Dana T2000 6 Speeds Long Drop Service Manual

Maintenance and Service Manual
T20000
Powershift Transmission
3 & 6 SPEED LONG DROP WITH RANGE SHIFT
SPICER OFF HIGHWAY-PRODUCTS
814982
TOWING OR PUSHING
Before towing the vehicle, be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing.
Note IF THE TRANSMISSION HAS 4 WHEEL DRIVE, DISCONNECT BOTH FRONT AND REAR DRIVELINES. BECAUSE OF THE DESIGN OF THE HYDRAULIC SYSTEM, THE ENGINE CANNOT BE STARTED BY PUSHING OR TOWING.
Copyright
DANA CORPORATION 1990. Unpublished material.
All rights reserved. Limited Distribution. No part of this work may be reproduced in any form under any means without direct written permission of the DANA CORPORATION.
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FOREWORD
This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF-HIGHWAY PRODUCTS product. Extreme care has been exercised in the design, selection of materials, and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, troubleshooting and adjustments, it is urged that the mechanic studies the instructions in this manual carefully and uses it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only SPICER OFF-HIGHWAY PRODUCTS approved parts as listed in the applicable parts manual should be used. Use of will-fit or non-approved parts may endanger proper operation and performance of the equipment. SPICER OFF-HIGHWAY PRODUCTS does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by SPICER OFF-HIGHWAY PRODUCTS .
IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS. When checking the difference between a 6-speed with range shift, a 3-speed standard ratio and a 3-speed deep ratio, you would notice that the difference is only on the idler and the output shaft. A 3-speed standard is similar to a 6-speed with range shift when high range is selected. While a 3-speed deep ratio is similar to a 6-speed with range shift when low range is selected. For this reason, we will use the 6-speed with range shift in most cases to explain the function of the 3 different transmissions.
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3-SPEED STANDARD RATIO
FWD
REV
2ND
1ST
3RD
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3-SPEED DEEP RATIO
FWD
REV
2ND
1ST
3RD
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6-SPEED RANGE SHIFT
FWD
REV
2ND
1ST
3RD
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Table of Contents
1. SAFETY PRECAUTIONS
2. CLEANING, INSPECTION AND LEGEND SYMBOLS

2.1 CLEANING .............................................................................................................................. 2-1 2.1.1 Bearings ..................................................................................................................... 2-1 2.1.2 Housings ..................................................................................................................... 2-1 2.2 INSPECTION ........................................................................................................................... 2-1 2.2.1 Bearings ..................................................................................................................... 2-1 2.2.2 Oil Seals, Gaskets, Etc. .............................................................................................. 2-2 2.2.3 Gears and Shafts ........................................................................................................ 2-2 2.2.4 Housing, Covers, etc. ................................................................................................. 2-2 2.3 LEGEND SYMBOLS ................................................................................................................ 2-2
3. TECHNICAL SPECIFICATIONS
3.1 IDENTIFICATION OF THE UNIT ............................................................................................. 3-1 3.2 WEIGHT, DIMENSIONS, OIL CAPACITY ................................................................................ 3-1 3.3 TIGHTENING TORQUES ........................................................................................................ 3-2 3.3.1 Torque specifications for lubricated or plated screw threads ..................................... 3-2 3.3.2 Elastic stop nut torque ................................................................................................ 3-3 3.3.3 O ring port plug torque chart .................................................................................... 3-3 3.3.4 Pipe plug torque chart ................................................................................................ 3-3 3.3.5 Permanent metric plug torque chart ........................................................................... 3-3 3.3.5 Coil and cartridge torque ............................................................................................ 3-4 3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS .......................................................... 3-5 3.5 ELECTRICAL SPECIFICATIONS ............................................................................................ 3-6 3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS ............................................... 3-6
4. MAINTENANCE
4.1 OIL SPECIFICATION .............................................................................................................. 4-1 4.1.1 Recommended lubricants ........................................................................................... 4-1 4.2 MAINTENANCE INTERVALS .................................................................................................. 4-3 4.2.1 Daily ............................................................................................................................ 4-3 4.2.2 Normal drain period .................................................................................................... 4-3 4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL ................................................ 4-4
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5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING .......................................................................................... 5-1 5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE ............................................... 5-2 5.3 EXTERNAL PLUMBING .......................................................................................................... 5-3 5.3.1 Optional: remote filter ................................................................................................. 5-3 5.3.2 Cooler & filter lines specifications ............................................................................... 5-3 5.4 SPEED SENSOR INSTALLATION ........................................................................................... 5-4
6. OPERATION OF THE TRANSMISSION

6.1 THE TRANSMISSION ASSEMBLY ......................................................................................... 6-1 6.1.1 The converter, pump drive section and pressure regulating valve ............................. 6-2 6.1.2 The input shaft and directional clutches ..................................................................... 6-3 6.1.3 The range clutches ..................................................................................................... 6-4 6.1.4 The output section ...................................................................................................... 6-4 6.1.5 The transmission controls (refer to hydraulic diagram) ............................................... 6-5 6.2 ELECTRIC SOLENOID CONTROLS ...................................................................................... 6-6 6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT 6.3.1 Neutral, 3rd clutch engaged and high range selected ................................................ 6-7 6.3.2 Forward 1st speed and high range selected .............................................................. 6-9 6.3.3 Forward 2nd speed and high range selected ........................................................... 6-11 6.3.4 Forward 3rd speed and high range selected ............................................................ 6-13 6.3.5 Reverse 1st speed and high range selected ............................................................ 6-15 6.3.6 Forward 1st speed and low range selected .............................................................. 6-17 6.4 GEAR AND CLUTCH LAY-OUT ............................................................................................. 6-19 6.4.1 3-Speed with standard ratio ...................................................................................... 6-19 6.4.2 3-Speed with deep ratio ............................................................................................ 6-20 6.4.2 6-Speed with range shift ........................................................................................... 6-21
7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION

7.1 T20000 TRANSMISSION ........................................................................................................ 7-1 7.2 TROUBLESHOOTING PROCEDURES .................................................................................. 7-1 7.2.1 Stall Test ..................................................................................................................... 7-1 7.2.2 Transmission pressure checks ................................................................................... 7-2 7.2.3 Mechanical and electrical checks ............................................................................... 7-2 7.2.4 Hydraulic checks ........................................................................................................ 7-2 7.3 TROUBLESHOOTING GUIDE ................................................................................................ 7-3 7.3.1 Low clutch pressure .................................................................................................... 7-3 7.3.2 Low charging pump output ......................................................................................... 7-3 7.3.3 Overheating ................................................................................................................ 7-3 7.3.4 Noisy converter ........................................................................................................... 7-3 7.3.5 Lack of power ............................................................................................................. 7-3 7.4 CHECK POINTS ...................................................................................................................... 7-4 7.5 SPEED SENSOR - STATIC STANDALONE TEST .................................................................. 7-7
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8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

GROUP - CONVERTER HOUSING ................................................................................................ 8-2 GROUP - TRANSMISSION CASE AND REAR COVER ................................................................. 8-4 GROUP - TURBINE SHAFT ............................................................................................................ 8-6 GROUP - DRIVE PLATE .................................................................................................................. 8-8 GROUP - TORQUE CONVERTER ................................................................................................ 8-10 GROUP - AUXILIARY PUMP DRIVE ............................................................................................. 8-12 GROUP - PUMP DRIVE ................................................................................................................ 8-14 GROUP - FORWARD SHAFT ........................................................................................................ 8-16 GROUP - REVERSE AND 2ND SHAFT ........................................................................................ 8-18 GROUP - REVERSE IDLER .......................................................................................................... 8-20 GROUP - LOW SPEED SHAFT ..................................................................................................... 8-22 GROUP - 3RD SHAFT ................................................................................................................... 8-24 GROUP - IDLER SHAFT (USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO) .................... 8-26 GROUP - IDLER SHAFT (USED IN 3 SPEED STANDARD RATIO) ............................................. 8-28 GROUP - OUTPUT SHAFT (6 SPEED) ........................................................................................ 8-30 GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO) ......................................................... 8-32 GROUP - OUTPUT SHAFT ( 3 SPEED DEEP RATIO) ................................................................. 8-34 GROUP - HI & LOW RANGE SHIFT CONTROL ........................................................................... 8-36 GROUP - CHARGING PUMP & FILTER ....................................................................................... 8-38 GROUP - ELECTRIC CONTROL VALVE MOUNTING .................................................................. 8-40 GROUP - ELECTRIC CONTROL VALVE ASSEMBLY ................................................................... 8-42
9. ASSEMBLY INSTRUCTIONS
10. DISASSEMBLY AND REASSEMBLY T20000 LD TRANSMISSION
11. OPTIONS
11.1 HYDRAULIC ACTUATED AXLE DISCONNECT ................................................................... 11-1 11.1.1 Sectional views and parts identification .................................................................... 11-1 11.1.2 Assembly instructions ............................................................................................... 11-4 11.1.3 Disassembly of output shaft with axle disconnect .................................................... 11-5 11.1.4 Reassembly of output shaft with axle disconnect ..................................................... 11-8 11.1.5 Disassembly of axle disconnect ............................................................................. 11-11 11.1.6 Reassembly of axle disconnect .............................................................................. 11-14 11.2 PARKING BRAKES ............................................................................................................. 11-18 11.2.1 Mechanical Brake ................................................................................................... 11-18 11.2.1.1 Sectional views and parts identification ....................................................... 11-18 11.2.1.2 Adjustment and rebuild criteria .................................................................... 11-23 11.2.1.3 Replacing friction pads ................................................................................ 11-23 11.2.1.4 Disassembly ................................................................................................. 11-24 11.2.1.5 Cleaning and inspection .............................................................................. 11-24 11.2.1.6 Assembly ..................................................................................................... 11-25 11.2.1.7 Replacing mount bushings .......................................................................... 11-25 11.2.1.8 Servicing rotor assembly ............................................................................. 11-25
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11. OPTIONS (Continued)

11.2.2 Spring applied hydraulic released brake (high pressure) ....................................... 11-26 11.2.2.1 Sectional views and parts identification ....................................................... 11-26 11.2.2.2 Operation ..................................................................................................... 11-31 11.2.2.3 Adjustment and rebuild criteria .................................................................... 11-31 11.2.2.4 Replacing friction pads ................................................................................ 11-31 11.2.2.5 Disassembly................................................................................................. 11-31 11.2.2.6 Cleaning and inspection .............................................................................. 11-32 11.2.2.7 Assembly ..................................................................................................... 11-32 11.2.2.8 Installation .................................................................................................... 11-33 11.2.2.9 Torque specs ............................................................................................... 11-33 11.2.3 Spring applied hydraulic released brake (low pressure) ......................................... 11-34 11.2.3.1 Sectional views and parts identification ....................................................... 11-34 11.2.3.2 Operation ..................................................................................................... 11-39 11.2.3.3 Adjustment and rebuild criteria .................................................................... 11-39 11.2.3.4 Replacing friction pads ................................................................................ 11-39 11.2.3.5 Disassembly................................................................................................. 11-39 11.2.3.6 Cleaning and inspection .............................................................................. 11-40 11.2.3.7 Assembly ..................................................................................................... 11-40 11.2.3.8 Installation .................................................................................................... 11-41 11.2.3.9 Torque specs ............................................................................................... 11-41
12. SERVICE TOOLS

12.1 REVERSE IDLER SHAFT NUT SOCKET (TG 1304-54)
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1. SAFETY PRECAUTIONS
To reduce the chance of personal injury and/or property damage, the following instruction must be carefully observed. Proper service and repair are important to the safety of the service technician and the safe, reliable operation of the machine. If replacement parts are required the part must be replaced by a spare part which has the same part number or with an equivalent part. Do not use a spare part of lesser quality. The service procedures recommended in this manual are effective methods for performing service and repair. Some of these procedures require the use of tools specifically designed for the purpose. Accordingly, anyone who intends to use a spare part, service procedure or tool, which is not recommended by SPICER OFF-HIGHWAY PRODUCTS, must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the spare part, service procedure or tool selected.
IMPORTANT IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS CAUTIONS AND NOTICES THAT MUST BE
CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR, OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE.
IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE CAUTIONS AND NOTICES ARE

FROM FAILURE TO FOLLOW THESE INSTRUCTIONS.
NOT EXHAUSTIVE,
BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL THE POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT
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2. CLEANING, INSPECTION AND LEGEND SYMBOLS

2.1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned.
CAUTION CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS, AND INHALATION OF VAPOURS WHEN USING
SOLVENT TYPE CLEANERS.
2.1.1 Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process. 2.1.2 Housings Clean interior and exterior of housings, bearing caps, etc, thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaner.
CAUTION CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN USING ALKALI CLEANERS. All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft, lintless absorbent wiping rags free of abrasive materials such as metal fillings, contaminated oil, or lapping compound.
2.2 INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date. 2.2.1 Bearings Carefully inspect all rollers: cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed.
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Cleaning, inspection and legend symbols
2.2.2 Oil Seals, Gaskets, Etc. Replacement of spring load oil seals, O-rings, metal sealing rings, gaskets, and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. When assembling new metal type sealing rings, these should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members. Lubricate all O-rings and seals with recommended type Automatic Transmission Fluid before assembly. 2.2.3 Gears and Shafts If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are true. 2.2.4 Housing, Covers, etc. Inspect housings, covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces, bearing bores, etc, are free from nicks or burrs. Check all parts carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures.
2.3 LEGEND SYMBOLS

Smontaggio di sottogruppi Disassembly of assembly groups Montaggio di sottogruppi Reassemble to from assembly group Smontaggio di particollari ingombranti Remove obstruction parts Montaggio di particollari ingombranti Reinstall - remount parts which had obstructed disassembly Attenzione, indicazione importante Attention! important notice Controllare regolare p.e. coppie, misure, pressione etc. Check - adjust e.g. torque, dimensions, pressures etc. T = Attrezzature speciali T = Special tool P = Pagina Sostituire con ogni montaggio Renew at each reassembly Togliere - mettere la sicura Unlock - lock e.g. split pin, locking plate, etc. Mettere la sicura, incollare (mastice liquido) Lock - adhere (liquid sealant) Evitare danni ai materiali, danni ai pezzi Guard against material damage, damage to parts Marchiari prima dello smontaggio (per il montaggio) Mark before disassembly, observe marks when reasembl. Carricare riempire (olio - lubrificante) Filling - topping up - refilling e.g. oil, cooling water, etc. Scarricare olio, lubrificante Drain off oil, lubricant Tendere Tighten - clamp ; tightening a clamping device Insere pressione nel circuito idraulico Apply pressure into hydraulic circuit Pulire To clean
P = Page
Rispettare direzione di montaggio Note direction of installation Controllare esaminare controllo visuale Visual inspection Eventualimente riutilizzable (sostituire se necessario) Possibly still serviceable, renew if necessary
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3. TECHNICAL SPECIFICATIONS
3.1 IDENTIFICATION OF THE UNIT 1. Model and type of the unit. 2. Serial number.
3.2 WEIGHT, DIMENSIONS, OIL CAPACITY Weight (dry): 174.6 kg (385 lb.) T-model 1015.6 mm (39.98) 571.8 mm (22.51) 1016.3 mm (40.01)
Maximum length: Maximum width: Maximum height: Oil capacity
18.9 l (5.0 US Gallon) without cooler and hydraulic lines. Consult operators manual on applicable machine for system capacity.
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Technical specifications
3.3 TIGHTENING TORQUES 3.3.1 Torque specifications for lubricated or plated screw threads
NOM. SIZE
FINE THREAD LBF - FT .2500 .3125 .3750 .4375 .5000 .5625 .6250 .7500 9 - 11 16 - 20 26 - 29 41 - 45 64 - 70 91 - 100 128 - 141 223 - 245 [N.m] [12 - 15] [22 - 27] [35 - 39] [56 - 61] [87 - 95]
GRADE 5
COARSE THREAD LBF - FT 8 - 10 12 - 16 23 - 25 37 - 41 57 - 63 82 - 90 113 - 124 200 - 220 [N.m] [11 - 14] [16 - 22] [31 - 34] [50 - 56] [77 - 85] [111 - 122] [153 - 168] [271 - 298]
[123 - 136] [174 - 191] [302 - 332]
NOM. SIZE
FINE THREAD LBF - FT .2500 .3125 .3750 .4375 .5000 .5625 .6250 .7500 11 - 13 28 - 32 37 - 41 58 - 64 90 - 99 128 - 141 180 - 198 315 - 347 [N.m] [15 - 18] [38 - 43] [50 - 56] [79 - 87]
GRADE 8
COARSE THREAD LBF - FT 9 - 11 26 - 30 33 - 36 52 - 57 80 - 88 115 - 127 159 - 175 282 - 310 [N.m] [12 - 15] [35 - 41] [45 - 49] [71 - 77] [108 - 119] [156 - 172] [216 - 237] [382 - 420]
[122 - 134] [174 - 191] [224 - 268] [427 - 470]
NOM. SIZE
LBF - FT M8 M10 M12 15 - 20 30 - 37 50 - 55
GRADE 8.8 or 9.8

