This document provides instructions for disassembling the transmission of a 120K motor grader. It lists the required tools and describes the step-by-step process to remove components like the transmission case assembly, shaft assemblies, gears, seals and pistons.
This document provides instructions for disassembling the transmission of a 120K motor grader. It lists the required tools and describes the step-by-step process to remove components like the transmission case assembly, shaft assemblies, gears, seals and pistons.
This document provides instructions for disassembling the transmission of a 120K motor grader. It lists the required tools and describes the step-by-step process to remove components like the transmission case assembly, shaft assemblies, gears, seals and pistons.
This document provides instructions for disassembling the transmission of a 120K motor grader. It lists the required tools and describes the step-by-step process to remove components like the transmission case assembly, shaft assemblies, gears, seals and pistons.
Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7575 Link Bracket 1 B 154-6181 Forcing Screw 2 C 6V-5221 Bolt 1 D 4C-8156 Fixture 1 E 6V-3918 Bolt 1 F 4C-8157 Fixture 2 G 1U-6405 Three Jaw Puller 1 H 1U-6341 Threaded Rod 1 J 5P-7970 Nut 1 K 9U-7479 Compressing Tube 1 L 5B-0637 High Idle Nut 1 5F-7353 Washer 1 1B-4207 Full Nut 2
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5F-7369 Puller Leg 2
3H-0465 Push-Puller Plate 2 5F-7366 Screw 1 5P-4808 Cap 2 1U-9895 Crossblock 1 9S-9151 Block 2 M 1B-4206 Nut 4 8B-7552 Bolt 2 N 1U-6343 Threaded Rod 1 P 6V-8149 Nut 1 Q 2P-8312 Pliers 1 1P-2326 Screw 1 1P-2325 Head 1 R 3H-0462 Bolt and Nut 4 8H-0709 Strap 4 5F-7373 Jaw 3 S 3E-3882 Eyebolt 1
Start By:
a. Remove the transmission control valve. Refer to Disassembly and Assembly, "Transmission Control Valve - Remove".
b. Remove the parking brake. Refer to Disassembly and Assembly, "Parking Brake - Remove".
c. Remove the transmission speed sensor.
d. Remove the transmission oil pump. Refer to Disassembly and Assembly, "Gear Pump (Transmission Charging and Scavenge) - Remove".
e. Remove the transmission magnetic screen base. Refer to Disassembly and Assembly, "Magnetic Screen - Remove and Install".
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Illustration 1 g00623100
1. Place transmission (1) level on the floor.
2. Remove 12 bolts (2), four covers, and the O-ring seals from transmission case assembly (3).
3. Remove 41 bolts (4) from the transmission case assembly (3).
Illustration 2 g00623105
Note: Identify the location of seal carrier (5) in the transmission case assembly (3) for assembly purposes.
4. Remove two bolts (6) from seal carrier (5).
5. Install Tooling (A) (not shown) in seal carrier (5). Remove seal carrier (5) and the three ring seals from the transmission case assembly bore (7).
6. Repeat Step 4 through Step 5 on the three remaining seal carriers (5).
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Illustration 3 g00623108
7. Remove seal rings (9) from seal carrier (5).
8. Remove three or four seals (8) from seal carrier (5).
9. Remove spring pin (10) from seal carrier (5).
10. Repeat Step 7 and Step 9 for the remaining three seal carriers (5).
Illustration 4 g00623110
11. Install Tooling (B) in the transmission case assembly (3). Tighten Tooling (B) evenly to separate transmission case assembly (3) from transmission cover assembly (11).
12. Attach Tooling (A) to transmission case assembly (3). Position a lifting device to Tooling (A). Secure the lifting device to a hoist. Slowly raise the transmission case assembly (3) from the transmission cover assembly (11). Be careful not to bind the transmission case assembly (3) during separation.
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Illustration 5 g00623113
13. Remove three bolts (12) from tube assembly (13). Remove tube assembly (13) from the transmission cover assembly (11).
14. Remove the O-ring seal from tube assembly (13).
Illustration 6 g00849491
Note: First/Third shaft assembly (14) and High/Low shaft assembly (15) must be removed together.
