Workshop Manual Transmission of HT200 SDLG Volvo

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Foreword This Service Manual deals with the design, working principles and repair instructions for transmissions HT200 and HT201. The instructions apply assuming that the transmission is removed from the machine or exposed in the machine. The necessary approach operations can be found in the Service Manual for the machine type concerned. The work procedures are based on the use of special(999)-tools, tools which can be made in your own workshop(E-tools)and standard tools generally available on the marker. All lifting devices such as strops, slings, ratchet blocks etc., must comply with appropriate National Regulations for such equipment. VME accept no responsibility if any lifting devices, tools or working methods other than those described in this publication are used.

This warning symbol will appear at various points in this manual in conjunction with warning statements. Its appearance means WARNING! BE ALERT! YOUR SAFETY IS INVOLVED!

The information and data given in this manual are valid at the time of publication. It is our policy to constantly strive to improve our products. The right therefore is reserved to make changes in design and improvements whenever it is believed the efficiency of the product will be improved, without incurring any obligation to incorporate such improvements in any product which has been shipped or is in service. Under our policy of continual product improvement, VME reserve the right to change specifications and equipment without prior notice. HT200 HT201VME

VME

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Contents FOREWORD......................................................................................................................... 1

SPECIFICATIONS................................................................................................................ 4

STANDARD TIGHTENING TORQUES............................................................................. 8

DESCRIPTION..................................................................................................................... 10

GENERAL REPAIR INSTRUCTIONS................................................................................ 11

REPAIR INSTRUCTIONS................................................................................................... 16 Transmission, reconditioning................................................................................................ 16Torque converter, rebuilding................................................................................................. 31Torque converter, reconditioning........................................................................................... 32 Oil pump and turbine shaft bearing, reconditioning.............................................................. 42 Damping valve, reconditioning............................................................................................. 45 Gear selector valve, reconditioning....................................................................................... 46 Lubricating oil valve, reconditioning..................................................................................... 52 Power take-off, reconditioning.............................................................................................. 52Forward and first clutches, dismantling and assembling....................................................... 54 Reverse and second clutches, dismantling and assembling................................................... 71 Third and fourth clutches, dismantling and assembling........................................................ 85 Transmission, assembling...................................................................................................... 103 Piston unit for parking brake HT200 ser.no.-2790, reconditioning....................................... 111 Piston unit for parking brake HT200 ser.no.2791-and HT201,reconditioning...................... 114

DRAWINGS OF E-TOOLS WHICH CAN BE MADE IN YOUR OWN WORKSHOP.... 130

DRAWINGS Clutch shaft, forward-first, HT200........................................................................................ 132 Clutch shaft, reverse-second, HT200.................................................................................... 134 Clutch shaft, third-fourth, HT200, transmission ser.no.-2205............................................... 136 Clutch shaft, third-fourth, HT200, transmission ser.no.2206-............................................... 138 Clutch shaft, forward-first, HT201........................................................................................ 140 Clutch shaft, reverse-second, HT201..................................................................................... 142 Clutch shaft, third-fourth,HT201........................................................................................... 144Torque converter.................................................................................................................... 146 Torque converter.................................................................................................................... 147

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............................................................................................................................... 16 ....................................................................................................................... 16 ............................................................................................................... 31 ....................................................................................................................... 32 ....................................................................................................... 42 ....................................................................................................................... 45 ............................................................................................................... 46 ....................................................................................................................... 52 ....................................................................................................................... 52 ....................................................................................... 54 ....................................................................................... 71 ....................................................................................... 85 ....................................................................................................................... 103 HT200-2790................................................................................. 111 HT200 2791- HT201................................................................ 114

E-...................................................................................... 130

HT200........................................................................................ 132 HT200........................................................................................ 134 HT200-2205...................................................................... 136 HT200 2206-..................................................................... 138 HT201........................................................................................ 140 HT201........................................................................................ 142 HT201........................................................................................ 144 ................................................................................................................................... 146 ................................................................................................................................... 147

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Specifications WEIGHTS Transmission with dropbox, Power take-off(2 pcs)and torque converter approx. 840kg 1852Ib Torque converter, approx. 110kg 243Ib

TIGHTENING TORQUES Nm kgf m Ibf ft Torque converter-transmission housing 80 8 59 Power take-off 45 4.5 33 Oil distributor 25 2.5 18 Suction strainer 25 2.5 18 Cover for suction strainer 20 2.0 15 Transmission oil pump 45 4.5 33 Torque converter attaching bolts 45 4.5 33 Drive flange nut 600 60 443 Cover for shafts 45 4.5 33 Brake housing-cover 45 4.5 33 Induction sender unit 45 4.5 33 Gear selector valve 25 2.5 18 Lubricating oil valve 25 2.5 18 Washer, turbine shaft 40 4.0 30 Gear selector valve sleeve, solenoid ASCO 25 2.5 18 Bolt ASCO 5 0.5 4 Sleeve, solenoid Skinner 12 1.2 9 Bolt skinner 3 0.3 2 Upper shaft in dropbox:3 pcs attaching bolts 1st tightening 40 4 30 Stop screws, 3 pcs, first tightening 20 2 15 Attaching bolts,3 pcs final tightening 80 8 59

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, (2 ) 840kg 1852Ib , . 110kg 243Ib

Nm kgf m Ibf ft - 80 8 59 45 4.5 33 25 2.5 18 25 2.5 18 20 2.0 15 45 4.5 33 45 4.5 33 600 60 443 45 4.5 33 45 4.5 33 45 4.5 33 25 2.5 18 25 2.5 18 , 40 4.0 30 ASCO 25 2.5 18 ASCO 5 0.5 4 , Skinner 12 1.2 9 skinner 3 0.3 2

:3 40 4 30 3 20 2 15 3 80 8 59

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TRANSMISSIONMake Volvo BM Type Hydro-mechanical Designation HT200 HT201 Clutch drum, end float Forward 0.1-0.7mm 0.004-0.028in First 0.2-1.0mm 0.008-0.039in Reverse 0.2-1.5mm 0.008-0.059in Third 0.4-1.3mm 0.016-0.051in Fourth 0.5-1.5mm 0.020-0.059in Disc clearance Forward clutch 1.9-5.3mm 0.075-0.209in First clutch 1.7-5.0mm 0.067-0.197in Reverse clutch 1.9-5.3mm 0.075-0.197in Second clutch 1.7-5.0mm 0.067-0.197in Third clutch 1.3-4.9mm 0.051-0.193in Fourth clutch 1.2-4.0mm 0.047-0.157in Return springs, first, second and third, loaded length, pressing force 944-1076N(212-242Ibf) 44mm 1.732in Return springs, forward and reverse, loaded length, pressing force 828-1076N(186-242ibf) 49mm 1.929in Return springs, fourth, loaded length

pressing force 927-1057N(208-237Ibf) 34mm 1.339in Shaft, end float Clutch shaft, forward-first 0.15-0.22mm 0.006-0.009 in Intermediate gear, preload 0.03-0.08mm 0.001-0.003in Output shaft, preload 0.03-0.08mm 0.001-0.003in Torque converter Make Rockford-division Type single-stage Gear selector valve Spring for main pressure, (HT200)length at a load of 387-427N(87-96Ibf) 53.8mm 2.118in Colour marking yellow Spring for main pressure, (HT201)length at a load of 430.6-462.6N(97-104Ibf) 53.8mm 2.118in Colour marking blue

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Volvo BM HT200 HT201 , 0.1-0.7mm 0.004-0.028in 0.2-1.0mm 0.008-0.039in 0.2-1.5mm 0.008-0.059in 0.4-1.3mm 0.016-0.051in 0.5-1.5mm 0.020-0.059in 1.9-5.3mm 0.075-0.209in 1.7-5.0mm 0.067-0.197in 1.9-5.3mm 0.075-0.197in 1.7-5.0mm 0.067-0.197in 1.3-4.9mm 0.051-0.193in 1.2-4.0mm 0.047-0.157in ,,,, 944-1076N(212-242Ibf) 44mm 1.732in ,,, 828-1076N(186-242Ibf) 49mm 1.929in ,, 927-1057N(208-237Ibf) 34mm 1.339in , ,- 0.15-0.22mm 0.006-0.009 in , 0.03-0.08mm 0.001-0.003in , 0.03-0.08mm 0.001-0.003in Rockford-division , (HT200)

387-427N(87-96Ibf) 53.8mm 2.118in , (HT201)

430.6-462.6N(97-104Ibf) 53.8mm 2.118in

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VOLVO STANDARD TIGHTENING TORQUES The tightening torques in the following tables apply to bolts with a tensile strength of 8.8.The table are to be considered as a general instruction for the tightening torque of nuts and bolts when no other torque is stated. N.B. For flanged bolts type U6FS the values should be increased by 10%. Nuts and bolts should be cleaned and lubricated with oil.

