30-11 - numeralkod

ASSEMBLE INPUT ASSEMBLY

Front Cover

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A-Input housingB-Idler shaft (2 used)C-Driven gear (2 used)D-Idler gear (2 used)E-Qil seal

::;TM84 (02SEP94)

F-Bearing (4 used)G-Ball bearingH-Bearing (3 used)I-BearingJ-Snap ring

K-Bearing spacerL-Q-ring (2 used)M-Q-ring (2 used)N-Magnetic pickup sensorO-Magnetic pickup cover

30-11

P-Hex cap screw (2 used)Q-O·ringR-Lock washer (2 used)S-Washer (2 used)T-Hex socket plug

YZ,CTM84,30,30 -19-13JAN94

OF Series 150 and 250090994

Front Cover

INSTALL OIL SEAL AND BALL BEARING

1. Position input housing with converter side up.

2. Install new oil seal.

NOTE: If outside diameter of oil seal is not alreadycoated with a sealer apply LOCTlTE® #620.

3. Position input housing with converter side down.

4. Install new ball bearing (D) into front cover.

CTM84 (02SEP94) 30-12

YZ,CTM84,30,14 -19-13JAN94

DF Series 150 and 250090994

Front Cover

INSTALL IDLER GEARS AND BEARINGASSEMBLIES

1. Place idler gear assembly (A) into auxiliary pump portof the front cover.

2. Position idler gear assembly into its cavity besideauxiliary pump port.

3. Install idler gear assembly (8) into charge pump portand place into cavity.

YZ,CTM84,30,15 -19-13JAN94

CTM84 (02SEP94) 30-13 DF Series 150 and 250090994

Front Cover

INSTALL IDLER SHAFTS

NOTE: Thru hole in idler shaft must line up with bolthole in input housing. Use a bolt to guide thealignment while installing.

1. Align bearing bore of idler gear assemblies (A) withinput housing shaft bore.

2. Lubricate O-ring (8) with grease and install in grooveon shaft.

3. Use grease to hold O-ring (C) to the bottom of theidler shaft during installation.

ALTERNATE O-RING INSTALLATION PROCEDURE

3a. Position O-ring (C) at the bottom of the shaft bore inthe input housing.

YZ.CTM84.30.16 -19-13JAN94

CTM84 (02SEP94) 30-14 OF Series 150 and 250090994

Front Cover

4. Use bolt to align thru hole in idler shaft with bolt holein the input cover.

5. Push idler shaft (0) through idler gear assembly intoinput housing.

6. Install the other idler shaft in this same manner.

YZ,CTM84.30.17 -19-13JAN94


Front Cover

INSTALL DRIVEN GEAR ASSEMBLY(AUXILIARY PUMP PORT SIDE)

1. Install driven gear assembly with the snap ring up.

2. Rotate idler gear (A) to align teeth with driven gear(8).

3. Push idler gear bearing into bore in input housing.


Front Cover

4. Install bearing spacer (C).

A CAUTI~N: Wear eye protection when installingsnap rings.

5. Install snap ring into groove.

;x;"'N>-

YZ,CTM84,30,22 -19-13JAN94


INSTALL MAGNETIC PICKUP

1. Lubricate O-ring.

2. Install new O-ring in groove on magnetic pickupsensor (A).

3. Push magnetic pickup sensor into front cover.

4. Install magnetic pickup cover (8).

5. Install cap screws and lock washers (C).

6. Tighten cap screws to 10.4 N·m (7 Ib-ft).

Front Cover

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YZ,CTM84,30,13 -19-13JAN94


Front Cover

ASSEMBLE FRONT COVER GROUP

cooRl>-

A-Input housing (SAE 3)B-Stator support tubeC-Gear,43TO-Converter input shaftE-Cotter pin

F-Thrust raceG-Needle bearingH-Hex cap screw,

12x280mm (4 used)I-Hex cap screw, 12x172mm

(3 used)

J-Q-ringK-Hex cap screw, 8x50mm

(7 used)L-Shipping plug

M-Lift hangerN-Cap screw (2 used)Q-Oeflector

:::TM84 (02SEP94) 30-19YZ,GTM84,30,31 -19-28MAR94


Front Cover

ASSEMBLE CONVERTER INPUT SHAFT ANDSTATOR TUBE

IMPORTANT: Install ridged spline of converter inputshaft toward converter.

