NMWR_Attachment.pdf

NMWR 9-28155--227744

*NMWR 9-2520-581

NATIONAL MAINTENANCE WORK REQUIREMENTS

FOR

3L80 TRANSMISSION

HMMWV FOV

NSN 2520-01-161-2136, P/N 12339146, CAGEC 19207

AVAILABILITY STATEMENT: This publication is not available through the AG publication centers. This publication is available through U.S. Army TACOM Life Cycle Management Command, Warren, MI 48397-5000

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

*Supersedes NMWR 9-2520-581, 21 March, 2003.

U.S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

AUGUST 2010

WARREN, MI

NMWR 9-2520-581

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to comply may result in serious injury or death to personnel.

Improper cleaning methods and use of unauthorized cleaning solutions may result in injury to personnel and/or damage to equipment.

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

Do not use compressed air to dry bearings.

Direct all personnel to stand clear during hoisting operations. A heavy swinging load can be extremely dangerous.

When steam cleaning, protective clothing must be used.

Degreasing solvent is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when solvent is used. Use only in well-ventilated places.

Use extreme care when handling heavy parts. Provide adequate support and use assistance during procedure.

Wear adequate protective goggles/shields to prevent injury from possible airborne fragments.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

The date of issue for original pages/work packages for the NMWR is:

Original . . . . . . . . 20 August 2010

TOTAL NUMBER OF WORK PACKAGES IS 26

THE PAGES/WORK PACKAGES CONSISTS OF THE FOLLOWING:

Page No

Warning a

Warning b blank

A

B blank i ii blank iii iv blank v vi vii viii blank

WP 0001 00 – 0026 00 ... 0

*Zero in this column indicates original page.

A/B blank

*NMWR 9-2520-581

U.S. ARMY

TACOM LIFE CYCLE MANAGEMENT COMMAND

WARREN, MI, 20 August 2010

NATIONAL MAINTENANCE WORK REQUIREMENTS

FOR

3L80 TRANSMISSION

HMMWV FOV

NSN 2520-01-161-2136, P/N 12339146, CAGEC 19207

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures i n this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on AEPS will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028 directly to U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The email address is tacomlcmc.daform2028 @us.army.mil. The fax number is DSN 793-0726 or Commercial (309)782-0726.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

* Supersedes NMWR 9-2520-581, 21 March 2003.

i/ii blank

TABLE OF CONTENTS

Work Package/Page No.

How to Use This National Maintenance Work Requirement (NMWR) ....................................................................................... v

CHAPTER 1 GENERAL INFORMATION

List of Acronyms and Definitions ....................................................... WP 0001 00 General Information .......................................................................... WP 0002 00 General Cleaning Instructions ........................................................... WP 0003 00 General Inspection Instructions ........................................................ WP 0004 00 General Repair Instructions .............................................................. WP 0005 00

CHAPTER 2 MAINTENANCE INSTRUCTIONS

Disassembly Into Subassemblies ..................................................... WP 0006 00 Case Repair ...................................................................................... WP 0007 00 Oil Pump Repair ................................................................................ WP 0008 00 Forward Clutch and Turbine Shaft Repair ........................................ WP 0009 00 Direct Clutch and Intermediate Sprag Repair ................................... WP 0010 00 Center Support Repair ...................................................................... WP 0011 00 Gear Unit Repair ............................................................................... WP 0012 00 Rear Servo Repair ............................................................................ WP 0013 00 Governor Repair ............................................................................... WP 0014 00 Assembly From Subassemblies ........................................................ WP 0015 00

CHAPTER 3 SUPPLEMENTAL INFORMATION

Testing .............................................................................................. WP 0016 00 Run In Test ....................................................................................... WP 0017 00 Special Packaging Instructions ......................................................... WP 0018 00 Guide Pin .......................................................................................... WP 0019 00 Torque Limits .................................................................................... WP 0020 00 Tools and Special Tools List ............................................................. WP 0021 00 Mandatory Replacement Parts List ................................................... WP 0022 00 Expendable and Durable Items List .................................................. WP 0023 00 Repair Parts Introduction .................................................................. WP 0024 00 Repair Parts ...................................................................................... WP 0025 00

References ........................................................................................ WP 0026 00

Index ................................................................................................. Index 1 iii/iv blank

NMWR9-2520-581

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

INTRODUCTION

This section explains the basic organization, contents, format, and special features of this NMWR.

After reading this section, spend some time reviewing the NMWR to familiarize yourself with the contents and layout. This will enable you to locate information easily and reduce the time needed to complete required procedures.

ORGANIZATION AND CONTENTS

This NMWR is divided into three main chapters. Chapter 1 presents general information;

Chapter 2 presents maintenance instructions; and Chapter 3 presents supplemental information.

Chapter 1

List of acronym/abbreviations used throughout this NMWR; general information;

general cleaning instructions; general inspection instructions; and general repair instructions.

Chapter 2

Disassembly into subassemblies; case repair; oil pump repair; forward clutch and turbine shaft repair; direct clutch and intermediate sprag repair; center support repair; gear unit repair; rear servo repair; governor repair; and assembly from disassemblies.

Chapter 3

Testing; run in test; special packaging instructions; guide pin; torque limits; tools and special tools list; mandatory replacement parts; expendable and durable items list; repair parts introduction; and repair parts.

You can locate specific information in the NMWR by using either the Table of Contents located at the front of the NMWR or the alphabetical subject index located at the back of the NMWR.

v

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR) (Cont’d)

FORMAT

Work Package (WP) Format

Each chapter in this NMWR is divided into WPs that group data into stand-alone informational or task-oriented units. As shown in the table, Chapter 1 contains informational WPs while Chapter 2 contains primarily task-oriented WPs (maintenance procedures) followed by supplementary information WPs in Chapter 3.

Here are some important things to know about the WP format:

Each WP has its own identification number, which appears in the upper right corner of each page. WPs are numbered sequentially throughout the manual.

Each WP starts with page number 1. Page numbers appear at the bottom of the pages following the WP number.