Metric coarse and fine threads Thread N m Kgf m Ibf ft M6M8M10 M12 M14 M16 M20 M24

10 f 2 24 5 48 10 85 18 140 25 220 45 430 85 740 150

1.0 f 0.22.4 0.54.8 1.08.5 1.814.0 2.522.0 4.543.0 8.574.0 15.0

7.4 f 1.5 18 3.5 35 7.4 63 13 103 18 160 33 320 63 550 110

UNC threads Thread N m Kgf m Ibf ft 1/45/163/87/161/29/165/83/47/81

9 f 218 433 854 1480 20120 30170 40300 70485 115725 175

0.9 f 0.21.8 0.43.3 0.85.4 1.48.0 2.012.0 3.017.0 4.030.0 7.048.5 11.572.5 17.5

6.6 f 1.513 3.024 5.940 1059 1589 22130 30220 52360 85530 130

UNF threads Thread N m Kgf m Ibf ft 1/45/163/87/161/29/165/83/47/81

10 f 3 22 5 40 10 63 18 98 23 145 35 200 50 355 85 565 135 800 200

1.0 f 0.32.2 0.54.0 1.06.3 1.89.8 2.314.5 3.520.0 5.035.5 8.556.5 13.580.0 20.0

7.4 f 2.2 16 3.7 30 7.4 46 13 72 17 110 26 150 37 260 63 420 100 590 150

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8.8 U6FS 10%

N m Kgf m Ibf ft M6M8M10 M12 M14 M16 M20 M24

10 f 2 24 5 48 10 85 18 140 25 220 45 430 85 740 150

1.0 f 0.22.4 0.54.8 1.08.5 1.814.0 2.522.0 4.543.0 8.574.0 15.0

7.4 f 1.5 18 3.5 35 7.4 63 13 103 18 160 33 320 63 550 110

N m Kgf m Ibf ft 1/45/163/87/161/29/165/83/47/81

10 f 219 434 855 1481 20121 30171 40301 70486 115725 175

0.9 f 0.21.8 0.43.3 0.85.4 1.48.0 2.012.0 3.017.0 4.030.0 7.048.5 11.572.5 17.5

6.6 f 1.513 3.024 5.940 1059 1589 22130 30220 52360 85530 130

N m Kgf m Ibf ft 1/45/163/87/161/29/165/83/47/81

10 f 3 22 5 40 10 63 18 98 23 145 35 200 50 355 85 565 135 800 200

1.0 f 0.32.2 0.54.0 1.06.3 1.89.8 2.314.5 3.520.0 5.035.5 8.556.5 13.580.0 20.0

7.4 f 2.2 16 3.7 30 7.4 46 13 72 17 110 26 150 37 260 63 420 100 590 150

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Description Transmissions HT200 and HT201 are hydro-mechanical, four-speed, power shift transmissions with torque converter, cylindrical spur gears with counter-rotating shafts and hydraulically actuated clutches. The transmission consists of three main parts. A front part with torque converter, transmission oil pump and power take-off. A centre part with cylindrical spur gears, hydraulic clutches and control valves. A rear part with dropbox and parking brake. The power from the engine to the road wheels is transferred hydraulically and mechanically through the transmission. The hydraulic transfer of power takes place in the torque converter which in addition to transferring the torque also multiplies it. The mechanical transfer of power is done by gear wheels which are in constant mesh. The gears on the clutch shafts rotate freely but are locked when a speed gear is engaged. There are three clutch shafts transferring the power and they are: one for forward and first speed gear, one for reverse and second speed gear and a third shaft for the third and fourth speed gears. The gear changing is by electro-hydraulic means. When a gear is selected, one or more of the gear selector valve solenoids are activated which actuate the gear selector valve spools, which in turn control the oil flow to the clutch shafts. The gear selector valve is fitted by the transmission oil filter and it consists of valve housing, six valve spools and five solenoids. One of the spools acts as a pressure control valve and it differs from the other spool which are alike and interchangeable. The spools, which on the hydraulic diagram are named S2, S3, S4and S5, are gear selector spools. Neutral and drive is selected with spool S1. The sixth spool controls the main pressure. The gear selector spools have two positions. They are kept in the resting position by a spring and caused to move to the other position by pressure differences controlled by the solenoids. In order to obtain the desired gear, electric current is required at one or more of the solenoids, which, in their turn actuate the valve spools. The neutral and forward/reverse drive spool can also be actuated mechanically, in the case of loss of electric power, by means of two adjusting screws. In order to prevent accidents, if there should be loss of current to one or more of the solenoids while operating, neutral or a higher gear will be automatically selected. The only exception is when operating in the fourth speed, shifting to the third speed will take place. As the down shift is only one step, the slowing-down of the machine will not be too sudden. A special valve(damping valve)is fitted on the outside of the gear selector valve. This damping valve controls the application for the forward and reverse clutches, giving the shifting between forward and reverse correctly balanced characteristics. HT200 HT201

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1 2 3 46 5 S2S3S4S5S1 6/

Transmission, HT 200/201 1 Torque converter 2 Lubricating oil valve 3 Parking brake housing HT 200/201

1 2 3

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Transmission, HT 200/201 1 Oil filter 2 Damping valve 3 Gear selector valve 4 End coverforward-firstreverse-second, obscured 5 End cover, third-fourth 6 Draining of gear selector valve, only HT 201 or the rebuilt version of HT 200 HT 200/201

1 2 3 4 -- 5 - 6 HT201 HT200

NEUTRAL POSITION The pumps P draw oil from tank N through strainer O. The flow from pump P2 is forced through filter S and on through line F to pressure-limiting valve U, which is a valve spool built into the gear selector valve. From the pressure-limiting valve the oil is conducted to the different gear selector spools. All spools are in the resting position. The valve spool L(neutral and drive spool)blocks the oil flow to spool H(forward and reverse spool). The spool M(high and low spool)allows flow of oil through duct V to spool K(controlling the third and fourth speed gears)which in this position conducts the oil to the third gear in clutch G, which thus becomes engaged. Because the neutral and drive spool is in the resting position and prevents oil flow to the forward and reverse spool, no transmission of power takes place. The valve spool J(controls the gears for the first and second speeds)does in this position not obtain any oil from valve spool M. When the main pressure has been built up, the spool in valve U moves to the open position and lets the oil through.

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This flow joins the flow pump P1 and is conducted through line X, with its safety valve AA protecting the torque converter, to torque convert A and through the same to the cooling circuit which thus controls the pressure in the torque converter. If the temperature is so high that the oil needs cooling, the thermostat directs the flow to cooler T. At lower temperatures the cooler is by-passed, and the flow is directed to the lubricating circuit where valve C limits the lubricating oil pressure. Through line Y the lubricating oil is supplied to all clutches which then are both cooled and lubricated. The superfluous oil from the lubricating oil valve is conducted by to the pump. Symbol diagram, neutral position, HT 200 and 201 A Torque converter C Lubricating oil valve F Connecting line, filter-gear selector valve G Third clutch H Forward and reverse gear shift spool I Thermostat J First and second gear shift spool K Third and fourth gear shift spool L Neutral and drive gear shift spool M High and low gear shift spool N Oil sump O Strainer P Pump R1 Reverse damping valve R2 Forward damping valve S Filter T Oil cooler U Pressure-limiting valve

V Pressure duct Y Lubrication ling X Line to torque converter AA Torque converter safety valve P N O P2 S F U U L H M V K 3 4 G J 1 2M U P1 X AA A T C Y

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A C F - G H I J K L M N O P R1 R2 S T U V X Y AA

Symbol diagram, neutral position HT200, ser. no.-2003 HT200-2003 For ser. No. 2004-. See the inset damping valves 2004-

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Symbol diagram, neutral position HT201 HT201

Flow diagram, neutral position. HT200 ser.no.-2003 HT200 -2003 For ser.no.2004-,see the inset damping valves 2004-A Torque converter A C Lubricating oil valve C D Forward and first clutches D E Reverse and second clutches E F Connecting line, filter-gear selector valve F -G Third and fourth clutches G H Forward and reverse gear shift spool H I Thermostat I J First and second gear shift spool J K Third and fourth gear shift spool K L Neutral and drive gear shift spool L M High and low gear shift spool M N Oil sump N O Strainer O P Pump P R1 Reverse damping valve R1

