D6D TRACTOR POWER TRAIN – Transmission And Transfer Gears (Power Shift)

Disassemble Transmission And Transfer Gears (Power Shift)

Start By:

a. remove transmission and transfer gears (power shift)


NOTICE

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.


1. Fasten a hoist to transmission (1) and position it on tool (A). Remove bolts (3) and cover (2). Check the gasket under the cover for damage. Replace if necessary.

2. Remove the transmission hydraulic controls as follows:

a. Remove bolts (4).

b. Remove pressure control valve (5).

c. Remove cover (8). Remove tube (7).

d. Remove bolts (6). Remove valve assembly (9). Check the condition of O-ring seals (10). Replace if damaged.

NOTE: For the disassembly procedure of the transmission hydraulic control valves, see Disassemble Transmission Hydraulic Control Valves.

4. Remove all sleeves (12) that were not removed with valve assemblies. Remove O-ring seals (14). Check the condition of the seals and replace if damaged.

5. Remove bolts (11).

6. Remove bolts (13).

7. Install two 1/2″-13 NC forged eyebolts in the top of the transmission case (15).

8. Fasten a hoist to the transmission case. Weight of the transmission case is 63 kg (140 lb.). Remove the transmission case.

9. Remove spring (17). Remove nuts (16) and the bolts.

10. Remove shaft (18) and levers (19).

11. Remove seal (20) and bearing (21).

12. Remove spring (23), lever (24), shaft (22) and lever (25).

13. Remove two seals (26) and the bearing.

14. Remove bolts (27) and locks (29).

15. Install two 3/8″- 16 NC forged eyebolts in bearing cage (28). Fasten a hoist to the bearing cage. Remove the bearing cage and input shaft as a unit. Weight of the unit is 27 kg (60 lb.).

16. Remove bolt (30). Remove washer (31) and flange (32).

17. Use tool (B) to remove seal (33).

18. Remove the retainer ring that holds the bearing cage on the input shaft. Remove the bearing cage from the input shaft.

19. Inspect seal (34). Install a new seal if necessary.

20. Remove the two retainer rings, one on each side, that hold the bearing (36) in the cage.

21. Remove spacer (35) and bearing (36).

22. Remove snap ring (37) that holds the bearing race (38) and two gears (39) on the shaft.

23. Use tooling (C) to remove two gears (39) and race (38).

24. Remove the bearing cage from the shaft with a soft hammer.

25. Remove snap ring (40).

26. Remove bearing (41).

27. Use tooling (D) and remove the bearing inner race from the shaft.

NOTE: Put identification on each of the clutch housings as to their sequence and location. The housings must be installed in the same location and reverse sequence that they were removed. Do not mix the disc assemblies or plate. Keep these parts with their respective clutch housing.

28. Remove nine bolts (42).

29. Install tooling (E) to keep the No. 1 clutch piston in the No. 1 clutch housing. Remove the other three bolts.

30. Install two 1/2″ – 13 NC forged eyebolts in the housing. Fasten a hoist to the housing. Weight of the housing is 25 kg (55 lb.). Remove the No. 1 clutch housing and its piston as a unit.

31. Turn the No. 1 clutch housing over. Remove tooling (E). Remove piston (43). Remove the two ring seals from the piston and No. 1 clutch housing.

32. Remove the five pins (44) and ten springs (45).

33. Install two 3/8″ – 16 NC forged eyebolts in the No.1 carrier. Fasten a hoist to the No.1 carrier. Weight of the No.1 carrier is 23 kg (50 lb.). Remove No.1 carrier (46).

34. Remove shafts (48), gears (49) and washers (50) from No.1 carrier. There is a washer on each side of the gears. Remove the bearings from the gears.


NOTICE

Do not lose balls (47). When shafts (48) are removed, balls (47) can fall out of the shafts.


