
The mechanical components within these (M) and high (H) ranges as well as reverse (R)
transmissions do not differ and the number of gears Clutch design allows shifting from one speed into
and therefore the maximum speed of the tractor is another when the tractor is moving. Clutches are
controlled by the electronic transmission control operated by the control oil from the respective
module (TCM) solenoid valves located into the control valve
When the optional creeper gear is fitted their are:– assembly attached to the right side of the
31 forward and 12 reverse ratios on the 40kph transmission housing.
option. The range gears are operated by two hydraulic
30 forward and 12 reverse ratios on the 30kph cylinders acting on two synchronisers. Hydraulic
option. cylinders are actuated by control oil from the
respective solenoid valves located into the control
The speed section of the semi powershift
valve assembly attached to the right side of the
transmission is actuated by 5 multiplate hydraulic
transmission housing.
clutch packs A, B, C, D and E which provide the 6
speeds for each of three ranges
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SECTION 6001 – POWER TRAIN 13
15
Typical examples for oil flow during engagement of
clutches, lubrication of transmission components
and power flows through both the speed and range
gears are shown on the following pages:–
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14 SECTION 6001 – POWER TRAIN
1 2
A
B
C D E
4 3
BSD2261A
16
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 15
1 2
A
B
C D E
4 3
BSD2261B
17
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16 SECTION 6001 – POWER TRAIN
A
B H
C D E R M
L
BSD2247B
18
Power Flow 1st Gear Medium Range–Forward
A and C Clutches Engaged
1. A Clutch 6. High Range
2. B Clutch 7. Low Range
3. C Clutch 8. Reverse Range
4. D Clutch 9. Medium Range
5. E Clutch
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SECTION 6001 – POWER TRAIN 17
A
B H
C D E R M
L
BSD2247C
19
Power Flow 2nd Gear Medium Range–Forward
B and C Clutches Engaged
1. A Clutch 6. High Range
2. B Clutch 7. Low Range
3. C Clutch 8. Reverse Range
4. D Clutch 9. Medium Range
5. E Clutch
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18 SECTION 6001 – POWER TRAIN
A
B H
C D E R M
L
BSD2247D
20
Power Flow 2nd Gear Medium Range–Reverse
B and C Clutches Engaged
1. A Clutch 6. High Range
2. B Clutch 7. Low Range
3. C Clutch 8. Reverse Range
4. D Clutch 9. Medium Range
5. E Clutch
NOTE: Reverse gears are only available in Medium
Range.
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SECTION 6001 – POWER TRAIN 19
LIMP HOME
1
WARNING
Care should be taken when operating the tractor with
the limp home harness connected. Clutch
engagement will be harsher than normal. Do not
leave the limp home harness connected when the
operation has been completed.
2
In the unlikely event of an electrical fault developing
within the transmission that renders the tractor
immobile, for example, failure of the supply voltage
to the PWM valves, the emergency ‘Limp Home
Harness’, Special Tool No. 380000489 for
21
Semi–Powershift transmissions, is available to
enable the tractor to be driven onto a transporter or
hard standing, in order that the repair can be carried
out in a suitable location. The Limp Home device is
not and must not be used as a means to continue
operating the tractor in its work environment.
To engage and operate the ‘Limp Home Harness’
proceed as follows:–
22
5.Connect the limp home harness connector,
marked with ‘HARNESS’, into the rear main
harness of the tractor.
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20 SECTION 6001 – POWER TRAIN
PRESSURE TESTING
Transmission Clutches, A,B,C,D and E
24
(iii)Start and run the tractor to warm the transmission
oil to a minimum operating temperature of 50°C
(122°F).
25
2. Install suitable pressure gauges (0–40bar,
0–600 lbf.in2), five if available, into each of the E D C
A B
TA6021003
26
1. Pressure gauge with adaptor
2. Adaptor (10–1.00 mm x 7/16 JIC)
3. Hose
27
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SECTION 6001 – POWER TRAIN 21
28
4. To select other clutches, B, C ,D or E, repeatedly
press the upshift switch and then depress the
downshift control to energise the solenoid.
29
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22 SECTION 6001 – POWER TRAIN
TIA35159
30
Figure 31 –1. Low synchroniser test point
2. Medium synchroniser test point
2
TIA355160
31
1. Prepare the tractor for pressure testing:
32
2. Install suitable (0–40bar, 0–600 lbf.in2) pressure
gauges, four if available, into each of the
synchroniser pressure test points, located in the
transmission side cover, Figure 33.
