INTRODUCTION

GENERAL Put plugs in the open fittings. Put tags for identifi-
cation on the lines.
This section has the repair procedures for the trans-
mission and torque converter, the control valves 11. H17.00-32.00C (H360-700C) - Units with
and the oil pump for the transmission. PERKINS diesel engines and earlier production
lift trucks with DETROIT DIESEL engines:
TRANSMISSION Disconnect the drive shaft at the output yoke of the
transmission.
Removal
H17.00-32.00C (H360-700C) - Late production
Use the following procedure to remove the engine units with DETROIT DIESEL engines and
and the transmission as an assembly: H20.00-32.00F (H440-700F/FS): a drive plate is
used between the torque converter and flywheel.
1. Put the lift truck on a level surface. Apply the
parking brake and lower the carriage. Put blocks Remove the capscrews and lock washers that fas-
on each side (front and back) of the drive tires. ten the drive plate to the flywheel. Use the access
hole in the flywheel housing on the side opposite
2. Disconnect the cables at the battery. Remove the starter to remove the capscrews.
the hood.
12. Connect a lifting device to the engine and trans-
3. Drain the oil from the transmission. Use the plug mission. Use the lifting eyes on the engine and on
at the bottom of the transmission housing. the transmission mount. Make sure the lifting device
has a capacity of 1500 kg (3300 lb).
4. Drain the coolant from the cooling system. Dis-
connect the hoses and remove the radiator. Put caps 13. Raise the lifting device so that it holds the en-
on the cooling line from the transmission. gine and transmission. Remove the capscrews that
hold the mount at the fan end of the engine to the
5. Remove the tubing between the engine and air frame. Remove the bolts at the transmission mounts.
cleaner. Carefully lift the engine and transmission from the
lift truck. Make sure all the connections have been
6. Disconnect the exhaust system. Remove the pipe removed.
at the turbocharger.
14. Use the following procedure to remove the
7. Disconnect the air lines at the air compressor. transmission from the engine:

8. Disconnect fuel lines at the fuel filter. Discon- a. Use blocks to hold the engine so that it has
nect throttle linkage. stability. Connect the lifting device to the lift-
ing eyes on the transmission mount.
9. Disconnect wires and wiring harnesses at the
engine and at the transmission. Disconnect the b. Remove the capscrews between the torque
heater hoses at the engine. converter housing and the flywheel housing.
Use the lifting device to move the transmis-
10. Disconnect the oil lines at the manifold block. sion from the flywheel housing. Before rais-
Put tags for identification on the lines. Put plugs in ing the transmission, make sure the impeller
the open fittings. Disconnect the oil lines at the cover is disengaged with the ring gear for
hydraulic pumps. the torque converter.
FIGURE 1. TORQUE CONVERTER
Transmission, Disassembly

STEP 3. Remove the transmission pump.

STEP 1. Remove the hydraulic pumps from the

torque converter housing. Remove
the transmission mount from the
transmission. Remove the manifold
block and modulatar valve from the
torque converter housing.

STEP 4. Remove the press regulator valve.

STEP 2. Remove the nuts that hold the transmis-

sion pump to the housing. STEP 5. Remove the sleeves for the pump shafts.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (1 of 17)

STEP 6. Remove the adapter for the hydraulic
pump.

STEP 9. Remove the capscrews for the impel-

ler cover.

STEP 7. Remove the capscrews for the bearing

cover on the impeller cover.

STEP 10. Use an alignment stud (a long capscrew

with the head removed) as a guide for
the impeller cover. Install the alignment
stud at the top of the impeller cover. Use
STEP 8. Remove the bearing cover. a prybar in the slots to remove the im-
peller cover.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (2 of 17)

STEP 11. Remove the impeller cover and tur-
bine as an assembly. STEP 14. Remove the stator and the spacer.

STEP 12. Remove the snap ring and the spacer STEP 15. Remove the spacer from the torque
from the impeller cover. Separate the converter housing.
impeller cover and the turbine.

STEP 13. Remove the snap ring for the stator. STEP 16. Remove the retainer ring for the oil baffle.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (3 of 17)

 STEP 20. Remove the impeller gear.
STEP 17. Use prybars in the slots in the torque
converter housing to remove the oil
baffle and the impeller.

STEP 21. Remove the oil baffle from the impeller.

STEP 18. Remove the impeller, oil baffle and the

hub for the impeller as an assembly.

STEP 19. Remove the retainer ring from the hub STEP 22. Remove the capsrews that hold the hub
of the impeller gear. to the impeller.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (4 of 17)

STEP 23. Remove the hub, O-ring and spacer
from the impeller.

STEP 26. Connect a lifting device to the torque

converter housing. Remove the
capscrews that hold the torque con-
verter housing to the transmission
housing.

STEP 24. Remove the capscrews for the stator tube.

STEP 27. Separate the torque converter housing

STEP 25. Remove the stator tube. Rotate the sta- from the transmission housing.
tor tube for clearance with the drive
gear.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (5 of 17)

STEP 28. Remove the capscrews for the hubs
for the drive gears for the hydraulic
pumps.

STEP 31. Remove the gear in the center.

STEP 29. Move the center gear toward the rear

of the housing, then remove the gear on
the right side.

STEP 32. Use snap ring pliers to disengage the

snap ring that holds the bearing retainer
in the housing. Use a prybar to remove
STEP 30. Remove the gear on the left side.
the reverse and second speed clutch
assembly.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (6 of 17)

STEP 33. Remove the spacer from the transmis- STEP 35. Remove the nut, washer and O-ring
sion housing. for the output yoke.

NOTE: A special socket (2 3/8 in) must be

made to remove the nut. Make the
outside diameter of the socket 78 mm
(3.085 in) for a length of 20 mm (0.75
in).

1. OUTPUT YOKE
STEP 34. Remove the pilot bearing for the shaft
for second speed clutch. STEP 36. Remove the output yoke.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (7 of 17)

STEP 37. Remove the bearing cover for the shaft
for first speed.

STEP 40. Remove the capscrews and the bear-

ing retainer.

