18-Speed PST Repair Manual-CTM168 PDF

DCT
18-Speed PST Repair

Manual
TECHNICAL MANUAL
18-Speed PST Repair Manual
CTM168 10DEC07 (ENGLISH)
John Deere Coffeyville Works

CTM168
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Some components from these transmission, may be
Essential tools required in performing certain service serviced without removing the complete transmission
work are identified in this manual and are assembly from the machine. You may have to
recommended for use. determine this procedure yourself for a safe removal of
such components. See information to remove and
Live with safety: Read the safety messages in the install the complete transmission assembly, found in
introduction of this manual and the cautions presented your vehicle technical manual.
throughout the text of the manual.
Clean transmission before servicing. Always work in a
clean work area.
This is the safety-alert symbol. When you see
this symbol on the machine or in this manual, be alert
Binders, binder labels, and tab sets can be ordered by
to the potential for personal injury.
John Deere dealers direct from the John Deere
Distribution Service Center.
Use this component technical manual in conjunction
with the machine technical manual. See the machine
This manual is part of a total product support program.
technical manual for information on component
removal and installation, and gaining access to the
• FOS MANUALS—REFERENCE
components.
• TECHNICAL MANUALS—MACHINE SERVICE
• COMPONENT MANUALS—COMPONENT
Information is organized in groups for the various
SERVICE
components requiring service instruction. At the
beginning of each group are summary listings of all
Fundamentals of Service (FOS) Manuals cover basic
applicable essential tools, service equipment and tools,
theory of operation, fundamentals of troubleshooting,
other materials needed to do the job, service parts kits,
general maintenance, and basic type of failures and
specifications, wear tolerances, and torque values.
their causes. FOS Manuals are for training new
personnel and for reference by experienced
This component technical manual covers the
technicians.
recommended repair procedure for the 18-speed PST
AG,OURX078,680 –19–28JUN00–1/1
Notice to the Dealer
This Component Technical Manual should be used Transmission Identification Plate

for the repair of 18-speed PST. and see General—Group 10.)
IMPORTANT: Before beginning repair or making

adjustments, become familiar with
AG,OURX078,679 –19–28JUN00–1/1
CTM168 (10DEC07) 18-Speed PST Repair Manual

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Contents
01
SECTION 01—General Information
Group 000—Safety
Group 10—General Information
SECTION 02—Repair and Adjustments

02
Group 15—Transmission
Group 20—Electrical
Group 25—Hydraulics
Group 30—Pump Drive
Group 35—Housings, Geartrain and Clutch Shafts
03
SECTION 03—Theory of Operation
Group 20—Theory of Operation
SECTION 05—Tools and Other Materials

Group 175—Special Tools
05
Group 195—Dealer Fabricated Tools
SECTION 06—Specifications
Group 205—Torque Value
06
INDX
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2001 - 2007
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
CTM168 (10DEC07) i 18-Speed PST Repair Manual

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Contents
01
02
03
05
06
INDX
CTM168 (10DEC07) ii 18-Speed PST Repair Manual

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01
Section 01
General Information
Contents
Page
Group 000—Safety . . . . . . . . . . . . . . . . . . . .01-000-1
Group 10—General Information

Identification Plate . . . . . . . . . . . . . . . . . . . . . . .01-10-1
General Repair Procedures . . . . . . . . . . . . . . . .01-10-2
Sealants and Adhesives Cross-Reference
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-10-3
Sealing Instructions . . . . . . . . . . . . . . . . . . . . . .01-10-4
Cold Weather Operation . . . . . . . . . . . . . . . . . .01-10-5
Oil Temperature Warning Signal . . . . . . . . . . . .01-10-6
Recommended Lubricants. . . . . . . . . . . . . . . . .01-10-6
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . .01-10-7
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . .01-10-7
Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-10-7
Alternative and Synthetic Lubricants . . . . . . . . .01-10-8
Check and Service Transmission Regularly . . .01-10-8
Intervals For Changing Transmission Oil
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-10-9
Fill The Transmission With Oil (Wheel
Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .01-10-10
Check Oil Lines and Fittings . . . . . . . . . . . . . .01-10-11
Hydraulic Connections. . . . . . . . . . . . . . . . . . .01-10-11
Transmission Storage . . . . . . . . . . . . . . . . . . .01-10-12
Transmission Removal From Storage . . . . . . .01-10-12
Towing The Vehicle. . . . . . . . . . . . . . . . . . . . .01-10-12
CTM168 (10DEC07) 01-1 18-Speed PST Repair Manual

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Contents
01

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Group 000
Safety
01
Recognize Safety Information 000
1
This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT –19–29SEP98–1/1
Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near

heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME –19–29SEP98–1/1
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TS204
DX,SPARKS –19–03MAR93–1/1
CTM168 (10DEC07) 01-000-1 18-Speed PST Repair Manual

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Safety
01
000 Prepare for Emergencies
2
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
–UN–23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 –19–03MAR93–1/1
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong

enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
–UN–23AUG88
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON –19–21APR93–1/1

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Safety
01
Handle Chemical Products Safely 000
3
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical

products used with John Deere equipment.)
DX,MSDS,NA –19–03MAR93–1/1
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands

X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID –19–03MAR93–1/1

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Safety
01
000 Park Machine Safely
4
Before working on the machine:
• Lower all equipment to the ground.

• Stop the engine and remove the key.
• Disconnect the battery ground strap.
–UN–24MAY89
• Hang a "DO NOT OPERATE" tag in operator station.
TS230
DX,PARK –19–04JUN90–1/1
Support Machine Properly
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
–UN–23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When implements or attachments are used with a

machine, always follow safety precautions listed in the
implement or attachment operator’s manual.
DX,LOWER –19–24FEB00–1/1
Wear Protective Clothing
Wear close fitting clothing and safety equipment

appropriate to the job.
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
–UN–23AUG88
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR –19–10SEP90–1/1

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Safety
01
Work in Clean Area 000
5
Before starting a job:
• Clean work area and machine.

• Make sure you have all necessary tools to do your job.
–UN–18OCT88
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN –19–04JUN90–1/1
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
–UN–23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE –19–04JUN90–1/1
Work In Ventilated Area
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR –19–17FEB99–1/1
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1

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Safety
01
000 Replace Safety Signs
6
Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement.
–UN–23AUG88
TS201
DX,SIGNS1 –19–04JUN90–1/1
Use Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe

injury or machine damage.
Follow recommended procedure for removal and

installation of components in the manual.
–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1
Avoid Harmful Asbestos Dust
Avoid breathing dust that may be generated when

handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers
–UN–23AUG88
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as
TS220
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for

cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Keep bystanders away from the area.
DX,DUST –19–15MAR91–1/1

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Safety
01
Avoid Heating Near Pressurized Fluid Lines 000
7
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can
–UN–15MAY90
accidentally burst when heat goes beyond the immediate
flame area.
TS953
DX,TORCH –19–10DEC04–1/1
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1

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Safety
01
000 Use Proper Tools
8
Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.
Use power tools only to loosen threaded parts and

fasteners.
–UN–08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR –19–17FEB99–1/1
Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When

constructing tools, use proper, quality materials, and good
workmanship.
–UN–01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.
LX1016749
DX,SAFE,TOOLS –19–10OCT97–1/1

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Safety
01
Dispose of Waste Properly 000
9
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1
Live With Safety
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
–19–07OCT88
TS231
DX,LIVE –19–25SEP92–1/1

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Safety
01
000
10

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Group 10
General Information
01
Identification Plate 10
1
The identification plate is located in the upper left on the

rear housing of the transmission. Should repair parts be
required, please specify the model, specification, and
serial number of your transmission.
–UN–01JUL03
YZ5049
YZ07927,000044C –19–23SEP05–1/1

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General Information
01
10 General Repair Procedures
2
NOTE: Before beginning the repair, review the Both the bearing cone and roller assembly should be
following guidelines. These are provided to replaced if either the cup or cone has excessive wear.
emphasize the need for attention to detail and
care when servicing the Transmission Inspect tapered bearings and roller bearing surfaces
assembly. for distortion, roughness, scoring, or wear.
Thoroughly clean the outside before disassembly. When installing bearing cups and cones, make sure
they are fully seated.
Handle parts carefully to prevent nicking or burring
machined surfaces. Cups and cones are properly seated if a 0.05 mm
(0.002 in.) feeler gauge will NOT pass for a 360°
Inspection Before Disassembly. circular sweep between cone or cup mounting surface.
Inspect the gears, shafts and bearing before removal Shafts

as follows:
Inspect the shaft bearing surfaces for wear or damage.
1. Wipe the lubricant from the internal working parts
and visually inspect the parts for excessive wear or Inspect shafts and replace if excessively worn or
damage. damaged.
2. Inspect the gears for roughness. Gear Assemblies
3. Inspect the gear teeth for signs of scoring, Examine the gear teeth for excessive wear. Replace
abnormal wear, or nicks/chips. as necessary.
Heating Bearing Fasteners and Tightening
IMPORTANT: Heat bearing in a bearing heater. Use Fasteners must be tightened to the specified torque.
a thermometer and DO NOT exceed
150°C (300°F). Fasteners must be replaced with the same property
class (grade).
Cleaning and Inspection
Follow the specified tightening pattern when listed.
Clean all parts with clean solvent and use
moisture-free air for drying. Different models of transmission and Early Version
Transmissions may have a different torque
Bearings specification and fastener than Later Version
Transmissions. Check the model number and/or the
Never dry bearings with compressed air. Spinning a fastener removed and use the correct torque
bearing without lubrication can damage the bearing. specification and fastener.
Clean bearings with clean solvent, dry thoroughly, and Assembly

oil before inspection. Inspect bearings for roughness of
rotation and excessive wear of rollers. Use the specified grease when installing seals.
Inspect bearing cups for excessive wear.
Continued on next page YZ,OURX078,687 –19–03JAN01–1/2

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General Information
01
During assembly, each part should be lubricated with 10
3
clean hydraulic oil.
YZ,OURX078,687 –19–03JAN01–2/2
Sealants and Adhesives Cross-Reference Chart

U.S. PART CANADIAN COLOR SIZE DESCRIPTION LOCTITE SIMILAR
NUMBER PART NUMBER NUMBER LOCTITE
PRODUCT
Bonding
PM37391 - CLEAR 3 gm Instant Gel Adhesive 454 416, 409, or 495
(0.11 oz)
Gasketing
PM38656 PM38627 RED 50 ml Rigid Form-in-Place 277 568
(1.69 oz) Gasket
PM38655 PM38625 PURPLE 50 ml Flexible Form-in-Place 515 518
(1.69 oz) Gasket
PM38657 PM38628 BLUE 50 ml High-Flex Form-in-Place 17430
(1.69 oz) Gasket
PM37553 PM37553 BURGUNDY 0.47 L High Tack Gasket — Permatex #98
(16 oz) Dressing
PM37465 - SILVER BLUE 88.7 ml Ultra Blue RTV Silicone 587 Permatex #77
(3 oz) Form-in-Place Gasket
Priming
PM37509 PM38611 GREEN 133 ml Cure Primer 7649 —
(4.5 oz)
Retaining
PM38651 PM38612 SILVER 50 ml Quick Metal Press Fit 660 —
(1.69 oz)
PM37485 - GREEN 50 ml Maximum Strength 680 635
(1.69 oz)
PM38652 PM38626 GREEN 50 ml High-Temperature 620
(1.69 oz)
Threadlocking and Threadsealing

PM37477 - BLUE 50 ml Medium Strength 242 241 or 243
(1.69 oz)
PM37418 PM38621 BLUE 6 ml Medium Strength 242 241 0r 243
(0.02 oz)
PM38654 PM38624 CLEAR 50 ml High Strength 271 262 or 609
(1.69 oz)
PM37421 PM38623 CLEAR 6 ml High Strength 271 262 or 609
(0.20 oz)
PM37397 PM38613 WHITE 50 ml Pipe Sealant w/TEFLON 592 565 or 567
(1.69 oz)
LOCTITE is a trademark of Loctite Corporation

QUICK METAL is a trademark of Loctite Corporation
TEFLON is a trademark of Du Pont Company RX,SEAL –19–22SEP05–1/1

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General Information
01
10 Sealing Instructions
4
Disassembly IMPORTANT: Do not use an excessive amount of

sealant.
On disassembly, the dowel pin holes provide a slip fit
with a normal depth of 15 mm (0.6 in.). Apply a THIN even layer of flexible gasket sealant to
ONE surface of the joint. Sufficient amount should be
Measure the length of protrusion to insure dowel pins applied so excess is seen around the outside edge of
will not prevent the housing from being drawn up tight. the flange. Narrow overlap areas must be covered with
gasket material. Put a bead of sealant around all bolt
If dowel pins protrude more than 15 mm (0.6 in.) from holes.
the components, remove the dowel pins, clean the
holes, and reinstall the dowel pins to the specified IMPORTANT: Temperature of adjoining parts and
depth. gasket material must be 13°C (55°F)
or above.
Cleaning
Apply flexible gasket sealant to the front housing
IMPORTANT: DO NOT use clean and cure primer machined surface.
to clean the surfaces. The primer
action will cause the new sealer to Install rear housing onto front housing.
set up TOO fast to allow adequate
assembly time. Tighten cap screws to the specified torque starting
from center and working toward top and bottom.
Clean surfaces with a brass brush or scraper to
remove old sealer material. Gel-type paint removers Allow the assembly to cure overnight before filling with
containing ethylene chloride or LOCTITE “Chisel” may oil.
be used.
IMPORTANT: Apply TY162851 Cure Primer to
Clean surfaces using rubbing alcohol to remove oil and sealing surfaces only if overnight
grease residue. curing is not possible.
Test for clean surface by applying a few drops of cool Apply primer to the sealing surfaces.
water to the surfaces. If water puddles or forms beads,
repeat the cleaning procedure. Use the same sealing application and cap screw
tightening procedures as previously instructed.
A file should be passed over burr on the joint faces to
insure no nicks are present. Prevent the gasket material from drying before
assembly is completed (1 hour maximum).
Keep surfaces clean and oil free after cleaning.
Allow 30 minutes minimum cure time at room
Application and Assembly temperature before filling with oil.
Front Housing-to-Rear Housing: Pump Housing-to-Front Housing:
LOCTITE is a trademark of Loctite Corporation
1
See Cross-Reference Chart for Canadian and Loctite Product
Numbers, this group.
Continued on next page AG,OURX078,688 –19–28JUN00–1/2

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General Information
01
Apply a THIN even layer of flexible gasket sealant to Apply primer to the sealing surfaces. 10
5
one surface of the joint. Sufficient amount should be
applied so excess is seen around the outside edge of Use the same sealing application and cap screw
the flange. Narrow overlap areas must be covered with tightening procedures as previously instructed.
gasket material. Put a bead of sealant around all bolt
holes. Prevent the gasket material from drying before
assembly is completed (1 hour maximum).
Tighten cap screws to specified torque beginning with
the center two cap screws, across from each other, Allow 30 minutes minimum cure time at room
and alternately working toward top and bottom. temperature before filling with oil.
Allow the assembly to cure overnight before filling with

oil.
IMPORTANT: Apply TY162851 Cure Primer to

sealant surfaces only if overnight
curing is not possible.
1
See Cross-Reference Chart for Canadian and Loctite Product
Numbers, this group.
AG,OURX078,688 –19–28JUN00–2/2
Cold Weather Operation
IMPORTANT: Preheat procedures are required ALTERNATE WARM-UP PROCEDURE:

when operating transmission below
the oil’s MINIMUM critical • Operate transmission in neutral for approximately 20
temperature which is viscosity grade minutes or until oil is warmed to the MINIMUM
dependent and will effect shift temperature.
performance.
HOT WEATHER OPERATION
NOTE: Refer to Operators Manual for the MINIMUM
transmission operating temperature Refer to AIR TEMPERATURE RANGE in the operators
recommended lubricants. manual for:
PREHEAT TRANSMISSION FLUID WITH AUXILIARY • Ambient temperatures consistently above 30°C
SOURCE (86°F).
• Frequent stop-and-go driving in hot weather.
• Preheat the transmission fluid to the MINIMUM • High grade climbing in hot weather.
temperature before operating.
DPSG,YZ07927,23 –19–12MAY99–1/1

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General Information
01
10 Oil Temperature Warning Signal
6
• The oil temperature gauge measures system oil

temperature. If temperature rises to 115°C (230°F) or
the transmission oil temperature warning light comes
on, stop the vehicle immediately. Shift to neutral and
–UN–30JAN01
run the engine at 1000—1200 rpm.
IMPORTANT: Do not stop the engine when the

transmission is overheating if the
YZ3008A
cooling system is known to be in
working order.
• The transmission oil temperature should soon lower to

the engine water temperature, or if an air-to-oil
exchanger is used, the temperature should soon lower
to ambient air temperature across the heat exchanger.
If the temperature does not lower, trouble is indicated.
• Correct overheating problem before the vehicle is
operated again.
DPSG,YZ07927,28 –19–12MAY99–1/1
Recommended Lubricants
Reference Operator’s Manuals for ambient air Recommended lubricant for 18-Speed Transmission is:
temperature charts and recommended transmission
fluids. • John Deere Standard JDM J20C
Standard HY-GARDTransmission fluids are available IMPORTANT: Use JDM J20C anything else will
through the John Deere dealer network worldwide. effect shift quality.
HY-GARD is a trademark of Deere & Company DPSG,YZ07927,22 –19–10DEC07–1/1

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General Information
01
Lubricant Storage 10
7
Equipment can operate at top efficiency only if clean Make certain all containers are correctly marked to
lubricants are used. identify contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant.
Store lubricants and containers in an area protected
from dust, moisture, and other contamination. Store
containers positioned to avoid water and dirt
accumulation.
RX,4310,12C –19–07JAN98–1/1
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Refer to OM for lubricant specifications and to obtain
Oil manufacturers blend additives to their oils to meet specific information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant
performance.
RX,4310,13C –19–07JAN98–1/1
Oil Analysis
Oil analysis is best used by sampling at regular • Glycol (Antifreeze), must not exceed 0% by volume.
intervals to establish a baseline analysis for the oil and • Water, must not exceed 0.05% by volume.
operation conditions present. Changes from this • Viscosity increase at 38°C (100°F), not more than
baseline may indicate unusual wear. 40% over new oil value.
• Total Acid Number (TAN) per ASTMD664, limit of
IMPORTANT: Change the oil and filter if an 3.0 over new lubricant value.
analysis of the used transmission oil
indicates any of the following limits
are exceeded.
DPSG,YZ07927,27 –19–12MAY99–1/1

121007
PN=23
General Information
01
10 Alternative and Synthetic Lubricants
8
Conditions in certain geographical areas may require The temperature limits and service intervals apply to
lubricant recommendations different from those in this both conventional and synthetic oils.
manual.
Refined base stock products may be used if the
Synthetic lubricants may be used if meeting the finished lubricant meets the performance requirements.
performance requirements in this manual.
RX,4310,11C –19–07JAN98–1/1
Check and Service Transmission Regularly
Routine checks will help prevent down time. The the engine, or when the vehicle is
operator can aid in preventative maintenance by parked and the engine is running.
reporting signs of leaks or malfunctions.
CHECK THE OIL LEVEL DAILY
Because the transmission operates in and by oil, most
of the maintenance is concerned with oil replenishment • Set parking brake.
and oil cleanliness. The type of service and operating • Put the gear selector lever in PARK position.
conditions shall determine the maintenance interval. • Operate the engine at idle speed.
• Make sure the transmission oil temperature is above
NOTE: Engage park brake before checking oil level. 38°C (100°F).
• Keep oil level at the “FULL” mark on the sight glass.
OIL LEVEL
IMPORTANT: The 18-speed PST should always be

in the PARK position before starting
DPSG,YZ07927,25 –19–12MAY99–1/1

121007
PN=24
General Information
01
Intervals For Changing Transmission Oil Filters 10
9
IMPORTANT: Change filter after the first 100 hours oil is bypassing the filter. Change
of transmission operation. The filter the oil filter if a “Filter Bypass
change intervals given here are for Signal” is indicated and the
normal service conditions. If the transmission is at normal operating
transmission is to be operated in temperature.
severe conditions contact the Funk
Service Department for additional • Change oil filter anytime the transmission is at
recommendations. normal operating temperature and a “Filter Bypass
Signal” is indicated.
FIRST OIL AND FILTER CHANGE: • Change oil and filter anytime there are signs of
contamination in the oil or the oil has a burnt odor.
• Change oil filter after first 100 hours of transmission • Change filter at every 750 hours or if indicator light
operation. comes on. Change filter and oil every 1500 hours of
transmission operation or if indicator light comes on.
ROUTINE OIL AND FILTER MAINTENANCE:
IMPORTANT: Some vehicles are equipped with

devices to alert the operator when
DPSG,YZ07927,26 –19–12MAY99–1/1

121007
PN=25
General Information
01
10 Fill The Transmission With Oil (Wheel Tractors Only)
10
AFTER INSTALLING TRANSMISSION IN VEHICLE: 8. Start the engine, run at 2100 rpm, with transmission
in park position, for at least 5 minutes to fill axles
1. Park machine on level surface. and return oil from the axles to the transmission.
2. Engage parking brake, block wheels.
3. Put transmission in PARK. CAUTION: While engine is running personal
injury may occur, if steering wheel is turned
IMPORTANT: Failure to prefill axles will shorten while checking oil level on sight gauge.
the life of the transmission.
9. Fill transmission with transmission-Hydraulic Oil at
4. Prefill axles with oil. fill tube. Oil level should be between the top two
5. Remove oil filler cap from oil fill tube on marks on the site gauge.
transmission.
6. Begin filling operation: IMPORTANT: Do not overfill transmission. This
will cause overheating. Damage to
Specification the transmission will result.
System Capacities—HY-GARD
JDM J20C Oil without PTO ........................................................ 129 L
(34 gal)
1. Stop engine and allow the oil level to stabilize in the
HY-GARD JDM J20C Oil with sight gauge for at least 5 minutes. Recheck oil level
PTO............................................................................................. 131 L and refill at fill tube as necessary.
(35 gal) 2. The final oil level at the completion of this checking
procedure, with engine off, should be between
marks at the top of the sight gauge.
IMPORTANT: The transmission will not hold
enough oil to supply axles, oil lines NOTE: During tractor operation, oil can appear foamy
and cooler on start-up. If in sight gauge.
transmission is operated outside the
proper oil level damage will occur Oil level in the sight gauge may appear low
which will shorten the life of the while engine is running.
transmission.
7. Check sight gauge.
DPSG,YZ07927,24 –19–10DEC07–1/1

121007
PN=26
General Information
01
Check Oil Lines and Fittings 10
11
Check all oil lines, hoses, and fittings regularly for

CAUTION: Escaping fluid under pressure
leaks or damage. Make sure all clamps are in position
can penetrate the skin causing serious
and tight. Make sure hoses are not twisted or touching
injury. Avoid the hazard by relieving
moving machine parts. If abrasion or wear occurs,
pressure before disconnecting hydraulic or
replace immediately.
other lines. Tighten all connections before
applying pressure. Search for leaks with a
Tubing with dents may cause the oil to overheat. If you
piece of cardboard. Protect hands and body
find tubing with dents, install new tubing immediately.
from high pressure fluids.
IMPORTANT: Tighten fittings as specified in
If an accident occurs, see a doctor
torque chart.
immediately. Any fluid injected into the skin
must be surgically removed within a few
When you tighten connections, use two wrenches to
hours or gangrene may result. Doctors
prevent bending or breaking tubing and fittings.
unfamiliar with this type of injury may call
the Deere & Company Medical Department in
Moline, Illinois, or other knowledgeable
medical source.
DPSG,YZ07927,13 –19–30APR99–1/1
Hydraulic Connections
There are several different combinations for hydraulic Refer to the vehicle repair manual and/or parts
lines and fittings for brakes, differential housings, and information for the actual application of a particular
lubrication lines. axle configuration.
AG,OURX078,695 –19–28JUN00–1/1

121007
PN=27
General Information
01
10 Transmission Storage
12
This procedure applies to those transmissions and • Seal all openings with moisture-proof covers or tape.
components that have been tested according to Funk • Spray 113 mL (4 oz) of atomized NOX RUST1 VCI
Manufacturing test specifications and have had the oil No. 10 oil or an equivalent into oil drain hole. This
drained from them prior to shipment. fluid is covered and approved per (MIL-P-46002 and
MIL-I-23310).
The following actions will help protect the unit and • Dip, spray, or brush all exposed unpainted surfaces
component items from internal rust and corrosion with NOX RUST X-110 or equivalent.
damage for approximately one year, provided the
transmissions are stored in a dry area:
1
NOX RUST is a trademark of Daubert Chemical Company.
DPSG,YZ07927,30 –19–12MAY99–1/1
Transmission Removal From Storage
• Wash off all external grease with a safety solvent.