15. Install Tooling (D) on First/Third shaft assembly (14) and High/Low shaft assembly (15). Use Tooling (C) and Tooling (E) in order to hold Tooling (D) on First/Third shaft assembly (14) and High/Low shaft assembly (15), as shown. First/Third shaft assembly (14) and High/Low shaft assembly (15) must be removed together.
16. Attach a suitable lifting device to Tooling (D). Carefully remove First/Third shaft assembly (14) and High/Low shaft assembly (15) from the transmission cover assembly (11). The weight of the two shaft assemblies is 177 kg (390 lb).
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Illustration 7 g00623117
17. Place First/Third shaft assembly (14) and High/Low shaft assembly (15) on Tooling (F) or on blocks and remove Tooling (D). Carefully separate First/Third shaft assembly (14) and High/Low shaft assembly (15). The weight of each shaft assembly is 89 kg (195 lb).
Illustration 8 g00623120
Illustration 9 g00849492
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Note: Place High/Low shaft (15) in a modified work bench or on blocks. Modify a substantial workbench by cutting a 116.0 ± 2.0 mm (4.60 ± 0.08 inch) clearance hole in the top of the bench.
Illustration 10 g00623124
Illustration 11 g00623126
Note: Do not attach Tooling (G) to rotor (17). If pressure is applied to rotor (17) with Tooling (G), rotor (17) will brake. Attach the Tooling (G) to gear assembly (18).
18. With High/Low shaft assembly (15) on the modified work bench or on blocks, use Tooling (G) in order to remove race and bearing (16), rotor (17), gear assembly (18), and two sleeve bearings (not shown) from High/Low shaft assembly (15). Press fit Bearing (16) and rotor (17) on High/Low shaft assembly (15).
19. Remove bearing (16), rotor (17), thrust disc (19), and gear assembly (18) from High/Low shaft assembly (15). Attach Tooling (G) to gear assembly (18). Do not attach Tooling (G) to rotor (17).
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Illustration 12 g00623129
20. Remove thrust disc (20) and the washer from High/Low shaft assembly (15).
Illustration 13 g00623131
21. Install Tooling (H) and Tooling (K) on High/Low shaft assembly (15) and clutch assembly (21). Tighten Tool (J) on Tooling (H) (not shown) in order to compress clutch assembly (21). Remove two half rings (22) and two lock rings (23) from the High/Low shaft assembly (15).
22. Carefully loosen Tool (J) on Tooling (H) in order to relieve pressure from clutch assembly (21). Remove Tooling (K) and Tooling (H) from High/Low shaft assembly (15) and clutch assembly (21). The clutch assembly (21) is made up of five clutch plates, six friction discs, and the hub assembly. Identify the position of the clutch assembly (21) for assembly purposes.
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Illustration 14 g00623132
23. Remove wave spring (25) from High/Low shaft assembly (15).
24. Remove piston (24) from High/Low shaft assembly (15).
Illustration 15 g00623134
25. Remove seal extension ring (27) and seal ring (26) from piston (22).
Illustration 16 g00623138
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26. Position High/Low shaft assembly (15), as shown. Place High/Low shaft (15) in the modified work bench, or on blocks. The weight of High/Low shaft assembly (15) is 50 kg (110 lb).
27. Install Tooling (L) and Tooling (M) on High/Low shaft assembly (15) and inner bearing (28). Remove inner bearing (28) from High/Low shaft assembly (15). Remove two thrust discs (29), two bearing sleeves, and gear assembly (30) from High/Low shaft assembly (15).
Illustration 17 g00623141
28. Remove thrust disc (31) and the washer from High/Low shaft assembly (15).
Illustration 18 g00623145
Note: Tooling (K) is the old style tool that is now modified. Tooling (K) (new style tool) works without being modified. Tooling (K) may need to be modified so the hole in the top of the tube will have clearance for Tooling (N).
29. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (15) and clutch assembly (32). Tighten Tooling (P) on Tooling (N) in order to compress clutch assembly (32). Remove two half rings (33) and two lock rings (34) from the High/Low shaft assembly (15).
30. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch assembly (32). Remove Tooling (K) and Tooling (N) from High/Low shaft assembly (15) and clutch
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assembly (32). The clutch assembly (32) is made up of eight clutch plates, seven friction discs, and the hub assembly. Identify the position of the clutch assembly (32) for assembly purposes.
Illustration 19 g00623148
Note: Tooling (K) is the old style tool that must be modified. Tooling (K) (new style tool) works without being modified. Tooling (K) may need to be modified so the hole in the top of the tube will have clearance for Tooling (N).
31. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (15) and balance piston (35). Tighten Tooling (P) on Tooling (N) in order to compress balance piston (35).
32. Use Tooling (Q) in order to remove retaining ring (36) from High/Low shaft assembly (15).
33. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston (35). Remove Tooling (K) and Tooling (N) in order to relieve pressure from High/Low shaft assembly (15) and balance piston (35).
Illustration 20 g00623149
34. Remove balance piston (35) and seal extension ring (37) from High/Low shaft assembly (15).
35. Remove 15 springs (38) from piston (39).
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36. Remove piston (39), the seal extension ring (not shown), and a ring seal (not shown) from High/Low shaft assembly (15).
Illustration 21 g00623150
37. Remove seal ring (40) and seal extension ring (41) from piston (39).
Illustration 22 g00623152
38. Place First/Third shaft assembly (14) on the modified work bench or on blocks. Use Tooling (F) in order to remove race and bearing (42), thrust disc (not shown), and gear assembly (43) from First/Third shaft assembly (14).
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Illustration 23 g00623154
39. Remove thrust disc (44) and gear assembly (45) from First/Third shaft assembly (14).
Illustration 24 g00623240
40. Remove sleeve bearing (not shown), thrust disc (46) and washer (47) from First/Third shaft assembly (14).
Illustration 25 g00623241
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41. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (14) and clutch assembly (48). Tighten Tooling (K) on Tooling (H) in order to compress clutch assembly (48). Remove two half rings (49) and two lock rings (50) from First/Third shaft assembly (14).
42. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (48). Remove Tooling (K) and Tooling (H) from First/Third shaft assembly (14) and clutch assembly (48). As you remove clutch assembly (48) from First/Third shaft assembly (14), identify the positions of the five clutch plates, the six friction disc, and the hub assembly for assembly purposes.
Illustration 26 g00623242
43. Remove wave spring (51) from First/Third shaft assembly (14).
44. Remove piston (52) from First/Third shaft assembly (14).
Illustration 27 g00623245
45. Remove seal extension ring (53) and seal ring (54) from piston (52).
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Illustration 28 g00623247
46. Position First/Third shaft assembly (14), as shown. Place First/Third shaft assembly (14) in the modified work bench, or on blocks. The weight of First/Third shaft assembly (14) is 55 kg (120 lb).
47. Remove the seal ring (not shown) from First/Third shaft assembly (14).
48. Use Tooling (R) in order to remove inner bearing (55), thrust disc (not shown), gear (56), and thrust disc (not shown).
49. Remove gear assembly (57), the bearing sleeve (not shown), the thrust disc, and the washer (not shown) from First/Third shaft assembly (14).
Illustration 29 g00623248
50. Install Tooling (K) and Tooling (H) on First/Third shaft assembly (14) and clutch assembly (58). Tighten Tooling (J) on Tooling (H) in order to compress clutch assembly (58). Remove two half rings (59) and two lock rings (60) from the First/Third shaft assembly (14).
51. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (58). Remove Tooling (H) and Tooling (K) from First/Third shaft assembly (14) and clutch assembly (58). As you remove clutch assembly (58) from First/Third shaft assembly (14),
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identify the position of the three clutch plates, four friction disc, and the hub assembly for assembly purposes.