1. Pressure gauge with adaptor
2. Adaptor (10–1.25 mm x 7/16 JIC)
3. Hose
TA6021013
33
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SECTION 6001 – POWER TRAIN 23
34
7. Depress the downshift control to activate all of
the synchroniser solenoids.
35
8. Each gauge should indicate 17±1 bar when the
solenoids are activated and zero when
de–activated.
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24 SECTION 6001 – POWER TRAIN
40
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SECTION 6001 – POWER TRAIN 25
41
If ‘CL’ or ‘CH’ are displayed after 4 seconds the
display will return to oil temperature and the tractor
may be operated to obtain the correct transmission
oil temperature. If it is not practical to wait for the oil
temperature to change press either of the upshift or
down shift switch while ‘CL’ or ‘CH’ is being
displayed. The display will then show an ‘A’ and
calibration can proceed.
43
Release the downshift switch, the display will change
to ‘b’, indicating that clutch B is ready for calibration.
44
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26 SECTION 6001 – POWER TRAIN
45
Pressing the downshift switch again will select mode
‘N’. This mode engages clutches A and C with the
synchronisers in neutral. This can be used to ‘free’
transmission components that may be suspected of
sticking , i.e,synchronisers.
WARNING
It should be noted that if a synchroniser is not actually
in neutral, this mode can cause the tractor to move.
46
Turn the key start switch off for at least 10 seconds to
store the calibration values.
48
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SECTION 6001 – POWER TRAIN 27
SEMI–POWERSHIFT
TRANSMISSION HOUSING
Removal – Installation
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity.Ensure that units
or parts are supported by suitable slings or
hooks.Ensure that no–one is in the vicinity of the load
to be lifted.
49
3. If the auxillary fuel tank is fitted, remove the clip
(1). Remove auxillary tank.
50
4. Remove engine as described in Section 10.
5. To drain the oil from the transmission. Remove
plug (1).
51
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28 SECTION 6001 – POWER TRAIN
52
53
8. Detach and remove the PTO and lift lubrication
tubes (3) and (4).
54
9. Detach and remove the power steering supply
and return lines (1 and 2).
55
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SECTION 6001 – POWER TRAIN 29
56
11. Loosen two bolts from the transmission housing
top cover, attach lifting chains to the housing and
keep them tensioned using a hoist.
12. Place a stationary stand under the draft sensing
unit bracket. Place the trolley jack of stand tool
no. CAS.30009A under the rear axle housing.
13. Detach the transmission housing retaining bolts
and remove the housing.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.
57
14. Fix the transmission housing on the rotary stand
tool no. 380000301 using front and rear
brackets, tools nos. 380000271 (1) and
380000272 (2), respectively.
58
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30 SECTION 6001 – POWER TRAIN
20270
59
Pattern for application of sealant during installation of the speed clutch–transmission housing to rear axle
housing.
Installation
1. Reinstall the transmission housing to the rear
axle housing and engine observing the following:
– Reinstallation follows the removal procedure
in reverse.
– Before reassembling housings, supports
and covers, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown.
– Tighten to correct torques as detailed on
page 3.
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SECTION 6001 – POWER TRAIN 31
SEMI–POWERSHIFT TRANSMISSION
Disassembly–Reassembly
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.
60
3. Detach the line (3) from transmission control
valve assembly and transmission housing.
61
4. Loosen the transmission control valve housing
retaining screws (4) and remove housing
62
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32 SECTION 6001 – POWER TRAIN
63
6. Loosen retaining screws and remove the range
control valve assembly (1) using a 80 mm long
bolt as an alignment pin.
64
7. Remove retainer nuts and support plate and slide
out the potentiometers(1).
65
8. Loosen retaining bolts and remove sensors (1
and 2).
66
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 33
67
10. Loosen the bolts attaching the clutch A cover (3)
to the transmission housing. Insert three bolts (4)
into the threaded holes and screw them in until
detaching the cover (3) along with clutch A from
the transmission housing.
68
11. Remove circlip (5) and retrieve clutch discs and
centering springs.
69
12. Assemble tool no. 380000291 (6) on clutch B
housing, turn the tool bolt to compress clutch B
release Belleville springs and remove spring
retaining ring. Remove tool from the bell housing
and retrieve Belleville springs.