STEP 38. Remove the bearing cover for the out-

put shaft.

STEP 39. Remove the lock wire from the STEP 41. Remove the retainer rings from the
capscrews for the bearing retainer. bearings on the output shaft and the
Remove the seal ring from the shaft. first speed shaft.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (8 of 17)

STEP 42. Remove the capscrews that hold the
rear cover to the transmission housing.
Use a prybar in the slots to remove the
rear cover. Hit the output shaft and first
speed shaft with a soft hammer to help
remove the cover.

STEP 44. Remove the bearing cup, outer bear-

ing cone and the spacer from the first
speed shaft.
STEP 43. Remove the lock balls from the bear-
ings. NOTE: The bearing cup, bearing cones and
spacer must be replaced as a complete
set.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (9 of 17)

 STEP 47. Remove the retainer for the snap ring.

STEP 45. Remove the inner bearing cone from

the first speed shaft.

NOTE: To remove the inner bearing cone

without damage, a special puller must
be made. Use a Timken bearing cone
No. 29520 with this special puller.
STEP 48. Remove the snap ring that holds the
second speed gear to the shaft.

STEP 46. Remove the snap ring for the re-

tainer on the second speed gear. STEP 49. Remove the second speed gear.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (10 of 17)

STEP 50. Remove the output shaft assembly. STEP 53. Remove the first speed clutch and
shaft assembly.

STEP 51. Remove the retainer ring for the drive STEP 54. Remove the bearing fron the first
gear for the first speed clutch. Remove speed shaft.
the drive gear.

STEP 52. Remove the forward and third speed

clutch. STEP 55. Remove the retainer for the snap ring.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (11 of 17)

STEP 56. Remove the snap ring for the first
speed gear.

STEP 59. Remove the inner bearing for the first

speed gear.

STEP 57. Remove the first speed gear and

bearing.

STEP 60. Remove the retainer ring for the snap

ring.

STEP 58. Remove the retainer ring and pressure

plate from the first speed clutch. Re-
move the friction discs and separator
plates.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (12 of 17)

 STEP 62. Remove the Belleville washers and the
spacer. Remove the piston from the
clutch housing.

NOTE: Use the same procedures to disas-

semble the clutch assemblies for for-
ward and reverse.

STEP 61. Remove the snap ring and the washer STEP 63. Remove the seal rings from the shaft.
that holds the Belleville washers in po-
sition. Use a sleeve and a press to com-
press the Belleville washers for removal
of the the snap ring.

STEP 64. Remove the retainer ring for the bear-

ing.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (13 of 17)

STEP 65. Remove the bearing and the spacer.
Do not lose the lock ball.
STEP 68. Use prybars to move the gear from
the shaft so that there is clearance for
a puller.

STEP 66. Use prybars to remove the inner race

for the bearing from the shaft.
STEP 69. Use a puller to remove the gear and
the outer bearing.

STEP 67. Remove the retainer ring from the shaft. STEP 70. Remove the retainer ring for the pres-
sure plate.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (14 of 17)

STEP 71. Remove the pressure plate.

STEP 74. Remove the snap ring for the inner

bearing.

STEP 72. Remove the friction discs and the

separator plates.

STEP 75. Remove the snap ring and the washer

that holds the Belleville washers in po-
sition. Use a sleeve and a press to com-
press the Belleville washers for removal
of the the snap ring. See Step 61 for
the dimensions of the sleeve.

STEP 73. Remove the inner bearing from the

shaft.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (15 of 17)

STEP 76. Remove the Belleville washers and the
spacer.

STEP 79. Remove the retainer ring for the pres-

sure plate. Remove the pressure
plate.

STEP 77. Remove the piston from the clutch

housing.

NOTE: Use the same procedures to disas-

semble the clutch assemblies for sec-
ond and third speed.

STEP 80. Remove the friction discs and the

separator plates.

STEP 78. Remove the gear and clutch hub.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (16 of 17)

STEP 81. Remove the snap ring that holds the
return spring for the piston in position.
Use a sleeve and a press to compress
the return spring for remaval of the snap STEP 82. Remove the retainer for the snap
ring. See Step 61 for the dimensions ring, spring retainer, return spring
of the sleeve. Remove the snap ring. and spring retainer. Remove the
piston from the clutch housing.

FIGURE 2. DISASSEMBLY OF THE TRANSMISSION (SHEET 17 OF 17)

Cleaning Inspect the friction discs for burned lining. Check
that the separator plates are not bent and do not
The housings for the transmission can be cleaned have burned areas on them. Inspect the teeth on the
with steam. Make sure any compound used to clean separator plates and friction discs for damage.
the housings is removed. Clean the other transmis-
sion parts in solvent and dry with compressed air. Inspect the pistons and the bores for the pistons
Clean the gasket material and sealants from the for scratches or wear.
housings and covers. Clean and flush the oil cooler
and the oil lines for the oil cooler. Inspect the housings and covers for wear or dam-
age. Check that the gasket surfaces are smooth.
Inspection Check that the bores for the bearings are not worn.

Inspect all bearing assemblies for worn or dam-

aged rollers or bearing surfaces.
Assembly
Inspect the gears or shafts for damaged rollers or
bearing surfaces. Assemble the transmission as shown in Figure 6.

Inspect the edges of the seal rings for wear or NOTE: Use the same procedures to assemble the
grooves. Inspect the bores for the seal rings for Forward and Reverse clutches. Lubricate the parts
grooves. with clean transmission oil.

Inspect the gears or shafts for damaged teeth or

splines.
FIGURE 3. HOUSING, TORQUE CONVERTER

FIGURE 4. HOUSING, TRANSMISSION

FIGURE 5. CLUTCH ASSEMBLIES
Transmission, Assembly

NOTE: Use the same procedures to assemble

the FORWARD and REVERSE
clutches. Lubricate the parts with clean
transmission oil.

STEP 1. Install new inner and auter seal rings on the piston. Lift trucks with transmission S/N
181987 FR and later: a white teflon seal is used as the outer seal ring. The teflon seal must fit tightly
on the piston. Hold a round object against the seal ring and rotate the piston. Rotate the piston until the
seal ring is even with the outer diameter of the piston.