• Remove covers or tape from all openings.
• Drain transmission completely.
• Tag transmission to indicate it needs to be filled with oil
after installing in vehicle.
DPSG,YZ07927,31 –19–12MAY99–1/1
Towing The Vehicle
AVOID DAMAGE TO TRANSMISSION: spring applied park brake and must

be manually pumped off before
• Run engine at idle speed to lubricate the clutches. towing.
— Do not exceed normal vehicle speeds while
towing. —Do not exceed 5 km/h (3 mph)
• If the engine cannot be run: —Tow no further than 2 km (1 mile)
—Disconnect drive line from transmission.
• If drive line can not be disconnected:
IMPORTANT: If the vehicle is equipped with

Internal Park Brake the unit has a
DPSG,YZ07927,29 –19–12MAY99–1/1

121007
PN=28
Section 02
Repair and Adjustments
Contents 02
Page Page
Group 15—Transmission Remove, Repair and Install Oil Filter Head . . . .02-25-6
Repair Stand Safety Precautions. . . . . . . . . . . .02-15-1 Remove, Repair and Install Main
Engine Repair Stand . . . . . . . . . . . . . . . . . . . . .02-15-1 Regulator Valve . . . . . . . . . . . . . . . . . . . . . . .02-25-6
Install Adapter to Engine Rollover Stand . . . . . .02-15-2 Remove and Install Lube Relief Bypass
Install Transmission Mounting Bracket . . . . . . .02-15-2 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-7
Install Transmission to Rollover Stand Remove and Install Cooler Relief Bypass
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-15-3 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-10
Remove Transmission from Rollover Remove Oil Level Sight Glass (Wheel
Stand Bracket . . . . . . . . . . . . . . . . . . . . . . . .02-15-6 Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .02-25-12
Remove and Install Yoke . . . . . . . . . . . . . . . . .02-15-6 Repair Oil Level Sight Glass (Wheel
Replace Input and Output Shaft Seals (In Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .02-25-12
Tractor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-15-8 Install Oil Level Sight Glass (Wheel
Replace Bearing Retainer O-Ring Seals . . . . . .02-15-9 Tractors Only) . . . . . . . . . . . . . . . . . . . . . . .02-25-13
Group 20—Electrical Group 30—Pump Drive

Remove and Install Wiring Harness Bracket . . .02-20-1 Remove and Install Oil Line to Input
Replacing the Transmission Wiring Harness . . .02-20-2 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-1
Front Housing Sensors and Ports . . . . . . . . . .02-20-14 Remove and Install Transmission Vent
Rear Housing Sensors and Ports . . . . . . . . . .02-20-16 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-2
Proportional Solenoid Identification - Left Remove Pump Drive Cover. . . . . . . . . . . . . . . .02-30-2
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-18 Disassemble and Assemble Pump Drive
Proportional Solenoid Identification - Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-3
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-20 Install Pump Drive Cover. . . . . . . . . . . . . . . . . .02-30-3
Remove Proportional Solenoid . . . . . . . . . . . .02-20-22 Remove, Repair and Install Oil Pump Gear
Install Proportional Solenoid Valve . . . . . . . . .02-20-23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-5
Remove and Install Input and Cylinder Remove Transmission Oil Pump . . . . . . . . . . . .02-30-8
Speed Magnetic Pickup Sensors . . . . . . . . .02-20-25 Disassemble, Inspect and Assemble
Remove and Install Fifth Stage Magnetic Transmission Oil Pump . . . . . . . . . . . . . . . . .02-30-9
Pickup Sensor (Speed) . . . . . . . . . . . . . . . .02-20-26 Install Transmission Oil Pump . . . . . . . . . . . . .02-30-11
Remove and Install Output Magnetic Pickup Remove and Install Pump Drive Input
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-27 Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-13
Remove and Install Oil Filter Head
Pressure Switch. . . . . . . . . . . . . . . . . . . . . .02-20-28 Group 35—Housings, Geartrain and Clutch Shafts
Remove and Install System Pressure Remove Rear Housing With Internal Park
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-20-29 Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-1
Remove and Install Temperature Sensor . . . .02-20-30 Disassemble Rear Housing . . . . . . . . . . . . . .02-35-14
Remove Clutch Shaft Sealing Ring Sleeve
Group 25—Hydraulics Old Style Rear Housing Design . . . . . . . . . . . . . . . . . . . . .02-35-16
System Components . . . . . . . . . . . . . . . . . . . . .02-25-1 Install Bore Sleeves Old Style Rear Housing Design. . . . . . .02-35-18
Remove and Install Suction Screen. . . . . . . . . .02-25-2 Remove Clutch Assemblies. . . . . . . . . . . . . . .02-35-19
Remove and Install Oil Filter . . . . . . . . . . . . . . .02-25-3 Exploded View— Output Shaft Without
Remove and Install Oil Filter Inlet Tube . . . . . .02-25-4 Internal Park Brake . . . . . . . . . . . . . . . . . . .02-35-22
Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-4 Exploded View— Output Shaft With Internal
Remove Oil Filter Switch . . . . . . . . . . . . . . . . . .02-25-5 Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . .02-35-23
Disassemble and Assemble Filter By-Pass
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-5 Continued on next page

121007
PN=1
Contents
Page Page
Remove and Install Axle Pump Stand Pipe . . .02-35-24 Cross-Sectional View—Seventh Stage Clutch
Remove, Disassemble and Assemble Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-53
02 Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-24 9620 Series Exploded View—Seventh
Remove Suction Tube Old Style Rear Housing . . . . . . . .02-35-27 Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-54
Remove Suction Tube. . . . . . . . . . . . . . . . . . .02-35-28 9620 Series Cross-Sectional View—
Install Output Shaft Assembly . . . . . . . . . . . . .02-35-29 Seventh Stage Clutch Shaft Assembly. . . . .02-35-55
Install Suction Tube Old Style Rear Housing . . . . . . . . . .02-35-30 Disassembly and Assembly of Clutch Stage
Install Suction Tube. . . . . . . . . . . . . . . . . . . . .02-35-30 Shaft Assemblies . . . . . . . . . . . . . . . . . . . . .02-35-56
Remove and Install Output Shaft Oil Dam. . . .02-35-31 Disassemble and Assemble Second Stage
Exploded View—First Stage Shaft Assembly Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-56
(Input Shaft). . . . . . . . . . . . . . . . . . . . . . . . .02-35-31 Disassemble and Assemble Fifth Stage Shaft
Exploded View—Second Stage Clutch Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-32 Disassemble and Assemble Seventh
Cross-Sectional View—Second Stage Clutch Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-82
Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-33 Disassemble and Assemble Sixth Stage
9620 Series Exploded View—Second Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-83
Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-34 Disassemble and Assemble Fourth Stage
9620 Series Cross-Sectional View— Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-86
Second Stage Clutch Shaft Assembly . . . . .02-35-35 Disassemble and Assemble Third Stage
Exploded View—Third Stage Clutch Shaft Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-93
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-36 Install Clutch Assemblies. . . . . . . . . . . . . . . . .02-35-96
Cross-Sectional View—Third Stage Clutch Install Rear Housing . . . . . . . . . . . . . . . . . . . .02-35-97
Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-37 Bearing Adjustment of Output Shaft Rear
9620 Series Exploded View—Third Stage Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-99
Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-38 Internal Park Brake Assembly . . . . . . . . . . . .02-35-102
9620 Series Cross-Sectional View—Third Bearing Adjustments to Clutch Stage
Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-39 Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-109
Exploded View—Fourth Stage Clutch Shaft Install Clutch Rotation Tools . . . . . . . . . . . . .02-35-110
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-40 Bearing Adjustment Of Fifth and Sixth
Cross-Sectional View—Fourth Stage Clutch Clutch Stage Shaft Assemblies . . . . . . . . .02-35-112
Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-41 Bearing Adjustment of Second, Third,
9620 Series Exploded View—Fourth Fourth and Seventh Clutch Stage Shaft
Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-42 Assemblies . . . . . . . . . . . . . . . . . . . . . . . .02-35-114
9620 Series Cross-Sectional View— Bearing Adjustment of Output Shaft Front
Fourth Stage Clutch Shaft Assembly . . . . . .02-35-43 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-120
Exploded View—Fifth Stage Clutch Shaft Bearing Adjustment of Input Shaft . . . . . . . . .02-35-123
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-44
Cross-Sectional View—Fifth Stage Clutch
Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-45
9620 Series Exploded View—Fifth Stage
Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-46
9620 Series Cross-Sectional View—Fifth
Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-47
Exploded View—Sixth Stage Clutch Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-48
Cross-Sectional View—Sixth Stage Clutch
Shaft Assembly . . . . . . . . . . . . . . . . . . . . . .02-35-49
9620 Series Exploded View—Sixth Stage
Clutch Shaft Assembly. . . . . . . . . . . . . . . . .02-35-50
9620 Series Cross-Sectional View—Sixth
Stage Clutch Shaft Assembly. . . . . . . . . . . .02-35-51
Exploded View—Seventh Stage Clutch Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-52

121007
PN=2
Group 15
Transmission
Repair Stand Safety Precautions
The engine repair stand should be used only by To prevent possible personal injury due to
qualified service technicians familiar with this transmission slippage, recheck to make sure
equipment. transmission is solidly mounted before releasing
02
support from transmission lifting device. 15
To maintain shear strength specifications, alloy steel 1
SAE Grade 8 or higher cap screws must be used to Never permit any part of the body to be positioned
mount adapters or transmission. under a load being lifted or suspended. Accidental
slippage may result in personal injury.
For full thread engagement, be certain that tapped
holes in adapters and transmission are clean and not The lifting jack is to be used when it is necessary to lift
damaged. A thread length engagement equal to 1-1/2 the transmission for rotation. When working on the
screw diameters minimum is required to maintain transmission, the jack should be at its lowest position
strength requirements. to keep the center of gravity low and the possibility of
tipping low.
To avoid structural or personal injury, do not exceed
the maximum capacity rating of 2722 kg (6000 lb). To prevent possible personal injury due to sudden
Maximum capacity is determined with the center of the transmission movement, lower transmission by
transmission located not more than 330 mm (13 in.) operating jack release valve slowly. Do not unscrew
from the mounting hub surface of the engine stand. release valve knob more than two turns from its closed
position.
To avoid an unsafe off-balance load condition, the
center of balance of the transmission must be located
within 51 mm (2 in.) of the engine stand rotating shaft.
DPSG,YZ07927,129 –19–15JUL99–1/1
Engine Repair Stand
NOTE: Only the 2722 kg (6000 lb) heavy-duty engine

rollover stand (A) No. DO5223ST manufactured
by Owatonna Tool Co., Owatonna, Minnesota is
referenced in this manual. When any other repair
stand is used, consult the manufacturer’s
instructions for mounting the transmission.
Refer to TM1623 (W) or TM1782 (T) technical manual for

steps to remove transmission from machine before
–UN–05DEC97
installing it on rollover stand.
A—Engine Rollover Stand

RG4929
DPSG,YZ07927,128 –19–15AUG03–1/1

121007
PN=31
Transmission
Install Adapter to Engine Rollover Stand
NOTE: The 205466 Engine Mounting Adapter if furnished

with the D05223ST Engine Rollover Stand.
02
15 Attach the No. 205466 Engine Adapter (A) to mounting
2 hub of D05223ST Engine Rollover Stand using SAE
Grade 8 Socket-Head screws (B).
Tighten screws.
–UN–28FEB01
Specification
Socket-head Cap
Screw-to-Repair Stand.—Torque ................................................. 135 N•m
RXA0052046
(100 lb-ft)
Remove end adapter (C) from engine mounting adapter

(A) if adapter is fastened to engine mounting adapter.
A—205466 Engine Mounting Adapter

B—Socket-Head Cap Screws (3 used)
C—51400 End Adapter
DPSG,YZ07927,127 –19–15JUL99–1/1
Install Transmission Mounting Bracket
Obtain JDG1476 Engine Rollover Stand Bracket.
IMPORTANT: Use the cap screws provided with the

brackets and tighten to correct
specification.
Install top bracket (A) to engine mounting adapter (D) and

tighten cap screws (B) and (C).
Specification
Bracket-to-Adapter Cap Screws
(B)—Torque .................................................................................. 300 N•m
(225 lb-ft)
Adapter-to-Bracket Cap Screws
(C)—Torque .................................................................................. 550 N•m
(400 lb-ft)
A—Top Bracket
–UN–26FEB01
B—Bracket-to-Adapter Cap Screws (2 used)

C—Adapter-to-Bracket Cap Screws (2 used)
D—Engine Mounting Adapter
RXA0051530
Continued on next page OURX078,0000008 –19–27JAN01–1/2

121007
PN=32
Transmission
Install bottom bracket (A) to adapter (B) and tighten cap

screws (C).
Specification
Adapter-to-Bracket Cap Screws
(C)—Torque .................................................................................. 550 N•m 02
(400 lb-ft) 15
3
A—Bottom Bracket
B—Engine Mounting Adapter
C—Adapter-to-Bracket Cap Screws
–UN–26FEB01
RXA0051529
OURX078,0000008 –19–27JAN01–2/2
Install Transmission to Rollover Stand

Bracket
Install adapter to engine rollover stand. (See Install

Adapter to Engine Rollover Stand, this group.)
Install transmission mounting bracket to engine mounting

adapter. (See Install Transmission Mounting Bracket, this
group.)
Rotate the transmission mounting bracket to the vertical

position.
–UN–26FEB01
RXA0051531
Continued on next page OURX078,0000009 –19–15APR03–1/3

121007
PN=33
Transmission
Position transmission with right side in mounting bracket

as shown.
Install bracket-to-transmission cap screws (A) and tighten.

02
Specification
15
Bracket-to-Transmission Cap
4
Screws—Torque ........................................................................... 475 N•m
(350 lb-ft)
A—Bracket-to-Transmission Cap Screws
–UN–26FEB01
RXA0051526

121007
PN=34
Transmission
Install bottom bracket-to-transmission cap screws (A) and

tighten.
Specification
Bottom Bracket-to-Transmission
Cap Screws (A)—Torque ............................................................. 240 N•m 02
(175 lb-ft) 15
5
Install outer bracket (B) to top bracket (C) and install cap
screws (D) and (E) and tighten.
Specification
Outer Bracket-to-Top Bracket
Cap Screws (D)—Torque ............................................................. 550 N•m
(400 lb-ft)
Outer Bracket-to-Transmission
Cap Screws (E)—Torque ............................................................. 475 N•m
(350 lb-ft)
A—Bottom Bracket-to-Transmission Cap Screws

B—Top/Outer Bracket
–UN–27FEB01
C—Top Bracket
D—Outer Bracket-to-Top Bracket Cap Screws
E—Outer Bracket-to-Transmission Cap Screws
F—Lift Chains
G—Lifting Brackets
RXA0051525
Old Style Transmission to Bracket
OURX078,0000009 –19–15APR03–3/3

121007
PN=35
Transmission
Remove Transmission from Rollover Stand

Bracket
Install JDG19 Lifting Brackets (G) and lift chains (F) and
02 attach to an overhead hoist.
15
6 Remove transmission assembly from mounting bracket in
reverse order of installation.
A—Bottom Bracket-to-Transmission Cap Screws

B—Top/Outer Bracket
C—Top Bracket
D—Outer Bracket-to-Top Bracket Cap Screws
E—Outer Bracket-to-Transmission Cap Screws
F—Lift Chains
G—JDG19 Lifting Brackets
–UN–27FEB01
RXA0051525
Old StyleTransmission to Bracket
OURX078,000000A –19–27JAN01–1/1
Remove and Install Yoke
NOTE: All yokes are installed and removed in the same

manner.
–UN–26FEB01
Install JDG924 Yoke Holding Tool (A) to yoke (B) using

yoke cap screws (C).
Remove yoke retaining cap screw.

RXA0051503
A—Yoke Holding Tool

B—Yoke
C—Cap Screws Remove Rear Output Yoke
Continued on next page OURX078,0000006 –19–27JAN01–1/3

121007
PN=36
Transmission
NOTE: Degrease cap screw threads and input shaft

tapped hole threads using a non-petroleum based
solvent.
Install yoke (A) to input shaft.

02
–UN–05FEB01
15
Apply T43512 Thread Lock and Sealer to cap screw 7
threads.
RXA0051502
Install O-ring (B), washer (C) and cap screw (D).
A—Yoke
B—O-Ring Install Rear Output Yoke
C—Washer
D—Yoke Retaining Cap Screw
OURX078,0000006 –19–27JAN01–2/3
Install JDG924 Yoke Holding Tool to the yoke to prevent

the yoke from rotating while tightening.
Tighten cap screw.
–UN–26FEB01
Specification
Input Yoke-to-Shaft Cap Screw—
Torque .......................................................................................... 435 N•m
(320 lb-ft)
RXA0051524
Tighten Rear Output Yoke Cap Screw
OURX078,0000006 –19–27JAN01–3/3

121007
PN=37
Transmission
Replace Input and Output Shaft Seals (In

Tractor)
NOTE: All shaft oil seals are removed and installed in the
02 same manner.
–UN–05FEB01
15
8 Disconnect driveline.
Remove yoke. (See Remove and Install Yoke, this group.)
RXA0051500
Remove and discard old oil seal.
Position new oil seal (A) in bearing retainer bore. Replace Input Shaft Oil Seal
A—Oil Seal
Install JDG1487A Seal Installer Plate (B). B—Seal Installer Plate
C—Bearing Installer
Position the JDG926A Bearing Installer (C) in the bore of
the seal installer plate.
DPSG,YZ07927,328 –19–05DEC07–1/2
Force the seal into the bearing retainer until the seal
bottoms on the bearing retainer oil seal flange.
Install yoke. (See Remove and Install Yoke, this group.)
–UN–05FEB01
Connect drive line.
A—Seal Installer Plate

B—Bearing Installer RXA0051501
Install Input Shaft Oil Seal
DPSG,YZ07927,328 –19–05DEC07–2/2

121007
PN=38
Transmission
Replace Bearing Retainer O-Ring Seals
Input Shaft

02
–UN–02FEB01
15
Remove bearing retainer cap screws (A), bearing retainer 9
(B) and shim pack (C).
RXA0051493
Do not lose or misplace the shim pack.
A—Bearing Retainer Cap Screws (4 used)

B—Bearing Retainer
C—Shaft End Play Shim Pack
OURX078,000000B –19–03JUN05–1/10
Remove and discard O-ring oil seal (B).
Lubricate new O-ring with transmission fluid and install on

bearing retainer.
–UN–05FEB01
A—Bearing Retainer
B—O-Ring Oil Seal
C—Shim Pack
RXA0051498
OURX078,000000B –19–03JUN05–2/10
Install the same shim pack (C) that was removed.
Install bearing retainer (B) and install and tighten cap

screws (A). –UN–02FEB01
Specification
Bearing Retainer-to-Front
Housing Cap Screws—Torque ....................................................... 87 N•m
(64 lb-ft)
RXA0051493

C—Shim Pack
Continued on next page OURX078,000000B –19–03JUN05–3/10

121007
PN=39
Transmission
Old Style Output Shaft without Internal Park Brake
Remove bearing retainer cap screws (A), bearing retainer

02
–UN–01MAR01
15 (B) and shim pack (C).
10
Do not lose or misplace shim pack.
RXA0051494
OURX078,000000B –19–03JUN05–4/10
Lubricate new O-rings with transmission fluid and install

on spacer and bearing retainer.
–UN–01MAR01
B—Bearing Retainer O-Ring Oil Seal
C—Shim Pack
RXA0051499
OURX078,000000B –19–03JUN05–5/10
Install bearing retainer (B).
Install and tighten bearing retainer cap screws (A).

–UN–01MAR01
Specification
(64 lb-ft)
RXA0051494


121007
PN=40
Transmission
Fifth and Sixth Clutch Stage Shafts
NOTE: Both the fifth and sixth stage clutch shaft O-ring
seals are replaced in the same manner.
02
–UN–02FEB01
Remove bearing retainer cap screws (A), bearing retainer 15
(B) and shim pack (C). 11
Do not lose or misplace the shim pack.
RXA0051495
C—Shaft End Play Shim Pack Sixth Stage Shaft Bearing Retainer
OURX078,000000B –19–03JUN05–7/10

bearing retainer.
–UN–02FEB01
B—O-Ring Oil Seal
C—Shim Pack
RXA0051496
OURX078,000000B –19–03JUN05–8/10
Install bearing retainer (B) and install and tighten cap

screws (A). –UN–02FEB01
Specification
(64 lb-ft)
RXA0051495
Second, Third, Fourth and Seventh Clutch Stage

Shafts
Sixth Stage Bearing Retainer
Bearing retainers for the second, third, fourth and seventh
clutch stage shafts are located behind the pump drive A—Bearing Retainer Cap Screws (4 used)
cover and DO NOT have O-ring seals. B—Bearing Retainer

121007
PN=41
Transmission
9620 Series
Earlier version of the 18-speed PST were not equiped

with thrust washers on shaft stage assemblies. When
repairing the 18-speed PST replace bearing retainers of
02
15 the old style with the new style bearing retainers, thrust
12 washers and screw.
–UN–31MAY05
A—Second Clutch Stage Shaft
B—Third Clutch Stage Shaft
C—Fourth Clutch Stage Shaft
D—Seventh Clutch Stage Shaft
YZ6213
OURX078,000000B –19–03JUN05–10/10

121007
PN=42
Group 20
Electrical
Remove and Install Wiring Harness Bracket
02
20
1
–UN–14APR03
YZ5047
A—Wiring Harness
–19–23SEP05–1/1

121007
PN=43
Electrical
Replacing the Transmission Wiring Harness
Should replacement of the entire transmission wiring to prevent mislocation, but the references listed below
harness become necessary, the following procedure should be used to correctly identify solenoids or
should be used. sensors if there is any doubt.
02
20
2 IMPORTANT: Correct routing and connection of The following references in Group 25 may prove
the harness is essential for proper helpful.
transmission operation. It also vital
that all connections are SECURELY • Transmission Wiring Harness
made, with connector locking tabs • Transmission Wiring Harness Table (for wire colors
engaged. and circuit numbers).
• Front Housing Sensors and Ports
It is important to match all harness connectors with • Rear Housing Sensors and Ports
their assigned solenoids or sensors. Identification of • Proportional Solenoid Identification
each branch of the harness can be done in two ways: • Transmission Mating Connector
• Transmission Harness Connector
• Each branch is individually labeled within two inches
of the connector on the end of the branch, Tools needed:
sometimes under the conduit, which can be carefully
pushed back to locate the label. • Ratchet with 16mm socket
• If the label is missing or obscured by paint, use the • 7mm open-end wrench
wire colors and circuit numbers to identify the • Narrow flat-blade screwdriver
branch. • 5/32” hex key / Allen wrench
Identifying labels are cast into the transmission

housing, and the harness branch lengths are designed
Continued on next page YZ07927,0000031A –19–16JUN04–1/17

121007
PN=44
Electrical
NOTE: You can use the new harness on the old

transmission but the bracket must match the style
of rear housing.
1. Begin removal of the existing wiring harness by using a

02
5/32” hex key to disconnect the tractor wiring harness 20
from the transmission wiring harness at the 40-way J6 3
connector located on the lower left side of the
transmission.
–UN–08APR03
NOTE: For this procedure, “left side” and “right side”
designations are defined by standing at the output
shaft side and facing the rear of the transmission.
YZ3935
J6 Connector Location New Style Rear Housing
–UN–09NOV01
YZ3473
YZ07927,0000031A –19–16JUN04–2/17
2. Disconnect the transmission harness connectors from
–UN–09NOV01
the solenoid valves, speed sensors, filter switch,
temperature sensor, and pressure sensor.
NOTE: When disconnecting the harness, it may be

YZ3474
helpful to use a narrow, flat-blade screwdriver to

pry gently up on the connector locking tab,
especially for the cylinder and output speed
sensors and the temperature sensor, which can
be more difficult to disconnect.

121007
PN=45
Electrical
3. Remove the two 16mm bolts securing the J6 connector

mounting bracket.
Install and tighten cap screws (A).
–UN–09NOV01
02
Specification
20
Wiring Harness Mounting
4
Bracket-to-Rear Housing Cap
YZ3475
Screw—Torque ........................................................................ 50 N&dot;m
(37 lb-ft)
A—Mounting Bracket Cap Srew
–UN–08APR03
YZ3936
New Style Rear Housing
YZ07927,0000031A –19–16JUN04–4/17
4. Remove the four 7mm screws securing the J6

connector to the mounting bracket. –UN–08NOV01
YZ3476

121007
PN=46
Electrical
5. Begin installation of the new harness by securing the

J6 connector to the mounting bracket, using the
orientation shown in the illustration.
–UN–08APR03
NOTE: The connector is divided into two halves. Install
02
the connector in the bracket so that the half with 20
the most terminals missing is nearest the top of 5
the transmission. This will simplify the harness
YZ3937
routing.
6. Secure the mounting bracket to the transmission, and

secure the yellow plastic terminal cover with tape until
ready to reconnect the tractor wiring harness.
YZ07927,0000031A –19–16JUN04–6/17
7. Make the connection to the clutch H solenoid, located

just above the mounting bracket.
–UN–08APR03
YZ3938

121007
PN=47
Electrical
NOTE: All wiring harness connectors have label tags that

corresponds with the mating connector.
02
20
6
–UN–09APR03
YZ3959
YZ07927,0000031A –19–16JUN04–8/17
8. Position the major harness branch near the lower

elbow of the metal tube as shown.
9. Identify the main branch carrying the input and cylinder

speed sensors and the connections for solenoids 2, A,
and M.
10. Route this branch below the main regulator and up

around the metal tube, as shown in the illustration.
–UN–08APR03
A—Route Over Tube
B—Main Regulator
C—Major Harness Branch
YZ3939
Rear View of Transmission

121007
PN=48
Electrical
11. Routing its harness to the outboard side of the metal

tube, make the connection to solenoid 2, which is the
topmost solenoid on the left side.
12. Routing its harness to the outboard side of the metal

02
tube, make the connection to solenoid A, located just 20
below solenoid 2. 7
IMPORTANT: Do not swap the connections for

solenoids 2 and A. Identify using
branch labels and circuit numbers; wire
colors for 2 and A are the same.
13. Route the harness for solenoid M between the

transmission housing and the branch which will be
routed up to the input and cylinder speed sensors.
IMPORTANT: Make certain that wires and conduit are

not positioned against sharp metal
edges in the area around the tube
–UN–08APR03
fitting.
A—Input and Cylinder Speed Sensor Branch
YZ3940
B—Solenoid 2 Branch
C—Clutch A Solenoid
D—Solenoid M Branch Routed Inboard of Speed
Sensors Branch

121007
PN=49
Electrical
14. The final connections on the left side are for the input
and cylinder speed sensors.
IMPORTANT: Make especially certain that the locking

tabs are securely engaged on these two
02
20 sensors, as these are the most difficult
8 to access for service when the
transmission is installed in the tractor.
–UN–08APR03
The wiring harness branch must go
over the top of the transmission behind
the oil tube as shown in the artwork.
YZ3941
The harness will be damaged if installed
wrong.
A—Input / Cylinder Speed Wiring Harness Branch

B—Input Speed Sensor (Left Front of Transmission)
C—Cylinder Speed Sensor
YZ07927,0000031A –19–16JUN04–11/17
15. Route the remaining major harness branch parallel to

the metal tube as shown, and make connections to
the system pressure (A) and Oil Pressure sensors
(B).
–UN–08APR03
16. Make the filter pressure switch connection behind the
main harness branch.
A—System Pressure Sensor YZ3942
B—Oil Pressure Sensor

121007
PN=50
Electrical
17. Make connections to solenoids 1 and B.

solenoids 1 and B. Identify using
branch labels and wire colors.
02
20
A—Clutch 1 (Forward Directional Clutch), Third Stage 9
Assembly
B—Clutch B (Speed Clutch), Third Stage Assembly
C—Clutch R (Reverse Directional Clutch), Fourth
Stage Assembly
D—Clutch C (Speed Clutch), Fourth Stage Assembly
–UN–08APR03
YZ3943

121007
PN=51
Electrical
18. Continuing down the right side of the transmission,

make connections to solenoids R and C.

solenoids R and C. Identify using
02
20 branch labels and wire colors.
10
A—Clutch 1 (Forward Directional Clutch), Third Stage
Assembly
B—Clutch B (Speed Clutch), Third Stage Assembly
C—Clutch R (Reverse Directional Clutch), Fourth
Stage Assembly
D—Clutch C (Speed Clutch), Fourth Stage Assembly
–UN–08APR03
YZ3943

121007
PN=52
Electrical
19. Continuing down the right side of the transmission,

make connections to solenoid L, fifth-stage speed
sensor (branch is labeled “INT”) and the Temperature
Sensor (A).
02
A—Temperature Sensor 20
B—Clutch L Solenoid 11
C—Fifth-Stage Speed Sensor
–UN–08APR03
YZ3944
YZ07927,0000031A –19–16JUN04–15/17
20. The final connections on the right side are for the
output #1 and output #2 speed sensors.
IMPORTANT: Do not swap the connections for the

output speed sensors. Identify using
branch labels and wire colors.
A—Output #1 Speed Sensor

B—Output #2 Speed Sensor
–UN–08APR03
YZ3945

121007
PN=53
Electrical
21. Secure the harness to the metal tube with a cable tie
at each of the two locations shown. The ties should
be snug, but not so tight that they deform the conduit
or draw it too tightly against the tube fitting.
02
20 22. Reconnect the tractor wiring harness to the
12 transmission at the 40-way J6 connector located on
the lower left side of the transmission.
23. Make a final check to verify that at the various
–UN–08APR03
branches in the harness, no exposed wires are drawn
tight across fittings or the transmission housing. Verify
that there are no harness pinch or rub points arising
from interference with hydraulic hoses or the tractor
YZ3946
frame, especially if this was the reason for replacing
the harness.
A—Cable Ties
YZ07927,0000031A –19–16JUN04–17/17