Informational WPs begin with a listing of the specific topics covered in the order in which they appear in the WP. This listing provides you with a quick overview of each WP and enables you to locate specific information easily.

WP may identify the following information: tools, replacement parts, personnel, and other materials needed to complete the procedure in the WP. The Initial Setup section may identify the equipment condition required before the procedure can be started. Before beginning a procedure, review the Initial Setup information to ensure all requirements have been met.

The task-oriented WPs (maintenance procedures) appear in the manual in the order of logical work sequence. This format makes the NMWR easy to follow and helps improve efficiency as you progress through the procedures.

Text and Illustration Modular Layout

Throughout this NMWR, WPs are set up in two-page modular layouts. This means that illustrations appear either on the same page as or on the page facing the step you are performing. This feature eliminates the need to search for illustrations that correlate with each procedural step.

In addition, procedural text is cross-referenced to numerical callouts in the illustrations, helping you immediately identify and locate specific parts mentioned. Figure and callout numbers referencing the illustrations appear in parenthesis in the text.

vi

NMWR9-2520-581

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR) (Cont’d)

SPECIAL FEATURES

Illustration Features

This NMWR utilizes a variety of illustration methods such as locator views and exploded views to help you locate and identify parts easily. Each illustration is identified by a figure number and title printed below it.

The illustrations contain numerical callouts to identify parts, components, etc. mentioned in the text. Numerical callouts generally appear in clockwise order in the illustrations beginning at the 11 o’clock position.

A special feature of this NMWR is that the callout numbers for mandatory replacement parts are circled in the illustrations. This visually distinguishes mandatory replacement parts from those that may be repairable or otherwise reusable.

Supplemental Information

The WPs at the end of this NMWR contain supplemental information that supports the procedures in the NMWR. This information is cross-referenced in the Initial Setup list of each overhaul WP. The following supplemental information is included in this NMWR:

Torque Limits – Torque specifications for all fasteners used to assemble the component being overhauled in this NMWR.

Tools and Special Tools – Name, P/N, and NSN for common and special tools required for the procedures in this NMWR.

Mandatory Replacement Parts – Nomenclature, P/N, and NSN for all parts that must be replaced during overall of the component; also includes cross-references to figure and item numbers in the Repair Parts WP.

Expendable and Durable Items – National Stock Number (NSN), description, Commercial and Government Entity Code (CAGEC), Part Number (P/N), and description for all expendable and durable items necessary to operate or maintain the equipment used in this NMWR.

Repair Parts – Item number, Source, Maintenance, and Recoverability (SMR) code; NSN;

CAGEC; part number; description and usable on codes (UOC); and quantity for all parts required for the procedures in this NMWR.

References – All publications referenced in this NMWR.

vii/viii blank

CHAPTER 1

GENERAL INFORMATION

NMWR 9-2520-581 0001 00

LIST OF ACRONYMS AND DEFINITIONS

THIS WORK PACKAGE (WP) COVERS:

Scope and Acronyms and Definitions

SCOPE

This Work Package (WP) lists acronyms and definitions that appear in this NMWR.

0001 00-1

NMWR 9-2520-581 0001 00

LIST OF ACRONYMS and DEFINITIONS (Cont’d)

ACRONYMS DEFINITIONS

AEPS Army Electronic Product Support

CAGEC Commercial and Government Entity Code

CPC Corrosion Prevention Control

ECP Engineering Change Proposal

EIR Equipment Improvement Recommendations

FOV Family of Vehicles

HMMWV High Mobility Multipurpose Wheeled Vehicle

IUID Item Unique Identification

NMWR National Maintenance Work Requirement

NSN National Stock Number

OEM Original Equipment Manufacturer

P/N Part Number

QA Quality Assurance

QTY Quantity

RPSTL Repair Parts and Special Tools List

SMR Source, Maintenance, and Recoverability

TACOM Tank-automotive and Armaments Command

TAMMS The Army Maintenance Management System

TAMMS-A The Army Maintenance Management System - Aviation

TM Technical Manual

UOC Usable On Code

WP Work Package

END OF WORK PACKAGE

0001 00-2

NMWR 9-2520-581 0002 00

GENERAL INFORMATION

Scope; Applicable Documents; Definitions; Maintenance Forms, Records, and Reports;

Reporting Equipment Improvement Recommendations (EIRs); Corrosion Prevention and Control (CPC); Quality of Material; Engineering Change Proposals (ECPs); Transmission Rebuild Description; After Repair Performance Test; and Item Unique Identification

SCOPE

This NMWR covers the repair of the 3L80 Transmission. The 3L80 Transmission is used in the High Mobility Multipurpose Wheeled Vehicle (HMMWV). The procedures contained in this NMWR describe disassembly, inspection, component repair, and assembly to ensure a product that is serviceable and issuable to all customers without limitation or restriction, Condition Code A.

APPLICABLE DOCUMENTS

You can receive copies of the applicable documents upon request by contacting:

Department of the Army, United States Army TACOM Life Cycle Management Command, 6501 East 11 Mile Road, Mail Stop 410, ATTN: AMSTA-LCC-CHLD, DAMI_HMMWV@conus.army.mil , Warren, MI 48397-5000.

0002 00-1

APPLICABLE DOCUMENTS (Con’t)

The following documents form a part of this NMWR to the extent specified herein.

1. TM 9-2320-280-24P

2. MIL-P-14105C

3. AR 385-10 (Army Safety Program)

4. AR 750-1 (Army Materiel Maintenance Policy)

5. DA PAM 750-8 (The Army Maintenance Management Systems (TAMMS) Users Manual)

6. ISO 9001: 2000 Standards

7. DoD Guide to Uniquely Identifying Items

DEFINITIONS

Rebuild: Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with OEM standards. Rebuild is the highest degree of material maintenance applied to Army equipment. The rebuild operation includes the action of returning to zero those age measurements (e.g., hours/miles) considered in classifying Army equipment/components.

OEM: The original equipment manufacturer. The company that originally manufactured, fabricated, or supplied an engine component or part. The OEM may include items manufactured by a subcontractor for an OEM provided that the name or trademark of the OEM is shown on the item, label, or container.