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R2 Forward damping valve R2 S Filter S T Oil cooler T U Pressure-limiting valve U V Pressure line V X Line to torque converter X Y Lubrication line Y AA Torque converter safety valve AA

Colour key: Red=Clutch pressure =Blue=Torque converter pressure =Yellow=Lubricating oil pressure =Green=Atmospheric pressure =

Repair Instructions TRANSMISSION, RECONDITIONING Op.no. 43771 Tools: 999 2628 Lifting chain 999 3131 Draw bolt 999 3387 Sleeve 999 3517 Spanner 999 3538 Draw bolt 999 3577 Spanner 999 3582 Spanner width across flats 2 5/8999 3586 Tooth segment 999 3590A Gear 999 3598 Tensioning tool 999 3599 Centre support 999 3616 Fitting tool 999 3659 Bearing puller 999 3712 Sleeve 999 3713 Draw bolt 999 3716 Press tool 6 999 001 Handle 6 999 002 Handle 6 999 010 Plug 6 999 060 Plate 6 999 070 Plate 6 999 080 Plate 6 999 088 Plate 6 999 090 Plate 6 999 100 Plate 6 999 105 Plate 6 999 110 Plate 6 999 115 Plate 6 999 120 Plate

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6 999 130 Plate 6 999 150 Plate E 943 Guide pin, 2 pcs E 1215 Fixture E 1224 Fixture E 1228 Lifting eye E 1630 Gauge Puller Kukko 15-3 Kukko 17-2 Kukko 18-2 Kukko 18-3 Kukko 20-20 OTC 943 with bolt 515S Bolt M8cut-off length 50 mm Bolt M8, cut-off length 160mm Bolt M10, length 60 mm, 2 pcs Bolt M10, length 100mm, 3 pcs Bolt M20, length 150mm, 4 pcs Adjustable stand Depth gauge, range 0-25 mm Dial gauge with magnetic base 11 666 013 pump 11 666 014 Jack

,Op.no. 43771 :999 2628 999 3131 999 3387 999 3517 999 3538 999 3577 999 3582 2 5/8999 3586 999 3590A 999 3598 999 3599 999 3616 999 3659 999 3712 999 3713 999 3716 6 999 001 6 999 002 6 999 010 6 999 060 6 999 070

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6 999 080 6 999 088 6 999 090 6 999 100 6 999 105 6 999 110 6 999 115 6 999 120 6 999 130 6 999 150 E 943 , 2 E 1215 E 1224 E 1228 E 1630 Kukko 15-3 Kukko 17-2 Kukko 18-2 Kukko 18-3 Kukko 20-20 OTC 943 with bolt 515S M8, 50mm M8, 160mm M10, 60 mm, 2M10, 100mm, 3M20, 150mm, 4, 0-25mm 11 666 013 11 666 014 Dismantling 1 Fit the transmission and check that the oil is drained. If the filter is left on the transmission, remove the filter and its console. On the HT201 also remove the oil draining pipe between gear selector valve and dropbox housing. 1 HT2012 Remove the damping valve 2 3 Remove the gear selector valve 3

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4 Mark and disconnect the oil hoses from the oil distributor plate and remove outer and inner oil distributor plate and intermediate plate. NOTE: The socket head bolts which retain the inner plate and oil pipes on the inside of the plate. 4

5 Mark and remove the hose from the lubricating oil valve and remove the lubricating oil valve.

5

6 Remove the oil distributor plate and remove the oil pipes from the oil distributor for second speed reverse. NOTE: The pipes on the inside of the plate. 6

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7 Remove the cover from the torque converter, take care of any shims. Undo any locking and remove the locking washer.

7

8 Lift up the torque converter. Weight approx. 110Kg(243 Ib)

8 110Kg243Ib

9 Remove both the power take-offs. 9

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10 Remove the oil pipes for forward-first, reverse-second and the connecting pipe to the torque converter foot. Also remove the lubrication oil pipe for forward-first and reverse-second and on HT201 the return oil pipe.

10 HT201

1 2 3 4 5 6 7 HT201

11 Remove the torque converter safety valve. Take out spring and ball. 11

12 Remove any circlip from the turbine shaft. Move pipe and spring guide for the torque converter safety valve and remove the pump cover. NOTE: Alternatively the oil pump can be removed as a complete unit as shown in the figure. Weight of complete oil pump approx.30 kg(66 Ib) 12

30KG66Ib

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13 Remove the oil distributors, torque converter foot and turbine shaft.

13

14 Remove inner circlip, spacer ring (HT200) and support ring from the reverse-second clutch shaft.

14 HT200

15 Remove outer circlip from the third-fourth clutch shaft. 15

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16 Remove the bolts for the housing halves and lift up the front half.

Weight approx. 125Kg (276Ib) Tap lightly on the third-fourth clutch shaft. Make sure that all clutch shafts remain in the Lower housing half.

16 125KG276Ib-

17 Lift away intermediate gear. 17

18 Lift out the clutch shafts in the order: reverse-second, forward-first and finally the third-fourth shaft. The weight of the clutch shafts are approx: reverse-second 50 Kg(110Ib), forward-first 50 kg(110Ib)and third-fourth 30Kg(66Ib).

18 50kg110Ib 50Kg 110Ib 30Kg66Ib

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19 Remove the cover for the suction strainer and take out the strainer.

19

20 Remove circlip, lock washer and the rear drive flange. 20

21 Remove the bearing retainer. Take care of any shims.

21

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22 Remove circlip, lock washer and the front drive flange. 22

NOTEWith effect from transmission ser.no.2791 the lower output shaft has been changed to the version shown blow. 2791

2791

TRANSMISSION ser.no.-2790 23 Remove the cover of the brake housing together with piston. -2790 23

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24 Take out the brake discs. Also remove the locking pin.

24

25 Take out the brake housing. Use two bolts as puller screws. NOTE: The threaded length of the bolts should be increased to approx. 40 mm.

25 40mm

Continue according to point 27 page 36. 27.

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TRANSMISSION ser.no.2791-or rebuilt version 2791-

23 Remove the three plugs in the cover of the parking brake and release the parking brake application by pulling in the three bolts in the piston. Remove the brake housing bolts and lift away the cover together with piston and spring

23

24 Pull away the bearing 24

25 Take out the brake discs. 25

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26 Take out the brake housing. NOTE: Use screwdrivers or pincbars.

26

27 Lift out the output shaft. 27

28 Remove the splash plate. 28

29 Remove the cover and remove the bearing retainer for the third-fourth shaft. Take care of any shims.

29 -

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30 Press the third-fourth shaft out of the gear. NOTE: Hold the gear so that it does not fall down to the bottom of the transmission.

30 -

31 Lift out the gear. 31

32 Remove the bearing cover for the reverse-second clutch shaft and remove the end washer of the shaft and the support ring of the bearing.

32

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33 press out the gear wheel for the second speed and the clutch drum.

NOTE: Hold the clutch drum so that it does not fall to the bottom of the transmission housing.

33

34 Remove the tool and take out the gear wheel. 34

35 When required, drive all remaining bearing out of the housing. The bearing of the intermediate gear are pulled out according to the figure.

35

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TORQUE CONVERTER, REBUILDING When repairing torque converter up to and including 2464transmission ser.no.2464, the torque converter should be rebuilt as described below: Regarding the changing of torque converter foot when a circlip has been introduced w.e.fr. 1639 130transmission ser.no.1639, see page 130.

1 In order to keep the stator according to earlier version, a recess has to be milled out in the stator for the wear washer. Then drill and ream a new hole for the guide pin.

1

1 Blunt end of rotor blade 2 Reference diameter 3 Reaming depth

2 Check that the thrust bearing has a running clearance in the torque converter foot. If this is not the case, the torque converter foot Should be machined as described below. 2

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TORQUE CONVERTER, RECONDITIONING

Op. no. 43711 Tools:

999 2628 Lifting chain 6 999 001 Handle

6 999 065 Plate 6 999 115 Plate Dial gauge with magnetic base

Dismantling 1 Mark the pump housing halves and part the halves. 1

2 Lift away turbine rotor and thrust bearing. 2

3 Remove the stator and thrust bearing. Take care of any shims. For rebuilding of stator, see page 39.

3

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4 Lift up the thrust and oil distributor washers. 4

5 Remove the bolts and lift away the pump rotor. 5

6 Tap out the bearing. 6

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7 Remove the circlip. 7

8 Drive out the drive sleeve. 8

9 Drive the bearing out of the pump housing half. 9

10 Clean and change necessary parts. 10

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Assembling

11 Fit a new O-ring in the drive sleeve. 11 O

12 Drive in the bearing in the gear which drives the power take-offs.

12

13 Fit the pump rotor on the gear which drives the power take-offs according to earlier made marks. Tighten the bolts to 95 N m(70 Ibf ft).

