07

3-SPEED POWERSHIFT TRANSMISSION
1. Specifications ............................................................................................................... 7-3
2. Description ................................................................................................................... 7-4

2.1 Torque Converter.................................................................................................................................. 7-4 1
2.2 Transmission......................................................................................................................................... 7-5
2.3 Power Flow ........................................................................................................................................... 7-6
2.4 Control Valve ........................................................................................................................................ 7-8 2
2.5 Main Regulator Valve............................................................................................................................ 7-8
2.6 Hydraulic Controls................................................................................................................................. 7-9
2.7 Speed Selector System ...................................................................................................................... 7-10
3
2.8 Control System ................................................................................................................................... 7-11
4
3. Suggestions for Removal and Installation.................................................................. 7-12
3.1 Removal.............................................................................................................................................. 7-12
3.1.1 Transmission removal ............................................................................................................................... 7-12
5
3.1.2 Torque converter removal ......................................................................................................................... 7-12
3.2 Torque converter installation............................................................................................................... 7-13 6
4. Disassembly and Reassembly ................................................................................... 7-14 7
4.1 Torque Converter................................................................................................................................ 7-14 7
4.1.1 Disassembly.............................................................................................................................................. 7-14
4.1.2 Inspection.................................................................................................................................................. 7-15
4.1.3 Reassembly .............................................................................................................................................. 7-18
8
4.2 Transmission....................................................................................................................................... 7-20
4.2.1 Disassembly.............................................................................................................................................. 7-20 9
4.2.2 Inspection.................................................................................................................................................. 7-30
4.2.3 Reassembly .............................................................................................................................................. 7-33
4.3 Control Valve ...................................................................................................................................... 7-41 10
4.3.1 Disassembly.............................................................................................................................................. 7-41
4.3.2 Inspection.................................................................................................................................................. 7-42
4.3.3 Reassembly .............................................................................................................................................. 7-43
11
4.4 Main Regulator Valve.......................................................................................................................... 7-44
4.4.1 Disassembly.............................................................................................................................................. 7-44 12
4.4.2 Inspection.................................................................................................................................................. 7-44
4.4.3 Reassembly .............................................................................................................................................. 7-44
13
5. Adjustment ................................................................................................................. 7-45
5.1 Brake pedal and inching pedal adjustment ......................................................................................... 7-45 14
5.2 Oil Pressure Measurement ................................................................................................................. 7-46
7-1
5.2.1 Main oil pressure measurement................................................................................................................ 7-46

5.2.2 Direction clutch oil pressure measurement ............................................................................................... 7-47
5.2.3 Torque converter inlet oil pressure measurement..................................................................................... 7-48
5.3 Stall Speed Measurement................................................................................................................... 7-48
5.4 10 m (33 ft) Start Acceleration Test .................................................................................................... 7-49
5.5 Travel Speed Select Switch ................................................................................................................ 7-50
6. Troubleshooting ......................................................................................................... 7-51
7. Service Data............................................................................................................... 7-56

7.1 Stall Speed, Hydraulic......................................................................................................................... 7-56
7.2 Pump Boss.......................................................................................................................................... 7-56
7.3 Pilot Boss ............................................................................................................................................ 7-57
7.4 Oil Pump ............................................................................................................................................. 7-57
7.5 Stator .................................................................................................................................................. 7-58
7.6 Flexible Plates..................................................................................................................................... 7-58
7.7 Clutches .............................................................................................................................................. 7-60
7.8 Forward Clutch Shaft, Reverse Clutch Shaft, 1st-Speed/3rd-Speed Clutch Shaft and Servo Case... 7-61
7.9 Backlash of Gears............................................................................................................................... 7-62
7.10 Control Valve ...................................................................................................................................... 7-63
7.11 Main Regulator Valve.......................................................................................................................... 7-64
7.12 Inching Pedal Control.......................................................................................................................... 7-65
7-2
1. Specifications
Truck Model P17500 P20000

Type 3-element, 1-stage, 2-phase
Torque converter Model MN 16
Stall torque ratio 2.51
Direction Electric, column shift
Control
Speed Automatic
1st: 2.402
Transmission Forward 2nd: 1.010
3rd: 0.558
Gear ratio
1st: 2.402
Reverse 2nd: 1.010
3rd: 0.558
7-3
2. Description
2.1 Torque Converter
7 5
2
From oil pump

4
1
8
To oil cooler
200550
1 Pilot boss 4 Turbine assembly 7 Pump (impeller)

2 Flexible plate 5 Stator 8 Stator shaft
3 Drive cover 6 Freewheel 9 Input shaft (transmission)
Oil pressurized in the torque converter flows from the outlet

passage in the stator shaft to the lubrication circuit of trans-
mission through the oil cooler.
The oil flow generated by rotation of the impeller rotates the
turbine and input shaft.
The freewheel is a kind of one-way clutch. When the rota-
tion speeds of the engine and input shaft are almost equal,
the freewheel allows the stator to turn freely and causes the
torque converter to act as a fluid coupling automatically.
The torque converter is operated efficiently even in high
speed rotation by the freewheel.
Type 3-element, 1-stage, 2-phase
Model MN 16
7-4
2.2 Transmission
11
10
2 F
R
5
3 1
6
212191
1 Flexible plate 5 Reverse clutch shaft 9 Pump idler gear

2 Torque converter assembly 6 1st-speed/3rd-speed clutch shaft 10 Pump drive gear
3 Input shaft 7 Output shaft 11 Pump case
4 Forward clutch shaft 8 PTO drive gear
The transmission is a 3-speed power shift transmission. The

speed is changed by the hydraulic multi-disc clutch auto-
matically at both forward and reverse operations.
7-5
2.3 Power Flow
Figures in ( ) indicate number of gear teeth.

Forward 1st (39)
(58)
(58)
(35)
(34) Forward 2nd

(58)
(46)
(24)
(58) (54) (35)
(56) (34)
Forward 3rd
(58)
(35)
(53)
(34)
(58)
(59)
(58)
(32)
212192
Speed Gears engaged Gear ratio

1st 35/34 58/58 58/58 56/24 2.402
2nd 35/34 53/54 1.010
3rd 35/34 58/58 58/58 32/59 0.558
PTO gear 58/46 39/58 0.848
7-6
Figures in ( ) indicate number of gear teeth.

Reverse 1st (39)
(58)
(34)
Reverse 2nd
(35) (46)
(58)
(24)
(58)
(58)
(54)
(56) (34)
(58)
Reverse 3rd (35)
(53)
(34)
(58)
(59)
(35)
(58)
(32)
212193
Speed Gears engaged Gear ratio

1st 35/34 58/58 56/24 2.402
2nd 35/34 58/58 53/54 1.010
3rd 35/34 58/58 32/59 0.558
PTO gear 58/46 39/58 0.848
7-7
2.4 Control Valve
Section A - A
A A
4
B
B 5
Section B - B
1
212194
1 Accumulator valve 3 1st-speed valve 5 2nd-speed/3rd-speed valve

2 Direction valve 4 Differential valve
2.5 Main Regulator Valve
10 9 8
7 6 5 4 3 2 1
212195
1 Bolts 5 Spool 9 Main pressure port

