Subassemblies

Case Bushing

Tools Required:

• Thread Impact Slide Hammer T50T-100-A
• Rear Case Bushing Replacer T80L-77110-A
• Seal Remover TOOL-1175-AC

Removal

To remove the transmission case bushing, use Thread Impact Slide Hammer T50T-100-A and Seal Remover TOOL-1175-AC or equivalent.

Installation

1. Position the replacement bushing on Rear Case Bushing Replacer T80L-77110-A and install in the bushing bore through the front of the case.

2. Thread Impact Slide Hammer T50T-100-A into the bushing installer through the back of the case and install the bushing.
   
   
   
   

Pump Seal

Tools Required:

• Front Pump Seal Replacer T63L-77837-A
• Impact Slide Hammer T59L-100-B
• Seal Remover TOOL-1175-AC

Removal

Remove the pump seal using Seal Remover TOOL-1175-AC and Impact Slide Hammer T59L-100-B.

Installation

Install the seal using Front Pump Seal Replacer T63L-77837-A.

Pump and Intermediate Clutch Piston

Disassembly

Tools Required:

• Lip Seal Protector T80L-77005-A

1. Remove the No. 1 thrust washer.
   
   
   
   

2. Remove the four pump seal rings.

   The reverse clutch rings are larger than the forward clutch rings.
   
   
   
   

3. Remove the pump body-to-case seal and discard.
   
   
   
   

4. Remove the spring retainer assembly by carefully dislodging the tabs.
   
   
   
   

5. Remove the clutch piston.
   
   
   
   

6. Remove the five 10mm stator support bolts.
   
   
   
   

7. Remove the stator support.
   
   
   
   

8. Remove the drive and driven pump gears from the pump body.
   
   
   
   

Assembly

1. Install the drive and driven pump gears in the pump body.
   
   
   
   

   NOTE: Chamfers on both gears face into the pump body.

   
   
   
   
   

2. Position the stator support to the pump body and install the retaining bolts. Tighten to 16-22 Nm (12-16 lb-ft).
   
   
   
   

3. Install new pump-to-case seal.
   
   
   
   

4. Install new seals on the clutch piston. Note the direction of the sealing lip before installation. The lips point away from the spring posts.
   
   
   
   
   
   
   
   

5. Install the clutch piston as follows:
   1. Coat the piston seals and the pump body sealing area with petroleum jelly.
   2. Install the piston in Lip Seal Protector T80L-77005-A.
      
      
      
      
   3. Install the piston in the pump body and push to the bottom of the bore by exerting even thumb pressure on the piston.

       CAUTION: The piston bleed hole must be located at 12 o'clock position (toward top of transmission).

      
      
      
      
      

6. Snap the spring retainer assembly into place on the pump body. Use even pressure.
   
   
   
   

7. Install the pump seal rings.

   NOTE: Stator support seal rings are the largest rings and are for the reverse clutch. These rings are closest to the pump. Stator support seal rings are for the forward clutch. These rings are farthest from the pump body.

   
   
   
   
   

Pump Bushing

Tools Required:

• Oil Pump Bushing Replacer T80L-77268-A
• Oil Pump Bushing Remover T80L-77268-B

Removal

Remove the bushing using Oil Pump Bushing Remover T80L-77268-B.

Installation

Install the bushing using Oil Pump Bushing Replacer T80L-77268-A.

Intermediate One-Way Clutch

Disassembly

1. Using snap ring pliers, remove the clutch retaining ring.
   
   
   
   

2. Remove the clutch retaining plate.
   
   
   
   

3. Remove the clutch outer race by lifting on the race while turning counterclockwise.
   
   
   
   

4. Carefully lift the one-way clutch from the inner race.
   
   
   
   

Assembly

1. Install one-way clutch to inner race.
   
   
   
   

2. Install clutch outer race on clutch while turning counterclockwise.
   
   
   
   

3. Install clutch retaining plate.
   
   
   
   

4. Using snap ring pliers, install retaining ring.
   
   
   