COARSE THREAD [N.m] [20 - 25] [40 - 50] [65 - 75] LBF - FT 22 - 26 44 - 48 74 - 81
GRADE 10.9
COARSE THREAD [N.m] [30 - 35] [60 - 65] [100 - 110]
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3.3.2 Elastic stop nut torque
THREAD SIZE
1" - 20 1 1/4" - 18 1 1/2" - 18 1 3/4" - 18
LB - FT
150 - 200 200 - 250 300 - 350 400 - 450
[N . m]
[203.4 - 271.1] [271.2 - 338.9] [406.8 - 474.5] [542.4 - 610.1]
3.3.3 O ring port plug torque chart
THREAD SIZE
9/16" - 18 3/4" - 16
LBF - FT
12 - 15 20 - 25
[N . m]
[16 - 20] [27 - 34]
3.3.4 Pipe plug torque chart
THREAD NPTF LBF - FT 1/16 - 27 1/8 - 27 1/4 - 18 3/8 - 18 1/2 - 14 3/4 - 10 1 - 11 1/2 1 1/4 - 11 1/2 5-7 7 - 10 15 - 20 25 - 30 30 - 35 40 - 45 55 - 50 60 - 65
TORQUE [N.m] [7 - 9] [9 - 14] [20 - 27] [34 - 41] [41 - 47] [54 - 61] [68 - 75] [81 - 88]
3.3.5 Permanent metric plug torque chart
THREAD SIZE LBF - FT M18 x 1.5 6H M18 x 1.5 6H 25-30 45-50
TORQUE [N.m] [34-41] [61-68]
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3.3.5 Coil and cartridge torque
A: tighten cartridge to 22-27 N.m (16-20 LBF-FT) B: tighten cartridge nuts to 5-7 N.m (4-5 LBF-FT)
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3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS Normal operating temperature 70 - 120 C (158 - 248 F) measured at temperature check port converter out (port 71 - **). Maximum allowed transmission temperature 120 C (248 F). Transmission regulator pressure (*) - (neutral) - port 31 (**). - At 600 RPM min. 16.5 bar (240 PSI) minimum. - At 2200 RPM: 19.3 bar (280 PSI) maximum.
Pump flow (*) - At 1800 RPM in neutral: 54.9 l/min. minimum (14.5 GPM).
Clutch pressures (*) - 1st clutch: port 41 (**). - 2nd clutch: port 42 (**). - 3rd clutch: port 43 (**). - Forward clutch: port 45 (**). - Reverse clutch: port 46 (**).
At 2000 RPM : - 16.5 - 19.3 bar (240 - 280 PSI) clutch activated. - 0 - 0.2 bar (0 - 3 PSI) clutch released.
Filter bypass valve set at 1.5 - 1.7 bar (*) (22 - 24 PSI). Lube pressure (*) (port 33) 0.7 - 1.4 bar (10 - 20 PSI) at 54.9 l/min. (14.5 GPM) pump flow (1800 RPM). Safety valve: cracking pressure (*) 8.2 - 12.1 bar (120 - 175 PSI). Converter out pressure (*) (port 32) 1.7 bar min. (25 PSI) at 2000 RPM and max. 4.8 bar (70 PSI) at no load governed speed.
(*) (**)
All pressures and flows to be measured with oil temperature of 82-93 C (180-200 F) Refer to section 7 Troubleshooting for check port identification.
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3.5 ELECTRICAL SPECIFICATIONS Solenoid (forward, reverse, 1st and 2nd). Coil resistance: - 12V: 9.79 0.5 . - 24V: 39.3 2 . Speed sensor: - Type: magneto resistive sensor. - Sensing distance: 0 - 1.8 mm (0 - 0.07). - Sensor signal: generates a square current with a fixed amplitude changing between 7 and 14 mA.
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS Minimum 19 mm (.75) internal diameter for lines and fittings. Suitable for operation from ambient to 120 C (248 F) continuous operating temperature. Must withstand 20 bar (290 PSI) continuous pressure and with 40 bar (580 PSI) intermittent surges. Conform SAE J1019 and SAE J517, 100RI.
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4. MAINTENANCE
4.1 OIL SPECIFICATION 4.1.1 Recommended lubricants 1. Caterpillar 2. John Deere 3. Military 4. Allison 5. Dexron* TO-4. J20 C, D. MIL-PRF-2104G. C-4. II Equivalent - See note below.
Note DEXRON* II EQUIVALENT IS ACCEPTABLE; HOWEVER IT IS NOT COMPATIBLE WITH TORQUE CONVERTERS OR
TRANSMISSIONS EQUIPPED WITH GRAPHITIC FRICTION MATERIAL CLUTCH PLATES.
Caution DEXRON* III, ENGINE OIL OR GL-5 OILS ARE NOT RECOMMENDED.
PREFERRED OIL VISCOSITY It is recommended that the highest viscosity monograde lubricant available be used for the anticipated ambient temperature. Typically this will be a CAT TO-4 qualified lubricant. When large swings in ambient temperature are probable, J20 C, D multigrades are recommended. Multigrade lubricants should be applied at the lower viscosity rating for the prevailing ambient temperature, i.e. a 10W20 should be used where a 10W monograde is used. If a C-4 multigrade is used in stead of J20 lubricant it is recommended that the viscosity span no more than 10 points, i.e. 10W20.
Caution SYNTHETIC LUBRICANTS ARE APPROVED IF QUALIFIED BY ONE OF THE ABOVE SPECIFICATIONS. OIL VISCOSITY GUIDELINES APPLY, BUT SYNTHETIC MULTIGRADES MAY SPAN MORE THAN 10 POINTS. FOR FIRE RESISTANT FLUID RECOMMENDATIONS PLEASE CONTACT SPICER OFF-HIGHWAY PRODUCTS.
Recommended SAE J300 Viscosity Grade Based on Prevailing Ambient Temperature SAE OW20 Dexron* II or equivalent. SAE 10W SAE 20 SAE 30 SAE 40
Celsius Fahrenheit
-40 -40
-30 -22
-20 -4
-10 14
0 32
10 50
20 68
30 88
40 104
50 122
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Maintenance
SUMP PREHEATERS Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up.
NORMAL OIL CHANGE INTERVAL Drain and refill system every 1000 hours for average environmental and duty cycle conditions. Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination. Judgement must be used to determine the required change intervals for extreme conditions.
EXTENDED OIL CHANGE INTERVAL Extended oil service life may result when using synthetic fluids. Appropriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals, over time, to determine a baseline. Wear metal analysis can provide useful information but a transmission should not be removed from service based solely on this analysis.
FILTERS Service oil filters element every 500 hours under normal environmental and duty cycle conditions.
*Dexron is a registered trademark of GENERAL MOTORS CORPORATION.

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Maintenance
4.2 MAINTENANCE INTERVALS 4.2.1 Daily Check oil level daily with engine running at idle (600 RPM) and oil at 82 - 93 C (180-200 F). Maintain oil level at full mark. 4.2.2 Normal drain period Normal drain period and oil filter element change are for average environment and duty cycle condition. Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterioration and contamination. For extreme conditions judgement must be used to determine the required change intervals. Every 500 hours Change oil filter element. Every 1000 hours Drain and refill system as follows (Drain with oil at 65 - 93 C (150 - 200 F)): 1. Drain transmission. 2. Remove and discard filter. Install new filter. 3. Refill transmission to FULL mark. 4. Run engine at 500 - 600 RPM to prime convertor and lines. 5. Recheck level with engine running at 500 - 600 RPM and add oil to bring level to LOW mark. When oil temperature is hot 82.2 - 93.3 C (180- 200 F) make final oil level check and adjust if necessary to bring oil level to FULL mark.
Note IT IS RECOMMENDED THAT OIL FILTER BE CHANGED AFTER 100 HOURS OF OPERATION ON NEW, REBUILT OR REPAIRED UNIT.
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4-3
Maintenance
4.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL The transmission, torque converter, and its allied hydraulic system are important links in the driveline between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other. Therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the job can be considered complete. After the overhauled or repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed.
The following are considered the minimum steps to be taken: 1. Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed from machine for cleaning. 3. Replace oil filter element. 4. The oil cooler must be thoroughly cleaned. The cooler should be back flushed with oil and compressed air until all foreign material has been removed. Flushing in direction of normal oil flow will not adequately clean the cooler. If necessary, cooler assembly should be removed from machine for cleaning, using oil, compressed air, and steam cleaner for that purpose.
IMPORTANT DO NOT USE FLUSHING COMPOUNDS FOR CLEANING PURPOSES. 5. Reassemble all components and use only type oil (See chapter 4.1.1 Recommended lubricants). Fill the transmission through filler opening until fluid comes up to FULL mark on transmission dipstick. Remove filler plug and fill oil until FULL mark. Run engine two minutes at 500 - 600 RPM to prime torque convertor and hydraulic lines. Recheck level of fluid in transmission with engine running at idle (500 - 600 RPM). Add quantity necessary to bring fluid level to LOW mark on dipstick. Recheck with hot oil 82.2 - 93.3 C (180 - 200 F). Adjust oil level to FULL mark on dipstick. 6. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.
T20000
3&6
LD RS
08/99
4-4
5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING Measure the A dimension (bolt circle diameter) and order drive plate kit listed below. Note three (3) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Three (3) kits with three intermediate drive plates.
(1) DRIVE PLATE AND WELD NUT ASSEMBLY
A A BOLT CIRCLE DIA. BACKING RING BOLT CIRCLE DIA. (2) INTERMEDIATE DRIVE PLATES BACKING RING (3) INTERMEDIATE DRIVE PLATES
A Dimension (Bolt circle diameter) 11.380 (288.900 mm) diameter Kit No. 814978. 13.125 (333.38 mm) diameter Kit No. 814977. 13.500 (342.90 mm) diameter Kit No. 814975. Each kit will include the following parts: 2 Intermediate drive plates. 1 Drive plate and weld nut assembly. 1 Backing ring. 6 Mounting screws. 6 Lockwashers. 1 Instruction sheet.
A Dimension (Bolt circle diameter) 11.380 (288.900 mm) diameter Kit No. 814979. 13.125 (333.38 mm) diameter Kit No. 814980. 13.500 (342.90 mm) diameter Kit No. 814981. Each kit will include the following parts: 3 Intermediate drive plates. 1 Backing ring. 6 Mounting screws. 6 Lockwashers. 1 Instruction sheet.
Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter. Align intermediate drive plates and backing plate with holes in torque converter assembly.
Note TWO DIMPLES 180 APART IN BACKING RING MUST BE OUT TOWARD ENGINE FLYWHEEL (HOLLOW SIDE FACING TORQUE CONVERTER ASSEMBLY). INSTALL CAP SCREWS AND LOCKWASHERS. TIGHTEN CAP SCREWS TORQUE 40 - 50 N.M. (30 - 37 LBF. FT.).
T20000
3&6
LD RS
08/99
5-1
Installation details
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

1. Remove all burrs from flywheel mounting face and nose pilot bore. Clean drive plate surface with solvent. 2. Check engine flywheel & housing for conformance to standard SAE No. 3 per SAE J927 and J1033 tolerance specifications for pilot bore size, pilot bore runout and mounting face flatness. Measure and record engine crankshaft end play (Fig. 1). 3. Install two 63,50 mm (2.50) long transmission to flywheel housing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole (Fig. 2). *4. Install a 101,60 mm (4.00) long drive plate locating stud .3750-24 fine thread in a drive plate nut. Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No. 3. 5. Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No. 3. Locate transmission on flywheel housing. Aligning drive plate to flywheel and transmission to flywheel housing guide studs. Install transmission to flywheel housing screws. Tighten screws to specified torque. Remove transmission to engine guide studs. Install remaining screws and tighten to specified torque. *6. Remove drive plate locating stud. 7. Install drive plate attaching screw and washer. Snug screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole. A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws. Rotate the engine flywheel and install the remaining seven (7) flywheel to drive plate attaching screws. Snug screws but do not tighten. After all eight (8) screws are installed. Torque each one 35 to 39 N.m. (26- 29ft.lbs.). This will require tightening each screw and rotating the engine flywheel until the full amount of eight (8) screws have been tightened to specified torque. 8. Measure engine crankshaft end play after transmission has been completely installed on engine flywheel. This value must be within 0,025 mm (0.001) of the end play recorded in step No. 2. * Does not apply to units having 3 intermediate drive plates. See Fig.4.
FLYWHEEL HOUSING FLYWHEEL
FLYWHEEL HOUSING MOUNT DIAL INDICATOR HERE
ENGINE
FLYWHEEL PILOT BORE
FLYWHEEL
FIG. 1
FLYWHEEL HOUSING
CONVERTER HOUSING
4"STUD
21/2"ALIGNING STUDS DRIVE PLATE
FIG. 2
SPECIAL STUD, WASHER AND SELF LOCK NUT FURNISHED BY ENGINE MANUFACTURER.
FLYWHEEL
IMPELLER COVER
INTERMEDIATE DRIVE PLATES
FIG. 3
FIG.4
PLATES TO BE INSTALLED WITH CONCAVE SIDE TOWARD ENGINE FLYWHEEL
FIG. 5
T20000
3&6
LD RS
08/99
5-2
5.3 EXTERNAL PLUMBING

From transmission out to cooler
Transmission cooler
From cooler to transmission in
Left side view
5.3.1 Optional: remote filter
To oil filter
From oil filter
.3750-16 UNC - 2B THD .88 [22.4] DEEP 3 HOLES
IN
OUT
Optional remote filter
5.3.2 Cooler & filter lines specifications Minimum 19 mm (.75 inch) internal diameter for lines and fittings. Suitable for operation from ambient to 120 C (248 F) continuous operating temperature. Must withstand 20 bar (290 psi) continuous pressure and with 40 bar (580 psi) intermittent surges. Conform SAE J1019 and SAE J517,100RI.
T20000
3&6
LD RS
08/99
5-3
5.4 SPEED SENSOR INSTALLATION
Position sign
On the sensor body there is a small plastic triangular position sign. Make sure the position sign on the sensor points as shown below in the direction of the movement of the gearteeth (Teeth rotation as shown).
Teeth rotation
1.65 (42.0) Screw Tighten to 5.9 - 7.4 lbf-ft (8 - 10 Nm) Support
Position sign "O"-ring
Plug "O"-ring
Screw Tighten to 5.9 - 7.4 lbf-ft (8 - 10 Nm)
Sensor installed
Hole plugged
Sensor position on transmission Turbine speed sensor location
Engine speed sensor location
FP
FC
3C
2P
2C RC
RP
RP
T20000
3&6
LD RS
08/99
5-4
5.4
SPEED SENSOR INSTALLATION (Continued)

Position sign
Pin 2 ( - )
Pin 1 ( + )
The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 mA and 14 mA. The sensor has an integrated AMP superseal 2 pin connector. The two pins are numbered 1 and 2. Following table shows the relation between wire colour, pin number and connection. COLOUR BROWN BLUE PIN NUMBER 1 2 FUNCTION Current input Current output CONNECTION Hot wire Ground wire
Note THE SENSOR WIRES HAVE A POLARITY. BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES, AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR !
T20000
3&6
LD RS
08/99
5-5
6. OPERATION OF THE TRANSMISSION