2 Cover 6 Body 10 Torque converter inlet pressure port
3 O-ring 7 Spring
4 Slug 8 Drain port
7-8
Transmission hydraulic circuit
2.6 Hydraulic Controls
Accumulator valve
Torque converter Pressure at start of
charging 0.3 MPa
Speed selector valve (3.1kgf/cm 2 )[43.5 psi]
Chassis area Last chance filter Pressure at end of
S2 (2nd /3rd speed)
charging 0.76 MPa
(7.8kgf/cm 2 )[110 psi]
Orifice: Diam. 0.8 mm
(0.031 in.) Main orifice: Diam. 2.2 mm(0.087 in.)
Torque converter Orifice: Diam. 0.8 mm(0.031 in.) Differential valve
Oil cooler bypass orifice: Setting: 0.2 MPa
Diam. 4.0mm (0.157 in.) (2.0kgf/cm 2 )
Speed selector valve [29 psi]
S1 (1st speed)
Last chance
filter 2 3
Torque converter
inlet relief valve Oil filter
Setting: 0.15 to 0.69 MPa
(1.53 to 7.0 kgf/cm 2 )
[21.8 to 100 psi] Tap (plug) for
torque converter
inlet pressure 1
Oil pump (marked "T")
Capacity: 70liters T/C in Oil filter for forward/ PS
(18.5 US gal.)/min reverse clutches
at 2300rpm (marked S)
PM (particle size )
Tap (plug) for
main pressure
Lubrication (marked "M") PD
line (marked D)
Main regulator valve
Suction strainer Setting: 0.88 to 1.08 MPa
C2 CF R C 3 C1 (9.0 to 11.0 kgf/cm )
with magnet 100mesh
[127.6 to 145 psi)
F R
Transmission oil reservoir
Solenoid valve Solenoid valve
(direction selection) (direction selection)
Last chance filter Last chance filter
Orifice: Diam. 0.8 mm(0.031 in.) Orifice: Diam. 0.8 mm(0.031 in.)
212196
7-9
2.7 Speed Selector System
Travel speed select switch
Travel speed 1st speed clutch

Output VCM (solenoid)
gear valve 2nd/3rd speed
clutch
Travel speed sensor Electric signal
Hydraulic pressure
0.5 mm Transmission case signal
(0.02 in.)
Control system
Power
source Transmission Travel speed select switch
shift lever
To meter panel VCM
Solenoid valve
Travel speed sensor
212197
Location of components
Automatic 3-speed transmission system consists of the
torque converter and 3-speed transmission. The speed con-
trol system consists of the travel speed sensor, VCM (Vehi-
cle Control Module) and solenoid valves.
The truck speed can be changed from automatic speed
mode to fixed 1st speed mode by the travel speed selector
switch to select the optimum truck speed according to the
working condition.
7-10
2.8 Control System
N 9
F To meter panel
5
1
4 7
3
8
4 2
212198
1 Transmission shift lever 6 VCM-3OP

2 Control valve 7 Inching pedal
3 Travel speed (solenoid) valve 8 Cutoff switch
4 Direction (solenoid) valve 9 Control relay
5 VCM-3
7-11
3. Suggestions for Removal and Installation

To remove the transmission assembly from the truck,
remove it together with the engine. Refer to GROUP 6
POWER TRAIN.
3.1 Removal
3.1.1 Transmission removal
(1) To separate the transmission from the engine, put the
engine on a stable stand, and support the transmission
with wood blocks.
(2) Remove the hydraulic pump from the transmission.
(3) The transmission has three lifting eyes, two eyes on the
differential side and one eye on the torque converter
side.
To lift the transmission, fasten two slings to the differ-
ential side eyes and one sling (chain with lever block) to
the torque converter side eye. Balance the transmission
with the lever block and lift it at three points just enough
to take the weight of the transmission.
(4) Remove the bolts that hold the flexible plates through
the access hole in the torque converter housing.
(5) Separate the transmission from the engine by lifting it
with a hoist.
212199
3.1.2 Torque converter removal

(1) To remove the torque converter assembly from the
transmission, slide the splines of the stator shaft, PTO
drive gear and input shaft away from the mating
splines.
NOTE
Remove the drain plug of the torque converter and drain the
oil.
7-12
3.2 Torque converter installation

(1) Install the torque converter to the transmission. Make
sure that the distance between the end face of the
14.5 mm (0.57 in.)
torque converter housing and the mating face of the
flexible plates is 14.5 mm (0.57 in.). If this distance is
more than 14.5 mm (0.57 in.), it is an indication that
spline engagement between the torque converter stator
shaft and transmission input shaft is improper; reinstall
the torque converter to the transmission.
(2) Lift the transmission, and bolt it to the engine.
(3) Make sure that the clearance between the flywheel and
flexible plates is 0 to 2 mm (0 to 0.08 in.) when the
transmission is bolted to the engine.
(4) Tighten the bolts that hold the flexible plates to the fly-
wheel through the access hole in the torque converter
housing. The bolts should be tightened evenly in a
crisscross pattern. When tightening those bolts, turn the
200557
torque converter with a heavy-duty screwdriver put to
the bolts.
(5) Mount the hydraulic gear pump to the transmission.
(6) Install the transmission harness.
Connect the travel speed sensor at the connector side,
and connect the torque converter thermo unit at the ter-
minal side.
Connect the following wire color harness to each sole-
noid.
Solenoid Valve Harness Wire Color
F solenoid
S1 RY
Travel speed
S2 LY
F GY
Transmission shift lever
R GL
(7) Pour in the torque converter oil.
R solenoid
S2 solenoid S1 solenoid
212200
7-13
4. Disassembly and Reassembly

4.1 Torque Converter
4.1.1 Disassembly
3 6
7
3
4
212201
(1) Sequence
1 Bolts, Spring washers, Plain washers 5 Thrust washers, Thrust bearing
2 Flexible plates, Pilot boss, O-ring, Bolts, 6 Stator, Rollers, Hub, Springs, Spring caps,
Spring washers Thrust washers
3 Bolts, Drive cover, Ball bearing, Drain plug, 7 Ball bearing, O-ring, Pump boss, Pump (impeller), Bolts,
Seal washers Toothed washers
4 Thrust washer, Turbine
7-14
(2) Suggestion for Disassembly

To remove the stator assembly, slightly force the stator
just like turning it counterclockwise to prevent the roll-
ers from falling and pull the stator together with the hub
by sliding the splines.
204530
4.1.2 Inspection
(1) Pump (impeller)
(a) Check for cracks.
(b) Check for oil leaks due to looseness of the bolts hold-
ing the boss to the pump, or defective O-ring.
(c) Check the face of the pump boss in contact with the oil
seal for wear.
(d) Check the face of the pump boss in contact with the
seal ring.
Oil seal O-ring

Seal ring
200561
7-15
(2) Stator
(a) Check the blades for cracks. Also check the fit of the
stator on the clutch cam.
(b) Check the clutch hub and cam for wear or flaws.
(c) Check the springs for damage. Also check the spring
caps for wear or distortion.
(d) Check the rollers for flaws, distortion or flat spots due
to wear.
(e) Check the clutch hub splines for defects.
(f) Check the thrust washers for wear or other defects.
Outside diameter of Standard value 67.951 to 67.97

clutch hub 1 (2.67523 to 2.6760)
mm (in.) Service limit 67.8 (2.669)
Diameter of clutch 10.185 to 10.2
Standard value
rollers 2 (0.40098 to 0.402)
3 4 1 2 5 6 7
Thickness of thrust 4.95 to 5
Standard value
washer 3 (0.1949 to 0.197)
Standard value
washer 4 (0.1555 to 0.157)
mm (in.) Service limit 3.8 (0.150) 200724
Standard value
washer 5 (0.114 to 0.118)
Standard value
washer 6 (0.193 to 0.197)
Standard value
washer 7 (0.1949 to 0.197)
7-16
(3) Turbine
(a) Check the vanes for cracks.
(b) Check the fit of the turbine boss in the turbine.
(c) Check the turbine boss splines for wear or other
defects.
(4) Pilot boss