1. Install converter input shaft.

NOTE: The splined end with ridge must be installed up(toward converter).

2. Place stator support tube (A) over converter inputshaft.

3. Align the oil passage and bolt holes in stator supporttube (A) with oil passage and bolt holes in the fronthousing.

IMPORTANT: Deflector (C) must be in place andinstalled correctly to properly direct oilflow. It also must not interfere withinstalling the input housing over thestator tube.

4. Install cap screws (8) and deflector (C).

5. Tighten cap screws to 37 N'm (27 Ib-ft).

YZ,CTM84,30,18 -19-13JAN94


-- -- ------------- ------

Front Cover

6. Lubricate all parts with clean transmission fluid.

7. Install new thrust race (C).

8. Install new needle thrust bearing (D).

9. Install new O-ring (E) flat against front housing.

10. Install 43 tooth gear (F).

11. Rotate gear to be sure it is centered and seated onbearings.

YZ,CTM84,30,19 ·19·13JAN94

~TM84 (02SEP94) 30-21 DF Series 150 and 250090994

Front Cover

INSTALL FRONT COVER ASSEMBLY TOMAIN CASE FRONT HOUSING

1. Install lifting device, make sure the input housingassembly hangs level.

NOTE: Be sure main case front housing is level beforeattempting to install input housing assembly.

2. Lower input housing assembly carefully over statortube and gear.

NOTE: Be sure the input housing goes down completelyand sits flat on the front housing.

3. Install seven cap screws (A).

4. Tighten cap screws to 87 N'm (64 Ib-ft)


SPECIFICATIONS

Item Measurement

Control Valve-to-Front Housing Cap TorqueScrew

Valve Clamp-to-Valve Housing Cap TorqueScrew

REMOVE AND INSTALL WIRING HARNESS

REMOVE WIRING HARNESS

1. Tag all connectors relative to proportional valves.

2. Disconnect all electrical connectors.

3. Remove bracket (A) and harness.

4. Inspect wiring and connectors.

INSTALL WIRING HARNESS

1. Install bracket (A) and harness.

2. Connect all electrical connectors.

Group 35Control Valve

Specification

25 N'm (18 Ib-ft)

10.4 N'm (7.5 Ib-ft)

YZ,CTM84,35,SPC-19-13JAN94

YZ,CTM84,35,1 -19-13JAN94


Control Valve

REMOVE CONTROL VALVE GROUP

A-Shipping plugB-Cap screw (11 used)C-Cap screw (10 used)

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O-Cap screw (6 used)E-Valve housingF-5hipping plug (2 used)

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G-GasketH-Plate

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0

0

0

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I-GasketJ-Plug

1. Tag and disconnect all electrical leads to controlvalve.

2. Remove cap screws (8), (C) and (D).

3. Remove valve assembly (E).

4. Remove gasket (G).

5. Remove plate (H).

6. Remove gasket (I).

YZ,CTM84,35,6 -19-13JAN94


Control Valve

DISASSEMBLE AND ASSEMBLE CONTROL VALVE

THE CARTRIDGE TYPE VALVES USED IN THISASSEMBLY ARE NOT USER SERVICEABLE. ANYVALVE FOUND TO BE DEFECTIVE MUST BEREPLACED AS A UNIT.

IMPORTANT: Cartridge valves require a O-ring.When assembling valves besure andgrease O-ring (B). Place O-ring intothe counter bore of the valve

housing (0), Install cartridge typevalve (A) through O-ring (B) intovalve housing (0). Placing the O-ringonto the cartridge type valve firstmay cause leaking.

USE THE DRAWINGS PROVIDED AS GUIDES FORFURTHER DISASSEMBLY AND ASSEMBLY OF THECONTROL VALVE.