STEP 2. Make sure the bore of the piston hous- STEP 4. Install the second Belleville washer.
ing is smooth. There must be no sharp Make sure the large diameter of the
edges to damage the seal rings. Care- bevel is away from the piston. Install
fully install the piston. the remaining Belleville washers. There
is a total of seven washers.

STEP 5. Install the retainer for the snap ring and

the snap ring. Use a sleeve and a press
STEP 3. Install the first Belleville washer. Make to compress the Belleville washers and
sure the large diameter of the bevel is install the snap ring.
toward the piston.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (1 of 20)

STEP 6. Install a separator plate against the pis- STEP 9. Install the retainer for the pressure plate.
ton.

STEP 10. Install the snap ring for the inner bear-
ing on the shaft. Install the inner bear-
ing for the drive gear on the shaft. The
STEP 7. Install a friction disc against the sepa- inner bearing does not have a seal.
rator plate. Install the remaining sepa-
rator plates and friction discs in an al-
ternate sequence. Make sure there is a
friction disc against the pressure plate.
There are 12 friction discs and 12 sepa-
rator plates.

STEP 11. Install the snap rings for the inner and
outer bearings in the hub for the drive
gear. Install the drive gear and hub on
the shaft. Make sure the splines on the
STEP 8. Install the pressure plate. hub are aligned with the teeth on the
friction discs.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (2 of 20)

STEP 12. Install the outer bearing for the drive
gear. Install the bearing so that the seal STEP 15. Install the bearing and the outer bear-
is toward the outside. ing race.

STEP 13. Install the snap ring that holds the outer
bearing on the shaft.

STEP 16. Install the lock ball and the bearing

spacer (FORWARD clutch only).

STEP 14. Install the inner race for the bearing. STEP 17. Install the snap ring that holds the
bearing on the shaft.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (3 of 20)

STEP 18. Install the seal rings on the shaft.

NOTE: Use the same procedures (Steps 19-23)

to assemble the second and third speed STEP 20. Install a separator plate against the
clutch assemblies. piston.

STEP 21. Install a friction disc against the

separator plate. Install the remain-
ing separator plates and friction
discs in an alternate sequence.
Make sure there is a friction disc
against the pressure plate. There
are six friction discs and six sepa-
rator plates.

STEP 19. Install new inner and outer seal

rings on the piston. Units with
transmission S/N 181987 FR
and later: a white teflon seal is used
as the outer seal ring. Install the
teflon seal ring as shown in Step 1
of the Assembly procedures. Install
the piston in the clutch housing. Be
careful not to damage the seal rings.
Install the return spring for the pis-
ton and the spring retainers. Install
the retainer for the snap ring and
the snap ring. Use a sleeve as shown
in the Disassembly procedures and
a press to compress the spring and STEP 22. Install the pressure plate.
then install the snap ring.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (4 of 20)

STEP 23. Install the retainer for the pressure
plate.

NOTE: Use the following procedures (Steps

24-29) for the first speed clutch only.
The Belleville washers for the first speed STEP 25. Install the snap ring. Use a sleeve as
clutch have four boles in them for iden- shown in the Disassembly procedures
tification. Do not use these washers in and a press to compress the Belleville
the other clutch assemblies. washers and install the snap ring.

STEP 26. Install the retainer for the snap ring.

STEP 24. Install new inner and outer seal rings
on the piston. Units with transmis-
sion S/N 181987 FR and later: a
black teflon seal is used as the outer
seal ring. Install the teflon seal ring as
shown in Step 1 of the Assembly pro-
cedures. Install the piston in the clutch
housing. Be careful not to damage the
seal rings. Install the spacer against the
piston. Install the first Belleville washer.
Make sure the large diameter of the
bevel is toward the piston. Install the
second Belleville washer. Make sure
the large diameter of the bevel is away
from the piston. Install the remaining
Belleville washers. There is a total of
five washers. STEP 27. Install the inner bearing on the shaft.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (5 of 20)

STEP 28. Install a separator plate against the pis- STEP 30. Install spacer that fits between the
ton. bearing cones.

NOTE: The friction discs for the first speed

clutch are different from the friction
discs in the other clutch assemblies.
The friction discs for the first speed
clutch have yellow paint at the out-
side edge and an “X” at the inner teeth.
Do not use these friction discs in the
other clutch assemblies.

Install a friction disc against the

separator plate. Install the remain-
ing separator plates and friction
discs in an alternate sequence. Make
sure there is a friction disc against
the pressure plate. There are nine STEP 31. Install the snap rings and bearing cups
friction discs and nine separator in the first speed gear. Install the first
plates. speed gear. Make sure the splines on
the hub are aligned with the teeth on the
friction discs.

STEP 29. Install the pressure plate. Install the STEP 32. Install the outer bearing on the shaft.
retainer for the pressure plate.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (6 of 20)

 STEP 35. Install the inner bearing race on the
shaft. Make sure the large diameter of
the race is toward the gear.

STEP 33. Install the snap ring on the shaft. Dif-

ferent size snap rings are available. Use
the thickest snap ring that will fit in the
groove. After installation, check that the
bearing rollers are tight against the bear-
ing cone. STEP 36. Install bearing for the first speed
clutch in the housing.

STEP 37. Install the first speed clutch from the

STEP 34. Install the retainer for the snap ring. rear of the transmission housing.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (7 of 20)

STEP 38. Install the third speed and forward
clutch assembly from the front of the
transmission housing.

STEP 39. Install the drive gear for first speed. In-
stall the snap ring that holds the drive
gear on the shaft.

STEP 41. Install the ball bearing and snap ring on

the shaft. Install the inner bearing cone
and spacer on the shaft. Install the bear-
ing cup and outer bearing cone.

STEP 40. Install the output gear on the output

shaft. Install the spacer on the shaft.
Make sure the small part of the spacer
fits into the output gear.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (8 of 20)

 STEP 44. Install the spacer on the shaft.