Check the surface in contact with the pilot bearing for
wear or other defects.
Diameter of portion Standard -0.007 -0.00028

value 20 -0.020 (0.7874 -0.00079) 1
in contact with
engine flywheel 1 Service
mm (in.) 19.85 (0.7815)
limit
200411
7-17
4.1.3 Reassembly
10 1
13
11
4
2
9
3
12 7
13 5
212202
(1) Sequence
1 Pump (impeller) 8 Thrust washer
2 Pump boss, O-ring, Bolts, Toothed washers 9 Thrust bearing, Thrust washers
3 Ball bearing 10 Turbine
4 Stator assembly 11 Drive cover, O-ring, Bolts, Washers
5 Springs, Spring caps 12 Thrust washer, Ball bearing, Pilot boss, O-ring, Bolts,
Washers
6 Rollers 13 Flexible plates, Bolts, Plain washers,
Spring washers
7 Hub
7-18
(2) Suggestions for Assembly

(a) Stator assembly
Put hub 7 in the stator as shown. Put spring 5 and spring 5 5
cap 5 in each hole, and press in roller 6 while pushing the
spring cap.
Install a total of eight rollers, and restore the hub to its 6
original position.
After having assembled the stator, turn the hub by hand,
making sure that it rotates in only one direction.
7 202885A
(b) Selection of spacer

Measure the dimensions A, B and C. Select a spacer
equal to the clearance (dimension D) and put it in posi-
tion.
Part number Thickness of spacer
A
92322 - 14700 2.9 mm (0.114 in.)
92322 - 14800 3.0 mm (0.118 in.)
92322 - 14900 3.2 mm (0.126 in.)
92322 - 06600 3.4 mm (0.134 in.)
B
92322 - 06700 3.5 mm (0.138 in.) D C
A 26.4 (1.039) 212203

Standard dimensions B 19 (0.75)
mm (in.)
0 0
C 4 -0.1 (0.16 -0.004 )
(c) Flexible plate

After having installed the flexible plate, measure the
face runout of the plates with a dial indicator. Replace
the plates if the runout has exceeded the service limit.
Face runout of flexible Standard value 0.2 (0.008)

plate (in free state)
205922
7-19
4.2 Transmission
4.2.1 Disassembly
(1)Control valve and external parts
7
4 3
5
7
6 2
1
13
16
10
15
17
14
8 11
8
12
212204
(a) Sequence
1 Air breather 9 Oil filter
2 Oil level gauge, Oil filler, O-ring, Stay, Clamp, Bolts, 10 Travel speed sensor, O-ring
Spring washers, Plug, Gasket, Nuts 11 Thermo unit
3 Oil pipe, Eye bolt, Gaskets 12 Drain plug, Gasket
4 Main regulator valve, Gasket, Bolts, Washers 13 Suction pipe, O-rings, Bolts, Spring washers
5 Oil pipe, O-rings, Bolts, Spring washers 14 Cover, O-ring, Bolts, Spring washers
6 Control valve, Gasket, Bolts, Spring washers 15 Magnet strainer assembly
7 Oil pipes, Eye bolts, Gaskets 16 Bracket, Bolts, Spring washers
8 Oil pipes, Eye bolts, Gaskets 17 Bracket, Bolts, Spring washers
7-20
(2)Transmission cover and shafts
12
13
23
24
22
21
20
11
4
16 19
17 14
15
18 9
8
6
10
4
3
5
1, 2
212205
1 Servo case, O-ring, Bolts, 7 Output gear (2nd speed) 16 Travel speed sensor gear,
Washers 8 Output gear (3rd speed) Washers, Bolts
2 Servo case, O-ring, Bolts, 9 Snap ring 17 Ball bearing

Washers 10 Baffle plate, Bolts, Washers 18 Output gear (1st speed)
3 Servo case, O-ring, Bolts, 11 1st-speed/3rd-speed clutch 19 Snap ring
Washers shaft assembly 20 Lock nut
4 Transmission cover subassembly, 12 Forward clutch shaft assembly 21 Input gear
Gasket, O-rings, Bolts, Washers 13 Reverse clutch shaft assembly 22 Snap ring
5 Oil seals 14 Baffle plate, Bolts, Washers 23 Input shaft, Ring seal
6 Ball bearing 15 Output shaft 24 Ball bearing
7-21
(b) Suggestions for Disassembly

Transmission cover subassembly 4 removal
Turn two Bolts (jack bolts) (special tool) in the M10 Jack bolt
1.25 holes in the cover evenly until the cover is approxi-
mately 25 mm (1 in.) apart (the bearings get out of place).
Then remove the cover. Do not attempt to remove the
lubrication line plug from the cover.
Special tool needed
Bolt 67284 - 15400
Output gear (outside) 7 (2nd speed) removal
Remove the output gear together with ball bearing 6 with
a gear puller.
205629
Output shaft 15 removal
Turn a sliding hammer in the M8 1.25 hole in the end of
the output shaft, and remove the shaft together with out- Output gear (1st speed)
put gear 18, ball bearing 17 and travel speed sensor gear Sliding hammer
16.
CAUTION
Be careful not to strike the travel speed sensor Travel speed
sensor gear
gear against the transmission case when remov-
ing the output shaft.
205480
The travel speed sensor gear will be deformed.
Ball bearing 17 removal

Remove output shaft 15 with a press and a tooling as
shown, or remove the gear with a puller, to remove the
bearing.
Tooling
205630
Lock nut 20 removal

Straighten the locking tab of lock nut 20 away from flat of
the input shaft 23 and remove the nut with a socket
wrench and an impact wrench. When removing the nut,
hold the splined end of the input shaft with a pipe wrench,
or put a bar to input gear 21 in such a manner as to pre-
vent the shaft from turning counterclockwise.
7-22
(3)Stator shaft and oil pump
7
8
9 13
2 1 18
3 12
19
4
3
15
14
16
17
11
20
23
21
10
22
212206
(a) Sequence
1 PTO cover, O-ring, Bolts, 9 Ball bearing 17 Stator shaft, Seal ring, Bolts,
Spring washers Spring washers
2 Snap ring 10 Torque converter housing, 18 Pump idler gear
Gasket, Flanged bolts
3 Pump drive gear, Seal rings 11 Oil seal 19 Roller bearing
4 Ball bearing 12 Idler gear shaft 20 Roller bearing (outer race)
5 Pump case, O-ring, Bolts, 13 Roller bearing 21 Roller bearing (outer race)
Spring washers
6 Pump plate, O-ring, Gasket 14 PTO drive gear 22 Roller bearing (outer race)
7 Internal gear 15 Ball bearing 23 Transmission case, Dowels
8 Pump drive gear 16 Ball bearing
7-23

Torque converter housing 10 removal
Turn two Bolts (jack bolts) (special tool) in the M10
1.25 holes in the housing evenly until the housing is
approximately 18 mm (0.7 in.) apart (the PTO drive gear
ball bearing gets out of place). Fasten a hoist to the hous-
ing and remove the housing.
Special tool needed
Bolt 67284 - 15400
Oil pump removal

Remove the oil pump as a subassembly including pump
case 5, pump plate 6, internal gear 7, pump gear 8 and ball
bearing 9.
Idler gear shaft 12 removal

Turn the Shaft puller (special tool) in the shaft hole.
M20 X 1.5
Install the sliding hammer (used in removing the output
shaft) to this puller and remove the shaft. M8 X 1.25
Special tool needed
12
Shaft puller (to be made by dealer)
210188
PTO drive gear 14 removal

Grip ball bearing 15 with a gear puller. Put a protective
plate on the end of the stator shaft and remove the gear
together with two ball bearings.
14
210193
7-24
Stator shaft 17 removal

