TorqueConverterDescriptionandOperation
DESCRIPTION
Thetorqueconverterhydraulicallyconnectstheenginetothetransmission.Thereisnodirectmechanicalconnectionbetweentheengineandthetransmission.SeeFigure2.
thestatorclutchpermitsthestatortorotateasaunit withtheimpellerandturbine.
NOTE: EARLIERMODELTORQUECONVERTERIS SHOWN.LATERMODELISSIMILAR.
1.DRIVEPLATE
5.TORQUE
Thetorqueconverterhasanimpeller,aturbine,and astatorwithastatorclutch.Theimpellerisfastened totheflywheelandhasasetofcurvedblades.The turbinealsohasblades,andisconnectedtotheinput shaftofthetransmissionbysplines.Thestatorisbetweentheturbineandtheimpeller.Thestatorclutch isaone-wayclutchthatpermitsthestatortoturn freelyinthedirectionofenginerotation,butlocks topreventrotationintheoppositedirectionfromenginerotation.SeeFigure3andFigure4.Whenthe turbineisrotatingatthesamespeedastheimpeller,
1.FORCE
3.TOOTHLOCKED
4.INNERRACE(FIXED)
OPERATION
Thetorqueconverterhastwomainfunctions.It operatesasafluidclutchtosmoothlytransferpower fromtheenginetothetransmission.Thetorque converterwillmultiplythetorquefromtheengine. Whentheengineworksagainstaload,thetorque convertercanmultiplythetorquefromtheengine andsendmoretorquetothetransmission.Themaximumtorquemultiplicationisavailablejustbefore thetorqueconverterstalls.Iftheneedfortorque multiplicationisnotrequired,thetorqueconverter operatesasafluidclutch.
TorqueConverterDescriptionandOperation1300SRM543
2.FLYWHEEL 3.ACCESSCOVER 4.HOUSING
CONVERTER
6.OILPUMP 7.INPUTSHAFT
Figure2.TorqueConverterArrangement
2.OUTERRACE (LOCKED)
4.INNERRACE (FIXED)
Figure3.Stator(One-Way)ClutchLocked
1.FREEROTATION 2.OUTERRACE 3.TOOTHUNLOCKED
Figure4.Stator(One-Way)ClutchUnlocked
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Theimpellerhasasetofcurvedbladesthatacceleratestheoilfromthecenteroftheimpellerwhenthe impellerturns.Thevolumeoftheimpellerdecreases towardtheoutercircumference.Thisdecreasingvolumeincreasesthespeedandenergyoftheoilasit leavesimpellerandflowsintotheoutercircumferenceoftheturbine.Theforcefromthehigh-speed oilhittingthebladesintheturbinetransfersmost oftheenergytotheturbineandcausesittomove inthedirectionoftheenginerotation.Theoilthen flowsfromtheoutercircumferencetowardthecenteroftheturbine.SeeFigure5.Theturbineblades changethedirectionoftheoilflowsotheoilleaving thecenteroftheturbineisgoinginthedirectionoppositeofenginerotation.Thisoilnowhasalower velocitybecauseithasgivenmostofitsenergytorotatetheturbine.
Thestatorisbetweentheturbineandimpellerinthe centerofthetorqueconverter.Whentheoilhitsthe statorblades,thestatorclutchpreventsthestator fromturninginthedirectionoppositeofenginerotation.
Thebladesofthestatorchangethedirectionofthe oilsotheoilenterstheimpellerinthedirectionof enginerotation.Theenergythatremainsintheoil flowasitleavesthestatorisaddedtothenewenergy beingaddedtotheimpellerbytheengine.Thisuse ofenergy,controlledbythestator,permitsthetorque convertertomultiplythetorqueoftheengine.
Resistancetotheflowofoilintheturbine,because ofcentrifugalforce,increasesasthespeedoftheturbineincreases.Thisresistancedecreasestheenergy andamountofoilflowtotheimpellerfromthestator.Whentheflowtotheimpellerdecreases,theadditionalforceaddedtotheimpellerdecreases.Less torqueisgeneratedwhenlesstorqueisneeded.
