Transmision DP40

POWERSHIFT TRANSMISSIONS
Structure and Function ........................................................................ 5 – 1

Torque Converter (All Models) .................................................................. 5 – 1
Single-speed Transmission
(GP/DP40 thru 45, STD transmission models) ....................................... 5 – 2
Clutch Shaft Assembly .............................................................................. 5 – 3
Control System (All Models) ..................................................................... 5 – 4
Control Valve for Single-speed Transmission (GP/DP40 thru 45) ............. 5 – 5
Single-speed Transmission Hydraulic Circuit (GP/DP40 thru 45) .............. 5 – 6
Automatic Two-speed Transmission (GP50, DP50)
(Optional for GP/DP40 thru 45) .............................................................. 5 – 9 5
Structure of Transmission ......................................................................... 5 – 10
Control Valve for Automatic Two-speed Transmission (GP50, DP50)
(Optional for GP/DP40 thru 45) .............................................................. 5 – 11
Control System for Automatic Two-speed Transmission (GP50, DP50)
Hydraulic Circuit for Automatic Two-speed Transmission (GP50, DP50)
Hydraulic Control (Forward 1st Speed) ..................................................... 5 – 14
Hydraulic Control (Forward 2nd Speed) .................................................... 5 – 15
Removal and Installation ...................................................................... 5 – 16
Torque Converter (All Models) .................................................................. 5 – 17
1-speed Transmission (GP/DP40 thru 45) ................................................ 5 – 21
Control Valve for Single-speed Transmission (GP/DP40 thru 45) ............. 5 – 39
Automatic Two-speed Transmission
(GP50, DP50 and All Models with Two-speed Transmission) ................. 5 – 39
Control Valve for Automatic Two-speed Transmission .............................. 5 – 58
Solenoid Valve .......................................................................................... 5 – 58
Test and Adjustment (All Models) ............................................................. 5 – 59
Structure and Function
Torque Converter (All Models)

The pump impeller 3 operates on a principle similar to
3 4 2 that of a centrifugal pump. The pressure of oil from the
pump impeller 3 acts on the blades of the turbine 4 and
1
9 7 6
rotates the turbine in the same direction as that of the
pump impeller.
5
The stator 5 is designed to redirect the flow of oil from
the turbine, like guide vanes, in such a way that the oil
10
flow will assist the rotation of the pump impeller 3.
8
When the output shaft 8 is under relatively large load,
the turbine 4 turns at a speed slower than the pump
impeller 3. This causes the stator 5 to increase the
pressure of oil from the pump impeller. As a result,
greater oil pressure acts on the turbine 4, causing the
11 output torque to rise. This is how a torque converter
multiply the torque.
When the output shaft 8 is subjected to relatively light
load, the turbine 4 turns at almost the same speed as the
pump impeller 3. This causes the stator 5 to rotate
208660 freely so that the oil flow is not obstructed. If the stator
5 was fixed, the flow of oil would be obstructed,
1 Flexible plate 7 Stator shaft
causing the torque converter efficiency to drop.
2 Drive cover 8 Output shaft
3 Pump impeller 9 Torque converter The torque converter receives oil from the oil pump 6.
4 Turbine inlet oil relief valve Oil from the oil pump 6 is first sent to the transmission
5 Stator 10 Inlet oil passage control valve. The control valve uses part of the oil to
6 Oil pump 11 Outlet oil passage engage the transmission clutches and diverts all the
remaining oil to the torque converter.
The drawing shown above illustrates the torque The pressure of oil flowing to the torque converter has
converter and related parts used on the diesel-engine been regulated by the inlet oil relief valve 9, which is
models equipped with a two-speed transmission. The built into the stator shaft 7. The regulated oil flows
torque converter used on the gasoline-engine models through the passage 10 and then around the periphery
equipped with a single-speed transmission has basically of the stator shaft 7, into the torque converter.
the same structure as that used on the diesel-engine Oil from the torque converter flows through the gap
models with a two-speed transmission. between the stator shaft 7 and output shaft 8, then to
The torque converter is a three-element type, consisting the torque converter oil cooler. The pressure of the
of a pump impeller 3, turbine 4 and stator 5. outlet oil is also regulated by the outlet relief valve (not
shown), which is located adjacent to the inlet oil relief
As the engine flywheel turns, the torque transmitted
valve 9.
through the flexible plate 1 causes the drive cover 2,
pump impeller 3 and oil pump 6 to rotate as a single The oil having been cooled by the oil cooler is used to
unit. cool the transmission clutches and also to lubricate the
gears and bearings.
The output torque from the torque converter is
transmitted to the output shaft 8, which is splined to the If the torque converter remains stalled for a long time
turbine 4, and then to the transmission. or the oil cooler is fouled, the oil becomes too hot,
shortening the service life of the transmission.
5-1
Single-speed Transmission
(GP/DP40 thru 45, STD transmission models)
a 4 b
3 2
II
c
1
6
e I
9
FWD REV
III
d
Offset
IV f
208661
8 g
h
Power flow
Range Path
Forward c➞e f g h
Reverse d b a e f g h
202879
1 Pilot boss 4 Control valve 7 Countershaft (3rd shaft)

2 Torque converter assembly 5 Countershaft (2nd shaft) 8 Output shaft (4th shaft)
3 Oil pump assembly 6 Clutch shaft (1st shaft) 9 Turbine shaft (1st shaft)
Gears in engagement
Drive gear Driven gear
1st shaft c 3rd shaft e
1st shaft d 2nd shaft b
2nd shaft a 3rd shaft e
3rd shaft f 4th shaft g
5-2
The single-speed transmission is a constant mesh The transmission hydraulic control valve 4 is located on
reduction gear system forming an integral unit with the the top of the transmission. The valve controls the
torque converter. On its clutch shaft 6, there is a supply of oil pressure to the clutches, regulates the oil
hydraulically-operated forward - reverse clutch, which pressure, and controls the supply of oil to the torque
disconnects and reconnects the power path to the converter.
transmission output shaft 8 and also switch the power At the bottom of the transmission case, there is an oil
flow between the forward and reverse gears. sump for the torque converter-transmission unit. The
The final reduction bevel gear (housed in the reduction oil pump 3 draws oil from the oil sump through the
gear system) and the bevel pinion h on the output shaft suction strainer fitted with magnets and sends it to the
8 form a hypoid gear set, with their centers offset from transmission control valve 4 which uses the oil for
each other. Each bevel gear and pinion pair is precisely various purposes.
matched in the factory.
Clutch Shaft Assembly
208662
6 Clutch shaft (1st shaft) 13 Clutch piston 17 Oil passage to reverse piston
9 Turbine shaft (1st shaft) 14 Clutch piston return spring 18 Lubricating oil passage
10 Clutch drum 15 Pressure plate c Forward gear
11 Mating plate (6 pieces) 16 Oil passage to forward piston d Reverse gear
12 Friction plate (5 pieces)
Structure and Function of Forward - Reverse has three holes; two of them (16 and 17) are used to
Clutch (Clutch Shaft Assembly) supply oil pressure to the forward and reverse pistons,
and the third one 18 is used to supply lubrication and
The clutch shaft assembly consists of the clutch shaft 6,
cooling oil to the clutches and gears.
the forward clutch, and the reverse clutch. The two
clutches are fitted on the clutch shaft back to back. The oil from the hydraulic control valve flows through
either the passage 16 or the passage 17 to engage the
Each clutch assembly consists of six mating plates 11
relevant clutch. This allows drive power to be
(or drive plates) which always rotate with the clutch
transmitted through the engaged clutch from the turbine
shaft and clutch drum 10; five friction plates 12 (or
shaft 9 of the torque converter to the engaged gears
driven plates) which rotate with the forward gear c or
where the speed is reduced and the torque increased.
reverse gear d; the clutch piston 13 which presses the
The drive power is then sent to the output shaft 8.
friction and mating plates together; the clutch piston
return spring 14; and the pressure plate 15. The shaft
5-3
Control System (All Models)
R
F N
206755
1 Transmission direction lever 4 Operating plunger