13 95N m70 Ibf ft.

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14 Fit the thrust and oil distributor washers in the pump housing half. NOTEThe locking of the washer in done with the guide pin.

14

15 Fit the thrust bearing 15

16 Insert any existing shims and the thrust washer. NOTE: The locking of the washer and the shims with the guide pin. NOTE: If parts which affect the end float have been changed, the determination of the shim thickness should be carried out according to point 23.Therefore, no shims should be fitted at this stage.

16 23

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17 Position the stator 17

18 Insert the thrust washer and thrust bearing. NOTE: The locking of the washer is done with the guide pin.

18

19 Fit the turbine rotor. 19

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20 Position the cover Use two bolts.

20

21 Drive the bearing into position in the pump housing half.(Applies to HT200 up to and including transmission ser.no.1638). Drive the bearing against the cover.(Applies to HT200 with effect from transmission ser.no.1639 or rebuilt version and HT201)

21 1638 1639 HT200 HT201

22 Assemble the pump housing halves according to earlier made marks. Use only four bolts. NOTE: The existing marks according to the Figure on both the housing halves should be Displaced 180erelative to each other.

22 180e

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23 Turn the torque converter. Make sure that stator and turbine rotor are at the bottom. Measure the total clearance between oil distributor washer and thrust bearing. Make sure that the feeler gauge on the E-tool does not flex. The reading on the dial gauge+ the thickness of the feeler gauge=the total end float. Select shims so that the clearance becomes 0.1-0.7 mm(0.004-0.028 in). Make a note of the shim thickness.

23 E-+= 0.1-0.7mm 0.004-0.028 in

24 Part the pump housing halves. 24

25 Lift away turbine rotor and thrust bearing and remove the stator.

25

26 Heat the stator in an oven to approx.125 (257eF)and remove the thrust washer. NOTE: If the stator is placed in the oven with the washer turned downwards, the washer may, under

favourable conditions, fall out of the stator. 26 125 257eF)

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27 With the stator still warm, position the shims calculated in point 23 and the seat for the thrust washer, provided washer and seat were parted.

27 23

28 Position the thrust washer. NOTE: The locking is done with the guide pin.Allow the stator to cool and make sure that seat and thrust washer are at the bottom when the parts have cooled down.

28

29 Position the stator. 29

30 Insert the thrust washer and thrust bearing. NOTE: The locking is done with a guide pin.

31 Fit the turbine rotor. 31

32 Assemble the pump housing halves according to earlier made marks. Use only four bolts. NOTE: The existing marks on both the housing halves should be displaced 180erelative to each other.

32

180e

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33 Position the torque converter with the cover downwards. Make sure that stator and turbine rotor are at the bottom. Check that the end float between oil distributor washer and thrust bearing is 0.1-0.7mm(0.004-0.028 in). If the clearance is not within the prescribed valve, the shims must be changed.

33 0.1-0.7mm(0.004-0.028in).

34 Drive the sleeve into position with a soft Hammer and lock with the circlip.

34

35 Position all bolts in the pump housing halves. Tighten the bolts to 55 N m(40 Ibf ft) 35

55N m40 Ibf ft

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OIL PUMP AND TURBINE SHAFT BEARING, RECONDITIONING Tools: 6 999 001 Handle 6 999 080 Plate

6 999 088 Plate Puller OTC 943 with puller bolt 515S OTC 943 515S Flat bar 70*20 mm, thickness 5 mm 70*20 mm 5 mm 1 Mark and dismantle the oil pump.

Remove gear and shafts. 1

2 Clean and check all parts. Change damaged and worn parts.

2

3 Position gear and shafts, thoroughly lubricated. 3

4 Assemble the oil pump. 4

5 When required, remove the circlip for the turbine shaft outer bearing race from the pump housing and pull out the bearing race. Remove the thrust washer. Or alternatively, make a weld bead in three places evenly distributed in the bearing race. Cool the bearing race and lift it out. NOTE: Cover the recess in the housing for the thrust bearing with a wet rag or similar. 5

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6 Remove the circlip and press off bearings and washers from the tubing shaft. Check that the lubricating hole in the shaft is open. 6

7 Change the turbine shaft sealing ring. 7

8 Heat inner thrust washer and bearings to approx. 100(212eF). Fit thrust washer and bearings into positon. The chamfer of the thrust washer should be turned away from the shoulder. 100212eF)

9 Fit the spacer washer and lock with the circlip. 9

10 Fit the thrust bearing and position the sealing ring. 10

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11 Fit thrust washer, 5mm, into position, Turn the chamfer downwards(against the torque converter) and drive in the turbine shaft outer bearing race. 11 5mm

12 Fit the circlip. 12

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DAMPING VALVE, RECONDITIONING Dismantling 1 Remove the two covers and take out the springs. 1 2 Take out pistons and springs. 2 3 Clean and change necessary parts. Change the O-rings. 3 O NOTE: There are two versions of the valve spool.

They are fully interchangeable. Use the same spool version. The newer spool gives a smoother

gear-shift.

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Assembling

4 Fit pistons and springs into position. 4

5 Insert the springs and fit the covers. 5

GEAR SELECTOR VALVE, RECONDITIONING Op.no.43709 Tools: 999 3577 Spanner(solenoid valve type ASCO) 999 3517 Spanner(solenoid valve type Skinner) 999 3577 ASCO 999 3517 Skinner

Dismantling

1 Remove cover and leads. NOTE: The lead marking in the cover. 1

2 Loosen the solenoid valves and lift them up NOTE: The star washers under the valves. 2

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3 Remove the retainer for the solenoid valves together with valve spool and spring. NOTE: The O-rings. 3 O

4 Remove the cover. 4

5 Remove the pressure-limiting valve spring together with the guide. 5

6 Lift out springs and spools. 6

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7 When required the solenoid valve seats can be removed. Use a small drift to drive out the seats. 7

8 Remove the cover. 8

9 Remove the pressure-limiting valve. 9

10 Clean and change necessary parts. Change The O-rings. 10 O

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Assembling

11 Position the washer of the pressure-limiting valve and the spring. 11

12 Drive the valve seats into position, if these were removed. Lock with locking fluid, strong. NOTE: The seat may be without a recess. 12 :

13 Bolt on the cover. Tighten the bolts to 15 Nm(11 Ibf ft). Bolt on the solenoid valve retainers

Together with valves, springs and O-rings. NOTE: Make sure that the tapered end of the spring sticks out of the valve. Tighten to 12 Nm(9 Ibf ft)(Skinner)and 25 Nm(18 Ibf ft)(ASCO).

13 15 Nm11 Ibf ft O 12 Nm9 Ibf ft skinner 25 Nm18 Ibf ft ASCO

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14 Position the locking for the solenoid Valves. A solenoid valve with separate retainer for locking of all solenoids is introduced on HT200 with effect from transmission ser.no.2097 and on HT201. Earlier version is provided with separate toothed washers under each solenoid valve.

14

HT200 2097 HT201.

15 Fit the solenoid valves. NOTE: Earlier version socket head Bolts. Connect the leads. For how to connect, see the Marking inside the cover.

15

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16 Fit the cover. 16

17 Position spring and spool in the respective Bores. 17

18 Position the spool for the clutch pressure-limiting valve.

18

19 Check that all spools move easily and bolt on the cover. Tighten the bolts to 15 Nm(11 Ibf ft).

19 15Nm11 Ibf ft.