STEP 42. Install the output shaft assembly in the

transmission housing.

STEP 43. Heat the bearing cone in oil, then install STEP 45. Install the bearing cup and the outer
the inner bearing cone on the shaft for bearing cone.
first speed.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (9 of 20)

STEP 46. Install the bearing retainer. Make sure
the chamfer on the hole is toward
the bearing

STEP 49. Put the two alignment studs in the

transmission housing. Install the lock
balls on the bearings. Use grease to
hold the lock balls in position. Move
the bearings so that the lock balls align
with the grooves in the rear cover.

STEP 47. Tighten the capscrews for the bearing

retainer. Install the lock wire between
the capscrews

STEP 48. Install the seal ring on the shaft. STEP 50. Install the rear cover and the gasket

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (10 of 20)

 STEP 53. Install the oil seal in the bearing cover
for the output shaft. Use a sealant be-
tween the seal and the bearing cover.
Install the bearing cover and tighten
STEP 51. Install and the tighten the capscrews. the capscrews.

STEP 54. Install the O-ring and gasket on the

bearing cover for the first speed shaft.
Install the bearing cover, being careful
not to damage the seal ring.

STEP 52. Install the retainer rings on the bearings

for the output shaft and the first speed
shaft. Make sure the retainer rings are
completely in the groove.

STEP 55. Install and tighten the capscrews for

the bearing cover.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (11 of 20)

STEP 56. Install the output yoke on the output
shaft.

STEP 59. Install the snap ring that holds the gear
on the shaft.

STEP 57. Install the O-ring, washer and nut on

the output shaft. Tighten the nut to 271-
340 N.m (200-250 lbf ft).

STEP 60. Install the retainer ring far the snap ring.

STEP 58. Install the drive gear for second speed STEP 61. Install the snap ring that holds the re-
on the shaft for first speed. tainer ring in position.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (12 of 20)

 STEP 64. Make sure the surface of the impeller is
clean. Make sure the threads in the im-
STEP 62. Install two alignment studs in the trans-
peller are clean and dry. Install the O-
mission housing. Install the gasket, O-
ring on the hub for the impeller. Put the
rings and the spacer.
plate on the impeller.

STEP 65. Install the hub in the impeller. Align the

STEP 63. Install the gasket and the O-rings on holes in the hub, the impeller and the
the spacer. plate.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (13 of 20)

STEP 66. Install the special capscrews until they
are within approximately 1.5 mm (0.06
in) of the plate. Use a torque wrench STEP 68. Install the seal on the outside edge of
to tighten the capscrews to 54-61 N.m the oil baffle.
(40-45 lbf

NOTE: The capscrews for the impeller hub

have a special adhesive on the
threads. The capscrews must be
tightened within 15 minutes of in-
stallation. The capscrews can be
used one time. When a capscrew is
removed, the hole must be cleaned and
the capscrew must be replaced.

STEP 69. Install the oil baffle on the impeller.

STEP 67. Apply a sealant to the outside of the

seal, then install the seal in the oil baffle.
Make sure the lip of the seal is toward STEP 70. Install the gear on the hub of the impel-
the outside of the oil baffle. ler.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (14 of 20)

STEP 71. Install the snap ring that holds the gear
on the hub.

STEP 74. Connect a lifting device to the torque

converter housing. Install the clutch
assembly for forward and second
speed in the torque converter housing.
Do not damage the seal rings. Use snap
ring pliers to install the snap ring that
STEP 72. Install the bearing with the snap ring on hold the froat bearing in the torque con-
the turbine shaft. Install the seal ring on verter housing. Make sure the snap ring
the turbine shaft. is in the groove in the housing.

STEP 73. Install the turbine shaft in the torque

converter housing. Install the drive gear STEP 75. Put the drive gear for the transmission
and the snap ring. Make sure the long pump in the center position.
side of the hub on the gear is away from
the housing.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (15 of 20)

STEP 76. Put the drive gear for the hydraulic pump
on the left side in position. STEP 79. Install the needle bearing on the shaft
for the second speed clutch.

STEP 77. Put the drive gear for the hydraulic

pump on the right side in position.
STEP 80. Install the torque converter housing on
the alignment studs. Carefully align the
hub and the friction discs for the sec-
ond speed clutch. Rotate the clutch
assemblies to make sure the hub is fully
engaged with the friction discs. Do not
use force to align the parts.

STEP 78. Install the capscrews that hold the

hubs for the drive gears in position.
Tighten the capscrews.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (16 of 20)

STEP 81. Install the capscrews that hold the
torque converter housing to the trans-
mission housing. Do not use the
capscrews to pull the housings to-
gether. Tighten the capscrews.

STEP 84. Put grease on the seal ring, oil seal and
the ring seal. Install the impeller and
oil baffle assembly in the torque con-
verter housing.

STEP 82. Install the expansion ring and the seal

ring on the stator tube. Make sue the
gap in the expansion ring is 180° from
the gap in the seal ring. Put the stator
tube in position on the torque con-
verter housing.

STEP 85. Install the retainer ring for the oil baffle.
Make sure the retainer ring is fully in
the groove.

STEP 83. Install and tighten the capscrews for

the stator tube.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (17 of 20)

 STEP 88. Install the turbine in the cover for the im-
peller.

STEP 86. Install the spacer for the stator. Make

sure the hook on the spacer is toward
the stator. Install the stator on the stator
tube.

STEP 89. Install the spacer and the snap ring on

the hub of the impeller cover.

STEP 87. Install the snap ring that holds the sta-
tor on the tube.
STEP 90. Install the O-ring in the groove in the
impeller. Install the turbine and the im-
peller cover.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (18 of 20)

 STEP 94. Install the adapters for the hydraulic
pumps.

STEP 91. Install and tighten the capscrews for the

impeller cover.

STEP 95. Install the sleeves for the hydraulic

STEP 92. Install the O-ring on the bearing cover. pumps.