2 Bracket 5 Inching pedal
3 Control valve 6 Clutch valve plunger
When the operator moves the transmission direction Depressing the pedal partially will cause the clutch to
lever 1 forward or backward, the transmission hydraulic partially disengage. Depressing the pedal fully will
control valve operating plunger moves accordingly cause the oil pressure in the clutch to drain off
forward or backward. The operating plunger is a completely, allowing the clutch to completely
directional control valve which directs oil to the disengage.
forward or reverse clutch. When the direction lever 1 is
moved to F, oil pressure is directed to the forward
clutch.
When the inching pedal 5 is depressed, the linkage will
cause the clutch valve plunger 6, which normally
remains pushed into the valve body while the vehicle is
being driven, to protrude from the valve body in the
direction of the arrow.
The movement of the plunger 6 restricts the oil pressure
being sent to the transmission clutch. At the same time
the oil pressure in the clutch is allowed to drain off.
5-4
Control Valve for Single-speed Transmission

(GP/DP40 thru 45)
Section A – A 2
A A 3
B B 4
Section B – B
208663
1 Accumulator valve 3 Clutch valve

2 Main regulator valve 4 Operating valve
The accumulator valve 1 is provided to ensure smooth The operating valve spool 4, connected via a linkage
clutch engagement. The valve helps moderate the with the direction lever on the steering column, is a
momentary pressure spike that would occur when the directional control valve which directs oil to either the
clutch is being engaged. It also dampens the shock load forward or reverse clutch.
as the truck drives off. For the flow of oil in the entire system and the
The main regulator valve 2 always maintains the operations of the valves, refer to the next page.
pressure of oil delivered from the pump at the specified
level. The regulated pressure can be checked by
measuring the M-tap pressure of the main regulator
valve.
The clutch valve 3 drains the pressure in the engaged
clutch in proportion to how far the operator has
depressed the inching pedal. When the inching pedal is
fully depressed, the oil in the clutch is drained
completely. Measuring the D-tap pressure enables
checking whether the pressure varies correctly
accordingly to position of the inching pedal.
5-5
Single-speed Transmission Hydraulic Circuit

(GP/DP40 thru 45)
Torque converter
Oil cooler Inlet relief valve: 98 to 490 kPa
(1 to 5 kgf/cm2)
[14 to 71 psi]
Accumulator valve
pressure at full charge:
570 kPa
(5.8 kgf/cm2)
[83 psi]
Transmission
lubrication
Main regulator valve:
880 to 1080 kPa
PM (9 to 11 kgf/cm2)
[130 to 156 psi]
M-tap:
Clutch valve
978 to 1220 kPa
(10 to 12.5 kgf/cm2)
[142 to 177 psi]
Operating valve
Oil pump (gear pump):

30 liter (8 U.S.gal)/min.
at 2400 rpm PC
F R
Strainer with magnets: 100 mesh D-tap
208664
The above drawing shows the hydraulic circuit for the single-
speed transmission.
The structures and functions of the major components are
described in the following.
Suction strainer with magnets

The suction strainer is located at the bottom of the
transmission case.
Three magnets are installed on the periphery of a 100-mesh
filter element. These magnets prevent metal swarf generated
as a result of wear of the gears and clutch plates, from
circulating through the system.
208665
5-6
Oil pump
The oil pump is a gear type as shown in the drawing on the
right. With the engine running, the gear A, which is coupled
to the torque converter input shaft, turns. As the gear A
turns, the internal gear B also turns in the same direction.
The oil from the inlet is trapped between the gear teeth and
the crescent and then carried to the outlet.
208666
Accumulator valve
When the direction lever is moved, the accumulator valve Bypass port
modulates the clutch engaging pressure, preventing it from
being applied suddenly onto the engaging clutch and thus
minimizing shock during standing starts.
The drawing on the right shows how the accumulator valve Orifice 1
modulates the clutch engaging pressure. To torque converter
• With the clutch engaged, the valve is held pressed against

the stop on the left end.
• As soon as the direction lever is moved in either direction,
Pump oil To clutch
the valve moves completely to the right, pushing oil
208667
through the bypass port to initially fill the clutch. Then,
oil flowing through the orifice 1 fills the clutch
completely.
• The modulation of the clutch engaging pressure is
achieved by the main orifice 1 , which restricts flow of
the oil to the valve so that the valve moves slowly to the
left and the pressure gradually increases.
Main regulator valve

The main regulator valve regulates the pump oil pressure at
the specified level regardless of the engine speed. The valve
should be adjusted to the specified pressure setting of 880 to
1080 kPa (9 to 11 kgf/cm2) [130 to 156 psi].
To torque converter
The drawing on the right shows the operation of the main
regulator valve as the clutch is being engaged.
• Pressurized oil moves the valve to the right, allowing the
pump-delivered oil to flow to the torque converter, which Valve spool
Pump oil
ensures that a constant clutch operating pressure is 208668
available.
• With the clutch engaged, all of the pump-delivered oil is
directed to the torque converter.
5-7
Clutch valve
Oil in clutch drains Oil passage narrowed
The clutch valve operates when the inching pedal is
depressed. Its function is to vary the hydraulic pressure
applied to the clutch gradually. Depressing the inching pedal
fully causes the valve to block the flow of oil to the clutch
and the oil in the clutch to drain off.
The drawing on the right shows the state of the clutch valve
when the inching pedal is partially depressed.
• The passage to the operating valve is narrowed while the
oil in the clutch is allowed to drain off. F R
208669
Operating valve
The operating valve has a spool connected via linkage to the
direction lever and directs the oil pressure to either the
forward or reverse clutch.
The drawing on the right shows the state of the valve when
the oil pressure is supplied to the forward clutch. F N R
• oil pressure from the oil pump is directed by the operating

valve to the forward clutch by way of the clutch valve.
F R 208670
Torque converter inlet relief valve

Torque converter outlet relief valve
The drawing on the right shows the inlet and outlet relief
valves for the torque converter combined with the single-
speed transmission.
The relief valves are incorporated in the stator shaft of the
torque converter.
The relief valves for the two-speed transmission are also
incorporated into the stator shaft of the relevant torque
converter, but their locations are different from those of the
single-speed transmission.
The inlet and outlet relief valves are identical except that the
lengths of their springs are different such that their opening
pressures are different. When the valves open, oil is drained
to the oil sump.
The opening pressures of the inlet and outlet relief valves
have been set as shown below. The settings cannot be
readjusted.
Inlet relief valve: 196 to 588 kPa (2 to 4 kgf/cm2) [30 to
56.8 psi]
Outlet relief valve: 147 to 245 kPa (1.5 to 2.5 kgf/cm 2)
[21 to 36 psi]
208671
5-8
Automatic Two-Speed Transmission (GP50, DP50)

(Optional for GP/DP40 thru 45)
207594
Power flow
Range Path
Forward 1st h f i j k
Forward 2nd g d i j k
Reverse 1st e b c f i j k
Reverse 2nd e b a d i j k
202918
1 Pilot boss 7 Input shaft (1st shaft)