Illustration 30 g00623249
52. Remove wave spring (61) from First/Third shaft assembly (14).
53. Remove piston (62) from First/Third shaft assembly (14).
Illustration 31 g00623250
54. Remove seal extension ring (63) and seal ring (64) from piston (62).
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Illustration 32 g00623252
Illustration 33 g00623253
55. Use Tooling (R) in order to remove inner bearing (66) and gear (67) from input shaft assembly (65). This is necessary at this time in order to remove the remaining two shaft assemblies.
Illustration 34 g01024451
56. Install Tooling (S) and remove Reverse/Second shaft assembly (68) from the transmission cover assembly (11). The weight of Reverse/Second shaft assembly (68) is 64 kg (140 lb).
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Illustration 35 g00623257
57. Place Reverse/Second shaft assembly (68) on the modified work bench, or on blocks.
58. Use Tooling (R) in order to remove race and bearing (69), spacer (70), and gear (71) from Reverse/Second shaft assembly (68).
Illustration 36 g00623258
59. Remove spacer (72) and thrust disc (not shown) from Reverse/Second shaft assembly (68).
60. Remove gear assembly (73), the sleeve bearing (not shown), the thrust disc (not shown), and the washer (not shown) from Reverse/Second shaft assembly (68).
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Illustration 37 g00623259
61. Install Tooling (K) and Tooling (H) on Reverse/Second shaft assembly (68) and clutch assembly (74). Tighten Tooling (J) on Tooling (H) in order to compress clutch assembly (74). Remove two half rings (75) and two lock rings (76) from Reverse/Second shaft assembly (68).
62. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch assembly (74). Remove Tooling (H) and Tooling (K) from Reverse/Second shaft assembly (68) and clutch assembly (74). As you remove clutch assembly (74) from Reverse/Second shaft assembly (68), identify the positions of the three clutch plates, four friction disc and the hub assembly for assembly purposes.
Illustration 38 g00623260
63. Remove wave spring (77) from Reverse/Second shaft assembly (68).
64. Remove piston (78) from Reverse/Second shaft assembly (68).
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Illustration 39 g00623261
65. Remove seal ring (80) and seal extension ring (79) from piston (78).
Illustration 40 g00623263
66. Position Reverse/Second shaft assembly (68), as shown. The weight of Reverse/Second shaft assembly (68) is 41 kg (90 lb).
67. Place Reverse/Second shaft assembly (68) on the modified work bench, or on blocks.
68. Install Tooling (L) and Tooling (M) on gear assembly (82) and Reverse/Second shaft assembly (68).
69. Remove inner bearing (81), the thrust race (not shown), the two thrust discs (not shown), and gear assembly (82) from Reverse/Second shaft assembly (68).
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Illustration 41 g00623264
70. Remove roller bearing (83) from Reverse/Second shaft assembly (68).
71. Remove thrust disc and washer (84) from Reverse/Second shaft assembly (68).
Illustration 42 g00623265
72. Use a second person in order to compress clutch assembly (85).
73. Remove two half rings (86) from Reverse/Second shaft assembly (68). Release the pressure from clutch assembly (85) slowly, until the spring (89) underneath clutch assembly (85) is extended and relaxed.
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Illustration 43 g00623269
74. Remove hub assembly (87) from Reverse/Second shaft assembly (68).
75. Remove spring (89) from Reverse/Second shaft assembly (68).
76. As you remove clutch plates (88) and friction discs (90), identify the locations of clutch plates (88) and friction discs (90) for installation purposes. Remove six clutch plates (88) and seven friction disc (90) from Reverse/Second shaft assembly (68).
Illustration 44 g00623270
77. Remove valve assembly (91) from Reverse/Second shaft assembly (68).
78. Remove piston (92) from Reverse/Second shaft assembly (68).
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Illustration 45 g00623276
79. Remove seal ring (93) and (94) from piston (92).
80. Remove the cup plug (not shown) from Reverse/Second shaft assembly (68).
Illustration 46 g01024454
81. Install Tooling (S) in Forward shaft assembly (95). Remove Forward shaft assembly (95) from the transmission cover assembly (11). The weight of Forward shaft assembly (95) is 64 kg (140 lb).
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Illustration 47 g00623279
82. Place Forward shaft assembly (95) on the modified work bench, or on blocks. Install Tooling (L) and Tooling (M) to Forward shaft assembly (95) and gear assembly (97).