Turn two Bolts (jack bolts) (special tool) in the M10
1.25 holes in one end of the shaft evenly, or hit the other
end by using a protective plate.
Special tool needed
Bolt 67284 - 15400
Roller bearing outer race removal

Do not remove outer races 20, 21 and 22 of the roller
bearings installed in the transmission case and the outer
race of roller bearing 19 installed on idler gear shaft 18
unless they are defective.
7-25
(4)Forward clutch shaft subassembly
5 12
13
15
4
14
3
2 16
1
14
15
13
12
11
10
6
7
11
11 8
9
10
11
212207
(a) Sequence
1 Seal rings 9 Thrust washer, Snap ring
2 Ball bearing 10 Snap rings, Pressure plates
3 Thrust washer 11 Friction plates, Mating plates
4 Gear (2nd-speed drive), Needle roller bearings 12 Snap rings, Retainers
5 Thrust washer 13 Clutch springs
6 Roller bearing 14 Clutch pistons, Piston seals
7 Thrust washer 15 Seal rings
8 Gear (forward drive), Needle roller bearings 16 Forward clutch shaft
NOTE
Do not attempt to remove the screws from the forward
clutch shaft
7-26

Ball bearing 2 removal
Grip 2nd-speed drive gear 4 with a gear puller and
remove the bearing together with the gear and thrust
washer 3.
Roller bearing 6 removal

Grip forward drive gear 8 with a gear puller and remove
the bearing together with the gear and thrust washer 7.
Forward clutch shaft disassembling

Using the Piston tool A (special tool) or an arbor press,
compress clutch spring 13 and retainer 12, and remove
snap ring 12.
Special tool needed A
Piston tool 92267 - 00300
207504
7-27
(5)1st-speed/3rd-speed clutch shaft subassembly
5 12
13
4 15
14
3
2 16
1
14
15
13
12
11
10
6
11 11 7
8
9
10
11
212208
(a) Sequence
1 Seal rings 9 Thrust washer
2 Ball bearing 10 Snap rings, Pressure plates
3 Thrust washer 11 Friction plates, Mating plates
4 Gear (3rd-speed drive), Needle roller bearings 12 Snap rings, Retainers
5 Thrust washer 13 Clutch springs
6 Roller bearing 14 Clutch pistons, Piston seals
7 Thrust washer 15 Seal rings
8 Gear (1st-speed drive), Needle roller bearings 16 1st-speed/3rd-speed clutch shaft
(b) Suggestion for Disassembly

NOTE For disassembly, make reference to the disassembly of
Do not attempt to remove the screws from the 1st-speed/ the forward clutch shaft.
3rd-speed clutch shaft.
7-28
(6)Reverse clutch shaft subassembly
9
10
12
11
13
2
1
3
4
8 5
6
7
212209
(a) Sequence
1 Seal rings 8 Friction plates, Mating plates
2 Ball bearing 9 Snap ring, Retainer
3 Roller bearing 10 Clutch spring
4 Thrust washer 11 Clutch piston, Piston seal
5 Gear (reverse drive), Needle roller bearings 12 Seal ring
6 Thrust washer, Snap ring 13 Reverse clutch shaft
7 Snap ring, Pressure plate
(b) Suggestion for Disassembly

NOTE For disassembly, make reference to the disassembly of
Do not attempt to remove the screws from the reverse clutch the forward clutch shaft.
shaft.
7-29
4.2.2 Inspection
(1) Oil pump
(a) Put the internal gear and pump gear in the pump case,
and measure top clearance 2.
(b) Using a dial indicator, measure side clearance 1
between the gears and pump case.
0.040 to 0.078
Side clearance 1 Standard value
(0.00157 to 0.00307)
mm (in.)
Service limit 0.09 (0.0035) 2
0.3 to 0.345
Top clearance 2 Standard value
(0.0118 to 0.0136)
mm (in.) 1
Service limit 0.35 (0.0138) 205486
(2) Stator shaft

(a) Check the splines for wear or damage.
(b) Check the oil passages for clogging.
(3) Friction plates and mating plates
(a) Check for sign of seizure, uneven contact, warpage or
excessive wear.
(b) Check the splines for wear or damage.
(4) Clutch drums
(a) Check the mating plate sliding surfaces for wear or
damage.
(b) Check the clutch piston sliding surfaces for wear or
damage.
7-30
Thickness of mating Standard 2.30.07

plate 1 value (0.0910.0028) 7, 8
Thickness of friction Standard 2.60.1
plate 2 value (0.1020.004)
Free movement of
Standard 0.10 to 0.30
friction plate on gear 3
value (0.0039 to 0.0118)
mm (in.)
Width of piston seal Standard 40.05 6 2 1 3
ring 4 value (0.160.002)
mm (in.) Service limit 3.5 (0.138) 4
Width of piston seal Standard +0.2 +0.008
value 4 +0.1 (0.16 +0.004 )
ring groove in piston 5
Free length of clutch 68 2 (2.68 0.08)
Standard
spring 6 k = 39.1(3.992) 5
value
mm (in.) [223.5] 212210
k: Spring constant
N/mm (kgf/mm) Service limit 65 (2.56)
[lbf/in.]
Width of clutch piston Standard 2.50.05
seal ring 7 value (0.0980.0020)
Width of clutch piston Standard +0.2 +0.008
value 2.5 +0.1 (0.098 +0.004 )
seal ring groove 8
7-31
(5) Forward clutch shaft, reverse clutch shaft and 1st-

speed/3rd-speed clutch shaft
(a) Check the seal rings and seal ring contact surfaces of
the shaft and servo case for wear or damage.
Width of piston seal Standard 2.50.05
ring for each clutch value (0.0980.0020)
shaft 1 1, 2
Width of piston seal Standard +0.2 +0.008

ring groove in each value 2.5 +0.1 (0.098 +0.004)
3
clutch shaft 2
Inside diameter of Standard +0.025 +0.00098

each servo case in value 35 0 (1.38 0 )
contact with seal
ring 3 Service limit 35.2 (1.386)
mm (in.)
205635
(b) Check the splines for wear or damage.

(c) Check the oil passages for clogging.
(6) Gears
(a) Check each gear for worn teeth or splines.
(b) Check the needle bearing sliding surfaces of the gear
for wear or damage.
(7) Magnet strainer assembly
Disassemble and clean the strainer. Replace the strainer
if defective.
(8) Transmission cover and torque converter housing oil
seals
Replace the oil seals with new ones.
7-32
4.2.3 Reassembly
(1) Forward clutch shaft subassembly
(1st-speed/3rd-speed clutch shaft subassembly/reverse clutch shaft subassembly)
5 10 9 7 8 4 7 8 4 9 10 5 11
16 6
14 15
6
21
20 19 17
12 13
18 2 3 2
212211
(a) Sequence
1 Forward clutch shaft, 1st-speed/3rd-speed clutch shaft, 11 Thrust washer
or reverse clutch shaft 12 Needle roller bearings
2 Sealing rings, Piston seals 13 Gear (forward drive)
3 Clutch pistons 14 Thrust washer
4 Clutch springs 15 Roller bearing
5 Retainers 16 Thrust washer
6 Snap rings 17 Needle roller bearings
7 Mating plates 18 Gear (2nd-speed drive)
8 Friction plates 19 Thrust washer
9 Pressure plates 20 Ball bearing
10 Snap rings 21 Seal rings
NOTE
The reassembly sequence and suggestions for the reverse
clutch shaft subassembly are similar to the forward clutch
shaft subassembly as far as the clutch is concerned.
7-33
(b) Suggestions for Reassembly
Piston installation
When putting pistons 3 in the clutch drum, apply ATF
(automatic transmission fluid) to their seal ring contact
surfaces.
Return spring installation