2 Torque converter assembly 8 Countershaft (3rd shaft)
3 Pump body assembly 9 Output shaft (4th shaft)
4 Control valve 10 Magnet strainer
5 Solenoid valve 11 Travel speed sensor
6 Countershaft (2nd shaft) 12 Lubrication oil passage
5-9
Structure of Transmission
The two-speed transmission has four shafts. The transmission hydraulic control valve 4 is located on
The 1st shaft is directly connected to the torque the top of the transmission. The valve has the functions
converter turbine and acts as a torque converter output of controlling the supply of oil pressure to the clutches,
shaft. regulating the oil pressure, and controlling the supply of
oil to the torque converter. The travel speed sensor
This shaft has two forward clutches, F1 and F2. It also
(pulse generator) 11 is embedded in the side of the
has the drive gear e which drives the 2nd shaft.
transmission case, near the 4th shaft. The sensor is
On the 2nd shaft, there are two reverse clutches, R1 and used for controlling the operation of the two-speed
R2. The gear e on the 1st shaft is constantly in mesh transmission.
with the gear b on the 2nd shaft, so the 2nd shaft rotates
The oil sump for the torque converter-transmission unit
in the direction opposite to the 1st shaft.
is located at the bottom of the transmission case. The
On the 3rd shaft, there are three gears. These gears are oil pump 3 draws oil through the magnet-equipped
constantly in mesh with the gears of the clutches F1, suction strainer 10 and sends it to the transmission
F2, R1 and R2 as indicated in the table on the right. control valve 4 where it is distributed for various
The 4th shaft has the bevel pinion k, which is meshed purposes.
with a bevel gear to constitute the final reduction
gearing. The bevel pinion k and the bevel gear form a
Gears in engagement
hypoid gear set, with their centers offset from each
other. Each bevel gear and pinion pair is precisely Drive gear Driven gear
matched in the factory. 1st shaft e 2nd shaft b
During operation of the truck, only one of the four
F1 clutch h
clutches is engaged. The gears irrelevant to the 3rd shaft f
engaged clutch are idly rotated by either the gear d or f R1 clutch c
on the 3rd shaft. F2 clutch g
The reduction ratio is smaller when power flows 3rd shaft d
R2 clutch a
through the clutch F2 than when it flows through the
clutch F1. Likewise, the power path through the clutch 3rd shaft i 4th shaft j
R2 provides smaller reduction ratio than that through
the clutch R1. In other words, the power path including
the clutches F2 and R2 is for high-speed operation and
the power path including the clutches F1 and R2 is for
high-traction operation.
Clutch engaging oil pressure is directed through the
solenoid valve and then through the oil passages in the
1st and 2nd shafts to the relevant clutch. The oil pushes
the piston to engage the clutch.
Cool oil from the oil cooler flows through the lube oil
passages 12 in the 1st and 2nd clutch shafts and is
sprayed on the clutches for both cooling and lubrication
purposes.
5-10
Control Valve for Automatic Two-speed Transmission (GP50, DP50)

2
Section A – A
A A
B B
Section B – B
208672
1 Accumulator valve 4 Operating valve

2 Main regulator valve 5 Solenoid valve
3 Clutch valve
The valves 1 to 4 have the same structures and

functions as those in the single-speed transmission. For
the system operation of these valves, refer to page 5-5
to page 5-8.
However, the automatic two-speed transmission is
structurally and functionally different from the single-
speed transmission in that it has the solenoid valve 5.
The solenoid valve acts as an automatic directional
control valve. It automatically directs oil pressure to
the forward or reverse clutch, whichever has been
selected by the operating valve 4, of either the 1st speed
or 2nd speed as appropriate according to the travel
speed of the truck. For details, refer to page 5-12 to
page 5-14.
5-11
Control System for Automatic Two-speed Transmission (GP50, DP50)

Travel speed select switch
ECU 1st speed

(pulse signal input is Solenoid clutch
Output
gear constantly compared valve 2nd speed
with the preset value.) clutch
Electrical signal
Travel speed sensor
(pulse signal input) Hydraulic pressure signal
0.5 mm
(0.02 in.) Transmission case
Travel speed
select switch
ECU
Power
source
Solenoid
valve
Travel speed sensor

206761A
Locations of control devices
The automatic 2-speed transmission consists of an F2- Select switch position Travel speed
R2 powershift transmission and a control system
0 to 9 km/h
comprising a travel speed sensor, an electronic control 1st speed
Automatic (0 to 5.6 mph)
unit (ECU) and a solenoid valve. (2-speeds) * 9 to 24.5 km/h
2nd speed
Using the selector switch, either the automatic shift (5.6 to 15.2 mph)
mode (“Auto”) or the constant 1st speed mode (“1st 1st speed (automatic 0 to 14 km/h
speed”) can be selected. When the “1st speed” is shifting prohibited) (0 to 8.7 mph)
selected, only the clutches F1 and R1 are operative. In * The speed point at which an automatic shift takes
this mode, greater traction is available while the truck place is different between upshifting and
can travel only at a low speed. downshifting. The speed range shown above is for
upshifting.
5-12
Hydraulic Circuit for Automatic Two-speed Transmission (GP50, DP50)

F1 F2 R1 R2
Inlet relief valve:
98 to 490 kPa
(1 to 5 kgf/cm2)
[14 to 71 psi]
Solenoid valve
Oil cooler
F R
Accumulator valve
pressure at full charge:
570 kPa
(5.8 kgf/cm2)
[83 psi]
Transmission
lubrication Main regulator valve:
880 to 1080 kPa
(9 to 11 kgf/cm2)
PM [130 to 156 psi]
Clutch valve
Oil pump (gear pump):

30 liter (8 U.S.gal)/min.
at 2400 rpm Operating valve
M-tap:
978 to 1220 kPa PC R
Strainer with magnets: (10 to 12.5 kgf/cm2) F
100 mesh [142 to 177 psi] D-tap
978 to 1220 kPa
(10 to 12.5 kgf/cm2)
[142 to 177 psi]
208674
For the operation of the solenoid valve, refer to the next

page. The operations of the other components are basically
the same as those in the single-speed transmission. Refer to
the description on the single-speed transmission.
5-13
Hydraulic Control (Forward 1st Speed)
When travel speed is up to 9 km/h (5.6 mph) or gear is fixed at 1st
Solenoid valve plunger

Pilot pressure
F1 F2 R1 R2
Solenoid valve OFF
(open)
ECU
Solenoid valve
Accumulator valve
Transmission
Output gear
Travel speed
sensor
Inching valve
Selector valve
Pilot pressure
High-pressure oil
203804
5-14
Hydraulic Control (Forward 2nd Speed)
When travel speed is 9 km/h (5.6 mph) or higher
Signal
Plunger input
Solenoid valve plunger

Pilot pressure
F1 F2 R1 R2
Solenoid valve ON
(open)
ECU
Solenoid valve
Accumulator valve
Transmission
Output gear
Travel speed
sensor
Inching valve
Selector valve
Pilot pressure
High-pressure oil
Signal
203805
5-15
Removal and Installation

(3) Sling the engine, transmission and differential as an
Removal
assembled unit with a hoist and install this
(1) Drain coolant and remove the radiator. assembled unit to the front axle housing.
(2) Drain gear oil from the front axle housing. (4) Fill the front axle housing with gear oil to the
(3) Remove the front axle shafts. specified level. Fill the transmission and torque
converter with automatic transmission fluid to the
(4) Dismount the engine, transmission and differential
specified level. Fill the engine with antifreeze
as an assembled unit from the truck.
coolant.
(5) Unscrew the flexible plate mounting bolts through
the access hole in the coupling case. NOTE
(6) Separate the transmission from the engine. At this For installation of the engine and transmission as
time, support the engine with stands and sling the an assembled unit, refer to the topics, “Removal
transmission with a hoist. and Installation" in the “GROUP 4 POWER
TRAIN”.
NOTE
For removal of the engine and transmission as an
assembled unit, refer to the topics, “Removal and
Installation” in the “GROUP 4 POWER TRAIN”.
Installation
(1) Couple the transmission to the engine. Install the
torque converter to the transmission case so that the
distance between the end face of the case and the
mating face of flexible plate is 42 to 44 mm (1.65
to 1.73 in.) (diesel-engine model). In the gasoline-
engine model, the distance between the end face of
coupling case and the mating face of flexible plate
should be 5 mm (0.20 in.). Make sure the clearance
between the flywheel and flexible plate is
approximately 2 mm (0.08 in.) when the
transmission is coupled to the engine. If the
clearance is zero, it is an indication that the torque
converter is improperly coupled to the pump gear
or splines; re-couple the transmission to the engine
correctly.
(2) Tighten the flexible plate mounting bolts through
the access hole in the transmission case (diesel-
engine model) or the access hole in the coupling
case (gasoline-engine model).
NOTE
Tighten the bolts evenly in a diagonal sequence.
5-16
Torque Converter (All Models)

Disassembly
This drawing shows the torque converter for a gasoline-engine model.