   

Reverse Clutch

Tools Required:

• Clutch Spring Compressor T65L-77515-A
• Reverse Clutch Outer Seal Protector T80L-77403-A
• Reverse Clutch Inner Seal Protector T80L-77403-B
• Reverse Clutch Spring Compressor Plate T80L-77405-A
• Air Nozzle TOOL-7000-DE

Disassembly

1. Remove the No. 2 needle bearing.
   
   
   
   

2. Remove the clutch pack retaining ring.
   
   
   
   

3. Remove the clutch pack.
   
   
   
   

4. Remove the wave snap ring using Clutch Spring Compressor T65L-77515-A and Reverse Clutch Spring Compressor Plate T80L-77405-A.
   
   
   
   
   
   
   
   

5. Remove the piston return spring and the thrust ring.
   
   
   
   

6. Remove the clutch piston.
   
   
   
   

   NOTE: To aid removal, it may be necessary to apply air pressure to the drum. Block the opposite hole with a finger.

   
   
   
   
   

Assembly

1. Install new seals on the clutch piston. Because the seals are square cut, the direction of installation is not important.

   NOTE: The piston check ball must be present and moving freely.

   
   
   
   
   
   
   
   
   

2. Install the clutch piston as follows:
   1. Coat the piston seals and clutch drum sealing area with petroleum jelly.
   2. Install Reverse Clutch Inner Seal Protector T80L-77403-B and Reverse Clutch Outer Seal Protector T80L-77403-A in the clutch drum.
      
      
      
      
   3. Coat the piston seals, the clutch drum sealing area and the seal protector with petroleum jelly.
   4. Position the piston and push it to the bottom of the drum using even thumb pressure.
      
      
      
      

3. Install the piston thrust ring and the piston return spring.
   
   
   
   

4. Install the wave snap ring (with points down) using Clutch Spring Compressor T65L-77515-A and Reverse Clutch Spring Compressor T80L-77405-A.
   
   
   
   
   
   
   
   

5. Install the clutch pack.
   
   
   
   

   NOTE: The apply plate must be installed first. Note that the dished side of the plate must face the piston.

   
   
   
   
   

6. Install the clutch pack retaining ring and check the clearance between the ring and the pressure plate using a feeler gauge. The pressure plate should be held downward as the clearance is checked.
   
   
   
   

   The clearance should be 1.02-1.91mm (0.040-0.075 inch).

   If the clearance is not within specification, selective snap rings are available in the following thicknesses:

   • 1.27-1.37mm (0.060-0.064 inch).
   • 1.87-1.98mm (0.074-0.078 inch).
   • 2.23-2.33mm (0.088-0.092 inch).
   • 2.59-2.69mm (0.102-0.106 inch).

   Install the correct size snap ring and check the clearance.

7. Check the clutch for proper operation using Air Nozzle TOOL-7000-DE or equivalent. The clutch should be heard and felt to apply smoothly and without leakage.
   
   
   
   

8. Install the No. 2 needle bearing.
   
   
   
   

Forward Clutch

Item	Part Number	Description
1	7F227	Outer Forward Clutch Piston Seal
2	7F228	Inner Forward Clutch Piston Seal
3	7F278	Forward and Reverse Clutch Pressure Plate
4	7D483	Forward Clutch Pack Retaining Ring
5	7G040	Number 3 Needle Bearing
6	7D051	Forward Clutch Hub
7	7E311	Internal Spline Clutch Plates
8	7B442	External Spline Clutch Plates
9	7E085	Wave Plate
10	388099	Retaining Snap Ring
11	7F229	Return Spring Retainer
12	7F230	Forward Clutch Piston Return Spring
13	7L140	Forward Clutch Piston
14	7F207	Forward Clutch Cylinder and Turbine Shaft Assy

Tools Required:

• Clutch Spring Compressor T65L-77515-A
• Forward Clutch Outer Lip Seal Protector T68P-7D158-A
• Forward Clutch Inner Lip Seal Protector T80L-77140-A
• Forward Clutch Spring Compressor Extension T80L-77515-A
• Air Nozzle TOOL-7000-DE

Disassembly

1. Remove the clutch hub and No. 3 needle bearing, if not already removed.
   
   
   
   

2. Remove the clutch pack selective retaining ring.

   NOTE: To aid handling, the clutch may set in the extension housing or a 51mm (2-inch) diameter hole may be cut in the work bench.