Whenthelifttruckistravelingataconstantspeed onlevelground,theturbineandimpellerrotateat approximatelythesamespeed.SeeFigure6.The centrifugalforceoftheoilisthesameforboththe impellerandturbine.Theoildoesnotflowthrough thestatorandtorqueisnotmultiplied.Therotating oilhitsthebackofthestatorbladesandturnsthe statorinthedirectionofenginerotation.Thestator clutchpermitsthestatortoturnwithenginerotation.Theimpeller,turbine,stator,andoilrotateas aunitwhentorquemultiplicationisnotrequired.
Whenthelifttruckbeginstotraveluparamp,the resistancetoturningtheturbineincreases.The centrifugalforceoftheoilintheturbinedecreases. Whenthespeedoftheturbineislessthanthespeed oftheimpeller,thestatorlocksinplace.Torqueis multipliedonlywhenthestatorisheldbythestator clutch.Theoilflowsfromtheimpeller,throughthe turbineandstator,andenterstheimpellertomultiplythetorque.Thetorqueconverteragainincreases thetorquewhenmoretorqueisneeded.
1300SRM543TorqueConverterDescriptionandOperation
A. VORTEXFLOW B. ROTARYFLOW
Figure5.TypesofFlow
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ClutchAssembliesDescriptionandOperation
DESCRIPTION
Thetransmissionhastwoclutchassemblies,aforwardclutchandareverseclutch.SeeFigure7.The forward andreverseclutchhousingsareontheinput shaft.Theinputshaftisconnectedtotheturbineof thetorqueconverter.Theforwardandreversehubs arealwaysengagedwiththeoutputgearandthereverseshaft.Hydraulicpressureisusedtoapplyone oftheclutchessopoweristransmittedfromtheenginethroughthetransmissiontothedrivewheels.
Eachclutchassemblyhasahousing,piston,friction discs, andseparatorplates.Thefrictiondiscsand separatorplatesareinstalledinthehousingina sequence.Eachfrictiondiscisnexttoaseparator plate.(Theseparatorplatethatisnexttothepiston hasaconcaveshape.)Theseparatorplateshavea smoothmetalsurface.Thefrictiondiscshaveafriction materialonthesurface.Thehubineachclutch assemblyengageswiththeinnersplinesofthefriction discs.Thesplinesintheoutercircumferenceof
theseparatorplatesengagethesplinesintheclutch housing.Apressureplateholdsthefrictiondiscs andseparatorplatesinthehousing.Alargereturn springkeepsthepistonretractedagainstthehousing.Thereisenoughclearanceintheclutchassemblytopermitthefrictiondiscstorotatewhenaclutch isnotapplied.Whenhydraulicpressureisappliedto thepiston,thefrictiondiscsandseparatorplatesare pressedtogetherandtheclutchassemblyrotatesas asingleunit.Thehydraulicpressurefortheclutches is1075to1370kPa(156to199psi)measuredatthe testportfortheclutchregulator.
Anorificeineachclutchpistonpermitsasmallcontinuousoilflowfromthepressurechamberinthe clutch.Thisorificemakessuretheclutchwillcompletelyrelease.Theorificealsomakessureoildoes notstayinthepressurechamberoftheclutchbecauseofcentrifugalforceaftertheclutchisreleased.
ClutchAssembliesDescriptionandOperation1300SRM543
Figure6. LiftTruckatConstantSpeed(NoTorqueMultiplication)
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Theinputshaftinthetransmissionhasoilpassages thatconnecttheclutchassembliestothecontrol valve.Therearealsooilpassagesinthetransmissionhousingandtheclutchassembliesforthe lubricationandcoolingoftheclutchassemblies. Sealringsononeendoftheinputshaftsealtheoil passagessooilcanflowfromthepassagesinthe transmissionhousingtothepassagesintheinput shaft.
OPERATION
Whentheengineisrunning,theinputshaftisturninginthedirectionofenginerotation.SeeFigure8. Whentheforwardclutchisengaged,thepowerfrom
theengineissentfromtheinputshaftandforward clutchassemblytotheoutputpinion.Theflowof powerisfromtheinputshaftthroughtheapplied clutchtotheforwardhub.Thegearontheforward hubisengagedwiththeoutputgearonthepinionof thedifferential.