A-Proportional 24 VoltValve (7)

B-Q-ring (8)C-Temperature SensorD-O-ring PackingE-Hex Socket Plug

CTM84 (02SEP94)

F-Standard Thread O-ringPlug (12 used)

G-Pipe PlugH-Steel Ball 9/32 (6 used)1-114 Pipe PlugJ-Q-ring

K-Q-ringL-Pipe PlugM-Proportional Solenoid

PlugN-Engagement Override

valve

35-3

o-Hex Cap Screw 6x16mm(8 used)

P-Valve Clamp (8 used)Q-Valve HousingR-Lube Regulator ValveS-Pressure Regulator Valve

YZ,CTM84,35,7 -19-26AUG94


Control Valve

INSTALL CONTROL VALVE GROUP

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I-GasketJ-Plug

G-GasketH-Plate

D

O-eap screw (6 used)E-Valve housingF-Shipping plug (2 used)

A-Shipping plugB-eap screw (11 used)C-eap screw (10 used)

o II

/

IMPORTANT: The gaskets and metal plate mustbe installed so that the large oilreturn slot aligns with the slot in thetransmission front cover.

3. Install gasket (G).

4. Install valve assembly (E).

1. Install gasket (I).5. Install cap screws (8), (C) and (0). Observetightening sequence and torque specifications givenin this section.

2. Install plate (H).6. Connect all electrical leads to control valve.

YZ,CTM84,35,12 -19-01JUN94


Control Valve

CAP SCREW TIGHTENING SEQUENCE AND TORQUE SPECIFICATIONS

Tighten cap screws in the sequence shown, in threestages of gradually-increasing torque.

1. First stage-tighten all cap screws to 31 % ofspecified torque.

2. Second stage-tighten all cap screws to 62% ofspecified torque.

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3. Third stage-tighten all cap screws to finalspecified torque.

CONTROL VALVE CAP SCREW TORQUESPECIFICATIONS.....25 N'm (18 Ib-ft)

YZ,CTM84,35,10 -19-13JAN94

::;TM84 (02SEP94) 35-5 DF Series 150 and 250090994

Control Valve

PIPING DIAGRAM, CONVERTER DRIVEN TRANSMISSION, (WITHOUT WET BRAKE)

Piping diagram for converter driven or direct drive OFseries transmission without wet brake option.

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------>-

A-Charge pump 91 Ipm(24gpm) at 2100 enginerpm.

B-Remote mount filter withbypass warning switch.

C-Heat exchanger Maximumallowable pressure dropswith converter 69 kPa(10psi) with direct drive345 kPa (50 psi).

D-Main control valve fortransmission

1-Transmission sumpsuction

2- 1 1/16-12UNC-2B JIC thdport.

3- 1 5/16-12UNC-2B JIC thdport.

YZ,CTM84,35,4 ·19·23MAR94


Control Valve

PRESSURE AND TEMPERATURE CHECK PORTS (WITHOUT WET BRAKE)

'"'"&Jo'"oZ=?

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A-Clutch 3B-Clutch 1C-Clutch 2D-Converter ReliefE-Press Inlet from Filter

Pump Pressure.

OPERATING CONDITIONS:

• Engine speed at 2200 rpm

F-Pressure RegulatorG-Clutch BH-Clutch AI-Clutch DJ-Clutch CK-EOV Valve

L-Pump Pressure CheckPort orInternal DisconnectPressureSupply port(9/16-18 UNF SAE O-ring)

PORT PRESSURES:

In neutral

M-Clutch 4N-Converter Out

(sump) oil TemperaturePort(112-20 UNF SAE O-ring)

• Transmission temperature range at 100o-160°F.

• Pump flow 23-27 gpm at 240-280 psi.

In neutral, "Converter In" pressure should always be higher than Lubepressure.

• Converter in 60-115 psi (see footnote)

• Converter out 40-90 psi

• Lube 40-60 psi

In gear

• Lube 20-40 psi

YZ,CTM84.35.8 -19-13JAN94


Control Valve

PRESSURE AND TEMPERATURE CHECK PORTS(WITHOUT WET BRAKE) continued

Following is identification of ports as they are marked onthe valve body casting.

Ports marked 1, 2, 3 and 4 are direction clutch ports.

• 1 and 2 are forward clutches.

• 3 and 4 are reverse clutches.

Ports marked A, B, C and D are Speed clutch Ports.

NOTE: All check ports are 7/16-20 UNF SAE a-ring,unless otherwise specified.

YZ,CTM84,35,3 ·19·13JAN94


Group 40Main Case Front Housing

OTHER MATERIAL

Number

T43513*

Name

LOCTITE® Thread Lock & Sealer(High Strength) # 262

Use

Piston-to-Shift Fork Cap Screws.