Using the Piston tool A (special tool) or an arbor press, A
compress springs 4 and retainers 5, and install snap rings

6.
Special tool needed
Piston tool 92267 - 00300
207504
Friction and mating plate installation
Make sure that the position and number of the plates are Mating plate
correct. Install the plates while applying ATF to them.
Friction plate
When replacing the friction plates, replace the mating
plates, too.
207516
Thrust washer installation
Install thrust washers 11, 14, 16 and 19 with the side that
has oil grooves toward the gear.
203800
Piston testing
After reassembling the clutch, apply pressure air of
approximately 690 kPa (7 kgf/cm2) [100 psi] to the oil
hole to make sure that the piston move freely without any
sign of air leaks.
7-34
(2)Stator shaft and oil pump
15 16
12
18
17
19
14 20
1 13
3
9
10
4
6
5 11
205638
(a) Sequence
1 Transmission case, Dowels 8 Idler gear shaft 15 Pump plate, O-ring, Gasket,
Bolts, Spring washers
2 Roller bearing 9 Roller bearing 16 Ball bearing
3 Idler gear 10 Oil seal 17 Pump drive gear, Seal rings
4 Stator shaft, Seal ring, Bolts, 11 Torque converter housing, 18 Ball bearing
Spring washers Gasket, Flanged bolts
5 Ball bearing 12 Pump case, O-ring, Bolts, Spring 19 Snap ring
washers
6 PTO drive gear 13 Internal gear 20 PTO cover, O-ring, Bolts,
7 Ball bearing 14 Pump gear Spring washers
NOTE
The dowels fitted into the transmission case should not been
removed. These dowels are for locating the pump case,
torque converter housing and transmission cover subassem-
bly for installation.
7-35
PTO drive gear 6 installation

Install ball bearings 5 and 7 to PTO drive gear 6. Install
the gear to stator shaft 4.
Oil seal 10 installation

Replace the oil seal with a new one. Install the oil seal to Unit: mm (in.)
the torque converter housing by using the oil seal installer

(special tool).
Special tool needed
Oil seal installer (to be made by dealer)
Oil pump reassembling

Put internal gear 13, pump gear 14 and pump plate 15 in 13 (0.51) 8 (0.31)
150 (5.91)
pump case 12. Apply oil to the internal gear and pump
gear. Do not forget to install the O-ring. 205491
Oil pump subassembly installation

Do not forget to put the gasket and the O-ring for the oil
hole when installing the oil pump subassembly.
Pump drive gear 17 installation

Install ball bearing 16 on pump drive gear 17. Install two
seal rings in position and apply oil to these seal rings.
Then drive the gear assembly into the transmission case
with the splines in alignment with those of pump gear 14.
Ball bearing 18 installation

When installing ball bearing 18 in pump case 12, hold the Unit: mm (in.)
pump drive gear with the Pump drive gear holder (special
tool), or have someone press the gear with a copper bar or
the like, in order to prevent the gear from coming off.
Special tool needed
Pump drive gear holder (to be made by dealer)
)
39
(0. 1)
10 (0.
3
8
)
39 10
)
(0. (1.
10 28
205492
7-36
(3)Shafts and transmission cover
25 1
17
19 4
26
7
27
2
18
24
23 22 21 20 14 16 9 15 10 11 12 13
212212
7-37
(a) Sequence
1 Roller bearing (outer race) 15 Baffle plate, Bolts, Spring washers
2 Roller bearing (outer race) 16 Baffle plate, Bolts, Spring washers
3 Roller bearing (outer race) 17 Forward clutch shaft subassembly
4 Ball bearing 18 1st-speed/3rd-speed clutch shaft subassembly
5 Input shaft 19 Reverse clutch shaft subassembly
6 Snap ring 20 Output gear (3rd speed)
7 Input gear 21 Output gear (2nd speed)
8 Lock nut 22 Ball bearing
9 Output shaft 23 Oil seals
10 Snap ring 24 Transmission cover subassembly, Gasket, Bolts,
11 Output gear (1st speed) Spring washers, O-rings
12 Ball bearing 25 Servo case, O-ring, Bolts, Spring washers

13 Travel speed sensor gear, Spring washers, Bolts 26 Servo case, O-ring, Bolts, Spring washers
14 Snap ring 27 Servo case, O-ring, Bolts, Spring washers
Input shaft 5 reassembling and installation

Install ball bearing 4 on input shaft 5, then install the shaft
in the transmission case.
Tighten nut 8 to the specified torque and bend it against
the flat of the input shaft for locking.
Tightening torque for nut:

294 to 392 Nm (30 to 40 kgfm) [217 to 289 lbfft]
When tightening the nut, hold the torque converter side of

the shaft with a pipe wrench, or put a bar to input gear 7 in
such a manner as to prevent the shaft from turning clock-
wise.
Output shaft 9 reassembling and installation

Reassemble output shaft 9, snap rings 10 and 14, output
gear 11, ball bearing 12 and travel speed sensor gear 13 in
a subassembly. Install the subassembly in the transmis-
sion case.
7-38
Oil seal 23 installation

Replace two oil seals with new ones. Apply grease to the
lips of the oil seals and, using the Oil seal installer (spe-
Transmission cover
cial tool), install the seals in position with the lips toward
inside.
205494
Special tool needed

Oil seal installer (to be made by dealer) Unit: mm (in.) 1 (0.04)chamfer
10 (0.39) 28 (1.10)
170 (6.69) 1.5 (0.06)
205495
Transmission cover installation

Install hooks in the jack bolt holes in the transmission
cover and hitch slings to these hooks. Put the gasket on
the transmission case. Hoist the cover and install it in
position. Do not forget to put the O-rings in the oil holes.
205640
Servo cases 25, 26 and 27 installation

When installing the servo cases, apply oil to the inside
surfaces of the cases and the seal rings of the shafts. Do
not forget to install the O-rings to the cases.
7-39
(4)Control valve and external parts
8
12 13
11
8
10 14
15
6
17
1
16
2
7 4
7
3
212213
(a) Sequence
1 Magnet strainer assembly 10 Control valve, Gasket, Bolts, Spring washers
2 Cover, O-ring, Bolts, Spring washers 11 Oil pipe, O-rings, Bolts, Spring washers
3 Plug, Gasket 12 Main regulator valve, Gasket, Bolts, Spring washers
4 Thermo unit 13 Oil pipe, Eye bolt, Gaskets
5 Travel speed sensor, O-ring 14 Oil level gauge, Oil filler, O-ring, Stay, Clump, Bolts,
Spring washers, Plug, Nut
6 Suction pipe, O-rings, Bolts, Spring washers 15 Air breather
7 Oil pipe, Eye bolt, Gaskets 16 Bracket, Bolts, Spring washers
8 Oil pipe, Eye bolt, Gaskets 17 Bracket, Bolts, Spring washers
9 Oil filter
7-40
4.3 Control Valve

4.3.1 Disassembly
1
2
3
4
5
18 17
19 4
A
17 6
2 A
1
15
13
14
7
16 13
10
9
12
11
212214
(1) Sequence
1 Solenoid valves, O-rings 7 Snap ring, Plug, O-ring 13 Pin, Seat, O-ring
2 Springs, Spring seats 8 Inching dummy spool 14 Oil filter, O-rings
3 Direction valve 9 Snap ring, Plug, O-ring 15 Last chance filters (four)
4 Solenoid valves, O-rings 10 Spring, Differential valve 16 Roller bearing, Plug
5 1st-speed valve, Spring 11 Plate, O-ring, Bolts, Washers 17 Roller bearing, Plug
6 2nd-speed/3rd-speed valve, 12 Accumulator valve piston, 18 Plug, O-ring
Spring Springs (inner and outer) 19 Valve body, Gasket
CAUTION
Slowly loosen each bolt and solenoid valve so that
the spring and plunger do not suddenly jump out.
7-41
4.3.2 Inspection
(1) Check the oil holes in the valve body for restriction.
(2) Check the valves for wear or damage. Make sure the
valve moves freely.
(3) Replace all oil seals with new ones.
(4) Replace oil filter 16 with a new one.
(5) Wash oil filter 15, or replace it with a new one.
Free length of selector 36.5 (1.44)

