JLG G12-55A AccuPlace Service Manual - Manual (Page 71)

6.5 G10-55A & G12-55A AccuPlace
Transmission
26. Remove any external transmission components as
required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings.
27. Remove the transmission oil filter (3) and dispose of
properly. Clean the filter mounting surface. Cover or
cap the oil filter mount.
28. If transmission oil is suspect to contamination or
torque converter is damaged, remove the converter
and flex plate from the transmission.
29. Remove the bolt and washers holding the converter
to the flex plate.
6.5.2 Transmission Inspection and Internal
Repair
Refer to the ZF Transmission Repair Manual
PN- 5872 135 002 (JLG P/N 31200241) which can be
obtained by calling your local JLG distributor.
If replacing the entire transmission, transfer the
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a
new transmission.
6.5.3 Transmission Installation
1. Install both rear transmission mounts on the
transmission. Torque capscrews to 125-140 lb-ft
(170-190 Nm).
2. Install two guide studs near the top of the bell
housing holes.
3. Ensure there are no burrs on the flywheel mounting
face and nose pilot bore. Clean the drive plate
surface with solvent.
4. Ensure the bolts securing the flex plate to the torque
converter are torqued to 26-29 lb-ft (35-39 Nm).
5. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
Make sure the engine flywheel and transmission flex
plate hole patterns are aligned and in the same
orientation with one hole at 6 o’clock on the engine
and the transmission.
6. Install the twelve bolts and washers and torque to
53 lb-ft (72 Nm). Remove the two alignment studs
and install and torque the last two transmission
mounting bolts.
7. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite
® 242 threadlock to the transmission mount
bolts and torque to 125-140 lb-ft (169-190 Nm).
8. Turn the engine over slowly by hand and align each
of the four torque convertor diaphragm bolts through
the access plug in the bell housing. Install them one
at a time. DO NOT fully tighten until all of the
capscrews and locknuts are in place. Torque to
26-29 lb-ft (35-39 Nm). Replace access plug.
9. Remove the hoist or overhead crane and sling.
10. Connect the transmission temperature switch
connector and shift solenoid wiring harness
connectors.
11. Secure the wiring harness to the transmission
housing.
12. Connect the transmission oil cooler inlet and outlet
hoses at the transmission.
13. Install the hydraulic pump. Refer to Section 8.7.3,
“Pump Replacement.”
14. Install the transmission-to-axle drive shafts. Refer to
Section 5.4.5, “Drive Shaft Installation.”
15. Install the air cleaner and tubing.
16. Clean the transmission oil filter mounting surface.
17. Apply a thin film of clean Mobilfluid 424 ®
(ISO Grade 46) to the new transmission filter gasket.
Install the new filter and torque to 20-25 lb-ft
(27-34 Nm).
18. Transmission oil may be added through the oil fill
tube. Remove the plug and add Mobilfluid 424 ®
(ISO Grade 46). Check the oil level by taking
intermittent dipstick readings as outlined in the
appropriate Operation & Safety Manual. DO NOT
overfill. Reinstall the oil fill tube plug and dipstick
when finished.
19. Install the engine cover.
20. Connect the battery negative (-) cable at the battery.
21. Close and secure the engine cover.
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