LOCTITE is a trademark of the Loctite Corporation.

•John Deere part number reference.

SPECIFICATIONS

Item Measurement

Dipstick Tube Assembly-to-Front TorqueHousing Cap Screws.

Front Housing-to-Rear Housing Cap TorqueScrews.

Main Case Front Housing. Weight

Cylinder Housing Cap Screws. Torque

Capscrew-to-Piston Torque

Solenoid Capscrews Torque

Thin Stop Nut-to-Coil Torque

Ground Driven Pump-to-Front TorqueHousing Capscrews.

~TM84 (02SEP94) 40-1

YZ.CTM84.40,OTH-19-01 JUN94

Specification

25 N'm (18 Ib-ft)

87 N'm (64 Ib-ft)

120 Kg (265 Ibs.)

25 N'm (18 Ib-ft)

25 N'm (18 Ib-ft)

25 N'm (18 Ib-ft)

50 inch pounds

87 N'm (64 Ib-ft)

YZ,CTM84,40,SPC-19-01JUN94


Main Case Front Housing

REMOVE AND INSTALL DIPSTICK ASSEMBLY

A-1/4 I.D. HoseB-Dipstick

REMOVE DIPSTICK TUBE

C-Dipstick tube assembly D-Cap screw (2 used)

INSTALL DIPSTICK TUBE

E-Dipstick gasket

1. Remove 1/4 inch hose (A) from valve and dipsticktube assembly (C).

2. Remove cap screws (D) from dipstick tubeassembly.

1. Install cap screws (D) in dipstick tube assembly.

2. Install 1/4 inch hose (A) from valve to dipsticktube assembly (C).

3. Tighten cap screws (D) to 25 N'm (18 Ib-ft).

YZ,CTM84,40,13 -19-13JAN94



REMOVE OUTPUT YOKE

1. Remove cap screw (E), washer (D), O-ring (C).

2. Remove yoke (B) and V-ring seal (A).

A-V-ring sealB-YokeC-o-ringD-Yoke washerE-eap screw

'"~z'"oZ::;>

YZ,CTM84,40,1 -19-13JAN94

REMOVE DISCONNECT

1. Remove thin stop nut (B).

2. Remove pin and coil assembly (A).

NOTE: Behind the core assembly (A) inside of thesolenoid cap (B) you will find solenoid spool,solenoid plunger, and spring solenoid.

3. Remove core assembly (A).

CTM84 (02SEP94) 40-3

YZ,CTM84,40,17 -19-13JAN94

YZ,CTM84,40,19 -19-13JAN94


4. Remove cap screws (A).

5. Remove solenoid cap.(A).


YZ,CTM84,40,20 -19-13JAN94

YZ,CTM84,40,21 -19-13JAN94


6. Remove gasket (A).

7. Remove cap screw (8).

8. Remove piston (A).


YZ,CTM84,40,22 -19-13JAN94

:TM84 (02SEP94) 40-5YZ,CTM84,40,23 -19-13JAN94


9. Remove lip seal (A) from piston (8).

10. Remove disconnect return spring (A).


YZ,CTM84,40,24 -19-13JAN94

11. Remove cap screws.


12. Remove cylinder housing.


YZ,CTM84,40,26 -19-13JAN94

~TM84 (02SEP94) 40-7 OF Series 150 and 250090994


INSTALL SEVENTH STAGE DISCONNECT

1. Install cylinder housing (A) and cap screw (B).

2. Tighten cap screws 25 N'm (18 Ib-ft.)

CTM84 (02SEP94) 40-8

YZ.CTM84,40.27 -19-13JAN94


3. Install disconnect return spring (A).

4. Install lip seal (A) onto piston (8).


YZ,CTM84.40.28 ·19·13JAN94

CTM84 (02SEP94) 40·9 DF Series 150 and 250090994


5. Apply loctite® # 262 to cap screw (8).

6. Place cap screw (8) into piston (A).

NOTE: Cap screw is held away from shift fork assemblyby disconnect return spring. Push piston and capscrew into cylinder housing to start cap screwthreads.

7. Install cap screw.

8. Tighten cap screw 25 N'm (18 Ib-ft.).

LGCTfTE is a trademark of the Loctite Corporation.