Whenthereverseclutchisapplied,theforward clutchisreleased.Theflowofpowerisfromthe inputshaftandreverseclutchhubtothereverse gearandshaft.Thereversegearandshafttransfers thepowertotheoutputgearandpinion.Thepinion willrotateintheoppositedirectionasitdidwhen theforwardclutchwasapplied.
1300SRM543ClutchAssembliesDescriptionandOperation NOTE: ONLATERMODELS,SPACERSANDTHRUSTWASHERSARENEEDLEBEARINGS. 1.SNAPRING 2.BEARING 3.BEARINGRETAINER (EARLIERMODELSONLY) 4.SPACER 5.REVERSEHUB 6.THRUSTWASHER 7.SNAPRING 8.RETAINER 9.SPRING 10.RETAINER 11.PRESSUREPLATE 12.FRICTIONDISC 13.SEPARATORPLATE 14.PISTON 15.SEALRING 16.FORWARDHUB
Figure7.ClutchAssembly
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HydraulicSystemOperation
Thepowershifttransmissionhasahydraulicsystem forcontrolandlubricationofthetransmission.The oilpumpforthetransmissionisdrivenbythetorque converter.SeeFigure2.Thetransmissionpump turnswiththetorqueconverterwhentheengineis running.Theoilsupplyforthesystemiskeptin thesumpofthetransmission.Ascreeninthesuctionlinetothetransmissionpumppreventslarge particlesfromenteringthehydraulicsystemofthe
transmission.Theoilflowsthroughthescreenin thesump,throughthetransmissionpump,bythereliefvalve,andthenthroughthefilter.SeeFigure9 orFigure10.Thepressure,whichiscontrolledby thereliefvalveforthetransmissionpump,is1170 to1470kPa(170to213psi).Fromthefilter,theoil flowsthroughpassagesinthetransmissionhousing tothecontrolvalve.
HydraulicSystemOperation1300SRM543
REVERSE
FORWARD
A.
B.
1.INPUTSHAFT 2.REVERSECLUTCHANDHUB 3.FORWARDCLUTCHANDHUB 4.REVERSEGEAR 5.REVERSESHAFT 6.OUTPUTGEAR 7.PINION 8.RINGGEAR
Figure8.ClutchOperation
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1300SRM543HydraulicSystemOperation 1.STRAINER 2.PUMP 3.CLUTCHPRESSURE REGULATOR 4.TORQUECONVERTER REGULATOR 5.TORQUECONVERTER 6.OILCOOLER 7.OILFILTER 8.CLUTCH 9.DIRECTIONSPOOL (SOLENOIDVALVE) 10.MODULATORSPOOL 11.INCHINGSPOOL
Figure9.HydraulicSchematic(EarlierModels)
Figure10.HydraulicSchematic(LaterModels)
1.STRAINER 2.PUMP 3.CLUTCHPRESSUREREGULATOR 4.TORQUECONVERTERREGULATOR 5.TORQUECONVERTER 6.OILCOOLER 7.OILFILTER 8.CLUTCH 9.DIRECTIONSPOOL(SOLENOIDVALVE) 10.ACCUMULATOR 11.INCHINGSPOOL 12.CHECKPORT 7
LegendforFigure10
ControlValveOperation
Thecontrolvalveisinstalledonthetopofthetransmission.Theinchingspool,modulatorcircuit,regulatorforclutchpressure,andregulatorforthetorque converterarepartofthecontrolvalve.Theposition oftheinchingspooliscontrolledbytheinching/brake pedal.SeeFigure20.
Asolenoidvalveisinstalledatthesideofthecontrol valve.Thesolenoidvalveisactuatedbytheshift lever.Thesolenoidvalvecontrolsthepositionofthe directionspool.
REGULATORFORCLUTCHPRESSURE
Theregulatorforclutchpressurecontrolstheoil pressureforapplyingtheclutchestoengagethe transmission.Thecontrolpressureoftheregulator is1075to1370kPa(156to199psi).Oilthatflowsto theregulatorforclutchpressureflowstothetorque convertercircuitandoillubricationcircuit.See Figure20.
INCHINGSPOOLASSEMBLY
Inchingistheslowmovementofalifttruckwhile ahighenginespeedisusedforfasteroperationof thehydraulicsystem.Theinchingfunctionisnormallyusedforfinemovementsofthelifttruckwhen handlingaload.Operationoftheinchingpedaldecreasestheoilpressuretoaclutchsotheclutchis notcompletelyapplied.SeeFigure20.