121007
PN=54
Electrical
02
20
13

121007
PN=55
Electrical
Front Housing Sensors and Ports
02
20
14
–UN–11OCT01
YZ1910A
Front Housing Without Internal Park Brake
A—Output Speed Sensors B—Output Speed Sensors C—Axle Lube Pump Air D—Front Axle Lube Return
(Top) (Bottom) Suction Port (9/16-18 Port (1 1/16-12 UN-2B)
UNF-2B)
Continued on next page OURX078,0000001 –19–13AUG03–1/2

121007
PN=56
Electrical
02
20
15
–UN–08APR03
YZ3933
Front Housing With Internal Park Brake
A—Output Speed Sensors B—Output Speed Sensors C—Axle Lube Pump Air D—Front Axle Lube Return
(Top) (Bottom) Suction Port (9/16-18 Port (1 1/16-12 UN-2B)
UNF-2B)
OURX078,0000001 –19–13AUG03–2/2

121007
PN=57
Electrical
Rear Housing Sensors and Ports
02
20
16
–UN–21SEP01
YZ1906B
Rear Housing Without Internal Park Brake
A—Lube Pressure Test Port F—C Clutch Pressure Port J—PTO Pressure Supply Port N—System Pressure Check
B—M Clutch Pressure Port G—R Clutch Pressure Port K—PTO Oil Drain Back Port Port
C—PTO Lube Port H—Transmission Oil Filter L—Vent to Axle Housing (T) O—H Clutch Pressure Port
D—Temperature Sensor Switch M—System Pressure Sensor
E—Diff-Lock Supply Pressure I—Fifth Stage Magnetic Pickup
Port Sensor (Speed)

121007
PN=58
Electrical
02
20
17
–UN–02MAY03
YZ3947
Rear Housing With Internal Park Brake
A—Lube Pressure Test Port F—C Clutch Pressure Port J—PTO Pressure Supply Port O—H Clutch Pressure Port
B—M Clutch Pressure Port G—R Clutch Pressure Port K—PTO Oil Drain Back Port P—Internal Park Brake Check
C—PTO Lube Port H—Transmission Oil Filter L—Vent to Axle Housing (T) Valve Assembly
D—Temperature Sensor Switch M—System Pressure Sensor Q—Internal Park Brake
E—Diff-Lock Supply Pressure I—Fifth Stage Magnetic Pickup N—System Pressure Check Release Port
Port Sensor (Speed) Port
OURX078,0000003 –19–13AUG03–2/2

121007
PN=59
Electrical
Proportional Solenoid Identification - Left Side
02
20
18
–UN–19SEP01
YZ1888A
Left Side Rear Housing Without Internal Park Brake
A—Clutch 2 (Forward B—Clutch A (Speed Clutch), C—Clutch M (Medium Range), D—Clutch H (High Range),
Directional Clutch), Second Second Stage Assembly Seventh Stage Assembly Sixth Stage Assembly
Stage Assembly

121007
PN=60
Electrical
02
20
19
–UN–08APR03
YZ3948
Left Side Rear Housing With Internal Park Brake
A—Clutch 2 (Forward B—Clutch A (Speed Clutch), C—Clutch M (Medium Range), D—Clutch H (High Range),
Directional Clutch), Second Second Stage Assembly Seventh Stage Assembly Sixth Stage Assembly
Stage Assembly
OURX078,0000002 –19–14AUG03–2/2

121007
PN=61
Electrical
Proportional Solenoid Identification - Right Side
02
20
20
–UN–19SEP01
YZ1889A
Right Side Rear Housing Without Internal Park Brake
A—Clutch 1 (Forward B—Clutch B (Speed Clutch), D—Clutch C (Speed Clutch), E—Clutch L (Low Range), Fifth
Directional Clutch), Third Third Stage Assembly Fourth Stage Assembly Stage Assembly
Stage Assembly C—Clutch R (Reverse
Directional Clutch), Fourth
Stage Assembly

121007
PN=62
Electrical
02
20
21
–UN–08APR03
YZ3949
Right Side Rear Housing With Internal Park Brake
A—Clutch 1 (Forward B—Clutch B (Speed Clutch), D—Clutch C (Speed Clutch), E—Clutch L (Low Range), Fifth
Directional Clutch), Third Third Stage Assembly Fourth Stage Assembly Stage Assembly
Stage Assembly C—Clutch R (Reverse
Directional Clutch), Fourth
Stage Assembly
OURX078,0000004 –19–14AUG03–2/2

121007
PN=63
Electrical
Remove Proportional Solenoid
Remove WEATHER PACK connector (A).
Remove nut (B).

02
20
22 Remove coil (C).
A—Weather Pack Connector
–UN–08APR03
B—Valve Spool Nut
C—Coil
YZ3950
WEATHER PACK is a trademark of Packard Electric DPSG,YZ07927,306 –19–15APR03–1/3
NOTE: A deep-well socket is required to remove the

valve stem.
Remove proportional valve stem.
A—Proportional Cartridge Valve Stem
–UN–08APR03
YZ3951
DPSG,YZ07927,306 –19–15APR03–2/3
Inspect components and replace as necessary.
A—O-Ring (3 used)
B—Valve Stem
C—Solenoid Coil
D—Nut
–UN–04DEC00
YZ3019
DPSG,YZ07927,306 –19–15APR03–3/3

121007
PN=64
Electrical
Install Proportional Solenoid Valve
Install solenoid valve stem (A).
02
20
23
–UN–08APR03
YZ3952
DPSG,YZ07927,307 –19–15APR03–1/4
Tighten valve stem.
Specification
Proportional Cartridge Valve
Stem-to-Rear Housing—Torque .............................................. 16—20 N•m
(142—177 lb-in.)
–UN–21APR03
YZ3953
Continued on next page DPSG,YZ07927,307 –19–15APR03–2/4

121007
PN=65
Electrical
Install coil (A) and nut (B).
Install WEATHER PACK connector (C).
02 A—Coil
20 B—Solenoid Coil Retainer Nut
24 C—Weather Pack Connector
–UN–09APR03
YZ3954
Tighten solenoid coil retainer nut (A).
Specification
Tighten Solenoid Coil Retainer
Nut-to-Coil—Torque............................................................... 4.5—6.8 N•m
(40—60 lb-in.)
A—Solenoid Coil Retainer Nut
–UN–09APR03
YZ3955
DPSG,YZ07927,307 –19–15APR03–4/4

121007
PN=66
Electrical
Remove and Install Input and Cylinder Speed

Magnetic Pickup Sensors
Remove input speed magnetic pickup sensor (A).

02
Remove cylinder speed magnetic pickup sensor (B). 20
25
–UN–09APR03
A—Input Speed Magnetic Pickup Sensor
B—Cylinder Speed Magnetic Pickup Sensor
YZ3956
DPSG,YZ07927,163 –19–15APR03–1/3
Check sensors for contamination.
Remove and inspect O-ring (A) and discard.
–UN–09APR03
Install new O-ring onto magnetic sensors.
A—Magnetic Pickup Sensor O-Ring
YZ3957
DPSG,YZ07927,163 –19–15APR03–2/3
NOTE: All wiring harness connectors have label tags that

corresponds with the mating connector.
Install sensors (A) and (B) into housing and tighten. –UN–09APR03
Specification
Magnetic pickup sensor-to-front
housing—Torque ..................................................................... 16—20 N•m
(142—177 lb-in.)
YZ3958
A—Input Speed Magnetic Pickup Sensor

B—Cylinder Speed Magnetic Pickup Sensor
DPSG,YZ07927,163 –19–15APR03–3/3

121007
PN=67
Electrical
Remove and Install Fifth Stage Magnetic

Pickup Sensor (Speed)
NOTE: This sensor is used for calibration and shifting.

02
20 Remove fifth stage speed magnetic pickup sensor (A).
26
A—Magnetic Pickup Sensor
–UN–09APR03
YZ3960
DPSG,YZ07927,169 –19–10DEC07–1/3
Check for wear or damage and discard.
Install new O-ring
–UN–05DEC00
A—O-Ring
YZ3010
Continued on next page DPSG,YZ07927,169 –19–10DEC07–2/3

121007
PN=68
Electrical
Install sensor (A) into housing and tighten.
Specification
Magnetic pickup
sensor-to-housing—Torque ................................................... 16—20 N•m
(142—177 lb-in.) 02
20
27
A—Magnetic Pickup Sensor
–UN–09APR03
YZ3960
DPSG,YZ07927,169 –19–10DEC07–3/3
Remove and Install Output Magnetic Pickup

Sensors
Remove output speed magnetic pickup sensors (A).
A—Output Magnetic Pickup Sensors
–UN–09APR03
YZ3961

121007
PN=69
Electrical
Check sensors for contamination.
Replace O-ring (A) on sensors.
Install sensors into housing and tighten.
–UN–05DEC00
02
20
28 Specification
Magnetic pickup
sensor-to-housing—Torque ..................................................... 16—20 N•m
YZ3010
(12—15 lb-ft)
A—Magnetic Pickup Sensor O-Ring
DPSG,YZ07927,168 –19–15APR03–2/2
Remove and Install Oil Filter Head Pressure

Switch
Disconnect pressure switch WEATHER PACK connector

(A).
Remove switch.
Install new pressure switch
Tighten pressure switch.
Connect pressure switch connector.
–UN–09APR03
A—Pressure Switch Connector
YZ3962

121007
PN=70
Electrical
Remove and Install System Pressure Sensor
Disconnect WEATHER PACK connector (A).
Remove system pressure sensor.

02
20
A—System Pressure Sensor Connector 29
–UN–09APR03
YZ3963
Inspect and discard O-ring (A).
Reverse steps to install system pressure sensor.
Tighten system pressure sensor.
–UN–30NOV00
Specification
System Pressure Sensor-to-Rear
Housing.—Torque........................................................................... 16 N•m
(142 lb-in.)
A—System Pressure Sensor O-Ring YZ3003
DPSG,YZ07927,296 –19–15APR03–2/2

121007
PN=71
Electrical
Remove and Install Temperature Sensor
Disconnect connector and remove temperature sensor

(A).
02
20 A—Temperature Sensor
30
–UN–09APR03
YZ3964
DPSG,YZ07927,297 –19–15APR03–1/3
Remove O-ring (A) from temperature sensor and discard.
Install new O-ring onto temperature sensor.
Install and tighten temperature sensor.
–UN–09APR03
Specification
Temperature Sensor-to-Rear
Housing—Torque........................................................................... 16 N•m
(142 lb-in.)
YZ3965
DPSG,YZ07927,297 –19–15APR03–2/3
NOTE: Old Style Temperature Sensor are located in the

center of the rear housing. The new style rear
housing the Temperature Sensor is located on the
right side of the rear housing.
Install and tighten temperature sensor.
Specification
Temperature Sensor-to-Rear
–UN–30NOV00
(142 lb-in.)
YZ3005
Old Style Temperature Sensor Location
DPSG,YZ07927,297 –19–15APR03–3/3

121007
PN=72
Group 25
Hydraulics
System Components
02
25
1
–UN–09APR03
YZ3966
Internal Park Brake Rear Housing System Components
A—Cooler Relief Bypass Valve D—Filter Bypass Valve F—Oil Filter H—Oil Fill Tube (Wheel Tractor
B—Main Regulator Valve E—Oil Filter Head G—Suction Screen Assembly Only)
C—Oil Filter Head Inlet Tube
YZ07927,0000479 –19–23SEP05–1/1

121007
PN=73
Hydraulics
Remove and Install Suction Screen
Remove cap screws (A).
02 A—Suction Screen Cover Cap Screws

25
2
–UN–09APR03
YZ3967
YZ07927,000047A –19–23SEP05–1/5
Remove suction screen cover (A).
Remove and discard O-ring (B)
A—Suction Screen Cover

B—O-Ring
–UN–09APR03
YZ3968
YZ07927,000047A –19–23SEP05–2/5
Remove suction screen (A).
Inspect for damage or contamination and clean or replace

as necessary.
A—Suction Screen
–UN–09APR03
YZ3969
Continued on next page YZ07927,000047A –19–23SEP05–3/5

121007
PN=74
Hydraulics
Install suction screen.
Lubricate new O-ring (B) with transmission fluid and install

on suction screen cover (A).
02
A—Suction Screen Cover 25
3
–UN–09APR03
B—O-Ring
YZ3968
YZ07927,000047A –19–23SEP05–4/5
Install suction screen cover assembly onto rear housing

and tighten cap screws.
Specification
Suction Screen Cover-to-Rear
Housing Cap Screw—Torque......................................................... 55 N•m
(40 lb-ft)
–UN–09APR03
YZ3970
YZ07927,000047A –19–23SEP05–5/5
Remove and Install Oil Filter
Remove oil filter (A).
Lubricate rubber gasket on new oil filter.
Install new oil filter onto oil filter head.

–UN–09APR03
Turn new oil filter until filter makes contact with oil filter
head and tighten 1/2 turn after contact.
YZ3971
A—Oil Filter
YZ07927,000047B –19–23SEP05–1/1

121007
PN=75
Hydraulics
Remove and Install Oil Filter Inlet Tube
Remove oil filter inlet tube (A).
IMPORTANT: Install oil filter inlet tube hand tight onto

02
25 filter head before tightening bolts in
4 filter head. Then tighten oil filter inlet
tube.
Install tube in reverse order.
–UN–09APR03
A—Oil Filter Inlet Tube
YZ3972
YZ07927,000047C –19–23SEP05–1/1
Oil Filter Head
–UN–09APR03
YZ3973
A—System Pressure (Filtered) B—By-Pass Valve D—Oil from Oil Pump E—By-Pass Oil (unfiltered) to
Oil C—Transmission Oil Filter Lube
Switch
YZ07927,000047D –19–23SEP05–1/1

121007
PN=76
Hydraulics
Remove Oil Filter Switch
NOTE: The filter head assembly is not a service item.

The following information is for cleaning only.
02
Remove oil filter switch. 25
5
Remove Filter By-Pass Valve Cap (A).
A—Filter By-Pass Valve Cap
–UN–09APR03
YZ3974
YZ07927,000047E –19–23SEP05–1/1
Disassemble and Assemble Filter By-Pass

Valve
A—O-Ring
B—Spring
C—Spool
–UN–09APR03
YZ3975
YZ07927,000047F –19–23SEP05–1/1

121007
PN=77
Hydraulics
Remove, Repair and Install Oil Filter Head
02
25
6
–UN–09APR03
YZ3976
YZ07927,0000480 –19–23SEP05–1/1
Remove, Repair and Install Main Regulator

Valve
Remove main regulator valve (A).
–UN–09APR03
A—Regulator Valve
YZ3979
YZ07927,0000481 –19–23SEP05–1/3
NOTE: The only serviceable items are the O-rings (A).
The Main Regulator Valve controls system pressure

throughout the transmission and is preset to 1790—1930
kPa (265—275 psi) at a flow of 99—106L (26—28 gpm) in
a temperature range of 130—150°C (105—115°F). If
system pressure falls out-of-tolerance, the main regulator
will need to be replaced.
–UN–09APR03
Remove and replace O-rings (A).

YZ3980
Continued on next page YZ07927,0000481 –19–23SEP05–2/3

121007
PN=78
Hydraulics
Install and tighten main regulator valve (A).
Specification
Regulator Valve-to-Housing—
Torque .......................................................................................... 142 N•m
(105 lb-ft) 02
25
7
–UN–09APR03
YZ3981
YZ07927,0000481 –19–23SEP05–3/3
Remove and Install Lube Relief Bypass Valve
Remove
Remove plug (A) on rear of transmission housing.
–UN–13DEC05
A—Plug
YZ6307

121007
PN=79
Hydraulics
Install JDG1808A Relief Valve Tool (A) into opening and

thread into the valve located in the internal bore.
A—JDG1808A
02
25
8
–UN–10APR06
YZ6480
–UN–10APR06
YZ6481
YZ07927,0000482 –19–12SEP06–2/8
Remove JDG1808A (A) with valve (B) attached.
Remove valve from tool.
–UN–10APR06
A—JDG1808AValve Removal Tool
B—Lube Relief Bypass Valve
YZ6482
YZ07927,0000482 –19–12SEP06–3/8
Inspect, clean or discard the valve as necessary.

–UN–10APR03
YZ3985

121007
PN=80
Hydraulics
Install
IMPORTANT: Install relief valve using JDG1808A

relief valve tool. The relief valve is made
02
of thin material and can be damaged. 25
–UN–10APR06
Tap lightly until the valve is fully 9
seated, or risk damaging the valve.
1. Install Relief Valve (A) onto JDG1808A Relief Valve
YZ6483
Tool (B).
A—Relief Valve
B—JDG1808A Relief Valve Removal Tool
YZ07927,0000482 –19–12SEP06–5/8
2. Attach JDG1808A to rear housing.
–UN–10APR06
YZ6484
YZ07927,0000482 –19–12SEP06–6/8
IMPORTANT: The lube relief valve is made of thin

material and can be damaged. Tap
lightly until the valve is fully seated, or
risk damaging the valve.
3. Install relief valve.

–UN–10APR06
YZ6485

121007
PN=81
Hydraulics
4. Install plug (A).

5. Tighten plug.
02
25
10
–UN–10APR06
YZ6479
YZ07927,0000482 –19–12SEP06–8/8
Remove and Install Cooler Relief Bypass

Valve
Remove
NOTE: The cooler relief bypass valve is located in the oil

cooler line housing bore (B) behind the main
regulator valve (A).
–UN–13DEC05
Remove main regulator valve (A).
YZ6308
A—Main Regulator Valve
B—Oil Cooler Line Housing Bore
YZ07927,0000483 –19–12SEP06–1/5
Install JDG1808A Relief Valve Tool (A) into oil cooler bore
opening.
Remove the tool (A) with valve (B) attached.

–UN–24APR06
A—JDG1808A Relief Valve Removal Tool

B—Cooler Relief Valve
YZ6486

121007
PN=82
Hydraulics
Remove the valve from the tool.
Install
02
IMPORTANT: Install relief valve using JDG1808A 25
–UN–10APR03
relief valve Tool. The relief valve can be 11
easily damaged during installation.
1. Clean or discard valve as necessary.
YZ3985
YZ07927,0000483 –19–12SEP06–3/5
2. Install cooler relief valve onto JDG1808A relief valve

removal tool.
IMPORTANT: The cooler relief valve is made of thin

material and can be damaged. Tap
lightly until the valve is fully seated, or
risk damaging the valve. The JDG1808A
is designed to provide a slide hammer
action for removing relief valves and by
–UN–17APR06
reversing the slide it is a guide to aid in
installing relief valves.
3. Push the slide into the valve bore located in the rear
YZ6487
housing.
4. Install cooler relief valve.
YZ07927,0000483 –19–12SEP06–4/5
5. Install main regulator valve (A).

6. Tighten main regulator valve (A).
Specification
Regulator Valve-to-Rear
Housing—Torque.......................................................................... 142 N•m
(105 lb-ft)
–UN–13DEC05
A—Main Regulator Valve

YZ6310
YZ07927,0000483 –19–12SEP06–5/5

121007
PN=83
Hydraulics
Remove Oil Level Sight Glass (Wheel

Tractors Only)
A—Sight Glass Cap Screws

02
25
12
–UN–26JAN01
YZ1993A
YZ07927,0000484 –19–23SEP05–1/1
Repair Oil Level Sight Glass (Wheel Tractors

Only)
A—O-Ring
–UN–16APR01
RXA0052610
Sight Glass
YZ07927,0000485 –19–23SEP05–1/1

121007
PN=84
Hydraulics
Install Oil Level Sight Glass (Wheel Tractors

Only)
Install and tighten cap screws.

02
Specification 25
Sight Glass Cap Screw-to-Rear 13
(142 lb-in.)
–UN–30NOV00
YZ1995
Install Sight Glass
YZ07927,0000486 –19–23SEP05–1/1

121007
PN=85
Hydraulics
02
25
14

121007
PN=86
Group 30
Pump Drive
Remove and Install Oil Line to Input Bearing
Remove lube oil line connector (A) from pump drive

housing fitting.
02
Remove fitting and replace O-rings as necessary. 30
1
A—Lube Oil Line Connector
–UN–06MAR01
RXA0052190
DPSG,YZ07927,308 –19–05DEC00–1/2
Remove lube oil line connector (A) from rear housing

fitting.
Remove oil line.
Remove fitting and replace O-ring as necessary.
Install fittings and line in reverse order.
A—Lube Oil Line Connector

–UN–05MAR01
RXA0052186
DPSG,YZ07927,308 –19–05DEC00–2/2

121007
PN=87
Pump Drive
Remove and Install Transmission Vent

Fitting
Remove and replace fitting (A) as necessary.

02
–UN–05MAR01
30 A—Fitting
2
RXA0052188
OURX078,0000001 –19–05MAR01–1/1
Remove Pump Drive Cover
Remove transmission from vehicle. (See TM1623 (W) or

TM1782 (T).)
Install transmission to rollover stand bracket. (See Install
–UN–27NOV00
Transmission to Rollover Stand Bracket, Group 15.)
Remove input bearing lube oil line from front cover. (See
Remove and Install Lube Oil Line to Input Bearing, this
YZ1959
group.)
Remove yoke. (See Remove and Install Input Yoke, A—Cap Screws
Group 15.) B—Spacer and Retainer with Oil Seal
C—Shims
Remove four cap screws (A).
Remove spacer and retainer with oil seal (B).
Remove shims (C).
OURX078,0000007 –19–15AUG03–1/3
Remove pump drive housing cap screws (A).
A—Pump Drive Housing Cap Screws (15 used)

–UN–27NOV00
YZ1960
Pump Drive Housing


121007
PN=88
Pump Drive
NOTE: Guide pins may be fabricated by removing the

heads from M12 x 130 mm cap screws.
Install guide pins (A) into the housing across from each
other.
02
30
Install JDG19 Lifting Brackets (B) and attach lift chains (C) 3
to a lifting device.
Remove drive housing cover (D).
–UN–01FEB01
A—Guide Pins (2 used)
B—Lifting Brackets
C—Lift Chains
RXA0051492
D—Pump Drive Housing Cover
OURX078,0000007 –19–15AUG03–3/3
Disassemble and Assemble Pump Drive

Cover
Inspect dowel pins (A) for wear or damage and replace as

necessary.
NOTE: Dowel pin holes provide a slip fit.
–UN–09APR03
Install new dowel pins to protrude 15 mm (0.6 in.).
A—Dowel Pins (2 used)
YZ3989
DPSG,YZ07927,301 –19–15APR03–1/1
Install Pump Drive Cover
Apply a thin film of TY16021 High-Flex Form-in-Place

Gasket to housing surface (A).
A—Front Housing Gasket Surface

–UN–22JAN01
YZ3175
Continued on next page DPSG,YZ07927,399 –19–15AUG03–1/4

121007
PN=89
Pump Drive

Install guide pins (A) into the housing across from each
other.
02
30
4 Install JDG19 Lifting Brackets (B) and attach lift chains (C)
to a lifting device.
Install pump housing cover (D).
–UN–01FEB01
A—Guide Pins (2 used)
B—Lifting Brackets
C—Lift Chains
RXA0051492
D—Pump Drive Cover
DPSG,YZ07927,399 –19–15AUG03–2/4
Install cover-to-housing cap screws (15 used) and tighten.
Specification
Pump Cover-to-Housing Cap
Screws—Torque ............................................................................ 50 N•m
(37 lb-ft)
–UN–17JAN01
YZ3172

121007
PN=90
Pump Drive
Install shims (C) and spacer and retainer (B).
Specification
Input Shaft 02
–UN–27NOV00
Spacer/Retainer-to-Cover Cap 30
Screws—Torque ............................................................................. 87 N•m 5
(64 lb-ft)
YZ1959
Install yoke. (See Remove and Install Input Yoke, Group
15.)
Install input bearing lube oil line to housing. (See Remove A—Cap Screws (4 used)
and Install Lube Oil Line to Input Bearing, this group.) B—Spacer and Retainer with Oil Seal
C—Shims
Remove transmission from rollover stand bracket. (See

Remove Transmission from Rollover Stand Bracket,
Group 15.)
Install transmission to vehicle. (See TM1623 (W) or

TM1782 (T).)
DPSG,YZ07927,399 –19–15AUG03–4/4
Remove, Repair and Install Oil Pump Gear

Assembly
Remove pump drive cover. (See Remove Pump Drive

Cover, this group.)
NOTE: Oil pump gear assembly is a slip fit and will not
–UN–27NOV00
require special tools to remove or install.
Remove oil pump gear assembly (A).

YZ1962
A—Oil Pump Gear Assembly
Continued on next page DPSG,YZ07927,177 –19–20SEP99–1/5

121007
PN=91
Pump Drive
Inspect gear and bearings and replace parts as

necessary.
02
30
6
–UN–01FEB01
RXA0051482
DPSG,YZ07927,177 –19–20SEP99–2/5
If necessary install tools and remove bearings (A) using a

hydraulic press.
A—Roller Bearings
B—D01267AA Bearing Puller
C—Spacer Disks
–UN–01FEB01
RXA0051483
DPSG,YZ07927,177 –19–20SEP99–3/5
CAUTION: Heat parts in a bearing heater. Use a

thermometer and do not exceed 150°C (300°F).
Plan a safe handling procedure to avoid burns.
Install heated bearings (A) on gear shaft so bearings are

–UN–01FEB01
tight against shoulder.
A—Roller Bearings
RXA0051484

121007
PN=92
Pump Drive
NOTE: Oil pump gear assembly is a slip fit and does not
require special tools to install.
Install oil pump gear assembly (A) into hydraulic oil pump.
02
Install pump drive cover. (See Install Pump Drive Cover, 30
this group.) 7
–UN–27NOV00
A—Oil Pump Gear Assembly
YZ1963
DPSG,YZ07927,177 –19–20SEP99–5/5

121007
PN=93
Pump Drive
Remove Transmission Oil Pump
NOTE: The old style oil pump has (A) Pump

Cover-to-Housing Cap Screw, (B) Pump
Assembly-to-Front Housing Cap Screws 6 used,
02
30 (C) Oil Pump Assembly.
8
Remove oil pump gear assembly. (See Remove, Repair
and Install Oil Pump Gear Assembly, this group.)
Remove cap screws (A) and remove pump assembly (B).
–UN–27FEB01
A—Pump Cover-to-Housing Cap Screw
B—Oil Pump Assembly
RXA0051497
Old Stryle Oil Pump
–UN–09APR03
YZ3990
New Style Oil Pump

121007
PN=94
Pump Drive
Inspect, remove and discard O-rings (A)
A—O-Rings
02
30
9
–UN–09APR03
YZ3992
DPSG,YZ07927,322 –19–15APR03–2/2
Disassemble, Inspect and Assemble

Transmission Oil Pump
Remove cap screw (A) and separate cover (B) from

housing (C).
A—Cover-to-Housing Cap Screw

B—Cover
C—Housing
–UN–09APR03
YZ3993

121007
PN=95
Pump Drive
IMPORTANT: Mark gears with a marker. Gears must

be re-installed exactly the same as
before inspection.
Mark pump gears (C).

