D6D TRACTOR POWER TRAIN – Transmission (Direct Drive And Special Application)

Remove And Install Transmission (Direct Drive And Special Application)

Start By: (for machines without a cab)

a. remove support and seat group (for machines without a cab)

b. remove universal joint (direct drive and special application)

c. remove dash

Start By: (for machines with a cab)

a. tilt cab back*

b. remove dash

c. remove universal joint (direct drive and special application)


*

1. Drain the oil from the bevel gear case and transmission.


NOTICE

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


2. Remove tube assembly (3), tube assembly (1) and hose assembly (2). Remove tube assembly (4) and tube assemblies (6) and (5).

3. Remove clip (7). Remove magnetic screen (9). Remove clip (8) and move heater hoses away from the top of the transmission.

4. Disconnect the wires from the forward-reverse directional switch.

5. Remove interlock linkage (10).

6. Remove two of the bolts that hold the top cover in position on the transmission. Install two 3/8″-16 NC forged eyebolts in the bolt holes as shown. Fasten tool (A) and a hoist to the transmission.

7. Remove nuts (11).

8. Install two 1/2″-13 NC forcing screws in the transmission case. Tighten the screws evenly to make a separation of the transmission from the bevel gear case.

9. Remove transmission (12). Make an adjustment to tool (A) as necessary so the transmission can be removed from the machine. The weight of the transmission is 500 lb (225 kg.).

10. Check the condition of O-ring seals (13) and (14) and replace if necessary.

NOTE: The following steps are for the installation of the transmission (direct drive and special application).

11. Fasten a hoist and tool (A) to the transmission.

12. Install O-ring seal (13). Put clean oil on the O-ring seal.

13. Install O-ring seal (14). Put clean oil on the O-ring seal.

14. Install transmission (12) with the nuts that hold the transmission in position.

15. Install interlock linkage (10).

16. Connect the wires for the forward and reverse directional switch.

17. Put heater hoses in position above the transmission. Install clip (8).

18. Install magnetic screen (9). Fasten the hoses and clip (4).

19. Install tube assembly (5). Install hose assembly (2) and tube assembly (1).

20. Install tube assembly (4) and tube assembly (3). Install tube assembly (6).

21. Fill the transmission and bevel gear case with oil to the correct level. See Operation and Maintenance Manual.

22. If necessary, make an adjustment to the interlock linkage. See Adjustment of Flywheel Clutch Interlock Linkage (Direct Drive) in Specifications.

End By: (for machines with a cab)

a. install universal joint (direct drive and special application)

b. install dash

c. tilt cab forward*

End By: (for machines without cab)

a. install dash

b. install universal joint (direct drive and special application)

c. install support and seat group


*


NOTICE

Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.


Disassemble Transmission (Direct Drive & Special Application)

Start By:

a. remove transmission (Direct Drive & Special Application)


NOTICE

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


1. Remove cover (1) from the shift lever.

2. Remove bolts (4) and washers that hold the shift lever to the cover.

3. Remove shift lever (3), springs, and lever (2) from the cover.

4. Remove washer (5), gaskets (6) and plate (7) from lever (3).

5. Remove cotter pin (11), cover (9), packing (8) and plate (10) from lever (3).

6. Remove the bolts (12) and cover (13) for the interlock mechanism.

7. Remove the plate for the interlock mechanism

8. Remove the plate from shaft (16). Remove shaft (16) and lever (14) from the cover. Remove the seal (15) from the cover.

9. Remove the springs (17) and plungers (18) from the interlock mechanism of the gear shift cover.

10. Install two 3/8″-16 NC forged eyebolts in the gear shift cover.

11. Fasten a hoist to the gear shift cover. Weight of the gear shift cover is (38 kg.) 84 lb. Remove the gear shift cover and shift forks from the transmission.

12. Disassemble the gearshift cover and fork as follows:

a. Remove the wire that keeps bolt (19) in position.

b. Remove bolt (19) from fork (21).

c. Remove cover (20).

d. Pull shaft (22) out of the cover and remove fork (21). Remove the wire from bolt (23). Remove the bolt.

e. Pull shaft (25) out of the cover and remove fork (24).

f. Remove the wire from the bolt that holds fork (26) in position on shaft (28). Remove shaft (28) and fork (26) from the cover. Remove the wire from bolt (30). Remove the bolt. Remove shaft (29) and fork (27) from the cover.

g. Remove the bolts and locks that hold plate (33) in position. Remove the plate. Loosen the bolt in lever (32). Remove the lever and shaft (31) from the cover. Remove the two keys from shaft (31). Remove two bearings (34) from the cover.

h. Remove the cotter pin that holds lever (35) in position on the shaft. Remove lever (35). Remove the dowel that holds the shaft in the cover with a hammer and punch. Remove the shaft from the cover.

i. Remove the two locks and bolts that hold gate (36) in position. Remove gate (36).

j. Remove the seal for the gearshift lever from the cover.