Standard
valve springs 1 k = 5.658 (0.577)
value 5 5
mm (in.) [32.3]
k: Spring constant Service
N/mm (kgf/mm) [lbf/in.] 35.5 (1.40)
limit
Free length of differential 60 (2.36) 1
Standard
valve spring 2 k = 1.677 (0.171)
value
mm (in.) [9.58]
N/mm (kgf/mm) [lbf/in.] 58 (2.28)
limit
Free length of accumulator 142.5 (5.61)
Standard
valve outer spring 3 k = 3.747 (0.3821)
value
mm (in.) [21.3] 2 1
N/mm (kgf/mm) [lbf/in.] 140 (5.51)
limit 4
3
Free length of accumulator 184.5 (7.26)
Standard
valve inner spring 4 k = 3.941 (0.4019) 212215
value
mm (in.) [22.50]
N/mm (kgf/mm) [lbf/in.] 182 (7.17)
limit
Free length of direction 32.5 (1.28)
Standard
valve springs 5 k = 4.23 (0.4313)
value
mm (in.) [24.15]
N/mm (kgf/mm) [lbf/in.] 31.5 (1.24)
limit
7-42
4.3.3 Reassembly
(1) Preparation
Wash the oil passages in the control valve thoroughly
and make sure they are not restricted.
17 3 16 17
18
18
4 5 13
Section A - A
12
A A
19
11
15
10
9 B 15
B
8
14
Section B - B
6
7
2 1
212216
(2) Sequence
1 Valve body 11 Inching dummy spool
2 Plug, Roller bearing 12 Plug, O-ring, Snap ring
3 Plug, Roller bearing 13 1st-speed valve, Spring
4 Last chance filters (four) 14 2nd-speed/3rd-speed valve, Spring
5 Oil filter, O-ring 15 Solenoid valves, O-rings (two)
6 Seat, O-ring, Pin 16 Direction valve
7 Springs (inner and outer), Accumulator piston 17 Spring seats, Springs
8 Plate, O-ring, Bolts, Spring washers 18 Solenoid valves, O-rings (two)
9 Differential valve, Spring 19 Plug, O-ring
10 Plug, O-ring, Snap ring
(3) Suggestions for Reassembly

(a) Replace oil seal 2 with a new one.
(b) Apply ATF (automatic transmission fluid) to the valves
and plungers when installing them in the valve body.
7-43

4.4.1 Disassembly
2
5
6 4 3
212217
(1) Sequence
1 Cover, O-ring, Bolts, Sprig washers 4 Spring
2 Slug 5 Cover, O-ring, Bolts, Sprig washers
3 Spool 6 Body
CAUTION
Slowly loosen bolts 1 so that the spring, spool and
slug do not suddenly jump out.
4.4.2 Inspection 4.4.3 Reassembly

(1) Check the oil holes in the valve body for restriction. (1) Sequence
(2) Check the valve spool for wear or damage. Make sure To reassemble, follow the reverse of disassembly se-
the spool moves freely. quence.
(3) Check the spring for damage or fatigue. (2) Suggestion for Reassembly
Apply oil to the spool and slug when putting them in the
body.
Free length of main 107 (4.21)
Standard
regulator valve spring k = 4.99 (0.5087)
value
mm (in.) [28.5]
N/mm (kgf/mm) [lbf/in.] 104 (4.09)
limit
7-44
5. Adjustment
5.1 Brake pedal and inching pedal adjustment
(1) Set inching pedal 1 at 45 by using bolt 2 and nut 3.
le)
e)
(2) Place brake pedal 4 at the same height as inching pedal
ang
k
tro
1 by using bolt 5 and nut 6.
(S
ting
(3) Eliminate the clearance between inching pedal 1 and
22
set
brake pedal 4 by using bolt 7 and nut 8.
dal
8 1
(Pe
45
7
2 3
212218
4 1
5, 6 2, 3
212219
(4) Adjust the switch position by using nut 9 so that the

switch protrudes 1 mm (0.04 in.) from the end of the Clearance
1 mm (0.04 in.)
switch body.
Cutoff point
4 mm (0.16 in.) 2 mm (0.08 in.)

(OFF) (ON)
Stroke
6 mm (0.24 in.)
212220
7-45
5.2 Oil Pressure Measurement
CAUTION
Front tires rotate during the measurement. Build a
fence around the truck to prevent access to it.
NOTE
Always perform pedal adjustments before oil pressure mea-
surement.
5.2.1 Main oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure
gauge to the main oil pressure outlet of the regulator Main pressure tap (M)
valve.
Special tools needed
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17713
NOTE
Parts marked with an asterisk (*) are included in the gauge
kit 64309 - 17701. 212221
(2) Idle the engine and check that the transmission oil is up
to the specified level.
(3) Warm up the engine to raise the transmission oil tem-
perature.
(4) Keep the engine idling (at between 1000 and 1500
rpm).
(5) Under the above condition, perform the oil pressure
measurement.
Main oil pressure 0.88 to 1.08 MPa
Standard
(with engine idling at (9.0 to 11.0 kgf/cm2)
value
1500100 rpm) [128 to 157 psi]
NOTE
Monitor the idling speed through engine tachometer during
measurement.
7-46
5.2.2 Direction clutch oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure
gauge to the direction clutch oil pressure outlet port of
the selector valve. Direction clutch pressure tap (PD)
NOTE
Use the same special tools as used for main oil pressure
measurement.
(2) Lift the front tires off the floor by either of the follow-
ing methods.
(a) The front axle housing is jacked up.
(b) The mast is tilted all the way backward first. With a 212222
wooden block applied under the outer mast, the mast is

tilted forward to lift the front tires. Then, an appropriate
stand is placed under the frame to keep the front tires
lifted.
(3) Put scotch blocks under the rear tires.
(4) Implement the steps (2) through (4) of main oil pres-
sure measurement.
(5) Place the direction lever into the forward position, then
release the parking brake.
(6) Release the inching pedal after fully depressing it, then
measure the direction clutch oil pressure.
Direction clutch oil
0.73 to 0.93 MPa
pressure Standard
(7.44 to 9.48 kgf/cm2)
(with engine idling at value
[105.9 to 134.9 psi]
1500 100 rpm)
7-47
5.2.3 Torque converter inlet oil pressure measure-

NOTE
ment
The parts marked with an asterisk (*) are included in the
(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure
gauge kit 64309 - 17701.
gauge to the torque converter inlet oil pressure inlet
port of the regulator valve.
Special tools needed
*Connector 64309 - 17733 Torque converter
inlet pressure tap (T)
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17714
perature.
(4) Keep the engine idling (at between 1000 and 1500
212223
rpm), measure the torque converter inlet oil pressure.
Torque converter inlet
0.15 to 0.69 MPa
oil pressure Standard
(1.5 to 7.0 kgf/cm2)
(with engine idling at value
[22 to 100 psi]
1500100 rpm)
NOTE
Monitor the idling speed through engine tachometer during
measurement.
5.3 Stall Speed Measurement

perature.
(3) Block the front and rear wheels, and apply the parking
brake.
(4) Run the engine at low idle.
7-48
(5) Move the direction lever to the forward position, and

gradually depress the accelerator pedal fully. Under
this condition, measure the stall speed with an engine
tachometer.
Stall speed
1950 rpm
(tolerance: 100 rpm)
CAUTION
Do not attempt to depress the inching pedal. Do
not continue operation in stall condition for more
than 30 seconds. Failure to follow this precaution
would result in destruction of the torque con-
verter.
(6) Similarly measure the stall speed for reverse drive.
NOTE
(a) Any stall speed within 10 rpm tolerance of the speci-
fication 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.
5.4 10 m (33 ft) Start Acceleration Test