After Market Part: Any part or component that has been manufactured or fabricated by a company other than the OEM or their approved subcontractors and sold as a replacement part for an OEM part or component.

Serviceable Part: Any part that is capable of meeting or exceeding the minimum OEM standards for performing the function for which it was originally designed.

Non-serviceable Part: Any part that no longer meets the minimum OEM standards.

Test: To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item in comparing those characteristics with prescribed standards on a scheduled basis (i.e., load testing of lifting devices and/or hydraulic testing of pressure hoses).

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; DA PAM 738-751, Functional Users Manual for The Army Maintenance Management – Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

0002 00-2

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your 3L80 transmission (NSN 2520-01-161-2136, P/N 12339146) needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. Put it on a SF 368 (Product Quality Deficiency Report). Mail it to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; or as specified by the acquiring activity. We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

1. Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

2. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

3. If a corrosion problem is identified, it can be reported using a SF 368. Use of key words such as “corrosion”, “rust”, “deterioration”, or “cracking” will ensure that the information is identified as a CPC problem.

4. The form should be submitted to the address specified in DA PAM 750-8.

QUALITY OF MATERIAL

Parts and material used for replacement, repair, or modification shall meet the requirements of the equipment drawings and specified if standards are not provided in this NMWR.

ENGINEERING CHANGE PROPOSALS (ECPs)

Engineering Change Proposals (ECPs) will be submitted using DD Form 1693 (Engineering Change Proposal [Short form]). (Refer to MIL-STD 973, Configuration Management, for instructions). Completed forms should be mailed directly to Department of the Army, United States Army TACOM Life Cycle Management Command, 6501 East 11 Mile Road, ATTN;

AMSTA-LCC-HLD, DAMI_HMMWV@conus.army.mil , Warren, MI 48397-5000

TRANSMISSION REBUILD DESCRIPTION

1. We will provide transmission assemblies, NSN 2520-01-161-2136, in various states of disrepair. Some parts may be missing from the transmissions. You will repair the transmissions so they meet the configuration of drawing 12339146 and the performance specifications described in WP 0018. This standard will provide a serviceable component, issuable to users without performance restrictions.

2. You can use OEM or equivalent after market repair parts when repairing the transmission.

When using other than OEM parts, the parts used must be able to be repaired or replaced using the existing procedures, tools, and repair parts specified in the HMMWV technical manuals.

0002 00-3

TRANSMISSION REBUILD DESCRIPTION (Con’t)

3. Rebuild transmission assemblies must maintain the same transmission-to-vehicle interface as the original equipment transmission.

4. Repair of cracks in the transmission case is limited to the bell housing area up to 3 inches away from the transmission oil pump face (see WP 0008). Any other crack is cause for disposal of the case. TACOM has provisioned the 3L80 transmission case, NSN 3040-01-448-9611; it may be used in instances where the case cannot be repaired.

5. You may cannibalize serviceable or repairable parts from any unrepairable transmission assembly for use when repairing other transmission assemblies.

6. During the course of repair, any sub-components/parts of the transmission assembly showing obvious signs of imminent failure, excessive wear, or deterioration will be replaced with a fully serviceable replacement.

7. The repaired transmission (including the torque converter) shall be free of contaminated oil.

AFTER REPAIR PERFORMANCE TEST

You will do a performance test on each transmission repaired using equipment such as the AIDCO 450 Automatic Transmission Service Evaluation Center http://www.aidcoint.com/products_testst450.htm (or the equivalent). The Repair Facility Quality Representative and/or the Dynamometer Operator must witness the testing. As part of the performance test, a test report should be kept at the repair facility for a minimum of two (2) years. A copy of the repair facility’s monthly production report, to include the manufacturer’s serial number of each repaired transmissions, will be provided to DAMI_HMMWV@conus.army.mil for tracking purposes. You will also attach a repair facility data plate of your design to the transmission.

ITEM UNIQUE IDENTIFICATION

NOTE

Reference the following OSD Web Link: http://www.acq.osd.mil/dpap/pdi/uid/index.html for the latest information on Directives; Guides; and National and International Standards, Policy, and Regulation along with other information and clarification for Item Unique Identification.

1. The Item Unique Identification (IUID) tag and serial number should be located on top of the bell housing.

2. Mark all transmissions in accordance with Item Unique Identification (IUID) instructions in

WP 0018.

0002 00-4

NMWR 9-2520-581 0003 00

GENERAL CLEANING INSTRUCTIONS

General Cleaning

GENERAL CLEANING

1. General instructions: Cleaning procedures will be the same for the majority of parts and components which make up the vehicle subassemblies. General cleaning procedures are detailed in "2" through "5".

2. The Importance of Cleaning: Great care and effort are required in all cleaning operations. The presence of dirt and foreign material is a constant threat to satisfactory vehicle operation and maintenance. The following will apply to all cleaning operations:

(a) Hands must be kept free of any accumulation of grease which can collect dust and grit.

(b) Clean all parts before inspection, after repair, and before assembly.

(c) After cleaning, all parts must be covered or wrapped in plastic or paper to protect them from dust and/or dirt.

3. Disassembled Parts Cleaning: Place all disassembled parts in wire baskets for cleaning.

(a) Dry and cover all cleaned parts.

(b) Place on or in "racks" and hold for inspection or repair.

(c) All parts subject to rusting must be lightly oiled and wrapped.

(d) Keep all related parts and components together. Do not mix parts.

WARNING

Improper cleaning methods and use of unauthorized cleaning solutions will injure personnel and damage equipment.

0003 00-1

NMWR 9-2520-581 0003 00

GENERAL CLEANING (Con’t)

4. Castings.

(a) Clean inner and outer surfaces of castings and all areas subject to grease and oil with cleaning solvents.

(b) Use a stiff brush to remove sludge and gum deposits.

Compress air used for cleaning purposes will not exceed 30 psi (207 kPa). Use o nly with effe ctive chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury to personnel and/or damage to equipment.

(c) Use compressed air to blow out all tapped capscrew holes and dry castings after cleaning.