STEP 96. Install the gasket and O-rings for the

pressure regulator valve for the trans-
STEP 93. Install the bearing cover and tighten the mission pump. Install the valve on the
capscrews. studs.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (19 of 20)

 STEP 97. Install the transmission pump
STEP 98. Install the hydraulic pumps on the
assembly.
housing

STEP 99. Install two alignment studs in the

torque converter housing. Install the
gasket for the modulator valve and
the modulator valve. Install the gas-
ket for the manifold block and the
manifold block Install and tighten
the capscrews for the manifold
block. Remove the alignment studs.

FIGURE 6. ASSEMBLY OF THE TRANSMISSION (20 of 20)

Installation b. Measure the movement of the crankshaft. Put a

dial indicator on the pulley at the front of the
1. H17.00-32.00C (H360-700C) - UNITS WITH engine. Move the crankshaft backward and for-
A PERKINS ENGINE AND EARLY PRODUC- ward. Make a note of this measurement.
TION LIFT TRUCKS WITH A DETROIT DIE-
SEL ENGINE: Use the following procedure to c. Install the ring gear for the torque converter on
install the ring gear for the torque converter. (See the flywheel. Install the back plate and the 32
FIGURE 7.) special capscrews. Install the capscrews until
they are approximately 1.5 mm (0.06 in) from
a. Clean the surface of the flywheel and the holes the fully installed position. Use a torque wrench
with threads. Make sure the threads are clean and to tighten the capscrews to 31 to 34 N.m (23 to
dry. 25 lb ft).
NOTE: Installation of the ring gear for the torque before replacing the capscrew.
converter must be completed within 15 minutes
after installing the first capscrew. The capscrews Make sure the epoxy coating on the capscrews is
have an epoxy coating that becomes hard after the completely hardened. Do not start the engine for
threads are engaged in the flywheel. The capscrews 12 hours after installation.
can loosen if they are not tightened to the correct
torque within 15 minutes. These capscrews can be d. Make sure the four studs are installed in the
used one time. If a capscrew is removed, it must flywheel housing. Install the spacer on the fly-
be replaced. Clean the threads in the flywheel wheel housing. Apply multi-purpose grease
to the pilot of the torque converter.

FIGURE 7. INSTALLATION OF TORQUE CONVERTER TO FLYWHEEL,

H17.00-32.00C (H360 - 650C, H370-700C)
 e. Connect a lifting device to the lifting eyes on f. Measure the movement of the crankshaft as
the transmission. Move the transmission to- described in Step b. The measurement in this
ward the flywheel housing. Carefully align step must be within 0.025 mm (0.001 in) of
the torque converter with the ring gear. Do the measurement in Step b. If the measure-
not damage teeth on the ring gear. Do not use ment is not correct, the torque converter is
the capscrews for the transmission housing not correctly aligned with the drive plate. If
to pull the torque converter into position with the measurement is correct, the installation
the ring gear. is complete.

f. After the torque converter is fully installed, g. Install the dipstick tube at the transmission.
install several capscrews to hold the torque
converter housing to the flywheel housing. h. Connect a lifting device to the engine and
Measure the movement of the crankshaft as transmission. Make sure the lifting device
described in Step 2. The measurement in this has a capacity of 1500 kg (3300 lb). Install
step must be within 0.025 mm (0.001 in) of the engine and transmission in the frame.
the measurement in Step 2. If the measure-
ment is not correct, the torque converter is i. Install the capscrews for the mount at the
not correctly aligned with the ring gear. If fan end of the engine. Install the capscrews
the measurement is correct, install all of the for the transmission mounts. Make sure the
capscrews for the transmission housing. parts are installed correctly. See FIGURE
2. H17.00-32.00C (H360-700C) - LATE PRO- 8. Tighten the nut until the parts are tight,
DUCTION UNITS WITH DETROIT DIESEL then use a torque wrench to tighten the
ENGINES: Use the following procedure to in- capscrew to 285 N.m (210 lbf ft). Remove
stall the transmission to the engine. (See FIGURE the lifting device.
7.)
a. Clean the surface of the flywheel and the
holes with threads. Make sure the threads
are clean and dry.

b. Measure the movement of the crankshaft. Put

a dial indicator on the pulley at the front of
the engine. Move the crankshaft backward
and forward. Make a note of this measure-
ment.

c. Connect a lifting device to the lifting eyes

on the transmission. Move the transmission
toward the flywheel housing. Carefully align
the torque converter drive plate with the fly- FIGURE 8. TRANSMISSION MOUNT,
wheel. Do not use the capscrews for the fly- H17.00-32.00C (H370-700C)
wheel housing to pull the torque converter
into position. j. Install the radiator. Connect the cooling hoses
and the transmission lines.
d. After the transmission is fully installed, in-
stall the capscrews that hold the transmis- k. Connect the wiring harness and wires at the
sion to the flywheel housing. Tighten the engine and transmission.
capscrews to 36 N.m (26 lbf ft).
l. Connect the throttle linkage and fuel lines at the
e. Fasten the torque converter drive plate to the engine. Connect the air cleaner to the engine.
engine flywheel. Use the access hole in the fly-
wheel housing on the side opposite the starter.
Install the capscrews and lock washers through m. Connect the air lines at the air compressor.
the flywheel and into the drive plate. Tighten
the capscrews to 36 N.m (26 1bf ft). n. Install and connect the pipes for the exhaust
system.
 t. Install the hood.

3. H20.00-32.00F (H440-700F/FS) - UNITS

WITH CUMMINS DIESEL ENGINES: Use the
following procedure to install the transmission to
the engine. (See FIGURE 10.)
a. Clean the surface of the flywheel and the holes
with threads. Make sure the threads are clean
and dry.

b. Connect a lifting device to the lifting eyes on

the transmission. Move the transmission to-
ward the flywheel housing. Carefully align the
torque converter drive plate with the flywheel.

FIGURE 9. ARRANGEMENT OF THE OIL

LINES, H17.00 - 32.00C (H370-700C)

o. Connect the oil lines from the shift control valve

to the manifold block. See the arrangement of
the oil lines in FIGURE 13.

p. Connect the oil lines to the hydraulic pumps.