6.1 THE TRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies: 1. 2. 3. 4. 5. The converter, pump drive section and pressure regulating valve. The input shaft and directional clutches. The range clutches. The output section. The transmission control valve.
FWD
REV
2ND
1ST
3RD
T20000
3&6
LD RS
08/99
6-1
Operation of the transmission
6.1.1
The converter, pump drive section and pressure regulating valve
Engine power is transmitted from the engine flywheel to the impeller through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque converter. This element receives fluid at its outer diameter and discharges it at its centre. The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. This recirculation will make the converter to multiply torque. The torque multiplication is function of the blading (impeller, turbine and reaction member) and the converter output speed (turbine speed). The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing. The hydraulic pump is connected with the pump drive gear. This pump drive gear is driven by the impeller hub gear. Since the impeller hub gear is connected with the impeller cover, the pump speed is in direct relation with the engine speed.
Note THE PRESSURE REGULATOR VALVE AND SAFETY VALVE ARE MOUNTED BEHIND THE FILTER, IN THE FILTER ADAPTER HOUSING.
FWD
REV
2ND
1ST
3RD
THE CONVERTER, PUMP DRIVE SECTION AND PRESSURE REGULATING VALVE
T20000
3&6
LD RS
08/99
6-2
6.1.2
The input shaft and directional clutches
The turbine shaft driven from the turbine transmits power to the forward or reverse clutch. These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston. The piston is oil tight by the use of sealing rings. The steel discs with external splines, and friction discs with internal splines, are alternated until the required total is achieved. A back-up plate is then inserted and secured with a retainer ring. A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch. To engage the clutch, the solenoid will direct oil under pressure through tubes and passages to the selected clutch shafts. Oil sealing rings are located on the clutch shafts. These rings direct the oil through a drilled passage in the shaft to the desired clutch. Pressure of the oil forces the piston and discs against the back-up plate. The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit. When the clutch is released, a return spring will push the piston back and oil will drain back via the shift spool, the bleed valve or holes in the clutch piston into the transmission sump. These bleed valves will only allow quick escape of oil when the pressure to the piston is released. As an option the engagement of the directional clutches can be modulated. This means that clutch pressure is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is still moving and will allow smooth engagement of drive. The modulation is done hydraulically.
FWD
REV
2ND
1ST
3RD
THE INPUT SHAFT AND DIRECTIONAL CLUTCHES
T20000
3&6
LD RS
08/99
6-3
6.1.3
The range clutches
Once a directional clutch is engaged power is transmitted to the range clutches (1st, 2nd or 3rd). Operation and actuation of the range clutches is similar to the directional clutches. The engagement of the range clutches are not modulated.
6.1.4
The output section
With a range clutch engaged, power is finally transmitted to the output shaft. Output rotation is opposite as the engine rotation when the forward clutch is engaged. A front and/or rear axle disconnect is optional and is located on the output shaft. The drive to the front and/ or rear axle can be disconnected or connected by manual shifting.
Note TO ENGAGE OR DISENGAGE THE AXLE DISCONNECT, THE VEHICLE IS NOT ALLOWED TO DRIVE, BUT NEEDS TO BE AT STANDSTILL. The 6-speed range shift transmission has a manual shifting to select low or high range.
Note TO SHIFT THE RANGE SHIFT, THE VEHICLE IS NOT ALLOWED TO DRIVE, BUT NEEDS TO BE AT STANDSTILL.
FWD
FWD
REV
2ND
1ST
REV
2ND
1ST
3RD
3RD
THE RANGE CLUTCHES
THE OUTPUT SECTION
T20000
3&6
LD RS
08/99
6-4
6.1.5
The transmission controls (refer to hydraulic diagram)
The transmission is controlled by the control valve. The control valve assembly is mounted directly on the side of the converter housing. The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutch. A provision is made on certain models for inching or declutch when the brakes are applied. This is accomplished through use of a brake actuated valve. The control valve has 4 solenoids and 4 shift spools. Operation of the valve Forward can be selected by activating the forward solenoid. The forward solenoid will then allow pilot pressure to move the forward shift spool. Due to this movement of the shift spool the forward clutch is fed with oil pressure. When the reverse solenoid is activated, pilot pressure will move the reverse shift spool. The reverse clutch will be fed with oil pressure. The shift spools of forward and reverse are located opposite each other separated by a return spring. This ensures that only one direction can be selected.
FP
FC
3C
2P
2C RC
RP
RP
Forward Solenoid Reverse Solenoid 2nd Solenoid 1st Solenoid
THE TRANSMISSION CONTROLS Selection of range If the range solenoids 1st and 2nd are activated, regulated pressure is fed through the shift spools to the 1st clutch. If the range solenoid 2nd is activated, regulated pressure is fed through the shift spools to the 2nd clutch. If no range solenoids are activated, the regulated pressure is fed to the 3rd clutch.
T20000
3&6
LD RS
08/99
6-5
6.2
ELECTRIC SOLENOID CONTROLS
Transmission gear Forward 3 Forward 2 Forward 1 Neutral 3 Neutral 2 Neutral 1 Reverse 3 Reverse 2 Reverse 1
Activated solenoids Forward Forward, 2nd Forward, 1st, 2nd 2nd 1st, 2nd Reverse Reverse, 2nd Reverse, 1st, 2nd
Activated clutches Forward, 3rd Forward, 2nd Forward, 1st 3rd 2nd 1st Reverse, 3rd Reverse, 2nd Reverse, 1st
T20000
3&6
LD RS
08/99
6-6
6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT

6.3.1 Neutral, 3rd clutch engaged and high range selected
NEUTRAL 3rd (POWERFLOW) HIGH RANGE
FWD
REV
2ND
1ST
3RD
FORWARD
3rd SUPPLY
REVERSE
2nd 1st
FWD
REV
2 ND
1 ST
NEUTRAL 3rd (ACTIVATED SOLENOIDS AND SPOOLS) HIGH RANGE
T20000
3&6
LD RS
08/99
6-7
6.3.1
T20000
OPERATOR COMPARTMENT
PRESSURE GAUGE X bar X C : TEMPERATURE CHECK PORT : PRESSURE CHECK PORT TEMPERATURE GAUGE
T20000 TRANSMISSION - HYDRAULIC DIAGRAM 3 AND 6 SPEED WITH RANGE SHIFT TRANSMISSION NEUTRAL AND 3RD CLUTCH ENGAGED
Neutral, 3rd clutch engaged and high range selected (continued)
3&6
CI bar CI C CO C CO bar LUBRICATION HOSE COOLER HOSE TORQUE CONVERTER OPTIONAL 2ND SOLENOID 1ST SOLENOID FORWARD SOLENOID MODULATION VALVE REVERSE SOLENOID 2P bar 1P bar FP bar RP bar 3C bar 2C bar 1C bar FC bar RC bar 3RD CLUTCH 2ND CLUTCH 1ST CLUTCH FORWARD CLUTCH REVERSE CLUTCH
LD RS
SAFETY VALVE 8.2 - 12.1 BAR CRACKING PRESSURE
PRESSURE REGULATOR VALVE 16.5 - 19.3 bar
08/99
OPTIONAL MODULATION VALVE
BY-PASS VALVE 1.5 - 1.7 bar
FILTER
PUMP
AIR BREATHER
SCREEN
OIL SUMP
6-8
(1 bar = 14.504 PSI)
6.3.2
Forward 1st speed and high range selected
FWD
FORWARD 1st (POWERFLOW) HIGH RANGE
REV
2ND
1ST
3RD
FORWARD
3 RD SUPPLY
REVERSE
2 ND 1 ST
FWD
REV
2 ND
1 ST
FORWARD 1st (ACTIVATED SOLENOIDS AND SPOOLS) HIGH RANGE
T20000
3&6
LD RS
08/99
6-9
6.3.2
T20000
T20000 TRANSMISSION - HYDRAULIC DIAGRAM 3 AND 6 SPEED WITH RANGE SHIFT TRANSMISSION FORWARD AND 1ST CLUTCH ENGAGED
Forward 1st speed and high range selected (continued)
3&6
LD RS
08/99
FILTER
PUMP
AIR BREATHER
SCREEN
OIL SUMP
6-10
(1 bar = 14.504 PSI)
6.3.3
Forward 2nd speed and high range selected
FWD
FORWARD 2nd (POWERFLOW) HIGH RANGE
REV
2ND
1ST
3RD
FORWARD
3 RD SUPPLY
REVERSE
2 ND 1 ST
FWD
REV
2 ND
1 ST
FORWARD 2nd (ACTIVATED SOLENOIDS AND SPOOLS) HIGH RANGE
T20000
3&6
LD RS
08/99
6-11
6.3.3
T20000
T20000 TRANSMISSION - HYDRAULIC DIAGRAM 3 AND 6 SPEED WITH RANGE SHIFT TRANSMISSION FORWARD AND 2ND CLUTCH ENGAGED
Forward 2nd speed and high range selected (continued)
3&6
LD RS
08/99
FILTER
PUMP
AIR BREATHER
SCREEN
OIL SUMP
6-12
(1 bar = 14.504 PSI)
6.3.4
Forward 3rd speed and high range selected
FWD
FORWARD 3rd (POWERFLOW) HIGH RANGE
REV
2ND
1ST
3RD
FORWARD
3 RD SUPPLY
REVERSE
2 ND 1 ST
FWD
REV
2 ND
1 ST
FORWARD 3rd (ACTIVATED SOLENOIDS AND SPOOLS) HIGH RANGE
T20000
3&6
LD RS
08/99
6-13
6.3.4
T20000
T20000 TRANSMISSION - HYDRAULIC DIAGRAM 3 AND 6 SPEED WITH RANGE SHIFT TRANSMISSION FORWARD AND 3RD CLUTCH ENGAGED
Forward 3rd speed and high range selected (continued)
3&6
LD RS
08/99
FILTER
PUMP
AIR BREATHER
SCREEN
OIL SUMP
6-14
(1 bar = 14.504 PSI)
6.3.5
Reverse 1st speed and high range selected
FWD
REVERSE 1st (POWERFLOW) HIGH RANGE
REV
2ND
1ST
3RD
FORWARD
3 RD SUPPLY
REVERSE
2 ND 1 ST
FWD
REV
2 ND
1 ST
REVERSE 1st (ACTIVATED SOLENOIDS AND SPOOLS) HIGH RANGE
T20000
3&6
LD RS
08/99
6-15
6.3.5
T20000
T20000 TRANSMISSION - HYDRAULIC DIAGRAM 3 AND 6 SPEED WITH RANGE SHIFT TRANSMISSION REVERSE AND 1ST CLUTCH ENGAGED
Reverse 1st speed and high range selected (continued)
3&6
LD RS
08/99
FILTER
PUMP
AIR BREATHER
SCREEN
OIL SUMP
6-16
(1 bar = 14.504 PSI)
6.3.6
Forward 1st speed and low range selected
FWD
FORWARD 1st (POWERFLOW) LOW RANGE
REV
2ND
1ST
3RD
FORWARD
3 RD SUPPLY
REVERSE
2 ND 1 ST
FWD
REV
2 ND
1 ST
FORWARD 1st (ACTIVATED SOLENOIDS AND SPOOLS) LOW RANGE
T20000
3&6
LD RS
08/99
6-17
6.3.6
T20000
T20000 TRANSMISSION - HYDRAULIC DIAGRAM 3 AND 6 SPEED WITH RANGE SHIFT TRANSMISSION FORWARD AND 1ST CLUTCH ENGAGED
Forward 1st speed and low range selected (continued)
3&6
LD RS
08/99
FILTER
PUMP
AIR BREATHER
SCREEN
OIL SUMP
6-18
(1 bar = 14.504 PSI)
6.4 GEAR AND CLUTCH LAY-OUT 6.4.1 3-Speed with standard ratio
Forward 1st, 2nd and Reverse Reverse idler 3rd and Idler Output Section
T20000
3&6
LD RS
08/99
6-19
6.4.2
3-Speed with deep ratio
T20000
3&6
LD RS
08/99
6-20
6.4.2
6-Speed with range shift
T20000
3&6
LD RS
08/99
6-21
7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION

The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly. When troubleshooting a transmission problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components. Proper operation of the transmission depends on the condition and correct functioning of the other components of the group. Therefore, to properly diagnose a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting lines, and controls, including the engine, as a complete system. By analysing the principles of operation together with the information in this section, it should be possible to identify and correct any malfunction which may occur in the system.
7.1 T20000 TRANSMISSION T20000 (power shift with torque converter transmission) troubles fall into three general categories: 1. Mechanical problems. 2. Hydraulic problems. 3. Electrical problems. In addition to the mechanical and electrical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit is most important. Transmission fluid is the life blood of the transmission. It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and hold the clutches from slipping, and to cool and lubricate the working components.
7.2 TROUBLESHOOTING PROCEDURES 7.2.1 Stall Test A stall test to identifies transmission, converter, or engine problems. Use following procedure: 1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block the wheels. 2. Put the directional control lever in FORWARD (or REVERSE, as applicable). 3. Select the highest speed. With the engine running, slowly increase engine speed to approximately one-half throttle and hold until transmission (converter outlet) oil temperature reaches the operating range.
CAUTION
FOR
DO NOT OPERATE THE CONVERTER AT STALL CONDITION LONGER THAN 30 SECONDS AT ONE TIME, SHIFT TO NEUTRAL 15 SECONDS AND REPEAT THE PROCEDURE UNTIL DESIRED TEMPERATURE IS REACHED. EXCESSIVE TEMPERATURE 120 C (250 F) MAXIMUM WILL CAUSE DAMAGE TO TRANSMISSION CLUTCHES, FLUID, CONVERTER, AND SEALS.
T20000
3&6
LD RS
08/99
7-1
Troubleshooting guide
7.2.2 Transmission pressure checks Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmission lubrication pressure can also be measured. 7.2.3 Mechanical and electrical checks Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical and electrical checks should be made: Check the parking brake and inching pedal for correct adjustment. Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points. The controls are actuated electrically. Check the wiring and electrical components. Be sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission. Air clean the radiator, if necessary. The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and maximum no-load governed speed specifications. 7.2.4 Hydraulic checks Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure and rate of oil flow, it is important to make the following transmission fluid check: Check oil level in the transmission. The transmission fluid must be at the correct (full level). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times.
Note THE TRANSMISSION FLUID MUST BE AT OPERATING TEMPERATURE OF 82 - 93 C (180 - 200 F) TO OBTAIN
CORRECT FLUID LEVEL AND PRESSURE READINGS.
DO NOT ATTEMPT TO MAKE THESE CHECKS WITH COLD OIL. To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at stall (Refer to 7.2.1 Stall test).
CAUTION BE CAREFUL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND CONVERTER AT STALL RPM.
T20000
3&6
LD RS
08/99
7-2
7.3 TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles. 7.3.1 Low clutch pressure CAUSE 1. Low oil level. 2. Clutch pressure regulating valve stuck open. 3. Faulty charging pump. REMEDY 1. Fill to proper level. 2. Clean valve spool and housing. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings. 5. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly.
7.3.2 Low charging pump output CAUSE 1. Low oil level. 2. Suction screen plugged. 3. Defective charging pump. REMEDY 1. Fill to proper level. 2. Clean suction pump. 3. Replace pump.
7.3.3 Overheating Cause 1. Worn oil sealing rings. 2. Worn charging pump. 3. Low oil level. 4. Dirty oil cooler. 5. Restriction in cooler lines. Remedy 1. Remove, disassemble, and rebuild converter assembly. 2. Replace charging pump. 3. Fill to proper level. 4. Clean cooler. 5. Change cooler lines.
7.3.4 Noisy converter Cause 1. Worn charging pump. 2. Worn or damaged bearings. Remedy 1. Replace charging pump. 2. A complete disassembly will be necessary to determine which bearing is faulty.
7.3.5 Lack of power Cause 1. Low engine RPM at converter stall. 2. See Overheating and make same checks. Remedy 1. Tune engine check governor. 2. Make corrections as explained in Overheating.
T20000
3&6
LD RS
08/99
7-3
7.4 CHECK POINTS
GRAVITY DRAIN PLUG 1-11.5 NPTF
PORT 33 CHECK PORT-LUBE PRESSURE .5625-18UNF-2B SAE "O"-RING PORT
FRONT VIEW
LIFTING HOLE .7500-10 UNC - 3B THD DEEP 1.12
PORT 71 CHECK PORT - CONVERTER OUT TEMPERATURE 1/2 - 14 NPTF PORT 32 CHECK PORT - CONVERTER OUT PRESSURE 1/8 - 27 NPTF
AIR/HYDRAULIC HIGH-LOW RANGE SHIFT OPERATING PRESSURE 4.1-10.3 BAR (60-150 PSI) ENERGIZE FOR LOW RANGE
MAGNET DRAIN PLUG 3/4 - 14 NPTF THD
REAR VIEW
T20000
3&6
LD RS
08/99
7-4
7.4 CHECK POINTS (CONTINUED)

ENGINE SPEED SENSOR PROVISION PUMP DRIVER GEAR BREATHER
TURBINE SPEED SENSOR PROVISION FORWARD CLUTCH DRUM GEAR
FP
PORT 31 CLUTCH PRESSURE .5625 - 18UNF - 2B SAE "O" - RING PORT