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LUBRICATING OIL VALVE, RECONDITIONING Dismantling 1 Remove both end covers and take out spring,

washer and spool. 1 2 Clean and change necessary parts. 2

3 Insert spool, washer and spring. NOTE: The stud of the spool towards the washer. Bolts on the end covers. 3

POWER TAKE-OFF, RECONDITIONING Op.no.48201

Tools6 999 001 Handle 6 999 050 Plate 6 999 065 Plate

Dismantling 1 Remove the circlip for the drive sleeve and take out the drive sleeve. 1

2 Remove the outer circlip of the bearing. 2

3 Press out the shaft. 3

4 Press the bearing from the shaft. 4

5 Clean and check and change necessary parts. 5

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Assembling 6 Press the larger bearing onto the shaft. NOTE: The bearing is positioned on the same side as the

circlip groove of the shaft. 6

7 Fit the smaller bearing in the housing. 7

8 Insert gear and spacer ring in the housing. Press in the shaft together with the bearing. Make sure that the pressing force is applied on

the inner race. Lock with the circlip.

8

9 Fit the drive sleeve into position and lock with the circlip.

9

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FORWARD AND FIRST CLUTCHES, DISMANTLING AND ASSEMBLING

Dismantling

1 Place the shaft in the fixture and remove the sealing rings(piston steel ring type)for the forward clutch from the shaft. Pull off the bearing. Remove the thrust washer.

1

2 Remove the thrust bearing and the thrust washer.

2

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3 Lift up the clutch drum. 3

4 Remove bearings, thrust washer, thrust bearing and thrust washer.

4

5 Remove the circlip and lift away the thrust plate.

5

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6 Lift up the disc pack 6

7 Apply the tool and remove the circlip. NOTE: Make sure that the bolt of the tool

can be screwed in at least another 100mm(4 in), before starting to compress the spring. NOTE: Compress the spring only so much as to make it possible to remove the circlip.

7 100mm(4 in).

The force of the compressed spring is 1000-1100 N (225-247 Ibf) 1000-1100 N (225-247 Ibf)

8 Remove the tool, the clutch hub and the spring.

8

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9 Lift up the support ring. 9

10 Remove the application piston. Remove the sealing rings(piston steel ring

type) piston and the gear wheel. 10

11 Turn the shaft, pull off the bearing and remove the spacer ring.

11

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12 Remove the circlip 12

13 Remove the wear ring by prising up the clutch drum.

13

14 Lift up the clutch drum together with the bearing. Remove the bearing and the wear ring. The wear ring may be left in place and removed to together with the hub according to point 19. 14 19

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15 Remove the coiled locking ring. NOTE: When removing , make sure that the end of the coiled locking ring is flush with

the end of the circlip, in order to be able to remove the coiled locking ring.

15

16 Remove the locking ring for the disc pack and lift up the thrust plate.

16

17 Lift up the disc pack 17

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18 Compress the return spring for the application piston. NOTE: The thrust plate. Remove the split locking washer. NOTE: Make sure that the bolt on the tool has a

movement of at least 100mm(4 in), after starting to compress the spring.

18 100mm

The force of the compressed spring is 1000-1100N(225- 247 Ibf) 1000-1100N225-247 Ibf

1 999 3598 2 999 3599-1 3 Thrust plate 4 Locking washer

19 Remove the tool and lift up the thrust washer, clutch hub and spring and also the wear ring, if not removed earlier. 19

20 Remove the application piston and remove the sealing rings (piston steel ring type) from the shaft and the

piston. 20

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21 Check that the holes for the cooling oil in the shaft and in the gear wheel align. It should be possible to insert a drill bit with a thickness of at least 5 mm through both holes. If this is not possible, change the gear wheel. The gear wheel is shrunk onto the shaft and must thus be heated before it is pressed off the shaft. When necessary press the shaft out of the gear wheel and the dual-stage application piston.

21 5mm

22 When necessary press the shaft out of the gear wheel and the dual-stage application piston. Remove the circlip, clean and change necessary parts. Make sure that the holes in the gear wheel, pistons and the ducts in the shaft are not clogged.

22

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Assembling

23 Heat the gear wheel and the dual-stage application piston in an oven to approx. 100(212eF), if these parts where Removed. Check that the circlip for the dual-stage application piston is in position on the shaft and put on the piston and the gear-wheel. NOTEMake sure that the dual-stage application piston fits closely up against the circlip even after the parts have cooled down.

23 100 212eF)

24 Turn the shaft and fit the sealing ring(piston steel ring type)on the first clutch shaft end.

Lubricate the ring with petroleum jelly. 24

25 Position the sealing rings(piston steel ring type) on the piston.

25

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26 Make the rings stay in position by coating them with petroleum jelly and position the piston.

26

27 Position spring and hub. Use a new spring. The ID of the spring is approx.72mm(2.83 in)and

the number of coils is 4.5. The length of the hub is approx.53mm(2.09 in).

27 ID 72mm(2.83in) 4.5 53mm(2.09in).

28 Position the tool and compress the spring using the thrust plate as a support for the tool.

Make sure that the hub enters the splines. Fit the locking ring halves with the chamfer

upwards. 28

29 Release the tension of the spring and make sure that the locking ring halves engage correctly.

Remove the tool and the thrust plate. 29

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30 Position the discs. Begin with an internally splined disc and then an externally splined disc and so on. There are 9 externally splined and 9 internally

splined discs. The disc thickness is 2.0mm(0.08in). The internal diameter of the discs is 99.1mm(3.90 in).Lubricate the discs.

30 99 2.0mm(0.08 in) 99.1mm(3.90 in)

31 Position the thrust plate and secure with the Circlip. Check the disc clearance which should be 1.7-5.0mm(0.067-0.197in).

31 1.7-5.0mm(0.067-0.197in)

32 Position the coiled locking ring. 32

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33 Position the wear ring approx.5.0mm(0.2 in), and the bearing. If necessary heat the ring to approx.100(212 eF). Lubricate the bearing with oil.

33 5.0mm(0.2 in) 100212eF)

34 Position the clutch drum. 34

35 Position bearing and wear ring approx.5.0mm 0.2 in If necessary heat ring to approx. 100 (212eF)

35 5.0mm(0.2in) 100(212eF)

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36 Position the circlip. 36

37 Check the end float which should be 0.2-1.0mm(0.008-0.040 in)

37 0.2-1.0mm0.008-0.040 in

38 Position the spacer ring, 5.0mm (0.2 in), heat the bearing in an oven to approx. 100(212 eF) and position the bearing..

38 5.0mm(0.2 in), 100(212eF)

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39 Turn the shaft and position the sealing rings(piston steel ring type) on the gear wheel for the forward clutch. Lubricate the rings with petroleum jelly.

39

40 Position the sealing ring(piston steel ring type) on the piston. 40

41 Fix the ring with some petroleum jelly and Position the piston.

41

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42 Position support ring, spring and hub. Use a new spring. The ID of the spring is approx.95 mm(3.74

In) and the number of coils is 4.5. The length of the hub is approx.77 mm(3.03 in).

42 ID 95mm(3.74In), 4.5. 77mm(3.03 in).

43 Position the tool and compress the spring. Make sure that the hub engages the splines. NOTE: The hub only fits in one particular

position. Make sure the circlip engages its groove Correctly. NOTE:Make sure the circlip engages its groove correctly.

43

44 Remove the tool and position the discs. Begin with an internally splined disc and

then one externally splined dis and so on. There are 10 externally splined discs and 10 internally splined discs. The disc thickness is 2.7mm(0.11 in). The ID is 133mm(5.24 in) Lubricate the discs.

44 1010 2.7mm(0.11 in) 133mm(5.24 in)

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45 Position the thrust plate and secure with the Circlip. Check that the disk clearance of the Clutch is 1.9-5.3 mm(0.075-0.209 in).

45 1.9-5.3mm(0.075-0.209 in).

46 Position the thrust washer, thrust bearing and another thrust washer. NOTE: The thickness of the washers is 2.4 mm(0.09 in)and their ID is 54.2 mm(2.13 in).Lubricate the parts.

46 2.4mm(0.09 in), 54.2mm(2.13 in).

47 Position the clutch drum. 47

48 Position the needle bearings. 48

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49 Position the thrust washers and the thrust Bearing. Fit the thin thrust washer, 2.4 mm (0.094 in) innermost and the thicker washer, 6.4 mm(0.25 in) outermost. The ID of the washers is 54.2mm(0.13 in). Lubricate the bearings.

49 2.4mm(0.094 in) 6.4mm(0.25 in) 54.2mm(0.13 in).

50 Heat the bearing in an oven to approx.100212eFand position the bearing.

50 100212eF

51 Check the end float which should be 0.1-0.7 mm(0.004-0.028 in). If the clearance is too great, change the thrust bearing and the thrust washer. NOTE: The sealing rings(piston steel ring type) should be fitted to the shaft after the end float has been adjusted.