Theinchingspoolassemblyhasaninchingspool,an inchingspoolplunger,andtwosprings.Oilflowsto theinchingspoolfromthetransmissionpump.The inchingspoolcontrolstheoilflowandpressureto thedirectionspool(solenoidvalve).Whentheinchingfunctionisnotused,theoilflowsthroughthe inchingspooltothedirectionspool.Operationofthe inchingfunctioncausesarestrictionoftheoilflow tothedirectionspoolandtheclutch.Thisoperation decreasestheoilpressuretothedirectionspool(and clutch)astheinchingspoolplungerisextended. Whentheinchingspoolplungeriscompletelyextended,theoilpressuretothedirectionspool(and clutch)isapproximatelyzero.Theclutchisthen releasedandthetransmissionisin NEUTRAL
DIRECTIONSPOOL
Thedirectionspoolisinsidethesolenoidvalveand controlstheoilflowfromtheinchingspooltothedirectionclutches.Thedirectionspoolhasthreepositions: FORWARD, NEUTRAL ,and REVERSE. Whenthedirectionspoolisinits FORWARD position,oilflowandpressureissenttoapplytheforward clutch.Whenthedirectionspoolisinits REVERSE position,oilflowandpressureissenttoapplythereverseclutch.Whenthedirectionspoolisinits NEUTRAL position,oilpressuretobothoftheclutches isreducedtoapproximatelyzero.Whenthedirectionspoolismovedtocontroladirectionoftravel,oil flowstoandfromtheclutchassembliesandalsoto themodulatorcircuit.SeeFigure20.
Electricswitchesinthedirectioncontrolleverenergizeandde-energizethesolenoidvalve.Whenthe directionsolenoidisenergized,thedirectionspool changespositiontochangetheflowofoil.
MODULATORCIRCUIT
Amodulatorcircuitisusedtocontroltherateofapplicationoftheclutches.Whenthedirectionspool ismovedtoselectadirectionoftravel,themodulatorcircuitcontrolstheapplicationoftheclutchduringa1.50to2.0-secondperiod.Themodulatorcircuitcontrolsthepressureincreasetoapplytheclutch smoothly.Thisdelayandsmoothapplicationofpressurereducestheshockandstresstothedrivetrain whenengagingthetransmissionorchangingdirections.SeeFigure20.
REGULATORFORTHETORQUE CONVERTER
Whentheenginespeedislow,theoilflowstothe torqueconverterthroughanorificeintheboreinthe clutchpressureregulator.Thepressureregulatorfor thetorqueconverterstayscloseduntilthepressure tothetorqueconverterincreasesto296to685kPa (43to99psi).Whenthepressureregulatorforthe torqueconverteropens,theoilthatdoesnotgotothe torqueconverterflowsdirectlytothepassagetocool andlubricateofthepartsofthetransmission.The oilthatflowstothetorqueconvertergoesthrough theoilcoolerbeforeenteringthepassagetocooland lubricatetheclutches.SeeFigure20.
ControlValveOperation 1300SRM543
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MONOTROL® PedalOperation
TheMONOTROLpedalcontrolsthespeedofthe engineandtheoperationofthesolenoidvalvefor directioncontrol.Thepedalpadisheldtothepedal framebyapivotshaft.Thepedalpadrotateson theshaftandisheldintheforwardorreversepositionbymagnetsinthepedalframe.Therearetwo switchesintheMONOTROLpedalassembly.When theMONOTROLpedalisintheforwardposition,
bothpedalswitchbuttonsareactuated.Battery powerflowsthroughbothpedalswitchestoenergize thesolenoidvalveandmovethedirectionspoolfor forwardtravel.WhentheMONOTROLpedalisin thereverseposition,bothpedalswitchbuttonsare released.Batterypowerflowsthroughbothpedal switchestoenergizethesolenoidvalveandmovethe directionspoolforreversetravel.SeeFigure23.