See the arrangement of the oil lines in FIG-
URE 9.

q. Connect the drive shaft to the transmission. Use

a thread locking compound on the capscrews.
Tighten the capscrews to 122 to 136 N.m (90
to 100 lbf fr).

r. Fill the cooling system with coolant. Connect

the cables at the battery.

s. Fill the transmission with 15 litres (15.9 qt) of FIGURE 10. INSTALLATION OF TORQUE
the correct oil (Detroit Diesel Allison Type C- CONVERTER TO FLYWHEEL, H20.00-32.00F
3), then check the oil level. Start the engine, (H440-700F/FS)
apply the brakes and put the transmission
through all the ranges. Put the transmission in c. After the transmission is fully installed, install
the NEUTRAL (N) position. Run the engine the capscrews that hold the transmission to the
at idle speed. Make sure the temperature of flywheel housing. Tighten the capscrews to 36
the transmission oil is 83 to 94°C (180 to 200° N.m (26 lbf ft).
F). Add oil as necessary until the level of the
oil reaches the “FULL” mark on the dipstick. d. Fasten the torque converter drive plate to the
Check for leaks from the engine and transmis- engine flywheel. Use the access hole in the fly-
sion. wheel
 housing on the side opposite the starter. In- k. Install and connect the pipes for the exhaust
stall the capscrews and lock washers system.
through the flywheel and into the drive plate.
Tighten the capscrews to 36 N.m (26 lbf ft). l. Connect the oil lines from the shift control valve
to the manifold block. See the arrangement of
e. Install the dipstick tube at the transmission. the oil lines in FIGURE 13.

f. Connect a lifting device to the engine and trans- m. Connect the oil lines to the hydraulic pumps.
mission. Make sure the lifting device has a ca- See the arrangement of the oil lines in FIG-
pacity of 1500 kg (3300 lb). Install the engine URE 11.
and transmission in the frame.
n. Connect the drive shaft to the transmission. Use
g. Install the capscrews for the mount at the fan a thread locking compound on the capscrews.
end of the engine. Install the capscrews for the Tighten the capscrews to 122 to 136 N.m (90
transmission mounts. Make sure the parts are to 100 lbf ft).
installed correctly. See FIGURE 8. Tighten the
nut until the parts are tight, then use a torque o. Fill the cooling system with coolant. Connect
wrench to tighten the capscrew to 285 N.m the cables at the battery. Fill the transmission
(210 1bf ft). Re-move the lifting device. as described in the PERIODIC MAINTE-
NANCE section.
h. Install the radiator. Connect the cooling hoses
and the transmission lines. MODULATOR VALVE AND MANIFOLD
BLOCK

Removal (See FIGURE 13.)

1. Put the lift truck on a level surface. Apply the park-

ing brake and lower the carriage. Put blocks on each
side (front and back) of the drive tires.

2. Disconnect the oil lines at the manifold block.

Put caps on the open lines.

3. Remove two of the capscrews from the torque

converter housing and replace them with alignment
studs. Remove the remaining capscrews that hold
the manifold block and the modulator valve to the
torque converter housing.

Disassembly (See FIGURE 12.)

Disassemble the modulator valve as shown in FIG-

URE 12. Be sure to keep the parts for each bore
together. Put tags on the parts so that they will be
installed in the same bore.
FIGURE 11. ARRANGEMENT OF THE OIL
LINES, H20.00 - 32.00F (H440-700F/FS)
Cleaning and Inspection
i. Connect the wiring harness and wires at the en- WARNING
gine and transmission. Cleaning solvents can be flammable and toxic,
and can cause skin irritation. When using clean-
j. Connect the throttle linkage and fuel lines at the ing solvents, always follow the solvent
engine. Connect the air cleaner to the engine. manufacturer’s recommended safety precau-
tions.
Clean all of the parts in solvent. Clean the gaskets Installation
from the surfaces of the parts. Inspect the spools
and bores for wear or damage. The spools must l. Install two alignment studs in the torque con-
move freely in the bores. verter housing. Install the gasket for the modulator
valve and the modulator valve. Install the gasket
Assembly (See FIGURE 12.) for the manifold block and the manifold block.

1. Lubricate all moving parts with clean transmis- 2. Install and tighten the capscrews for the mani-
sion oil. fold block. Remove the alignment studs.

2. Install the spools and springs in their original 3. Connect the oil lines to the manifold block. See
bores. Install the O-rings and the plugs or caps for FIGURE 13.
the springs.

FIGURE 12. MODULATOR VALVE AND MANIFOLD BLOCK

 * NOTE: THE LETTERS F AND R ON THE HOUS-
ING ARE OPPOSITE OF THE FORWARD
AND REVERSE HOSE CONNECTIONS.
11892

FIGURE 13. OIL LINE CONNECTIONS

SHIFT CONTROL VALVE 2. Disconnect the oil lines from the shift control
valve. Remove the capscrews that hold the shift
control valve to the frame.

Removal (See FIGURE 13.) Disassembly (See FIGURE 15.)

1. Remove the capscrews that hold the cover to

1. Disconnect the air cylinder from the inching the valve body. Disconnect the wires at the sole-
plunger. Disconnect the wiring harness from the noids and remove the cover and the gasket.
shift control valve.
2. Remove the plunger assembly from the bore for 5. Install the solenoids with O-rings in the valve
the inching spool. Remove the snap ring for the body. Connect the wires to the solenoids. See the
sleeve, then remove the sleeve, inching spool, location of the wires in FIGURE 15.
springs and the guide.
6. Install the seal and cover for the solenoids on
3. Remove the plug for the direction spools. Re- the valve body.
move the forward and the reverse spools and the
spring. 7. The air cylinder for inching is shown in FIG-
URE 14. Tighten the capscrews that hold the cyl-
4. Remove the plug for the range spools. Remove inder together to 6.7 to 7.3 N.m (5 to 5.4 lbf ft).
the spring and spool for third speed. Remove the Make sure the stroke of the cylinder is correctly ad-
roll pin from the stop. Remove the stop and the justed. Tighten the jam nut for the cylinder rod to 40
spool for first and second speed. to 54 N.m (30 to 37 lbf ft).