FC 3C
PORT 45 CHECK PORT - FORWARD CLUTCH PRESSURE .5625 - 18UNF - 2B SAE "O" - RING PORT
2P
2C RC
RP
RP
PORT 41 CHECK PORT - 1ST CLUTCH PRESSURE .5625 - 18UNF - 2B SAE "O" - RING PORT
PORT 42 CHECK PORT - 2ND CLUTCH PRESSURE 1/8-27 NPTF
PORT 46 CHECK PORT - REVERSE CLUTCH PRESSURE 1/8-27 NPTF
PORT 43 CHECK PORT - 3RD CLUTCH PRESSURE .5625 - 18UNF - 2B SAE "O" - RING PORT
RIGHT SIDE VIEW
PORT 11 TO COOLER 1.0625 - 12 UN - 2B SAE "O" - RING PORT
PORT 12 FROM COOLER 1.0625 - 12 UN - 2B SAE "O" - RING PORT
AIR/HYDRAULIC HIGH - LOW RANGE SHIFT OPERATING PRESSURE 4.1 - 10.3 bar (60 - 150 PSI) ENGINE FOR HIGH RANGE
LEFT SIDE VIEW
T20000
3&6
LD RS
08/99
7-5
7.4 CHECK POINTS (CONTINUED)
PORT 31 CLUTCH PRESSURE .5625 - 18 UNF - 2B SAE "O" - RING PORT
DIPSTICK
TOP VIEW
T20000
3&6
LD RS
08/99
7-6
7.5 SPEED SENSOR - STATIC STANDALONE TEST
In order to be able to sense the currents, a series resistor of e.g. 200 Ohms must be used. This resistor is integrated in the controller, but when the sensor is to be tested, it must be connected externally. The idea is to connect the sensor to an external power source and measure the DC voltage across the series resistor. The voltage reading should be either 1.2V-1.6V (for the 7mA 1mA current level) or 2.6-3.0V (for the 14mA 1mA current level) If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.
T20000
3&6
LD RS
08/99
7-7
8. SECTIONAL VIEWS AND PARTS IDENTIFICATION
T20000
3&6
LD RS
08/99
8-1
GROUP - CONVERTER HOUSING
17 15 16 3 1 13 14 9 11 10 8 10 12
9 2 13 14 4
11
13
14
14 13 14 13 6 7
8-2
08/99
T20000
3&6
LD RS
GROUP - CONVERTER HOUSING Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Housing - Converter Sleeve - Converter housing Plug - pipe Plug - pipe Gasket - Converter housing to to transmission case Screw - Converter housing to transmission case Lockwasher - Converter housing to transmission case screw Pin - Converter housing to transmission case dowel Clip Screw - Clip Lockwasher - Clip screw Air - Breather Plug O-ring Plug - Speed sensor port O-ring - Speed sensor Screw - Speed sensor Quantity 1 2 1 1 1 18 18 1 2 2 2 1 5 5 1 1 1
T20000
3&6
LD RS
08/99
8-3
GROUP - TRANSMISSION CASE AND REAR COVER
35
34 29 15 28 10 26 11 27 5 20 D 12 13 23 12 14 C 5 19 18 B 25 24 1 17 27 26 28 21 22 16 30 31
3332
19
21
19 5 19
13
4 A C 6
D 3
2 8 7 9
8-4
08/99
T20000
3&6
LD RS
GROUP -TRANSMISSION CASE AND REAR COVER Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Description Assembly - Transmission case Assembly - Suction tube O-ring - Suction tube assembly Tube - Low speed pressure Sleeve - Clutch pressure tube Tube - 3rd clutch pressure Clip Screw - Tube clip Lockwasher - Tube clip screw Plug O-ring Plug O-ring Cover - Rear Plug O-ring Oil - Baffle Gasket - Transmission case to rear cover O-ring - Clutch pressure tube O-ring - Clutch pressure Pin - Transmission case to rear cover dowel Screw - Rear cover to transmission case Lockwasher - Rear cover to transmission case Plug - Magnetic drain Plug - Drain back hole Plug - Speed sensor port O-ring - Speed sensor Screw - Speed sensor Plug - Dipstick hole Cover Gasket - Cover Screw - Cover Lockwasher - Cover screw Assembly - Dipstick hole Dipstick Quantity 1 1 1 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 4 1 2 20 20 2 1 2 2 2 1 1 1 2 2 1 1
T20000
3&6
LD RS
08/99
8-5
GROUP - TURBINE SHAFT
2 1
3 8 4 10 6 5
9 7
13
11
12
14
8-6
08/99
T20000
3&6
LD RS
GROUP - TURBINE SHAFT Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Assembly - Turbine shaft & hub Ring -Retainer Bearing - Ball Snap ring - Bearing Washer - Bearing support Ring - Bearing retaining Ring - Piston Support - Stator Screw - Stator support Ring - Piston Baffle - Oil Seal - Oil baffle Ring - Oil baffle seal Ring - Oil baffle retaining Quantity 1 1 1 1 1 1 1 1 6 1 1 1 1 1
T20000
3&6
LD RS
08/99
8-7
GROUP - DRIVE PLATE
3 5 4
8-8
08/99
T20000
3&6
LD RS
GROUP - DRIVE PLATE Item 1 2 3 4 5 Description Assembly - Drive plate Drive - Plate Ring - Drive plate backing Screw - Drive plate mounting Lockwasher - Drive plate mounting Quantity 1 2 1 6 6
T20000
3&6
LD RS
08/99
8-9
GROUP - TORQUE CONVERTER
2 1 7 3
7 5 4 6
8-10
08/99
T20000
3&6
LD RS
GROUP - TORQUE CONVERTER Item 1 2 3 4 5 6 7 Description Assembly - Torque converter Bearing - Impeller hub gear Ring - External snap Plug - Torque converter O-ring - Torque converter plug Ring - Snap Ring - Turbine retaining Quantity 1 1 1 1 1 1 2
T20000
3&6
LD RS
08/99
8-11
GROUP - AUXILIARY PUMP DRIVE
10 7 8
10
6 1 4 5 3
8-12
08/99
T20000
3&6
LD RS
GROUP - AUXILIARY PUMP DRIVE Item 1 2 3 4 5 6 7 8 9 10 Description Support - Pump drive bearing Screw - Bearing support Pin - Bearing support Bearing - Ball Ring - Drive gear bearing retaining Gear - Auxiliary pump drive Cover - Pump mounting permanent Gasket - Shipping cover Screw - Pump mounting permanent cover Lockwasher - Pump cover screw Quantity 1 1 1 1 1 1 1 1 2 2
T20000
3&6
LD RS
08/99
8-13
GROUP - PUMP DRIVE
9 6 1 4 5 2 3 8
7 12 11 10 12 11
8-14
08/99
T20000
3&6
LD RS
GROUP - PUMP DRIVE Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12
Support - Pump drive bearing Pin - Bearing support Screw - Bearing support Bearing - Ball Ring - Drive gear bearing retaining Gear - Charging pump drive Gear - Pump drive idler Shaft - Idler gear stub Ball - Idler shaft lock Bearing - Ball Ring - Idler gear bearing location Ring - Idler gear bearing retaining
1 1 1 1 1 1 1 1 1 1 2 2
T20000
3&6
LD RS
08/99
8-15
GROUP - FORWARD SHAFT
3 2 5 6 4
8 9 7 10
13
11
12
15 17 16 14
8-16
08/99
T20000
3&6
LD RS
GROUP - FORWARD SHAFT Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Assembly - Forward shaft and drum Piston - Clutch Seal - Clutch piston (Outer) Seal - Clutch piston (Inner) Disc - Clutch (Inner) Disc - Clutch (Outer) Spacer - Piston return spring Plate - Clutch disk backing Snap ring - Backing plate Assembly - Disc spring Snap ring - Spring retaining Ring - Forward shaft piston Bearing - Forward shaft pilot Bearing - Ball Ring - Gear retaining Ring - Bearing retaining Gear - First drive
1 1 1 1 8 8 1 1 1 1 1 2 1 1 1 1 1
T20000
3&6
LD RS
08/99
8-17
GROUP - REVERSE AND 2ND SHAFT
33 21 32
21
19
26 12
24 23 25
22 20
17 6 1 7
3 2 10 8 4
14
13
27 31 29 16 15 14 13 9 11 18 30 28
8-18
08/99
T20000
3&6
LD RS
GROUP - REVERSE AND 2ND SHAFT Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Assembly - Reverse, 2nd shaft & drum Piston - Clutch Seal - Clutch piston (Outer) Seal - Clutch piston (Inner) Piston - Clutch Seal - Clutch piston (Outer) Seal - Clutch piston (Inner) Disc - Clutch (Inner) Disc - Clutch (Inner) Disc - Clutch (Outer) Disc - Clutch (Outer) Spacer - Piston return spring Plate - Clutch disc backing Snap ring - Backing plate Spring - Piston return Retaining - Spring Assembly - Disk spring Snap ring - Spring retaining Bearing - Clutch driven gear Bearing - Clutch driven gear Ring - Reverse clutch gear bearing Bearing - Ball Ring - Front bearing retaining Snap ring - Front bearing Ring - Piston Snap ring - Spring retaining Hub - 2nd clutch Ring - 2nd clutch disc hub retaining Bearing - Needle Retainer - Retaining ring Ring - Retainer location Spacer - Reverse clutch gear Gear - Reverse clutch
1 1 1 1 1 1 1 8 6 8 6 1 2 2 1 1 1 1 1 1 2 1 1 1 3 1 1 1 1 1 1 1 1
T20000
3&6
LD RS
08/99
8-19
GROUP - REVERSE IDLER
4 5 2
6 3 7
8-20
08/99
T20000
3&6
LD RS
GROUP - REVERSE IDLER Item Description Quantity
1 2 3 4 5 6 7 8
Shaft - Reverse idler Assembly - Reverse idler bearing Washer Nut - Bearing retaining Washer - Bearing retaining Lockball - Idler shaft Gear - Reverse idler O-ring - Idler shaft
1 1 1 1 1 1 1 1
T20000
3&6
LD RS
08/99
8-21
GROUP - LOW SPEED SHAFT
21
14
10 12 20
14 17 16 19 13
18 15 1 3 2 4
6 5 8 11 9 7
8-22
08/99
T20000
3&6
LD RS
GROUP - LOW SPEED SHAFT Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Assembly - Low shaft, hub and drum Piston - Clutch Seal - Clutch piston (Outer) Seal - Clutch piston (Inner) Disc - Clutch (Inner) Disc - Clutch (Outer) Plate - Clutch disc backing Ring - Backing plate retaining Assembly - Disc spring Snap ring - Spring retainer Spacer - Belleville washer Bearing - Low speed gear Bearing - Low speed gear Ring - Low speed gear location Ring - Low shaft piston Bearing - Ball Spacer - Low speed gear bearing Bearing - Ball Snap ring Retainer - Belleville washer Gear - Low clutch
1 1 1 1 8 8 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1
T20000
3&6
LD RS
08/99
8-23
GROUP - 3RD SHAFT
2 3 1 4
14 13 12 15
16 17 10 9 8 7 5 6 11 18
8-24
08/99
T20000
3&6
LD RS
GROUP - 3RD SHAFT Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Assembly - 3rd shaft & drum Assembly - Clutch piston Seal - Clutch piston (Outer) Seal - Clutch piston (Inner) Disc - Clutch (Inner) Disc - Clutch (Outer) Plate - Clutch disc backing Snap ring - Backing plate Spring - Piston return Retainer - Spring Snap ring - Spring retaining Ring - Front bearing retaining Bearing - Ball Snap ring - Front bearing Ring - Piston Hub - 3rd clutch Ring - 3rd clutch disc hub retaining Bearing - Needle
1 1 1 1 6 6 1 1 1 1 1 1 1 1 2 1 1 1
T20000
3&6
LD RS
08/99
8-25
GROUP - IDLER SHAFT (USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO)
5 10 9 7 8 4 6
1 3 2
8-26
08/99
T20000
3&6
LD RS
GROUP - IDLER SHAFT (USED IN 6 SPEED AND 3 SPEED WITH DEEP RATIO) Item Description Quantity
1 2 3 4 5 6 7 8 9 10
Shaft - Idler Bearing - Ball Snap ring - Bearing Bearing - Roller Nut - Bearing Washer - Bearing nut Spacer - Idler shaft gear Snap ring Gear - Idler Gear - Idler
1 1 1 1 1 1 1 1 1 1
T20000
3&6
LD RS
08/99
8-27
GROUP - IDLER SHAFT (USED IN 3 SPEED STANDARD RATIO)
5 9 7 8 4 6
1 3 2
8-28
08/99
T20000
3&6
LD RS
GROUP - IDLER SHAFT (USED IN 3 SPEED STANDARD RATIO) Item Description Quantity
1 2 3 4 5 6 7 8 9
Shaft - Idler Bearing - Ball Snap ring - Bearing Bearing - Roller Nut - Bearing Washer - Bearing nut Spacer - Idler shaft gear Snap ring Gear - Idler shaft
1 1 1 1 1 1 1 1 1
T20000
3&6
LD RS
08/99
8-29
GROUP - OUTPUT SHAFT (6 SPEED)
15 14 17 13 11 12 3 5 16 23 18 19
8 21 9 2 4 6 1 10 20 9 6 7 6 6
16 18 17 22
19
8-30
08/99
T20000
3&6
LD RS
GROUP - OUTPUT SHAFT (6 SPEED) Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Shaft - Output Bearing - Output shaft front Bearing - Output shaft rear Snap ring - Front bearing retaining Ring - Output shaft rear bearing retaining Bearing - Hi/Low gear Spacer - Bearing Spacer - Bearing Washer - Gear thrust Hub - Range shift Cap - Rear bearing Gasket - Rear bearing cap Stud - Rear bearing cap Lockwasher - Rear bearing cap stud Nut - Rear bearing cap stud Seal - Output shaft O-ring - Output flange Washer - Output flange Nut - Output flange Gear - Low range Gear - High range Flange - Output front Flange - Output rear
1 1 1 2 1 4 1 1 2 1 1 1 4 4 4 2 2 2 2 1 1 1 1
T20000
3&6
LD RS
08/99
8-31
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO)
10 9 14 8 11 12 2 4 7 19 15 16
17 5 3 5 13 1
7 15 14 18
16
8-32
08/99
T20000
3&6
LD RS
GROUP - OUTPUT SHAFT (3 SPEED STANDARD RATIO) Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Shaft - Output Bearing - Output shaft rear Bearing - Output shaft front Ring - Output shaft rear bearing Ring - Output shaft front bearing retaining Washer - Output shaft rear bearing Seal - Output shaft Stud - Bearing cap Lockwasher - Bearing cap screw Nut - Stud Cap - Output shaft rear bearing Gasket - Output bearing cap Spacer - Gear O-ring - Flange Washer - Flange Nut - Flange Gear - Output Front - Flange Rear - Flange
1 1 1 1 2 1 2 4 4 4 1 1 1 2 2 2 1 1 1
T20000
3&6
LD RS
08/99
8-33
GROUP - OUTPUT SHAFT (3 SPEED DEEP RATIO)
9 8 14 7 10 11 2 4 6 19 15 16
6 15 14 18
5 13 1
17
12
16
8-34
08/99
T20000
3&6
LD RS
GROUP - OUTPUT SHAFT (3 SPEED DEEP RATIO) Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Shaft - Output Bearing - Output shaft rear Bearing - Output shaft front Ring - Output shaft rear Ring - Output shaft front bearing retaining Seal - Output shaft Stud - Bearing cap Lockwasher - Bearing cap screw Nut - Stud Cap - Output shaft rear bearing Gasket - Output bearing cap Spacer - Gear Spacer - Gear O-ring - Flange Washer - Flange Nut - Flange Gear - Output Front - Flange Rear - Flange
1 1 1 1 2 2 4 4 4 1 1 1 1 2 2 2 1 1 1
T20000
3&6
LD RS
08/99
8-35
GROUP - HI & LOW RANGE SHIFT CONTROL
19 18 12 17 7 8 14 16 6 13 11 10 5 9 15 16
2 3
1 4
12
18 16 16
19
10 9 11
13 14 15
17
8-36
08/99
T20000
3&6
LD RS
GROUP - HI & LOW RANGE SHIFT CONTROL Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Fork - Shift Screw - Shift fork Lockwasher - Shift fork Assembly - Air shift cylinder O-ring Stud - Pump mounting Nut Lockwasher Body - Cylinder Seal - Piston rod O-ring - Seal Tube - Cylinder Rod - Piston O-ring Piston Cup - Seal Nut O-ring Cap - Cylinder end
1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 2 1 1 1
T20000
3&6
LD RS
08/99
8-37
GROUP - CHARGING PUMP & FILTER
5 6 1
8-38
08/99
T20000
3&6
LD RS
GROUP - CHARGING PUMP & FILTER Item Description Quantity
1 2 3 4 5 6
Pump - Charging Assembly - Hydraulic spin on filter Gasket - Pump assembly to converter housing O-ring Screw - Pump mounting Lockwasher - Pump mounting screw
1 1 1 1 5 5
T20000
3&6
LD RS
08/99
8-39
GROUP - ELECTRIC CONTROL VALVE MOUNTING
3 4 1
8-40
08/99
T20000
3&6
LD RS
GROUP - ELECTRIC CONTROL VALVE MOUNTING Item Description Quantity
1 2 3 4
Assembly - Electric control valve Gasket - Control valve to front cover Screw - Valve to converter housing Lockwasher - Valve to converter housing screw
1 1 9 9
T20000
3&6
LD RS
08/99
8-41
GROUP - ELECTRIC CONTROL VALVE ASSEMBLY
7 8 22 23 7 8 4 21 5 12 4 20 9 10 11 6 13
19
15 3
2 14 26 25 27 24 30 28 30 29 18 17 32 31 18 16
8-42
08/99
T20000
3&6
LD RS
GROUP - ELECTRIC CONTROL VALVE ASSEMBLY Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Description Housing control valve Cover - Control valve Gasket - Control valve cover Spool - Forward and reverse shift Spring Spool - Range (3rd) Valve housing plug Valve housing plug O-ring Spool stop Pin Plug stop Spool - Range (1st and 2nd) Spring Pipe plug Plug Screw Screw Lockwasher Stop - Spool Forward and reverse declutching spool Spring - Declutch Plug O-ring - Plug Cartridge - Ball valve O-ring - Cartridge O-ring - Cartridge O-ring - Cartridge Coil 12V Nut - Solenoid O-ring Cover - Solenoid Spacer - Cover Quantity 1 1 1 2 2 1 2 2 1 1 1 1 1 8 1 1 2 3 1 1 1 1 1 4 4 4 4 4 4 8 1 2
T20000
3&6
LD RS
08/99
8-43
9. ASSEMBLY INSTRUCTIONS
T20000
3&6
LD RS
08/99
9-1
Assembly instructions
9. ASSEMBLY INSTRUCTIONS (CONTINUED)
10
9
FWD
13 2 5 5 7 8 4
REV 2ND 1ST
4 8 3 5 9
3RD
2 6 7
.23 [6] Min
T20000
3&6
LD RS
08/99
9-2

11
11
GROUND DRIVEN EMERGENCY STEERING PUMP DRIVE
OPTIONAL DISC BRAKE MOUNTING
DRUM PARKING BRAKE BRAKE ACTUATING LEVER
DRAIN PLUGS SPEEDOMETER DRIVE
T20000
3&6
LD RS
08/99
9-3