35. Remove bolts (54), locks (51) and plates (53). Remove gear (52) from the No.1 carrier.

36. Position the No.1 carrier on its side. Remove shafts (56) and tubes (57).


NOTICE

Do not lose balls (55). When shafts (56) are removed, balls (55) can fall out of the shafts.


37. Remove gears (60) and washers (59).

38. Remove bearings (58).

39. Remove bearing (61) from carrier No.1.

40. Remove ring gear (62), three clutch disc assemblies (63), two plates (65) and plate (64).

41. Install two 1/2″ – 13 NC forged eyebolts in No.2 clutch housing. Fasten a hoist to the No.2 clutch. The weight of the No.2 clutch is 25 kg (55 lb.). Remove the No.2 clutch.

42. Remove ten springs (66).

43. Remove ring gear (67), clutch disc assemblies (68) and plates (69) from the No.2 clutch housing. Remove the piston from the housing. Remove the seal rings from the housing and piston.

44. Remove bolts (70), and the locks and plates that hold the No.3 clutch housing in position.

45. Install two 1/2″ – 13 NC forged eyebolts in No.3 clutch housing. Fasten a hoist to the No.3 clutch housing. the weight of the No.3 clutch housing is 25 kg (55 lb.). Remove the No.3 clutch housing.

46. Remove five pins (71) and ten springs (72) from the No.4 and 5 clutch housings.

47. Remove ring gear (73), clutch disc assemblies (74), plate (75) and the piston from the clutch housing. Remove the seal rings from the piston and the clutch housing.

48. Install tooling (E) to keep the No.4 and No.5 clutch pistons in the clutch housing.

49. Install two 1/2″ – 13 NC forged eyebolts in No.4 and No.5 clutch housing. Fasten a hoist to No.4 and No.5 clutch housing. Remove the clutch housing and piston as a unit. Weight of the unit is 29 kg (65 lb.).

50. Remove ten springs (80), clutch disc assemblies (81), ring gear (83) and plate (82).

51. Remove ring gear (76), clutch disc assemblies (77) and plate (78) from the clutch housing.

52. Turn the clutch housing over. Remove tooling (E). Remove piston (79). Remove the ring seals from piston and housing.

53. Remove bolts (84) and the locks that hold No.2 carrier (85) to the transfer gear case.

54. Install three 3/8″ – 16 NC forged eyebolts into the No.2 carrier. Fasten a hoist to the No.2 carrier. Weight of the No.2 carrier is 23 kg (50 lb.). Remove the No.2 carrier.

55. Put the No.2 carrier on its side. Pull shafts (89) part of the way out and remove gear (93) and washers (92). Remove bearings (90) from gear (93).

NOTE: There is a washer (92) on each side of gear (93).

56. Remove shafts (89), gear (91) and the washers. Remove the bearings from gear (91).

NOTE: There is a washer (92) on each side of gear (91).


NOTICE

Use caution to prevent loss of balls (88) when shafts (89) are removed.


57. Remove shafts (86), gear (87) and the washers. Remove the bearings from the gear.

NOTE: There is a washer on each side of the gear.


NOTICE

Use caution to prevent the loss of the balls when shafts (86) are removed.


58. Remove cage (94), retainer ring (96) and output shaft (95).

59. Remove dowel (98) from cage with a 6-40 screw. Remove bearing (97).

60. Remove cage (99) with three 1/2″ – 13 NC forcing screws. Remove bearing (100).


NOTICE

Use caution to prevent the loss of ball (102) when cage is removed.


61. Inspect piston ring type seals (101). Install new seals if necessary.

62. Remove plate assembly (103).

63. Remove bolts (104) and locks (105) that hold case assembly (106) to transfer gear case (107).

64. Remove the dowels that hold the case assembly in position on the transfer gear case with 1/2″ – 13 NC bolts 3 in. long. Remove case assembly (106).