5. Remove the solenoids from the valve body. Installation (See FIGURE 13.)

6. The air cylinder for inching is shown in FIG- 1. Install the shift valve on the frame.
URE 14.
2. Connect the air cylinder to the plunger. Connect
Cleaning and Inspection the oil lines to the valve body. Connect the wiring
harness at the solenoid cover.
Clean all of the parts in solvent. Clean the gaskets
from the surfaces of the parts. Inspect the spools
and bores for wear or damage. The spools must
move freely in the bores.

Assembly

1. Lubricate all moving parts with clean transmis-

sion oil.

2. Install the forward and the reverse spools and

spring in their bore. (The forward and the reverse
spools are the same parts.) Install the O-rings and
the plug.

3. Install the two springs for the inching spool guide.

Install the C spring and the inching spool. Install
the sleeve and the snap ring. Install the O-ring and
the plunger assembly.

4. Install the spool for first and second speed. In-

stall the spring and the guide. Install the roll pin in FIGURE 14. AIR CYLINDER FOR INCHING,
the guide. Make sure the roll pin is below the sur- H17.00-32.00C (H360-700C)
face of the valve body. Install the spool for third
speed. Install the spring, O-ring and plug for the
spool.
 FIGURE 15. SHIFT CONTROL VALVE

OIL PUMP Disassembly (See FIGURE 16.)

Removal 1. Remove the filter housing from the filter adapter.

Remove the spring, filter element and O-ring. Remove
the by-pass valve assembly from the filter adapter.
See Step 1 of FIGURE 2. Remove the capscrews
that hold the oil pump to the transmission housing. 2. Remove the capscrews that hold the filter adapter
Remove the oil pump. Remove the sleeve from the to the pump housing. Separate the filter adapter from
drive gear for the pump. the pump housing. Remove the nuts
that hold the pump housing to the body for the pres- from the surfaces of the parts. Check the spools
sure regulator valve. Remove the pump body. and bores for wear or damage. The spools must
move freely in the bores. Check the gear teeth and
3. Remove the gears, seals and bearing assemblies bearing surfaces for wear or damage. Check the
from the pump housing. pump body for wear or damage.

4. Remove the seals and O-rings from the body for Assembly and Installation
the pressure regulator valve. Remove the roll pin (See FIGURE 16.)
to remove the check valve assembly from the valve
body. Remove the roll pin to remove the pressure 1. Lubricate all moving parts with clean transmis-
regulator assembly from the valve body. sion oil.

Cleaning and Inspection 2. Install the sleeve and the snap ring in the gear
for the pump shaft.
Clean all of the parts in solvent. Clean the gaskets

FIGURE 16. OIL PUMP

3. Install the check valve assembly and the pres- 6. Install the bearing assemblies on the gears. In-
sure regulator valve in the body for the pressure stall the shaft seals. Install the gasket and filter
regulator valve. Install the roll pin for each valve adapter on the pump body. Install the lock washers
assembly. Install the oil seal for the drive gear in and capscrews.
the valve body. Make sure the spring on the lip of
the seal is away from the drive gear. 7. Install the by-pass valve assembly in the filter
adapter. Install the O-ring, oil filter, spring and the
4. Install the O-rings in the body for the pressure filter housing.
regulator valve. Install the gasket and the valve
body on the transmission housing. See Steps 94 TRANSMISSION CONTROL ASSEMBLY
through 98 of FIGURE 6. H17.00-32.00C (H360-650C, H370-700C)
5. Install the gasket, bearing assemblies and gears Removal and Disassembly
in the valve body for the pressure regulator. Install
(See FIGURE 17.)
the pump body on the valve body. Install the lock
washers and the nuts.
1. Remove the bolts that hold the range selector
assembly to the plate for the seat. Disconnect the
wiring harness at the range selector.

FIGURE 17. TRANSMISSION CONTROL ASSEMBLY H17.00-33.00C (H360-700C)

2. Remove the parts from the range selector as- 2. Use the following procedure to install the con-
sembly as follows: trol lever:

a. To remove the switch, remove the knob from a. Install the rubber bushing in the crank. Install
the lever and remove the cover. Remove the the yoke on the crank using the pin.
screws that hold the switch to the bracket. Dis-
connect the wire connectors at the wiring har- b.Install the lever in the yoke with the nuts. Push
ness. Remove the switch. the lever into the rubber bushing until the le-
ver touches the pin in the yoke. Tighten the
b. To remove the lever or crank, remove the knob lower nut against the yoke. Loosen the lower
from the lever and remove the cover. Remove nut one-half turn, then tighten the nut on top of
the pin from the yoke, then remove the lever. the yoke. Move the lever from side to side to
Remove the rubber bushing from the crank. make sure it returns to the center position.
Remove the bolt from the bracket to remove
the crank. 3. Use the following procedure to install the switch:

Assembly And Installation a. Put the range selector lever in the NEUTRAL
(See FIGURE 17. and FIGURE 18.) position.

1. Use the following procedure to install the crank b.Put the switch in the NEUTRAL position.
for the lever: (Wires B and C in the four pin connectors will
make a closed circuit only in NEUTRAL.)
a. Install the crank for the switch in the bushing
in the bracket.
c. Install the switch on the rod, then install the
b. Install the bushings and spacer in the crank. screws and spacers. Connect the wire con-
Install the bolt in the bracket, then install the nectors to the wiring harness.
thrust washers and crank. Install the thrust
washer and nut on the bolt.

FIGURE 18. ELECTRICAL SCHEMATIC, TRANSMISSION CONTROL ASSEMBLY,

H17.00-32.00C (H370-700C)
TRANSMISSION CONTROL ASSEMBLY capscrews and switch assemblies. Put tags on the
H20.00-32.00F (H440-700F/FS) wires for identification. Remove the wires from
the switches.
Removal and Disassembly
(See FIGURE 19. and FIGURE 20.)

