TRANSMISSION AND TORQUE CONVERTER 5540F/YB5515 SERVICE MANUAL
7-38 Published 10-21-2010, Control# 198-04
Casings
If the gearbox casings are to be renewed, be sure to fit
blanking plugs and adaptors as required. Inspect the original
casings and identify the blanking plug and adaptor positions.
Transfer the plugs and adaptors to the new casings. Apply
Loctite 242 to the threads.
Note that new plugs may be supplied with a sealant 'patch',
in which case sealant need not be applied. Torque plugs to
18.4 - 20 Ib ft (25 - 28 Nm).
Before fitting adapter C (Figure 7-43), be sure to fit the orifice
restrictor inside the port.
If the torque converter housing has been removed,
temporarily replace it. The gearbox can again be positioned
standing on the face of the housing ready for assembly.
Layshaft
1. Smear bearing surface of shaft with Mobil HP222
Grease and fit needle roller bearings 1a (wider bearing
first), followed by 2nd gear 1b.
2. Fit the synchro assembly 2, then press fit the bearing
track 3a.
3. Slide 1st gear needle roller bearings 3b over the track.
Smear bearings with oil. Fit 1st gear 3c over needle
roller bearings.
4. Assemble 4WD transfer gear 4 over splines. On 2WD
machines slide spacer over splines.
5. Press bearing 5a and 5b onto the assembled layshaft.
Smear the bearings with Mobil HP222 Grease.
Mainshaft
6. Coat bearing surface of mainshaft with Mobil HP222
Grease. Install the needle roller bearings 6a and 6b
Reference Only
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