51 0.1-0.7mm(0.004-0.028 in).

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REVERSE AND SECOND CLUTCHES, DISMANTLING AND ASSEMBLING.

Dismantling

1 Press or alternatively pull off gear wheel and bearing race.

1

2 Remove the thrust bearing and thrust washers.

2

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3 Remove the clutch drum. 3

4 Remove the needle bearings. 4

5 Remove the thrust bearing and the thrust washers.

5

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6 Remove the circlip for the disc pack and lift up the thrust plate.

6

7 Lift up the disc pack. 7

8 Tighten down the tool and remove the circlip. NOTE: Make sure that the bolt on the tool has a

movement of at least 100 mm(4 in), after beginning to compress the spring. NOTE: Only compress the spring so much that the circlip can be removed.

8 100 mm4 in

The force of the compressed spring is 1000-1100N (225-247 Ibf).

1000-1100N (225-247 Ibf)

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9 Remove the tool and lift up the hub, spring and support ring.

9

10 Remove the application piston and remove the Sealing ringspiston steel ring typefrom the Piston and the gear wheel. 10

11 Turn the shaft and remove the coiled locking ring from the second clutch shaft end. NOTE: When removing, make sure that the

coiled locking ring end is flush with the end of the circlip in order to be able to remove it.

11

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12 Remove the circlip for the disc pack. 12

13 Lift up the thrust plate and lift up the disc pack. 13

14 Compress the return spring for the application piston. NOTE: The thrust plate. NOTE: Make sure that the bolt of the tool has a movement of at least 100 mm(4 in), after starting to compress the spring.

14 100 mm4 in

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15 Remove the tool and lift off the pressure plate, Clutch hub and spring. 15

16 Remove the application piston and remove the seals from the piston and the shaft.

16

17 Make sure that the holes for the cooling oil in the shaft and in the gear wheel align. It should

be possible to insert a drill bit which is at least 5 mm thick through both boles. If this is not possible the gear wheel must be changed. The gear wheel is shrunk onto the shaft and must therefore be heated before it is pressed off.

17 5mm

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18 If necessary press the shaft out of the gear wheel and the dual-stage piston.

18

19 Clean and change necessary parts. Make sure that the holes in the gear wheel(one from either side) in the pistons and the duct in the shaft are not clogged. 19

Assembling

20 Heat the gear wheel and the dual-stage piston in an oven to approx.100(212eF), if these parts where removed. Check that the circlip for the dual-stage piston is correctly positioned on the shaft and fit piston and gear wheel. NOTE: Make sure that the dual-stage piston fits right up against the circlip, also when the parts have cooled down.

20 100(212eF)

21 Turn the shaft and position the sealing ring( piston steel ring type) on the second cluth shaft. Lubricate the ring with petroleum jelly. 21

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22 Position the sealing rings(piston steel ring type) on the piston. 22

23 Attach the rings by lubricating them with petroleum jelly and fit the piston.

23

24 Position spring and hub. Use a new spring. The ID of the spring is approx.72 mm(2.83 in) and the number of coils is 4.5. The length of the

hub is approx.53 mm(3.09 in). 24 72mm(2.83 in),

4.5 53mm(3.09 in)

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25 Position the tool and compress the spring. Use the thrust plate as a support for the tool. Make sure that the hub engages the splines. Fit the locking ring halves with the chamfer facing upwards. 25

26 Release the tension of the spring and make sure that the locking ring halves are correctly positioned. Remove the tool and the thrust plate.

26

27 Fit the discs. Begin with an internally splined disc and then one Externally splined disc and so on. Turn the

rounded side of the teeth upwards. There are 9 discs of each kind. The disc thickness is 2.0 mm(0.08 in) The ID of the discs is 99.1 mm(3.90 in). Lubricate the discs.

27 9 2.0mm(0.08 in) 99.1 mm(3.90 in)

28 Postion the thrust plate and secure with the circlip. Check the disc clearance of the clutch which

should be 1.7-5.0mm(0.07-0.20 in). 28 1.7-5.0mm(0.07-0.20 in)

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29 Position the coiled locking ring. 29

30 Turn the shaft and position the sealing rings (piston steel ring type) on the gear wheel for the reverse shaft. 30

31 Position the sealing ring(piston steel ring type) on the piston.

31

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32 Fix the rings with some petroleum jelly and position the piston.

32

33 Postion support ring, spring and hub. Use a new spring. The ID of the spring is approx.95 mm(3.74 in), and the number of coils is 4.5. The length of

the hub is approx.77 mm(3.03 in). 33 95mm(3.74 in), 4.5 77mm(3.03 in)

34 Position the tool and compress the spring. Make sure that the hub engages the spines. NOTE: The hub only fits in one position. Fit the circlip. NOTE: Make sure the circlip engages its

groove correctly. 34

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35 Remove the tool and position the discs. Begin with an internally splined disc and then fit an externally splined disc and so on. The number of disc are 10 of each kink. The

disc thickness is 2.9mm(0.11 in) The ID of the discs is 133 mm(5.24 in).

35 10 2.9mm (0.11 in) 133mm(5.24 in)

36 Position the thrust plate and secure with the Circlip. Check the disc clearance which should be 1.9-5.3 mm(0.07-0.21 in).

36 1.9-5.3mm(0.07-0.21 in)

37 Position thrust washer, thrust bearing and another thrust washer. NOTE: The thickness of the thrust washers is 2.4 mm(0.09 in).The ID of the discs is 54.3 mm(2.14 in). Lubricate.

37 2.4mm(0.09 in). 54.3 mm2.14 in

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38 Postion the clutch drum. 38

39 Postion the needle bearings. Lubricate. 39

40 Position the thrust washers and the thrust bearing. The thickness of the washers is 2.4mm(0.09 in)

and the ID is 54.3 mm. Lubricate.

40 2.4mm(0.09 in), 54.3mm

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41 Heat the gear wheel and the inner bearing race to approx. 100 and 212eF and fit the gear and the bearing race into position.

41 100 210eF

42 Check that the gear wheel and the bearing race fit up against the shoulder when they have cooled

down. Check the end float which should be 0.2-1.5 mm (0.008-0.059 in). If the clearance is too great, change thrust bearing and thrust washers. NOTE: The sealing rings(piston steel ring type) should be fitted on the shaft after adjusting the shaft end float in the transmission.

42 0.2-1.5mm(0.008-0.059in).

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THIRD AND FOURTH CLUTCHES, DISMANTLING AND ASSEMBLING

Dismantling

1 Remove the sealing ring(piston steel ring type) from the shaft. NOTE: With effect from transmission ser.no.2206 the clutch drums and the externally splined discs are the same as those in the other clutches. Other parts have not been changed and therefore, earlier type clutch shafts can be rebuild to the new type. See also figure on page 148. 1 2206 148

2 Remove the circlip and the spacer ring and pull off the bearing. 2

3 Remove the spacer ring and lift up thrust bearing and thrust washer. 3

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4 Lift up the clutch drum. 4

5 Remove the needle bearing. 5

6 Remove washers and thrust bearings. 6

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7 Remove the coiled locking ring. NOTE: In order to be able to remove the coiled

locking ring from its groove, its end should be flush with the end of the circlip.

7

8 Remove the circlip for the disc pack and lift up the thrust plate. 8

9 Lift up the disc pack. 9

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10 Compress the return spring for the application piston. NOTE: The thrust plate. NOTE: Make sure that the bolt on the tool has a movement of at least 100 mm(4 in), after starting to compress the spring.

10 100mm(4 in)

The force of the compressed spring is 1000-1100N (225-247 Ibf). 1000-1100N(225-247 Ibf)Remove the split locking washer.

11 Remove the tool and lift up the thrust plate, clutch hub and spring. 11

12 Remove the application piston and remove the sealing rings(piston type rings) from the shaft and the piston. 12

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13 Turn the shaft and remove the circlip. 13

14 Remove washers and thrust bearing. 14

15 Lift up the clutch drum. 15

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16 Remove both needle bearings. 16

17 Remove washers and thrust bearing. 17

18 Remove the coiled locking ring. NOTEIn order to be able to remove the coiled locking ring from its groove, its end should be flush with the end of the circlip. 18

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19 Remove the circlip for the disc pack and lift up the thrust plate. 19

20 Remove the disc pack. 20

21 Compress the return spring for the application piston. NOTEThe thrust plate. Remove the split locking washer. NOTE: Make sure that the bolt of the tool has a movement of at least 100 mm(4 in), after starting to compress the spring.

