JLG 4013PS Service Manual - Manual (Page 91)

6-5 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
27. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
28. Remove any external transmission components as
required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings.
29. Remove the transmission oil filter (3) and dispose of
properly. Clean the filter mounting surface. Cover or
cap the oil filter mount.
30. If transmission oil is suspected of contamination or
torque convertor is damaged, remove the convertor
and flex plate from the transmission.
31. Remove the six bolts and washers holding the
convertor to the flex plate.
6.5.2 Transmission Inspection and Internal
Repair
If replacing the entire transmission, transfer the
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a
new transmission.
Detailed internal service instructions are provided in the
Dana Spicer Repair Manual, which can be obtained by
contacting your local JLG Distributor.
6.5.3 Transmission Installation
1. Install both the rear transmission mounts on the
transmission. Torque capscrews to 120 Nm
(88 lb-ft).
2. Install guide studs near the top of the bell housing
holes and in the flex plate.
3. 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.
4. Align the torque convertor, align the transmission
bolt holes with the guide studs in the bell housing
and flex plate. Install the eight bolts and washers
and torque to 63 Nm (46 lb-ft). Remove the
alignment studs and install and torque the last two
transmission mount bolts and torque to 63 Nm
(46 lb-ft).
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite
® 243 TM to the transmission mount bolts
and torque to 210 Nm (155 lb-ft).
6. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Install
them one at a time. Torque to 35-39 Nm (26-29 lb-ft).
Replace access plug.
7. Remove the hoist or overhead crane and sling.
8. Connect the transmission temperature switch
connector and shift solenoid wiring harness
connectors.
9. Secure the wiring harness to the transmission
housing.
10. Uncap and connect the transmission oil cooler inlet
and outlet hoses at the transmission.
11. Install the hydraulic pump. Refer to Section 8.7.3,
“Pump Replacement.”
12. Install the transmission-to-axle drive shafts. Refer to
Section 5.4.5, “Drive Shaft Installation.”
13. Install air cleaner and tubing.
14. Clean the transmission oil filter mounting surface.
15. Apply a thin film of clean hydraulic oil to the new
transmission filter gasket. Install the new filter and
torque to 27-34 Nm
(20-25 lb-ft).
MZ0680
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