5. Oil Passages. Particular attention must be given to all oil passages in castings and machined parts. Oil passages must be clean and free of any obstructions.

(a) Clean passages with wire probes to break up any sludge or gum deposits.

(b) Wash passages by flushing with solvents.

(c) Dry passages with compressed air.

6. Nonmetallic Parts.

CAUTION

Do not allow solvents to come in contact with seals, cables, or Flexible hoses. F ailure t o c omply m ay cause leather, rubber, and synthetic materials to dry out, rot, and lose pliability making them unserviceable.

Clean hoses and other nonmetallic parts with soap and water.

END OF TASK

0003 00-2

NMWR 9-2520-581 0004 00

GENERAL INSPECTION INSTRUCTIONS

General Inspection

GENERAL INSPECTION

1. General Instructions: Procedures for inspections will be the same for many parts and components which make up the vehicle subassemblies. General procedures are detailed in "2" through "9". Dimensional standards for parts have been fixed at extremely close tolerances, so use specification tables. Use specified inspection equipment for inspection where cracks and other damage cannot be spotted visually. Exercise extreme care in all phases of inspection.

Repair or replace all unserviceable components.

2. Castings:

(a) Inspect all ferrous and nonferrous castings for cracks. See MIL-STD-6866, Inspection, Penetrant Methods. Particularly check areas around studs, pipe plugs, threaded inserts, and sharp corners. Replace cracked castings.

(b) Inspect machined surfaces for nicks, burrs, and raised metal. Mark damaged areas for repair or replacement.

(c). Inspect all pipe plugs, pipe plug openings, capscrews, and capscrew openings for damage and stripped threads. Replace if damaged or threads are stripped.

(d) Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straightedge or surface plate. Inspect mating flanges for discolorations which may indicate leakage. Replace if warped.

(e) Check all castings for conformance to applicable repair standards.

3. Machined Parts:

(a). Check machined parts for cracks, distortion, and damage.

(b) Check all surfaces for nicks, burrs, and raised metal.

4. Studs, Bolts, Capscrews, and Nuts: Replace if bent, loose, stretched, or threads are damaged.

0004 00-1

NMWR 9-2520-581 0004 00

GENERAL INSPECTION (Con’t)

5. Gears.

NOTE

When gear teeth wear limits are not established, good jud gement is required to determine if gear replacement is necessary.

(a) Inspect all gears for cracks and missing teeth. Replace if cracked or teeth are missing.

(b) Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.

(c) Inspect splines for wear, burrs, and galled or pitted surfaces.

(d) Check keyway slots for wear and/or damage.

6. Oil Seals: Oil seals are mandatory replacement items.

7. Casting Plugs: Inspect for leakage. Replace plugs when leakage is present.

8. Springs: Inspect for damaged, distorted, and collapsed coils.

9. Snap Rings, Retaining Rings, and Washers: Many of these parts are mandatory replacement items. Inspect all others for obvious damage.

0004 00-2

NMWR 9-2520-581 0005 00

GENERAL REPAIR INSTRUCTIONS

General Repair

GENERAL REPAIR

1. General Instructions: Repair of most parts and components is limited to general procedures outlined in applicable maintenance instructions and the following detailed procedures “2” through “8.”

Repaired items must be thoroughly cleaned to remove metal chips and abrasives to prevent them from entering working parts of vehicle components.

2. Castings:

a. All cracked castings will be replaced.

b. Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove minor nicks, burrs, and/or scratches by:

(1) Using fine mill file.

(2) Using abrasive cloth dipped in cleaning solvent.

(3) Lapping across a surface plate.

(4) Remachining of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted. Replace castings.

(5) Repair damaged threaded pipe plug and/or capscrew holes with a thread tap or repair oversize holes with threaded inserts.

0005 00-1

NMWR 9-2520-581 0005 00

GENERAL REPAIR (Con’t)

4. Studs: Replace all bent and stretched studs. Repair minor thread damage with a thread restorer file. Replace studs having stripped or damaged threads as outlined below:

a. Remove, using a stud remover. Back studs out slowly to avoid heat buildup and seizure which can cause stud to break off.

b. If studs break off too short to use a stud remover, use extractor to remove.

c. Replacement studs have a special coating and must have a small amount of antiseize compound (appendix B, item 5) applied on threads before stud is installed. Install replacement stud slowly to prevent heat buildup and snapping off.

5. Gears:

a. Remove gears using pullers, as required.

b. Use the same methods described in paragraph b above, for castings to remove minor nicks, burrs, or scratches on gear teeth.

c. If keyways are worn or enlarged, replace gear.

6. Bushings and Bushing T ype Bearings: When bushings and bushing type bearings seize to a shaft and spin in the bore, the associated part must also be inspected and replaced, as required.

7. Oil Seals:

a. Remove oil seals, being careful not to damage casting or adapter bore.

b. Always install new seal in bore using proper seal replacing tool.

8. Locking Threads: When using thread sealing compound:

a. Apply a liberal amount to both male and female threads on through-hole assemblies.

b. Apply a liberal amount into the bottom of a blind hole (non-through hole assemblies).

Installing the fastener pneumatically forces the adhesive onto the threads.

c. Assemble parts shortly after applying thread sealing compound to allow adequate coating of threads.

0005 00-2

CHAPTER 2

MAINTENANCE INSTRUCTIONS

NMWR 9-2520-581 0006 00

DISASSEMBLY INTO SUBASSEMBLIES

Initial Setup; Torque Converter; Holding Fixture; Oil Pan Removal; Oil Filter Removal; Governor Removal; Control Valve Removal; Detent Solenoid Removal; Check Ball Removal; Front Servo Removal; Rear Servo Removal; Oil Pump Removal; Forward Clutch and Turbine Shaft; Direct Clutch; Manual Linkage; Front Band; Intermediate Clutch; Gear Unit; Center Support; Rear Band

INITIAL SETUP:

Tools General mechanic’s tool kit; automotive WP 0021, Item 1 SATS WP 0021, Item 2

Special Tools Transmission holding fixture base WP 0021, Item 5 Transmission holding fixture WP 0021, Item 6 Gear unit holding tool WP 0021, Item 7 Slide hammer adapters WP 0021, Item 8

General Safety Instructions Torque converter must be supported during removal.

