Service Manual User Manual

Transmission
7-7
IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at
the factory. Mark the drive shaft yoke at the transmission
for return to its original position.
14. Mark the transmission to transfer case drive shaft
yoke at the transmission-mounting flange. Remove
the M12 hex-head capscrews and lock washers
securing the flange yoke to the transmission. Lower
the transmission end of the drive shaft safely to the
ground, out of the way of the transmission.
15. FOR CUMMINS ENGINES: Working from beneath
the vehicle, on the left or boom side of the engine,
just behind the engine-to-chassis mount bracket,
remove the rubber hole plug and metal cover plate.
The plate covers a flywheel inspection hole
(Fig. 7–6) on the engine.
FOR PERKINS ENGINES: Remove the starter.
Remove the rubber hole plug above and to the left of
the starter opening.
Figure 7–6. Cummins engine flywheel inspection hole.
IMPORTANT: The engine flywheel and the transmission
drive plate are factory-balanced units. Mark the flywheel
and the transmission drive plate for return to their original
positions during re-installation.
16. Insert an engine barring tool into the rubber plug hole
opening (Fig. 7–6, Cummins engine shown). If an
engine barring tool is not available, use a pry bar or
other suitable device to alternately turn and bar the
engine flywheel. The tool will be used to advance,
then lock, the flywheel to permit removal of the
capscrews and washers securing the transmission
drive plate to the flywheel.
17. Working through the flywheel inspection hole on the
engine (Fig. 7–6, Cummins engine shown), remove
the eight 3/8-24 NF x 1-3/4" Grade 8 hex-head
capscrews (Cummins engine) or 3/8-24 NF x 2"
Grade 8 hex-head capscrews (Perkins engine) and
the eight 3/8" washers securing the transmission
drive plate to the engine flywheel. Use the engine
barring tool to prevent the flywheel from turning while
removing the capscrews and washers.
18. Obtain four M12 x 80 mm capscrews with several
washers each, as needed, and thread one capscrew/
washer set into the tapped holes of each
transmission mount bracket boss (Fig. 7–4).
19. Connect an engine lift strap or sling to the M12 x
80mm capscrews, and to a suitable hoist or overhead
crane. Avoid sling contact with the transmission shift
solenoids and the two modulation valve assemblies
mounted on the top of the transmission. Operate the
hoistorcranetoremoveslackfromthesling,butDO
NOT raise the transmission at this time.
IMPORTANT: Mark a capscrew locating hole on the
transmission converter housing and the engine flywheel
housing to aid in reinstallation, as the sides of the trans-
mission case do not align vertically with the engine or
with the chassis (Fig. 7–7).
Figure 7–7. Mark a capscrew locating hole on the trans-
mission converter housing and engine flywheel housing.
20. Remove the twelve M10 x 1,5 x 30mm PC8.8 hex-
head capscrews and M10 lock washers securing the
transmission to the engine. Separate the
transmission from the engine.
21. Carefully remove the transmission from the vehicle.
Avoid causing damage to the transmission and to the
drive plate. Reposition the lift strap as needed to
adjust for load shifting during transmission removal.
22. Lift the transmission clear of the vehicle and lower it
onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
thetransmissionsothatitwillnotmoveorfall.
MS0750
Rubber plug hole
Engine flywheel
inspection hole
Boom side
engine mount
WARNING: Risk of personal injury. The trans-
mission may move while hoisting it out of the
chassis. Carefully move the transmission and
adjust the sling as needed. Keep fingers,
hands, legs and other body parts clear of the
transmission.
Mark
MS0760
Model 3606 • Origin 10/99