207586
Sequence
1 Bolts, Spring washers, Plate 7 Spacer, Ball bearing, O-ring, Pump boss,
2 Flexible plate, *Pilot boss, O-ring Pump impeller, Bolts
3 Bolts, Drive cover, Ball bearing
4 Spacer, Turbine assembly *: The pilot boss for a diesel-engine model is different
5 Thrust washer, Thrust bearing in shape from that for a gasoline-engine model.
6 Stator, Rollers, Hub, Spring, Spring cap
Suggestion for Disassembly

The torque converter assembly has no drain plug and cannot
be drained completely. Drain the converter by turning the
pump boss side down.
5-17
Inspection and Repair
Pump impeller
(1) Check for cracks.
(2) Check for oil leaks due to looseness of bolts securing
pump boss to impeller or defective O-ring.
(3) Check for wear of the face of pump boss in contact with
oil seal.
Stator
(1) Check the blades for cracks and loose fit to the clutch 206772
cam.
(2) Check the clutch hub and cam for wear or flaws.
(3) Check the springs and spring caps for wear, breakage or
distortion.
(4) Check the rollers for flaws, distortion or wear.
(5) Check the clutch hub splines for defects.
(6) Check the thrust washers for wear or other defects.
A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP40 thru GP50, 1
Item DP40 thru DP50
− 0.03 − 0.0012
4
A 65 − 0.049 (2.56 − 0.00193 )
Outside diameter of
clutch hub 1
B 64.8 (2.551)
0 0
A 8.1 − 0.015 (0.32 − 0.00059 )
Diameter of clutch
rollers 2 3
B 7.985 (0.31437)
0 0 2
A 4.0 − 0.05 (0.16 − 0.0020 ) 206756
Thickness of thrust
washer 3
B 3.75 (0.1476)
0 0
A 4.0 − 0.05 (0.16 − 0.0020 )
Thickness of thrust
washer 4
B 3.75 (0.1476)
Turbine assembly
(1) Check the blades for cracks.
(2) Check the fit of turbine boss in the runner.
(3) Check the turbine boss splines for wear or other defects.
5-18
Pilot boss
Check the surface in contact with the pilot bearing for wear
or other defects.
1
Unit: mm (in.)
Truck Model GP40 thru GP50,
Item DP40 thru DP50
− 0.007 − 0.00028 207587
Diameter of shank in A 20 − 0.020 (0.78 − 0.00079 )
contact with pilot
bearing 1 B 19.85 (0.7815)
Flexible plate
(1) After installing flexible plate, measure the face runout of
the plate with a dial gauge. Replace the plate if the
runout exceeds the service limit.

Unit: mm (in.)
Item DP40 thru DP50
A 0.2 (0.008)
Face runout of flexible
plate
B 0.5 (0.020)
(2) Make sure the distance between the end face of coupling
case and the mating face of flexible plate is 208658
approximately 5 mm (0.20 in.) (gasoline-engine model).
(3) Make sure the distance between the end face of

transmission case and the mating face of flexible plate is
42 to 44 mm (1.65 to 1.73 in.) (diesel-engine model).
NOTE
After installing the flexible plate, fasten the plate to the
transmission case with wire.
208659
5-19
Reassembly
1
7
6 5
❋
This drawing shows the torque converter for a gasoline-engine model. The diesel-engine
model’s torque converter has a pilot boss 2 shorter than the one shown here. 207588
Sequence
7 ➞ 6❋ ➞ 5 ➞ 4 ➞ 3 ➞ 2 ➞ 1
Suggestions for Reassembly
1. Stator assembly 6
(1) Position hub 1 in the stator as shown. Put spring 2 and
spring cap 3 in each hole, and press in the roller 4 while
pushing the spring cap.
(2) Install a total of ten rollers, and restore the hub to its
original position.
(3) Upon reassembling, rotate the hub by hand, making sure
that it rotates in one direction.
202885A
5-20
2. Selection of spacer
Measure dimensions A, B and C to obtain dimension D.
Select a spacer whose thickness is smaller than dimension D
by 0.2 to 0.8 mm (0.008 to 0.031 in.) (thrust clearance).
Part number Thickness of spacer
91823 - 01700 2.5 mm (0.098 in.)
91823 - 01600 2.7 mm (0.106 in.)

202884
91823 - 01400 3.0 mm (0.118 in.)
A 25 mm (0.98 in.)
Standard
B 14 mm (0.55 in.)
dimensions
0 0
C 8.0 − 0.1 mm (0.315 − 0.004 in.)
1-speed Transmission (GP/DP40 thru 45)

Disassembly
Control Valve and Strainer
Sequence
1 Drain plug, Washer
2 Torque converter thermo unit
3 Level gauge, Control valve
4 Subplate, Gasket
5 Strainer pipe
6 Strainer assembly, Gasket
202886
5-21
Pump Body Assembly
202887
Sequence
1 Pump body, Oil seal, Bushing 4 Valve, Spring, Washer, Snap ring
2 Internal gear, Drive gear, O-ring 5 Gasket
3 Stator shaft, Cap, Dowel pin 6 Turbine shaft, Seal ring, Snap ring
NOTE
It is not necessary to remove the cap and dowel pin from the stator shaft or the bushing and oil seal from the
pump body unless they are defective.
Removing pump body assembly

Unscrew all bolts securing the pump body assembly, and
remove the assembly with the jack bolt holes in the stator
shaft.
Special tool needed
Jack bolt MCF - 1046

202888
5-22
Countershaft (2nd shaft)
202889
Sequence
1 Snap ring 5 Countergear
2 Rear cover, O-ring 6 Ball bearing
3 Countershaft 7 Countergear, Snap ring
4 Ball bearing
Removing bearings
Remove snap ring 1 from its groove in advance. Screw a
sliding hammer into the tapped hole in shaft 3, pull off the
shaft, and remove bearings 4 and 6 from the transmission
case.
5-23
Countershaft (3rd shaft)
202890
Sequence
1 Snap ring 5 Countergear
2 Rear cover, O-ring 6 Roller bearing
3 Countershaft 7 Countergear, Snap ring
4 Ball bearing
Output Shaft (4th shaft)
202891
Sequence
1 Output cover 4 Output gear
2 Output shaft subassembly 5 Shims
3 Ball bearing
5-24
1. Removing output shaft

Using special tool A, pull off the output shaft. The output
gear will interfere with the input shaft drum; this makes it
necessary to remove the output shaft by tapping the output
gear with a copper hammer through countershaft (3rd shaft)
mounting hole.
Special tool needed
Output shaft puller A MCF - 1036

202892
2. Shims
Unit: mm (in.)
Reuse the shims removed during disassembly. M16 × 1.5
Nut
Washer
110 (4.33)
160 (6.30) 10
(0.39)
(0.67)
17
13
0(
5.1
2) M10 × 1.25
202893
5-25
Forward-reverse Clutch Shaft
20
8
6
7 25
5 26
4 27
3 28 29
2 29
1 30
23
1
16
15 24
14 9
22 10
21 19 12
16 11
13
17
18
19
207589
Sequence
1 Servo case, O-ring 12 Needle roller bearing 21 Retainer
2 O-ring 13 Thrust washer 22 Spring
3 Seal ring 14 Snap ring 23 Clutch piston, Ball, Screw
4 Ball bearing 15 Pressure plate 24 Seal ring
5 Thrust washer 16 Friction plates, 25 Snap ring
6 Forward gear Mating plates 26 Retainer
7 Needle roller bearing 17 Snap ring 27 Spring
8 Thrust washer 18 Pressure plate 28 Clutch piston, Ball, Screw
9 Ball bearing 19 Friction plates, 29 Seal ring
10 Thrust washer Mating plates 30 Clutch shaft
11 Reverse gear 20 Snap ring
NOTE
It is not necessary to remove the balls and screws from
the clutch piston, the screw from the clutch shaft, or the
steel ball from the servo case.
5-26
Disassembling clutch drum

Using special tool A or an arbor press, compress return
springs 22 and 27, and remove snap rings 20 and 25.
Special tool needed
Piston tool A MCF - 1035
207504A
1. Oil pump
(1) Install the internal gear and drive gear in the pump body,
and measure top clearance 2.
(2) Using a dial gauge, measure side clearance 1 between the
gears and pump case.
(3) Measure clearance 3 of drive gear in pump boss (notch).
(4) Check the relief valve for distortion or other defects.