FROM FILTER
TO FILTER
11 11
DISC PARKING BRAKE
T20000
3&6
LD RS
08/99
9-4
12
12
7 7
HYDRAULIC DISCONNECT FRONT - AND REAR OUTPUT 12 12
7 7
AIR DISCONNECT FRONT - AND REAR OUTPUT 12 7 7
12
MANUAL DISCONNECT FRONT - AND REAR DISCONNECT
T20000
3&6
LD RS
08/99
9-5
9. ASSEMBLY INSTRUCTIONS (CONTINUED) All lead in chamfers for oil seals, piston rings, and O-rings must be smooth and free from burrs. Inspect at assembly. Lubricate all piston ring grooves and O-rings with oil before assembly. Apply a thin coating of grease between seal lips on lip type seals prior to assembly. Use only precoated pipe plugs. On uncoated pipe plugs apply a light coat of Loctite no. 592. After assembly of parts using Loctite, there must not be any free or excess material which might enter the oil circuit. Apply a light coat of Loctite no. 262 or no. 270 to all thru hole stud holes.
1
Tighten oil filter to 20-25 lbf.ft [27-34 N.m]. Fwd. and rev. with standard piston & low clutch. 8 Outer steel discs and 8 inner friction discs. Insert one (1) Steel disc. Insert one (1) friction disc. Alternate steel and friction discs until proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction.
Low clutch springs concave side of first belleville spring to be placed against clutch piston. Remaining six springs of each clutch to be stacked alternately reversed as shown.
4 5 6
Must be loose internal fit bearing with a no. 3 etched on the bearing. Shields must be sized prior to assembly. Two clutches (2nd & 3rd). 6 Outer steel discs and 6 inner friction discs. Start with outer steel disc alternate friction and steel.
7 8 9
Tighten to 200 - 250 lbf.ft [271.2 - 339.0 N.m]. Shielded bearings, be sure that bearing shield is on the outside. Forward and reverse clutch springs concave side of first belleville spring to be placed against clutch piston. Remaining four springs of each clutch to be stacked alternatly reversed as shown.
T20000
3&6
LD RS
08/99
9-6

