Lull 944E-42 Service Manual User Manual download pdf (Page 186)

100

101

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

MU6500

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Lull 944E-42 Service Manual User Manual Page 186

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