Lull 944E-42 Service Manual - Manual (Page 186)

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4
6.10 Model 644E-42/944E-42 Rev. 6/04
6.7.2 Transmission Inspection and Internal
Repair
Refer to the ZF 4WG-92/98 TSC Transmission Repair
Manual, JLG P/N 8990495 (ZF P/N 5871.134.002) for
information on internal component repair or replacement.
Refer to the ZF 4WG-92/98 TSC Transmission Technical
Data Manual and Maintenance Manual, JLG P/N
8990494 (ZF P/N 5872 135 002) for information on
transmission diagnosis and internal schematics.
If replacing the entire transmission, transfer the
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a
new transmission.
6.7.3 Transmission Installation
1. Install the transmission temperature switch (1), inlet
(2) and outlet (3) cooler hose fittings.
2. Clean the transmission oil filter mounting surface.
3. Apply a thin film of clean Universal Tractor Fluid to
the new transmission filter gasket. Install the new
filter (4) and torque to 20-25 lb-ft (27-34 Nm).
4. Carefully position the transmission assembly under
the engine pod.
5. Connect a lifting strap or chain to the lifting ring (5) at
the top of transmission, and to a suitable hoist or
overhead crane. Operate the hoist or crane to
remove any slack prior to lifting, but DO NOT raise
the transmission at this time.
6. Clean all mating surfaces on both the engine and the
transmission prior to assembly.
7. Operate the hoist or crane to lift and position the
transmission against the flywheel housing. Raise or
lower the flywheel end of the engine as needed to
align the transmission with the engine. Be careful not
to lower the engine to the point where the fan will
contact the radiator fins.
8. Begin securing the transmission to the flywheel
housing with twelve M10 x 1.5 x 45 mm hex head
capscrews (6). Tighten the capscrews evenly, in
stages, to insure that the transmission converter
housing installs evenly against the engine
transmission housing. When all of the capscrews
have been installed, torque the capscrews to 39-45
lb-ft (54-61 Nm).
WARNING:
Risk of severe personal
injury. NEVER lift a transmission alone; enlist
the help of at least one assistant or use a
suitable hoist or overhead crane and sling.
WARNING:
The transmission must be
properly installed using fasteners of the correct
size and grade, and torqued to their specified
values.
MU1000
1
2
3
4
MU6500
5
6
7
8
9
8
8