1. Remove the transmission control assembly as

follows:

a. Disconnect the negative cable at the battery.

b. Disconnect the electrical wire harness from the

bottom of the control assembly.

c. Disconnect the electrical wire harness or wires

from the other switches on the cover of the
control assembly. Put tags on the wires or har-
ness for identification.

d. Remove the four capscrews and washers that

fas-ten the cover to the bracket. Remove the
knobs from the threaded shafts of the control
levers, then remove the cover.

e. Remove the connector links between the con-

trol levers and the shafts in the control assem-
bly. Remove the roll pin, then remove the shaft
for the control levers

f. Remove the two capscrews that hold the con-

trol assembly to the bracket. Remove the con-
trol assembly.

2. Disassemble the control assembly as follows:

a. Remove the bottom and side covers from the

housing for the control assembly.

b. Loosen the four detent plungers from the hous-

ing. Push the shafts out of the bottom of the
bores. Remove the snap rings and spacers.

c. Remove the shafts from the bottom of the hous- FIGURE 19. TRANSMISSION CONTROL
ing. ASSEMBLY, H20.00 - 32.00F (H440 - 700F/FS)

d. The switch assemblies are fastened to the two

mounting bars by capscrews. Remove the
FIGURE 20. TRANSMISSION CONTROL ASSEMBLY, H20.00-32.00F (H440-700F/FS)
Assembly and Installation f. Install the bottom and side covers on the hous-
(See FIGURE 19. and FIGURE 20.) ing.

1. Assemble the transmission control assembly as 2. Install the housing as follows:

follows:
a. Use the two capscrews and install the housing
a. Install the switches to the two mounting bars on the bracket at the steering column.
in the housing. Connect the wires to the cor-
rect terminals on the four switches. b. Install the control levers in the bracket. In-
stall the bushing, thrust washers and levers in
b. Install a new O-ring on the direction shaft. position, then install the shaft. Install the roll
Install the correct interlock bushings on the pin to keep the shaft in position.
direction and range shafts. Install the snap
rings on the ends of the shafts. c. Install the connector links between the spools
and the control levers.
c. Install new O-rings at the top of the housing.
d. Install the cover with switch assemblies and
d. Install the range shaft into the correct bore wires over the control levers and onto the
from the bottom of the housing. Install the in- bracket. Install the cover with the four
terlock ball and then install the direction shaft. capscrews and washers. Install the knobs on
Tighten the detent plungers so that the balls the control levers.
make contact with the detents in the shafts.
Install the plug in the housing for the interlock e. Connect the wires or wire harness to the
ball. switches. Connect the wire harness to the con-
nector at the bottom of the housing. Connect the
e. Install the spacer in the bottom of the bore for negative cable at the battery.
the direction shaft.
CHECKS AND ADJUSTMENTS
CHECK THE STALL SPEED OF THE 6. Apply the brake pedal and slowly increase the speed
TORQUE CONVERTER of the engine to full throttle. Check the stall speed in
each speed range and direction position. The tachom-
The stall check is a measurement of maximum engine eter must indicate as follows:
rpm with the engine working against the torque con-
verter at a full stall. This test will help find defects in a. Detroit Diesel Engine 2010 to 2210 rpm
the transmission, torque converter or engine. b. Perkins Engine 2040 to 2140 rpm
1. Make sure the coolant level in the cooling system c. Cummins Engine 1950 to 2050 rpm
is correct. Make sure the oil level in the transmission
is correct. CAUTION
2. Operate the transmission until the oil in the trans- Do not check the stall speed of the torque con-
mission is at least 83 to 94°C (180 to 200°F). Make verter for more than a 30 second test. The heat
sure the throttle linkage is correctly adjusted to per- generated in the torque converter can cause dam-
mit full throttle. age in the transmission unless cooling is permit-
ted between the tests.
3. Make sure the brakes operate correctly. The drive
7. If the stall speed is 50 to 200 rpm below specifica-
wheels must not turn during this test.
tions, the engine is generating full power. Check the
4. Use a tachometer to check the speed of the en- condition of the engine and fuel system.
gine. Apply the parking brake. 8. If the stall speed is 50 to 200 rpm greater than the
specifications, the transmission can be the problem.
5. Start the engine and move the transmission lever to Do the stall speed checks for FORWARD, RE-
FORWARD and REVERSE in each speed range. VERSE and all the speed ranges. A high reading in
only one direction or speed indicates the defective
clutch assembly.
CHECK THE OIL PRESSURE OF THE sion is at least 83 to 94°C (180 to 200°F). Con-
TRANSMISSION (See FIGURE 21.) nect a tachometer to the engine.

NOTE: If the correct pressure cannot be reached, Check the Pressure of the Clutch and
check the Troubleshooting table. Pump Circuits (Check Port 1)

During all pressure checks, the drive wheels must Run the engine at 2000 rpm and engage all the
be raised from the floor. Start the engine, tilt the clutches several times. The correct pressure for
mast backward and put blocks under the outer chan- both the clutch and pump circuits is 1655 to 1930
nels of the mast. Tilt the mast forward to raise the kPa (240 to 280 psi). All clutch pressures must be
drive wheels from the floor. Put blocks under the equal within 35 kPa (5 psi).
frame of the lift truck. DO NOT use the inching
pedal while making the pressure checks. Check the Pressure for the Torque Con-
verter Circuit (Check Port 2)
Connect pressure gauges to the check ports shown
in FIGURE 21. Check that the oil level in the trans- Put the transmission lever in the NEUTRAL posi-
mission is correct. Operate the transmission in all tion. Operate the engine at 2000 rpm. The mini-
ranges and directions until the oil in the transmis- mum pressure is 172 kPa (25 psi). Operate the
engine at 2600 rpm. The maximum pressure is 482
kPa (70 psi).

* Check pressure at fitting for temperature sending unit on left side

of the transmission.

NOTE: All pressure checks with engine speed at 2000 rpm and
transmission oil temperatures at least 83°C (180°F)

FIGURE 21. PRESSURE CHECK PORTS

TROUBLESHOOTING
TROUBLESHOOTING