10
Stator support screw assembly: 1. Clean stator support mounting surface and tapped holes with solvent. Dry thoroughly. Being certain tapped holes are clean and dry. 2. Install 6 special stator support screws. Tighten screws to 12 - 16 lbf.ft [16.3 - 21.7 N.m] torque.
Note ASSEMBLY OF STATOR SUPPORT TO CONVERTER HOUSING MUST BE COMPLETED WITHIN A 15 MINUTE PERIOD FROM
START OF SCREW INSTALLATION. THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION ONLY. IF SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED. THE PROPER TAP AND CLEANED WITH SOLVENT.
LOCTITE LEFT IN THE HOLES MUST BE REMOVED WITH THE DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION.
11 12 13
Torque screws of pump cover up to 20 - 25 lbf.ft [27 - 34 N.m]. Tighten to 91 - 100 lbf.ft [123.4 - 135.6 N.m]. Snap ring is to be assembled with sharp edges to front.
T20000
3&6
LD RS
08/99
9-7
Disassembly and reassembly T20000 LD transmission
T20000 3 & 6
LD RS
08/99
10-1
Disassembly T20000 LD transmission
Figure 1 Front view of the T20000 series long drop transmission.The transmission being disassembled is the 6-speed version.
Figure 4 Remove pressure regulating valve and charging pump bolts.
Figure 2 Loosen filter assembly.
Figure 5 Remove valve and pump assembly.
Figure 3 It is recommended a small pan be used to catch the oil left in the filter element. Remove filter element.
Figure 6 Remove drive plate mounting screws and washers.
T20000 LD 3 & 6
LD RS
08/99
10-2
Figure 7 Remove drive plate and backing ring.
Figure 10 Though bore plug hole, remove turbine retaining ring.
Figure 8 Remove impeller cover bore plug retainer ring.
Figure 11 Remove torque converter assembly.
Figure 9 Using two small screw drivers as shown, remove plug.
Figure 12 Remove turbine locating ring.
T20000 LD 3 & 6
LD RS
08/99
10-3
Figure 13 Using slots provided in converter housing. Remove oil baffle retaining ring.
Figure 16 Remove idler gear and bearing assembly.
Figure 14 Baffle and sealing ring removed.
Figure 17 Remove pump drive idler gear locating ring.
Figure 15 Remove pump drive idler gear retaining ring.
Figure 18 From the rear through the pump drive hole, remove pump drive bearing support screw. See figure 281.
T20000 LD 3 & 6
LD RS
08/99
10-4
Figure 19 From the front, tap pump drive gear and bearing support from housing.
Figure 22 From the front, tap pump drive gear and bearing from housing.
Figure 20 From the rear, remove pump hole cover, screws, lockwashers and gasket.
Figure 23 Remove solenoid protection cover screw and lockwashers.
Figure 21 Remove auxiliary pump drive bearing support screws. See figure 284.
Figure 24 Protection cover removed.
T20000 LD 3 & 6
LD RS
08/99
10-5
Figure 25 Remove control valve bolts and lockwashers.
Figure 28 Support converter housing with a chain hoist. Remove remaining bolt.
Figure 26 Remove control valve and gasket.
Figure 29 Separate converter housing from transmission case assembly. NOTE: Reverse and 2nd and 3rd clutch will remain in converter housing.
Figure 27 Remove all bolts but one securing transmission to converter housing.
Figure 30 Using spreading type snap ring pliers, spread ears on the reverse clutch front bearing retaining ring.
T20000 LD 3 & 6
LD RS
08/99
10-6
Figure 31 Holding snap ring open pry reverse and 2nd clutch assembly from converter housing.
Figure 34 Remove output shaft front flange nut, washer, O-ring and flange.
Figure 32 Using spreading type snap ring pliers, spread ears on the 3rd clutch front bearing retaining ring.
Figure 35 Remove output shaft rear flange nut, washer, O-ring and flange.
Figure 33 Holding snap ring open tap 3rd clutch from converter housing.
Figure 36 Remove pump hole cover, cover gasket screws and lockwashers.
T20000 LD 3 & 6
LD RS
08/99
10-7
Figure 37 Remove output shaft rear bearing cap nuts and lockwashers.
Figure 40 Remove piston rod nut.
Figure 38 Output shaft rear bearing cap removed.
Figure 41 Remove shift cylinder mounting nuts and lockwashers.
Figure 39 Remove shift cylinder end cap.
Figure 42 Shift cylinder removed.
T20000 LD 3 & 6
LD RS
08/99
10-8
Figure 43 Remove rear cover screws and lockwashers.
Figure 46 Remove low clutch rear bearing.
Figure 44 Using pry slots provided, pry cover from transmission housing. Using a shoft hammer tap on idler and output shafts to prevent cover from binding.
Figure 47 Remove 3rd clutch disc and retaining ring.
Figure 45 Rear cover removed.NOTE: output and idler shaft bearing outer races remaining in cover.
Figure 48 Remove 2nd clutch disc hub, retaining ring, retaining ring retainer and retainer locating ring.
T20000 LD 3 & 6
LD RS
08/99
10-9
Figure 49 Open ears on idler shaft front bearing locating ring so that it is out of the groove.
Figure 52 Tap the rear sufficiently so that bearing groove is past snap ring i.e. that snap ring remain in open position on the bearing outer diameter when it is released.
Figure 50
Tap to the rear sufficiently so that the bearing groove is past snap ring i.e. that snap remain in open position on the bearing outer diameter when it is released. NOTE: If bearing seems difficult to move recheck locating ring, being sure ring is clear of the ring groove.
Figure 53 Remove the low (1st) clutch and the idler shaft together.
Figure 51 Open ears on low shaft front bearing locating rings so that it is out of the groove.
Figure 54 Remove shift fork.
T20000 LD 3 & 6
LD RS
08/99
10-10
Figure 55 From the front tap output shaft from the front bearing, bearing remains in transmission case.
Figure 58 From the front tap output shaft bearing from housing.
Figure 56 Remove output shaft assembly from housing.
Figure 59 Open ears on forward shaft rear bearing locating ring.
Figure 57 Remove output shaft front bearing locating ring.
Figure 60 While holding locating ring open, use a hammer puller to remove forward shaft and clutch assembly. Internal THD M10 x 1.5 deep 15mm.
T20000 LD 3 & 6
LD RS
08/99
10-11
Disassembly of low (1st) clutch
Figure 61 Remove low gear and hub, low shaft front bearing and clutch gear outer bearing.
Figure 64 Turn clutch over. Remove inner and outer clutch discs.Do not mix low clutch friction discs with friction discs in other clutches.
Figure 62 Remove end plate retainer ring.
Figure 65 Remove low speed gear bearing spacer.
Figure 63 Remove end plate.
Figure 66 Remove low speed gear inner bearing.
T20000
3 & 6 LD RS
08/99
10-12
Disassembly of low (1st) clutch
Figure 67
Remove clutch piston return spring. A 1-1/2 x 1 sleeve with a portion removed is recommended for removing the clutch piston spring, washer and retainer ring. Sleeve shown is a common pipe with a 1-1/1 x (39,0 x 26,0 mm) opening. The pipe is 6 x 3-1/4 x 2- 3/4 (155,0 x 85,0 x 78,0 mm). Compress spring retainer washer. Through opening remove spring retainer snap ring. Release tension on spring retainer.
Figure 70 Remove clutch shaft piston ring.
Figure 68 Remove snap ring retainer and retaining ring, disc spring and spacer.NOTE: Do not mix disc springs with any other disc springs as they are matched spring packs. SEE PAGE 10-60.
Figure 69 Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston.
T20000
3 & 6 LD RS
08/99
10-13
Reassembly of low (1st) clutch
Figure 71
Refer to the Cleaning and Inspection pages. The bleed valve in the clutch drum must be clean and free of any foreign material. Install clutch piston outer seal ring. NOTE: Ring must be sized before installing in clutch drum. Sizing is best accomplished by rotating clutch while holding a round object against the new seal ring. Rotate piston until seal ring is flush with outer diameter of piston.
Figure 74 Install piston spring spacer and piston return springs. First spring with large diameter toward spacer (see figure 77). Alternate seven (7) springs. See note in figure 68.
Figure 72 Install clutch piston inner seal ring and size as described in figure 71.
Figure 75 Position spring snap ring. Compress spring and install snap ring.
Figure 73 Position piston in low clutch drum as shown. Use caution as not to damage inner and outer piston scaling rings.
Figure 76 Install snap ring retainer.
T20000
3&6
LD RS
08/99
10-14
Spacer
Piston
LOW
Figure 77
Figure 80 Install clutch disc end plate.
Figure 78 Install one steel disc.
Figure 81 Install end plate retainer ring.
Figure 79
Install one friction disc. NOTE: the friction discs in the low clutch has a higher co-efficient rating than the friction discs in the other clutches therefore the discs must not be mixed.The low clutch friction disc has a yellow make of non-soluble paint on the outer diameter for permanent identification.Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston in steel last disc installed is friction.
Figure 82 Install low speed gear inner bearing.
T20000
3&6
LD RS
08/99
10-15
Figure 83 Install low speed gear bearing spacer.
Figure 86 Install low shaft font bearing with bearing groove up.
Figure 84
Install clutch driven gear and hub into clutch drum.Align splines on clutch hub with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs.
Figure 87 Install low shaft sealing ring.
Figure 85 Install low speed gear outer bearing. NOTE: outer bearing has a shield in it, this shield must be up.
T20000
3&6
LD RS
08/99
10-16
Disassembly of reverse clutch
Figure 88 Remove clutch shaft piston rings.
Figure 91 Pry reverse gear from clutch assembly far enough to use a gear puller.
Figure 89 Remove clutch shaft front bearing retainer ring.
Figure 92 Remove reverse clutch gear and outer bearing.
Figure 90 Remove clutch shaft front bearing.
Figure 93 Remove clutch gear bearing spacer.
T20000
3&6
LD RS
08/99
10-17
Figure 97 Remove clutch gear inner bearing.
Figure 98 Compress piston return disc springs. Remove return spring retainer ring.
Figure 96 Remove inner and outer discs.
Figure 99 Remove piston return disc springs and piston spacer. See note in figure 68.
T20000
3&6
LD RS
08/99
10-18
Figure 100 Remove clutch piston.2nd being disassembled.
T20000
3&6
LD RS
08/99
10-19
Disassembly of 2nd clutch
Figure 104 Compress piston return spring. Remove retainer ring.
Figure 105 Remove return spring, spring retainer and retainer ring.
Figure 103 Remove inner and outer clutch discs.
Figure 106 Remove clutch piston. Reverse and 2nd clutch reassembly 2nd being assembled.
T20000
3&6
LD RS
08/99
10-20
Reassembly 2nd clutch
Figure 107
Refer to the Cleaning and Inspection pages. The bleed valve in the clutch piston must be clean and free of any foreign material. Install clutch piston outer seal ring. Size as explained in figure 71.
Figure 110 Compress return spring and install retainer ring.
Figure 108 Install clutch piston inner seal ring. Size explained in figure 71. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.
Figure 109 Position piston return spring, spring retainer and retainer ring.
Figure 112 Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is a friction disc.
T20000
3&6
LD RS
08/99
10-21
Reassembly 2nd clutch
Figure 113 Install end plate and retainer ring.
T20000
3&6
LD RS
08/99
10-22
Reassembly of reverse clutch
Figure 114
Refer to the Cleaning and Inspection pages. The bleed valve in the clutch piston must be clean and free of any foreign material. Install clutch piston outer seal ring. Size as explained in figure 71.
Figure 117 Position spring snap ring. Compress spring. Install snap ring.
Spacer
Piston
FWD REV
Figure 115 Install clutch piston inner seal ring. Size as explained in figure 71. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.
Figure 118
Figure 116 Position spring spacer and piston return springs. First spring with large diameter toward spacer, see figure 118. Alternate five (5) springs. See note in figure 68.
T20000
3 & 6 LD RS
08/99
10-23
Figure 120 Install one friction disc. Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is a friction disc.
Figure 123 Install clutch gear inner bearing. NOTE: this bearing does not have a shield in it.
Figure 121 Install end plate.
Figure 124 Install clutch gear bearing spacer.
Figure 125 Install reverse gear into clutch drum. Align splines on reverse gear with internal teeth of friction discs. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs.
T20000
3 & 6 LD RS
08/99
10-24
Figure 126 Install clutch gear outer bearing. NOTE: outer bearing has a shield in it, this shield must be up.
Figure 129 Install clutch shaft piston rings.
Figure 127 Install clutch shaft front bearing. NOTE: bearing outer diameter locating groove must be up.
Figure 128 Install bearing retainer ring.
T20000
3 & 6 LD RS
08/99
10-25
Disassembly 3rd clutch
Figure 133 Compress piston return spring and spring retainer. Remove retainer ring.
Figure 134 Remove return spring, spring retainer and retainer ring.
Figure 132 Remove inner and outer discs.
Figure 135 Remove clutch piston.
T20000
3&6
LD RS
08/99
10-26
Disassembly 3rd clutch
Figure 136 Remove clutch shaft piston rings.
Figure 137 Remove clutch shaft front bearing retainer ring.
Figure 138 Remove clutch shaft front bearing.
T20000
3&6
LD RS
08/99
10-27
Reassembly 3rd clutch
Figure 139
Refer to the Cleaning and Inspection pages. The bleed valve in the clutch drum must be clean and free of any foreign material. Install clutch shaft front bearing. NOTE: bearing outer diameter locating ring groove must be up.
Figure 142 Install clutch piston outer seal ring. Size as explained in figure 71.
Figure 140 Install clutch shaft front bearing retainer ring.
Figure 143 Install clutch piston inner seal ring. Size as explained in figure 71. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.
Figure 141 Install clutch shaft piston rings.
Figure 144 Position piston return spring, spring retainer and retaining ring.
T20000
3&6
LD RS
08/99
10-28
Reassembly 3rd clutch
Figure 145 Compress return spring and install retainer ring.
Figure 146 Install on steel disc.
Figure 147 Install one friction disc. Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is a friction disc.
T20000
3&6
LD RS
08/99
10-29
Disassembly of forward clutch
Figure 153 Compress piston return disc springs. Return spring retainer ring.
Figure 154 Remove piston return disc springs and piston spacer. See note in figure 68.
Figure 152 Remove inner and outer clutch discs.
Figure 155 Remove clutch piston.
T20000
3&6
LD RS
08/99
10-30
Disassembly of forward clutch
Figure 156 Remove forward clutch shaft piston rings.
Figure 159 Remove forward clutch shaft rear bearing.
Figure 157 Remove 1st drive gear retaining ring.
Figure 158 Remove 1st drive gear.
T20000
3&6
LD RS
08/99
10-31
Reassembly of forward clutch
Figure 160
Refer to the Cleaning and Inspection pages. The bleed valve in the clutch drum must be clean and free of any foreign material. Install forward clutch shaft rear bearing. NOTE: bearing outer diameter locating ring groove must be down.
Figure 163 Install forward clutch shaft piston rings.
Figure 161 Install 1st drive gear. NOTE: with hub of gear down.
Figure 164 Install clutch piston outer seal ring. Size as explained in figure 71.
Figure 162 Install 1st drive gear retaining ring.
Figure 165 Install clutch piston inner seal ring. Size as explained in figure 71. Install clutch piston in clutch drum, use caution as not to damage sealing rings.
T20000
3&6
LD RS
08/99
10-32
Figure 166 Position spring spacer and piston return springs. First spring with large diameter toward spacer, see figure 168. Alternate five (5) springs: see note in figure 68.
Figure 167 Position spring nap ring. Compress spring. Install snap ring.
Figure 170 Install one friction disc. Alternate steel and friction discs, until the proper amount of discs are installed. First disc next to the piston in steel, last disc installed is a friction disc.
Spacer
Piston
FWD REV
Figure 168
T20000
3&6
LD RS
08/99
10-33
T20000
3&6
LD RS
08/99
10-34
Disassembly of converter housing
Figure 173 Straighten tang on reverse idler bearing retainer nut lockplate.
Figure 176 Remove idler gear and outer taper bearing from idler shaft.
Figure 174 Remove idler shaft bearing retainer nut. Use TG 1304-54. See section 12: Service tools.
Figure 177 Remove idler gear bearing spacer.
Figure 175 Remove idler shaft bearing retainer nut, lockplate.
Figure 178 Remove idler gear inner taper bearing.
T20000
3&6
LD RS
08/99
10-35
Figure 179 Remove idler gear inner taper bearing spacer.
Figure 182 Remove stator support screws.
Figure 180 Remove idler shaft , use caution as not to lose shaft lock ball.
Figure 183 Tap stator support from converter housing.
Figure 181 Using spreader type pliers spread ears on the turbine shaft bearing snap ring. Tap turbine shaft and baring from converter housing.
Figure 184 Remove oil sealing ring sleeve retainer and washer. Remove sleeve lock.
T20000
3&6
LD RS
08/99
10-36
Figure 185 Using a sleeve puller like the one shown, remove sleeve.
Figure 188 Remove turbine shaft oil sealing ring.
Figure 186 Remove support bearing retaining ring.
Figure 189 Remove turbine shaft bearing retaining ring and washer.
Figure 187 Remove bearing from support. Remove support oil seal ring.
Figure 190 Remove turbine shaft bearing.
T20000
3&6
LD RS
08/99
10-37
Reassembly of converter housing
Figure 191
Refer to the Cleaning and Inspection pages.
Figure 194 Install new stator support oil sealing ring. Press support bearing into position. NOTE: bearing part number must be up.
Press turbine shaft bearing into position. Bearing groove must be down.
Figure 192 Position bearing spacer and bearing retaining ring.
Figure 195 When installing a new sleeve it is recommended a press or a driver be used to prevent damage to the sleeve and be sure the notch in the sleeve is aligned with sleeve lock notch.
Figure 193 Install new turbine shaft oil sealing ring.
Figure 196 Install sleeve lock and cap screw, tighten screw to specified torque (see torque chart).
T20000
3&6
LD RS
08/99
10-38
Figure 197
Clean stator support mounting surface and tapped holes with solvent. Dry thoroughly, being certain tapped holes are clean and dry. Position support in converter housing aligning holes in support with holes in housing. Tap support into position.
Figure 200 With new O-ring on shaft , position idler shaft in converter housing. Tap shaft into position. Install lock ball.
Figure 198
Install 6 special stator support screws. Tighten screws to 12 - 16 lbs. Ft. (16.3 21.6 Nm.) torque. NOTE: assembly of the stator support to converter housing must be completed within a 15 minute period from start of screw installation. The special screw is to be used for one installation only. If the screw is removed for any reason it must be replaced. The Loctite left in the holes must be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use a screw for reinstallation.
Figure 201 Install idler shaft spacer.
Figure 199 Spread ears on turbine shaft bearing retainer ring located in reaction member support. Tap turbine shaft and bearing into position, being certain bearing snap ring is in full position in snap ring groove.
Figure 202 Install idler gear inner taper baring in shaft with large diameter of taper down.
T20000
3&6
LD RS
08/99
10-39
Figure 203 Position bearing spacer on shaft.
Figure 206 Install reverse idler baring retainer nut lockplate as shown.
Figure 204 Position idler gear on bearing with hub of gear up.
Figure 207 Install reverse idler bearing nut with chamfer down.
Figure 205 Install taper bearing on shaft with large diameter of taper up.
Figure 208 Tighten nut 200 to 250 ft. lbs. Torque (271.2 338.8 Nm.). Use TG 1304-54.
T20000
3&6
LD RS
08/99
10-40
Figure 209 Bend over tag of lock plate that aligns with one of the slots of the lock nut, to secure it (See figure 210).
Figure 212
Spread ears on 3rd clutch front bearing locating ring. Tap clutch assembly into converter housing. Align the snap ring groove in the front bearing with the snap ring in the housing, being certain bearing snap ring is in full position in snap ring groove.
Reverse idler
Figure 210
Figure 213 Position the 2nd speed clutch shaft and 3rd speed clutch pilot bearings on clutch shaft, a light coat of good quality grease will hold bearing in position on shaft.
Figure 211 Spread ears on reverse clutch front bearing locating ring. Tap reverse and 2nd clutch assembly into converter housing.Align the snap ring groove in the bearing with the snap ring in the housing, being certain bearing snap ring is in full position in snap ring groove.
T20000
3&6
LD RS
08/99
10-41
Disassembly of idler shaft
Long Hub
6-speed Front Rear
Long Hub
Figure 214 6-Speed cross section. The idler shaft being disassembled is a 6-speed (see figure above). For 3-speed cross section see figure 215.
Figure 217 Remove idler shaft, rear bearing inner race spacer.
3-speed standard Front 3-speed deep ratio Rear
Long Hub
Figure 215 3-Speed cross section.
Figure 218 Remove idler shaft gear (rear) and rear bearing inner race.
Figure 216 Remove idler shaft nut.
Figure 219 Remove idler shaft gear (front).
T20000 3 & 6
LD RS
08/99
10-42
Disassembly of idler shaft
Figure 220 Remove idler shaft gear spacer.
Figure 221 Remove idler shaft front bearing.
T20000 3 & 6
LD RS
08/99
10-43
Reassembly of idler shaft
Figure 222 Refer to the Cleaning and Inspection pages. Install idler shaft front bearing. NOTE: snap ring groove in front bearing must be up.
Figure 225 Install idler shaft gear (rear) with long hub of gear down.
Figure 223 Install idler shaft gear spacer.
Figure 226 Install idler shaft rear bearing inner race.
Figure 224
Install idler shaft gear (front) with long hub of gear up !
Figure 227 Position bearing inner race washer and retainer nut.
T20000
3&6
LD RS
08/99
10-44
Reassembly of idler shaft
Figure 228 Tighten retainer nut to 200 250 lbs.ft. torque. (271.2 338.8 Nm.).
T20000
3&6
LD RS
08/99
10-45
Disassembly of output shaft
Front
Rear
Figure 229 6-Speed cross section. The output shaft being disassembled is a 6-speed (see figure above). For a 3-speed cross section see figure 230.
Figure 232 Remove low range gear.
Front 3-speed deep ratio 3-speed standard
Rear
Figure 230 3-Speed cross section
Figure 233 Remove low range gear bearings and spacer.
Figure 231 Remove low range gear thrust washer.
Figure 234 Remove range shaft hub.
T20000
3&6
LD RS
08/99
10-46
Disassembly of output shaft
Figure 235 Remove high range gear, gear thrust and rear bearing inner race.
Figure 236 Remove high range gear bearings.
T20000
3&6
LD RS
08/99
10-47
Reasssembly of output shaft
Figure 237 Refer to the Cleaning and Inspection pages. Install high range gear bearings.
Figure 240 Install range shift hub.
Figure 238 Install high range gear.
Figure 241 Install low range gear bearings and spacer.
Figure 239 Install high range gear thrust washer and rear bearing inner race.
Figure 242 Install low range gear.
T20000
3&6
LD RS
08/99
10-48
Reasssembly of output shaft
Figure 243 Install low range gear thrust washer.
T20000
3&6
LD RS
08/99
10-49
Reassembly of transmission
Figure 244 Refer to the Cleaning and Inspection pages. Install forward clutch shaft rear bearing retaining ring.
Figure 247 Install low clutch shaft and idler shaft front bearing retaining ring.
Figure 245 Position forward assembly into transmission bearing bore.
Figure 248 From the front install new output shaft seal with lip of seal towards bearing side. From the rear install output shaft front bearing and outer retaining ring.
Figure 246 Spread rear bearing retaining ring. Align snap ring grove with snap ring, release snap ring in groove being sure snap ring is in full position in ring groove.
Figure 249 Install front bearing inner retaining ring.
T20000
3&6
LD RS
08/99
10-50
Figure 250 Install output shaft assembly.
Figure 253 Install low clutch shaft rear bearing.
Figure 251 Install shaft fork and rod as an assembly on shift hub.
Figure 254 Position new gasket and O-ring on rear of transmission housing. A thin coat of chassis grease will hold the gasket and O-ring in place.
Figure 252
The low clutch (1st) and the idler shaft must be installed in the transmission case together. The help of an assistant or by replacing the transmission case on the front face may facilitate this step. Spread ears on low and idler shaft front bearing retaining ring. From the rear, tap low and idler shaft into position being sure snap rings are in full position in ring grooves.
Figure 255
Install rear cover and bearing outer races as an assembly. NOTE: two aligning studs facilitate cover to housing assembly. Tap cover bores in place aligning shaft bearings with bearing bores. Use caution as not to damage low clutch shaft sealing ring. Remove aligning studs and install cover bolts and lockwashers.
T20000
3&6
LD RS
08/99
10-51
Figure 256 Tighten rear cover screws to specified torque (see torque chart).
Figure 259
Press new seal in bearing cap with lip of seal toward bearing side of bearing cap. Position new gasket on bearing cap. NOTE: some units will have O-rings between the cap and the cover.
Figure 257 Install pump hole cover, gasket, screws and lockwasher.
Figure 260 Install lockwashers and stud nuts. Tighten nuts to specified torque (see torque chart).
Figure 258 Tighten screws to specified torque (see torque chart).
Figure 261 Install output flange, O-ring, washer and nut.
T20000
3&6
LD RS
08/99
10-52
Figure 262 Block flange to prevent turning. Tighten flange nut 200- 250 lbs. ft. (271.2 339.0 Nm.). Before installing shaft cylinder assembly replace all O-rings and sealing rings (see figure 263 and 264).
Figure 265 Install new piston rod O-ring, position shift cylinder assembly on piston rod. Use caution as not to damage piston rod sealing ring.
Piston seal rings (2 req'd) Note: Open face of seal away from each other.
Figure 263
Figure 266 Install piston retaining lock nut.
Cylinder body "O" ring
Piston rod seal Cylinder tube "O" ring
Figure 264
Figure 267 Tighten lock nut to 26 29 lbs. ft. (35 39 Nm.).
T20000
3&6
LD RS
08/99
10-53
Figure 268 Position new cylinder end cap O-ring into end cap.
Figure 271 Install forward clutch pilot bearing.
Figure 269 Install cap and O-ring on cylinder tube. Tighten cap securely.
Figure 272 Install 2nd disc hub, hub retaining ring, retaining ring retainer and retainer locating ring. See figure 273.
2nd clutch disc hub
Retainer locating ring
Retaining ring retainer
Disc hub retaining ring Low clutch shaft
Figure 270 Install cylinder body lockwashers and stud nuts. Tighten nut 37 41 ft. lbs. torque (50.2 55.5 Nm.).
Figure 273
T20000
3&6
LD RS
08/99
10-54
Figure 274 Install 3rd clutch disc hub and retaining ring.
Figure 277 Position new O-ring and gasket on front of transmission housing. A light coat of chassis grease will hold O-ring and gasket in place.
Figure 275 Install front output flange , O-ring, washer and flange nut.
Figure 278
The use of two aligning studs will facilitate aligning the converter housing to the transmission housing. Install converter housing assembly to transmission assembly using extreme caution as to align the clutch pilots to clutch disc hubs. As the clutch pilots enter the disc hubs, turn the turbine shaft and output shaft back and forth. This will help align all of the clutch inner discs with the disc hubs. DO NOT FORCE THIS OPERATION. When all clutches are properly aligned, the converter housing will be tight against the transmission housing. Install two housing to housing capscrews and lockwashers. Remove aligning studs. Install remaining capscrews and lockwashers.
Figure 276 Block flange to prevent turning. Tighten flange nut 200 250 lbs. ft. (371.2 339.0 Nm.).
Figure 279 Tighten cap screws to specified torque (see torque chart).
T20000
3&6
LD RS
08/99
10-55
Figure 280 Position auxiliary pump drive gear in converter housing. See figure 281.
Figure 283 Position charging pump drive gear (see figure 284) and install cap screw with Loctite No. 243. Tighten cap screw to specified torque (see toque chart).
Auxiliary pump drive gear
Pump drive gear
Figure 281
Figure 284
Figure 282 Install cap screw with Loctite No. 243. Tighten cap screw to specified torque (see torque chart).
Figure 285 Using a new gasket and O-ring, position charging pump assembly. Install cap screws and lockwashers. Tighten screws to specified torque (see toque chart).
T20000
3&6
LD RS
08/99
10-56
Figure 286 Install cap screws and lockwashers: tighten screws to specified torque (see torque chart).
Figure 289 Install idler gear bearing retaining ring.
Figure 287 Install new oil filter. Tighten 20 to 25 ft. lbs torque (27.1 - 33.9 N.m.). NOTE: it is recommended that the filter cartridge be changed after 100 hours of operation on new and rebuilt or repaired units.
Figure 290 Position pump idler gear and bearing in stab shaft.
Figure 288 Install pump hole cover, news gasket, screws and lockwashers. Tighten screws to specified torque (see torque chart).
Figure 291 Install idler gear bearing locating ring.
T20000
3&6
LD RS
08/99
10-57
Figure 292 Press new seal in baffle with lip of seal toward impeller hub bearing. Position new oil baffle sealing ring on oil baffle.
Figure 295 Position converter assembly on stator support and turbine shaft. NOTE: use extreme caution as not to cut, break or unhook the oil sealing ring in the support.
Figure 293 Position oil baffle in housing and install retaining ring. Be sure ring is in full position in ring groove.
Figure 296 Install converter assembly retaining ring.
Figure 294 Position inner turbine locating ring on turbine shaft.
Figure 297 With new O-ring in place, install bore plug.
T20000
3&6
LD RS
08/99
10-58
Figure 298 Install bore plug retaining ring.
Figure 301 Position control valve assembly on aligning studs.
Figure 299 See special section on page 5-1 for drive plate installation.
Figure 302 Install control valve to converter housing screws and lockwashers, tighten screws to specified toque (see torque chart).
Figure 300 To install control valve assembly it is recommended two aligning studs be used to position new control valve gasket.
Figure 303 Install protection cover, screws and lockwashers. Tighten screws to specified torque (see torque chart).
T20000
3&6
LD RS
08/99
10-59
Disassembly and reassembly of the T20000 LD transmission
Note:
PRE-PACKED IN QUANTITIES TO REPAIR ONE
CLUTCH RETURN DISC SPRING PACKS ARE CERTIFIED ACCORDING TO COMPRESSION WEIGHT SPECIFICATIONS AND ARE (1) SPECIFIC CLUTCH.
The disc spring packs are to be used as complete assemblies and care should be taken not to intermix the individual disc springs with disc springs in another clutch or disc spring pack. Each disc spring assembly is made up of selected springs to precisely match each part within this assembly. Failure to replace all piston return springs can result in unequal deflection within the spring pack. The result of this imbalance may adversely affect overall life of springs.
T20000
3&6
LD RS
08/99
10-60
11.
OPTIONS
11.1 HYDRAULIC ACTUATED AXLE DISCONNECT The information contained herein must be used in conjunction with a T20000 LD section.
11.1.1 Sectional views and parts identification Refer to following pages.
T20000
3&6
LD RS
08/99
11-1
GROUP - HYDRAULIC ACTUATED AXLE DISCONNECT
19 17 16 29 28 31 30 26 24 37 13 20 25 26 27 32 18 44 38 39 40