02
30
10 Inspect parts for wear or damage.
A—Cover
B—Housing
C—Pump Gears
D—Cover Pump Gear Bores
–UN–09APR03
YZ3994
OURX078,0000005 –19–15APR03–2/3
Remove pump gears (A) from housing.
Inspect parts for wear or damage and replace as

necessary.
Lubricate parts with transmission fluid.
Align pump gears and assemble in reverse order.
–UN–09APR03
Specification
Pump Cover-to-Housing Cap
Screw—Torque ............................................................................... 50 N•m
(37 lb-ft)
YZ3995
A—Pump Gears
B—Housing Pump Gear Bores
C—Housing
OURX078,0000005 –19–15APR03–3/3

121007
PN=96
Pump Drive
Install Transmission Oil Pump
NOTE: For the old style front housings, guide pins may
be fabricated by removing the heads from M10 x
100 mm cap screws to guide the oil pump onto
02
the housing. The old style pump, oil sump suction 30
tube will not protrude through front housing. The 11
new style front housing has the oil sump tube that
can be used as a guide for installing the oil pump.
–UN–09APR03
Clean oil pump-to-housing mating surface.
YZ3996
A—Oil Sump Tube
DPSG,YZ07927,323 –19–15APR03–1/3
Lubricate and install new O-rings (A) to oil pump

assembly.
A—O-Rings
–UN–09APR03
YZ3992

121007
PN=97
Pump Drive
Install oil pump assembly (B).
Specification
02 Oil Pump Assembly-to-Front
30 Housing Cap Screws—Torque ....................................................... 50 N•m
12 (37 lb-ft)
–UN–09APR03
Install oil pump gear assembly. (See Remove, Repair and
Install Oil Pump Gear Assembly, this group.
A—Pump Cover-to-Housing Cap Screw
YZ3990
B—Oil Pump Assembly
DPSG,YZ07927,323 –19–15APR03–3/3

121007
PN=98
Pump Drive
Remove and Install Pump Drive Input Gear
Remove pump drive cover and oil pump gear assembly.

(See Remove, Repair and Install Oil Pump Gear
Assembly, this group.)
02
30
Install tools and remove bearing cone (A). 13
A—Bearing Cone
C—457 mm (18 in.) Puller Legs
D—270 kN (30 Ton) Push Puller
E—180 kN (20 Ton) Hydraulic Bottle Jack
F—Spacer Disks
–UN–01FEB01
RXA0051481
DPSG,YZ07927,405 –19–22FEB07–1/4
Install tools and remove pump drive input gear (A).
A—Pump Drive Gear

B—JDG1473 Pump Drive Gear Puller
D—180 kN (20 Ton) Hydraulic Bottle Jack
E—Spacer Disks
F—270 kN (30 Ton) Push Puller
–UN–30JAN01
RXA0051434
Continued on next page DPSG,YZ07927,405 –19–22FEB07–2/4

121007
PN=99
Pump Drive
Place input gear (A) onto input shaft.
Install forcing screw (C) into threaded input shaft.
Place the sleeve (B) over the forcing screw and install
02
30 washer and nut (D).
14
Tighten forcing screw nut (C) to properly position input
gear onto input shaft.
A—Pump Drive Input Gear

B—JDG1472AA Pump Drive Gear Installer Sleeve
C—JDG1472A Pump Drive Gear Installer Forcing
Screw
D—JDG1472A Pump Drive Gear Installer Forcing
Screw Nut and Washer
–UN–30JAN01
RXA0051435
DPSG,YZ07927,405 –19–22FEB07–3/4

Install heated bearing (A) on shaft so bearing cone is tight

against shoulder.
Install oil pump gear assembly and pump cover. (See

Remove, Repair and Install Oil Pump Gear Assembly, this –UN–01FEB01
group.)
A—Bearing Cone
RXA0051487
DPSG,YZ07927,405 –19–22FEB07–4/4

121007
PN=100
Group 35
Housings, Geartrain and Clutch Shafts
Remove Rear Housing With Internal Park
Brake
Remove yoke assembly.

02
Remove oil filter. 35
1
A—Yoke Assembly
B—Oil Filter
–UN–10APR03
YZ3997

121007
PN=101
02
35
2
–UN–10APR03
YZ3998
SEQUENCE FOR REMOVING BRAKE COVER CAP Remove cap screws following procedure below.
SCREWS.
1. Loosen cap screw labeled number 1 one complete
IMPORTANT: The brake cover is under belleville turn.
spring pressure. All brake cover cap
screws must be removed in 2. Loosen cap screw number 2 one complete turn.
sequence. Failure to remove in
sequence will result in damage to 3. Loosen cap screw number 3 one complete turn.
Internal Park Brake Cover and cap
screws. 4. Loosen cap screw number 4 one complete turn.
Beside each cap screw is a number 5. Loosen cap screw number 5 one complete turn.
that has been cast into the Internal
Park Brake Cover. The numbers one 6. Loosen cap screw number 6 one complete turn.
through seven and the numbered
sequence must be followed 7. Loosen cap screw number 7 one complete turn.
whenever removing or installing the
Internal Park Brake Cover. When 8. Continue loosening cap screws, one complete turn,
removing or installing cap screws in sequence until all tension is relaxed.
turn the cap screw no more than one
complete turn then move to the next
numbered cap screw. Keep all cap
screws evenly engaged.

121007
PN=102
IMPORTANT: All belleville tension will be relaxed

when you can measure 17.78 mm (.700
in.) gap between rear housing and
brake cover housing.
02
Failure to follow SEQUENCE FOR 35
REMOVING BRAKE COVER CAP 3
SCREWS, group 35 will result in
damage to the transmission.
–UN–10APR03
YZ3999
DPSG,YZ07927,315 –19–12SEP06–3/25
Remove cap screws 3 and 6 after tension is removed

from all cap screws.
Install guide pins (A) into cap screw bores 3 and 6.
–UN–10APR03
A—Guide Pin
YZ5000

121007
PN=103
IMPORTANT: When removing Brake Cover with

transmission in vertical position slowly
remove brake cover be sure the
belleville (B) doesn’t fall and damage
output shaft bearing, spline or falls out
02
35 causing personel injury.
4
Remove brake cover.
–UN–10APR03
A—Wet Brake Cover
B—Belleville Spring
YZ5001
DPSG,YZ07927,315 –19–12SEP06–5/25
Remove Belleville (A).
Remove Spacer (B).
Remove Belleville (C).
A—Belleville
–UN–23APR03
B—Spacer
C—Belleville
YZ5002
DPSG,YZ07927,315 –19–12SEP06–6/25
Remove lube tube.
Inspect for wear or damage.
Discard O-ring.
–UN–10APR03
A—Lube Tube
YZ5003

121007
PN=104
Rotate transmission to horizontal position.
Remove output bearing.
02
35
5
–UN–10APR03
YZ5004
DPSG,YZ07927,315 –19–12SEP06–8/25
Remove Piston with gear pullers.
NOTE: The Seal Ring (A) can be located on the piston or

inside the rear housing internal park brake
assembly bore.
Remove seal ring (A).
Inspect for wear and damage.
Discard seal ring (A).
A—Seal Ring
–UN–10APR03
YZ5005

121007
PN=105
IMPORTANT: Use caution not to damage the spacer.
Remove Brake Spacer (A).
02 A—Brake Spacer
35
6
–UN–21JUN04
YZ5006A
DPSG,YZ07927,315 –19–12SEP06–10/25
Remove Brake Spacer seals.
Inspect inner and outer seal for wear or damage.
Discard inner and outer seal ring.
A—Outer seal ring
–UN–21JUN04
YZ5184

121007
PN=106
Remove Separator and brake disks.
Remove oil sump filter assembly (A).
A—Oil Sump Filter Assembly 02

35
7
–UN–10APR03
YZ5007
DPSG,YZ07927,315 –19–12SEP06–12/25
I BRAKE VALVES AND SENSORS
A—Brake 2 Valve Assembly

B—Brake Pressure Sensor
C—Brake 1 Valve Assembly
–UN–10APR03
YZ5008

121007
PN=107
CAUTION: If working on transmission in the

vehicle, personal injury can occur when
removing park brake components which are
under pressure. The park brake pressure
02 system may be under pressure if one of the two
35 park brake valves stick open, even with the
–UN–10APR03
8
engine off.
When diagnosing the park brake system,

always attach a pressure gauge to the park
YZ5009
brake pressure port before removing any park
brake component.
A—Coil Nut
NOTE: The brake valve assemblies have washers behind B—Coil
the coils for clearance. These are the only two C—Washer
solenoid valves that will have washers behind the
coils. Failure to install washers will cause damage
to the coil.
Remove coil nut (A) coil (B) and washers (C).
DPSG,YZ07927,315 –19–12SEP06–14/25
IMPORTANT: While possible to install Park 2 into

park 1. Doing so will prevent the brake
from functioning correctly.
Remove Brake Valves.
Inspect for wear and damage.
Remove and discard O-rings.
A—Brake 2
B—Brake 1
–UN–10APR03
YZ5010

121007
PN=108
Remove Brake Pressure Sensor (A).
A—Brake Pressure Sensor
02
35
9
–UN–17APR06
YZ6488
–UN–24APR06
YZ5011A
DPSG,YZ07927,315 –19–12SEP06–16/25
Remove Brake Pressure Relief Valve.

–UN–17APR06
YZ6489

121007
PN=109
IMPORTANT: The relief valve used behind the main

regulator valve and used in the cooler
port are not the same relief valve as
used in the brake system. Do not mix
and match relief valves.
02
35
–UN–10APR03
10 Inspect for wear and damage.
YZ3985
DPSG,YZ07927,315 –19–12SEP06–18/25
Install
1. Place relief valve onto JDG1808A.

2. Place into Rear housing into brake pressure sensor
bore.
–UN–17APR06
YZ6489
DPSG,YZ07927,315 –19–12SEP06–19/25
3. Screw JDG1808A (A) into rear housing.
IMPORTANT: The relief valve is made of thin material

and can be damaged. Tap lightly until
the valve is fully seated, or risk
damaging the valve. Do not install
without using JDG1808A tooling. Failure
to use the JDG1808A could damage the
relief valve. –UN–17APR06
4. Install relief valve.

YZ6490
A—JDG1808A Relief Valve Tool

121007
PN=110
5. Install Brake Pressure Sensor (A).
A—Brake Pressure Sensor
02
35
11
–UN–17APR06
YZ6493
–UN–17APR06
YZ6491
DPSG,YZ07927,315 –19–12SEP06–21/25
6. Tighten Brake Pressure Sensor.
Specification
Brake Pressure Sensor-to-Rear
Housing—Torque............................................................................ 18 N•m
13 (lb-ft)
–UN–17APR06
YZ6492

121007
PN=111
Install transmission to rollover stand bracket. (See Install

Transmission to Rollover Stand Bracket, Group 15.)
Drain oil from transmission assembly.

02
35 Remove all yokes. (See Remove and Install Yoke, Group
12 15.)
Remove hydraulic oil pump. (See Remove Hydraulic Oil

Pump, Group 30.)
–UN–30JAN01
Remove pump drive input gear. (See Remove and Install
Pump Drive Input Gear, Group 30.)
RXA0051433
Remove wiring harness bracket and wiring harness. (See
Remove Wiring Harness Bracket and Wiring Harness,
Group 20.)
A—Rear-to-Front Housing Cap Screws (24 used)
Remove all proportional solenoid valves. (See Remove
Proportional Solenoid, Group 20.)
Remove all magnetic pickup sensors. (See Remove

Output Magnetic Pickup Sensors, Remove and Install
Input and Cylinder Speed Magnetic Pickup Sensors and
Remove and Install Fifth Stage Magnetic Pickup Sensor
(Speed), Group 20.)
Remove suction screen. (See Remove and Install Suction

Screen, Group 25.)
Remove oil filter. (See Remove and Install Oil Filter,

Group 25.)
Remove oil filter head. (See Remove, Repair and Install

Oil Filter Head, Group 25.)
Remove rear-to-front housing cap screws (A).

Install four guide pins, one at each corner of rear cover.

121007
PN=112
Install JDG1489 Transmission Rear Cover Lifting Bracket

(A) to suction screen cover threaded holes.
Install JDG19 Lifting Brackets (B) or Equivalent.

02
–UN–02FEB01
A—Lift Bracket 35
B—Lifting Brackets (3 used) 13
RXA0051599
DPSG,YZ07927,315 –19–12SEP06–24/25
Attach lift chains (A) to brackets and overhead hoist.
NOTE: Housing joint is sealed with liquid gasket and may

have to be pried apart.
Keep the rear housing parallel with the front

housing, while lifting, to avoid binding the clutch
shafts in the rear housing.
Carefully remove rear cover from transmission assembly.
A—Lift Chains
–UN–10APR03
YZ5014
DPSG,YZ07927,315 –19–12SEP06–25/25

121007
PN=113
Disassemble Rear Housing
Remove plug with O-ring.
Inspect for contamination or damage.

02
35
14 Remove and discard O-ring (A).

plug.
Install and tighten plug.
–UN–10APR03
A—Diagnostic Receptacle
B—Plug with O-ring
YZ5012
OURX078,000000C –19–15APR03–1/4
–UN–05JAN01
YZ3095
Continued on next page OURX078,000000C –19–15APR03–2/4

121007
PN=114
Turn rear housing (A) over.
A—Rear Housing
02
35
15
–UN–10APR03
YZ5015
OURX078,000000C –19–15APR03–3/4
NOTE: Bearing cups are a slip fit.
Remove bearing cups (A).
A—Rear Housing Bearing Cups (7 used)
–UN–10APR03
YZ5016
OURX078,000000C –19–15APR03–4/4

121007
PN=115
Remove Clutch Shaft Sealing Ring Sleeve Old Style Rear Housing Design
02
35
16
–UN–03AUG99
YZ1896
Old Style Rear Housing Clutch Shaft Sealing Ring Sleeves
A—Fourth Stage Bore Sleeve C—Second Stage Bore Sleeve E—Sixth Stage Bore Sleeve F—Fifth Stage Bore Sleeve
B—Third Stage Bore Sleeve D—Seventh Stage Bore Sleeve
Continued on next page DPSG,YZ07927,316 –19–16JUN04–1/4

121007
PN=116
NOTE: Old style rear housing are equipped with bore

sleeves. New style rear housings design is without
bore sleeves.
NOTE: For Blind Hole Puller (B), use JT01732 and for
02
Forcing Screw and Nut, use JT01716 Forcing 35
–UN–30JAN01
Screw and JT01717 Nut from D01061AA Blind 17
Hole Puller Set
Assemble the sleeve remover tool.
YZ3049A
A—JDG1490 Sealing Ring Bore Sleeve Remover
Sleeve
B—JTO1732 Collet
C—JTO1717 Forcing Screw and Nut
DPSG,YZ07927,316 –19–16JUN04–2/4
Insert the tool into the sleeve and expand the blind hole
puller to firmly attach beneath the inner end of the sleeve
in the bore.
Tighten the forcing screw nut (A) to remove the sleeve

from the bore.
A—Nut
–UN–07DEC00
YZ3050

121007
PN=117
Inspect bore sleeve (A) for wear and damage.
A—Bore Sleeve
02
35
18
–UN–07DEC00
YZ3053
Bore Sleeve
DPSG,YZ07927,316 –19–16JUN04–4/4
Install Bore Sleeves Old Style Rear Housing Design
IMPORTANT: Bore Sleeve (A) must be installed as

shown. The inside chamfer (B) must be
facing out.
–UN–30JAN01
Position the sleeve (A) in the bore with the inside chamfer
(B) facing out.
YZ3054A
A—Bore Sleeve
B—Sleeve Inside Chamfer
–UN–01FEB01
RXA0051485

121007
PN=118
Install bore sleeve with JDG1479 Sealing Ring Sleeve

Installer (A).
Install until installer tool bottoms on housing face.

02
A—Sealing Ring Sleeve Installer 35
19
–UN–07DEC00
YZ3055
DPSG,YZ07927,317 –19–15APR03–2/2
Remove Clutch Assemblies
Remove rear housing. (See Remove Rear Housing, this

group.)
IMPORTANT: DO NOT install used seal rings when

assembling transmission.
Remove and discard seal rings from all clutch assemblies.
–UN–06JAN01
YZ3106

121007
PN=119
Place JDG1471 Clutch Stack Lifting Fixture (A) onto

clutch assemblies.
A—Clutch Stack Lifting Fixture

02
35
20
–UN–10APR03
YZ5017
DPSG,YZ07927,363 –19–15APR03–2/5
Secure the latches (A) and install the input shaft retaining
cap (B).
NOTE: Keep the lifting fixture parallel with the housing

surface to prevent the clutch shafts from binding
in the housing.
Carefully remove the clutch nest from the front housing

using an overhead hoist.
A—Clutch Assembly-to-Lifting Fixture Latches

B—First Stage (Input Shaft) Retaining Cap
–UN–10APR03
YZ5018

121007
PN=120
Place clutch stack nest into JDG1470 Clutch Stack Nest

Fixture.
A—Clutch Stack Nest Fixture

02
35
21
–UN–30JAN01
RXA0051429
DPSG,YZ07927,363 –19–15APR03–4/5
NOTE: Keep the lifting fixture parallel with the housing

in the housing.
Disengage clutch assembly latches, remove input shaft

retaining cap and remove clutch assembly lifting tool.
–UN–28FEB01
RXA0051428
DPSG,YZ07927,363 –19–15APR03–5/5

121007
PN=121
Exploded View— Output Shaft Without Internal Park Brake
B
02
35
22
–UN–01MAR01
RXA0052137
A—Eighth Stage 36T L.H. B—Rear Bearing Cone C—Front Bearing Cone
Helical Shaft
DPSG,YZ07927,154 –19–30JUL99–1/1

121007
PN=122
Exploded View— Output Shaft With Internal Park Brake
02
35
23
–UN–30APR03
YZ5048
Output Shaft Assembly With Internal Park Brake
A—Front Bearing Cone B—Eighth Stage 36T L.H. C—Rear Bearing Cone
Helical Shaft
YZ07927,00000B8 –19–30APR03–1/1

121007
PN=123
Remove and Install Axle Pump Stand Pipe
Remove axle pump stand pipe cap screw (A).
Remove pipe and O-ring (B).

02
35
24 Install axle pump stand pipe with New O-ring (B) into
housing.
Install and tighten cap screw (A).
Specification
Axle Pump Stand Pipe-to-Rear
Housing Cap Screw—Torque....................................................... 122 N•m
(90 lb-ft)
A—Cap Screw
B—Stand Pipe with O-Ring
–UN–10APR03
YZ5019
DPSG,YZ07927,161 –19–15APR03–1/1
Remove, Disassemble and Assemble Output

Shaft Assembly
CAUTION: Output shaft assembly weight is

–UN–10APR03
approximately 32.18 Kg (71 lbs).
Remove clutch stack. (See Remove Clutch Assemblies,

this group.)
YZ5021
Remove cap screws (A).
A—Oil Baffle Cap Screws (2 used)

B—Oil Baffle Plate

121007
PN=124
Install JDG1112 Eyebolt (A) and remove output shaft from

transmission front housing using a lifting device.
A—Eyebolt
B—Output Shaft 02
35
25
–UN–10APR03
YZ5020
DPSG,YZ07927,343 –19–15APR03–2/4
Place shaft between sturdy supports.
Install puller tools and remove rear bearing (A) from shaft.

Install heated bearing to shaft tight against shaft shoulder

and allow to cool.
A—Rear Bearing Cone

D—Hydraulic Bottle Jack
E—Spacer Disks
–UN–26FEB01
RXA0051566

121007
PN=125
Turn shaft over and install puller tools.
Remove front bearing cone (A) from shaft.
02 CAUTION: Heat parts in a bearing heater. Use a

35 thermometer and do not exceed 150°C (300°F).
26
Install heated bearing to shaft tight against shaft shoulder

and allow to cool.
A—Front Bearing Cone

D—Hydraulic Bottle Jack
E—Spacer Disks
–UN–26FEB01
RXA0051567
DPSG,YZ07927,343 –19–15APR03–4/4

121007
PN=126
Remove Suction Tube Old Style Rear Housing
Remove cap screw (A) and remove tube.
A—Cap Screw (2) 02
–UN–23MAR01
35
27
RXA0051569
0ld Style Rear Housing
YZ07927,000009F –19–21APR03–1/2
Remove o-ring (A).
Inspect o-ring for wear and damage and discard.
A—O-ring
–UN–06MAR01
YZ3068A
YZ07927,000009F –19–21APR03–2/2

121007
PN=127
Remove Suction Tube
Remove cap screw (A) and remove tube.
02 A—Cap Screws (1 used)

35
28
–UN–10APR03
YZ5022
DPSG,YZ07927,318 –19–15APR03–1/1

121007
PN=128
Install Output Shaft Assembly
Place output shaft assembly (A) into front housing using

JDG1112 Eyebolt (B) and a lifting device.
02
A—Output Shaft Assembly 35
B—Eyebolt 29
–UN–10APR03
YZ5024
DPSG,YZ07927,365 –19–15APR03–1/2
Install oil baffle and tighten cap screws.
Specification
Output Shaft Assembly Cap
Screw-to-Front Housing—Torque................................................... 50 N•m
(37 lb-ft)
–UN–10APR03
Install clutch stack. (See Install Clutch Assemblies, this

group.)
YZ5025
DPSG,YZ07927,365 –19–15APR03–2/2

121007
PN=129
Install Suction Tube Old Style Rear Housing
Lubricate new o-ring (A) with transmission fluid and install

onto suction tube.
02
35 A—Suction Tube O-ring
30
–UN–06MAR01
YZ3069A
YZ07927,00000A0 –19–21APR03–1/1
Install Suction Tube
Position suction tube into front housing.
Install cap screw and tighten.
–UN–10APR03
YZ5026
DPSG,YZ07927,319 –19–15APR03–1/1

121007
PN=130
Remove and Install Output Shaft Oil Dam
Remove cap screws (A) and oil dam.
Inspect dam for wear or damage and replace as

02
necessary. 35
31
Inspect Lubricating bore (B) for contamination.
Install in reverse order, tightening cap screws top

specification.
–UN–10APR03
A—Oil Dam Cap Screws (2 used)
B—Lubricating bore for output shaft bearing
YZ5023
DPSG,YZ07927,320 –19–15APR03–1/1
Exploded View—First Stage Shaft Assembly (Input Shaft)
–UN–02FEB01
YZ501552A
A—First Stage 32 T R.H. B—Rear Bearing Cone

Helical Shaft
DPSG,YZ07927,16 –19–05MAY99–1/1

121007
PN=131
Exploded View—Second Stage Clutch Shaft Assembly
02
35
32
–UN–23MAR01
YZ501577
1—Ring Seal 6—Tapered Bearing Set 11—Retaining Ring 17—Clutch Piston

2—Bearing Cone 7—Retaining Ring 12—Snap Ring Retainer 18—2nd and 4th Shaft
3—Bearing Cone 8—Clutch Plate Retainer 13—Clutch Return Spring (12) Assembly
4—Bearing Cup 9—Clutch Plate (20) 14—Lube Shutoff Washer 19—Ball Bearing (2)
5—46T R.H. Helical Clutch 10—Clutch Separator Plate 15—O-Ring 20—52T R.H. Helical Clutch
Gear (Clutch A) (20) 16—Outer Piston Seal Gear (Clutch 2)
DPSG,YZ07927,152 –19–30JUL99–1/1

121007
PN=132
Cross-Sectional View—Second Stage Clutch Shaft Assembly
9 18 9 20
10 10
3 4 5 6
02
35
2 33
3
13 15 15 13
11 14 14 11 12 19
12
17
–UN–22MAR01
RXA0052435
7 8 16 16 8 7
1—Ring Seal 6—Tapered Bearing Set 11—Retaining Ring 17—Clutch Piston

2—Bearing Cone 7—Retaining Ring 12—Snap Ring Retainer 18—2nd and 4th Shaft
3—Bearing Cone 8—Clutch Plate Retainer 13—Clutch Return Spring (12) Assembly
4—Bearing Cup 9—Clutch Plate (20) 14—Lube Shutoff Washer 19—Ball Bearing (2)
5—46T R.H. Helical Clutch 10—Clutch Separator Plate 15—O-Ring 20—52T R.H. Helical Clutch
Gear (Clutch A) (20) 16—Outer Piston Seal Gear (Clutch 2)
OURX078,0000003 –19–14MAR01–1/1

121007
PN=133
9620 Series Exploded View—Second Stage Clutch Shaft Assembly
02
35
34
–UN–03MAY05
YZ6197
1—Seal Ring (3 used) 7—Clutch Plate (20 used) 13—O-ring (2 used) 18—52T Gear (Clutch 2)
2—Bearing Cone Assembly 8—Separator Plate (20 used) 14—Outer Piston Seal (2 used) 19—Thrust Washer
3—Bearing Cone 9—Retaining Ring (2 used) 15—Piston (2 used) 20—Tapered Roller Bearing
4—Bearing Cup 10—Snap Ring Retainer (2 16—2nd and 4th Shaft 21—46T Gear (Clutch A)
5—Retaining Ring (2 used) used) Assembly 22—Screw
6—Clutch Plate Retainer (2 11—Belleville Spring (12 used) 17—Ball Bearing (2 used)
used) 12—Lube Shutoff Washer (2
used)
YZ07927,000043A –19–09MAY05–1/1

121007
PN=134
9620 Series Cross-Sectional View—Second Stage Clutch Shaft Assembly
02
35
35
–UN–02MAY05
YZ6196
1—Ring Seal (3 used) 7—Belleville Spring (12 used) 13—52T Gear (Clutch 2) 18—Clutch Piston (2 used)
2—Bearing Cone 8—Clutch Plate (20 used) 14—Screw 19—Outer Piston Seal (2 used)
3—Bearing Cone (2 used) 9—Lube Shutoff Washer (2 15—Thrust Washer 20—Bearing Cone Assembly
4—46T Gear (Clutch A) used) 16—Clutch Plate Retainer (2 21—Bearing Cone
5—Retaining Ring (2 used) 10—O-Ring (2 used) used) 22—2nd and 4th Shaft
6—Snap Ring Retainer (2 11—Retaining Ring (2 used) 17—Separator Plate (20 used) Assembly
used) 12—Ball Bearing (2 used)
YZ07927,0000439 –19–09MAY05–1/1

121007
PN=135
Exploded View—Third Stage Clutch Shaft Assembly
02
35
36
–UN–23MAR01
YZ501581
Continued on next page DPSG,YZ07927,151 –19–30JUL99–1/2

121007
PN=136
1—Ring Seal (3) 6—Tapered Bearing Set 12—Snap Ring Retainer (2) 17—Clutch Piston (2)
2—Bearing Cone 7—Retaining Ring (2) 13—Clutch Return Spring (12) 18—Third Shaft Assembly
3—Bearing Cone (2) 8—Clutch Plate Retainer (2) 14—Lube Shutoff Washer (2) 19—Ball Bearing (2)
4—Bearing Cup 9—Clutch Separator Plate (20) 15—O-Ring (2) 20—64T L.H. Helical Clutch
5—Clutch Gear Assembly 10—Clutch Plate (20) 16—Outer Piston Seal (2) Gear (Clutch 1)
(Clutch B) 11—Retaining Ring (2)
02
35
37
DPSG,YZ07927,151 –19–30JUL99–2/2
Cross-Sectional View—Third Stage Clutch Shaft Assembly
5
18 20
9 10 9 10
6
4
3 3
2
13
15 15
11 12 19
11
13 14 14 12
17
–UN–22MAR01
16
RXA0052440
8 8
7 7
5—Clutch Gear Assembly 10—Clutch Plate (20) 16—Outer Piston Seal (2) Gear (Clutch 1)
(Clutch B) 11—Retaining Ring (2)
OURX078,0000004 –19–14MAR01–1/1