9. Install gasket (A).

YZ,CTM84,40,29 ·19·13JAN94

CTM84 (02SEP94) 40-10YZ,CTM84,40,30 -19-13JAN94



10. Install solenoid cap.

11. Install cap screws (A) and tighten to 25 N'm (18Ib-ft.).

12. Place solenoid plunger assembly (A) into coreassembly (8).

13. Install core assembly and plunger assembly intosolenoid cap.

14. Tighten core assembly.

15. Place pin and coil assembly (A) onto core assembly.

16. Install thin stop nut.

17. Tighten to 50 inch pounds.

YZ,CTM84,40,33 -19-02JUN94

YZ.CTM84,40,32 -19-02JUN94

:TM84 (02SEP94) 40-11 DF Series 150 and 250090994


DISASSEMBLE AND ASSEMBLE FRONT HOUSING

A-Hex cap screws12x120mm (18 used)

B-Lube relief valve

CTM84 (02SEP94)

C-Front housingD-Bore sleeves (4 used)

E-Bearing cupF-Dowel pin (3 used)

40-12

G-1 5/8 std. plug withC-ring (2 used)

YZ,CTM84,40,18 -19-13JAN94



JISASSEMBLE AND ASSEMBLE GROUND DRIVEN PUMP

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A-Shipping PlugB-O-ringC-External Retaining RingO-Bearing

:TM84 (02SEP94)

E-Hex Cap Screw (3)F-AdapterG-BearingH-GearI-O-ring

40-13

YZ,CTM84,40,34 -19-24MAR94



1. Remove three cap screws (A).

2. Remove ground driven pump assembly (8).

DISASSEMBLE GROUND DRIVEN PUMP

1. Remove external retaining ring (A).

YZ,CTM84,40,36 -19-24MAR94


Disassemble Pump


Assemble Ground Driven Pump

1. Press Gear (C) from Adapter (A).

2. Remove bearings from gear (C) and from adapter(A).

3. Discard bearings (D) and (F).

1. Install new bearing (D) onto gear (C).

2. Press gear (C) and bearing (D) into adapter (A).

3. Start bearing (F) onto gear (C) and press bearinginto adapter (A).

4. Install external retaining ring (8) into groove ingear (C).

YZ,CTM84,40,37 -19-24MAR94



5. Install O-ring (A) onto ground pump assembly.

INSTALL GROUND DRIVEN PUMP

1. Install ground driven pump onto main case fronthousing.

2. Install cap screws (A).

3. Torque cap screws to 87 N'm (64 Ib-ft).

YZ,CTM84,40,38 -19-24MAR94

YZ,CTM84,40,39 -19-24MAR94


REMOVE FRONT HOUSING

1. Remove cap screws from front housing.


YZ,CTM84,40,2 -19-13JAN94

:;TM84 (02SEP94) 40-17 OF Series 150 and 250090994


NOTE: See group 99 for special tools.

1. Use four threaded holes (A) in front housing to attachlifting tool.

NOTE: Use only high grade fasteners for holding thelifting tool to the front cover.

2. Attach lifting tool (8) onto front housing.

YZ,CTM84,40,3 ·19·13JAN94



A CAUTION: Front housing weight isapproximately 265 Ibs.

3. Lift front housing (A) from rear housing (8).

DISASSEMBLE FRONT HOUSING

YZ,CTM84,40,4 -19-13JAN94

'"o<0N>-

A-Lube relief valve

CTM84 (02SEP94)

B-Bore sleeve (4)

40-19

C-Bearing cup

YZ,CTM84,40,11 -19-13JAN94



REMOVE BORE SLEEVES

1. Inspect bore sleeves (A) for wear or damage.

NOTE: When removing bore sleeves from the 150 seriesyou must pull sleeves. The front housing of the150 series transmission has a shoulder in thebore.

NOTE: See group 99, special tools.

2. Remove bore sleeves from front side of front housing.

YZ,CTM84,40,S -19-23MAR94



INSTALL BORE SLEEVES

1. Position front housing with bearing bore side up.

IMPORTANT: Install bore sleeves with the internalchamfer up.

2. Place bore sleeve (A) onto driving tool (8) withI outside diameter chamfer of bore sleeve to end of tool.


I 3. Install bore sleeve flush with shoulder.