13. Remove the two bolts, locks, washers and seal that hold the flange on the shaft.

14. Remove flange (37) with tooling (A).

15. Remove bolts (38) that hold cover (39) to the transmission case. Remove cover (39).

16. Install the cover with three bolts as shown.

NOTE: Make sure the three bolts are installed evenly around the corner.

17. Install tooling (B) as shown.


NOTICE

To prevent damage to the cover make sure each leg on the puller is in alignment with a bolt that holds the cover in position.


18. Use tooling (B) to push the forward-reverse shaft from the case.

19. Remove tooling (B) and the cover.

20. Remove the seal from the cover with tooling (C).

21. Remove bearing cup (44), bearing cone (43), spacer (42) and bearing cone (41) from cage (40).

NOTE: Put identification on the bearing cups and bearing cones as to their location in the transmission case.

22. Check the seal on the cage for damage. If the seal is damaged, use new parts for replacement.

23. Pul shaft (46) out of the transmission case and remove gear (45).

24. Remove shaft (46) from the transmission case.

25. Remove ring (47) that holds bearing (48) on the shaft.

26. Remove bearing (48) from the shaft with a press.

27. Install three 1/2″ – 13 NC forcing screws in the upper cage. Tighten the screws evenly until the cage is loose. Remove the cage for the upper shaft from the transmission case.

28. Remove bearing cup (49) from the cage with a hammer and punch.

29. Remove cover (50) from the transmission case.

30. Check seal (53) for damage. If the seal is damaged, use new parts for replacement.

31. Remove two bolts (54), lock and retainer (51) from the shaft.

32. Install three 1/2″ – 13 NC forcing screws in cage from the transmission case.

33. Remove shims (55).

34. Check seal (56) for damage. If the seal is damaged, use new parts for replacement.

35. Remove cage (52) from the shaft with tooling (B).

36. Remove bearing and bearing race (57) from the cage.

37. Remove spacer (58) from the shaft.

38. Install bolts (59) of tooling (D) in the reverse idler gear. Use tooling (D) to loosen the bearing in the reverse idler gear.

39. Remove bearing cone (60) from the shaft.

40. Remove gear (61) from the shaft.

NOTE: The gear in the Special Application transmission is removed the same way that gear (61) is removed. The gear looks different because the transmission in the Special Application machine is a 6 speed transmission.

41. Remove spacer (64) from the shaft.

42. Move gear (62) forward. Remove bearing cone (63) from the shaft with a soft hammer.

43. Remove bearing cups (65) and (66) from the reverse idler gear.

44. Pull shaft (68) out of transmission case. Remove gears (67) from the shaft as the shaft is being removed from the transmission case.

45. Remove the ring that holds bearing (69) on shaft (68). Remove the bearing from the shaft with tooling (E).

46. Remove two bolts (70), lock and retainer (71).

47. Remove bolts (72) and cover (73) from the transmission case.

48. Check seal (74) on cage (76) for damage. If the seal is damaged, use new parts for replacement.

49. Remove two bolts (75), lock, washer (77) and plate.

50. Install three 1/2″ – 13 NC forcing screws in age (76) and make a separation of the cage from the transmission case.

51. Remove cage (76) from the transmission case with tooling (F). Tooling (F) will push the shaft out of the transmission case. Remove tooling (F). Remove the spacer and bearing from the end of the shaft.

52. Remove the plug and dowel that holds the bearing race in cage (76). Remove the bearing race from the cage.

53. Pull shaft (78) out of the transmission case. Remove the six gears and spacer as the shaft is removed from the transmission case.

54. Remove bearing (79) and spacer (80) from the shaft with tooling (G).

55. Remove bolts (81) and lock that holds the tube in the transmission case.

56. Remove the tube from the transmission case.

57. Remove the plugs that hold the dowels in the transmission case with tool (H). Remove the dowels that hold the bearing races (82) in position with a 6-40 screw. Remove the dowels that hold bearing races (83) in position with a 1/4″ – 20 NC bolt.

58. Remove bearing races (82) and (83) from the transmission case.

Assemble Transmission (Direct Drive And Special Application)


NOTICE

Before the transmission is assembled, make sure all the oil passages in the case are clean and free of dirt and foreign material. Contaminants put into the system may cause rapid wear and shortened component life. Contaminants put into the system may cause rapid wear and shortened component life.