0006 00-1

TORQUE CONVERTER

Torque converter must be supported during removal and installation. Failure to comply may result in injury to personnel and/or damage to equipment.

Ensure torque converter turns freely. Record any abnormal looseness or noise.

Remove torque converter (Figure 1, Item 2) from transmission (Figure 1, Item 1). Discard torque converter (Figure 1, Item 2).

1 2

Figure 1. Torque Converter

0006 00-2

HOLDING FIXTURE

Do not overtighten screws. This will bind center support.

1. Install transmission holding fixture (Figure 2) into locating holes on side of transmission (Figure 2, Item 1).

2. Install transmission holding fixture (Figure 2) and transmission (Figure 2, Item 1) into transmission holding fixture base (Figure 2).

3. Position front of transmission (Figure 2, Item 1) up and allow to drain.

Figure 2. Hold Fixture

0006 00-3

TRANSMISSION

HOLDING FIXTURE

TRANSMISSION

HOLDING FIXTURE BASE

OIL PAN REMOVAL

1. Position transmission case (Figure 3, Item 6) so oil pan (Figure 3, Item 2) faces upward.

2. Remove thirteen capscrews (Figure 3, Item 1), oil pan (Figure 3, Item 2), and oil pan gasket (Figure 3, Item 3) from transmission case (Figure 3, Item 6). Discard oil pan gasket (Figure 3, Item 3).

END OF TASK

OIL FILTER REMOVAL

1. Remove shoulder bolt (Figure 3, Item 13), oil filter (Figure 3, Item 4), intake pipe (Figure 3, Item 12), and spacer (Figure 3, Item 5) from case (Figure 3, Item 6). Discard oil filter (Figure 3, Item 4).

2. Remove intake pipe O-ring seal (Figure 3, Item 11) from case (Figure 3, Item 6). Discard O-ring seal (Figure 3, Item 11).

END OF TASK

GOVERNOR REMOVAL

1. Remove four capscrews (Figure 3, Item 9), governor cover (Figure 3, Item 8), and gasket (Figure 3, Item 7) from case (Figure 3, Item 6). Discard gasket (Figure 3, Item 7).

2. Remove governor (Figure 3, Item 10) from case (Figure 3, Item 6).

3. Clean mating surfaces of governor cover (Figure 3, Item 8) and case (Figure 3, Item 6).

Figure 3. Oil Pan

END OF TASK 0006 00-4/5 blank

6 7

Figure 4. Valve Body

0006 00-6

17 1

CONTROL VALVE REMOVAL

1. Remove eight capscrews (Figure 4, Item 1), detent roller and spring (Figure 4, Item 17), and three capscrews (Figure 4, Item 2) from control valve (Figure 4, Item 3) and case (Figure 4, Item 10).

2. Remove control valve (Figure 4, Item 3), gasket (Figure 4, Item 4), and governor pipes (Figure 4, Item 16) from case (Figure 4, Item 10). Discard gasket (Figure 4, Item 4).

3. Remove governor screen (Figure 4, Item 15) from governor feed pipe (Figure 4, Item 16) or feed pipe hole (Figure 4, Item 11).

4. Remove modulator value (Figure 4, Item 7) from case (Figure 4, Item 10).

DETENT SOLENOID REMOVAL

1. Disconnect detent solenoid wire (Figure 4, Item 12) from electrical connector (Figure 4, Item 9).

2. Remove two capscrews (Figure 4, Item 14) and detent solenoid (Figure 4, Item 13) from case (Figure 4, Item 10).

3. Remove control valve spacer plate (Figure 4, Item 5) and gasket (Figure 4, Item 6) from transmission case (Figure 4, Item 10). Discard gasket (Figure 4, Item` 6).

4. If necessary, compress three tabs on electrical connector (Figure 4, Item 9) and remove electrical connector (Figure 4, Item 9) and O-ring seal (Figure 4, Item 8) from case (Figure 4, Item 10). Discard O-ring seal (Figure 4, Item 8).

0006 00-7

CHECK BALL REMOVAL

Do not scratch marks on any machined surface of transmission case.

There may only be six check balls.

1. Note location of seven check balls (Figure 5, Item 2) in passages in case (Figure 5, Item 1) for assembly.

2. Remove seven check balls (Figure 5, Item 2) from case (Figure 5, Item 1).

Figure 5. Check Balls

0006 00-8

FRONT SERVO REMOVAL

Remove front servo pin (Figure 6, Item 4), piston (Figure 6, Item 2), retaining ring (Figure 6, Item 3), spring retainer (Figure 6, Item 5), and spring (Figure 6, Item 6) from case (Figure 6, Item 7).

REAR SERVO REMOVAL

1. Remove six capscrews (Figure 6, Item 1), servo cover (Figure 6, Item 12), and gasket (Figure 6, Item 11) from case (Figure 6, Item 7). Discard gasket (Figure 6, Item 11).

2. Remove rear servo piston (Figure 6, Item 10), accumulator piston (Figure 6, Item 9), and spring (Figure 6, Item 8) from case (Figure 6, Item 7).

Figure 6. Servo

END OF TASK 0006 00-9

7 8

OIL PUMP REMOVAL

1. Position transmission case (Figure 7, Item 5) so oil pump (Figure 7, Item 3) faces up.

2. Remove six capscrews (Figure 7, Item 1), seal washers (Figure 7, Item 2), and oil pump (Figure 7, Item 3) from transmission case (Figure 7, Item 5). Discard seal washers (Figure 7, Item 2).

3. Install slide hammer adapters (Figure 7) into threaded holes in oil pump (Figure 7, Item 3).

4. Using slide hammer and adapters (Figure 7), remove oil pump (Figure 7, Item 3) and gasket (Figure 7, Item 4) from transmission case (Figure 7, Item 5). Discard gasket (Figure 7, Item 4).