YZ.CTM84,40,6 -19-02JUN94



REMOVE LUBE RELIEF VALVE

1. Position front housing with bearing bore side up.

2. Remove lube relief valve (A).


INSTALL LUBE RELIEF VALVE

1. Position front housing with bearing bore side down.

2. Install lube relief valve (A).


REMOVE BEARING CUP

1. Remove bearing cup.

YZ,CTM84,40,7 -19-13JAN94 t

CTM84 (02SEP94) 40-22YZ,CTM84,40,9 -19-13JAN94



INSTALL BEARING CUP

1. Install new bearing cup (A).

REMOVE OIL SEAL

1. Remove oil seal (A).

INSTALL OIL SEAL

NOTE: Apply Loctite #242 or equivalent to outsidediameter of oil seal before installation.

1. Install new oil seal flush with shoulder.

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YZ,CTM84,40,10 -19-13JAN94

CTM84 (02SEP94) 40-23YZ,CTM84,40,14 -19-01JUN94



INSTALL FRONT HOUSING TO REARHOUSING

1. Attach lift tool to front housing.

NOTE: Refer to remove front housing for information onattaching lifting tool.

2. Install new gasket onto rear housing.

3. Install front housing (A) to rear housing (B).


4. Install cap screws.

5. Tighten cap screws to 87 N'm (64 Ib-ft).


YZ,CTM84,40,16 -19-13JAN94


SPECIFICATIONS

Item

Seventh Stage without Disconnect.

Clutch Stages less Output Stage.

Oil Trough-to-Rear Housing CapScrews.

Measurement

Weight

Weight

Torque

Group 45Gear Ratio Group

Specification

30 Kg (65 Ibs.)

272 Kg (600 Ibs.)

25 N'm (18 Ib-ft)

YZ,CTM84,45,SPC-19-01JUN94

REMOVE MAGNETIC PICKUP FROM REARHOUSING

1. Remove cap screws and washers (A).

2. Remove cover (B), note position of cut out in cover.

3. Pull out magnetic sensor (C) with a-ring (D).

A-Cap screws and washersB-CoverC-Magnetic sensorO-Q-ring

YZ,CTM84,45,3 -19-13JAN94

:::TM84 (02SEP94) 45-1 OF Series 150 and 250090994

Gear Ratio Group

REMOVE SEVENTH STAGE OUTPUT GROUP

1. Remove cap screws (A) from oil trough assembly (8).

A CAUTION: Approximate weight of output groupis 75 Ibs.

2. Remove seventh stage output group and oil trough.

YZ,CTM84,45,1 -19-13JAN94

CTM84 (02SEP94) 45-2YZ,CTM84,45,2 -19-13JAN94


Gear Ratio Group

DISASSEMBLE AND ASSEMBLE SEVENTH STAGE OUTPUT GROUP (NO DISCONNECT)

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A-Bearing cone (2 used)

IMPORTANT: Do not attempt to remove gear fromshaft. This is a permanemtassembly. Damage to parts willresult.

Disassemble

B-Seventh stage output shaftgear assembly

1. Remove bearing cones (A).

Assemble

1. Install new bearing cones (A).

YZ,CTM84,45,13 -19-22MAR94


Gear Ratio Group

DISASSEMBLE AND ASSEMBLE SEVENTH STAGE OUTPUT GROUP (WITHDISCONNECT)

.....;::N>-

1-Hose2-Standard thread O-ring

plug3-Solenoid cap4-output disconnect shaft5-Bushing6-Bearing cone7-Thrust bearing8-Thrust race9-Shift collar10-Snap ring (external)

11-Seventh stage outputshaft

12-Bearing cone13-Shims (.18mm, .51mm,

.13mm)14-Bearing retainer15-Cap screw (6 used)16-o-ring17-Shift fork assembly18-Cylinder housing

19-Disconnect retainerspring

20-o-ring21-Cap screw m8x2522-Piston23-Lip seal24-Cap screw m8x2025-Gasket26-Solenoid cap27-Cap screw (2 used)

