wsm M7040 - Servicing

CONTENTS
1. TROUBLESHOOTING.................................................................................................................3-S1
2. SERVICING SPECIFICATIONS ..................................................................................................3-S3
3. TIGHTENING TORQUES............................................................................................................3-S5
4. CHECKING AND ADJUSTING....................................................................................................3-S6
[1] SHUTTLE LEVER .................................................................................................................3-S6
(1) Engine Start Condition.....................................................................................................3-S8
[2] GEAR SHIFTING LINKAGE ..................................................................................................3-S9
(1) Main Gear Shift................................................................................................................3-S9
(2) Range Gear Shift...........................................................................................................3-S11
[3] SHUTTLE VALVE................................................................................................................3-S12
[4] 2WD-4WD CLUTCH ............................................................................................................3-S13
5. DISASSEMBLING AND ASSEMBLING ....................................................................................3-S14
[1] HYDRAULIC SHUTTLE VALVE AND SOLENOID VALVE ASSEMBLY.............................3-S14
(1) Removing Fuel Tank (ROPS Model) .............................................................................3-S14
(2) Removing Fuel Tank (CABIN Model) ............................................................................3-S14
(3) Hydraulic Shuttle Valve .................................................................................................3-S16
(4) Solenoid Valve Assembly ..............................................................................................3-S16
[2] PREPARATION FOR SEPARATING EACH BLOCK..........................................................3-S17
(1) Lubricant and Coolant ...................................................................................................3-S17
(2) 4WD Propeller Shaft and Power Steering Hose............................................................3-S17
(3) Front Axle Rocking Restrictor........................................................................................3-S18
(4) Bonnet (ROPS Model)...................................................................................................3-S18
(5) Bonnet and Muffler Pipe (CABIN Model).......................................................................3-S19
(6) Air Cleaner Harness Connector.....................................................................................3-S19
[3] SEPARATING ENGINE AND CLUTCH HOUSING CASE ..................................................3-S20
(1) ROPS Model..................................................................................................................3-S20
(2) CABIN Model.................................................................................................................3-S22
[4] SEPARATING CLUTCH HOUSING CASE FROM TRANSMISSION CASE.......................3-S24
(1) Preparation for CABIN Model ........................................................................................3-S24
(2) Preparation for ROPS Model.........................................................................................3-S24
(3) Separating Transmission Case .....................................................................................3-S28
[5] SEPARATING TRANSMISSION CASE ..............................................................................3-S28
[6] DAMPER DISC....................................................................................................................3-S29
[7] HYDRAULIC SHUTTLE CLUTCH .......................................................................................3-S30
[8] SHIFT COVER ....................................................................................................................3-S33
[9] CLUTCH HOUSING ............................................................................................................3-S36
(1) Creep Gear Assembly ...................................................................................................3-S36
(2) 1st Shaft, 2nd Shaft and 3rd Shaft ................................................................................3-S36
(3) 1st Shaft ........................................................................................................................3-S38
(4) 2nd Shaft .......................................................................................................................3-S40
(5) 3rd Shaft ........................................................................................................................3-S40
(6) Removing DT Propeller Shaft........................................................................................3-S40
[10]TRANSMISSION CASE ......................................................................................................3-S41
(1) Removing Solenoid Valve Assembly.............................................................................3-S41
(2) PTO Clutch Pack ...........................................................................................................3-S41
(3)
R
emoving 4WD Clutch ..................................................................................................3-S42
(4) Disassembling 4WD Clutch Pack ..................................................................................3-S43
(5) Removing Differential Gear and Bevel Pinion Shaft......................................................3-S45
[11]DIFFERENTIAL GEAR........................................................................................................3-S47
SERVICING
KiSC issued 07, 2012 A