Unit: mm (in.)
Item DP40 thru DP50
0.07 to 0.11
A
(0.0028 to 0.0043)
Side clearance 1
B 0.20 (0.0079)
0.3 to 0.33
A
(0.012 to 0.0130) 202897
Top clearance 2
B 0.45 (0.0177)
0.2 to 0.4
A
Drive gear clearance in (0.008 to 0.016)
pump boss notch 3
B 1.0 (0.039)
5-27
2. Pump boss

Unit: mm (in.)
Item DP40 thru DP50
0 0
Diameter of fitting A 70 − 0.046 (2.76 − 0.00181 )
surface in contact with
oil seal and bushing 1 B 69.90 (2.7520)
70.06 to 70.10 206772

A
Inside diameter of (2.7583 to 2.7598)
boss bushing 2
B 70.3 (2.768)
3. Stator shaft
(1) Check to make sure that bearings fit tight to the shaft.
(2) Check the splines for wear or damage.
(3) Check the oil passages for clogging.
4. Clutch pistons
(1) Shake each piston, making sure that the balls move freely
in the piston.
NOTE
Do not overhaul the pistons unless they are defective.
(2) Check the seal rings and their grooves for wear or
damage. 207590
5. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact, warpage or
excessive wear.
6. Clutch drums
(1) Check the mating plate sliding surfaces for wear or
damage.
(2) Check the clutch piston sliding surfaces for wear or
damage.
5-28
7. Clutch gears (forward and reverse)

(1) Check the gear and splines for wear or damage.
(2) Check the gear surface in contact with needle roller
bearing for wear or damage.

Unit: mm (in.)
Item DP40 thru DP50
2.3 ± 0.07
A
Thickness of mating (0.091 ± 0.0028)
plate 1
B 2.1 (0.083)
2.6 ± 0.1
A
Thickness of friction (0.102 ± 0.004)
plate 2
B 2.2 (0.087)
Backlash of friction 0.10 to 0.30

A
plate with gear 3 (0.0039 to 0.0118)
− 0.01 − 0.0004
A 4 − 0.03 (0.16 − 0.0012 )
Width of seal ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 )
Width of seal ring
202900
groove in piston 5
B 4.5 (0.177)
Free length of clutch 63 (2.48)

A
spring 6 k = 39.1 (3.992) [223.3]
Spring constant:
k = N/mm (kgf/mm)
B 61 (2.40)
[lbf/in.]
2.5 ± 0.05
A
Width of clutch piston (0.098 ± 0.0020)
seal ring 7
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch piston
seal ring groove 8
B 3.0 (0.118)
5-29
8. Turbine shaft and clutch shaft

Check the seal rings, shaft and case for wear or damage.

Unit: mm (in.)
Item DP40 thru DP45
2.5 ± 0.05
A
Width of turbine shaft (0.098 ± 0.0020)
seal ring 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of piston seal ring
groove in turbine shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of stater A 35 0 (1.38 0 )
shaft in contact with seal
ring 3 B 35.2 (1.386)
2.5 ± 0.05
A
Width of clutch shaft seal (0.098 ± 0.0020)
ring 4
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch shaft seal
ring groove 5
B 3.0 (0.118)
+ 0.021 + 0.00098
Inside diameter of servo A 35 0 (1.38 0 )
case in contact with seal
ring 6 B 35.2 (1.386)
207591
5-30
9. Clutch shaft, countershafts, and output shaft

(2) Check oil passages for clogging.
10. Gears
Check each gear for worn teeth or splines.
11. Strainer assembly

Disassemble and clean. Replace the strainer if defective.
5-31
Reassembly
Forward-reverse Clutch Shaft (1st shaft)
❋A
1, ❋2
203799
Sequence
2❋
➞
A❋ ➞ 1
Start by:
(a) Install the following parts to the transmission case in
advance:
• Ball bearing B for output shaft
• Outer race C of roller bearing for countershaft (3rd
shaft)
• Ball bearing D for countershaft (2nd shaft)
(b) Put output gear E in the transmission case.

(1) Install the forward-reverse clutch shaft as an assembly.
(2) Apply ATF oil to the inside surface of servo case and the
seal ring.
5-32
Clutch Shaft Assembly A
❋ ❋ ❋ ❋ ❋
20 14 15 16 23 19 18 17 25
6 11
❋5
10❋
4 9
3
7 12
❋8 13❋
21 22 24 28 29 30 27 26
❋ ❋ ❋
207592
Sequence
➞ 29 ➞ 28❋ ➞ 27❋ ➞ 26 ➞ 25 ➞ 19❋ ➞ 18❋ ➞ 17 ➞ 13❋ ➞ 12 ➞ 11 ➞ 10❋ ➞ 9
30
➞ 24 ➞ 23❋ ➞ 22❋ ➞ 21 ➞ 20 ➞ 16❋ ➞ 15❋ ➞ 14 ➞ 8❋ ➞ 7 ➞ 6 ➞ 5❋ ➞ 4 ➞ 3

(1) When inserting pistons 28, 23 into clutch drum 30,
apply ATF oil to their seal ring portions.
(2) Installing return spring
Using special tool A or an arbor press, compress springs
27, 22 and install snap rings 25, 20.
Special tool needed
207504A
5-33
(3) Installing clutch plates

(a) Make sure that the combination and number of the
plates are correct. Install the plates while applying
ATF oil to them. When replacing the friction plates,
replace the mating plates as a set.
207593
(b) Installing thrust washers

Make sure that the oil-groove side of thrust
washers 13, 8, 10, 5 faces the gear when installed.
203800
(4) After assembling the clutch, apply air pressure of

approximately 69 kPa (0.7 kgf/cm2) [10 psi] to the oil
hole to make sure that the clutch parts move smoothly
without any sign of air leaks.
5-34
❋
2
6 10 9 7 8 11 1213 14
202905
2❋
3
1
4
5
202905
Sequence
3 ➞ 4 ➞ 5 ➞ 2❋ ➞ 1
Suggestion for Reassembly

Install the output shaft as an assembly 2. (3) Tighten nut 13 to the specified torque, and stake it
If the hypoid gear set is replaced, a tooth contact in place to prevent loosening.
adjustment must be performed. For the adjustment
353 to 392 N·m
instructions, refer to page 6-14 in the “GROUP 6 Tightening torque for
(36 to 40 kgf·m)
FRONT AXLE AND REDUCTION DIFFERENTIAL” nut 13
[260 to 289 lbf·ft]
and page 4-4 in the “GROUP 4 POWER TRAIN”.
(1) Reassembly sequence for output shaft
Special tool needed
7 ➞ 8 ➞ 9 ➞ 10
➞ 11 ➞ 12 ➞ 13 ➞ 14 Wrench MCF - 1050
6
(2) Put LG2 grease on the oil seal.
5-35
7
❋1
2 6
4
5
202907
Sequence
3 ➞ (1)❋ ➞ 7 ➞ 6 ➞ 5 ➞ 1 ➞ 4 ➞ 2

Reassemble shaft 3, snap ring 1, gear 7 and roller bearing
inner race 6 outside the transmission case, without fitting the
snap ring in its groove, then put the shaft in the case, and fit
it to gear 5 inside the case.
202908
5-36
❋ ❋
5 1 7 1 6
2
3
202909
Sequence
3 ➞ 7 ➞ (1)❋ ➞ 5 ➞ 6 ➞ 1 ➞ 4 ➞ 2

Install shaft 3 to the transmission case with snap ring 1
temporarily fitted to the shaft.
1 3 1
202910
5-37
Pump Body Assembly
❋
3 2
1❋
4 3
202911 202912
Sequence
6 ➞ 5 ➞ 3 ➞ 4 ➞ 2❋ ➞ 1❋
Suggestions for Reassembly Control valve and strainer

(1) Install the pump body to the transmission case as an To reassemble, follow the reverse of disassembly
assembly. sequence. Replace the gaskets.
(2) Apply engine oil to the internal gear and drive gear
2 when installing them to pump body 1.
(3) Apply LG2 grease to the oil seal and bushing of
pump body 1.
(4) Upon reassembling, measure each gear backlash
with a dial gauge.
Unit: mm (in.)
Backlash of countergear 0.14 to 0.27
and output gear (0.0055 to 0.0106)
0.14 to 0.26
Backlash of other gears
(0.0055 to 0.0102)
5-38
Control Valve for Single-speed Transmission (GP/DP40 thru 45)