28-Solenoid spool29-Snap ring30-90 JIC fitting31-Roll pin32-Core assembly33-Solenoid plunger34-Solenoid spring35-Thin stop nut36-Pin and coil 24 volt

assembly

YZ,CTM84,45,41 -19-13JAN94


Gear Ratio Group

DISASSEMBLE SEVENTH STAGE WITHDISCONNECT

1. Remove oil trough (A).

2. Remove shift fork.

CTM84 (02SEP94) 45-5YZ,CTM84,45,8 -19-13JAN94


3. Remove output disconnect shaft (A).

4. Remove thrust race (B).

5. Remove thrust bearing (A).

Gear Ratio Group

YZ,CTM84,45,10 -19-13JAN94


6. Remove shift collar (8).

7. Remove bearing cone (A).

ASSEMBLE SEVENTH STAGE WITHDISCONNECT

NOTE: See group 99 for special tool (B).

1. Install bearing cone (A).

Gear Ratio Group

YZ,CTM84,45,11 -19-13JAN94

~TM84 (02SEP94) 45-7YZ,CTM84,45,12 -19-13JAN94


Gear Ratio Group

2. Press sleeve (A) into output disconnect shaft.

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3. Install new bearing cone (A).

4. Install shift collar (B).

CTM84 (02SEP94) 45-8YZ,CTM84,45,45 ·19·13JAN94


5. Install new thrust bearing (A).

6. Install new thrust race (8)

7. Install output disconnect shaft (A).

Gear Ratio Group

YZ,CTM84,45,47 -19-13JAN94


Gear Ratio Group

8. Install shift fork assembly (A) with threaded end up.

9. Install oil trough (A) with bolt holes down.

CTM84 (02SEP94) 45-10YZ,CTM84.45,49 -19-13JAN94


Gear Ratio Group

REMOVE ALL CLUTCH STAGE ASSEMBLIES

A CAUTION: Approximate weight of all clutchstage assemblies is 600 Ibs.

IMPORTANT: Lift all clutch stage assemblies atone time using lift tool.

NOTE: See group 99 for special tools.

1. Install lift tool (A).

2. Lock holders (8) into place.

3. Install bolt (C) into sixth stage assembly.

4. Lift all clutch stage assemblies from rear housing.

YZ,CTM84,45,5 -19-13JAN94

CTM84 (02SEP94) 45·11 OF Series 150 and 250090994

Gear Ratio Group

5. Place stages on work table.

6. Remove lift tool from clutch stage assemblies.

YZ,CTM84,45.6 -19-13JAN94


FIRST STAGE SHAFT ASSEMBLY

Gear Ratio Group

A-Seal ring

CTM84 (02SEP94)

B-Bearing C-First stage shaftassembly

45-13

D-Bearing

YZ,CTM84,45,17 -19-13JAN94


Gear Ratio Group

SECOND STAGE CLUTCH ASSEMBLY

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A-Second stage shaftassembly

B-Piston outer seal (2 used)C-o-ring (2 used)D-Clutch piston (2 used)E-Lube shut off washer (2

used)F-Clutch return spring (12

used)

CTM84 (02SEP94)

G-Retaining ring (2 used)H-Snap ring retainer (2

used)I-Clutch separator plate

(DF-150 20 used)I-Clutch separator plate

(DF-250 22 used)

J-Clutch plate (DF-150 20used)


K-Clutch plate retainer (2used)

L-Snap ring (2 used)

45-14

M-55T clutch gearN--61T clutch gearo-Bearing (2 used)P-Bearing (2 used)Q-Bearing (2 used)R-Snap ring (2 used)S-Seal ring (3 used)

YZ,CTM84,45,16 ·19·13JAN94


Gear Ratio Group

THIRD STAGE CLUTCH ASSEMBLY

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A-Third stage clutchassembly

B-Piston outer sealC-o-ringD-clutch pistonE-Lube shut off washerF-Clutch return spring (6

used)

::;TM84 (02SEP94)

G-Retaining ringH-Snap ring retainerI-Clutch separator plate

(DF-150 10 used)I-Clutch separator plate

(DF-250 11 used)



K-Clutch plate retainerL-Snap ring

45-15

M-61T clutch gearN-BearingQ-BearingP-Bearing (2 used)Q-Snap ringR-Seal ring (2 used)