83. Remove race and bearing (96), two thrust disc (not shown), and gear assembly (97) from Forward shaft assembly (95).
Illustration 48 g00623280
84. Remove roller bearing (98) from Forward shaft assembly (95).
85. Remove the thrust disc and washer (99) from Forward shaft assembly (95).
Illustration 49 g00623281
86. Use a second person in order to compress clutch assembly (100).
87. Remove two half rings (101) from Forward shaft assembly (95). Release the pressure from clutch assembly (100) slowly, until the spring (104) underneath clutch assembly (100) is extended and relaxed.
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Illustration 50 g00623284
88. Remove hub assembly (102) from Forward shaft assembly (95).
89. Remove spring (104) from Forward shaft assembly (95).
90. Remove six clutch plates (105) and seven friction disc (103) from Forward shaft assembly (95). Identify the positions of the clutch plates (105) and friction discs (103) for assembly purposes.
Illustration 51 g00623285
91. Remove valve assembly (106) from Forward shaft assembly (55).
92. Remove piston (107) from Forward shaft assembly (95).
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Illustration 52 g00623287
93. Remove two seal rings (108) from piston (107).
Illustration 53 g00623288
94. Position Forward shaft assembly (95), as shown. The weight of Forward shaft assembly (95) is 43 kg (95 lb). Place Forward shaft assembly (95) in the modified work bench or on blocks.
95. Install Tooling (L) and Tooling (M) to Forward shaft assembly (95) and gear assembly (110).
96. Remove inner bearing (109), the thrust race (not shown), the two thrust disc (not shown), and gear assembly (110) from Forward shaft assembly (95).
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Illustration 54 g00623289
97. Remove roller bearing (111) from Forward shaft assembly (95).
98. Remove the thrust disc and washer (112) from Forward shaft assembly (95).
Illustration 55 g00623291
99. Use a second person in order to compress clutch assembly (113).
100. Remove two half rings (114) from Forward shaft assembly (95).
101. Release the pressure from clutch assembly (113) slowly, until the spring (116) underneath clutch assembly (113) is extended and relaxed.
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Illustration 56 g00623292
102. Remove hub assembly (115) from Forward shaft assembly (95).
103. Remove spring (116) from Forward shaft assembly (95).
104. Remove six clutch plates (117) and seven friction discs (118) from Forward shaft assembly (95). Identify the positions of the clutch plates (117) and friction disc (118) for assembly purposes.
Illustration 57 g00623294
105. Remove valve assembly (119) from Forward shaft assembly (95).
106. Remove piston (120) from Forward shaft assembly (95).
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Illustration 58 g00623297
107. Remove two seal rings (121) from piston (120).
108. Remove the cup plug (not shown) from Forward shaft assembly (95).
Illustration 59 g01024466
109. Install Tooling (S) in Input shaft assembly (65). Remove Input shaft assembly (65) from the transmission cover assembly (11). The weight of Input shaft assembly (65) is 23 kg (50 lb).
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Illustration 60 g00623299
110. Remove two seal rings (122) from Input shaft assembly (65).
111. Remove inner bearing (123) and gear (124) from Input shaft assembly (65).
112. Remove the cup plug (not shown) from input shaft assembly (65).
Illustration 61 g00623300
113. Remove four bolts (125) from gear assembly (126). Rotate gear assembly (126) in order to locate the two bolts (not shown).
114. Remove gear assembly (126) from the transmission cover assembly (11).
Illustration 62 g00623301
115. Position gear assembly (126), as shown. Use Tooling (Q) to remove snap ring (129) from gear assembly (126).
116. Position gear assembly (126) to the opposite side. In order to drive ball bearing (127) off gear assembly (126), push a small driver through three small holes (not shown).
117. Remove ball bearing (127) from bearing retainer (128).
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Note: This is a slip fit.
Illustration 63 g00623302
118. Remove five bearing outer races (130) from the transmission cover assembly (11).
119. Repeat Step 118 for transmission case assembly (3).
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