13. Blow compressed air into the oil supply hole to
clutch B to expel the clutch drive piston.
70
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34 SECTION 6001 – POWER TRAIN
71
15. Loosen the cover (1) retaining screws. Using a
plastic hammer engage the Medium/reverse
synchroniser with the medium gear. Place tool
no. 380000491 (2) on the transmission housing,
loosen the output shaft locknut using spanner
tool no. 380000459 (3). Return the
Medium/reverse sychroniser to the neutral
position. Retrieve cover.
72
16. Remove retaining bolts and detach the range
gear output and input shaft bearing cap (1).
73
17. Using a puller tool no. 38000542 (1) and a
suitable insert, remove the medium range driven
gear, bearing and bush.
74
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 35
75
19. Loosen the plugs (3) and retrieve springs and
actuating balls. Remove plug from the
transmission housing and withdraw the medium
and reverse control fork lock pin.
76
20. Slide out the range selector dog (4) retaining
spring pins and remove rails.
77
21. Remove the medium and reverse control fork (1)
along with the synchroniser (2).
78
6–66000 – 06 – 2002
36 SECTION 6001 – POWER TRAIN
79
23. Loosen the reverse idler gear shaft setscrew (5).
80
24. Using adapter m10x1.25 adaptor (7) and slide
puller (6) remove the reverse idler gear shaft (8).
81
25. Slide out the low range driven gear (1).
82
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 37
26. Remove the low and high range control fork (4),
synchroniser (3) and output shaft (2).
23476
83
27. Remove input shaft (5).
84
28. Remove the position sensor control forks (6).
Retrieve bushings and seals at the outside of the
transmission housing.
85
29. Loosen the retaining screws and remove the
front cover plate (1).
86
6–66000 – 06 – 2002
38 SECTION 6001 – POWER TRAIN
30. Slide out the drive gear (2) and bearing. (3).
87
31. Remove the ring (4) retaining the gears on the
input shaft.
88
32. Slide out the input shaft (5) with the bearing inner
races from the opposite side of the housing.
Retrieve gears, thrust washer and adjustment
shim.
89
33. Install tool no. 380000466 (1) on the output shaft,
insert a spanner (2) to hold the shaft in position,
screw tool no. 380000465 (3) to the housing and
tighten the tool screw to support the tool.
90
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 39
91
35. Withdraw the manifold (4) and bearing thrust
washer from the output shaft. Detach tool no.
380000465 (3), spanner (2) and tool no.
380000466 (1) from rear side.
92
36. Remove the output shaft (5) seals and, using an
aluminium punch and a hammer, partially
remove the shaft.
93
37. Turn the transmission housing upright, withdraw
the output shaft (1) and retrieve the
clutch/gear/bearing assembly along with the
bearing.
94
6–66000 – 06 – 2002
40 SECTION 6001 – POWER TRAIN
95
39. Detach the fitting from the housing and slide out
the lubrication line from the inside of the
transmission housing.
96
40. Dismantle the clutch C by removing the circlip (3)
and collecting the clutch driven and drive discs.
97
41. Fix tool no. 380000291 (1) to the clutch bell
housing, screw in the tool bolt until compressing
the Belleville springs, then remove the spring
retaining ring. Loosen tool bolt, retrieve Belleville
springs and detach tool from the clutch bell
housing.
98
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 41
99
44. Remove the retaining ring (1), the bearing inner
lock ring and retrieve the hubs of the clutches A
and B along with the bearing and clutch A discs
and centering springs.
100
45. Remove seal (3).
101
46. Remove the outer (4) and inner circlips from the
outside of clutch A (5), withdraw clutch A from the
cover. Retrieve the bearing.
102
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42 SECTION 6001 – POWER TRAIN
103
48. Place the clutch A housing on the cover (2), blow
compressed air into the control oil inlet hole and
remove the piston (1).
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 43
105
51. While assembling clutches C, D, and E and their
shafts to the transmission housing, take care to
match reference marks (1).
106
52. Install front bearing (7) using tools no. 50108 (6)
and 380000460 (5).
107
53. After installing the components of the output
shaft, lock the shaft with the nut. Temporarily
install the front cover (9) and install the supply
tubes (8).