Figure 7. Oil Pump

0006 00-10

SLIDE

HAMMERS

SLIDE HAMMER

ADAPTERS

FORWARD CLUTCH AND TURBINE SHAFT

1. Remove forward clutch and turbine shaft (Figure 8, Item 1) from case (Figure 8, Item 6).

2. Remove forward clutch hub thrust washer (Figure 8, Item 8) from forward clutch and turbine shaft (Figure 8, Item 1) and tag for assembly.

DIRECT CLUTCH

1. Remove snapring (Figure 8, Item 2) securing direct clutch backing plate (Figure 8, Item 6) to direct clutch housing (Figure 8, Item 5).

2. Remove direct clutch housing plate (Figure 8, Item 3), six composition clutch plates (Figure 8, Item 4), and six steel clutch plates (Figure 8, Item 7) from direct clutch housing (Figure 8, Item 5). Discard six composition clutch plates (Figure 8, Item 4).

3. Remove direct clutch housing (Figure 8, Item 5) from transmission case (Figure 8, Item 7).

Figure 8. Direct Clutch

0006 00-11

MANUAL LINKAGE

1. Remove nut (Figure 9, Item 6) securing shift lever (Figure 9, Item 5) to manual shaft (Figure 9, Item 4) and remove shift lever (Figure 9, Item 5).

2. Loosen jam nut (Figure 9, Item 8) from manual shaft (Figure 9, Item 4).

3. Remove manual shaft retaining pin (Figure 9, Item 1) from case (Figure 9, Item 2).

4. Remove manual shaft (Figure 9, Item 4), jam nut (Figure 9, Item 8), and detent lever (Figure 9, Item 7) from case (Figure 9, Item 2).

5. Remove manual shaft seal (Figure 9, Item 3) from case (Figure 9, Item 2). Discard shaft seal (Figure 9, Item 3).

Figure 9. Lever Manual

0006 00-12

FRONT BAND

Lift front band (Figure 10, Item 1) away from anchor pin (Figure 10, Item 3) and remove front band (Figure 10, Item 1) from case (Figure 10, Item 2).

Figure 10. Front Band

0006 00-13

INTERMEDIATE CLUTCH

1. Remove snapring (Figure 11, Item 1) from intermediate clutch backing plate (Figure 11, Item 2) and case (Figure 11, Item 5).

2. Remove backing plate (Figure 11, Item 2), three-composition clutch plates (Figure 11, Item 3), and three steel clutch plates (Figure 11, Item 4) from case (Figure 11, Item 5). Discard three-composition clutch plates (Figure 11, Item 3).

Figure 11. Intermediate Clutch

0006 00-14

GEAR UNIT

1. Using 3/8 in. 12-point socket, remove center support-to-case aligning bolt (Figure 12, Item 5) from case (Figure 12, Item 4).

2. Remove center support-to-case snapring (Figure 12, Item 1) from case (Figure 12, Item 4).

3. Using gear unit holding tool (Figure 12), slide hammer adapter (Figure 12), and slide hammer (Figure 12), remove center support and gear unit assembly (Figure 12, Item 2) and rear case thrust washer (Figure 12, Item 3) from case (Figure 12, Item 4). Install rear case thrust water (Figure 12, Item 3) on center support and gear unit assembly (Figure 12, Item 2).

Figure 12. Gear Unit

0006 00-15

4 5

GEAR UNIT

HOLDING TOOL

SLIDE HAMMER ADAPTER

CENTER SUPPORT

1. Remove slide hammer (Figure 13), slide hammer adapter (Figure 13), and gear holding tool (Figure 13) from gear unit (Figure 13, Item 5).

2. Remove center support (Figure 13, Item 1) from gear unit (Figure 13, Item 5).

3. Remove center support thrust washer (Figure 13, Item 3) from center support (Figure 13, Item 1) and tag for assembly.

4. Remove outer sun gear thrust bearing race (Figure 13, Item 2) from center support (Figure 13, Item 1) and place over sun gear shaft (Figure 13, Item 4).

Figure 13. Center Support

0006 00-16

SLIDE HAMMER

SLIDE HAMMER

ADAPTER

HOLDING TOOL

REAR BAND

1. Remove rear selective washer (Figure 14, Item 5) from case (Figure 14, Item 3).

2. Remove center support-to-case spacer (Figure 14, Item 1) from case (Figure 14, Item 3).

3. Lift rear band (Figure 14, Item 2) away from anchor pins (Figure 14, Item 4) and remove rear band (Figure 14, Item 2) from case (Figure 14, Item 3).

Figure 14. Rear Band

0006 00-17/18 blank

NMWR 9-2520-581 0007 00

CASE REPAIR

Scope and Repair Parts

General mechanic’s tool kit; automotive WP 0021, Item 1

Special Tools

Bushing service kit WP 0021, Item 3

General Safety Instructions

Compressed air for cleaning purposes will not exceed 30 psi (207 kPa) Protective clothing must be used when steam cleaning

0007 00-1

CLEANING/INSPECTION

Work area should be well-ventilated, clean, and free from blowing dirt and dust.

For general cleaning instructions, refer to WP 0003.

1. Remove transmission case (Figure 1, Item 3) from transmission holding fixture.

When steam cleaning, protective clothing must be used.

Failure to comply may result in injury to personnel and/or damage to equipment.

2. Thoroughly steam clean transmission case (Figure 1, Item 3).

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shields, gloves, etc).

3. Blow all dirt and cleaning solution from transmission case (Figure 1, Item 3) with compressed air.

For general inspection instructions, refer to WP 0004.

4. Inspect all surfaces and general overall condition of transmission case (Figure 1, Item 3).

5. Inspect front and rear band anchor pins (Figure 1, Item 2) for looseness. Replace transmission case (figure 1, Item 3) if anchor pins (Figure 1, Item 2) are loose or missing.

Figure 1. Transmission Case

0007 00-2

3 2 1

6. Inspect intermediate clutch plate lugs (Figure 2, Item 4) for damage. Replace transmission lugs (Figure 2, Item 5) are damaged.

7. Inspect governor bore (Figure 2, Item 7) for scoring, pitting, or damage. Replace transmission case (Figure 2, Item 5) if scored, pitted, or damaged.