Disassembly
200219
Sequence
1 Cover, O-ring 6 Oil seal
2 Accumulator piston, Spring 7 Plug, Bearing Roller, O-ring
3 Main regulator valve, Spring seat, O-ring, 8 Accumulator spring seat, Pin, O-ring
Spring, Slug 9 Drain plug, Gasket
4 Inching valve plunger, Spring, Valve, Return 10 Orifice screw
spring, Slug, Stopper pin, O-ring
5 Operating plunger, Plug, Detent spring, Steel
ball, Stopper pin, O-ring
NOTE
Do not remove oil seal 6 unless it is defective.
5-39

(1) Check the valve housing for clogged oil passages.
(2) Check each plunger for trace of wear, damage or seizure.
(3) Check the oil seals for damaged lips.
(4) Check the operating plunger steel ball and its seating
surface for abnormal condition.
(5) Check the orifice in the main regulator valve for
clogging. Also check the valve spring for fatigue,
weakness or damage.
200220
Unit: mm (in.)
Item DP40 thru DP50
Free length of main relief valve 75 (2.95)

A
inner spring 1 k = 2.11 (0.2154) [12.05]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 72 (2.83)
Free length of main relief valve 50 (1.97)

A
outer spring 2 k = 0.838 (0.0855) [4.78]
Spring constant:
Free length of clutch valve 39 (1.54)

A
spring 3 k = 2.13 (0.217) [12.1]
Spring constant:
Free length of clutch valve 28 (1.10)

A
spring 4 k = 0.478 (0.0488) [2.73] 208673
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 26.5 (1.04)
Free length of torque converter 32 (1.26)

A
inlet/outlet pressure regulating k = 4.56 (0.465) [26.0]
valve spring 5
Spring constant:
B 31 (1.22)
k = N/mm (kgf/mm) [lbf/in.]
Free length of accumulator 91 (3.58)

A
valve outer spring 6 k = 7.30 (0.7447) [41.7]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 89 (3.50) 203001
Free length of accumulator 130 (5.12)

A
valve inner spring 7 k = 0.676 (0.0609) [3.40]
Spring constant:
5-40
Reassembly
8
2
10 1
Section A – A
3
7
A A
4 4
4
B B
Section B – B
6
C C
5
Section C – C
5
❋ 200417
Sequence
10 ➞ 8 ➞ 7 ➞ 6 ➞ 5❋ ➞ 4 ➞ 3 ➞ 2 ➞ 1 ➞ 9
Start by:
Thoroughly wash the oil passages in the valve, and make sure
that they are not clogged.

With the spring and steel ball 5 placed in the valve housing,
insert the operating plunger 5 as shown.
203801
5-41
Automatic Two-speed Transmission

(GP50, DP50 and All Models with Two-speed Transmission)
Disassembly
Control Valve and Side Cover
202920
Sequence
1 Drain plug, Washer 6 Subplate, O-ring, Gasket
2 Torque converter thermo unit 7 Generator cover, Sensor
3 Oil level gauge 8 Strainer assembly, O-ring
4 Solenoid valve 9 Side cover, Gasket
5 Control valve
5-42
203806
Sequence
1 Output cover 3 Taper roller bearing, Race, Nut, Snap ring
2 Output shaft subassembly 4 Output gear
Suggestions for Disassembly

(1) Removing output shaft
Use the special tool A to remove the output shaft
subassembly. The output gear will interfere with the
gear of countershaft (3rd shaft). This makes it necessary
to remove the shaft while tapping the output gear with a
copper hammer through side cover hole.
Special tool needed
202892
Output shaft puller A MCF - 1036
(The same tool as that used for 1-speed transmission)
(2) Disassembling output shaft

Usually, it is not necessary to disassemble the output
shaft. When it has to be disassembled, use an arbor
press to remove the bearing. Take care not to lose the
shims during disassembly.
200091
5-43
Pump Body
202922
Sequence
1 Pump body, Roller bearing (outer race), 2 Stator shaft, Valve, Spring washer,
Bushing, Oil seal, Gasket, O-ring Snap ring, Steel ball
3 Drive gear, Driven gear

(1) Removing pump body assembly
Unscrew all body mounting bolts and, using the jack
bolts, remove the assembly.
Special tool needed
Jack bolt MCF - 1046
(2) Do not remove the steel ball and plug fitted to the pump
body or the bushing, oil seal, steel ball, and cap, fitted to
the stator shaft, unless they are defective.
202923
5-44
202924A
Sequence
1 Roller bearing (inner race) 6 Countershaft
2 Collar 7 Gear (forward 1st speed countergear)
3 Output gear (countergear) 8 Ball bearing
4 Spacer 9 Gear (forward 2nd speed countergear)
5 Cover, O-ring

(1) Removing roller bearing
To remove roller bearing 1, attach a gear puller to output
gear 3, and remove the bearing, gear and collar 2 as a
set.
(2) Removing countershaft
Attach a sliding hammer to countershaft 6, and remove
the shaft complete with ball bearing 8.
5-45
Input Shaft (1st shaft)
207595
A: Input shaft assembly (consisting of parts 2 thru 17)
Sequence
1 Servo case, O-ring 10 Thrust washer
2 Seal ring 11 Snap ring, Pressure plate
3 Ball bearing 12 Friction plates, Mating plates
4 Thrust washer 13 Snap ring, Retainer
5 Gear (forward 2nd speed drive), Needle roller 14 Clutch spring
bearing 15 Clutch piston, Ball, Screw, Seal ring
6 Thrust washer 16 Seal ring
7 Ball bearing 17 Input shaft
8 Thrust washer
9 Gear (forward 1st speed drive), Needle roller
bearing
NOTE
Do not remove the steel ball fitted to the servo case or
the screw fitted to the input shaft.
5-46

(1) Removing input shaft ball bearing
Use the special tools to remove ball bearing 3 from the
1
input shaft.
Special tools needed
Ref.
Tool name Part No.
No.
2 3
1 Puller 4
207503
2 Plate
Complete puller
assembly
3 Bolt
MCF - 1052
4 Gear puller
(2) Disassembling input shaft

Using the special tool or an arbor press, compress clutch
spring 14, and remove snap ring 13.
Special tool needed
207504A
(3) Clutch piston

Shake each piston 15, making sure that the balls move
freely in the piston.
5-47
207596
B: Countershaft assembly (consisting of parts 2 thru 17)

Sequence
1 Servo case, O-ring 10 Thrust washer
2 Seal ring 11 Snap ring, Pressure plate
3 Ball bearing 12 Friction plates, Mating plates
4 Thrust washer 13 Snap ring, Retainer
5 Gear (reverse 2nd speed drive), Needle roller 14 Clutch spring
bearing 15 Clutch piston, Seal ring, Steel ball, Screw
6 Thrust washer 16 Seal ring
7 Snap ring 17 Countershaft
8 Thrust washer
9 Gear (reverse 1st speed drive), Needle roller
bearing

For disassembly of the countershaft and clutch piston, refer
to the previous paragraph “Disassembly of Input Shaft”.
5-48

For the following parts, refer to the section “1-speed
Transmission”:
(1) Oil pump
(2) Pump boss
(3) Stator shaft
(4) Clutch pistons
(5) Friction plates and mating plates
(6) Clutch drums
(7) Clutch gears
(8) Input shaft, countershafts, output shaft
(9) Gears
(10) Strainer assembly
Input shaft, servo case and seal rings

Check the contact surfaces of each part for wear or damage.

Unit: mm (in.)
Truck Model
GP50, DP50
Item
2.5 ± 0.05
A
Width of input shaft (0.098 ± 0.0020)
seal ring 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of seal ring
groove in input shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of A 35 0 (0.38 0 )
stator shaft in contact
with seal ring 3 B 35.2 (1.386)
2.5 ± 0.05
A
Width of input shaft (0.098 ± 0.0020)
seal ring 4
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of input shaft
seal ring groove 5
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of A 35 0 (1.38 0 )
clutch shaft in contact
with seal ring 6 B 35.2 (1.386)
5-49
NOTE
The dimensions of the seal rings and their grooves for the
countershaft are identical with those for the input shaft.
207597
5-50
Reassembly
Ball Bearing and Oil Seals
❋2
202930
Sequence
1 Ball bearing
❋2 Oil seals
NOTE
Removal of the output shaft will leave the ball bearing
and oil seals in the transmission case. Remove them for
replacement only when they are found defective.