15 33 35
34 36 4 11 14 21 6 22 23
9 42 10 3 5 2 1 12 41 10 7 8 7 7 7
27 39 38 43
40
11-2
08/99
T20000
3&6
LD RS
GROUP - HYDRAULIC ACTUATED AXLE DISCONNECT Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Shaft - Output Bushing Bearing - Output shaft front Bearing - Output shaft rear Snap ring - Front bearing retaining Ring - Output shaft rear bearing retaining Bearing - Hi Low gear Spacer - Bearing Spacer - Bearing Washer - Gear thrust Ring - Output shaft rear retaining Hub - Range shift Housing - Diconnect O-ring - Diconnect housing O-ring - Diconnect housing Plug - Diconnect housing O-ring - Bore plug O-ring - Bore plug Ring - Bore plug retaining Shaft - Diconnect Stud - Disconnect housing cap Lockwasher - Disconnect housing stud Nut - Disconnect housing stud Plug - Disconnect housing Bearing Ring - Bearing retaining Seal - Output shaft Piston - Hydraulic actuator O-ring - Piston Spring - Air/hydraulic actuator piston - outer Spring - Air/hydraulic actuator piston - inner Ring - Piston seal glyd Lockscrew - Shift fork Hub - Shift Fork O-ring - Disconnect housing Plug - Shipping O-ring - Output flange Washer - Output flange Nut - Output flange Gear - Low range Gear - High range Flange - Output (front) Flange - Output (rear)
1 1 1 1 2 1 4 1 1 2 1 1 1 1 1 1 1 1 1 1 4 4 4 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1
T20000
3&6
LD RS
08/99
11-3
Options
11.1.2
TIGHTEN SECURELY AND LOCK WIRE TO PREVENT LOOSENING APPLY A LIGHT COAT OF LOCTITE 557 TO THE OUTER DIAMETER OF THE HOUSING PLUG.
T20000
3 & 6 LD RS
08/99
11-4
11.1.3
Disassembly of output shaft with axle disconnect
T20000 3 & 6 LD RS
08/99
11-5
Figure 1 6-Speed cross section with axle disconnect.
Figure 4 Remove low range gear bearings and spacer.
Figure 2 Remove low range gear thrust washer.
Figure 5 Remove range shift hub.
Figure 3 Remove low range gear.
Figure 6 Remove bearing inner race retaining ring.
T20000 3 & 6 LD RS
08/99
11-6
Figure 7 Remove high range gear, gear thrust washer, bearing spacer and bearing inner race.
Figure 8 Remove high range gear bearings.
T20000 3 & 6 LD RS
08/99
11-7
11.1.4
Reassembly of output shaft with axle disconnect
T20000
3&6
LD RS
08/99
11-8
Figure 9 Refer to the Cleaning and inspection pages. If bushing worn out, install new bushing.
Figure 12 Install, high range gear thrust washer, bearing spacer and bearing inner race.
Figure 10 Install high range gear bearings.
Figure 13 Install rear bearing inner race retaining ring.
Figure 11 Install high range gear.
Figure 14 Install range shift hub.
T20000
3&6
LD RS
08/99
11-9
Figure 15 Install low range gear bearings and spacer.
Figure 16 Install low range gear.
Figure 17 Install low range gear thrust washer.
T20000
3&6
LD RS
08/99
11-10
11.1.5
Disassembly of axle disconnect
T20000 3 & 6
LD RS
08/99
11-11
Figure 18 Remove the inner and outer actuator piston springs.
Figure 21 Remove piston bore plug retainer ring.
Figure 19 The output oil seal must be destroyed by using a punch to drive through the oil seal housing and picking the oil seal out of the disconnect housing.
Figure 22 Remove disconnect shaft outer bearing retainer ring.
Figure 20 Remove disconnect housing plug.
Figure 23 Remove the shift fork lock screw.
T20000 3 & 6
LD RS
08/99
11-12
Figure 24 Remove disconnect housing plug.
Figure 27 Shift and shift fork removed.
Figure 25 Remove actuator piston.
Figure 26 Tap disconnect shaft and bearing from housing.
T20000 3 & 6
LD RS
08/99
11-13
11.1.6
Reassembly of axle disconnect
T20000 3 & 6
LD RS
08/99
11-14
Figure 28
Refer to the Cleaning and inspection pages. Position shift fork on shift hub. Insert actuator into disconnect housing. Hold shift hub and fork in housing, align shift fork and actuator piston. Insert piston in shift fork.
Figure 31 Align hole in actuator piston with hole in shift fork. Install shift fork lock screw. Tighten securely and lock wire to prevent loosening.
Figure 29 Install O-ring and glyd ring on actuator piston (see figure 29).
Figure 32 Align splines on disconnect shaft with splines in shift hub.
GLYD ring
"O" ring
Figure 30
Figure 33 Tap shaft and bearing in place.
T20000 3 & 6
LD RS
08/99
11-15
Figure 34 Install shaft bearing outer retainer ring.
Figure 37 Secure bore plug with retaining ring.
Figure 35 Press seal in disconnect housing with lip of seal in.
Figure 38 Apply a light coat of Loctite 577 to the outer diameter of the housing plug. Tap plug into position in housing.
Figure 36 Position two new O-rings on piston bore plug. Align hole in plug with hole in housing. Install plug.
Figure 39 Install disconnect housing O-rings in housing.
T20000 3 & 6
LD RS
08/99
11-16
Figure 40 Insert the actuator piston inner and outer return springs in piston.
Figure 43 Install output flange O-ring, washer and flange nut.
Figure 41 Use new O-rings on assembly. Position disconnect assembly on disconnect mounting studs. Install stud nuts and lockwashers.
Figure 44 Block flange to prevent turning. Tighten flange nut to specified torque (see elastic stop nut chart).
Figure 42 The actuator piston springs must be compressed against the rear cover to start the stud nuts and lockwasher. Tighten stud nuts to specified torque (see torque chart).
T20000 3 & 6
LD RS
08/99
11-17
11.2 PARKING BRAKES 11.2.1 Mechanical Brake
11.2.1.1 Sectional views and parts identification
T20000
3&6
LD RS
08/99
11-18
GROUP - DISC BRAKE (MECHANICAL BRAKE)
2 3
4 8 5
11-19
08/99
T20000
3&6
LD RS
GROUP - DISC BRAKE (MECHANICAL BRAKE) Item Description Quantity
1 2 3 4 5 6 7 8
Caliper - Parking brake Disc - Brake Assembly - Mounting bracket Screw - Bracket assembly to brg cap mtg Washer - Bracket assembly to brg cap mtg flat screw Screw - Flange Screw - Caliper to mounting bracket Spacer
1 1 1 4 4 6 2 2
T20000
3&6
LD RS
08/99
11-20
GROUP - MECHANICAL BRAKE
16 14 12
10 13
15
11 4 6 8
2 5 1 3
11-21
08/99
T20000
3&6
LD RS
GROUP - MECHANICAL BRAKE Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Screw Anti-rotation clip Washer Lever Spring Shaft - Seal Housing O-ring Bushing Ball Ball - Spacer Rotor Plain bearing Rotor - Seal Lever side pad Carrier side path
1 1 1 1 1 1 1 4 2 3 1 1 1 1 1 1
T20000
3&6
LD RS
08/99
11-22
11.2.1.2 Adjustment and rebuild criteria 1. Check to insure floating parts move freely and that all other parts are mounted securely. Tighten hardware as required. 2. Check actuator linkage to insure that there is adequate freedom of movement for positive brake operation. Adjustment of pad gap is to be accomplished by adjusting the actuating cable or linkage. If adjustment is used up, back off cable or linkage. Unbend tab on anti-rotation clip and loosen screw enough to disengage lever spline. Rotate the lever one tooth, in the direction opposite the actuation direction, and retorque the screw making sure the spline teeth are properly engaged. Bend up a tab that aligns with one of the screw head flats, to prevent screw rotation. Both lever and linkage must be free to return to home position. An external return spring is required. 3. Check disc surface condition. Replace if it is badly warped, pitted, or below minimum recommended thickness. Check for loose mount bolts. Retighten if necessary. 4. Check to insure friction pads are not worn to less than .039 (1.0mm) thick. Replace worn friction pads. Generally, if the disc is still running true and the pad clearance is still adjustable, no other maintenance is required. To check for wear, measure the distance from the carrier side casting face to disc face. If the distance is less than .060 (1.5mm), replace the friction pads.
11.2.1.3 Replacing friction pads
Note
SPECIFIES THE FRICTION MATERIAL TYPE.
STAMPED ON THE BACK OF EACH FRICTION PAD IS A CODE. THE FIRST 1 OR 2 CHARACTERS IS A NUMBER THAT CHECK TO INSURE NEW PADS ARE THE SAME AS THE WORN PADS REMOVED. REPLACE FRICTION PADS ONLY IN PAIRS.
To replace the friction pads it is necessary to release the brake and disconnect the actuator from the brake lever. 1. Remove one brake mounting bolt. Swing the brake up over the disc to expose the brake pads. In close clearance applications the brake may be removed from the vehicle. Using a flat bladed screw driver, pry out the used brake pads from their respective positions. The lever side friction pad is snapped onto the plastic actuator cover. Care should be used in removing the friction pad from the plastic actuator cover so as not to break off the center snap tabs. 2. Place the new friction pads in their respective positions. The lever side friction pad has a center hole which snaps over the plastic snap tabs of the actuator cover. The flat on the lever side pad must align with the flat on the plastic rotor cover, allowing the pad to sit flat. If the snap tabs are gone dab some silicone gasket adhesive around the back edge of the friction pad and press firmly into place aligned as described above. Before placing the carrier pad in postition, clean out excisting pad glue from the pad compartment. Place a layer of silicone gasket adhesive all along the back edge of the carrier friction pad and press firmly in place. Push the lever side pad into the brake as far as possible. 3. Swing the brake over the disc and install the mounting bolt and tighten all mounting bolts. 4. After friction pad replacement, the brake actuating lever is no longer in the correct position for the actuating linkage. Unbend tab on anti-rotation clip and loosen screw enough to disengage the lever spline. Rotate the lever to the OEM and torque screw to 110 - 140 in.lbs.(12.4 -15.8 Nm). Bend up a tab on the antirotation clip that aligns with one of the screw head flats, to prevent screw rotation. Attach actuating cable or linkage to the lever. Adjustment of pad gap is accomplished by adjusting the actuating cable or linkage.
T20000
3&6
LD RS
08/99
11-23
11.2.1.4 Disassembly Perform disassembly on a clean work bench. 1. Disconnect the actuator cable or linkage and remove brake from its mounting. 2. Remove friction pads. (see Replacing Friction Pads) 3. Unbend anti-rotation clip tab away from lever holding screw. Remove screw, anti-rotation clip, washers, lever, and spring. 4. Push out rotor assembly from the casting.
Caution BALL SPACER AND 3 BALL BEARINGS MAY COME OUT WITH THE ROTOR ASSEMBLY. (FOR ROTOR DISASSEMBLY SEE SERVICING ROTOR ASSEMBLY).
5. Remove 3 ball bearings and ball spacer. 6. Shaft seal need only be replaced if excessively wom or cracked. If replacement is necessary, press out the plastic shaft seal from inside the casting, using a steel spacer block 1.078"(27.38mm) diameter by 2.5 (63.5mm) long and an arbor press.
Note POPULAR BRAND NAME 3/8" DRIVE 13/16" HEX DEEP SOCKET WORKS WELL AS A SPACER BLOCK.
7. After the shaft seal is pressed out, remove the sliver of plastic that may be left in the groove in the casting.
This completes disassembly of the brake.
11.2.1.5 Cleaning and inspection 1. Clean all parts with denatured alcohol and either wipe dry with a clean lint free cloth or blow dry with an air hose. 2. Examine all parts carefully for signs of excessive wear, damage, or corrosion. Replace any parts found to be damaged. 3. Check rotor assembly for cracks. Replace if necessary. 4. Inspect the casting ball pockets for scoring, pitting, cracks or corrosion. A corroded or deeply scored casting should be replaced. Light scoring and stains may be removed. 5. Check to see that the disc is not bent or misshaped. 6. Check lever spring for breakage.
T20000
3&6
LD RS
08/99
11-24
11.2.1.6 Assembly Prior to assembly make sure all parts are clean and serviceable. 1. Install a new shaft seal by inserting the seaI from the outside of the casting with the extended smooth surface inserted first. Using an arbor press, with a protective spacer block between the arbor press and the seal, gently press the seal in until it snaps into the groove in the casting. 2. Coat with grease, the ball pockets in the casting, the shaft and ball pockets of the rotor assembly. 3. Insert 3 ball bearings and ball spacer into the pockets in the casting. 4. From the inside of the casting slide the shaft of the rotor assembly thru the shaft seal and seat the ball pockets against the ball beanrings. 5. PIace the spring over the large diameter pilot on the outside of the castng. 6. Install the lever, making sure the small diameter of the spring is piloted on the outside of the 4 pins in the lever. Set the lever in the OEM position. 7. Install the washers and anti-rotation clip with its tab inserted into the lower hole in the lever. 8. Insert screw into rotor assembly shaft and tighten to 110 - 140 in.lbs.(12.4 - 15.8Nm), while guiding lever over rotor assembly spline. 9. After the proper torque is achieved and the lever is in the OEM position, bend up a tab on the anti-rotation clip that aligns with one of the screw head flats, to prevent screw rotation. 10. Install the friction pads onto the rotor assembly and carrier. (see Replacing Friction Pads). 11. Stroke lever in its proper direction. The lever must rotate thru 60 degrees of rotation. Return lever to the OEM position and make sure the lever side friction pad is fully rerurned.
11.2.1.7 Replacing mount bushings 1. Push mount bushings completely out of the brake casting. 2. Remove the four (4) O-rings from the grooves in the casting, being carefull not to damage the grooves. Clean the grooves and the bore with denatured alcohol or cleaning solvent. Let dry. Lubricate the grooves and O-rings with the grease furnished with the service kit. Install the O-rings into the grooves. 3. Coat the bushings with kit grease. Insert bushing through the O-ring. Wipe off any excess grease.
11.2.1.8 Servicing rotor assembly Disassemble brake as previously described. 1. Using a sharp knife, make several cuts through the outside diameler of the rigid plastic rotor cover. Break apart the plastic, remove and discard. 2. Discard the plain bearing from under the plasic cover 3. ThoroughIy clean all dirt and grease residue from the rotor. 4. Amply grease one face of the new plain bearing and place it into the new rotor cover, grease to plastic. Amply grease the other face of the insert. 5. To assemble the new plastic rotor cover a bench vise is necessary. Snap a friction pad onto the plastic cover. Place the plastic cover over rte rotor, place in a vice, and slowly squeeze the cover and rotor until the cover snaps in place. Remove the friction pad and reassemble the brake as previously described.
T20000
3&6
LD RS
08/99
11-25
11.2.2
Spring applied hydraulic released brake (high pressure)
Note PLEASE READ INSTRUCTIONS BELOW BEFORE ATTEMPTING ANY WORK ON THE BRAKE.
T20000
3&6
LD RS
08/99
11-26
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE))
4 7 5
11-27
08/99
T20000
3&6
LD RS
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE)) Item Description Quantity
1 2 3 4 5 6 7
Caliper - Parking brake Disc - Brake Assembly - Mounting bracket Screw - Bracket assembly to brg cap mtg Washer - Bracket assembly to brg cap mtg flat screw Screw - Flange Spacer
1 1 1 4 4 6 4
T20000
3&6
LD RS
08/99
11-28
SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE)
17 2 22 21 8 6 20 14 15 16 3 12 13 9 11 10 7 4 24 5
23
18
19
11-29
08/99
T20000
3&6
LD RS
SPRING APPLIED HYDRAULIC RELEASED BRAKE (HIGH PRESSURE) Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Torque plate Bolt - Hex Jamnut Housing - Spring Plug Bolt - Adjustment Shim Spring disc Piston Seal - O-ring Back-up ring Piston Seal - O-ring Back-up ring Seal - O-ring Wiper Bolt Nut Lining Bleeder Spring - Urethane Washer - Flat Cap - Plug Seal - O-ring
1 2 2 1 1 1 AR* 10 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1
AR*: As Required
T20000 3&6 LD RS 11-30
08/99
11.2.2.2 Operation Ten disc springs (8) are used to hold the park brake in the actuated state. The springs (8) push the pistons (9,12) into the lining and carrier assembly (19) which squeezes a driveline mounted disc. The brake is released by fluid entering a SAE 7/16-20 threaded inlet in the side of the torque plate (1) which pushes the pistons back and compresses the springs (8). 11.2.2.3 Adjustment and rebuild criteria 1. 2. 3. 4. Apply hydraulic pressure to the brake. Remove plug (5) and set running clearance (.020 - .030) using the adjustment bolt (6). Replace plug (5). Even up running clearance on each side of the disc by adjusting the carrier retaining bolt ( 17).
The brake should be rebuilt when one or more of the following criteria are met: 1. Any signs of fluid leakage. 2. Lining thickness less than .031". 3. Cracked or chipped linings. 11.2.2.4 Replacing friction pads 1. Apply hydraulic pressure to the brake and remove plug (5) and carrier bolt (17). 2. With pressure applied, back-off adjustment bolt (6) until piston (12) is flush with piston (9). 3. Release hydraulic pressure from the brake and remove lining and carrier assemblies (19). 11.2.2.5 Disassembly
Caution
REGARDING THE REMOVAL OF THE SPRING HOUSING
IF THE PARK BRAKE IS BEING DISASSEMBLED WHILE ON THE VEHICLE, IT IS IMPORTANT TO FOLLOW THE DIRECTIONS (4) AND THE LINING AND CARRIERS (19) VERY CLOSELY.
1. 2. 3. 4. 5. 6.
Apply hydraulic pressure to the brake and remove plug (5) and carrier bolt (17). With pressure applied, back-off adjustment bolt (6) until piston (12) is flush with piston (9). Release hydraulic pressure from the brake and remove lining and carrier assemblies (19). Using a press, compress springs (8) to reduce the force on the spring housing (4). Use a spanner wrench to remove the spring housing (4) (counter-clockwise direction). The springs (8) will be accessible when the spring housing is removed.
Note THE SPRING HOUSING (4) MAY BE REMOVED WITHOUT COMPRESSING THE SPRINGS (8), HOWEVER IT IS NOT RECOMMENDED DUE TO THE HIGH TORQUE REQUIRED. 7. The adjustment bolt (6) threaded part of the way into the hydraulic piston (9) may be used to remove the pistons (9 and12) if brake is mounted on the vehicle. 8. If brake is not mounted to the vehicle it is easier to press the pistons out from the lining and carrier (19) side of the torque Plate (1).
Caution
REMOVING THE PISTONS
DO NOT DAMAGE SEALS (10,13,15) OR BACK-UP RINGS (11,14) OR THE WIPER (16) WHEN (9 AND12).
9. Piston (12) may be removed from piston (9) by pushing on piston (12) through adjustment bolt hole with a small nut-river or similar device.
T20000
3&6
LD RS
08/99
11-31
11.2.2.6 Cleaning and inspection 1. Clean all metal parts prior to assembly. 2. Blow excess cleaning solution off of all parts and out of all fluid passages. 11.2.2.7 Assembly 1. Apply a thin coat off fluid (compatible with mineral oil based hydraulic fluid) to seals (10,13,15), Back-up rings (11,14) and the wiper (16). 2. Install seal (15) in seal groove on piston (12). 3. Slide the adjustment piston (12) into the bore located in the hydraulic piston (9) until it hits the bottom of the bore. 4. Install wiper (16), back-up ring (14), and seal (13) in the grooves located in the small hole in the torque plate (1). 5. Install seal (10) and back-up ring (11) in larger grooves in torque plate (1). 6. Install piston assembly into torque pIate. (1). 7. Thread adjustment bolt (6) into the hydraulic piston (9) until the bolt contacts the adjustment piston (12). 8. Place springs (8) in the torque plate (1). Springs should be placed in an alternating cupped face to cupped face orientation. The springs on the outside ends of the stack should be oriented cupped face out. 9. If the brake contained a shim (7) when it was disassembled, place the shim (7) so it will be in the bottom of the spring housing (4) when it is installed. See illustration below for a graphical representation.
Note SPRINGS ARE MATCHED AND PRETESTED. IF NEW SPRINGS ARE BEING INSTALLED ADD A SHIM ONLY IF THE NEW
SPRINGS ARE SHIPPED WITH ONE.
SHIM
SPRINGS
10. Thread spring housing (4) into torque plate (1) about 3 turns or until it makes contact, with the springs (8). 11. Using a press, compress springs (8) to reduce the force on the spring housing (4). 12. Use a spanner wrench to tighten spring-housing until the face bottoms out on the counterbore face in the torque plate (1). Tighten to 500 - 600 lb.-in torque. 13. Assemble washer (22) and the urethane spring (21) on the mounting bolt (2) then slide mounting bolts through bolt holes in the torque Plate (1). 14. Thread jam nut/sleeve (3) onto mounting bolt. The cylindrical part of the jam nut/sleeve should extend into the torque plate.
T20000
3&6
LD RS
08/99
11-32
15. Install lining and carrier assemblies (19). Thread lining and carrier adjustment bolt into hex nut (8) located in the slot in the back side of the torque plate (1). 16. Install the bleeder (20) in the port located on the top side of the torque plate (1). 17. After brake is mounted and adjusted, snap plug (5) onto spring housing (4). 11.2.2.8 Installation 1. Slide brake over disc and into the mounting position. 2. Start mounting bolts (2) into mounting surface far enough to just support the brake. 3. Remove plug (5) and tighten adjustment bolt (6) until linings (19) are clamped to the disc. 4. Tighten mounting bolts (2) until they make contact with the urethane springs (21), then tighten 1 to 2 flats more. 5. Tighten jam nut/sleeve (3) against mounting surface to torque shown in section 11.2.2.9.
Caution BRAKE LININGS ARE SUSCEPTIBLE TO CONTAMINATION. WHEN INSTALLING OR SERVICING BRAKES KEEP ALL OIL AND FLUIDS AWAY FROM THE LININGS. POOR BRAKE PERFORMANCE MAY RESULT. 6. Attach brake line to inlet port located on the side of the torque plate (1). 7. Bleed brake system to remove trapped air as follows.
Note USE BLEEDER HOSE ON BLEEDER SCREWS (PREFERABLY CLEAR TUBING) TO ROUTE FLUID AWAY
FROM THE BRAKE AND LININGS.
Caution BRAKE USES HIGH PRESSURE, OPEN BLEEDER SCREW (20) VERY SLOWLY WHEN PERFORMING BLEEDING PROCEDURE. 8. Apply pressure to brake and slowly open the bleeder screw (20) observe any air bubbles that flow from the brake. 9. Repeat above paragraph until no air is observed in the fluid from the bleeder screw (20). 11.2.2.9 Torque specs PART (ITEM NO.) BLEEDER SCREW (20) JAMNUT/SLEEVE (3) THREAD SIZE 7/16 - 20 3/4 - 10 DRY TORQUE 200 - 250 (LB-IN) 200 (LB-IN)
T20000
3&6
LD RS
08/99
11-33
11.2.3
Spring applied hydraulic released brake (low pressure)
Note PLEASE READ INSTRUCTIONS BELOW BEFORE ATTEMPTING ANY WORK ON THE BRAKE.
T20000
3&6
LD RS
08/99
11-34
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE))
4 7 5
11-35
08/99
T20000
3&6
LD RS
GROUP - DISC BRAKE (SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE)) Item Description Quantity
1 2 3 4 5 6 7
Caliper - Parking brake Disc - Brake Assembly - Mounting bracket Screw - Bracket assembly to brg cap mtg Washer - Bracket assembly to brg cap mtg flat screw Screw - Flange Spacer
1 1 1 4 4 6 4
T20000
3&6
LD RS
08/99
11-36
SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE)
37 24 23
25 26 27 28 29 30 21 31
32
33 5 17 38
18 19 2 4 36 35 10 9 10 13 14 11 34 8 6 34 7
16 15 3
13
12
20
22
11-37
08/99
T20000
3&6
LD RS
SPRING APPLIED HYDRAULIC RELEASED BRAKE (LOW PRESSURE) Item Description Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Torque plate Bolt - Hex Jamnut Housing - Spring Plug Bolt - Adjustment Shim Spring disc Cam Ball - Bearing Cam Bearing - Needle Washer - Hardened Seal - O-ring Piston Seal - O-ring Lever Ring - Retainer Bolt Nut Pin - Cotters Lining and carrier assembly Cylinder - Hydraulic Screw Piston Seal - STD poly pack Sliding ring Rod Ring - Retaining Rod excluder Jamnut Clevis Clevis pin Pin - Dowel Spring - Urethane Washer - Flat Cap - Plug Seal - O-ring
1 2 2 1 1 1 AR* 10 1 3 1 1 2 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 3 2 2 1 1
AR*: As Required
T20000 3&6 LD RS 11-38
08/99
11.2.3.2 Operation Ten disc springs (8) are used to hold the park brake in the actuated state. The springs push the cams (9,11) and piston (15) into the lining and carrier assembly (22) which squeezes a driveline mounted disc. The brake is released by fluid entering a SAE 7/16-20 threaded inlet in the top of the hydraulic cylinder (23) which pushes the piston (25) down, thereby rotating the lever (17) and cam (11), compressing the springs (8). 11.2.3.3 Adjustment and rebuild criteria 1. 2. 3. 4. Apply hydraulic pressure to the brake. Remove plug (5) and set running clearance (.020 - .030) using the adjustment bolt (6). Replace plug (5). Even up running clearance on each side of the disc by adjusting the carrier retaining bolt ( 19).
The brake should be rebuilt when one or more of the following criteria are met: 1. Any signs of fluid leakage. 2. Lining thickness less than .031. 3. Cracked or chipped linings. 11.2.3.4 Replacing friction pads 1. Apply hydraulic pressure to the brake and remove plug (5) and carrier retaining bolt (19). 2. With pressure applied remove adjustment bolt (6). 3. Release hydraulic pressure from the brake and remove lining and carrier assemblies (22). 11.2.3.5 Disassembly
Caution IF THE PARK BRAKE IS BEING DISASSEMBLED WHILE ON THE VEHICLE, IT IS IMPORTANT TO FOLLOW THE FOLLOWING SPRING HOUSING (4) AND THE LINING & CARRIERS (22) VERY CLOSELY.
DIRECTIONS REGARDING THE REMOVAL OF THE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Apply hydraulic pressure to the brake and remove plug (5) and carrier retaining bolt (19). With pressure applied remove adjustment bolt (6). Release hydraulic pressure from the brake and remove lining and carrier assemblies (22). Use a spanner wrench to remove the spring housing (4) (counter-clockwise direction). The springs (8) will be accessible when the spring housing is removed. Remove hair pin (21) and pin (33) from the clevis (32). Remove hydraulic cylinder (23) from torque plate (1) by removing cylinder mounting bolts (24). Remove retaining ring (18) and lever (17) from the spline on the cam (11). The opposing cams (9, 11), adjustment piston (15) and dowel pins (34) can be removed by pressing them out of the torque plate (1) from the lining and carrier (22) side. Remove balls (10) and adjustment piston (15) from cams (9, 11). The O-ring seal (16) can be removed from the adjustment piston (15) if necessary. Remove needle bearing (12), hardened washers (13), and O-ring seal (14) from the torque plate (1) once the cams (9, 11) are removed. Slide the rod (28) and clevis (32) out of the hydraulic cylinder (23). Remove the rod excluder (30) from the hydraulic cylinder (23) by prying with a small screwdriver. The retaining ring (29) may be removed once the rod excluder (30) has been removed. Press piston (25) out of the hydraulic cylinder (23) by pushing on the top of the piston with a long slender rod.
T20000
3&6
LD RS
08/99
11-39
Note DO NOT SCAR CYLINDER WALLS OR NICK THE PISTON DURING REMOVAL. 11.2.3.6 Cleaning and inspection 1. Clean all metal parts prior to assembly. 2. Blow excess cleaning solution off of all parts and out of all fluid passages. 11.2.3.7 Assembly 1. Apply a thin coat of fluid to seals (14,16). 2. Install seal (16) in seal groove on adjustment piston (15). 3. Slide the adjustment piston (12) into the bore located in the cam (11) until the seal (16) is inside the bore. 4. Install seal (14) in the grooves located in the small hole in the torque plate (1). 5. Install needle bearing (12) between the two hardened washers (13). 6. With bearing and washers (12,13) in place, install cam (11) and balls (10) into torque plate (1). 7. Install cam (9) and dowel pins (34) into torque plate (1). 8. Thread adjustment bolt (6) into the cam (9) until the bolt contacts the adjustment piston (15). 9. Place springs (8) in the torque plate (1). Springs should be placed in an alternating cupped face to cupped face orientation. The springs on the outside ends of the stack should be oriented cupped face out. 10. Replace the shim (7) in the bottom of the spring housing (4) before adding the springs if the brake contained a shim when it was disassembled. See illustration below for a graphical representation.
Note SPRINGS ARE MATCHED AND PRETESTED. IF NEW SPRINGS ARE BEING INSTALLED ADD A SHIM ONLY IF THE NEW SPRINGS ARE SHIPPED WITH ONE.
SHIM
SPRINGS
11. Apply a thin coat of Never-Seez to the spring housing (4) threads. 12. Screw spring housing (4) onto torque plate (1). Tighten with a spanner wrench until the spring housing face bottoms out on the counterbore face in the torque plate (1). 13. Assemble washer (36) and the urethane spring (35) on the mounting bolt (2) then slide mounting bolts through bolt holes in the torque plate (1). 14. Thread jam nut/sleeve (3) onto mounting bolt. The cylindrical part of the jam nut/sleeve should extend into the torque plate. 15. Apply a thin coat of fluid to seal (25) and sliding ring (27). 16. Install seal (25) and the sliding Ring (27) on the Piston (25).
T20000
3&6
LD RS
08/99
11-40
17. Install piston (25) into the hydraulic cylinder (23) with the flat side facing the top of the cylinder. 18. Push the piston (25) to the top of the hydraulic cylinder (23) and install the retaining ring (29) in the groove at the bottom of the cylinder.
Note MAKE SURE INLET PORT IS UNCAPPED WHEN INSTALLING PISTON (25). 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Press rod excluder (30) with the rubber side facing out of the hydraulic cylinder (23). Thread clevis (32) with the 3/8-16 jam nut installed into the rod (28). Insert the rod (28) and clevis (32) through the rod excluder (30) into the hydraulic cylinder (23). Position assembled hydraulic cylinder (23) onto torque plate (1) and install the cylinder mounting bolts (24) into their respective holes. Pin clevis (32) to the lever (17) with clevis pin (33) and hair pin (21). Adjust rod (28) until it contacts the rod retaining hole in piston (25) and tighten the jam nut. Install lever (17) on the spline of cam (11). The centerline of the lever should be oriented parallel to the top of the torque plate (1). Install retaining ring (18) in groove on the cam (11). Install lining and carrier assemblies (22). Thread carrier adjustment bolt (19) into hex nut (18) located in the slot in the back side of the torque plate (1). After brake is mounted and adjusted, snap plug (5) onto spring housing (4).
11.2.3.8 Installation 1. 2. 3. 4. Slide brake over disc and into the mounting position (per vehicle specification). Start mounting bolts (2) into mounting surface far enough to just support the brake. Remove plug (5) and tighten adjustment bolt (6) until linings (22) are clamped to the disc. Tighten mounting bolts (2) until they make contact with the urethane springs (35), then tighten 1 to 2 flats more. 5. Tighten jam nut / sleeve (3) against mounting surface to torque shown in section 11.2.3.9.
Caution BRAKE LININGS ARE SUSCEPTIBLE TO CONTAMINATION. WHEN INSTALLING OR SERVICING BRAKES KEEP ALL OIL AND FLUIDS AWAY FROM THE LININGS. POOR BRAKE PERFORMANCE MAY RESULT. 6. Attach brake line to inlet port located on the top of the hydraulic cylinder (23). 11.2.3.9 Torque specs PART (ITEM NO.) PLUG-INLET (37) JAM NUT/SLEEVE (3) THREAD SIZE 7/16 - 20 3/4 - 10 DRY TORQUE 12/17 (LB-IN) 200 (LB-IN)
T20000
3&6
LD RS
08/99
11-41
12. SERVICE TOOLS