21 100mm(4 in)

The force of the compressed spring is 1000-1100N (225-247 Ibf). 1000-1100N(225-247 Ibf)

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22 Remove the tool and lift up the thrust plate, clutch hub and spring. 22

23 Remove the application piston and remove the sealing rings(piston steel ring type) from the shaft and the piston.

23

24 Clean and change necessary parts. Make sure that the holes in the separator plate and

the ducts in the shaft are not blocked. 24

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Assembling

25 Postion the sealing ring(piston steel ring type) on the third clutch shaft. 25

26 Postion the sealing rings(piston steel ring type) on the piston. 26

27 Fix the rings with some petroleum jelly and position the piston. 27

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28 Postion the spring and the hub. Use a new spring. The ID of the spring is approx.72mm(2.83 in) and the number of coils is 4.5. The length of the hub is approx.52 mm(2.05 in). 28 72mm(2.83 in) 4.5 52mm2.05 in

29 Position the tool and compress the spring. Use the thrust as a support for the tool. Make sure that the hub engages the splines. Fit the locking ring halves with the chamfer

upwards. 29

30 Release the spring tension and make sure that the locking ring halves engage their grooves correctly. Remove the tool and the thrust plate. 30

31 Position the discs. Begin with an internally splined disc then one

externally splined disc and so on. There are twelve externally splined discs and thirteen internally splined discs. The disc thickness is 1.5mm(0.06 in). The ID of the disc is 99 mm(3.90 in). Lubricate the discs.

31 12 13 1.5mm0.06 in 99 mm3.90 in

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32 Postion the thrust plate and secure with the circlip. Check the disc clearance of the clutch which should be 1.3-4.9mm(0.06-0.19 in).

32 1.3-4.9mm0.06-0.19 in

33 Fit the coiled locking ring in position. 33

34 Position thrust washer and thrust bearing. Place the thinner thrust washer 1.5mm(0.06

in) innermost and the thicker washer 2.4 mm (0.09 in)outermost. Lubricate the bearings.

34 1.5mm 2.4mm

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35 Position the needle bearings. 35

36 Position the clutch drum. 36

37 Fit washer and thrust bearing. NOTE: The thickness of the washer is 2.4mm(0.09

in).Fit the spacer ring, thickness 5 mm(0.20 in). 37 2.4mm0.09 in 5mm0.20in

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38 Fit the circlip. 38

39 Press the spacer ring up against the circlip and check the end float which should be 0.4-1.3mm(0.016- 0.051 in). If the clearance is too great, change the thrust bearing and the thrust washer. 39 0.4-1.3mm0.016-0.151 in

40

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41 Position the sealing rings(piston steel ring type) on the piston. 41

42 Fix the rings with petroleum jelly and position the piston.

42

43 Position the spring and the hub. Use a new spring. The ID of the spring is approx.72 mm(2.83 in) and the number of coils is 3.5. The length of the hub is approx.38 mm(1.50 in). 43 72mm2.83 in 3.5 38mm1.50 in

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44 Position the tool and compress the spring. Use the thrust plate as a support for the tool. Make sure that the hub engages the splines. Fit the locking ring halves with the chamfer Upwards.

44

45 Release the tension of the spring and make sure that the locking ring halves engage their grooves.

45

46 Position the discs. Begin with an internally splined disc and then

continue with an externally splined disc and so on. The number of discs are 7 externally splined and 8 internally splined discs. The disc thickness is 1.5 mm(0.06 in). The ID of the discs is 99mm(3.90 in). Lubricate the discs.

46 7 8 1.5mm0.06 in 99mm3.90 in

47 Position the thrust plate and secure with the Circlip. Check that the clutch disc clearance is 1.2-4.0 mm(0.05 in-0.16 in).

47 1.2-4.0mm0.05 in

-0.16 in

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48 Fit the coiled locking ring. 48

49 Position thrust washers and thrust bearing. The thin thrust washer 1.5 mm(0.06 in) should be

fitted innermost and the thicker washer 2.4 mm(0.09 in)should be fitted outermost. The ID of the washers is 54mm(2.13 in). Lubricate the bearing.

49 1.5mm0.06 in 2.4mm0.09 in 54mm2.13 in

50 Position the needle bearing. 50

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51 Position the clutch drum. 51

52 Fit the thrust washer and thrust bearing. The thickness of the washer is 2.4mm(0.09 in)and its ID is 54mm(2.13 in). Fit the spacer washer on top of the thrust bearing. The thickness of the spacer washer is 5 mm(0.197

in) and its ID is 46 mm(1.81 in). 52 2.4mm0.09 in 54mm 2.13 in 5mm0.197 in 46mm 1.81 in

53 Heat the bearing in an oven to approx.100(212 eF)and fit the bearing.

The groove in the bearing should be facing upwards.

53 100(212eF)

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54 Fit the spacer washer and secure with the circlip. 54

55 Press the bearing upwards and check the end float which should be 0.5-1.5 mm(0.02 in-0.06 in). If the clearance is too great, change thrust bearing and washers. NOTEThe sealing rings(piston steel ring type) should be fitted on the shaft after adjusting the end float.

55 0.5-1.5mm(0.02in-0.06in)

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TRANSMISSION, ASSEMBLING Reverse-second output shaft -

36 Remove the circlip for the inner bearing for the second clutch drum and change the bearing. Refit the circlip.

36

37 Pull off the bearing inner race for the second Clutch drum, if the bearing is to be changed. 37

38 Heat the inner bearing race to approx.100212eFand fit the inner race.

38 100(212eF

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39 Fit the bearing and the gear for the reverse-second clutch output shaft. NOTE: The protruding hub boss should be facing downwards( towards the dropbox). If necessary heat the bearing in an oven to

approx.100(212eF). 39 - 100(212eF)

40 Insert the output gear for the second clutch and the clutch drum in the outer gear. 40

41 Press the output gear into position NOTE: Make sure that the bearing enters

squarely. 41

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42 Heat the inner bearing race for the second clutch shaft to approx. 100(212eF) and fit it on the shaft. NOTE: The support hitch of the bearing race should be innermost.

42 100212eF

43 Fit the bearing and the support ring. 43

44 Screw down the hexagon head bolts flush with the contact face on the washer to the shaft and tighten the bolts to 40 Nm(30 Ibf ft) Lock with the hexagon socket bolts tightening them to 20 Nm(15 Ibf ft). Tighten finally to 80 Nm(59 Ibf ft). Change the O-ring on the bearing cover and

bolt on the cover. 44 40 Nm30 Ibf ft 20 Nm(15 Ibf ft) 80 Nm(59 Ibf ft) O

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Third-fourth output shaft

45 Remove the bearing from the third-fourth output shaft. 45 -

46 Drive the outer bearing race into position on the third-fourth output shaft. Position the bearing. If necessary heat the bearing in an oven to

approx.100(212eF). 46 - 100(212eF)

47 Insert the gear(protruding hub boss away from the torque converter side). If necessary heat the bearing in an oven to approx.100(212eF).

47 100(212eF)

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48 Position shaft and tool. 48

49 Make sure that the tool centres on the inner bearing race. Press the shaft into the gear wheel and the bearing.

49

50 Heat the bearing in an oven to approx.100 (212eF)and fit it. Make sure that the bearing fits up against the shoulder when it has cooled

down. 50 100(212eF)

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51 Change the bearing race in the bearing retainer for the third clutch outer shaft.

51

52 Bolt on the bearing retainer without an O-ring with three bolts and washers as shown in the figure. Tighten the bolts until the wavy

washers become fully compressed. Then slacken the bolts approx. one turn in order to release any preload. NOTE: While tightening the bolts, make sure that the bearing retainer slides easily in the housing and that the retainer is not in an oblique position when the bolts have been slackened. Rotate the shaft at least five revolutions. Measure the slot where the shims are to be fitted in at least two places. Work out the average thickness. Select and reduce the shim thickness so that a preload of 0.03-0.08 mm(0.0012-0.0031 in) is obtained.

52 5

0.03-.008mm(0.0012-0.0031 in) O

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53 Bolt on the cover. Use a new O-ring and tighten the bolts to 45 Nm 33 Ibf ft.