DirectionControlLeverOperation
Thedirectioncontrolleverisusedtocontroltheoperationofthedirectionspool(solenoidvalve).Ifthe lifttruckhasadirectioncontrollever,anaccelerator pedalisusedtocontrolthespeedoftheengine.The movementofthecontrolleveractuatesfourswitches.
Inthe NEUTRAL position,alloftheswitchesare closed.Thelevermustbeinthispositiontostart
theengine.Movingthelevertothe FORWARD positionopenstheforwardswitchandclosesthereverseswitch.Thisactionshiftsthedirectionspoolfor forwardtravel.Movingthelevertothe REVERSE positionopensthereverseswitchandclosestheforwardswitch.Thisactionshiftsthedirectionspoolfor reversetravel.SeeFigure28.
DifferentialOperation
Theringandpiniongearstransferpowertotheaxle shaftsatrightanglestothetransmission.Thering andpinionisalsoagearreductionwhichincreases thetorquetothedrivewheels.Thedifferentialassemblypermitsthetwodrivewheelstoturnatdifferentspeedswhenthelifttruckisturningacorner.
Theringandpiniongearsareheldinpositioninthe transmissioncasebythedifferentialhousing.The housingforthedriveaxleisfastenedtothedifferentialhousing.Theoutputgearforthetransmissionis installedonthepinionshaft.Theoutputgearisin constantmeshwiththegearsoftheforwardclutch hubandthereverseshaft.
TorqueConverterandTransmissionPumpRepair
NOTE: Theprocedureforremovalofthetransmissionisfoundinthesection Frame 100SRM545.
NOTE: Thetorqueconvertercannotberepaired.
REMOVEANDDISASSEMBLE
CAUTION
Becarefultonotdamageanypartsofthe torqueconverterortransmissionwhenthe transmissionisseparatedfromtheengine. Keepthetransmissionandengineinalignmentuntiltheyarecompletelyseparated,so thepartsofthetransmissionarenotdamaged. Useacraneorliftingdevicetoseparatethe transmissionfromtheengine.
1. Removeaccesscoverfromtopoftorqueconverter housing.SeeFigure11.
2. Removecapscrewsthatholddriveplatetoflywheel.
3. Removecapscrewsthatholdtorqueconverter housingtoengine.Removestarter.Carefully separatetransmissionfromengine.Makesure torqueconverterstayswithtransmission.
4. Removetorqueconverterfromtransmission.
5. Removetransmissionpumpfromhousing.See Figure12.Disassemblepumpasfollows:
1300SRM543TorqueConverterandTransmissionPumpRepair
9
a. Removeeightcapscrewsthatholdpumpto torqueconverterhousing.Removetwocover capscrewsfrompump.
b. Installtwopumpmountingcapscrewsin coverholes.Tightentwocapscrewstopush pumpfromhousing.
c. Removegearsfrompump.Removesealand O-ringfrompump.
INSPECT
1. Inspectpumpgearsforwearordamage.
2. Checkallpartsthathavesplinesfordamageto splines.Checkfornotchesworninsplines.
3. Inspectbushinginpumpbodyforwearordamage.
4. Inspectsurfaceofsealontorqueconverterfor wearordamage.
ASSEMBLEANDINSTALL
1. Applysiliconegasketmaterialtomountingsurfaceoftransmissionhousing.Installtorqueconverterhousingontransmissionhousing.Besure toalignholesintorqueconverterhousingwith holesinbearingcarrier.Whenholesarealigned, installhousingstogether.SeeFigure11andFigure12.
2. Usethread-lockingadhesiveandinstallsocket headcapscrewsforbearingretainer.SeeFigure14.Tightencapscrewsto10N•m(7lbfft). Installcapscrewsthatholdhousingstogether andtightenthemto41N•m(30lbfft).
NOTE: EARLIERMODELHOUSINGISSHOWN.LATERMODELISSIMILAR. 1.ENGINECRANKSHAFT
TorqueConverterandTransmissionPumpRepair1300SRM543
2.FLYWHEEL 3.DRIVEPLATE 4.TORQUECONVERTER
6.ACCESSCOVER 7.TORQUECONVERTERHOUSING
5.OILPUMP
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Figure11.TorqueConverterandHousing
3. Assembletransmissionpumpasfollows:
a. Lubricateallpartsofpumpwithcleantransmissionoil.
b. Installnewoilsealinpumpbody.
c. Installgearsandstatorshaftonpumpbody. Makesuresideofdrivegearwithgroovesis towardtorqueconverter.Usegasketsealant onbothsidesofwashersandinstalltwocapscrews.Tightencapscrewsto9to16N•m(7 to12lbfft).
d. InstallnewO-ringonpumpbody.