1. Install tube (1) in the transmission case. Install the lock and bolts that hold the tube in position.

2. Lower the temperature of bearing races (2), (3) and (4). Install the bearing races in the transmission case. Make sure the holes in the bearing races are in alignment with the holes in the transmission case.

3. Install dowels (5) in the transmission case. Install new plugs that hold the dowels in position.

4. Put spacer (7) on shaft (8). Heat bearing (6) to a maximum temperature of 135°C (275°F). Install bearing (6) on shaft (8).

5. Install three 3/8″ – 16 NC forged eyebolts in the front of the transmission case. Fasten a hoist to the transmission case.

6. Lift the transmission case until shaft (8) can be installed under the transmission case. Lower the transmission case half way onto the shaft.


NOTICE

Make sure bearing (6) is in alignment with the bearing race in the transmission case.


7. Put gear (9), spacer (10), gear (11) and gear (12) on the shaft. Lower the transmission case more on to the shaft. Install gears (13), (14) and (15) on the shaft. Lower the transmission case the rest of the way down.

8. Remove the hoist from the transmission case and install spacer (16).

9. Lower the temperature of bearing race (19) and install the bearing race in cage (18). Make sure the hole in the bearing race is in alignment with the hole in the cage.

10. Install dowel (17) that holds the bearing race in the cage.

11. Put the cage in position in the transmission case. Install three 3/8″ – 16 NC bolts 1 1/2″ long in the cage. Tighten the bolts until the cage makes contact with the transmission case. Remove the three bolts.

12. Position bearing (20) on the end of the shaft. Install the bearing on the shaft with retainer (21) and two 3/8″ – 24 NF bolts 2 in. long. After the bearing is installed, remove the two bolts.

13. Install retainer (21), and the lock and bolts that hold the retainer to the shaft.

14. Install the plate in the cage and over the shaft.

15. Install a new seal (25) in the cage. Put clean SAE 30 oil on the seal.

16. Put cover (23) on the cage with grove (22) in alignment with groove (24).

17. Install retainer (28), lock (27) and bolts (26) on the end of shaft (8).

18. Heat bearing (29) to a maximum temperature of 135°C (275°F). Install the bearing on shaft (31). Install ring (30).

19. Clean the oil hole and oil passages on shaft (31).

20. Lower the temperature of bearing cups (32) and (33). Install the bearing cups in the reverse idler gear.

21. Install two 3/8″ – 16 NC forged eyebolts in the front of the transmission case. Fasten a hoist to the transmission case.

22. Lift the transmission case and put shaft (31) in position under the bore in the transmission case. Lower the transmission case half way on to the shaft.

23. Lower the temperature of inner bearing cup for cage (34) and install it into the cage with tooling (A).

24. Put gears (35), (36) and (37) on the shaft.

25. Heat bearing cone (38) to a maximum temperature of 135°C (275°F). Install the bearing on the shaft.

26. Install spacer (40) and reverse idler gear (39).

27. Heat bearing cone (41) to a maximum temperature of 135°C (275°F). Install the bearing on the shaft.

28. Install spacer (42).


NOTICE

Make sure that bearing (29) is in alignment with the bearing race in the transmission case.


29. Lower the transmission case all of the way down on the shaft.

30. Put the original amount of shims (43) in the correct position on the transmission case.

31. Install a new seal (44) on cage (34). Put clean SAE 30 oil on the seal.

32. Make sure the oil hole in the cage is clean and free of dirt.

33. Put cage (34) in the transmission case (45) with oil hole in alignment with the oil passage in the transmission case.

34. Heat bearing cone (47) to a maximum temperature of 135°C (275°F). Install the bearing on the shaft.

35. Install spacer (48). Heat bearing cone (49) to a maximum temperature of 135°C (275°F). Install the bearing on the shaft. Use retainer (50) and two3/8″-24 NF bolts 2 in. long to install the bearing cone on the shaft. Remove the two bolts. Lower the temperature of bearing cup (46) and install the bearing cup in the cage.

36. Install a new seal (51). Put clean SAE 30 oil on the seal.

37. Clean the oil passage in retainer (50). Install a new seal (53). Put clean SAE 30 oil on the seal.

38. Install retainer (50), lock and bolts (52).

39. Put cover (54) in position on the cage so the groove in the cover is in alignment with the groove in the cage. Install bolts (55).


NOTICE

Do not damage seal (53) when the cover is installed.