12.1 REVERSE IDLER SHAFT NUT SOCKET (TG 1304 - 54) Made from Snap-on IM662A Socket 2 1/16 drive 3/4.
63
-0 61 +0.1
10
45
4 SLOTS
6 +0 -0.1
T20000
3&6
LD RS
08/99
12-1
Prepared and printed for SPICER OFF-HIGHWAY PRODUCTS by Brouwer Technisch Bureau
Printed in Belgium
Brugge, Belgium

Dana T2000 6 Speeds Long Drop Service Manual

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Maintenance and Service Manual

SPICER OFF HIGHWAY-PRODUCTS

DANA CORPORATION 1990. Unpublished material.

3-SPEED STANDARD RATIO

3-SPEED DEEP RATIO

6-SPEED RANGE SHIFT

2. CLEANING, INSPECTION AND LEGEND SYMBOLS

6. OPERATION OF THE TRANSMISSION

7. TROUBLESHOOTING GUIDE FOR THE T20000 TRANSMISSION

8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

10. DISASSEMBLY AND REASSEMBLY T20000 LD TRANSMISSION

11. OPTIONS (Continued)

12. SERVICE TOOLS

IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE CAUTIONS AND NOTICES ARE

2. CLEANING, INSPECTION AND LEGEND SYMBOLS

Cleaning, inspection and legend symbols

2.3 LEGEND SYMBOLS

Maximum length: Maximum width: Maximum height: Oil capacity

[123 - 136] [174 - 191] [302 - 332]

[122 - 134] [174 - 191] [224 - 268] [427 - 470]

GRADE 8.8 or 9.8

3.3.2 Elastic stop nut torque

3.3.3 O ring port plug torque chart

3.3.4 Pipe plug torque chart

3.3.5 Permanent metric plug torque chart

THREAD SIZE LBF - FT M18 x 1.5 6H M18 x 1.5 6H 25-30 45-50

TORQUE [N.m] [34-41] [61-68]

3.3.5 Coil and cartridge torque

*Dexron is a registered trademark of GENERAL MOTORS CORPORATION.

(1) DRIVE PLATE AND WELD NUT ASSEMBLY

5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

FLYWHEEL HOUSING MOUNT DIAL INDICATOR HERE

FLYWHEEL PILOT BORE

21/2"ALIGNING STUDS DRIVE PLATE

INTERMEDIATE DRIVE PLATES

PLATES TO BE INSTALLED WITH CONCAVE SIDE TOWARD ENGINE FLYWHEEL

5.3 EXTERNAL PLUMBING

From cooler to transmission in

Left side view

5.3.1 Optional: remote filter

From oil filter

.3750-16 UNC - 2B THD .88 [22.4] DEEP 3 HOLES

Optional remote filter

5.4 SPEED SENSOR INSTALLATION

1.65 (42.0) Screw Tighten to 5.9 - 7.4 lbf-ft (8 - 10 Nm) Support

Position sign "O"-ring

Screw Tighten to 5.9 - 7.4 lbf-ft (8 - 10 Nm)

Sensor position on transmission Turbine speed sensor location

Engine speed sensor location

SPEED SENSOR INSTALLATION (Continued)

6. OPERATION OF THE TRANSMISSION

Operation of the transmission

The converter, pump drive section and pressure regulating valve

THE CONVERTER, PUMP DRIVE SECTION AND PRESSURE REGULATING VALVE

Operation of the transmission

The input shaft and directional clutches

THE INPUT SHAFT AND DIRECTIONAL CLUTCHES

Operation of the transmission

The range clutches

The output section