65. Remove bolts (108) and the lock. Remove retainer (109).

66. Remove the pinion from the transfer gear case.

67. Remove bearings (110) and the spacer with tooling (F).

68. Remove the transfer gear from the transfer gear case.

69. Use tooling (G) and remove bearings (112) from transfer gear (111).

70. Remove the plugs and dowels (114). Use a 6-40 screw to remove the dowels.

71. Remove races (113).

72. Remove the plugs and dowels (116). Use a 6-40 screw to remove the dowels.

73. Remove races (115).

Assemble Transmission And Transfer Gears (Power Shift)

1. Lower the temperature of race (115). Using tooling (A), install the race with the hole in the race in alignment with the hole in the case. Install the dowel and plug that hold the race in position in the case.

2. Lower the temperature of the bearing race. Using tooling (B), install the bearing in the case with the hole in alignment with the hole in the case. Install the dowel and plug that hold the bearing race in the case.

3. Lower the temperature of bearing race (113). Using tooling (A), install the bearing race with the hole in the race in alignment with the hole in the case. Install the dowel and plug that hold the race in position in the case.

4. Lower the temperature of the bearing race. Using tooling (A), install the race with the hole in the race in alignment with the hole in the case. Install the dowel and plug that hold the race in position in the case.

5. Heat bearings (112) to a maximum temperature of 135°C (275°F). Install a bearing (112) on each end of transfer gear (111). Make sure the bearings are in contact with the shoulders on the gear.

6. Install the transfer gear in the case as shown.

7. Heat bearing (110) to a maximum temperature of 135°C (275°F). Install the bearing on the pinion gear until it makes contact with the shoulder on the gear. Turn the gear over. Install the spacer on the pinion gear with the flat side of the spacer against the gear. Heat the bearing (6) to a maximum temperature of 135°C (275°C). Install the bearing on the pinion gear (7) until it makes contact with the shoulder on the gear. Turn the gear over. Install the spacer on the pinion gear with the flat side of the spacer against the gear. Heat the bearing for the other side of the pinion gear to a maximum temperature of 135°C (275°C). Install the bearing until it makes contact with the spacer.

8. Put the pinion gear in position on the case and install the locks, washers and bolts.

9. Put the case in position on the transfer gear case. Install the three dowels that hold the cases together.

10. Install locks (105) and bolts (104).

11. Turn the transfer gear case over and install plate (103).

12. Lower the temperature of bearing (100). Install the bearing in cage (99).

13. Inspect piston ring type seals (101). Replace the seals if necessary. Put clean grease on the seals.


NOTICE

Do not damage piston ring type seals (12) when the cage is installed.


14. Position ball (102) and install cage (99).

15. Lower temperature of the bearing. Using tooling (B), install the bearing in cage (94) with the hole in the bearing in alignment with hole in cage. Install the dowel and plug that holds the bearing in the cage.

16. Position output shaft (95) in the transfer gear case. Install retainer ring (96) and the bearing cage.

17. Install bearings (90) in gears (91), (87) and (93). Put clean oil on the bearings.

18. Position shafts (86) in the carrier.


NOTICE

Make sure the balls (88) are in the shaft.


19. Put gears (87) and washers (92), one washer on each side of the gears, in the carrier. Install shafts (86) through the gears into the carrier.

20. Position shafts (89) in the carrier.

21. Put gears (91) and (93) and washers (92), one on each side of the gear, in position in the carrier. Install shafts (89) through the gears and into the carrier.

22. Install 3/8″ – 16 NC forged eyebolts in the No.2 carrier. Fasten a hoist to the carrier. Put the No.2 carrier in position on the output shaft and remove the hoist.

23. Install the bolts and locks that hold the No.2 carrier to the transfer gear case.

24. Fasten a hoist to the transfer gear case and position it on tool (C). Fasten the transfer gear case to tool (C) for assembly of the transmission.

25. Install the rings on piston (79) and in the clutch housing. Put clean oil on the rings.


NOTICE

Do not damage the rings when the piston is installed.