40. Fasten a hoist to the transmission. Put the transmission in a horizontal position.

41. Heat bearing (57) to a maximum temperature of 135°C (275°F). Install the bearing on the shaft. Install ring (56) that holds the bearing in position.

42. Put shaft (59) half way into the transmission case. Install forward-reverse gear (58). Push the shaft all of the way into the transmission case.


NOTICE

Make sure that bearing (57) is in alignment with the bearing race in the transmission case.


43. Make sure the oil hole in the cage for the upper shaft is clean and free of dirt.

44. Lower the temperature of the bearing cup and install it in cage (60).

45. Put cage (60) in position on the transmission case. Make sure the oil hole in the cage is in alignment with the oil hole in the transmission case. Put cover (61) in position over the cage and install bolts (62). Tighten the bolts until the cage is in all of the way.

46. Remove bolts (62) and cover (61) from cage (60).

47. Heat bearing cone (65) to a maximum temperature of 135°C (275°F). Install the bearing cone on the shaft. Install spacer (63).

48. Heat bearing cone (66) in oil to a maximum temperature of 135°C (275°F). Install the bearing on the shaft.

49. Lower the temperature of bearing cup (67). Install the bearing cup in the cage.

50. Install seal (64) in cover (61) with tooling (B). Install the seal with the lip of the seal toward the inside of the cover and until it is 7.6 mm (.298 in.) below the outside surface of the cover.

51. Install a new seal on the cage. Put clean SAE 30 oil on the seal.

52. Install cover (69) and bolts (70).

53. Put flange (71) in position on the upper shaft. Install the flange on the upper shaft (59) with retainer (73) and two 3/8″-24 NF bolts 2 in. long. After the flange is installed, remove the two bolts.

54. Put a new seal between the retainer and the upper shaft. Put clean SAE 30 oil on the seal.

55. Install retainer (73), lock and bolts (72).

56. Assemble the gear shift cover and forks as follows:

a. Install the seal in the cover with tooling (D). Install the seal with the lip toward the outside of the cover. Install the seal until it makes contact with the bottom of the counterbore in the cover.

b. Install the two bearings in the cover with tooling (E). Install the lower bearing until it is even with the counterbore in the cover. Install the upper bearing until it is even with the outside surface of the cover.

c. Position gate (76) in the cover. Install the two locks and bolts that hold it.

d. Position shaft (74) in the cover. Install the dowel that holds it.

e. Install the bearing in lever (75) with tooling (F). Position the lever on the shaft. Install the cotter pin that holds it.

f. Put lever (77) in position in the cover. Install the two keys in the shaft. Install shaft (78) in the cover and through the lever.

g. Put plate (79) into position in the cover. Install the locks and bolts that hold it. Put fork (80) into position in the cover. Install the shaft through the cover and into the fork (80). Install the bolt and wire that holds the fork to the shaft.

h. Put fork (83) into position in the cover. Install shaft (84) in the cover and through the fork. Install the bolt and wire that holds the fork to the shaft.

i. Put fork (81) into position in the cover. Install shaft (86) through the cover and into fork (81). Install the bolt and wire that holds the fork to the shaft.

j. Put fork (82) into position in the cover. Install the shaft (85) through the cover and into the fork. Install the bolt and wire that holds the fork to the shaft.

57. Fasten a hoist to the cover for the shifter forks. Put the cover in the correct position on the transmission. Make sure the forks are in the correct grooves for their respective gears.

58. After the forks are in the correct position on the gears, lower the cover onto the transmission. Install the bolts and washers that hold the cover to the transmission.

59. Install cover (87), spring (93), cover (88), packing, cover (94), gasket (89), plate (90) and cotter pin (95) on the shift lever.

60. Put gaskets (91), plate (96) and ring (92) in position on the shift lever.

61. Install the seal in the interlock mechanism housing with tooling (C). Install the seal with the lip toward the inside of the housing and until it makes contact with the bottom of the counterbore in the housing.

62. Install the shaft and lever in the interlock mechanism housing.

63. Put plate (97) in the housing as shown.

64. Install the springs and plungers in the interlock mechanism. Make sure the plungers are installed with the bevel on the plungers toward the rear of the transmission.

65. Install housing (98) and plate (99). Install the bolts and washers that hold the interlock mechanism to the transmission.

66. Install forward-reverse lever (100) and spring (101) on the transmission case.

67. Install the shift lever in the transmission with the shift lever engaged with the shifting gate. Install the cover over the shifting lever.

End By:

a. install transmission (Direct Drive & Special Application)


NOTICE

Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.


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