121007
PN=137
9620 Series Exploded View—Third Stage Clutch Shaft Assembly
02
35
38
–UN–04MAY05
YZ6199
1—Seal Ring (3 used) 8—Clutch Plate Retainer (2 13—Belleville Spring (12 used) 18—3rd Stage Shaft Assembly
2—Bearing Cone Assembly used) 14—Lube Shutoff Washer (2 19—Ball Bearing (2 used)
3—Bearing Cone 9—Clutch Plate (20 used) used) 20—64T Gear (Clutch I)
4—Bearing Cup 10—Separator Plate (20 used) 15—Outer Piston Seal (2 used) 21—Thrust Washer
5—Gear Assembly (Clutch B) 11—Retaining Ring (2 used) 16—O-Ring (2 used) 22—Screw
6—Tapered Roller Bearing 12—Snap Ring Retainer (2 17—Clutch Piston (2 used)
7—Retaining Ring (2 used) used)
YZ07927,000043C –19–04MAY05–1/1

121007
PN=138
9620 Series Cross-Sectional View—Third Stage Clutch Shaft Assembly
02
35
39
–UN–03MAY05
YZ6198
1—Seal Ring (3 used) 7—Belleville Spring (12 used) 12—Screw 17—Separator Plate (20 used)
2—Bearing Cone Assembly 8—Clutch Plate (20 used) 13—Thrust Washer 18—Clutch Piston (2 used)
3—Bearing Cone 9—Lube Shutoff Washer (2 14—Ball Bearing (2 used) 19—Outer Piston Seal (2 used)
4—Gear Assembly (Clutch B) used) 15—Clutch Plate Retainer (2 20—Tapered Roller Bearing
5—Retaining Ring (2 used) 10—O-Ring (2 used) used) 21—Bearing Cup
6—Snap Ring Retainer (2 11—64T Gear (Clutch I) 16—Retaining Ring (2 used) 22—3rd Stage Shaft Assembly
used)
YZ07927,000043B –19–03MAY05–1/1

121007
PN=139
Exploded View—Fourth Stage Clutch Shaft Assembly
02
35
40
–UN–23MAR01
YZ501583
Continued on next page DPSG,YZ07927,150 –19–30JUL99–1/2

121007
PN=140
5—70T R.H. Helical Clutch 10—Clutch Plate (20) 16—Outer Piston Seal (2) Gear (Clutch R)
Gear (Clutch C) 11—Retaining Ring (2)
02
35
41
DPSG,YZ07927,150 –19–30JUL99–2/2
Cross-Sectional View—Fourth Stage Clutch Shaft Assembly
18
5 9 9 10
10
4 20
3 6 3
2
15 15 13
11 12 19
11
13 14 14
12
17
16
–UN–22MAR01
RXA0052438
8 8
7 7
5—70T R.H. Helical Clutch 10—Clutch Plate (20) 16—Outer Piston Seal (2) Gear (Clutch R)
Gear (Clutch C) 11—Retaining Ring (2)
OURX078,0000005 –19–14MAR01–1/1

121007
PN=141
9620 Series Exploded View—Fourth Stage Clutch Shaft Assembly
02
35
42
–UN–05MAY05
YZ6201
1—Seal Ring (3 used) 8—Clutch Plate Retainer (2 13—Belleville Spring (12 used) 18—2nd and 4th Stage Shaft
2—Bearing Cone Assembly used) 14—Lube Shutoff Washer (2 Assembly
3—Bearing Cone Assembly 9—Clutch Plate (20 used) used) 19—Ball Bearing (2 used)
4—Bearing Cup 10—Separator Plate (20 used) 15—Outer Piston Seal (2 used) 20—64T Gear (Clutch R)
5—70T Gear (Clutch C) 11—Retaining Ring (2 used) 16—Clutch Piston (2 used) 21—Thrust Washer
6—Tapered Roller Bearing 12—Snap Ring Retainer (2 17—O-ring (2 used) 22—Screw
7—Retaining Ring (2 used) used)
YZ07927,000043E –19–05MAY05–1/1

121007
PN=142
9620 Series Cross-Sectional View—Fourth Stage Clutch Shaft Assembly
02
35
43
–UN–05MAY05
YZ6200
1—Seal Ring (3 used) 7—Clutch Plate (20 used) 13—Thrust Washer 18—Clutch Piston (2 used)
2—Bearing Cone Assembly 8—Lube Shutoff Washer (2 14—Ball Bearing (2 used) 19—Outer Piston Seal (2 used)
3—70T Gear (Clutch C) used) 15—Clutch Plate Retainer (2 20—Tapered Roller Bearing
4—Retaining Ring (2 used) 9—O-ring (2 used) used) 21—Bearing Cup
5—Snap Ring Retainer (2 10—64T Gear (Clutch R) 16—Retaining Ring (2 used) 22—2nd and 4th Stage Shaft
used) 11—Bearing Cone Assembly 17—Separator Plate (20 used) Assembly
6—Belleville Spring (12 used) 12—Screw
YZ07927,000043D –19–24MAY05–1/1

121007
PN=143
Exploded View—Fifth Stage Clutch Shaft Assembly
02
35
44
–UN–21MAR01
YZ501504
1—Ring Seal (2) 6—O-Ring 11—Clutch Separator Plate 15— O-Ring

2—Bearing Cone (2) 7—Lube Shutoff Washer (14) 16—Ball Bearing
3—Fifth Stage Shaft Assembly 8—Clutch Return Spring (8) 12—Clutch Plate (14) 17—41T L.H. Helical Clutch
4—Outer Piston Seal 9—Snap Ring Retainer 13—Clutch Plate Retainer Gear (Clutch L and M)
5—Clutch Piston 10—Retaining Ring 14— Retaining Ring 18—Ball Bearing
DPSG,YZ07927,149 –19–30JUL99–1/1

121007
PN=144
Cross-Sectional View—Fifth Stage Clutch Shaft Assembly
11 13 14
12 02
4 5
17 35
45
3
2 2
6 7 8 10 9 16 18
15
–UN–23MAR01
RXA0052260
3—Fifth Stage Shaft Assembly 8—Clutch Return Spring (8) 12—Clutch Plate (14) 17—41T L.H. Helical Clutch
4—Outer Piston Seal 9—Snap Ring Retainer 13—Clutch Plate Retainer Gear (Clutch L and M)
OURX078,0000006 –19–14MAR01–1/1

121007
PN=145
9620 Series Exploded View—Fifth Stage Clutch Shaft Assembly
02
35
46
–UN–27APR05
YZ6191
1—Seal Ring (2 used) 7—Lube Shutoff Washer 12—Clutch Plate (14 used) 17— 41T Gear (Clutch L and
2—Bearing Cone (2 used) 8—Belleville Spring (8 used) 13—Clutch Plate Retainer M)
3—5th Stage Shaft Assembly 9—Snap Ring Retainer 14—Retaining Ring 18—Ball Bearing
4—O-ring 10—Retaining Retainer 15—O-ring 19—Thrust Washer
5—Clutch Piston 11—Separator Plate (14 used) 16—Ball Bearing 20—Screw
6—Outer Piston Seal
YZ07927,0000432 –19–27APR05–1/1

121007
PN=146
9620 Series Cross-Sectional View—Fifth Stage Clutch Shaft Assembly
02
35
47
–UN–27APR05
YZ6190
1—Ball Bearing 6—Washer 11—Clutch Piston 16—Retaining Ring
2—Ball Bearing 7—Clutch Plate (14 used) 12—Bearing Cone 17—Retaining Ring
3—Retainer 8—5th Stage Shaft Assembly 13—Ring Gear (2 used) 18—41T Gear (Clutch L and M)
4—Retainer 9—Outer Piston Seal 14—Separator Plate (14 used) 19—Thrust Washer
5—Belleville Spring (8 used) 10—O-ring 15—O-ring 20—Screw
YZ07927,0000431 –19–27APR05–1/1

121007
PN=147
Exploded View—Sixth Stage Clutch Shaft Assembly
02
35
48
–UN–21MAR01
YZ501508
1—Ring Seal (2) 5—O-Ring 10—Clutch Plate (14) 15—O-Ring
2—Bearing Cone (2) 6—Ball Bearing 11—Retaining Ring 16—Outer Piston Seal
3—Ball Bearing 7—Retaining Ring 12—Snap Ring Retainer 17—Clutch Piston
4—46T R.H. Helical Clutch 8—Clutch Plate Retainer 13—Clutch Return Spring (8) 18—Sixth Stage Shaft
Gear (Clutch H) 9—Clutch Separator Plate (14) 14—Lube Shutoff Washer Assembly
DPSG,YZ07927,148 –19–30JUL99–1/1

121007
PN=148
Cross-Sectional View—Sixth Stage Clutch Shaft Assembly
02
35
49
–UN–24SEP01
YZ3452
1—Ring Seal (2) 5—O-Ring 10—Clutch Plate (14) 15—O-Ring
2—Bearing Cone (2) 6—Ball Bearing 11—Retaining Ring 16—Outer Piston Seal
3—Ball Bearing 7—Retaining Ring 12—Snap Ring Retainer 17—Clutch Piston
4—46T R.H. Helical Clutch 8—Clutch Plate Retainer 13—Clutch Return Spring (8) 18—Sixth Stage Shaft
Gear (Clutch H) 9—Clutch Separator Plate (14) 14—Lube Shutoff Washer Assembly
OURX078,0000007 –19–14MAR01–1/1

121007
PN=149
9620 Series Exploded View—Sixth Stage Clutch Shaft Assembly
02
35
50
–UN–02MAY05
YZ6195
1—Seal Rings (2 used) 7—Clutch Plate Retainer 12—O-Ring 17—Outer Piston Seal
2—Bearing Cone 8—Belleville Spring (8 used) 13—6th Stage Shaft Assembly 18—Clutch Piston
3—Ball Bearing 9—Lube Shutoff Washer 14—Tapered Roller Bearing 19—Retaining Ring
4—Gear 46T (Clutch H) 10—Clutch Plate (14 used) 15—Screw 20—Retaining Ring
5—Ball Bearing 11—Separator Plate (14 used) 16—Thrust Washer 21—O-Ring
6—Snap Ring Retainer
YZ07927,0000438 –19–02MAY05–1/1

121007
PN=150
9620 Series Cross-Sectional View—Sixth Stage Clutch Shaft Assembly
02
35
51
–UN–29APR05
YZ6194
1—Seal Rings (2 used) 7—Clutch Plate Retainer 12—O-Ring 17—Outer Piston Seal
2—Bearing Cone 8—Belleville Spring (8 used) 13—6th Stage Shaft Assembly 18—Clutch Piston
3—Ball Bearing 9—Lube Shutoff Washer 14—Tapered Roller Bearing 19—Retaining Ring
4—Gear 46T (Clutch H) 10—Clutch Plate (14 used) 15—Screw 20—Retaining Ring
5—Ball Bearing 11—Separator Plate (14 used) 16—Thrust Washer 21—O-Ring
6—Snap Ring Retainer
YZ07927,0000437 –19–29APR05–1/1

121007
PN=151
Exploded View—Seventh Stage Clutch Shaft Assembly
02
35
52
–UN–21MAR01
YZ501512

3—Seventh Stage Shaft 8—Clutch Return Spring (8) 12—Clutch Plate (14) 17—41T L.H. Helical Clutch
Assembly 9—Snap Ring Retainer 13—Clutch Plate Retainer Gear (Clutch L and M)
DPSG,YZ07927,153 –19–30JUL99–1/1

121007
PN=152
Cross-Sectional View—Seventh Stage Clutch Shaft Assembly
11 12 13
5
3 14 17 02
4
35
53
2 2
15
9
6 8 10 18
16
7
–UN–22MAR01
RXA0052465
3—Seventh Stage Shaft 8—Clutch Return Spring (8) 12—Clutch Plate (14) 17—41T L.H. Helical Clutch
Assembly 9—Snap Ring Retainer 13—Clutch Plate Retainer Gear (Clutch L and M)
OURX078,0000008 –19–14MAR01–1/1

121007
PN=153
9620 Series Exploded View—Seventh Stage Clutch Shaft Assembly
02
35
54
–UN–28APR05
YZ6193
1—Seal Ring (2 used) 6—Outer Piston Seal 11—Separator Plate (14 used) 16—Ball Bearing
2—Bearing Cone (2 used) 7—Lube Shutoff Washer 12—Clutch Plate (14 used) 17—41T Gear (Clutch L and M)
3—Seventh Stage Shaft 8—Belleville Spring (8 used) 13—Clutch Plate Retainer 18—Ball Bearing
Assembly 9—Snap Ring Retainer 14—Retaining Ring 19—Thrust Washer
4—O-ring 10—Snap Ring 15—O-ring 20—Screw
5—Clutch Piston
YZ07927,0000435 –19–28APR05–1/1

121007
PN=154
9620 Series Cross-Sectional View—Seventh Stage Clutch Shaft Assembly
02
35
55
–UN–02MAY05
YZ6192
1—Seal Ring (2 used) 6—Shutoff Lube washer 11—Screw 15—Snap Ring
2—Bearing Cone (2 used) 7—Belleville Springs (8 used) 12—Thrust Washer 16—Outer Piston Seal
3—Clutch Piston 8—Clutch Plates (14 used) 13—41T Gear (Clutch L and M) 17—Seventh Stage Shaft
4—O-Ring 9—Snap Ring Retainer 14—O-Ring Assembly
5—Separator Plate (14 used) 10—Ball Bearing
YZ07927,0000433 –19–27APR05–1/1

121007
PN=155
Disassembly and Assembly of Clutch Stage

Shaft Assemblies
Remove clutch stack. (See Remove Clutch Assemblies,

02 this group.)
35
56 NOTE: All clutch stage shaft assemblies in the 18-speed
PST assemble and disassemble in the same or
similar manner.
OURX078,000000D –19–18MAY05–1/1
Disassemble and Assemble Second Stage

Shaft Assembly
CAUTION: Second stage shaft assembly weight

is approximately 78 Kg (170 lbs).
Remove second stage shaft assembly from next fixture

using JDG1106 Lifting Hook (A).
A—Lifting Hook
–UN–20FEB01
YZ3104A

121007
PN=156
Place second stage shaft assembly on sturdy supports.
02
35
57
–UN–26FEB01
RXA0051532
DPSG,YZ07927,364 –19–06DEC07–2/36
Disassemble Second Stage Clutch A Clutch Assembly
Place JDG1482 Shaft Protector (A) on end of shaft and

install puller tools.
Remove rear bearing cone (G).
A—Shaft Protector
E—Spacer Disks
G—Rear Bearing Cone
–UN–26FEB01
RXA0051533

121007
PN=157
Install puller tools and remove clutch gear (G).
IMPORTANT: Fifth, sixth, and seventh stage assembly

clutch gears will have an O-ring. The
O-ring is for lubrication to the clutches.
02
35
58 Inspect parts for wear and damage and replace as
necessary.
A—JDG1482 Shaft Protector

B—JDG1480 Gear Puller
E—Spacer Disks
–UN–26FEB01
G—Clutch A Gear
RXA0051534
DPSG,YZ07927,364 –19–06DEC07–4/36
Remove clutch gear bearing (A).
Remove both rear and front bearing cups from clutch gear
Inspect parts and remove and replace as necessary.
A—Clutch A Gear Rear Bearing Cone
–UN–08JAN01
YZ3111

121007
PN=158
CAUTION: Wear eye protection when removing

retaining ring.
Remove retaining ring (A).

02
35
A—Retaining Ring 59
–UN–08JAN01
YZ3112
DPSG,YZ07927,364 –19–06DEC07–6/36
Remove clutch plate retainer (A).
Inspect for wear and damage and replace as necessary.
A—Clutch Plate Retainer
–UN–08JAN01
YZ3114

121007
PN=159
Remove clutch disks and separator plates (A).
A—Clutch Disks (10 used) and Plates (10 used)
02
35
60
–UN–26FEB01
RXA0051535
DPSG,YZ07927,364 –19–06DEC07–8/36
Install puller tools and remove bearing (D).

B—JDG1477 Puller Legs
C—JDG542 Gear and Pulley Puller
D—Clutch Gear Front Bearing
–UN–26FEB01
RXA0051536

121007
PN=160
Use a press and JDG1485 Spring Compressor Tool (A)

and compress clutch return springs (B).
Remove snap ring (C) and retaining ring (D).

02
A—Clutch Piston Return Spring Compressor 35
B—Clutch Return Springs (6 used) 61
C—Snap Ring Retainer
D—Snap Ring
–UN–26FEB01
RXA0051537
DPSG,YZ07927,364 –19–06DEC07–10/36
IMPORTANT: Pay attention to the assembly of the

clutch return springs. They must be
reassembled correctly.
Remove clutch return springs (A) and lube shut off washer
(B).
A—Piston Return Springs (6 used)

B—Lube Shut Off Washer
–UN–20DEC00
YZ3086

121007
PN=161

piston from cylinder. If cylinder is damaged DO
NOT place hand on top of piston. If cylinder is
turned upside down the piston will blow all the
02 way out of the cylinder. Air pressure must be
35 applied to the system pressure port to remove
62
piston.
–UN–02FEB01
Using a rubber-tipped air nozzle, apply air pressure to the
oil passage.
YZ3088A
Remove clutch piston (A).
A—Clutch Piston
DPSG,YZ07927,364 –19–06DEC07–12/36
Disassemble Clutch Piston
Remove outer piston seal (A) from clutch piston (B) and
discard.
Inspect piston for wear and damage and replace as

necessary.
–UN–31AUG99
A—Piston Seal
B—Clutch Piston
YZ1921
DPSG,YZ07927,364 –19–06DEC07–13/36
Remove O-ring (A) from shaft.
A—O-Ring
–UN–02FEB01
YZ3089A

121007
PN=162
Assemble and Install Clutch Piston
Lubricate new O-ring (A) with transmission fluid and install

on shaft.
02
A—O-Ring 35
63
–UN–02FEB01
YZ3121A
DPSG,YZ07927,364 –19–06DEC07–15/36
Lubricate new outer piston seal (A) with transmission fluid

and install onto piston.
Position piston in piston bore and install into place.
A—Outer Piston Seal
–UN–02FEB01
YZ3122A

121007
PN=163
Assemble Clutch
Install lube shut off washer (B).
IMPORTANT: Clutch return springs must be installed

02
35 stacked as shown.
64
Install clutch piston return springs (A).
–UN–20DEC00
A—Piston Return Springs (6 used)
B—Lube Shut Off Washer
YZ3086
–UN–02FEB01
YZ853A
DPSG,YZ07927,364 –19–06DEC07–17/36
Position the spring compressor (A) on top of return

springs (B).
Position snap ring retainer (C).
Place snap ring (D) on shaft.
Using a press, compress the return springs enough to

allow snap ring (D) to be installed in the shaft snap ring
groove inside the snap ring retainer (C).
Install snap ring.
Release pressure on clutch return springs slowly making

sure the snap ring and snap ring retainer are correctly
positioned.
A—JDG1485 Clutch Piston Return Spring

Compressor
–UN–26FEB01
B—Return Springs
C—Snap Ring Retainer
D—Snap Ring
RXA0051537

121007
PN=164

Install heated front bearing cone (A) onto shaft tight 02

against the shoulder. 35
65
Position JDG1475A Clutch Disk Alignment Guide (B) on

clutch shaft.
Alternately install disks (C) and separator plates (D),

starting with a plate against the piston.
A—Clutch Front Bearing Cone

B—Clutch Disk Alignment Guide
–UN–26FEB01
C—Clutch Disks (10 used)
D—Clutch Separator Plates (10 used)
RXA0051538

121007
PN=165
IMPORTANT: The retaining ring (B) is designed with a

die break edge on one side. The die
break edge must be installed with the
die break edge up or facing away from
the clutch plate retainer.
02
35
66 Install clutch plate retainer (A) and retaining ring (B).
Remove alignment tool (C).
A—Clutch Plate Retainer

B—Retaining Ring
C—Alignment Tool
–UN–16JUL03
YZ5062
B—Retaining Ring
–UN–30JUL03
YZ5082

121007
PN=166
Verify that there is clearance in the clutch pack. A

B
• Speed and Directions Clutches Assemblies will have 10
clutch disks per side and measure 3.81 mm — 4.57 mm C
(.150—.180 in.)
02
• Range Clutch Assemblies will have 14 clutch disks and
–UN–23FEB01
35
measure 5.20 mm—6.35 mm (.205—.250 in.) 67
Check free clearance on Speed and Directions Clutches
RXA0052103
Assemblies, 10 clutch disks per side, and measure
3.81mm — 4.57mm (.150—.180 in.) or Range Clutch
Assemblies, 14 clutch disks, and measure 5.20 mm—6.35
mm (.205—.250 in.) clearance (C) between retainer (A)
and first disk (B) or clutch piston.
IMPORTANT: If minimum clearance is not present,

disassemble and determine the cause.
Transmission will not calibrate in
tractor if clutch assembly free clearance
is not between minimum and maximum
free clearance tolerances.
This can be checked using a couple of methods:
• Using indicator placed on first disk.
• Using indicator placed on piston.
• Using feeler gauge between retainer and snap ring.
–UN–24APR06
A—Retainer
B—Clutch Disk
YZ6494
C—Clearance

121007
PN=167
NOTE: Whichever method used to check free clearance

be sure to check more than once. The piston,
retainer, or clutch disks can stick.
IMPORTANT: Make sure clutch disk teeth are aligned

02
35 to allow clutch gear installation.
68
Install clutch gear (A).
–UN–31JAN01
RXA0051540
Install clutch gear rear bearing cone (B) into gear tight
against shoulder.
A—Clutch Gear
B—Clutch Gear Rear Bearing
DPSG,YZ07927,364 –19–06DEC07–22/36

Install shaft rear bearing cone (A) onto shaft tight against
shoulder.
A—Shaft Rear Bearing Cone –UN–31JAN01

RXA0051541

121007
PN=168
Disassemble Second Stage Clutch 2 Clutch Assembly
9620 Series
Remove Screw (A) and Thrust Washer (B).

02
35
A—Screw 69
B—Thrust Washer
–UN–31MAY05
YZ6207
–UN–31MAY05
YZ6206

121007
PN=169
IMPORTANT: All 9620 series tractors will have thrust

washers on all shaft assemblies. All
other 9020 series tractors equipped with
the 18-Speed Power Shift
Transmissions will need to have thrust
02
35 washers installed at time of repair.
70
Using JDG1484 Eyebolt (A) place on sturdy supports.
A—Eyebolt
–UN–31JAN01
RXA0051542
DPSG,YZ07927,364 –19–06DEC07–25/36
NOTE: Spacer disks (A) must have a minimum thickness

of 38 mm (1.50 in.) and 67 mm (2.625 in.)
diameter to allow bearing removal.
Place spacer disks (A) on end of shaft.
Install puller tools and remove shaft front bearing cone

(G).
A—Spacer Disks
E—Spacer Disks
G—Shaft Front Bearing
–UN–31JAN01
RXA0051543

121007
PN=170
A—Spacer Disks
02
35
E—Spacer Disks
71
G—Clutch Gear
–UN–31JAN01
RXA0051544
DPSG,YZ07927,364 –19–06DEC07–27/36
Remove roller ball bearing (A) from clutch gear.
Inspect parts for wear and damage and replace as

necessary.
A—Clutch Rear Roller Ball Bearing
–UN–31JAN01
RXA0051545

121007
PN=171

retaining ring.
Remove retaining ring (A) and clutch plate retainer (B).

02
35 Inspect parts for wear and damage and replace as
72
necessary.
A—Retaining Ring
B—Clutch Plate Retainer
–UN–31JAN01
RXA0051550
DPSG,YZ07927,364 –19–06DEC07–29/36
Remove clutch disks and separator plates (A).
Inspect parts for wear and damage and replace as

necessary.
A—Clutch Disks (10 used) and Separator Plates (10

used)
–UN–31JAN01
RXA0051551

121007
PN=172
Install puller tools and remove clutch rear roller ball

bearing (A) from shaft.

B—Spacer Disks 02
C—JDG1477 Puller Legs 35
D—JDG542 Gear and Pulley Puller 73
–UN–31JAN01
RXA0051552

121007
PN=173
Disassemble remaining Clutch 2 components from gear

clutch using the same procedures and tools as used for
Clutch A.
Assemble Clutch 2 components into gear clutch using the

02
35 same procedures and tools as used for Clutch A, up to
74 the rear roller ball bearing installation.
–UN–02FEB01
YZ1932A
DPSG,YZ07927,364 –19–06DEC07–32/36
Position roller ball bearing (A) onto shaft and place

JDG1474 Installer Plate (B) on top of bearing.