If transmission was manufactured before March 1, 1990 and a new transmission case is to be used, install a new center support assembly.

8. Inspect all threaded holes in transmission case (Figure 2, Item 5) for damage. Repair any damaged threaded hole with thread repair inserts. If unable to repair threaded hole, replace transmission case.

9. Inspect rear case bushing (Figure 2, Item 3) for damage. If damaged, perform steps 10 through 12.

10. Working from rear of transmission case (Figure 2, Item 5), use bushing remover and installer (Figure 2) J21465-8 and driver handle (Figure 2) to remove bushing (Figure 2, Item 3) from transmission case (Figure 2, Item 5). Discard bushing (Figure 2, Item 3).

11. Working from front of transmission case (Figure 2, Item 5), use driver handle (Figure 2), driver handle adapter (Figure 2) J21465-13, bushing remover and installer (Figure 2) J21465-8, and adapter ring (Figure 2) J21465-9 to install bushing (Figure 2, Item 3). Place bushing (Figure 2, Item 13) on remover and installer with lube passage (Figure 2, Item 2) on bushing (Figure 2, Item 3) facing adapter ring (Figure 2). Install bushing (Figure 2, Item 3) on transmission case (Figure 2, Item 5) until adapter ring (Figure 2) bottoms.

12. Working from rear of transmission case (Figure 2, Item 5), use staking tool (Figure 2) to stake bushing (Figure 2). Stake marks must be in bushing grove (Figure 2, Item 1).

Welding of the transmission case (Figure 2, Item 5) is limited to the bell housing area up to 3 inches away from the transmission oil pump face (Figure 2, Item 6).

END OF WORK PACKAGE 0007 00-3/4 blank

3 2

STAKING TOOL

DRIVER HANDLE

BUSHING REMOVER

AND INSTALLER

DRIVER HANDLE

BUSHING REMOVER

AND INSTALLER

DRIVER HANDLE

ADAPTER

ADAPTER RING

Figure 2. Case Bushing

NMWR 9-2520-581 0008 00

OIL PUMP REPAIR

Initial Setup; Disassembly; Cleaning; Inspection; and Assembly

General mechanic’s tool kit; automotive WP 0021, Item 1 SATS WP 0021, Item 2

Special Tools Slide hammer adapter WP 0021, Item 8 Bushing service set WP 0021, Item 3 Driver handle WP 0021, Item 9 Oil pump seal installer WP 0021, Item 10

Materials/Parts Retainer packing WP 0022, Table 1, Item 1 O-ring seal WP 0022, Table 1, Item 3 Oil seal WP 0022, Table 1, Item 2 Sealing compound WP 0023, Table 1, Item 8 Transmission fluid WP 0023, Table 1, Item 4

Work area should be well ventilated, clean, and free from

0008 00-1

Figure 1. Oil Pump

0008 00-2

DISASSEMBLY

Pressure regular is spring loaded. Failure to comply may result in injury to personnel and/or damage to equipment.

1. Remove snapring (Figure 1, Item 9) and boost valve bushing (Figure 1, Item 10), valve (Figure 1, Item 11), pressure regulator spring (Figure 1, Item 12), regulator valve (Figure 1, Item 15), spring retainer (Figure 1, Item 13), and spacer(s) (Figure 1, Item 14) from pump cover (Figure 1, Item 4).

2. Remove oil pump O-ring (Figure 1, Item 1) from pump cover (Figure 1, Item 4). Discard O-ring seal (Figure 1, Item 1).

3. Remove two o-ring retainer packing seals (Figure 1, Item 2) and selective washer (Figure 1, Item 3) from pump cover (Figure 1, Item 4). Discard oil seal rings (Figure 1, Item 2).

4. Remove five capscrews (Figure 1, Item 16) and pump cover (Figure 1, Item 4) from pump body (Figure 1, Item 7).

5. Mark drive gear (Figure 1, Item 6) and driven gear (Figure 1, Item 5) for assembly.

6. Remove drive gear (Figure 1, Item 6), driven gear (Figure 1, Item 5), and oil seal (Figure 1, Item 9) from pump body (Figure 1, Item 7). Discard oil seal (Figure 1, Item 8).

0008 00-3

CLEANING

Refer to Cleaning, WP 0003, for general cleaning instructions.

INSPECTION

Refer to Inspection, WP 0004 for general inspection instructions

1. Place drive gear (Figure 2, Item 2) and driven gear (Figure 2, Item 1) in pump body (Figure 2, Item 3)

2. Check pump body (Figure 2, Item 3) to drive gear (Figure 2, Item 2) face and diven gear (Figure 2, Item 1) face clearance using a straight edged feeler gauge. Clearance should be within 0.0008-0035 inch (0.02-0.09 mm). If clearance does not meet specifications, replace oil pump.

3. Inspect gear pockets (Figure 2, Item 5), crescent (Figure 2, Item 4), drive gear (Figure 2, Item 1), driven gear (Figure 2, Item 1), and pump body (Figure 2, Item 3) for scoring, galling, or damage. Replace oil pump if any parts are scored, galled, or damaged.

4. Inspect snapring (Figure 2, Item 6), boost balve bushing (Figure 2, Item 8) for damage.

Replace all items if one item is damaged.

5. Inspect pressure regulator spring (Figure 2, Item 9), spring retainer (Figure 2, Item 10), spacer(s) (Figure 2, Item 11), and regulator valve (Figure 2, Item 12) for damage. Replace any damaged items.

Figure 2. Oil Pump Drive Gear

0008 00-4

INSPECTION (Con’t)

6. Inspect pump bushing (Figure 3, Item 2). If damaged, perform steps 7 and 8. If not, go to step 9.

7. Using driver handle (Figure 3) and bushing remover and installer (Figure 3) J21465-17, remove bushing (Figure 3, Item 2) from pump body (Figure 3, Item 1). Discard bushing (Figure 3, Item 2).