To install the oil seals, use the special tool to press them
squarely.
Special tool needed
Installer MCF - 1051
203479
5-51
Countershaft (2nd shaft) and Input Shaft (1st shaft)
1
B
❋ 14
13
1
3
A
2 12
❋
4 5 6 11 15 16 10 9 8 7 2 17
❋
207598
Start by:
(a) Reassemble the countershaft subassembly B.
(b) Reassemble the input shaft subassembly A.
Sequence for input shaft subassembly
17 ➞ 16 ➞ 15❋ ➞ 14❋ ➞ 13 ➞ 12❋ ➞ 11 ➞ 10 ➞ 9 ➞ 8 ➞ 7

➞ 2
6 ➞ 5 ➞ 4 ➞ 3
NOTE
Reassembly sequence and suggestion for reassembly for
the countershaft are the same as those for the input shaft.
Sequence for countershaft
1 ➞ B Countershaft subassembly ➞ A Input shaft subassembly
5-52

(1) Installing clutch spring
Using the special tool A or an arbor press, compress
clutch spring 14, and fit snap ring 13.
Special tool needed
(2) When inserting clutch piston 15 into the drum of the

207503
countershaft 17 or input shaft 17, apply ATF oil to the
seal rings.
(3) Installing clutch plate
Make sure that the combination and number of the
plates are correct. Reassemble the plates while applying
ATF oil to each plate. When replacing the friction
plates, replace the mating plates as a set.
(4) After reassembling, apply air pressure of approximately
69 kPa (0.7 kgf/cm2) [10 psi] to the oil hole to make sure
that the clutch parts move smoothly without any sign of
air leaks.
5-53
5
7
3
6
❋9
1
2
4
206764
Sequence
9❋ ➞ 6 ➞ 7 ➞ 3 ➞ 4 ➞ 8 ➞ 5 ➞ 2 ➞ 1
(4; Temporary reassembly)

When placing gear (forward 2nd speed countergear) 9 in the
transmission case, slightly pull out the input shaft
subassembly and countershaft subassembly (2nd shaft) to
prevent interference of these shafts with the gear.
5-54
Pump Body
1❋
3❋
206765
Sequence
1❋ ➞ 3❋ ➞ 2

(1) Install the pump body to the transmission case as an
assembly.
(2) Apply ATF oil to the internal gear and drive gear when
installing them to the pump body.
(3) Put LG2 grease on the oil seal and bushing of the pump
body 1.
5-55
Output Shaft
❋2
3
4
206766
Sequence
4 ➞ 2❋ ➞ 3 ➞ 1

(1) Install the output shaft as subassembly 2.
(2) Shim adjustment of output shaft
Centerline of axle
Before installing the bearing, determine the required

c
thickness of shims by referring "a" and "b" to this
formula:
a
Thickness of shims (c) = 1.7 + 100 − b ±b
Where a: machining error indicated in a unit of 1/100
± a
mm (0.0004 in.) on differential carrier by 100 202825
punching
Unit: mm (in.)
b: machining error of bevel pinion
Backlash of 1st speed gear 0.14 to 0.23
(3) Apply LG2 grease to the oil seals fitted to the
and forward 2nd speed gear (0.0055 to 0.0091)
transmission case.
Backlash of forward gear 0.14 to 0.24
(4) Upon reassembling, measure each gear backlash with a and reverse gear (0.0055 to 0.0094)
dial gauge.
Backlash of countergear 0.14 to 0.25
and output gear (0.0055 to 0.0098)
5-56
Torque Converter
205799
Reassembly Control Valve and Side Cover

Install the torque converter assembly to the To reassemble, follow the reverse of disassembly
transmission. sequence.
9 ➞ 8 ➞ 7 ➞ 6 ➞ 5 ➞ 4 ➞ 3 ➞ 2 ➞ 1
(1) Align the splines of the transmission-side stator
shaft, turbine shaft and pump boss. The distance Replace the gaskets and O-ring.
between the end face of housing and the mating
face of flexible plate will be 42 to 44 mm (1.65 to
1.73 in.) when the torque converter is properly
placed in the transmission. Apply ATF oil to the
sliding surfaces of oil seal and bushing.
(2) Fasten the flexible plate to the housing with wire to
prevent the torque converter from sliding out.
5-57
Control Valve for Automatic Two-Speed Transmission
Flow the same disassembly and reassembly procedures as those for the single-speed transmission control valve
(pages 5-39 to 5-41) except for the solenoid valve disassembly and reassembly procedures which are described
below.
Solenoid Valve
Disassembly
202936
Sequence
1 Cover, Gasket 4 Spring
2 Solenoid, O-ring 5 Valve
3 Cover, O-ring 6 Body, Gasket
Inspection and Repair Reassembly

(1) Check the valve body for clogged oil passages. Follow the disassembly sequence in reserve.
(2) Check the valve for wear, damage or seizure.
(3) Check the spring for damage or fatigue.

Unit: mm (in.)
Truck Model
GP50, DP50
Item
Free length of solenoid 65 (2.56)

A
valve spring k = 1.79 (0.183) [55.9]
Spring constant:
k = N/mm (kgf/mm)
B 63 (2.48)
[lbf/in.]
5-58
Test and Adjustment (All Models)

Oil pressure measurement
The correct oil pressures for the individual hydraulic circuits
are as shown below. There is no means for adjusting the
pressures of these circuits. Main pressure (M14 × 1.5)
Unit: kPa (kgf/cm2) [psi] Torque converter inlet
pressure (PT 1/8)
Item DP40 thru DP50
Main pressure (Tap M) 978 to 1220

(10 to 12.5) Cooler
(engine at 1600 ± 100 rpm) [142 to 177]
Clutch pressure (Tap D) 978 to 1220 M

(engine at 1600 ± 100 rpm) (10 to 12.5)
[142 to 177]
Torque converter inlet pressure 98 to 490 D

(engine at 1600 ± 100 rpm) (1 to 5)
[14 to 71]
Lube oil pressure*1 1-Speed 49 to 294

(engine at 1600 ± 100 rpm) (.5 to 3.0) Clutch pressure (M14 × 1.5)
[7 to 42]
202913
Lube oil pressure*2 2-Speed 10 to 147
(0.1 to 1.5) Location of pressure taps (hydraulic control
(engine at 1600 ± 100 rpm) [1.42 to 21.3] valve for single-speed transmission)
*1 Since there is no pressure tap, measurement of this
pressure is impossible unless a special arrangement is
provided.
*2 This pressure can be measured only with the two-speed Lube oil pressure (PT 1/8)
transmission (which has a pressure tap). Main pressure (M14 × 1.5)
1. Measurement of main and clutch pressures

(1) Connect a pressure gauge (1961 kPa (20 kgf/cm2) [284
psi]) to the pressure tap (M14 × 1.5 thread).
Special tool needed
Connector (M14 × 1.5) MCF - 1039
To oil
*Hose 64309 - 17722 M cooler
*Connector 64309 - 17731

D
*Gauge 64309 - 17713
O-ring Service Set MCF-1039-1
Torque converter inlet
(2) Start and run the engine at an idling speed, and check pressure (PT 1/8)
that the oil level is correct in the transmission case. Clutch pressure (M14 × 1.5) 202937
(3) Warm up until the torque converter oil temperature gauge
indicates the green zone. Location of pressure taps (hydraulic control
(4) Run the engine at a speed between 1000 and 1500 rpm. valve for two-speed transmission)
NOTE
Observe the engine tachometer reading.
5-59
2. Measurement of torque converter inlet and lube oil

pressures
Use the 64309 - 17733 Connector (Rc 1/8 thread) to measure
these pressures.
3. Measurement of Clutch valve pressure
Start by:
(a) Raise the front axle housing with a jack and place wood
blocks under the outer mast. Tilt the mast forward to
raise the front wheels.
(b) Block the rear wheels.
CAUTION
Remember, the front wheels will rotate when the
clutch pressure is tested.
Procedure
(1) Set the inching pedal stroke to the specified value.
(2) Connect a pressure gauge to the clutch pressure tap D
(M14 × 1.5). 981
(10)
kPa (kgf/cm2) [psi]
Use the same special tools in page 5-59.