(1) Stand ready to start with the engine running at low idle,
the direction lever in the neutral position and the travel
speed select switch in D (automatic 3-speed) position.
(2) At the signal, move the direction lever to the forward
position and, at the same time, depress the accelerator
pedal all the way.
(3) Measure the time required for the truck to travel 10 m
(33 ft) with a stopwatch.
(4) Conduct the same test for reverse travel, too.
Travel time (no load) 5 seconds, maximum
7-49
5.5 Travel Speed Select Switch

Move the travel speed select switch mounted on the console
box to each position, and make sure that the speed selector D
system functions properly. Move the switch when the truck
is at standstill.
Travel speed select switch
212224
7-50
6. Troubleshooting
Engine Poor performance Tune up engine.

Oil level too low Refill.
Air being sucked in on suction side Retighten or replace gasket.
Main regulator valve not operating properly Repair or replace.
Main regulator valve spring fatigued Replace.
Oil pump gears worn, resulting in reduced capacity Overhaul and check or replace defec-
Torque con- tive parts.
verter Magnet strainer clogged Replace.
Seal rings or O-rings worn Replace after measuring oil pressure.
Stator freewheel seized Replace stator assembly, hub and
Not
enough roller.
output Blades of running members damaged or rubbing Repair or replace.
power Replace bearing.
Air being sucked in on suction side Retighten or replace.
Outlet pressure too low to suppress internal foaming Readjust.
Water in oil Replace oil.
Transmission
Main pressure too low, resulting in slipping clutches Readjust after measuring oil pressure.
Seal rings or O-rings worn Replace after measuring oil pressure.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.
Wheels High mechanical resistance Check and adjust brake system.
7-51
Flexible plates broken Replace.

Torque con- Oil pump drive defective Replace.
verter Turbine shaft broken Replace.
Main pressure too low Check pump gears for wear or
replace.
Seal rings worn in servo case Replace.
No power O-rings on input shaft worn Replace.
flow Plug on input shaft loose or slipped off, resulting in oil Repair.
leaks
Transmission Clutch seized Replace.
Shafts broken Replace.
Clutch drum, particularly snap ring groove, defective Replace.
Snap ring fitted to clutch drum broken Replace.
Oil line to clutch piston clogged Clean or replace.
Shaft splines worn Replace shaft.
Power train Broken parts in reduction and differential or front axle Refer to each section.
7-52
Flexible plate broken Replace.

Bearings damaged Replace.
Torque con- Rubbing vanes of running members Replace.
verter Bolts loose Retighten or replace.
Splines worn Replace.
Oil pump worn Inspection or replace.
Clutch seized and dragging Replace clutch plate.
Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
Splines worn Replace.
Abnormal Oil strainer clogged Clean or replace.
noise Main regulator valve spool defective Wash or replace.
Restriction in oil pipe Replace.
Loud noise
Oil too viscous in cold weather Replace oil.
Instruments out of order Replace.
Improper oil used Replace oil.
Oil strainer clogged Clean or replace.
Oil pump defective Replace.
Excessive oil leaks
Low noise Main regulator valve spring defective Replace.
Main regulator valve spool defective Repair or replace.
Air being sucked in Retighten or replace packing.
Leaking oil seals Check lips and sliding surfaces for

wear.
Replace seals.
Leaking joint of case Retighten or replace packing.
Leaking pipe connection or joint Repair or replace pipe, gasket and O-
rings.
Oil leaks Leaking drain plug Retighten or replace gasket.

Cracks or blowholes in case Replace.
Oil blowing out of transmission case
Water in oil Replace oil.
Air being sucked in on suction side Replace packing and retighten.
Oil leaks from air breather Repair.
Oil level too high Lower oil level.
7-53
Oil level too high or too low Keep correct oil level.
Oil strainer clogged Clean or replace.
Rubbing vanes of running members Repair or replace.
Stator freewheel defective Replace stator assembly.
Torque con- Air being sucked in Retighten or replace O-ring.
verter Water in oil Replace oil.
Restriction in oil pipe (resulting in reduced circulation Repair or replace.
flow)
Oil tem-
perature is Bearings worn or seized Repair or replace.
too high Instruments out of order Replace.
Clutches dragging Replace clutch plates.
Transmission
Bearings worn or seized Repair or replace.
Truck not operated properly Advice user to drive truck properly.
Others
Others Cooling fan belt damaged Replace.
Oil cooler clogged Clean or replace.
Brakes grabbing Check and readjust.
Main regulator valve defective Repair or replace valve assembly.

Main pressure is too high Oil viscosity too high in cold weather Replace oil.
Improper oil used Replace oil.
Magnet strainer clogged Clean or replace.

Oil pump defective Replace.
Spring defective in main regulator valve. Replace.
Main pressure is too low Main regulator valve spool defective Repair or replace.
Air being sucked in Retighten or replace packing.
Inching valve out of order Repair or replace.
7-54
Magnet strainer clogged Clean or replace.

Oil pump worn or defective Replace.
Spring defective in main regulator valve. Replace.
Main regulator valve spool defective Repair or replace.
Clutch pressure is too low Air being sucked in Retighten or replace packing.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch seal rings broken Replace.
Lack of engine power if the speed is slightly low in both Tune up engine.
forward and reverse drive
Stall speed out of specifi-
Stator and freewheel defective if the speed is excessively Replace stator assembly.
cation
low in both forward and reverse drive
Clutch slipping if the speed is too high Repair or replace.
Travel speed select switch in Fixed 1st speed position Move switch to 2 or D position.
Solenoid valve defective Replace.
No automatic shifting Solenoid valve inlet orifice clogged Clean or replace.
Solenoid valve spool or spring defective Repair or replace.
ECU control box internally defective Check or replace.
Transmission shifts up Harness open Repair.

when travel speed select
Travel speed select switch defective Replace.
switch is in Fixed 1st
speed position
7-55
7. Service Data
7.1 Stall Speed, Hydraulic

Stall speed (tolerance: 100 rpm) rpm Standard value 1950
Main pressure, Speed clutch pressure (engine at 1500100
rpm) Standard value 0.88 to 1.08 (9.0 to 11.0) [128 to 156]
MPa (kgf/cm2) [psi]
Direction clutch pressure (engine at 1500100 rpm)
Standard value 0.73 to 0.93 (7.44 to 9.48) [105.9 to 134.9]
MPa (kgf/cm2) [psi]
Torque converter inlet pressure (engine at 1500100 rpm)
Standard value 0.15 to 0.69 (1.5 to 7.0) [21 to 100]
MPa (kgf/cm2) [psi]
Lubrication line pressure (engine at 1500100 rpm)
Standard value 0.02 to 0.13 (0.2 to 1.3) [3 to 19]
MPa (kgf/cm2) [psi]
10 m (33 ft) start acceleration (no load) Standard value 5 seconds, maximum
7.2 Pump Boss

0 0
Diameter of portion in contact with oil seal 1 Standard value 100 -0.035 (3.94 -0.00138)
200721
7-56
7.3 Pilot Boss

-0.007 -0.00028
Diameter of portion in contact with engine flywheel 1 Standard value 20 -0.020 (0.79 -0.00079)
212225
7.4 Oil Pump