Figure 3. Bushing Removal

0008 00-5

DRIVER HANDLE

BUSHING REMOVER

AND INSTALLER

8. Using driver handle (Figure 4) and busing remover and installer (Figure 4) J21465-17, install bushing (Figure 4, Item 1) in pump body (Figure 4, Item 3) until bushing (Figure 4, Item 1) is

0.010 in. (0.25 mm) below gear pocket face (Figure 4, Item 2).

Figure 4. Bushing Install

0008 00-6

DRIVER HANDLE

9. Inspect pump cover (Figure 5, Item 3) for galling or scoring. Replace pump cover (Figure 5, Item 3) if damaged.

10. Inspect stator shaft splines (Figure 5, Item 2) for damage. Replace pump cover (Figure 5, Item 4) if splines (Figure 5, Item 2) are damaged.

11. Inspect oil ring grooves (Figure 5, Item 4) for damage. Replace pump cover if grooves (Figure 5, Item 4) are damaged.

12. Inspect front and rear stator shaft bushings (Figure 5, Item 1) for damage. If damaged, perform steps 13 through 14. If not, go to ASSEMBLY.

Figure 5. Bushing Removal

0008 00-7

Replacement procedures for front or rear stator shaft bushings are basically the same. Steps 12 through 14 cover the front stator shaft bushing.

13. Mount pump cover (Figure 6, Item 3) in soft-jawed vise.

14. Using bushing remover J21465-15 (Figure 6), slide hammer adapter (Figure 6), and slide hammer (Figure 6), remove stator shaft bushing (Figure 6, Item 1) from stator shaft (Figure 6, Item 2). Discard bushing (Figure 6, Item 1).

Figure 6. Bushing Removal

0008 00-8/9 blank

SLIDE HANDLE

SLIDE HAMMER

ADAPTER

J21465-15

Figure 7. Pump

0008 00-10

B

6 A

A

6 B

C

ASSEMBLY

● Cleanliness is essential in assembly operations. Dirt and dust, even in minute quantities are abrasive. Parts must be cleaned as specified and kept clean. Wrap or cover parts when assembly procedures are not immediately completed.

● All transmission parts must be lubricated with clean transmission fluid before assembly. Foreign material will cause transmission damage.

1. Install drive gear (Figure 7, Item 3) and driven gear (Figure 7, Item 4) in pump body (Figure 7, Item 5) with reference marks and tangs (Figure 7, Item 2) on drive gear (Figure 7, Item 3) aligned face up.

2. Install pump cover (Figure 7, Item 1) on pump body (Figure 7, Item 5), align pump cover (Figure 7, Item 4) and pump body (Figure 7, Item 8), and install five capscrews (Figure 7, Item 6). Tighten five capscrews (Figure 7, Item 6) to 18 lb-ft (24 N●m).

See table for proper location of capscrews.

Table for Capscrew Location

Capscrew A 5/16 X 18 X1 Capscrew B 5/16 X 18 X 1-1/2 Capscrew C 5/16 X 18 X 1-3/4

0008 00-11

ASSEMBLY (Con’t)

3. Install regulator valve (Figure 8, Item 11), spacer(s) (Figure 8, Item 10), spring retainer (Figure 8, Item 9), spring (Figure 8, Item 8), boost valve (Figure 8, Item 7), boost valve bushing (Figure 8, Item 6), and snapring (Figure 8, Item 5) in pump cover (Figure 8, Item 4).

4. Install selective washer (Figure 8, Item 3) and two oil ring seals (Figure 8, Item 2) on pump cover (Figure 8, Item 4). Ensure lap joints on oil ring seals (Figure 8, Item 2) are properly joined.

5. Install O–ring seal (Figure 8, Item 1) on pump cover (Figure 8, Item 4).

Figure 8. Regulator Valve

0008 00-12

6. Apply sealing compound to utside diameter of oil seal (Figure 9, Item 1).

7. Using oil pump seal installer, install oil seal (Figure 9, Item 1) in oil pump (Figure 9, Item 2).

Figure 9. Oil Pump Seal

0008 00-13/14 blank

OIL PUMP

SEAL INSTALLER

NMWR 9-2520-581 0009 00

FORWARD CLUTCH AND TURBINE SHAFT REPAIR

Clutch spring compressor WP 0021, Item11 Clutch spring compressor adapter WP 0021, Item 12

Materials/Parts

Five composition clutch plates WP 0022, Table 2, Item 1 Inner piston seal WP 0022, Table 2, Item 3 Outer piston seal WP 0022, Table 2, Item 2 Petrolatum WP 0023, Item 6 Transmission fluid WP 0023, Item 4

Air pressure must not exceed 50 psi (345 kPa) when air checking clutch piston.

0009 00-1

1. Remove snapring (Figure 1, Item 1), direct clutch hub (Figure 1, Item 2), forward clutch hub (Figure 1, Item 3), thrust washer (Figure 1, Item 4), five composition clutch plates (Figure 1, Item 7), and steel clutch plates (Figure 1, Item 5) from forward clutch housing (Figure 1, Item 6).

Discard composition clutch plates (Figure 1, Item 7).

Figure 1. Clutch Housing

0009 00-2

DISASSEMBLY (Con’t)

2. Place clutch housing (Figure 2, Item 3) in press. Using clutch spring compressor (Figure 2) and clutch spring compressor adapter (Figure 2), compress spring retainer (Figure 2, Item 2) and remove snapring (Figure 2, Item 1) and spring retainer (Figure 2, Item 2) from clutch housing (Figure 2, Item 3).

Figure 2. Clutch Spring

0009 00-3

CLUTCH SPRING COMPRESSOR

CLUTCH SPRING

COMPRESSOR ADAPTER

Keep forward clutch release springs separate from direct clutch release springs.

3. Remove spring retainer (Figure 3, Item 1), sixteen release springs (Figure 3, Item 2), and clutch piston (Figure 3, Item 4) from clutch housing (Figure 3, Item 7).

4. Remove inner piston seal (Figure 3, Item 5) and outer piston seal (Figure 4, Item 6) from clutch piston (Figure 3, Item 7). Discard seals (Figure 3, Items 5 and 6).

5. Remove clutch piston apply ring (Figure 3, Item 3) from clutch…