B—Roller Ball Bearing Installer Plate
–UN–31JAN01
RXA0051553

121007
PN=174
NOTE: Bearing will drop freely between the two shaft

diameters (D) and (E).
Place JDG1485 Spring Compressor (A) on top of bearing

installer plate (B) and using a press, force the bearing (C)
02
past the first shaft diameter (D) and onto shaft diameter 35
(E) tight against shoulder. 75
A—Clutch Piston Return Spring Compressor

B—Roller Ball bearing Installer Plate
C—Clutch Rear Roller Ball Bearing
D—Shaft Diameter For Clutch Front Roller Ball
Bearing
E—Shaft Diameter For Clutch Rear Roller Ball
Bearing
–UN–31JAN01
RXA0051554
DPSG,YZ07927,364 –19–06DEC07–34/36
IMPORTANT: Make sure clutch disk teeth are aligned

to allow clutch gear installation.
Install clutch gear (A).
Install clutch gear front bearing (B) using JDG1474

Bearing Installer Plate (C) and JDG1485 Spring
Compressor (D).
Use a press and install bearing (B) tight to bottom bore of

clutch gear.
A—Clutch Gear
B—Clutch Gear Front Roller Bearing
C—Roller Ball Bearing Installer Plate
D—Clutch Piston Return Spring Compressor
–UN–31JAN01
RXA0051555

121007
PN=175

02 Install heated front bearing cone (A) to shaft tight against
–UN–31JAN01
35 shoulder.
76
Remove clutch shaft assembly from supports using

JDG1484 Eyebolt and turn over.
RXA0051556
Install second stage shaft assembly into nest fixture using
JDG1106 Lifting Hook.
A—Shaft Front Bearing Cone
DPSG,YZ07927,364 –19–06DEC07–36/36
Disassemble and Assemble Fifth Stage Shaft

Assembly
CAUTION: Fifth stage shaft assembly weight is

approximately 47 kg (103 lb)
Remove fifth stage shaft assembly from nest fixture using

JDG1106 Lifting Hook (A).
A—Lifting Hook
–UN–26FEB01
RXA0051557
Continued on next page OURX078,000000F –19–24MAY05–1/8

121007
PN=176
Place fifth stage shaft assembly on sturdy supports
02
35
77
–UN–26FEB01
RXA0051558
OURX078,000000F –19–24MAY05–2/8
Disassemble Fifth Stage Shaft Assembly
Place JDG1482 Shaft Protector (B) on end of shaft and

Remove rear bearing cone (A).
A—Rear Bearing Cone

B—Shaft Protector
C—D01267AA Bearing Puller
D—458 mm (18 in.) Puller Legs
F—Spacer Disks
G—270 kN (30 Ton) Push Puller
–UN–26FEB01
RXA0051559

121007
PN=177
9620 Series
A—Hex Head Cap Screw

B—Thrust washer
02
35
78
–UN–31MAY05
YZ6204
–UN–31MAY05
YZ6202

121007
PN=178

02
washers installed at time of repair. 35
79
Turn fifth stage shaft assembly (A) over using JDG1484
Eyebolt (B) and a lifting device.
Place shaft assembly on sturdy supports.
A—Fifth Stage Shaft Assembly

B—Eyebolt
–UN–26FEB01
RXA0051560
OURX078,000000F –19–24MAY05–5/8

of 38 mm (1.50 in.) and 67 mm (2.625 in.)
Place spacer disks (A) on end of shaft.
Install puller tools and remove shaft front bearing Cone

(B).
A—Spacer Disks
B—Shaft Front Bearing Cone
C—D01067AA Bearing Puller
F—Spacer Disks
–UN–26FEB01
RXA0051561

121007
PN=179
Disassemble and Assemble Fifth Stage Clutch L
Install puller tools and remove clutch gear (A).
02 A—Clutch Gear L
35 B—Spacer Disk
80 C—D01067AA Bearing Puller
F—Spacer Disks
–UN–26FEB01
RXA0051562

121007
PN=180
NOTE: All single stage clutch shaft clutch assemblies will

have an O-ring (B).
Remove bearing (A), inspect for wear and damage and

replace as necessary.
02
35
Remove and discard O-ring (B). 81
Lubricate new O-ring (B) with transmission fluid and install

on gear.
–UN–20DEC00
Disassemble remaining clutch L components following the
same procedures as for clutch 2 of the second stage shaft
assembly.
YZ3077
Assemble clutch L components and fifth stage shaft
assembly following the same procedures as for clutch 2 A—Clutch L Gear Front Roller Ball Bearing
and second stage shaft assembly. B—O-Ring
Remove clutch shaft assembly from supports and turn

over using JDG1484 Eyebolt.
Install fifth stage shaft assembly into nest fixture using

OURX078,000000F –19–24MAY05–8/8

121007
PN=181
Disassemble and Assemble Seventh Stage

Clutch Shaft Assembly
Remove seventh stage shaft assembly (A) from nest

02 fixture using JDG1106 Lifting Hook (B.
35
82
CAUTION: Seventh stage shaft assembly weight
is approximately 52 Kg (115 lb).
Disassemble seventh stage shaft assembly clutch M

components following the same procedures as for clutch L
of the fifth stage shaft assembly.
–UN–26FEB01
Assemble clutch M components and seventh stage shaft
assembly following the same procedures as for clutch L
and fifth stage shaft assembly.
RXA0051563
Remove clutch shaft assembly from supports.
9620 series tractors

A—Seventh Stage Shaft Assembly
B—Lifting Hook
washers installed at time of repair.
Remove thrust washer and turn over using JDG1484

Eyebolt.
Install seventh stage shaft assembly into nest fixture using

OURX078,0000011 –19–24MAY05–1/1

121007
PN=182
Disassemble and Assemble Sixth Stage

Clutch Shaft Assembly
CAUTION: Sixth stage shaft assembly weight is

approximately 63 Kg (139 lb). 02
35
83
Remove sixth stage shaft assembly from nest fixture using
A—Lifting Hook
–UN–26FEB01
RXA0051600
Continued on next page OURX078,0000013 –19–24MAY05–1/3

121007
PN=183
Place sixth stage shaft assembly on sturdy supports.
Place JDG1482 Shaft Protector (A) on end of shaft and

02
35 Remove rear bearing cone (G).
84
A—Shaft Protector
E—Spacer Disks
–UN–26FEB01
RXA0051602

121007
PN=184
Disassemble sixth stage shaft assembly clutch H

components following the same procedures as for clutch L
of the fifth stage shaft assembly.
02
35
Assemble clutch H components and sixth stage shaft 85
assembly following the same procedures as for clutch L
and fifth stage shaft assembly.
Remove and install sixth stage shaft assembly front

bearing cone following the same procedures as for fifth
stage shaft assembly.

–UN–27FEB01
Eyebolt .
Install sixth stage shaft assembly into nest fixture using
RXA0051603

B—JDG1480 Gear Puller
E—Spacer Disk
G—Clutch H Gear
OURX078,0000013 –19–24MAY05–3/3

121007
PN=185
Disassemble and Assemble Fourth Stage

Shaft Assembly
CAUTION: Fourth stage clutch shaft assembly

02 weight is approximately 93 Kg (206 lb).
35
86
Remove fourth stage shaft assembly from nest fixture
using JDG1106 Lifting Hook (A).
A—Lifting Hook
–UN–26FEB01
RXA0051606
Continued on next page OURX078,0000015 –19–03JUN05–1/8

121007
PN=186
Place fourth stage clutch shaft assembly on sturdy

supports.
02
35
87
–UN–26FEB01
RXA0051607

121007
PN=187
Install puller tools and remove rear bearing cone (G).

02
35
E—Spacer Disks
88
–UN–28FEB01
RXA0051609

121007
PN=188
Install puller tools and remove clutch C gear (G).
Disassemble and assemble clutch C components

following the same procedures as for clutch A of the
second stage clutch shaft assembly.
02
35
Install the rear bearing cone following the same 89
procedures as for second stage clutch shaft assembly.

E—Spacer Disk
G—Clutch C Gear
–UN–26FEB01
RXA0051610
OURX078,0000015 –19–03JUN05–4/8
9620 Series
A—Thrust Washer
B—Cap Screw
–UN–31MAY05
YZ6214

121007
PN=189

02
35 washers installed at time of repair.
90
Turn shaft assembly over.
Remove thrust washer and place on sturdy supports using

JDG1484 Eyebolt (A).
A—Eyebolt
–UN–26FEB01
RXA0051611

121007
PN=190

of 38 mm (1.50 in.) and 67 mm (2.625 in.)
Install puller tools and remove front bearing cone (G).

02
35
A—Spacer Disks 91
E—Spacer Disks
G—Front Bearing Cone
–UN–26FEB01
RXA0051613

121007
PN=191
Install puller tools and remove clutch gear R.
Disassemble and assemble clutch R components

following the same procedures as for clutch A of the
second stage clutch shaft assembly.
02
35
92 Install the rear bearing cone following the same
Remove clutch shaft assembly from supports and turn

over using JDG1484 Eyebolt .
Install fourth stage shaft assembly into nest fixture using

A—Clutch Gear R
E—Spacer Disks
–UN–26FEB01
RXA0051614
OURX078,0000015 –19–03JUN05–8/8

121007
PN=192
Disassemble and Assemble Third Stage

Shaft Assembly
CAUTION: Third stage clutch shaft assembly

weight is approximately 97 Kg (213 lb). 02
35
93
Remove third stage shaft assembly from nest fixture using
A—Lifting Hook
–UN–26FEB01
RXA0051615
OURX078,0000017 –19–24MAY05–1/5
Place third stage clutch shaft assembly on sturdy

supports.
Install puller tools and remove rear bearing cone (G).

E—Spacer Disks
G—Rear Bearing Cone –UN–26FEB01
RXA0051617

121007
PN=193
Install puller tools and remove clutch B gear (G) and 70

tooth gear (H).
Disassemble and assemble clutch B components following

the same procedures as for clutch A of the second stage
02
35 clutch shaft assembly.
94
Install the rear bearing cone following the same

E—Spacer Disk
G—Clutch B Gear
H—70 Tooth Gear
–UN–26FEB01
RXA0051618
OURX078,0000017 –19–24MAY05–3/5

of 38 mm (1.50 in.) and 67 mm (2.625 in.)
Turn shaft assembly over and place on sturdy supports

using JDG1484 Eyebolt.
Install puller tools and remove front bearing cone (G).
A—Spacer Disks
E—Spacer Disks
G—Front Bearing Cone
–UN–26FEB01
RXA0051622

121007
PN=194
Install puller tools and remove clutch gear 1.
Disassemble and assemble clutch 1 components following

the same procedures as for clutch A of the second stage
clutch shaft assembly.
02
35
Install the rear bearing cone following the same 95

–UN–26FEB01
Eyebolt.
RXA0051623
Install third stage shaft assembly into nest fixture using
A—Clutch Gear 1
E—Spacer Disks
OURX078,0000017 –19–24MAY05–5/5

121007
PN=195
Install Clutch Assemblies
Position the clutch shaft assemblies in the clutch stack

nest fixture.
02
35 IMPORTANT: Keep the lifting fixture level during
96 installation to the clutch shaft
assemblies to prevent damage to the
shaft sealing ring grooves.
–UN–21APR03
Install lifting fixture (A) onto clutch nest.
Secure the latches (B) and install input shaft retaining cap
(C).
YZ5027
Carefully remove the clutch nest from the nest fixture.
A—JDG1471 Clutch Stack Lifting Fixture
NOTE: Keep the lifting fixture parallel with the housing B—First Stage (Input Shaft) Retaining Cap
in the housing.
Carefully install the clutch nest into the front housing.
Disengage clutch assembly latches, remove input shaft

retaining cap and remove clutch lifting fixture.

121007
PN=196
IMPORTANT: DO NOT install used seal rings.
Compress the sealing rings past the meeting point.
Install the sealing rings onto the shaft starting with the
02
bottom sealing ring groove.
–UN–03MAR94
35
97
Check the installed sealing rings and make sure there is
not a large gap and that the sealing ring joints are
staggered.
RW35217
–UN–10APR03
YZ5028
OURX078,0000018 –19–15APR03–2/2
Install Rear Housing
Install JDG1489 Transmission Rear Cover Lifting Bracket

(A) to suction screen cover threaded holes.
–UN–02FEB01
Install JDG19 Lifting Brackets (B).
NOTE: Adjust lift chain lengths so that the mating

surfaces of the front and rear housings will be
RXA0051599
parallel.
Attach lift chains to the lifting brackets and overhead hoist.

Old Style Rear Housing
A—Rear Cover Lift Bracket

B—Lifting Brackets (3 used)
–UN–10APR03
YZ5013

121007
PN=197
Apply a thin film of TY16021 High-Flex Form-in-Place

Gasket to front-to rear housing mating surface.

02
35
98 Install four guide pins, one at each corner of rear cover.
IMPORTANT: Keep the rear housing parallel with the

front housing, while installing, to avoid
binding the clutch shafts in the rear
housing.
Carefully install rear cover to transmission assembly.
A—Lift Chains
–UN–30JAN01
RXA0051432
OURX078,0000019 –19–15APR03–2/3
NOTE: Tighten cap screws in a criss-cross pattern

starting from the middle of the transmission case.
Specification
Rear-to-Front Transmission
Housing Cap Screws—Torque ..................................................... 216 N•m
(159 lb-ft)
DO NOT install additional parts, proceed to bearing

–UN–30JAN01
adjustment procedures.
A—Rear-to-Front Housing Cap Screws (24 used)

RXA0051433
OURX078,0000019 –19–15APR03–3/3

121007
PN=198
Bearing Adjustment of Output Shaft Rear Housing
1. Install guide pins.
–UN–10APR03
A—Guide Pin 02
B—Internal Park Brake Cover 35
99
YZ5029
YZ07927,00000A2 –19–30JUN05–1/6
2. Install Yoke washer and cap screw (A).
IMPORTANT: Tighten seven internal park

brake-to-rear housing cap screws
evenly to the torque specification listed
–UN–10APR03
below.
Install seven cap screws (B).
YZ5030
Tighten seven cap screw (B).
Specification A—Washer and Cap Screw

Internal Park Brake-to-Rear B—Cap Screw
Housing Cap Screw—Torque......................................... 2.8 N•m (25 lb-in)
YZ07927,00000A2 –19–30JUN05–2/6
3. Rotate output shaft 2 turns clockwise.
Check cap screw torque
Specification
–UN–10APR03
Internal Park Brake

Housing-to-Rear Housing Cap
Screw—Torque ............................................................... 2.8 N•m (25 lb-in)
YZ5031
A—Output shaft
Continued on next page YZ07927,00000A2 –19–30JUN05–3/6

121007
PN=199
IMPORTANT: A gap measurement in more than one

location must be taken to obtain an
average reading.
4. Measure and record gap adjacent to four cap screws

02
35 90° apart using a feeler gage.
–UN–10APR03
,100
Add the four measurements and divide by four to
determine the average measurement.
YZ5032
Remove cap screws and remove internal park brake
cover.
IMPORTANT: To obtain shim thickness for shimming

add 0.064 mm (0.003 in.) to the average
gap measurement.
5. Install determined shim pack.
6. Install internal park brake housing.
IMPORTANT: Tighten cap screws using a criss-cross

pattern in two separate steps.
7. Install and tighten cap screws in a cross-cross pattern.
Specification
Internal Park Brake
Screw — Initial Torque—Torque .................................................... 40•N•m
(30 lb-ft)
Specification
Internal Park Brake
Screw — Final Torque—Torque .................................................... 80 N•m
(60 lb-ft)
8. Rotate output shaft two turns clockwise.

121007
PN=200
9. Using a push pull torque wrench check end play.
Specification
Push Pull Torque Wrench—Push
Pull Output Shaft .......................................................................... 400 N•m
(300 ft-lbs) 02
35
Adjust if necessary by adding or subtracting shims to ,101
–UN–14APR03
meet specifications
Specification
Output Shaft—End Play .................................................... 0.02—0.12 mm
(0.001 — 0.005 in.)
YZ5033
NOTE: After bearing adjustment of output shaft (rear
housing) remove internal park brake cover and
install internal park brake components.
IMPORTANT: When installing the internal brake cover

onto the guide pins the internal brake
cover will not set flush witht he main
case rear housing. There will be a 17.78
mm (.700 in.) gap between the main
case rear housing and the internal park
brake cover.
If you do not have the 17.78 mm (.700

in.) gap between the main case rear
housing and the internal park brake
cover double check to be sure that the
belleville springs are installed correctly.
Slowly tighten the cap screws following

the tightening sequence. DO NOT USE
torque gun to tighten cap screws.
Failure to follow the tightening
sequence will damage the seals. Seals
must move slowly across rear housing
and brake cover housing chanfers to
prevent damage to seals.
Install brake cover-to-rear housing cap screw.
1. Tighten cap screw labeled number 1, one complete

turn.
turn.

121007
PN=201

turn.
turn.
02
35 turn.
,102 6. Tighten cap screw labeled number 6, one complete
turn.
turn.
8. Continue tightening cap screws, one complete turn, in
sequence until final torque.
YZ07927,00000A2 –19–30JUN05–6/6
Internal Park Brake Assembly
IMPORTANT: When removing internal brake housing

retain shims installed under the internal
park brake cover.
1. Alternately install brake disks and separator plates,
–UN–14APR03
starting with a separator plate (A) against the rear
housing bore, then install brake disk (B). Continue this
process until all clutch (B) and separator (A) plates are
YZ5034
installed.
A—Separator Plate
B—brake disk
Continued on next page YZ07927,00000A1 –19–22APR05–1/15

121007
PN=202
2. Install new seal ring (A) onto rear housing .
A—Internal seal ring
02
35
,103
–UN–21JUN04
YZ5185
YZ07927,00000A1 –19–22APR05–2/15
3. Install new seal ring (A) into brake spacer.
4. Install brake spacer (A).
–UN–21JUN04
YZ5184

121007
PN=203
5. Install new seal rings onto brake piston (A).
A—Brake Piston
02
35
,104
–UN–14APR03
YZ5036
YZ07927,00000A1 –19–22APR05–4/15
Install brake piston (A).
A—Brake Piston
–UN–14APR03
YZ5037

121007
PN=204
IMPORTANT: The Belleville Springs can be installed

wrong. Be sure and install springs
properly. The illustration with key
–UN–13MAY03
callouts 1, 2 and 3 shows proper
installation. Belleville (1) is concave
02
toward the spring spacer (2) and 35
Bellville (3) is concave toward the
YZ5050
,105
spring spacer (2).
6.
1—Belleville Spring
2—Spring Spacer
3—Belleville Spring
YZ07927,00000A1 –19–22APR05–6/15
Install belleville spring (A) and spring spacer (B).
A—Belleville Spring
B—Spring Spacer
–UN–14APR03
YZ5038
YZ07927,00000A1 –19–22APR05–7/15
7. Install second belleville spring (A).
A—Belleville Spring
–UN–14APR03
YZ5039

121007
PN=205
8. Install new o-rings onto oil tube.
Install oil tube assembly.
02 A—Oil Tube
35
,106
–UN–14APR03
YZ5040
YZ07927,00000A1 –19–22APR05–9/15
9. Install guide pins (A) and shims (B).
NOTE: Refer to Bearing Adjustment of Output Shaft Rear
Housing in this group for determined shims.
NOTE: Check Oil Tube (B) and Brake housing (A) align.
10. Lubricate new o-ring with transmission fluid and install
–UN–14APR03
onto brake housing.
A—Guide Pin
YZ5041
B—Shim
YZ07927,00000A1 –19–22APR05–10/15
Install brake housing (A) onto guide pins.
A—Brake Housing
B—Oil Tube
–UN–14APR03
YZ5042

121007
PN=206
IMPORTANT: When installing the internal brake cover

onto the guide pins the internal brake
cover will not set flush with the main
case rear housing. There will be a 17.78
mm (.700 in.) gap between the main
02
case rear housing and the internal park 35
brake cover.
–UN–14APR03
,107
If you do not have the 17.78 mm (.700

in.) gap between the main case rear
housing and the internal park brake
YZ5043
cover double check to be sure that the
belleville springs are installed correctly.
Slowly tighten the cap screws following

the tightening sequence. DO NOT USE
torque gun to tighten cap screws.
Failure to follow the tightening
sequence will damage the seals. Seals
must move slowly across rear housing
and brake cover housing chamfers to
prevent damage to seals.
11. Follow numbered tightening sequence to tighten cap

screws.
12.Install brake cover-to-rear housing cap screw.
1. Tighten cap screw labeled number 1, one

complete turn.
complete turn.
complete turn.
complete turn.
complete turn.
complete turn.
complete turn.
8. Continue tightening cap screws, one complete
turn, in sequence until final torque.

121007
PN=207
Tighten cap screw.
Specification
Brake Housing-to-Rear Housing
–UN–14APR03
Cap Screw — Initial Torque—
02 Torque ............................................................................................ 40 N•m
35 (30 lb-ft)
,108
Specification
YZ5044
Brake Housing-to-Rear Housing
Cap Screw — Final Torque—
Torque ............................................................................................ 80 N•m
(60 lb-ft)
YZ07927,00000A1 –19–22APR05–13/15
13. Install yoke (A).
14. Install O-ring (B).
–UN–14APR03
15. Install washer (C).
16. Install cap screw (D).
YZ5045
A—Yoke
B—O-ring
C—Washer
D—Cap screw

121007
PN=208
17. Tighten cap screw.
Specification
Output Yoke-to-Shaft Cap
Screw—Torque ............................................................................. 435 N•m
(320 lb-ft) 02
35
,109
–UN–14APR03
YZ5046
YZ07927,00000A1 –19–22APR05–15/15
Bearing Adjustments to Clutch Stage Shafts
NOTE: To make bearing adjustments install JDG1486

Clutch Rotation Tools and attach to air supply to
engage two clutch assemblies using air. When
seating bearings the input or output shaft must be
rotated. The forward sixth gear (F6) can be
engaged by applying air pressure to clutch “2” and
“B”.
–UN–30APR01
A—JDG1486-1 Hose Assembly
B—JDG1486-2 Input Fitting Assembly
C—Quick Coupler Fitting (Dealer Furnished)
RXA0052927
OURX078,000000B –19–11APR01–1/1

121007
PN=209
Install Clutch Rotation Tools
Install input fitting assembly (A) into clutch port “2”

opening (B).
02
35 A—JDG1486-2 Input Fitting Assembly1
,110 B—Clutch Port “2” Opening
–UN–25APR01
YZ3179A
1
JDG1486-2 Input Fitting Assembly is part of JDG1486 Clutch Rotation
Tool Set
DPSG,YZ07927,406 –19–03JUN05–1/5
Install one end of hose assembly to special plug.
A—JDG1486-1 Hose Assembly1
–UN–22JAN01
YZ3180
1
JDG1486-1 Hose Assembly is part of JDG1486 Clutch Rotation Tool
Set

121007
PN=210
Install special plug (A) into clutch port “B” opening (B).
A—JDG1486-2 Input Fitting Assembly1

B—Clutch Port “B” Opening
02
–UN–29MAR01
35
,111
RXA0052607
1
Tool Set
DPSG,YZ07927,406 –19–03JUN05–3/5
Attach end of hose assembly (A) to input fitting assembly

(B).
Attach tool to air supply.
–UN–29MAR01
A—JDG1486-1 Hose Assembly1
B—JDG1486-2 Input Fitting Assembly2
RXA0052608
1
JDG1486-1 Hose Assembly is part of JDG1486 Clutch Rotation Tool
Set
2
Tool Set
DPSG,YZ07927,406 –19–03JUN05–4/5
IMPORTANT: To properly rotate shaft assemblies

during bearing adjustment procedures,
the input shaft alignment fixture MUST
be installed.
Install JDG1481 Input Shaft Alignment Fixture (A) to the

transmission.
Temporarily install yokes to input and/or output shafts.

–UN–31MAY05
A—Input Shaft Alignment Fixture

YZ6215
DPSG,YZ07927,406 –19–03JUN05–5/5

121007
PN=211
Bearing Adjustment Of Fifth and Sixth Clutch Stage Shaft Assemblies
IMPORTANT: All clutch stage shaft assemblies

MUST have the bearings set with the
correct end play.
02
35
,112 Item Measurement Specification
Clutch Stage Shaft Assemblies End Play 0.02—0.12 mm

(0.001—0.005 in.)
DPSG,YZ07927,407 –19–23JAN01–1/7
Position the transmission in the rollover stand so that the

clutch shafts are in a vertical position.
Remove bearing retainer cap screws (A).
–UN–06MAR01
YZ3184A
DPSG,YZ07927,407 –19–23JAN01–2/7
Remove bearing retainer with O-ring.
Remove shims.
–UN–24JAN01
YZ3185
Continued on next page DPSG,YZ07927,407 –19–23JAN01–3/7

121007
PN=212
Install bearing retainer without O-rings or shims.
Install and tighten four cap screws.
Specification
Bearing Retainer-to-Front 02
Housing Cap Screw—Torque........................................................ 2.8 N•m 35
(25 lb-in) ,113
Install clutch rotation tools. (See Install Clutch Rotation

Tools, this group.)
–UN–24JAN01
Apply air pressure to engage clutches “2” and “B”.
Rotate shaft two complete turns clockwise; then rotate two
YZ3186
complete turns counterclockwise.
Release air pressure.
Retighten cap screws.
Specification
Housing Cap Screw—Torque........................................................ 2.8 N•m
(25 lb-in)
DPSG,YZ07927,407 –19–23JAN01–4/7

average reading.
Measure and record gap adjacent to each cap screw

between front housing and bearing retainer using a feeler
gage.
–UN–24JAN01

YZ3187
Remove cap screws and remove bearing retainer.
Continued on next page DPSG,YZ07927,407 –19–23JAN01–5/7

121007
PN=213

gap measurement.
Install determined shim pack.

02
–UN–24JAN01
35
,114 Lubricate new O-ring with transmission fluid and install to
bearing retainer.
YZ3185
Install bearing retainer.
DPSG,YZ07927,407 –19–23JAN01–6/7

Install and tighten cap screws in a criss-cross pattern.
–UN–24JAN01
Specification
Housing Cap Screw—Initial
Torque ............................................................................................ 40 N•m
(30 lb-ft)
YZ3189
Specification
Housing Cap Screw—Final
Torque ............................................................................................ 80 N•m
(60 lb-ft)
DPSG,YZ07927,407 –19–23JAN01–7/7
Bearing Adjustment of Second, Third, Fourth

and Seventh Clutch Stage Shaft Assemblies
IMPORTANT: All clutch stage shaft assemblies MUST

have the bearings set with the correct
end play.
Item Measurement Specification

(0.001—0.005 in.)
All Clutch Stage Shaft Assemblies Push Pull Torque Wrench Setting 340 N•m
(250 lb-ft)

121007
PN=214
NOTE: Second, third and fourth clutch stage shafts are

located behind the pump drive cover.
Remove pump drive input gear (A). (See Remove and

Install Pump Drive Input Gear, Group 30.)
02
35
,115
–UN–22JAN01
A—Pump Drive Input Gear
YZ3175
OURX078,0000002 –19–07JUN05–2/13
Second, Third and Fourth Clutch Stage Shafts
NOTE: Shaft alignment tool is used to position the input

shaft for proper gear teeth alignment when shafts
are rotated.
Install JDG1481 Input Shaft Alignment Fixture (E) to the

transmission.
–UN–31MAY05
NOTE: There is no O-ring seal on the bearing retainers.
Follow the same procedures used for fifth and sixth stage
shaft assemblies. (See Bearing Adjustment of Fifth and
YZ6208
Sixth Clutch Stage Shaft Assemblies, this group.)
NOTE: 9620 Series shows new style of bearing retainer

the old style bearing retainers should be replaced A—Second Stage Clutch Shaft Bearing Retainer
B—Third Stage Clutch Shaft Bearing Retainer
with new style at time of repair. C—Fourth Stage Clutch Shaft Bearing Retainer
D—Seventh Stage Clutch Shaft Bearing Retainer
E—Input Shaft Alignment Fixture

121007
PN=215
Seventh Stage Clutch Shaft Assembly
Remove transmission oil pump. (See Remove

Transmission Oil Pump, Group 30.)
02
35 Remove bearing retainer cap screws (A).
,116
–UN–03JUN05
B—Plugs
YZ6209
OURX078,0000002 –19–07JUN05–4/13
Remove bearing retainer (A) and shim pack (B).
B—Shim Pack
–UN–31MAY05
YZ6210

121007
PN=216
NOTE: End play must be present to properly set end

play. If end play is not present add .010
thousands shim to shims.
Install bearing retainer without shims.