4. Installpumponhousing.Usethreadlockingadhesiveandinstallcapscrews.Tightencapscrews to20N•m(15lbfft).Checkthatdrivegearrotatesfreelyinbody.
5. Installtorqueconverter,makingsurenotches alignwithgearinoilpump.
ClutchAssembliesRepair
REMOVEANDDISASSEMBLE
1. Removetorqueconverterhousing.
2. Removesnapring,bearing,spacer,andreverse gearfromreverseshaft.SeeFigure13.
3. Removeinputshaftandclutchassemblyfrom transmission.SeeFigure14.
4. Removesealringsfrombothendsofinputshaft.
5. Removesnapringforballbearing.Usepullerto removebearingcarrierandballbearing.
6. Removespacerandreverseclutchhub.
7. Removeretainingringandpressureplatefrom reverseclutch.Removefrictiondiscsandseparatorplates.
8. Removepistononlyifthereisaproblemwith pistonorseals.Usetwopunchestopushspring
retainerdown.SeeFigure15.Removesnap ringforretainer.Removeretainer,spring,and piston.Pullpistonfromclutchhousing.Remove sealfromcircumferenceofpistonandO-ring fromshaft.
WARNING
Thespringforpistoniscompressed.Makesure springandspringretainercannotcauseinjury whensnapringisremoved.
NOTE: Someservicepeoplemakeaspecialbracketso thespringandretainercanbecompressedandheld withapresstoremovesnapring.
9. Removesnapringforballbearingforforward clutch.Usepullertoremoveforwardclutchhub, spacer,andballbearing.
10. Removeremainingclutchpartsasdescribedin Step7andStep8.
1300SRM543ClutchAssembliesRepair
1.O-RING 2.BODY 3.SEAL 4.STATOR 5.BUSHING
Figure12.TransmissionPump
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ClutchAssembliesRepair1300SRM543 1.CLUTCHASSEMBLY 2.TRANSMISSIONHOUSING 3.BEARINGCAP 4.RINGGEAR 5.PINION 6.BEARING 7.SHIMS 8.SEAL 9.OUTPUTGEAR 10.WASHER 11.NUT 12.LOCKWASHER 13.LOCKNUT 14.SNAPRING 15.RETAINER 16.REVERSESHAFT 17.REVERSEGEAR 18.SPACER
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Figure13.TransmissionArrangement
1300SRM543ClutchAssembliesRepair
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Figure14.ClutchAssemblies
INSPECT
1. Inspectgearsforclutchassembliesanddifferentialgearsforwearordamage.
2. Checkallpartsthathavesplinesfordamageto splines.Checkfornotchesworninsplines.
3. Inspectfrictiondiscsforburnedliningorbent surfaces.Checkforsmallholesinlining.Replace frictiondiscsifone-halfdepthofoilgroovesare wornawayordiscsaredamaged.Discardfrictiondiscthathasthicknesslessthan1.70mm (0.067in.).
4. Checkseparatorplates.Platesmustnotbebent, havedamagedsurfaces,orhavelargeblueareas fromtoomuchheat.
5. Inspectbearingsforwearordamage.
6. Inspectpistonfordamage.Makesuresealing surfacesaregood.Makesureorificeisclean.
7. Checkforgroovesorotherdamageonmachined surfacesofshaft.Checksealringsfordamage andwear.Checksealringsurfacesinhousing fordamage.
ASSEMBLEANDINSTALL
NOTE: Lubricateallpartsofclutchassemblieswith cleantransmissionoil.SeeFigure13andFigure14.
1. Usethefollowingproceduresforeitherforward orreverseclutch:
a. Installsealsonpistonandonshaft.Install pistoninhousing.
WARNING
Thespringfortheclutchmustbecompressed. Makesurethespringandspringretainer cannotcauseinjurywhenthesnapringis installed.