Clutch pressure,
[142]
(3) Move the operating plunger to the forward position. 588
(6.0)
(4) Gradually pull out the clutch valve plunger from its fully [85]
pushed position, and plot the oil pressure curve relative
to the plunger stroke. Make sure that the pressure curve
is identical with the curve shown. 0 5 10
(0.20) (0.39)
Inching valve stroke, mm (in.)
202914A
5-60
Stall Speed Measurement

Truck
(1) Run the engine at an idling speed, and check that the oil Model GP40 thru GP50 DP40 thru DP50
level is correct in the transmission case.
Item
(2) Warm up the torque converter oil.
Stall speed 2070 ± 100 rpm 1950 ± 100 rpm
(3) Block the front and rear wheels, and apply the parking
brake.
(4) Run the engine at an idling speed.
(5) Depress the brake pedal strongly by the left foot, move
the forward-reverse lever to the forward position, and
gradually depress the accelerator pedal all the way by the
right foot. Under this condition, observe the engine
tachometer reading.
CAUTION
Do not attempt to depress the inching pedal. Do
not continue “stall speed” run for more than 30
seconds. Continuing stall speed run too long could
cause the torque converter to overheat, shortening
its service life.
(6) Similarly read the stall speed for reverse drive.
NOTE
(a) Any stall speed within ± 100 rpm of the specification
is satisfactory.
(b) If the engine or torque converter is changed, the stall
speed will vary since the stall speed is determined by
the combination of engine and torque converter.
10 m (33 ft) Starting Acceleration Test

(1) Stand ready to start with the engine idling and the
forward-reverse lever in the neutral position.
(2) At a signal, shift into forward and, at the same time,
depress the accelerator pedal all the way.
(3) Measure the amount of time the truck elapses to travel 10
m (33 ft) with a stopwatch.
(4) Measure for reverse travel, too.
Travel time (no load) 5 seconds, maximum
5-61
Inching Pedal Adjustment
1. Adjusting brake
(1) Bleed air out of the brake lines from the reserve tank
through master cylinder to the wheel cylinders.
NOTE
For bleeding, refer to page 8-23 in the “GROUP 8
BRAKE SYSTEM”.
(2) Screw the rod fully into the clevis on the brake pedal
side.
202814
(3) Screw the lock nut on the operating rod of booster.

Screw the operating rod into the rod until the remaining
thread length measures 14 mm (0.55 in.) and tighten the
lock nut.
201815
(4) Adjust the brake pedal height A to 223 mm (8.8 in.) by

turning the operating rod, and tighten the lock nut on the
pedal side.
(5) Decrease the brake pedal height A to 220 mm (8.7 in.) by
the stopper bolt (until the operating rod push the booster
slightly).
202817
5-62
(6) Adjust and confirm the brake shoe lining clearance. Do

not adjust this clearance by setting the push rod length;
the clearance is to be adjusted with the automatic
adjuster.
Unit: mm (in.)
Truck Model
GP40 thru GP45, GP50,
Item DP40 thru DP45 DP50
Clearance 0.25 to 0.40 0.40 to 0.60

between brake
lining and drum (0.010 to 0.015) (0.015 to 0.023)
2. Adjusting inching pedal

(1) Connect a pressure gauge to the clutch pressure tap.
NOTE
For the special tools, make reference to item (2) in the
paragraph “Inching Valve Test”.
(2) Adjust the height A of inching pedal to 220 mm (8.7 in.)

by the stopper bolt. Adjust the clearance between
inching pedal and brake pedal B. 202915
Unit: mm (in.)
Item DP40 thru DP50
Clearance between brake 0.1 to 0.5

pedal and inching pedal (0.004 to 0.020)
(3) Start the engine, and release the brake pedal. Depress
the inching pedal until the brakes start applying (that is,
the pedal encounters resistance). Under this condition,
reposition the rod and ball joint so that inching valve
plunger stroke D is 16 mm (0.63 in.) at 0 kgf/cm 2
pressure.
Unit: mm (in.) 202916

Truck Model GP40 thru GP45, GP50,
Item DP40 thru DP45 DP50
Inching pedal 60 to 65 50 to 55
stroke at which
brakes start applying (1.85 to 3.03) (0.94 to 1.69)
5-63
(4) Release the inching pedal, and make sure that inching
valve plunger stroke C is 6 to 9.5 mm (0.24 to 0.37 in.)
at a pressure of 883 to 1079 kPa (9 to 11 kgf/cm2) [128 to
156 psi]. If the stroke is incorrect, readjust the brake and
brake pedal, and repeat the adjustment.
D
If the inching valve plunger stroke is more than 9.6 mm
(0.38 in.), the lining-to-drum clearance is too small. C
If the inching valve plunger stroke is less than 5.9 mm
(0.23 in.), the lining-to-drum clearance is too large.
Unit: mm (in.)
981
Inching pedal height (10)
A 220 (8.7) [142]
(from frame to top of pedal pad) Clutch oil pressure,
588 kPa (kgf/cm2) [psi]
(6.0)
Clearance between inching pedal 0.1 to 0.5 [85]
B
and brake pedal (0.004 to 0.020)
10 5 0
(0.39) (0.20)
6 to 9.5
C Inching valve plunger stroke Inching valve plunger stroke, mm (in.)
(0.24 to 0.37)
207686
Inching valve plunger stroke at
D 16 (0.63)
which brakes start applying
Rod and ball joint length

E 228 (8.98)
(standard value)
Travel Speed Select Switch Test

Move the select switch to each position, and make sure that
the transmission functions properly.
In the “1ST SPEED” position, the truck runs at a maximum
speed of 14 km/hr (8.7 mph) and a greater torque is available
at the drive axle.
In the “AUTO” position, the transmission automatically
shifts from 1st to 2nd range when the travel speed reaches 9
km/hr (5.6 mph) to allow the truck to run at a maximum
speed of 24.5 km/hr (15.2 mph).
208741
5-64

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POWERSHIFT TRANSMISSIONS

Structure and Function ........................................................................ 5 – 1

Structure and Function

Torque Converter (All Models)

1 Pilot boss 4 Control valve 7 Countershaft (3rd shaft)

Clutch Shaft Assembly

Control System (All Models)

1 Transmission direction lever 4 Operating plunger

Control Valve for Single-speed Transmission

1 Accumulator valve 3 Clutch valve

Single-speed Transmission Hydraulic Circuit

Oil pump (gear pump):

Suction strainer with magnets

• With the clutch engaged, the valve is held pressed against

Main regulator valve

• oil pressure from the oil pump is directed by the operating

Torque converter inlet relief valve

Automatic Two-Speed Transmission (GP50, DP50)

1 Pilot boss 7 Input shaft (1st shaft)

Control Valve for Automatic Two-speed Transmission (GP50, DP50)

1 Accumulator valve 4 Operating valve

The valves 1 to 4 have the same structures and

Control System for Automatic Two-speed Transmission (GP50, DP50)

Travel speed select switch

ECU 1st speed

Travel speed sensor

Locations of control devices

Hydraulic Circuit for Automatic Two-speed Transmission (GP50, DP50)

Oil pump (gear pump):

For the operation of the solenoid valve, refer to the next

Hydraulic Control (Forward 1st Speed)

When travel speed is up to 9 km/h (5.6 mph) or gear is fixed at 1st

Solenoid valve plunger

Hydraulic Control (Forward 2nd Speed)

When travel speed is 9 km/h (5.6 mph) or higher

Solenoid valve plunger

Main regulator valve

Removal and Installation

Torque Converter (All Models)

This drawing shows the torque converter for a gasoline-engine model.

Suggestion for Disassembly

Inspection and Repair

A: Standard value B: Repair or service limit

A: Standard value B: Repair or service limit

(3) Make sure the distance between the end face of

Suggestions for Reassembly

Part number Thickness of spacer

91823 - 01700 2.5 mm (0.098 in.)

91823 - 01600 2.7 mm (0.106 in.)

1-speed Transmission (GP/DP40 thru 45)

Control Valve and Strainer

Pump Body Assembly

Suggestion for Disassembly

Removing pump body assembly

Jack bolt MCF - 1046

Countershaft (2nd shaft)

Suggestion for Disassembly

Countershaft (3rd shaft)

Output Shaft (4th shaft)