   
   
   
   
   

3. Remove the clutch pack.
   
   
   
   

4. Compress the piston return spring using Clutch Spring Compressor T65L-77515-A, and Forward Clutch Spring Compressor Extension T80L-77515-A.
   
   
   
   

   Remove the retaining ring and spring retainer.
   
   
   
   

5. Remove the clutch piston.

   Note the position and direction of the lip seals and remove.
   
   
   
   
   
   
   
   

   NOTE: Ensure check balls in clutch cylinder are free and clean. Check for proper seating.

   
   
   
   
   

Assembly

1. Install new seals on the clutch piston. Note the direction of the sealing lip before installation.
   
   
   
   
   
   
   
   

2. Install the clutch piston as follows:
   1. Coat the piston seals and the clutch drum sealing area with petroleum jelly.
   2. Install the Forward Clutch Inner Lip Seal Protector T80L- 77140-A over the clutch cylinder hub.
   3. Install the piston in the Outer Lip Seal Protector, T68P-7D158-A.
      
      
      
      
   4. Position the seal protector and piston in the clutch drum. Push the piston to the bottom of the drum using even thumb pressure.
      
      
      
      

3. Install the piston return spring, the spring retainer and the retaining ring.
   
   
   
   

   Compress the piston return spring using Clutch Spring Compressor T65L-77515-A and Forward Clutch Spring Compressor Extension T80L-77515-A.
   
   
   
   

4. Install the clutch pack.
   
   
   
   

   NOTE: The wave plate must be installed first.

   
   
   
   
   

5. Install the clutch pack retaining ring and check the clearance between the ring and the pressure plate using a feeler gauge.

   The pressure plate should be held downward as the clearance is checked.
   
   
   
   

   The clearance should be 1.27-2.26mm (0.050-0.089 inch)

   If the clearance is not within specification, selective snap rings are available in the following thicknesses:

   • 1.27-1.37mm (0.060-0.064 inch).
   • 1.87-1.98mm (0.074-0.078 inch).
   • 2.23-2.33mm (0.088-0.092 inch).
   • 2.59-2.69mm (0.102-0.106 inch).

   Install the correct size snap ring and recheck the clearance.

6. Check the clutch for proper operation using Air Nozzle TOOL-7000-DE or equivalent. The clutch should be heard and felt to apply smoothly and without leakage.
   
   
   
   

Sun Gear and Drive Shell

Disassembly

1. Remove the No. 4 needle bearing from the drive shell.
   
   
   
   

2. Remove the forward sun gear and No. 5 needle bearing from the drive shell.
   
   
   
   

3. Remove the No. 5 needle bearing from the forward sun gear.
   
   
   
   

   NOTE: The sun gear and drive shell is assembled as part of the transmission assembly procedure.

Center Support and Planetary One-Way Roller Clutch

Disassembly

1. Remove the center support from the planetary carrier. Rotate the center support counterclockwise and lift.
   
   
   
   

2. Carefully remove the planetary one-way roller clutch from the planetary assembly.
   
   
   
   

Assembly

1. If necessary, assemble the one-way roller clutch.
   
   
   
   

2. Install the one-way roller clutch in the planetary carrier.
   
   
   
   

3. Install the center support into the one-way roller clutch by rotating the center support counterclockwise.

   Lubricate the clutch races and the clutch assembly with petroleum jelly to aid in assembly.
   