NOTE: Someservicepeoplemakeaspecialbracketso thespringandretainercanbecompressedandheld withapresstoinstallsnapring.
b. Installpistonspringandretainer.SeeFigure15.Usetwopunchestopushspringretainerdown.Installsnapringforretainer.
NOTE: Thereisoneseparatorplatewithconcave shapeineachclutchassembly.
c. Installfrictiondiscsandseparatorplates inalternatesequence.Startwithseparator platewithconcaveshape.SeeFigure7. Makesureconcavesideisawayfrompiston, theninstallremainingfrictiondiscsand separatorplates.Installpressureplateand retainingring.
d. Installthrustwasherandclutchhub.Make sureinnerchamferonthrustwasheristowardclutchpack.
ClutchAssembliesRepair1300SRM543
1.SEALRING 2.SNAPRING 3.BEARING 4.SPACER 5.FORWARDHUB 6.THRUSTWASHER 7.RETAINER 8.SPRING 9.RETAININGRING 10.PRESSUREPLATE 11.FRICTIONDISC 12.SEPARATORPLATE 13.PISTON 14.PISTONSEAL 15.CLUTCHHOUSING 16.BEARINGRETAINER 17.REVERSEHUB
LegendforFigure14
1.PUNCH 2.SNAPRING 3.SPRINGRETAINER 4.PISTON Figure15.PistonReturnSpring
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2. Onforwardclutch,installthrustwasherandball bearingonshaft.Makesureinnerchamferon thrustwasheristowardclutchpack.Installsnap ring.Installsealringsonshaft.
3. Onreverseclutch,installthrustwashersothat innerchamferonthrustwasheristowardclutch pack.ApplyLoctite242inareaofbearingcarrier forbearing.Installbearing,makingsureadhesivedoesnotgetintobearing.Afteradhesiveis
REMOVEANDDISASSEMBLE
dry,installbearingonshaft.Installsnapring andsealring.
4. Lubricatesealringsandinstallclutchassembly inhousing.SeeFigure13andFigure14.
5. Installreversegear,spacer,bearing,andsnap ringonreverseshaft.
DifferentialRepair
1. Disassembleonlypartsofdifferentialthatmust berepaired.Ifringgearandpinionarenottobe replaced,checkcontactpatternbeforedisassembly.Patternandgearclearanceareusedasreferencesforassembly.SeeAssembleandInstall procedure.
2. Beforeremovingdifferentialassembly,measure outsidediameterofcaseasshowninFigure16. Thisdimensionisnecessarywhenassembling parts.
5. Removeouterbearingcupandshims.Makenote ofshimarrangement.Ifpinionwillnotbereplaced,shimarrangementwillbeapproximately samewhendifferentialisassembledagain.Removeinnerbearingcupandoilseal.
6. Disassembledifferentialasneededtomakerepairs.Removeringgearfromdifferentialcase. Removerollpinandshaft.Removedifferential pinions,sidegears,andthrustwashers.SeeFigure17.
7. Ifnecessary,removereverseshaftfromhousing. Removecapscrewsforbearingretainer,then removeshaftassembly.Removesnapringand bearingfromshaft.
INSPECT
1. Checkpinionandringgearforwear.Inspectside gearsanddifferentialpinionsforwornteeth.Inspectshaftforwearwheregearsturn.Shaftand holesforshaftindifferentialcasemustfittightly.
2. Checkallbearingsforwearanddamage.Replace wornordamagedparts.
ASSEMBLEANDINSTALL
Figure16.DifferentialCaseMeasurement
3. Makenoteofpositionsofadjustingnutsforring gear.Removebearingcaps,adjustingnuts,and differentialassembly.
4. Removenutsandlockwasherfrompinionshaft. Removeoutputgear.Pushpinionshaftfrom bearings.
NOTE: Whenaringgearandpinionarewornor damaged,theymustbereplacedasaset.Always checkthatthegearsareamatchedset.
NOTE: Thepinionvariationnumberisontheend ofpinion.Thenumberisusedtoadjustthedepth ofthepinioninthehousing(forexample,+0.01or 0.02).Thepinionvariationnumberisindicated inhundredthsofmillimeters.Thisprocedureisdescribedinthefollowingparagraphs.
1300SRM543 DifferentialRepair
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