YZ.CTM84.45.38 -19-13JAN94


Gear Ratio Group

FOURTH STAGE CLUTCH ASSEMBLY

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A-Seal ring (3 used)B-BearingC-Snap ring (2 used)D-BearingE-4th clutch assembly gearF-Bearing (2 used)G-Snap ring (2 used)H--clutch plate retainer

CTM84 (02SEP94)

I--clutch plate (DF-150 20used)

I--clutch plate (DF-250 22used)

J--clutch separator plates(DF-150 20 used)

J--clutch separator plates(DF-250 22 used)

K-Retaining ring (2 used)L-Snap ring retainer (2

used)M--clutch retainer spring (12

used)N-Lube shutoff piston (2

used)O--clutch piston (2 used)

45-16

P-Piston outer seal (2 used)Q-O-ringR-4th and 5th stage shaft

assembly5-38th clutch gearT-BearingU-Bearing

YZ,CTM84,45,40 -19-13JAN94


Gear Ratio Group

FIFTH STAGE CLUTCH ASSEMBLY

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A-Seal ring (3 used)B-Bearing (2 used)C-Snap ring (2 used)D-Bearing (2 used)E-75 tooth clutch gear (2

used)F-Bearing (2 used)G-Snap ring (2 used)

CTM84 (02SEP94)

H-Clutch plate retainer (2used)

I-Clutch plate (DF-150 20used)

I-Clutch plate (DF-250 22used)

J-Clutch separator plate(DF-150 20 used)

J-Clutch separator plate(DF-250 22 used)

K-Retaining ring (2 used)L-Snap ring retainer (2

used)M-Clutch retainer spring (12

used)

45-17

N-Lube shutoff washer (2used)

O-Clutch piston (2 used)p-outer piston seal (2 used)a-o-ring (2 used)R-4th and 5th stage shaft

assembly

YZ,CTM84,45,39 -19-13JAN94


Gear Ratio Group

DISASSEMBLE CLUTCH STAGE ASSEMBLY

All clutch stage assemblies in the OF seriestransmission assemble and disassemble in the samemanner. In this manual we show the disassemblyand assembly of the second stage clutch.

1. Remove three teflon seal rings.

CTM84 (02SEP94) 45-18YZ,CTM84,45,18 -19-13JAN94


Gear Ratio Group

2. Install bearing removal tool (A).

3. Install gear puller (8) onto bearing removal tool.

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4. Remove bearing (C) from shaft assembly.


Gear Ratio Group

5. Remove snap ring (D) from shaft assembly.

6. Install gear puller.

7. Remove gear and ball bearing from shaft assembly.

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4

CTM84 (02SEP94) 45-20

YZ,CTM84,45,20-19-13JAN94


Gear Ratio Group

8. Remove snap ring (A).

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9. Turn shaft assembly over. Remove all clutch andseparator plates.

CTM84 (02SEP94) 45-21

YZ,CTM84,45,21 -19-13JAN94

'"..,.'"N>-

YZ,CTM84,45,15 -19-13JAN94


Gear Ratio Group

10. Turn shaft assembly over.

11. Install puller.

12. Remove ball bearing.

L- .c..;yZ"".C::..:.T""M8::;:4"".4S"'".2=-2---'-.19"--.1:.:::3J:::.:A::..::N9:....:.4---l4


Gear Ratio Group

13. Place shaft assembly on press.

14. Use press tool (8) to compress clutch return springs.

NOTE See'group 99 for special tools.

15. Remove snap ring (C).


Gear Ratio Group

IMPORTANT: Pay attention to the assembly of theclutch return springs. They must bereassembled in the same way.

16. Lift out snap ring, retaining ring, and clutch returnsprings.

17. Remove lube shutoff washer.

CTM84 (02SEP94) 45-24 DF Senes 150 and 250090994

Gear Ratio Group

A CAUTION: Wear eye protection when removingpiston from cylinder.

18. Apply air pressure through oil passage to forcepiston from shaft assembly.

19. Remove piston from cylinder.

20. Remove O-ring and piston outer seal from piston.

21. Inspect all parts.


Gear Ratio Group

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44. Install lube sh.utoff washer (0).

3. Install clutch piston (C).

ASSEMBLE CLUTCH STAGE ASSEMBLY

2. Install new piston outer seal (B).

1. Install new O-ring (A).

YZ,CTM84,45,26 -19-·13JAN94


30-11 - numeralkod

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