108
6–66000 – 06 – 2002
44 SECTION 6001 – POWER TRAIN
54. Blow compressed air into the lines (1) and check
for correct operation of the clutches C, D, and E.
After this test, remove lines (1) and detach front
cover. Install the input shaft complete with its
accessory parts. After installing the front cover
and tightening attaching bolts, perform again the
above test to check that there are no leaks from
the manifold.
109
55. Upon reassembly of the clutch A, install the
bearing (1), then raise the hub (8) using a 1
suitable tool and insert the circlip (10).
10
8
110
56. When reinstalling the circlip (1) on to the clutch
cover (8), check that the oil leak–off hole (7) is
exactly in the middle of the outer circlip ends.
111
57. To assist assembly of clutch B disc retaining ring,
insert two suitable dowels (1) into two oil
discharge holes to keep the clutch centering
springs compressed.
112
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 45
113
59. With the clutch A housing assembled to the
transmission housing, install the bearing (7)
using tool no. 380000460. Fix bearing with the
retaining rings and install the seal.
114
60. Heat and install the bearing (3) on to the input
shaft using tool no. 50060 (2) shown on page 8.
Using tool no. 50013 (1) (see page 7), keep the
bearing properly seated against the gear during
cooling.
115
61. Heat and install the bearing (1) on to the output
shaft using tool no. 50061 (2) shown on page 7.
Using tool no. 50018 (1) (see page 6), keep the
bearing properly seated against the gear during
cooling.
NOTE: Remove tools nos. 50060 (2, Fig. 115) and
50061 (2, Fig. 116) when the bearings (3 and 1) have
completely cooled down.
116
6–66000 – 06 – 2002
46 SECTION 6001 – POWER TRAIN
117
Pattern for application of sealant during installation of: range control valve housing, top cover, front cover of
clutches A and B.
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 47
TRANSMISSION HOUSING
Proceed as follows:
62. Place the transmission input shaft (1) on a bench,
slide on the gear (6), spacer (5), a 3.5 mm test
shim (4), gear (3). Lock the assembly with a
circlip (2).
63. Settle the assembly. Using a feeler gauge (7),
measure the end play between the circlip (2) and
gear (3).
64. Shim to be assembled is given by the measured
dimension plus the test shim minus the specified
end play.
Example:
119
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48 SECTION 6001 – POWER TRAIN
TRANSMISSION HOUSING
Transmission driven gear bearing adjustment
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.
Proceed as follows:
1. Assemble the ’C’ clutch hub to the special tool,
No 380000497, complete with bearings, spacer
and original shim. Tighten the bolt of the special
tool to 140 Nm.
120
2. Wrap a length of string around the smaller of the
two gears and attach to a suitable spring
balance. Measure the rolling resistance of the
bearings during rotation, not at the point where
rotation begins.
3. The rolling resistance should equate to
0.5–0.8Kg on the spring balance. If outside the
specification install a thinner shim to increase the
resistance or install a thicker shim to reduce the
resistance.
121
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 49
TRANSMISSION HOUSING
Proceed as follows:
4. Install cover (2) without adjust shim. Install tool
no. 50013 (1) on to the input shaft (see page7).
122
5. Screw installer tool no. 380000458 (2) on tool no.
50013 (3). Place a dial indicator (1) with the
stylus touching the bearing inner race. Turn the
shafts to settle the bearing rollers, reset dial to
zero ensuring that the assembly is bottoming.
Through the lever of installer tool no. 380000458
(2). bring the assembly to touch the cover (4) and
read the travel (L) on the dial indicator.
Adjust shim to be added is given by:
S = L – (0 to 0.06 mm)
where:
S = Test shim.
L = Travel reading.
0 to 0.06 mm =Input shaft bearing end play.
123
NOTE: Available adjust shims for the range input
shaft bearings are listed on page 3.
6. Dismantle tools (2 and 3), remove cover (4),
assemble the shim as previously found, reinstall
cover (4) and tools (2 and 3). Repeat step 73 to
check that end play is to specification, 0 to 0.06
mm.
Remove tools (2 and 3).
6–66000 – 06 – 2002
50 SECTION 6001 – POWER TRAIN
where:
S1 = Adjust shim.
Sp = Test shim.
H = Travel reading.
0 to 0.06 mm = Output shaft bearing end play.
NOTE: Available adjust shims for the range output
shaft bearings are listed on page 3.