26. Install the piston in the clutch housing.

27. Install tooling (D) on the clutch housing to hold the piston in position.


NOTICE

Make sure the disc assemblies are free from dirt and oil. Do not cause damage to the teeth of the discs.


28. Install gear (83) on the case. Install ten springs (80). Starting with a disc assembly, install clutch disc assemblies (81) and plate (82).

29. Install two 1/2″ – 13 NC forged eyebolts in the clutch housing. Fasten a hoist to the clutch housing and install the housing.


NOTICE

Do not damage the seal rings.


30. Install the seal rings on piston (30) and the housing. Put clean oil on the rings.


NOTICE

Make sure the disc assemblies are free from dirt and oil.


31. Install the piston in the housing. Install clutch disc assemblies (77), the plate and the ring gear in the housing. Remove tooling (D).

32. Install the seal rings on the piston and the No.3 clutch housing. Put clean oil on the rings. Install the piston in the housing.


NOTICE

Do not damage the seal rings when the piston is installed.



NOTICE

Make sure the disc assemblies are free of dirt and oil. Do not cause damage to the teeth of the disc assemblies.


33. Starting with a disc assembly, install clutch disc assemblies (74) and plate (75). Install ring gear (73).

34. Install five pins (71) and ten springs (72).

35. Install two 1/2″-13 NC forged eyebolts in the No. 3 clutch housing. Fasten a hoist to the eyebolts. Install the housing on the springs and pins.

36. Install the washers and bolts that hold the No. 3 clutch housing in position. Tighten the bolts to a torque of 115 ± 7 N·m (85 ± 5 lb.ft.).


NOTICE

Do not damage the seal rings when the piston is installed.


37. Install the seal rings on the piston and in the No. 2 clutch housing. Put clean oil on the rings. Install the piston in the housing.


NOTICE

Make sure the clutch disc assemblies are free of dirt and oil. Do not damage the teeth of the discs.


38. Starting with a disc assembly, install clutch disc assemblies (68) and plates (69). Install ring gear (67).

39. Install two 1/2″-13 NC forged eyebolts in the No. 2 clutch housing. Fasten a hoist to the eyebolts.

40. Install ten springs (66) and position the housing on the springs. Remove the hoist and eyebolts.

41. Position plate (64) on the No. 2 clutch housing.


NOTICE

Make sure the clutch disc assemblies are free from dirt and oil. Do not cause damage to the teeth of the discs.


42. Starting with a disc assembly, install clutch disc assemblies (63) and plate (65). Install ring gear (62).

43. Lower the temperature of the bearing for the No. 1 carrier. Install the bearing in the carrier.

44. Install bearings (58) in gears (60). Install tubes (57) in shafts (56). Position the shafts in the No. 1 carrier. Install balls (55) in shafts (56). Position gears (60) and washers (59), one washer on each side of the gears, in the No. 1 carrier. Install the shafts through gears and into the No. 1 carrier.


NOTICE

Make sure balls (55) are in the shafts when the shafts are installed.


45. Put gear (52) in the No. 1 carrier. Install plates (53), locks (51) and bolts (54).

46. Install balls (47) in shafts (48). Install the bearings in gear (49). Put a washer (50) on each side of gears (49). Position the gears in the No. 1 carrier and install shafts (48).

47. Starting with a disc assembly, install the three clutch disc assemblies and the two plates. Install the ring gear.

48. Install two 3/8″-16 forged eyebolts in No. 1 carrier (46) and install the carrier.

49. Install new rings in piston (43) and the No. 1 clutch housing.

50. Put a small amount of clean oil on the rings. Install the piston (43) in the No. 1 clutch housing.


NOTICE

Do not damage the rings when the piston is installed in the clutch housing.