02
35
Install and tighten four cap screws. ,117
–UN–03JUN05
Specification
(25 lb-in)
YZ6209
Install clutch rotation tools. (See Install Clutch Rotation
Tools, this group.)
Apply air pressure to engage clutches “2” and “B”.
Rotate shaft two complete turns clockwise; then rotate two

complete turns counterclockwise.
Release air pressure.
Specification
(25 lb-in)
OURX078,0000002 –19–07JUN05–6/13
Install JDG1795 Seventh Stage End Play Adjustment Tool

(A) and dial indicator tools (B).
A—JDG1795 Seventh Stage End Play Adjustment

Tool
B—Dial Indicator Tools
–UN–31MAY05
YZ6211

121007
PN=217
Install JDG1797 seventh stage pivot block and pry bar.
A—JDG1797 Seventh Stage Pivot Block

B—JDG1795 Seventh Stage End Play Adjustment
Tool
02
35
,118
–UN–31MAY05
YZ6212
OURX078,0000002 –19–07JUN05–8/13
Install a standard socket under JDG1797 seventh stage

pivot block as shown.
Move shaft assembly up using prybar and note the end

play reading.
Remove tools, cap screws and bearing retainer.
C—Socket
–UN–03JUN05
YZ6216

121007
PN=218

gap measurement. Refer back to
Bearing Adjustment of Fifth and Sixth
Clutch Stage Shaft Assemblies for how
02
to obtain the average gap measurement. 35
,119
–UN–31MAY05
Install determined shim pack (B).
Install bearing retainer (A).
YZ6210
B—Shim Pack
OURX078,0000002 –19–07JUN05–10/13

Install and tighten cap screws (A) in a criss-cross pattern.
Specification
–UN–03JUN05
Torque ............................................................................................ 40 N•m
(30 lb-ft)
Specification
YZ6209
Torque ............................................................................................ 80 N•m
(60 lb-ft)

121007
PN=219
NOTE: Second, Third, Fourth and Seventh shaft stage

assemblies will have thrust washers.
Install Thrust Washer (A).

02
35 Apply TY9370 High Strength Threadlock and Sealer to
,120 screw.
Install Screw (B).
–UN–03JUN05
A—Thrust Washer
B—Screw
YZ6217
OURX078,0000002 –19–07JUN05–12/13
Tighten Screw.
Specification
Screw-to-Shaft Assembly—
Torque ..................................................................................... 54—80 N•m
40—59 (lb-ft)
–UN–03JUN05
YZ6218
OURX078,0000002 –19–07JUN05–13/13
Bearing Adjustment of Output Shaft Front Housing
IMPORTANT: The output shaft MUST have the

bearings set with the correct end play.
Output Shaft End Play 0.02—0.12 mm

(0.001—0.005 in.)
Continued on next page OURX078,000001A –19–02FEB01–1/7

121007
PN=220
Position the transmission in the rollover stand so that the

shaft is in a vertical position.
Remove bearing retainer cap screws (A).

02
–UN–27FEB01
A—Bearing Retainer Cap Screws (4 used) 35
,121
RXA0051643
OURX078,000001A –19–02FEB01–2/7
Remove bearing retainer (A) with O-ring (B).
Remove and discard O-ring.
Remove shims (C).
–UN–01MAR01
C—Shim Pack
RXA0051499

121007
PN=221
Install bearing retainer without oil seal, O-ring or shims.
–UN–27FEB01
Specification
02 Bearing Retainer-to-Front
35 Housing Cap Screws—Torque ...................................................... 2.8 N•m
,122 (25 lb-in)
RXA0051644
Install yoke to output shaft without installing the retaining
components.
Rotate output shaft two complete turns clockwise; then

rotate two complete turns counterclockwise.
Remove yoke and retighten cap screws.
Specification
(25 lb-in)
–UN–27FEB01
RXA0051647
OURX078,000001A –19–02FEB01–4/7

average reading.

–UN–27FEB01

gage.

RXA0051645
Remove cap screws and remove spacer and bearing

retainer.

121007
PN=222

gap measurement.
Install determined shim pack (C).

02
–UN–01MAR01
35
Install new oil seal (B) in bearing retainer (A). ,123
Install bearing retainer with O-ring.
RXA0051499
C—Shim Pack
OURX078,000001A –19–02FEB01–6/7

–UN–27FEB01
Specification
Torque ............................................................................................ 40 N•m
RXA0051644
(30 lb-ft)
Specification
Torque ............................................................................................ 80 N•m
(60 lb-ft)
OURX078,000001A –19–02FEB01–7/7
Bearing Adjustment of Input Shaft
IMPORTANT: All clutch stage shaft assemblies

MUST have the bearings set with the
correct end play.

(0.001—0.005 in.)

121007
PN=223
Position the transmission in the rollover stand so the shaft

is in a vertical position
Install pump drive cover. (See Install Pump Drive Cover,

Group 30.)
02
–UN–27FEB01
35
,124 Remove bearing retainer cap screws (A).
RXA0051650
DPSG,YZ07927,167 –19–19AUG99–2/7
Remove bearing retainer (A) with O-ring (B).
Remove oil seal from inner diameter of retainer and

discard.
–UN–05FEB01
Remove O-ring (B) from retainer and discard.
Remove shims (C).
RXA0051498
B—O-Ring Oil Seal
C—Shim Pack

121007
PN=224
Install bearing retainer without oil seal, O-rings or shims.
Specification
02
–UN–27FEB01
Housing Cap Screw—Torque........................................................ 2.8 N•m 35
(25 lb-in) ,125
Install yoke to input shaft without installing the retaining
RXA0051651
components.
Rotate input shaft two complete turns clockwise; then

rotate two complete turns counterclockwise.
Remove the yoke.
–UN–27FEB01
Specification
(25 lb-in)
RXA0051649
DPSG,YZ07927,167 –19–19AUG99–4/7

average reading.
–UN–27FEB01
gage.
RXA0051652
Remove cap screws and remove bearing retainer.

121007
PN=225

gap measurement.
Install determined shim pack (C).

02
–UN–05FEB01
35
,126 Lubricate new O-ring (B) with transmission fluid and install
to bearing retainer (A).
RXA0051498
Install bearing retainer.
B—O-Ring Oil Seal
C—Shim Pack
DPSG,YZ07927,167 –19–19AUG99–6/7

–UN–27FEB01
Specification
Torque ............................................................................................ 40 N•m
(30 lb-ft)
RXA0051651
Specification
Torque ............................................................................................ 80 N•m
(60 lb-ft)
DPSG,YZ07927,167 –19–19AUG99–7/7

121007
PN=226
Section 03
Theory of Operation
Contents
Page
Group 20—Theory of Operation

Transmission Operation . . . . . . . . . . . . . . . . . .03-20-1 03
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . .03-20-2
Clutch Actuation . . . . . . . . . . . . . . . . . . . . . . . .03-20-3
Gear Train Operation . . . . . . . . . . . . . . . . . . . .03-20-4
Directional and Speed Clutch Operation . . . . . .03-20-6
Range Clutch Operation . . . . . . . . . . . . . . . . . .03-20-8
Internal Park Brake Operation . . . . . . . . . . . . .03-20-10
Transmission Hydraulic Diagram . . . . . . . . . . .03-20-12
Transmission Hydraulic Diagram - Internal
Park Brake Model . . . . . . . . . . . . . . . . . . . .03-20-14
Transmission Pump Operation . . . . . . . . . . . .03-20-16
Oil Filter Head . . . . . . . . . . . . . . . . . . . . . . . . .03-20-17
Main Regulator Valve . . . . . . . . . . . . . . . . . . .03-20-18
Main Regulator Valve Operation . . . . . . . . . . .03-20-20
Proportional Solenoid Valve Operation . . . . . .03-20-22
Powershift Control Unit . . . . . . . . . . . . . . . . . .03-20-24

121007
PN=1
Contents
03

121007
PN=2
Group 20
Theory of Operation
Transmission Operation
The engine is connected to the input shaft of the proportional valve. The rate of pressure rise behind
transmission. The Powershift transmission (PST) has each clutch piston is determined by the Powershift
18 speeds forward and 6 reverse speeds. When the Control Unit (PCU) providing the current to each valve.
transmission is in gear, the engine power is connected The engine power may be disconnected from the
to the output shaft of the transmission at different transmission output shaft by depressing the clutch
speed ratios depending on which directional, speed pedal or by shifting the transmission to the neutral or
and range clutches are engaged. Each clutch is park position.
engaged hydraulically and controlled by an individual
03
20
YZ07927,0000022 –19–01FEB01–1/1 1

121007
PN=229
Theory of Operation
Gear Selection
Three clutches—one directional, one speed and one

range—must be engaged in order to transmit torque from
the transmission input to the transmission output shaft. In
neutral all clutches are disengaged.
The following table shows which clutches are engaged in

each gear.
03 18-SPEED PST GEAR TABLE

20 Gear Clutches Engaged Gear Ratio
2
1F 1AL 4.648
2F 2AL 3.776
3F 1AM 3.410
4F 1BL 3.054
5F 2AM 2.771
6F 2BL 2.481
7F 1BM 2.241
8F 1CL 2.007
9F 2BM 1.821
10F 2CL 1.631
11F 1CM 1.473
12F 1AH 1.333
13F 2CM 1.197
14F 2AH 1.083
15F 1BH 0.876
16F 2BH 0.712
17F 1CH 0.576
18F 2CH 0.468
N - -
1R RAL 4.648
2R RAM 3.410
3R RBL 3.054
4R RBM 2.241
5R RCL 2.007
6R RCM 1.473
YZ07927,000002F –19–01FEB01–1/1

121007
PN=230
Theory of Operation
Clutch Actuation
Hydraulic oil pressure is directed from the proportional clutch pack, compressing the clutch return springs, and
valve, through passages in the rear housing, to the removing the free clearance in the clutch. The piston
seal rings on the end of the clutch shaft. The oil also moves the lube shut-off washer, trapped between
pressure is transferred from the stationary housing to the piston and the clutch return springs, causing it to
the rotating shaft in the area between the shaft seal uncover the lube holes that provide increased cooling
rings. The oil then travels down a hole in the shaft until oil flow to the clutch. Once the free clearance in the
it enters the area enclosed by clutch shaft weldment, clutch is eliminated, the piston applies pressure to the
the clutch apply piston and the piston seals. Here it clutch plates, causing the clutch to transmit torque in
acts on the piston area, causing it to move toward the proportion to the oil pressure applied. 03
20
3
YZ07927,0000025 –19–01FEB01–1/1

121007
PN=231
Theory of Operation
Gear Train Operation
03
20
4
–UN–24JUN03
YZ5051
A—First Stage (Input) Shaft C—Third Stage Shaft E—Fifth Stage Shaft Assembly G—Seventh Stage Shaft
Assembly Assembly (B, 1) (L) Assembly (M)
B—Second Stage Shaft D—Fourth Stage Shaft F—Sixth Stage Shaft H—Output Shaft Assembly
Assembly (A, 2) Assembly (C, R) Assembly (H)
The clutches labeled “1”, “2” and “R” are referred to as train to the range clutches of the transmission.
directional clutches. Clutches “1” and “2” will engage Working in conjunction with the directional clutches up
forward gears and clutch “R” will engage reverse to 18 speed ranges in forward and 6 speed ranges in
gears. The directional clutches connect the input shaft reverse are possible. The speed clutches are located
of the transmission through various ratios to the on the seal ring side of the double clutch stage
cylinder gears located in the upper part of the assemblies in the upper part of the transmission.
transmission. Directional clutches are located opposite
the seal ring side of the double clutch stage Clutches “L”, “M” and ”H” are referred to as range
assemblies. These clutches have two passages clutches. They are single clutches located in the lower
through the shaft in order to supply the “lube flow” to portion of the transmission and have three lube
cool the clutches. passages for cooling. These clutches are used for
modulation during the shift and when using the clutch
Clutches “A”, “B” and “C” are referred to as speed pedal.
clutches. The speed clutches connect the cylinder gear
YZ07927,000002E –19–30JUN03–1/1

121007
PN=232
Theory of Operation
03
20
5

121007
PN=233
Theory of Operation
Directional and Speed Clutch Operation
03
20
6
–UN–08MAR01
YZ3321
A—Lube Passage D—Lube Shutoff Washer F—Directional Clutch H—Speed Clutch

B—Seal Rings E—Clutch and Separator G—Piston
C—System Pressure Passage Plates
Continued on next page YZ07927,0000026 –19–01FEB01–1/2

121007
PN=234
Theory of Operation
Directional and speed clutches are located in the Speed Clutches

upper part of the transmission. Directional and speed
clutches make up the double clutch shaft assemblies. Speed clutches (H) are designated A, B, and C.
The directional clutches are located opposite the seal
ring end. The speed clutches are located on the seal System pressure oil passage (C) is used to engage
ring end of the shaft assembly. the clutches. The oil pressure for each clutch is kept
separated by the clutch shaft seal rings (B). The piston
Directional Clutches applies pressure to the clutch and separator plates
once the free clearance between the clutch and
Directional clutches (F) are designated 1, 2 and R. separator plates is eliminated and the clutch transmit
Clutches 1 and 2 engage forward gears, clutch R torque in proportion to the oil pressure applied. When 03
engages reverse gears. Directional clutches are the clutch piston is engaged, the lube shut-off washer 20
7
modulated along with the range clutches when using (D) moves to uncover the oil passage allowing more
the clutch pedal. lubrication to the clutch.
The clutch pressure oil passage (C) is used to engage Lubrication oil comes from the cooler through oil
the clutch piston. The clutch pressure oil for each passages in the main case rear housing. The
clutch is kept separated by the clutch shaft seal rings lubrication oil enters the shaft through an axially drilled
(B). The piston applies pressure to the clutch and hole. All clutches have a lubrication shut-off washer
separator plates (E) using clutch pressure oil against (D) that restricts lubrication oil flow to the clutch when
the piston (G). Once the free clearance between the it is not engaged. The extra oil flow provides additional
clutch and separator plates is eliminated the clutch lubrication and cooling.
transmits applied torque in proportion to the oil
pressure. When the clutch is disengaged, clutch pressure oil
becomes pressure free-oil and remains in the
The lubrication oil enters the shaft through an axially passages ready to be pressurized again.
drilled hole. Lubrication oil comes from the cooler
through oil passages in the rear housing into lube Range Clutches
passages (A) in the shaft assembly.
Range clutches L, M, and H are located in the lower
When the clutch is disengaged, system pressure oil part of the transmission, on the single-clutch shafts.
becomes pressure-free oil and remains in the
passages, ready to be pressurized again.
YZ07927,0000026 –19–01FEB01–2/2

121007
PN=235
Theory of Operation
Range Clutch Operation
03
20
8
–UN–07MAR01
YZ3320
A—Sealing Ring C—Clutch and Separator E—Oil to Sump I—Seal Rings

B—Passage to Lubricate Plates F—Seal Ring End of Shaft J—Clutch Pressure Passage
Clutch and Separator D—Cross Section of Shaft G—Clutch Piston K—Lube Passage
Plates Assembly H—Shutoff Washer
Continued on next page YZ07927,000007D –19–08FEB01–1/2

121007
PN=236
Theory of Operation
Range clutches have a third lube passage in the shaft time moving the lubrication shut-off washer and
to provide additional flow for cooling. They also have uncovering the oil passage, allowing more lubrication
more clutch and separator plates (C) than in the to the clutch pack. The extra oil flow provides
directional and speed clutches. The extra plates additional lubrication and cooling.
provide more friction area and higher thermal capacity.
These clutches are modulated along with directional Clutch pressure oil (J) is used to engage the clutches.
clutches during shifting and inching pedal operations. Lubrication oil (K) comes from the cooler through oil
passages in the rear housing. The oil pressures for
Range clutches have a sealing ring (A) that helps each clutch are kept separated by the clutch shaft seal
contain oil in the clutch. This causes the lubrication oil rings (I). The lubrication oil enters the shaft through an
(K) to flow mainly through the holes in the clutch gear axially drilled hole. Once the free clearance between 03
hub (B) to the clutch and separator plates (C) and out the clutch and separator plates is eliminated, the 20
9
the holes in the clutch cylinder (E) back to sump. All piston applies pressure to the clutch and separator
clutches have a lubrication shut-off washer (H) that plates, causing the clutch to transmit torque in
restricts lubrication oil flow to the clutch when it is not proportion to the oil pressure applied. When the clutch
engaged. is disengaged, clutch pressure oil becomes pressure
free-oil and remains in the passages ready to be
When the clutch is engaged, the piston (G) moves to pressurized again.
apply pressure to the clutch plates and at the same
YZ07927,000007D –19–08FEB01–2/2

121007
PN=237
Theory of Operation
Internal Park Brake Operation
03
20
10
–UN–10JUL03
YZ5061
A—Transmission Rear C—Brake Disk F—Springs I—Internal Park Brake
Housing D—Oil Passage G—Disks and Plates Assembly
B—Transmission Output Shaft E—Piston H—Separator Plates
The internal park brake assembly (I) is located on the The park brake is OFF when system pressure oil
rear end of the transmission output shaft (B). The moves from the parking brake valve through the oil
brake disks (C) are splined to a hub on the output passage (D). The system pressure oil moves the
shaft and the separator plates (H) are tabbed to the piston against the springs and releases the brake disks
transmission rear housing (A). (C) and plates.
The park brake is ON when there is no hydraulic Park brake components are cooled and lubricated by
pressure applied to the piston (E). The spring (F) transmission oil moving through passages in the
applies pressure to the piston forcing the brake disks transmission housings.
and plates (G) together. This locks the transmission
output shaft to the rear housing.
Continued on next page YZ07927,00000D7 –19–09JUL03–1/2

121007
PN=238
Theory of Operation
The park brake is spring applied and hydraulically connected to and holds the transmission output shaft
released. This multi-plate brake is immersed in an oil stationary to prevent drive train rotation when applied.
filled chamber located on the transmission. It is
YZ07927,00000D7 –19–09JUL03–2/2
03
20
11

121007
PN=239
Theory of Operation
Transmission Hydraulic Diagram
03
20
12
–UN–26SEP01
YZ3322
A—Park Brake Release H—Pressure Sensor N—To Axle Lube Pump S—From Cooler
B—To PTO Lube I—Switch O—From Axle Lube (4WD T—Sump
C—Transmission Lube J—Transmission Pump Only) U—To Supplement Steering
D—Lube Bypass K—Suction Screen P—Filter Assembly Charge
E—Cooler Bypass L—Stand Pipe Q—Filter Bypass V—Diff. Lock
F—Main Regulator M—From Steering Return (LTV R—To Cooler W—To PTO Control
G—Filter Element Only)
Continued on next page YZ07927,00000C0 –19–13MAR01–1/2

121007
PN=240
Theory of Operation
03
20
13
–UN–26SEP01
YZ3323
T—Sump X—Proportional Solenoid Y—Clutches
YZ07927,00000C0 –19–13MAR01–2/2

121007
PN=241
Theory of Operation
Transmission Hydraulic Diagram - Internal Park Brake Model
03
20
14
–UN–07AUG03
YZ5084
Continued on next page YZ07927,00000F0 –19–07AUG03–1/2

121007
PN=242
Theory of Operation
1—To PTO Control 8—From Axle Lube (4WD 14—Bypass Indicator 3.4 Bar 22—Port Orifice
2—To DIFF Lock Only) 15—Regulator 19.3 Bar 23—Pressure Transducer
3—To Supplement Steering 9—To Axle Lube Pump 16—Cooler Bypass 6.2 Bar 24—Park Brake Clutch
Charge Pump (Track only) 10—From Steering Pump 17—Lube Bypass 6.2 Bar 25—Park Brake Relief 22.4 Bar
4—Transmission Lube (Track Only) 18—Inlet Check Valve 26—Pressure Transducer
5—From Cooler 11—Rear Housing 78.6 cc/rev 19—S2 Solenoid 27—Clutches
6—To Cooler 12—Filter Head 20—S1 Solenoid 28—Sump
7—Filter Bypass 4.0 Bar 13—Elment 21—To Cab Connection Point
03
20
YZ07927,00000F0 –19–07AUG03–2/2 15

121007
PN=243
Theory of Operation
Transmission Pump Operation
A—Cover-to-Housing Cap Screw

B—Cover
C—Housing
–UN–01FEB01
03
20
16
RXA0051489
Older Style Transmission Oil Pump
YZ07927,000002D –19–15AUG03–1/2
The transmission gear pump draws oil from the

transmission sump through a suction screen. It travels
through an internal suction tube to the inlet side of the
pump. The pump is an internal gear pump with fixed
clearance. The gear shafts are supported by bushings.
The pump is driven by a gear train directly coupled to the
engine and has a minimum flow of 63.5 L/m (16.8 gpm) at
1000 engine rpm. It must maintain operating pressure and
deliver maximum flow of 208 L/m or (55 gpm) at 2240
engine rpm. Nominal flow at 2100 engine rpm is 190 L/m
(50 gpm)
–UN–01JUL03
YZ5059
Newer Style Transmission Oil Pump
YZ07927,000002D –19–15AUG03–2/2

121007
PN=244
Theory of Operation
Oil Filter Head
03
20
17
–UN–30NOV00
YZ1990
A—System Pressure (filtered) B—Bypass Valve D—Oil from Oil Pump E—Bypass Oil (unfiltered) to
Oil C—Pressure Switch Lube
From the pump the oil is directed to a filter assembly. filter (A). If the difference in pressure is greater than
Under normal operation the oil flows into the filter head 415 kPa (60 psi) the bypass valve will open and allow
(D) down through the filter (not shown) and out the unfiltered oil to pass only to the lube circuit (E). This
system pressure port (A). Under extreme cold or when will reduce the inlet pressure to protect the filter from
the filter element is at or near its capacity, the bypass over-pressurization. The filter head also contains a
valve (B) will open and allow unfiltered oil to pass into pressure switch (C) that senses the same pressures
the lube circuit by flowing out the bypass oil port (E). the bypass valve (B) does. Before the bypass valve
The bypass valve works by sensing the pressure on opens, the pressure switch will activate at 345 kPa (50
the inlet side of the filter (D) and the outlet side of the psi) and warn the operator of impending filter bypass.
YZ07927,0000110 –19–23JUL01–1/1

121007
PN=245
Theory of Operation
Main Regulator Valve
Filtered oil from the filter assembly is directed into the rear
transmission housing. The main regulator valve is teed
into the main system pressure along with the proportional
solenoids and the pressure sensor. The main regulator
works to give the regulated pressure circuit priority over
the cooler circuit. Any oil not needed to maintain
–UN–09APR03
1790-1930 kPa (260-290 psi) is allowed to flow through
the regulator valve and into the cooler circuit. The
03 regulated pressure is used to fill and engage clutches,
20 and make up the leakage in engaged clutches and the
YZ3981
18
proportional solenoids.
The oil cooler is supplied the remaining oil, and that oil is A—Main Regulator Valve
cooled before being returned to the transmission to be
used to lubricate all of the clutches, and bearings. The oil
cooler is supplied by the vehicle manufacturer and must
be able to flow up to 55 gpm oil at a pressure up to 2000
kPa (290 psi). It should be sized to provide sufficient
cooling in maximum ambient operating temperatures.
YZ07927,000010F –19–30JUN03–1/1

121007
PN=246
Theory of Operation
03
20
19

121007
PN=247
Theory of Operation
Main Regulator Valve Operation
03
20
20
–UN–06AUG03
YZ5083
A—Spool D—Shims Springs G—O-ring (Dampening Seals) J—System Pressure Oil
B—Cooler Pressure Port E—Outer Compression Spring H—Snap Ring K—Low Pressure Oil
C—Sump Port F—Inner Compression Spring I—Inlet Port L—Pressure Free Oil
System pressure oil (J) flows from the transmission oil captured between the spool and the plug at the other
filter and enters the pressure regulator valve at the end of the cartridge. Once the regulated pressure is
inlet port (I). The cooler pressure port (B) remains met, the spool will open and let all of the extra oil into
closed until sufficient pressure is reached. The the cooler circuit. Any drops in regulated pressure will
regulated pressure acts on the open end of the spool cause the spool to close the cooler port to try and
(A). The force from on the spool is counter acted by maintain regulated pressure. Any oil that leaks past the
the springs on the opposite side of the spool. The spool is returned to tank through the sump port (C).
pressure is determined by the preload of the springs
YZ07927,0000024 –19–01FEB01–1/1

121007
PN=248
Theory of Operation
03
20
21

121007
PN=249
Theory of Operation
Proportional Solenoid Valve Operation
03
20
22
–UN–24JUL01
YZ3426
A—Solenoid Coil F—Sump Port J—Spring N—System Pressure Oil
B—Armature G—Spool K—Screen O—Pressure Free Oil
C—Push Pin H—Clutch Port L—Orifice P—Proportional Solenoid
D—Ball I—Inlet Supply M—Pilot Cavity Valve—De-Energized
E—Seat
The proportional solenoid valve (P) is a pilot operated, to trap large particles, preventing them from
pressure-reducing cartridge valve. Its function is to contaminating the orifice. The orifice is used to meter
provide a regulated pressure to the clutch port that can the inlet flow into the pilot cavity (M). The passage
be controlled by the Powershift Control Unit (PCU) to a from the inlet supply port is always open to the pilot
pressure less than the supply pressure. Variations in cavity, regardless of the spool position, to maintain a
inlet pressure will not affect the regulated pressure pressure source to the pilot cavity.
setting as long as the inlet pressure remains higher
than the desired regulated pressure. Pilot cavity operation enables the valve to work at a
current level that the PCU is capable of controlling.
In operation, supply pressure enters the inlet supply The armature (B), push pin (C), and ball (D)
port (I) where it is blocked by a spool (G) which configuration controls the pilot cavity pressure which in
prevents the flow from going to the clutch port (H). The turn provides the force required to move the main
inlet supply must pass through a filter screen (K) spool.
before reaching the orifice (L). The filter screen is used
Continued on next page YZ07927,0000021 –19–01FEB01–1/2

121007
PN=250
Theory of Operation
With the solenoid valve de-energized, flow is free to increases, the magnetic force on the armature (B)
travel from the clutch port (H) to the sump port (F). increases, causing the push pin (C) to push against
The orifice (L) is used to meter the flow into the pilot the ball (D) to restrict flow exiting the pilot cavity (M).
cavity (M). Flow coming into the pilot cavity then This restriction causes a rise in pressure in the pilot
passes through the seat (E) and past the ball (D) cavity (M) and applies a force on the end of the main
which is in the open position when the solenoid coil (A) spool (G), causing it to move and compress the spring
is de-energized. This flow then travels out through (J). As the spool (G) moves, it closes the passage
slots on the outside threads of the valve to connect to from the clutch port (H) to the sump port (F) and
the sump port (F). begins to open slightly the supply pressure port (I).
The flow of oil causes the pressure in the clutch to
Because the ball has no restriction to the flow of fluid rise. 03
exiting the pilot cavity, no pressure is built up in the 20
23
pilot cavity to act against the spool end. A bias spring The clutch port pressure is fed to the spring end of the
(J) is located on the opposite end of the spool to main spool via the feedback passage causing the main
maintain spool position and prevents any slight spool to close as the clutch pressure and spring force
pressure build up from actuating the clutch. The bias becomes equal to the pilot cavity pressure. The output
spring requires a nominal pressure of 83 KPa (.008273 pressure from the valve is zero at zero current and
bar) (12 psi) to start spool movement. increases to within 103 kPa (1 bar) (15 psi) of the inlet
pressure as the current to the coil is increased. At
To provide proportional control, the solenoid coil (A) is approximately 100% duty cycle, the ball (D) rests
energized by the use of a pulse-width-modulated against the seat (E); the flow past the seat is
(PWM) signal by a varying duty cycle of 0% to 100%. essentially stopped; and the pressure in the pilot cavity
The increased duty cycle acts to increase the effective (M) is the same as the supply pressure at the inlet
current in the solenoid coil windings (A) causing an supply port (I) minus the bias pressure from the spring.
increase in the magnetic force. As the duty cycle
YZ07927,0000021 –19–01FEB01–2/2