   
   
   

Direct Clutch

Tools Required:

• Clutch Spring Compressor T65L-77515-A
• Direct Clutch Inner Lip Seal Protector T80L-77234-A
• Direct Clutch Outer Lip Seal Protector T80L-77254-A
• Air Nozzle TOOL-7000-DE

Disassembly

1. Remove the No. 7 direct clutch hub inner needle bearing.
   
   
   
   

2. Remove bearing support.
   
   
   
   

3. Remove the clutch pack selective retaining snap ring.
   
   
   
   

4. Remove the clutch pack from the cylinder.
   
   
   
   

5. Using Clutch Spring Compressor T65L-77515-A, compress the piston return springs. Remove the piston retaining ring using expanding- type snap ring pliers.
   
   
   
   

6. Remove the spring retainer assembly and piston from the cylinder.
   
   
   
   

   Note the position and direction of the lip seals and then remove.
   
   
   
   

Assembly

1. Install the inner piston seal on the clutch cylinder hub as follows:
   1. Position Direct Clutch Inner Lip Seal Protector T80L-77234-A over the clutch cylinder hub.
   2. Lubricate the seal and the seal protector with petroleum jelly.
   3. Position the seal over the installer tool with the sealing lip facing down.
      
      
      
      
   4. Push the seal down until it snaps off the end of the protector onto the clutch hub.
   5. Remove the seal protector from the clutch hub.
   6. Slide the seal up until it seats in the seal groove.
      
      
      
      

2. Inspect the piston check ball. Ensure the ball is present and moves freely. Check for leakage by performing the Direct Clutch Piston Check Ball Leakage procedure as outlined.
   
   
   
   

3. Install the outer clutch piston seal. Note the direction of the sealing lip before installation. The lip points away from the spring posts.
   
   
   
   

4. Install the clutch apply piston as follows:
   1. Coat the piston seals, the clutch cylinder sealing area and the piston inner seal area with petroleum jelly.
   2. Install the piston in the Direct Clutch Outer Lip Seal Protector T80L-77254-A.
      
      
      
      
   3. Position the tool in the clutch drum and push the piston to the bottom of the drum using even thumb pressure.
      
      
      
      

5. Install the piston spring and retainer assembly and retaining ring using Clutch Spring Compressor T65L-77515-A.
   
   
   
   

6. Install the clutch pack.
   
   
   
   

7. Install the clutch pack selective retaining ring and check the clearance between the ring and the pressure plate using a feeler gauge. The pressure plate should be held downward as the clearance is checked.
   
   
   
   

   The clearance should be:

   • Six Plate 1.57-2.16mm (0.062-0.085 inch).
   • Five Plate 1.27-1.80mm (0.050-0.071 inch).

   If the clearance is not within limits, selective snap rings are available in the following thicknesses:

   • 1.27-1.37mm (0.050-0.054 inch).
   • 1.62-1.72mm (0.064-0.068 inch).
   • 1.98-2.08mm (0.078-0.082 inch).
   • 2.33-2.43mm (0.092-0.096 inch).

   Install the correct size snap ring and check the clearance.

8. Check the clutch for proper operation using Air Nozzle TOOL-7000-DE or equivalent. The clutch should be heard and felt to apply smoothly and without leakage.
   
   
   
   

9. Install No. 7 needle bearing support.
   
   
   
   

10. Install No. 7 needle bearing (black side up).
    
    
    
    

Output Shaft

Disassembly

1. Remove the ring retaining the output shaft hub to the ring gear.
   
   
   
   

2. Separate the output shaft and hub assembly from the ring gear.
   
   
   
   

3. Remove the direct clutch from the ring gear and the No. 8 needle bearing from the back of the direct clutch.
   
   
   
   

4. Remove the four output shaft seal rings and the hub-to-output shaft retaining ring. Separate the hub from the output shaft.
   