51. Install five pins (44) and ten springs (45).

52. Use tool (D) to hold the piston in No. 1 clutch housing.

53. Install two 1/2″-13 NC forged eyebolts in No. 1 clutch housing. Fasten a hoist to No. 1 clutch housing and install it in the correct position as shown.

54. Install three bolts (42) at equal distance apart. Tighten to a torque of 115 ± 7 N·m (85 ± 5 lb.ft.).

55. Install the other six bolts. Tighten to a torque of 115 ± 7 N·m (85 ± 5 lb.ft.).

56. Heat the race to a temperature of 135°C (275°C). Install the race on the shaft. Install the ring seal on the race.

57. Install bearing (41) and ring (40).

58. Slide the shaft through the bearing and the cage. Use a soft faced hammer to install the cage onto the shaft.

59. Slide gears (39) onto the shaft.

60. Heat race (37) to a temperature of 135°C (275°F). Install the race and ring (38).

61. Install spacer (35) and bearing (36). Install the two rings that hold the bearing and spacer in position.

62. Install a new seal (34). Put a small amount of clean oil on the seal. Position the cage on the shaft.

63. Install the retainer ring that holds the cage in position.

64. Put clean SAE 10 oil on the lip of the lip type seal. Install the lip type seal with the lip toward the inside of the cage and until it makes contact with the shoulder in the cage.

65. Install flange (32), washer (31), the lock and bolts (30). Tighten to a torque of 55 ± 7 N·m (40 ± 5 lb.ft.).

66. Install two 3/8″-16 NC forged eyebolts in the bearing cage. Fasten a hoist to the bearing cage. Install the bearing cage and shaft.

67. Install locks (29) and bolts (27) that hold bearing cage (28) and shaft in position.

NOTE: Check to make sure the pistons are free in their clutch housings with tool (F) as follows:

a. Use clean dry air, pressurized between 7.0 to 10.5 kg/cm2 (690 to 1030 kPa), (100 to 150 psi) into each of the four oil passages.

b. If the pistons do not move, put a small amount of clean SAE 30 oil in each passage. Check for movement again. If the pistons still do not move, the transmission must be disassembled and the pistons checked.

68. Using tooling (E), install the two bearings in location (X). Install the inside bearing until it is even with the inside surface of the case. Install the outside bearing until it makes contact with the bottom of the bore in the case.

69. Using tooling (E), install the two bearings in location (Y). Install the inside bearing until it is even with the inside surface of the case. Install the outside bearing until it is even with the bottom of the counterbore in the case.

70. Using tooling (E), install seal (26), with the lip toward the inside of the case, until it makes contact with the bottom of the counterbore. Put clean oil on the lip of the seal.

71. Install one lever (19) and shaft (22). Install one lever (19) and spring (17).

72. Slide shaft (18) into the case. Slide levers (19) onto the shaft.

73. Install the bolts and nuts (16). Tighten to a torque of 35 ± 4 N·m (25 ± 3 lb.ft.).

74. Install spring (17).

75. Install two 1/2″-13 NC forged eyebolts in case (15). Fasten a hoist to the case. Install case (15).

76. Install the bolts that hold transmission case (15).

77. Install the bolts that hold the input shaft bearing cage to transmission case (15).

78. Coat the seals on sleeves (12) and install the sleeves.


NOTICE

Make sure the O-ring seals are in position on the clutch housings before the hydraulic controls are installed. Put clean oil on the O-ring seals.


79. Position valve assembly (9) in the transmission. Install three bolts (6) and tighten to a torque of 45 ± 4 N·m (35 ± 3 lb.ft.).

80. Install tube (7).

81. Install cover (8) and the bolts.

82. Lightly coat O-ring seals (10) with clean oil and install the seals.

83. Install pressure control valve (5).

84. Install three bolts (4). Tighten to a torque of 45 ± 4 N·m (35 ± 3 lb.ft.).

85. Install the gasket, cover (2) and the bolts and washers.

End By:

a. install transmission and transfer gears (power shift)

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