8. Dismantle tools (3 and 4), remove disc (1),
replace test shim (Sp) with adjust shim (S1),
reinstall disc (1) and tools (3 and 4). Repeat step
75 to check that end play is to specification, 0 to
0.06 mm. Remove tools (3 and 4) and screw in
the output shaft lubrication plug.
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 51
Removal – Installation
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity.
Ensure that units or parts are supported by suitable
slings or hooks.
Ensure that no–one is in the vicinity of the load to be
lifted.
125
3. Detach and remove the accumulator (2) tubes.
126
4. Loosen the retaining screws and remove
accumulator (shown with auxillary tank removed
for clarity).
127
6–66000 – 06 – 2002
52 SECTION 6001 – POWER TRAIN
128
6. Disconnect all accessory control lines from their
fittings located in the lower part of the range
control valve housing (1).
129
7. Remove PTO and lift lubrication line fittings (3
and 4), loosen retaining screws and remove the
SEMI–POWERSHIFT range control valve
assembly (3) using two alignment pins.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.
130
8. Reinstall the SEMI–POWERSHIFT range
control valve assembly to the transmission
housing observing the following:
– Installation follows the removal procedure in
reverse.
– Before reassembling the
SEMI–POWERSHIFT range control valve
assembly thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the
figure on page 46.
– Tighten to correct torques as detailed on
page 3.
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 53
Disassembly–Reassembly
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.
131
2. Remove the fitting (1).
132
3. Remove the regulated low pressure sensor.
133
6–66000 – 06 – 2002
54 SECTION 6001 – POWER TRAIN
134
5. Remove the FWD pressure sensor (1), and the
differential lock sensor pressure (2).
135
6. Remove the hydraulic fitting (1) and retrieve the
coller bypass valve, and spring.
136
7. Loosen retaining bolts and remove the range
synchroniser drive pistons (1).
137
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 55
138
9. Remove the retaining ring (1). Remove the
sliding guide cover, inner ring and piston.
139
10. Using a suitable punch, drive out the inner
retaining ring (2) and retrieve inner ring.
140
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56 SECTION 6001 – POWER TRAIN
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 57
Replacement
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.
142
3. Detach connector (1) from the solenoid valve.
143
4. Loosen the retaining nut (2) and remove the
solenoid (3).
144
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58 SECTION 6001 – POWER TRAIN
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 59
SEMI–POWERSHIFT TRANSMISSION
CONTROL VALVE ASSEMBLY
146
3. Loosen the bolt attaching the steps (6) to the
bracket.
147
4. Loosen the bolt and nut attaching the steps (1) to
the cab platform.
148
6–66000 – 06 – 2002
60 SECTION 6001 – POWER TRAIN
149
6. Loosen the clamp and detach the tube (3)
between the main and auxiliary tanks.
7. Detach the fuel return line (2) from the pump to
the auxiliary tank. Remove the auxiliary tank.
150
8. Detach all connectors (4) from the
SEMI–POWERSHIFT clutch control solenoid
valve assembly.
NOTE: Before detaching connectors from the control
valve housing, mark each connector and respective
solenoid valve to assist reassembly and avoid
reversal of connections.
151
9. Disconnect lines (5 and 6), loosen retaining
screws and remove the control valve housing.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.
6–66000 – 06 – 2002
SECTION 6001 – POWER TRAIN 61
SEMI–POWERSHIFT TRANSMISSION
SOLENOID VALVE
Replacement
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.
153
3. Loosen the screw attaching the steps (6) to the
bracket.
154
4. Loosen the screw attaching the steps (1) to the
cab platform.
155
6–66000 – 06 – 2002
62 SECTION 6001 – POWER TRAIN
156
6. Detach the fuel return line (2) from the pump to
the auxiliary tank. Remove the auxiliary tank.
157
7. Detach connector (4) from the solenoid valve to
be replaced.
158
8. Unscrew the locknut (1), remove washer (2) and
solenoid coil (3). Then unscrew the solenoid (4).
9. Reinstall the solenoid valve into the
SEMI–POWERSHIFT transmission control
valve assembly observing the following:
– Reinstallation follows the removal procedure
in reverse, from step 10 back to step 1.
– Check seals and replace if damaged.
– Tighten to correct torques as detailed on
page 11.
159
6–66000 – 06 – 2002