121007
PN=251
Theory of Operation
Powershift Control Unit
The Powershift Control Unit (PCU) controls the designed algorithm to determine the best fill time and
transmission. Its main functions are: hold pressures for each.
1. Clutch control for shifting and calibration Park Brake Control

2. Park brake control
3. Monitoring transmission solenoids, sensors and The PCU controls the tractor’s park brake based on
operator commands present operating conditions and the operator’s
4. Communication with other devices on the tractor command, as received from the ACU. The park brake
03 • Engine Control Unit (ECU). is spring-applied and hydraulically released.
20 • Chassis Control Unit (CCU).
24
• Armrest Control Unit (ACU). The PCU has a special and separate control system
• Instrument Cluster Unit (ICU). within it called the Park brake Backup Controller
• Corner Post Display (CPD). (PBC). The purpose of the PBC is to make sure that if
5. Reporting operational status and diagnostics power is lost to the PCU while the tractor is moving,
information. the park brake will not engage until the tractor has
slowed down. The PBC has its own separate supply
Clutch Control for Shifting and Calibration voltage and output speed sensor, and drives one of
the two park solenoids. The PCU monitors the other
• The PCU uses electrohydraulic proportional valves output speed sensor, controls the other park solenoid,
to engage and disengage the transmission clutches, and monitors the park brake pressure.
which are arranged in a 3 x 3 x 3 design:
• 1, 2, R - Directional Both park solenoids must be on to release the park
• A, B, C - Speed brake. The PCU and PBC maintain a system of
• L, M, H - Range checks-and-balances to ensure that the two output
speed sensors are in agreement and that the status of
The solenoid on each valve is driven by a pulse-width the park solenoids is correct for the present operating
modulated signal from the PCU that produces conditions. Both solenoids must be off to engage Park.
proportional pressure changes. The electrical current in
each solenoid is monitored by the PCU and is Monitoring Transmission Solenoids, Sensors and
increased or decreased to maintain the commanded Operator Commands
setpoint, and therefore the proper clutch pressure.
Modulating the solenoid drive signal and monitoring • The PCU monitors all components critical to
the solenoid current greatly enhances shift quality. transmission operation and control:
• Clutch solenoids
Shift commands from the operator are sent by the • Speed sensors
ACU to the PCU via the CCD bus. Based on the • Transmission oil temperature
command and the present operating conditions, the • Transmission system pressure
PCU will engage and disengage the appropriate • Park solenoids
clutches. • Park brake pressure
• Clutch pedal position
The PCU has a separate operating mode used during • Clutch pedal switch states
transmission calibration. During calibration the PCU • CAN communications bus information
controls the clutches automatically per a carefully • CCD communications bus information
Continued on next page YZ07927,0000023 –19–03JUL03–1/2

121007
PN=252
Theory of Operation
Communication with Other Devices on the Tractor functions. The PCU generates a diagnostic code to
indicate potential problems. Depending on the severity
The PCU is only one of several controllers on the of the fault, the fault response and alarm level vary
tractor, each having its own specific function. The PCU accordingly. A minor fault may result in only an
communicates with several of these devices by various informational indication to the operator, while a major
means, receiving information from and/or supplying fault may require the operator to stop the engine until
information to them. the problem is resolved.
1. With the ECU, via CAN bus The PCU reports diagnostic codes related to these
• Engine speed and torque to the PCU. areas:
• Transmission sump temperature to the ECU. 03
2. With the CCU, via CCD bus • The clutch solenoids 20
25
• “PCU present and working” message, vehicle • The transmission speed sensors
model and serial number information, engine speed, • Transmission oil temperature and system pressure
transmission oil temperature, status of clutch pedal, sensors
throttle position, and PTO • The park brake system
• Output speed information to CCU via a frequency • The clutch pedal and switches
signal. • Calibration
3. With the ACU, via CCD bus • PCU self-checks
• Commanded gear and speedmatch gear • Shift lever position and relay logic
4. With the ICU, via CCD bus
• Alarms, warnings, diagnostic codes to the ICU The presently active diagnostic code may be viewed
5. With the CPD, via CCD bus on the ICU during normal operation or while in
• Present gear information, calibration diagnostic diagnostic mode.
and status data to the CPD
In addition to reporting diagnostic codes during normal
The CAN and CCD busses are critical serial operation, the PCU has a special diagnostic mode
communications lines that link the various controllers which provides the ability to perform first-step
on the tractor. While the PCU can communicate using troubleshooting of the sensors, solenoids, clutch pedal,
either bus, the other devices are capable of just one and relay logic. Diagnostic mode also makes it
type. CAN is considerably faster than CCD. possible to retrieve certain information about the PCU,
the tractor model and serial number, and any
See “PCU System Interface” in “General References” diagnostic codes that may have been stored.
for devices communicating with the PCU. Information is conveyed to the operator via the CPD
while in diagnostic mode rather than via the ICU.
Reporting Operational Status and Diagnostics
Information
Reporting operational status and diagnostic information

to the operator is one of the PCU’s most important
YZ07927,0000023 –19–03JUL03–2/2

121007
PN=253
Theory of Operation
03
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26

121007
PN=254
Section 05
Tools and Other Materials
Contents
Page
Group 175—Special Tools

Essential Tools For JDG9x20PST . . . . . . . . . .05-175-1
Essential Tools for JDG9x20PSTWB. . . . . . . .05-175-6
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .05-175-8
Group 195—Dealer Fabricated Tools

DFRW146 Relief Valve Removal Tool. . . . . . .05-195-1
05
Guide Pins For Front And Rear Housing . . . . .05-195-1
Guide Pin for Shims, Caps and Pump
Housings . . . . . . . . . . . . . . . . . . . . . . . . . . .05-195-2

121007
PN=1
Contents
05

121007
PN=2
Group 175
Special Tools
Essential Tools For JDG9x20PST
Essential Tools
NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company YZ07927,00003E0 –19–05DEC07–1/26
RW37204 –UN–15JUN99
Engine Rollover Stand . . . . . . . . . . . . . . . . D05223ST

05
Disassemble and Assemble Transmission 175
1
YZ07927,00003E0 –19–05DEC07–2/26
RW25560 –UN–29AUG96
Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . JDG19
Attach transmission assembly to lifting device
YZ07927,00003E0 –19–05DEC07–3/26
RW25383 –UN–02APR96
Yoke Holding Tool . . . . . . . . . . . . . . . . . . . . . JDG924
Remove and install yokes
YZ07927,00003E0 –19–05DEC07–4/26
RW25381 –UN–14JUN95
Bearing Installer . . . . . . . . . . . . . . . . . . . . . JDG926A
Install input and output shaft oil seals. Use with

JDG1487A Seal Installer Plate.
YZ07927,00003E0 –19–05DEC07–5/26
Engine Rollover Stand Bracket. . . . . . . . . . . . JDG1476
Install transmission to engine rollover stand

–UN–12FEB01
RXA0051546
Continued on next page YZ07927,00003E0 –19–05DEC07–6/26

121007
PN=257
Special Tools
RW25388 –UN–15JUN95
Seal Installer Plate . . . . . . . . . . . . . . . . . . JDG1487A
Install input and output shaft seals. Use with JDG926A

Bearing Installer.
YZ07927,00003E0 –19–05DEC07–7/26
Pump Drive Gear Installer . . . . . . . . . . . . . . JDG1472A
Install pump drive gear to input shaft
–UN–20FEB01
05
RXA0051452
175
2
YZ07927,00003E0 –19–05DEC07–8/26
Pump Drive Gear Puller . . . . . . . . . . . . . . . . JDG1473
Remove pump drive gear from input shaft
–UN–13FEB01
RXA0051547
YZ07927,00003E0 –19–05DEC07–9/26
RXA0051446 –UN–20FEB01
Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . JDG1106
Remove and install clutch stage shafts to nest fixture
YZ07927,00003E0 –19–05DEC07–10/26
RXA0051447 –UN–20FEB01
Eyebolt . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1112
Remove and install output shaft to transmission front

housing

121007
PN=258
Special Tools
Clutch Stack Nest Fixture . . . . . . . . . . . . . . . JDG1470
Hold clutch shaft assemblies for access for disassembly
–UN–20FEB01
RXA0051448
YZ07927,00003E0 –19–05DEC07–12/26
Clutch Stack Lifting Fixture . . . . . . . . . . . . . . JDG1471

05
Remove and install clutch shaft assemblies to 175
transmission front housing 3
–UN–20FEB01
RXA0051450
YZ07927,00003E0 –19–05DEC07–13/26
RXA0051456 –UN–20FEB01
Roller Ball Bearing Installer . . . . . . . . . . . . . . JDG1474
Install roller ball bearings to clutch shafts. Use with

JDG1485 Clutch Piston Return Spring Compressor.
YZ07927,00003E0 –19–05DEC07–14/26
RXA0051458 –UN–20FEB01
Clutch Disk Alignment Guide . . . . . . . . . . . . . JDG1475
Align clutch disks for clutch shaft assembly
YZ07927,00003E0 –19–05DEC07–15/26
Puller Legs . . . . . . . . . . . . . . . . . . . . . . . . JDG1477
Remove roller ball bearings from clutch shafts

–UN–20FEB01
RXA0051462

121007
PN=259
Special Tools
RXA0051466 –UN–20FEB01
Sealing Ring Sleeve Installer . . . . . . . . . . . . . JDG1479
Install sealing ring sleeves in transmission rear housing
YZ07927,00003E0 –19–05DEC07–17/26
RXA0051470 –UN–20FEB01
Input Shaft Alignment Fixture. . . . . . . . . . . . . JDG1481
Position input shaft during bearing endplay setting rotating

procedure
YZ07927,00003E0 –19–05DEC07–18/26
RXA0051472 –UN–20FEB01
Shaft Protector . . . . . . . . . . . . . . . . . . . . . . JDG1482

05
175 Protect sealing ring end of clutch shaft assemblies during
4 disassembly
YZ07927,00003E0 –19–05DEC07–19/26
Clutch Rotation Tools. . . . . . . . . . . . . . . . . . JDG1486 B

A
–UN–30APR01
Engage shaft clutches to allow clutch shaft rotation
A—JDG1486-1 Hose Assembly

B—JDG1486-2 Input Fitting Assembly B
RXA0052923
C—Quick Coupler Fitting (Dealer Furnished)
C
YZ07927,00003E0 –19–05DEC07–20/26
RXA0051463 –UN–23FEB01
Transmission Rear Cover Lifting Bracket . . . . . JDG1489
Remove and install transmission rear housing to front

housing
YZ07927,00003E0 –19–05DEC07–21/26
RXA0051548 –UN–12FEB01
Sealing Ring Sleeve Remover . . . . . . . . . . . . JDG1490
Remove sealing ring sleeves from transmission rear

housing

121007
PN=260
Special Tools
JDG1974 Bore Sleeve Puller Kit. . . . . . . . . . . JDG1974
Remove Sealing ring sleeves from transmission rear

housing.
–UN–11OCT05
YZ6251
YZ07927,00003E0 –19–05DEC07–23/26
Clutch Gear Puller—2nd Stage Shaft

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . JDG1480 05
175
Remove clutch gear from clutch shaft 5
–UN–12FEB01
RXA0051549
YZ07927,00003E0 –19–05DEC07–24/26
Clutch Piston Return Spring Compressor . . . . . JDG1485
Install roller ball bearings to clutch shafts
–UN–20JAN05
YZ7112
YZ07927,00003E0 –19–05DEC07–25/26
RXA0051474 –UN–20FEB01
Eyebolt . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1484
Lift shaft to measure shaft end play
YZ07927,00003E0 –19–05DEC07–26/26

121007
PN=261
Special Tools
Essential Tools for JDG9x20PSTWB
Pry Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1803
Use for all pivot and pull blocks to help set end play on all
shaft assemblies.
–UN–29JUN05
YZ6219
YZ07927,0000441 –19–16JUN05–1/10
Seventh Stage End Play Adjustment Shaft . . . . JDG1795

05
175 Use with JDG1797 to help set end play on the 7th stage
6 shaft assembly
–UN–29JUN05
YZ6224
YZ07927,0000441 –19–16JUN05–2/10
Seventh Stage End Play Pivot Block . . . . . . . . JDG1797
Use with JDG1795 to help set end play on the 7th stage
shaft assembly
–UN–29JUN05
YZ6223
YZ07927,0000441 –19–16JUN05–3/10
Second, Third, and Fourth Stage End Play Adjustment

Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1793
Use with JDG1754 to help set end play on the 2nd, 3rd,
–UN–29JUN05
and 4th shaft assemblies

YZ6226
Continued on next page YZ07927,0000441 –19–16JUN05–4/10

121007
PN=262
Special Tools
Second, Third, and Fourth Stage End Play Pivot

Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1754
Used with JDG1793 to help set end play on the 2nd, 3rd,
–UN–29JUN05
4th, 5th, and 6th shaft assemblies
YZ6227
YZ07927,0000441 –19–16JUN05–5/10
Fifth and Sixth Stage End Play Adjustment

Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1794 05
175
Used with JDG1754 to help set end play on the 5th and 7
–UN–29JUN05
6th shaft assemblies
YZ6225
YZ07927,0000441 –19–16JUN05–6/10
Internal Brake Piston Spacer Installer . . . . . . . JDG1918
Used to install brake piston spacer on 18-speed PST

transmissions used on 9020 series tractors. Used to install
–UN–29JUN05
brake piston spacer on DF230 Series Transmission in
870D and 872D Series Motor Grader.
YZ6229
YZ07927,0000441 –19–16JUN05–7/10
EYEBOLT - 20 MM . . . . . . . . . . . . . . . . . . . JDG1798
Use with JDG1799 to set output shaft end play

–UN–29JUN05
YZ6222
Continued on next page YZ07927,0000441 –19–16JUN05–8/10

121007
PN=263
Special Tools
Output End Play Pivot Block . . . . . . . . . . . . . JDG1799
Use with JDG1798 to set output shaft end play
–UN–29JUN05
YZ6221
YZ07927,0000441 –19–16JUN05–9/10
Theaded Shaft . . . . . . . . . . . . . . . . . . . . . . JDG1802

05
175 Use to help set end play on the output shaft assembly.
8
–UN–29JUN05
YZ6220
YZ07927,0000441 –19–16JUN05–10/10
Other Material
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Retain yoke retaining cap screws
TY9473 (Canadian) Strength)
242 (LOCTITE)
TY16021 (U.S.) High Flex Form-In-Place Gasket Seal pump drive cover-to-front
TY9484 (Canadian) housing joint
17430 (LOCTITE)
TY16021 (U.S.) High Flex Form-In-Place Gasket Seal transmission rear

TY9484 (Canadian) housing-to-front housing joint
17430 (LOCTITE)
LOCTITE is a trademark of Loctite Corp. YZ07927,00003E1 –19–02MAR05–1/1

121007
PN=264
Group 195
Dealer Fabricated Tools
RXA0052902 –UN–23APR01
DFRW146 Relief Valve Removal Tool C

A B
Material Required:
• 3/4 in. x 10 Threaded Rod

• 3/4 in. x 10 Nut (2 used) D
Cut threaded rod (A) to 165 mm (6.5 in.) length.

A—Washer
B—Nut
Weld one nut (C) to end of threaded rod. C—Nut
D—Threaded Rod
Assemble nut (B) and washer (A) to threaded rod.
05
195
1
OURX078,000000C –19–11APR01–1/1
Guide Pins For Front And Rear Housing
M16 Guide pins to be used when installing rear housing

onto front housing.
Material required:
• Two M16 cap screw cut to 200 mm (7.875 in) length.
Remove hex head of cap screw to give 200 mm (7.875 in)

length.
Chamfer end of cap screw to 30°.
A—6 mm (.236 in.)

B—30° Angle
C—16 mm (.629 in.)
D—M16 thd
E—25 mm (.984 in.)
F—200 mm (7.783 in.)
–UN–30JUN05
YZ6230
YZ07927,0000442 –19–30JUN05–1/1

121007
PN=265
Dealer Fabricated Tools
Guide Pin for Shims, Caps and Pump

Housings
Guide Pins to be used when installing shims, caps and

pump housing onto front housing.
Material required:
• Two M10 cap screw cut to 100 mm (3.936 in.) length.
Remove hex head of cap screw to give 100 mm (3.936

in.) length.
Chamfer end of cap screw to 30°.
05 A—100 mm (3.936 in.)

195 B—6 mm (.236 in.)
–UN–30JUN05
2 C—30° Angle
D—10 mm (.393 in.)
E—8.40—8.35 mm (.330—.328 in.)
F—25 mm (.984 in.)
YZ6231
YZ07927,0000443 –19–30JUN05–1/1

121007
PN=266
Section 06
Specifications
Contents
Page
Group 205—Torque Value

Metric Bolt and Screw Torque Values . . . . . . .06-205-1
Unified Inch Bolt and Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-205-2
Fittings, O’ring and Hose. . . . . . . . . . . . . . . . .06-205-3
06

121007
PN=1
Contents
06

121007
PN=2
Group 205
Torque Value
Metric Bolt and Screw Torque Values
–UN–01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
TS1670
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N•m lb-ft N•m lb-ft N•m lb-ft
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N•m lb-ft
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
06
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190 205
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300 1
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. instructions are given for the specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 –19–24APR03–1/1

121007
PN=269
Torque Value
Unified Inch Bolt and Screw Torque Values

TS1671 –UN–01MAY03
Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c
Screw Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N•m lb-ft N•m lb-ft
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N•m lb-ft N•m lb-ft
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N•m lb-ft N•m lb-ft N•m lb-ft
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N•m lb-ft
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
06 9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
205
2 5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 –19–24APR03–1/1

121007
PN=270
Torque Value
Fittings, O’ring and Hose
The scope is for parts or components that are connected

or attached by use of fasteners.
The purpose is to provide a procedure for identifying

torque requirements for Funk Product.
The reference is Funk Quality Manual, Section 4.0.
QSO4.01.3 Engineering Specification

TORQUES FOR SAE J1926
O-RING PORT SUTDS AND LOCK NUTS
WRENCHING SYSTEM ACCURACY = +15% -20%
REFERENCE: JOHN DEERE STANDARD JDV 14
THREAD DASH METRIC (N•m) ENGLISH (lb-ft)
SIZE THD SIZE Ttarget Tmin Tmax Ttarget Tmin Tmax
3/8 24 -3 8.0 6.4 9.2 6.0 4.8 6.9
7/16 20 -4 12.0 9.6 13.8 9.0 4.8 6.9
1/2 20 -4 16.0 12.8 18.4 12.0 9.6 13.8
9/16 18 -6 24.0 19.2 27.6 18.0 14.4 20.7 06
205
3/4 16 -8 46 37 53 34 27 39 3
7/8 14 -10 62 50 71 46 37 53
1 1/16 12 -12 102 82 117 75 60 86
1 3/16 12 -14 122 98 140 90 72 104
1 5/16 12 -16 142 114 163 105 84 121
1 5/8 12 -20 190 152 219 140 112 161
1 7/8 12 -24 217 174 250 160 128 184
YZ07927,00000A3 –19–24APR03–1/1

121007
PN=271
Torque Value
06
205
4

121007
PN=272
Index
Page Page
A Shims
Caps
Adhesives and sealants . . . . . . . . . . . . . . . . .01-10-3 Pump Housing . . . . . . . . . . . . . . . . . .05-195-2
Axle
General repair procedures . . . . . . . . . . . . .01-10-2
Sealing instructions . . . . . . . . . . . . . . . . . . .01-10-4
H
Hydraulic pump, transmission. . . . . . . . . . . .03-20-16

B
Bearing adjustment output shaft

Rear housing bearing adjustment output shaft I
Output shaft bearing adjustment rear
housing . . . . . . . . . . . . . . . . . . . . . . .02-35-99 Inlet tube . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-4
Bearing Adjustments to Clutch Stage Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-31
Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-109
Bore sleeves . . . . . . . . . . . . . . . . . . . . . . . .02-35-16
L
C Lube relief bypass valve . . . . . . . . . . . . . . . . .02-25-7
Clutch actuation . . . . . . . . . . . . . . . . . . . . . . .03-20-3

Clutch Assemblies . . . . . . . . . . . . . . . . . . . .02-35-19
Cooler relief bypass valve . . . . . . . . . . . . . .02-25-10 M
Indx
Magnetic pickup sensor . . . . . . . . . . . . . . . .02-20-25
1
Main pressure regulator valve . . . . . . . . . . .03-20-20
D Main regulator valve . . . . . . . . . . . . . . . . . . . .02-25-6
Directional and speed clutch operation . . . . . .03-20-6
O
E Oil
Filter Head . . . . . . . . . . . . . . . . . . . . . . . .03-20-17
Engine rollover stand . . . . . . . . . . . . . . . . . . .02-15-2 Oil and filter changes . . . . . . . . . . . . . . . . . . .01-10-9
oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-25-3
Oil filter head . . . . . . . . . . . . . . . . . .02-25-4, 02-25-6
F Oil filter head pressure switch . . . . . . . . . . .02-20-28
Oil Filter Switch . . . . . . . . . . . . . . . . . . . . . . .02-25-5
Fifth Stage Clutch Shaft Assembly . . . . . . . .02-35-44 Oil level sight glass . . . . . . . . . . . . . . . . . . .02-25-12
Fifth stage magnetic pickup sensor . . . . . . .02-20-26 Oil pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-30-8
Filter by-pass valve . . . . . . . . . . . . . . . . . . . .02-25-5 Oil pump gear assembly. . . . . . . . . . . . . . . . .02-30-5
Fourth Stage Clutch Shaft Assembly . . . . . .02-35-40 Output magnetic pickup sensors. . . . . . . . . .02-20-27
Output shaft . . . . . . . . . . . . . . . . . . . . . . . . .02-35-22
G
P
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . .03-20-2
Gear train operation . . . . . . . . . . . . . . . . . . . .03-20-4 Proportional solenoid . . . . . . . . . .02-20-18, 02-20-20
Guide Pin Proportional Solenoid Valve Operation . . . . .03-20-22
Front and Rear Housing . . . . . . . . . . . . . .05-195-1 Pump drive cover . . . . . . . . . . . . . . . . . . . . . .02-30-2
CTM168 (10DEC07) Index-1 18-Speed PST Repair Manual

121007
PN=1
Index
Page Page
R Transmission oil pump . . . . . . . . . . . . . . . . . .02-30-9

Transmission pressure regulator. . . . . . . . . .03-20-20
Range Clutch Operation . . . . . . . . . . . . . . . . .03-20-8 Transmission pump operation. . . . . . . . . . . .03-20-16
Rear housing . . . . . . . . . . . . . . . . . . . . . . . . .02-35-1
Recommended Lubricants . . . . . . . . . . . . . . .01-10-6
V
S Valve
Main regulator. . . . . . . . . . . . . . . . . . . . . .03-20-18
Sealants and adhesives . . . . . . . . . . . . . . . . .01-10-3
Sealing instructions . . . . . . . . . . . . . . . . . . . .01-10-4
Second stage clutch shaft . . . . . . . . . . . . . .02-35-32
W
Sensor and ports, front housing . . . . . . . . . .02-20-14
Sensor and ports, rear housing . . . . . . . . . .02-20-16
Wet brake assembly. . . . . . . . . . . . . . . . . .02-35-102
Seventh Stage Clutch Shaft Assembly . . . . 02-35-52,
02-35-54
Sixth Stage Clutch Shaft Assembly . . . . . . .02-35-48
Solenoid operation . . . . . . . . . . . . . . . . . . . .03-20-22 Y
Speed clutch
Operation . . . . . . . . . . . . . . . . . . . . . . . . . .03-20-6 Yoke, install and remove . . . . . . . . . . . . . . . .02-15-6
Speed clutch operation. . . . . . . . . . . . . . . . . .03-20-6
Stand pipe . . . . . . . . . . . . . . . . . . . . . . . . . .02-35-24
Suction screen . . . . . . . . . . . . . . . . . . . . . . . .02-25-2
Suction tube . . . . . . . . . . . . . . . . .02-35-27, 02-35-28
System pressure sensor . . . . . . . . . . . . . . . .02-20-29
Indx
2
Temperature sensor . . . . . . . . . . . . . . . . . . .02-20-30

Theory of
Clutch Actuation . . . . . . . . . . . . . . . . . . . . .03-20-3
Directional Clutch Operation . . . . . . . . . . . .03-20-6
Gear Selection . . . . . . . . . . . . . . . . . . . . . .03-20-2
Gear train operation . . . . . . . . . . . . . . . . . .03-20-4
Main Regulator Valve Operation . . . . . . . .03-20-20
Proportional Solenoid Valve Operation . . .03-20-22
Range Clutch Operation . . . . . . . . . . . . . . .03-20-8
Speed Clutch Operation . . . . . . . . . . . . . . .03-20-6
Transmission Operation . . . . . . . . . . . . . . .03-20-1
Transmission Pump Operation
Oil Filter Head
Main Regulator Valve. . . . . . . . . . . . .03-20-16
Theory of internal park brake
Internal park brake . . . . . . . . . . . . . . . . . .03-20-10
Third Stage Clutch Shaft Assembly . . . . . . .02-35-36
Transmission
Operation . . . . . . . . . . . . . . . . . . . . . . . . . .03-20-1
Transmission control unit operation . . . . . . .03-20-24
Transmission Hydraulic Diagram . . . . . . . . .03-20-12
Transmission Hydraulic Diagram - IPB . . . . .03-20-14
Transmission mounting bracket . . . . . . . . . . .02-15-2
CTM168 (10DEC07) Index-2 18-Speed PST Repair Manual

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18-Speed PST Repair

John Deere Coffeyville Works

Notice to the Dealer

This Component Technical Manual should be used Transmission Identification Plate

IMPORTANT: Before beginning repair or making

CTM168 (10DEC07) 18-Speed PST Repair Manual

SECTION 02—Repair and Adjustments

SECTION 05—Tools and Other Materials

All information, illustrations and specifications in this manual are based on

CTM168 (10DEC07) i 18-Speed PST Repair Manual

CTM168 (10DEC07) ii 18-Speed PST Repair Manual

Group 000—Safety . . . . . . . . . . . . . . . . . . . .01-000-1

Group 10—General Information

CTM168 (10DEC07) 01-1 18-Speed PST Repair Manual

CTM168 (10DEC07) 01-2 18-Speed PST Repair Manual

This is a safety-alert symbol. When you see this symbol

Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

Do not charge a frozen battery; it may explode. Warm

CTM168 (10DEC07) 01-000-1 18-Speed PST Repair Manual

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

CTM168 (10DEC07) 01-000-2 18-Speed PST Repair Manual

Direct exposure to hazardous chemicals can cause

(See your John Deere dealer for MSDS’s on chemical

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin

Avoid the hazard by relieving pressure before

Search for leaks with a piece of cardboard. Protect hands

If an accident occurs, see a doctor immediately. Any fluid

CTM168 (10DEC07) 01-000-3 18-Speed PST Repair Manual

Before working on the machine:

• Lower all equipment to the ground.

Support Machine Properly

Always lower the attachment or implement to the ground

When implements or attachments are used with a

Wear Protective Clothing

Wear close fitting clothing and safety equipment

Prolonged exposure to loud noise can cause impairment

Wear a suitable hearing protective device such as

Operating equipment safely requires the full attention of

CTM168 (10DEC07) 01-000-4 18-Speed PST Repair Manual

Before starting a job:

• Clean work area and machine.

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is

Illuminate Work Area Safely