Side clearance 1 Standard value 0.040 to 0.078 (0.00157 to 0.00307)
Top clearance 2 Standard value 0.3 to 0.345 (0.0118 to 0.0136)
1
212226
7-57
7.5 Stator

Outside diameter of clutch hub 1 Standard value 67.951 to 67.97 (2.67523 to 2.6760)
Diameter of clutch rollers 2 Standard value 10.185 to 10.2 (0.40098 to 0.402)
Thickness of thrust washer 3 Standard value 4.95 to 5 (0.1949 to 0.197)
3 4 1 2 5 6 7
212227
7-58
7.6 Flexible Plates

Face runout of flexible plates 1 Standard value 0.2 (0.008)
(in free state) mm (in.) Service limit 0.5 (0.020)
Distance between end face of torque converter housing and
Standard value 14.5 (0.57)
mating face of flexible plates 2 mm (in.)
200725
7-59
7.7 Clutches

Thickness of mating plate 1 Standard value 2.30.07 (0.0910.0028)
Thickness of friction plate 2 Standard value 2.60.1 (0.1020.004)
Free movement of friction plate on gear 3
Standard value 0.10 to 0.30 (0.0039 to 0.0118)
(looseness of mating splines) mm (in.)
Width of piston seal ring 4 Standard value 40.05 (0.160.002)
+0.2 +0.008
Width of seal ring groove in piston 5 Standard value 4 +0.1 (0.16 +0.004 )
682 (2.680.08)
Free length of clutch spring 6 mm (in.) Standard value
k = 39.1 (3.992) [223.5]
k: Spring constant N/mm (kgf/mm) [lbf/in.]
Service limit 65 (2.56)
6 2 1 3
212228
7-60
7.8 Forward Clutch Shaft, Reverse Clutch Shaft, 1st-Speed/3rd-Speed Clutch Shaft and Servo Case

Width of seal ring for each shaft 1 Standard value 2.50.05 (0.0980.0020)
+0.2 +0.008
Width of seal ring groove in each shaft 2 Standard value 2.5 +0.1 (0.098 +0.004)
Inside diameter of servo case and clutch shaft in contact with Standard value 35
+0.025
0 (1.38
+0.00098
0 )
seal ring 3 mm
(in.) Service limit 35.2 (1.386)
+0.025 +0.00098
Inside diameter of stator shaft in contact with seal ring 4 Standard value 35 0 (1.38 0 )
Width of clutch piston seal ring for each shaft 5 Standard value 2.50.05 (0.0980.0020)
+0.2 +0.008
Width of clutch piston seal ring groove in each shaft 6 Standard value 2.5 +0.1 (0.098 +0.004)
0 0
Width of seal ring 7 mm (in.) Standard value 2.4 -0.1 (0.094 -0.0039)
+0.1 +0.0039
Width of seal ring groove 8 mm (in.) Standard value 2.5 0 (0.098 0 )
Tightening torque for lock nut 9
Standard value 294 to 392 (30 to 40) [217 to 289]
Nm (kgfm) [lbfft]
1, 2 3 5, 6
7, 8
9 4
212230
7-61
7.9 Backlash of Gears

Input gear and forward and reverse gears 1 mm (in.) Standard value 0.12 to 0.28 (0.0047 to 0.0110)
Forward gear and reverse and 1st-speed/3rd-speed gears 2
mm (in.)
2nd-speed gear and output gear 3 mm (in.) Standard value 0.12 to 0.28 (0.0047 to 0.0110)
1st-speed gear and output gear 4 mm (in.) Standard value 0.13 to 0.30 (0.0051 to 0.0118)
3rd-speed gear and output gear 5 mm (in.) Standard value 0.13 to 0.30 (0.0051 to 0.0118)
Pump drive gear and idler gear 6 mm (in.) Standard value 0.12 to 0.26 (0.0047 to 0.0102)
PTO drive gear and idler gear 7 mm
(in.)
1 6
2 7
3
2
2
1
3
5
4
3 1
212229
7-62
7.10 Control Valve

36.5 (1.44)
Free length of selector valve spring 1 mm (in.) Standard value
k = 5.658 (0.577) [32.3]
Service limit 35.5 (1.40)
59.5 (2.34)
Free length of differential valve spring 2 mm (in.) Standard value
k = 2.311 (0.2357) [13.2]
125.5 (4.94)
Free length of accumulator valve outer spring 3 mm (in.) Standard value
k = 5.363 (0.5469) [30.6]
170.5 (6.71)
Free length of accumulator valve inner spring 4 mm (in.) Standard value
k = 4.128 (0.4210) [23.5]
32.5 (1.28)
Free length of direction valve springs 5 mm (in.) Standard value
k = 8.616 (0.8786) [49.2]
5 5
2 1
4
3
212231
7-63

107 (4.21)
Free length of main regulator valve spring 1 mm (in.) Standard value
k = 4.99 (0.5087) [28.5]
212232
7-64
7.12 Inching Pedal Control

Inching pedal height (from frame to top end of pedal) 1
Standard value 178 (7.01)
mm (in.)
212233
7-65

07

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3-SPEED POWERSHIFT TRANSMISSION

1. Specifications ............................................................................................................... 7-3

2. Description ................................................................................................................... 7-4

5.2.1 Main oil pressure measurement................................................................................................................ 7-46

6. Troubleshooting ......................................................................................................... 7-51

7. Service Data............................................................................................................... 7-56

Truck Model P17500 P20000

From oil pump

1 Pilot boss 4 Turbine assembly 7 Pump (impeller)

Oil pressurized in the torque converter flows from the outlet

1 Flexible plate 5 Reverse clutch shaft 9 Pump idler gear

The transmission is a 3-speed power shift transmission. The

2.3 Power Flow

Figures in ( ) indicate number of gear teeth.

(34) Forward 2nd

(58) (54) (35)

Speed Gears engaged Gear ratio

Figures in ( ) indicate number of gear teeth.

Speed Gears engaged Gear ratio

2.4 Control Valve

1 Accumulator valve 3 1st-speed valve 5 2nd-speed/3rd-speed valve

2.5 Main Regulator Valve

1 Bolts 5 Spool 9 Main pressure port

2.7 Speed Selector System

Travel speed select switch

Travel speed 1st speed clutch

Travel speed sensor

2.8 Control System

1 Transmission shift lever 6 VCM-3OP

3. Suggestions for Removal and Installation

3.1.2 Torque converter removal

3.2 Torque converter installation

(7) Pour in the torque converter oil.

4. Disassembly and Reassembly

(2) Suggestion for Disassembly

Oil seal O-ring

Outside diameter of Standard value 67.951 to 67.97

(4) Pilot boss

Diameter of portion Standard -0.007 -0.00028

(2) Suggestions for Assembly

(b) Selection of spacer

A 26.4 (1.039) 212203

(c) Flexible plate

Face runout of flexible Standard value 0.2 (0.008)

(2)Transmission cover and shafts

2 Servo case, O-ring, Bolts, 9 Snap ring 17 Ball bearing

(b) Suggestions for Disassembly

Ball bearing 17 removal

Lock nut 20 removal

(3)Stator shaft and oil pump

(b) Suggestions for Disassembly

Oil pump removal

Idler gear shaft 12 removal

PTO drive gear 14 removal

Stator shaft 17 removal

Roller bearing outer race removal

(4)Forward clutch shaft subassembly

(b) Suggestions for Disassembly

Roller bearing 6 removal

Forward clutch shaft disassembling

Piston tool 92267 - 00300

(5)1st-speed/3rd-speed clutch shaft subassembly

(b) Suggestion for Disassembly