   
   
   
   
   
   
   

5. Remove the two direct clutch seal rings from the output shaft.
   
   
   
   

Assembly

1. Install two direct clutch seal rings.
   
   
   
   

2. Install output shaft hub.
   
   
   
   

3. Install four output shaft seal rings and hub-to-output shaft retaining ring.
   
   
   
   

4. Install direct clutch and No. 8 needle bearing.
   
   
   
   

5. Install output shaft and hub assembly to ring gear.
   
   
   
   

6. Install output shaft-to-ring gear retaining ring.
   
   
   
   

Governor

Disassembly

1. Remove the screws retaining the counterweight to the governor body.

2. Remove the cover screws and cover.

3. Remove the plug, sleeve and governor valve from the governor body.

4. Remove screen from governor body.

Assembly

1. If removed, install the clip and spring on the governor valve.

2. Install governor valve in governor body.

3. Install the sleeve in the governor body with the points outward.

4. Install the plug in the sleeve with the knurled face inward.

5. Position the cover and install the retaining screws. Tighten the retaining screws to 2.3-3.4 Nm (21-30 lb-in).

   NOTE: The steel band (brass colored) goes inward and the top of the screen faces outward.

6. Install the screen in the body.

   NOTE: The finished face of the governor body should be flush with the face of the counterweight. (If it is not, the body is installed backwards.)

7. Position the governor body on the counterweight and install the retaining screws.

   Tighten retaining screws to 6-7 Nm (54-61 lb-in).

Parking Pawl

Removal

1. Slide the park pawl shaft out the rear of the case and remove the parking pawl.

2. Remove the return spring.
   
   
   
   

Installation

1. Hook the squared end of the spring into the notch on the park pawl.

2. Hold pawl and spring in place and hook curved end of spring into the recess in the case.

3. Install the park pawl shaft.
   
   
   
   

Neutral Start Switch

Tools Required:

• Neutral Start Switch Socket T74P-77247-A

Removal

1. Using the Neutral Start Switch Socket T74P-77247-A, remove switch from case.

2. Remove the O-ring seal and discard.
   
   
   
   

Installation

1. Install a new seal on the neutral start switch.

2. Install the switch in the case using the Neutral Start Switch Socket T74P-77247-A. Tighten to 11-15 Nm (8-11 lb-ft).
   
   
   
   

Manual and Throttle Linkage

Tools Required:

• Puller T58L-101-B
• Impact Slide Hammer T59L-100-B
• Shift Shaft Seal Replacer T74P-77498-A

NOTE: Before disassembling the linkage, observe the location of the various levers.

Disassembly

1. Grasp the outer throttle lever firmly and loosen the lever retaining nut.

    CAUTION: The outer throttle lever must be held in the position shown to prevent the inner throttle lever from rotating against the machined valve body surface. Failure to observe this precaution could result in damage to the valve body surface.

   
   
   
   
   

   Remove the retaining nut, the lockwasher, and throttle lever.
   
   
   
   

2. Using a small screwdriver or awl, remove the seal from the outer manual lever counterbore. Discard seal.
   
   
   
   

3. Using a narrow, sharp screwdriver, carefully remove the manual shaft retaining pin from the case.
   
   
   
   

4. Slide a 5/8-inch box end wrench over the inner manual lever, close to the bottom of the lever. Do not allow the wrench to contact the "rooster comb" area. Using a 21mm wrench, remove the manual lever retaining nut while securely holding the inner manual lever.
   
   
   
   

   Thread the nut off the shaft and remove the lever.
   
   
   
   

5. Remove the inner throttle lever and TV lever torsion spring.
   
   
   
   

6. Remove the inner manual lever and parking pawl actuating rod as an assembly.
   
   
   
   

   After removal, the rod may be disengaged from the lever.
   
   
   
   

7. Remove the manual lever shaft seal from the case using Puller T58L-101-B and Impact Slide Hammer T59L-100-B. Discard seal.
   
   
   
   

Assembly

To assemble the manual throttle linkages, reverse the disassembly except for the following:

1. Install a new manual lever seal using Shift Shaft Seal Replacer T74P-77498-A.
   
   
   
   

2. Before installing the outer throttle lever, install a new seal in the outer manual lever. To seat the seal, a 13mm thin wall socket may be used. Position the ratchet end of the socket against the seal.

   NOTE: The seal identification number must face outward.