53 O 45 Nm33 Ibf ft

Output shaft

54 Change bearings and O-rings on the output shaft. Pull off the bearings as shown in the figure. 54 O

Heat the bearings in an oven to approx.100(212eF) and fit them. NOTE: If necessary the shaft is pressed out of the gear wheel. Heat or press the shaft back into position. 100(212eF)

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55 Bolt on the splash plate. Tighten the bolts to 45 Nm(33 Ibf ft). Insert the shaft. NOTEOn HT200 ser.no.2791-and on HT201, there is no bearing fitted. 55 45 Nm33 Ibf ftHT200 2791 HT201

56 Change the O-ring and on HT200 ser.no.-2790 also the outer bearing race in the parking brake

housing. Lubricate the O-ring with petroleum jelly. Position the brake housing. 56 O HT200 2790

O

57 Position the guide pin for the brake discs and insert the discs. Begin with one internally splined and then

continue with one externally splined disc and so on. There are 7 internally, and 6 externally splined discs.

57 76

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58 On transmission HT200 ser.no.2791-and on HT201. Heat the bearing in an oven to approx.100 (212eF)and position the bearing. Make sure the bearing fits up against the

shoulder when it has cooled down. 58 HT200 2791 HT201

100(212eF)

Piston unit for parking brake, HT200 ser.no.-2790, reconditioning HT200 2790

59 Remove the piston unit from the parking brake housing cover. Slacken the bolts evenly all the way round. NOTE: The force of the spring.

59

60 Change the O-ring and if necessary the springs.

The free length of the springs should be 74.3 mm(2.93 in)and 66 mm(2.60 in)at a pressing force of 900-1100N(202-247 Ibf). Change the seal. Drive the seal into position using handle and Plates. 60 O 74.3mm(2.93 in), 900-

1100N202-247 Ibf 66mm 2.60 in

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61 Dismantle piston and piston stop. Change the piston and the sealing rings and

the under-lying O-rings. To facilitate the fitting of the sealing rings, they may be heated in warm water which will make them more supple. Fit the sealing rings without using hard or sharp objects. NOTE: The lips of the sealings should be facing each other.

61 O O

62 Lubricate the rings with oil and assemble piston and piston stop.

62

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63 Fit the piston unit on the cover for the parking brake housing. It may be necessary to rotate the piston stops

slightly to make the bolts fit. Tighten the bolts to 25 Nm18 Ibf ft.

63 25 Nm18 Ibf ft

64 Release the parking brake application by tightening in the three bolts in the cover until stop. Then slacken the bolts one turn.

64

65 Fit the brake housing cover. NOTE: The O-ring. Tighten the bolts to 45 Nm(33 Ibf ft). 65

O 45 Nm(33 Ibf ft).

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Piston unit for parking brake, HT200 ser.no.2791-and HT201reconditioning HT200 2791 HT201

58 Remove the three bolts from the cover. Slacken the bolts evenly all the way round. NOTE: The spring force. Lift away the cover. 58

59 Change seal and bearing race in the cover. 59

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60 If necessary remove the springs. The free length of the springs should be 74.3 mm(2.93 in)and 66mm(2.60 in)at a pressing force of 900-1100N(202-247 Ibf). Change the sealing rings. To facilitate the fitting, heat the rings in hot water making them more supple. Fit the sealing rings without using hard or sharp objects. NOTE: The lips of the seals should be facing each other. 60 74.3mm2.93 in

900-1100N202-247 Ibf 66mm

61 Position the O-ring on the shaft outside the bearing and also the O-ring on the housing. Lubricate the sealing rings on the piston and the chamfered surfaces in the housing with petroleum jelly. Position the piston. Make sure that the sealing ring enters into to chamfered area.

61 O

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62 Position the springs on the piston and put on the cover. Make sure that the springs remain located in their positions. Tighten down the cover as far as the bolts allow. Tighten the bolts evenly all the way round. Check that the sealing ring on the piston enters the housing evenly all the way round. 62

63 Fit the ordinary attaching bolts for the cover tightening them evenly all the way round to a torque of 45 Nm(33 Ibf ft). Replace the three long bolts. 63 45 Nm(33 Ibf ft)

64 Release the parking brake application by tightening in the three bolts in the cover until stop. Then slacken them one revolution. 64

65 Fit the space between the lips of the seals with grease. 65

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Transmission, assembling

66 Change seal and bearing race in the bearing retainer for the output shaft.

Use handle 6 999 001, plate 6 999 080 and 6 999 105 for the seal and handle 6 999 001, Plate 6 999 105 and 6 999 120 for the bearing race. 66 6 999 001 6 999 080 6 999

105 6 999 001 6 999 105 6 999 120

67 Bolt on the bearing retainer without an O-ring with three bolts and washers as shown in the figure. Tighten the bolts until the wavy washers become fully compressed. Then slacken the bolts approx. one turn in order to release any preload. NOTE: While tightening the bolts, make sure that the bearing retainer sliders easily in the housing and that the retainer in not in an oblique position when the bolts have been slackened. Rotate the shaft at least five revolutions. Measure the clearance where the shims are to be fitted in at least two places. Work out the average. Select shims whit a correct thickness reduced by 0.03-0.08mm(0.0012-0.0031 in) in order to obtain a preload. Fit a new O-ring. NOTE: It is important that the parking brake is released as described on page 121 point 64 or alternatively page 124 point 64.

67 0.03-0.08mm(0.0012-0.0031 in) O 64

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68 Position the bearing retainer together with shims and O-ring. Tighten the bolts to 45 Nm(33 Ibf ft) Fit a new O-ring on the shaft.

68 O 45 Nm33 Ibf ft O

69 Fit the rear drive flange. Tighten the nut to 600 Nm443 Ibf ft NOTEThe tool increases the torque on the nut 15 times. Secure with the circlips. 69 600 Nm443 Ibf ft 15

70 Fit the front drive flange. Tighten the nut to 600 Nm(442 Ibf ft). NOTE: The tool increases the torque on the nut 15 times. Secure with locking washer and circlip. There are two versions of the washer. The

difference between them is the pitch. Before removing the tool, try out which locking washer fits best. Never reduce the torque of the nut. Remove the tool.

70 600 Nm(442 Ibf ft) 15

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71 Drive the plug out of the cover for the forward-first clutch shaft. Put the cover back but without an O-ring and without shims leaving a slot between the cover and the housing of a approx.1 mm(0.04 in).

71 - O 1mm(0.04 in)

72 Drive the bearing for the forward-first clutch shaft into position.

72 -

73 Position the clutch shafts in the housing in the following order: third-fourth, forward-first and finally

reverse-second. NOTE: Grease the rollers in the output shaft for the reverse-second clutch. Make sure that none of the rollers fall out of the cage. When in doubt, remove the cover at the end of the dropbox for the reverse-second output shaft in order to check that all rollers are in position. The reverse-second clutch shaft must be shaken down in order to make the disc splines engage. The shaft is fully home when the reverse gear is at the same level as the gear for the fourth clutch.

73 ------

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74 Position the bearing for the intermediate gear. 74

75 Position the intermediate gear. 75

76 Turn the torque converter housing and drive in the outer bearing race for the bearing of the forward-first clutch shaft.

76 -

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77 Place guards over the clutch shafts, i.e. plastic, rubber or similar and assemble the housing halves. Do not forget the O-ring on the suction duct. Use sealing compound. Tighten the bolts to 80 Nm(59 Ibf ft). NOTEThe torque converter housing must be in the horizontal position when assembling,

otherwise the bearings may be damaged. 77

80 Nm59 Ibf ft.

78 Lubricate the bearing for the reverse-second clutch shaft and drive the bearing into position. Secure with the circlip. 78 -

79 Fit support ring, spacer ringHT 200and circlip on the clutch shaft. NOTEThe inner chamfer of the support ring

should be facing the torque converter(outwards). Press down the circlip by raising the shaft while at the same time pressing down the circlip using the tool 999 3616.

79 HT 200 999 3616

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80 Put the outer circlip for the third-fourth clutch shaft on the shaft. Lift the shaft with the aid of the tool and insert the circlip.

80 -

81 Fit the turbine shaft. 81

NOTEOn HT200 ser. no. 1639-a circlip has been introduced on the turbine shaft to limit its end movement, see figure. If parts of the torque converter are damaged, a change to the new version should be made as follows: If earlier type shaft or cover are damaged, the shaft, cover and torque converter foot must be changed. Any shims are omitted and instead replaced by the circlip. If the torque converter is damaged, change shaft and torque converter foot in addition to the torque converter. The circlip is added. If the torque converter foot is damaged, no other parts need to be changed apart from the torque converter foot. The earlier version of the to