Content      ..     27      28      29      30     ..

JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 29

Section F

Transmission

Section F

112 - 3

Synchro Shuttle Gearbox

112 - 3

Assembly (cont’d)

9

Transfer Gear/Output Shaft Assembly

Note: Make sure that the layshaft bearing outer cup is fitted

to the rear casing before fitting the transfer gear/output

shaft.

a Liberally coat output shaft inner bearing with JCB

HP Grease before fitting inner bearing P.

S

b Fit the service solid spacer N (13.70 mm) over

R

output shaft and assemble into casing.

c Lightly oil output shaft outer bearing and cup R and

fit to output shaft, do not fit oil seal S at this stage.

N

P

A388000

10

a Fit special tool sleeve A which temporarily replaces

the output yoke and secure with special tool nut B,

torque tighten to 50 Nm (36.9 lbf ft).

B

Note: Check for end float while tightening nut B, if there is

no end float check:

The bearing cups are pushed fully into the casing.

A

The correct bearings are fitted, check parts

catalogue.

The solid spacer N is 13.70 mm.

D

b Ensure that the layshaft setting ring is slightly below

layshft cover facing on the rear case. Fit special tool

C

support pillar C (892/01076) so that the fork end

engages in special tool nut B, tighten bolt D.

A396650

9803/3280

Issue 1

Section F

Transmission

Section F

112 - 4

Synchro Shuttle Gearbox

112 - 4

Assembly (cont'd)

B

E

11

a Fit dial test indicator E (DTI) .

b Set torque wrench F to 35 Nm and measure the end

float while rotating the output shaft.

A

c To select the right size spacer, subtract the end

float obtained at step 11b from the solid spacer

(13.70 mm). Also subtract 0.120 mm to allow for

D

F

theoretical bearing tolerance and pre load. If there is

no spacer of this size, fit the next smallest spacer.

C

Example

Service spacer

13.70

Subtract end float

0.41

Total

13.29

Subtract tolerance & preload

0.12

Result

13.17

Use next smallest spacer ie.

13.15

A396650

d Remove special nut B and sleeve A. Remove rear

bearing and 13.70 mm spacer. Fit correct size

spacer (Do no fit the oil seal at this stage). Take care

to avoid damaging the outer bearing.

e Fit sleeve A and initially tighten nut B to 50 Nm (36.9

lbf ft). Check there is no end float and rolling torque

less than 1.5 Nm (1.0 lbf ft). If the rolling torque

exceeds 1.5 Nm (1.0 lbf ft) check that the output

shaft has been assembled correctly.

f

If the rolling torque measured is too high, fit the next

larger size spacer. If there is end float, fit the next

smaller size spacer.

9803/3280

Issue 2*

Section F

Transmission

Section F

112 - 5

Synchro Shuttle Gearbox

112 - 5

Assembly (cont'd)

12

a Remove nut B and sleeve A. Fit new oil seal S,

grease between seal lips before fitting. Note that the

seal does not fix to the back of the housing - use

servicel tool to locate the seal. Fit the output yoke Y.

Y

b Fit the stepped washer W the correct way round

T

with the plain face uppermost as shown.

W

c Fit NEW retaining nut T and progressively torque

tighten to 300 Nm (221 lbf ft). Provided the correct

size spacer has been selected, the rolling torque

S

should be 2.0 Nm (1.5 lbf ft) when nut T is fully

torque tightened.

Note: If the rolling torque measured is too high, fit the next

larger size spacer. If the rolling torque is too low, fit the next

smaller size spacer.

A388180

d Finally, carefully stake nut T into slot using a

square-ended staking tool.

13

Press idler gear spindle into front casing.

13

Note: Before proceding further, make sure that the 3 shaft

14

front bearing outer cups are correctly located inside the

casing V.

14

Grease forward reverse shaft front bearing, then

carefully lower forward/reverse unit into casing. Fit the

V

shaft sealing rings and smear with grease.

221180

9803/3280

Issue 1

Section F

Transmission

Section F

112 - 6

Synchro Shuttle Gearbox

112 - 6

Assembly (cont'd)

15

Smear mainshaft output end bearing with JCB HP

19

Grease and place mainshaft L in position, followed by

the forward/reverse assembly M.

18a

16

Fit idler gear spacer.

17a

17

Fit thrust washers and bearing assembly. Lubricate and

*

fit the needle roller bearing 17a.

17

18

Fit synchro cone to 3rd gear (mainshaft L). Fit the idler

16

gear 18a to the spindle whilst tilting mainshaft L to one

side.

18

19

Fit thrust washers and bearing assembly.

*

M

L

S407370

21a

20

Smear front end bearing of layshaft with JCB HP

Grease, and carefully lower layshaft into position.

21

21

If re-using synchro assembly fit the parts in their original

positions.

22

Using a suitable wire support locate interlock plunger

into its bore. A smear of grease will hold the plunger in

20

position. If required, access is available via a¹/₄

BSP

side drilling.

22

221090

9803/3280

Issue 2*

Section F

Transmission

Section F

112 - 7

Synchro Shuttle Gearbox

112 - 7

Assembly (cont'd)

23

Fit selector forks into position.

24

24

Slide selector rods into position, taking care not to

dislodge the interlock plunger. Apply JCB Threadlocker

and Sealer to selector fork retaining screws H, and

tighten to 35 Nm (26 lbf ft).

J

25

Fit 1st gear selector detent ball and spring at position A.

M

Apply JCB Threadlocker and Sealer to the detent plug

25a, screw in and tighten.

H

23

H

26

Temporarily fit the 3rd and 4th gear selector detent

assembly at position B, do not apply sealant to the plug

H

at this stage.

27

Check that each gear engages fully, and that the

interlock plunger prevents simultaneous engagement of

H

23

2 ratios.

25

28

Remove the 3rd and 4th gear selector detent assembly

25a

from position B. Lift the selector rod J to select 4th

A

gear. With 4th gear selected, temporarily lock the rod in

in position by screwing in service tool 892/01077 at B.

Temporarily fit service tool 892/01078 to the torque

B

converter end of mainshaft M. If the tool is not available

a suitable M8 bolt approximately 100 mm long can be

used.

29

Apply a bead of JCB Multigasket to mating face of

casing. Insert 'O' rings Z. Smear grease onto reverser

shaft ring seals, and apply JCB HP Grease to bearings

29

prior to fitting output end casing.

Z

Note: Make sure that the forward/reverse shaft ring seals are

in good condition before fitting output end casing.

Z

A388010

9803/3280

Issue 1

Section F

Transmission

Section F

112 - 8

Synchro Shuttle Gearbox

112 - 8

Assembly (cont'd)

30

Make sure that the 3 bearing outer cups C are correctly

located; note that 2 cups locate inside the casing and 1

locates in the centre of the output shaft transfer gear G.

Carefully lower rear casing into position. Note that the

forward/reverse unit shaft engages with the casing first,

followed by 3rd/4th gear selector rod. To ensure that

the mainshaft locates with the output shaft it will be

necessary to push on tool T to keep the shaft correctly

C

aligned. Rotate the output shaft S back and forth to

engage the gears on the layshaft. Do not use excessive

C

force when fitting the casing.

G

C

31

Apply JCB Threadocker and Sealer to bolts and torque

to 56 Nm (42 lbf ft).

32

Remove service tool at position B. Fit the detent ball

and spring. Apply JCB Threadlocker and Sealer to

selector detent plug, install and tighten.

A395340

30

S

31

B

T

9803/3280

Issue 1

Section F

Transmission

Section F

112 - 9

Synchro Shuttle Transmission

112 - 9

Assembly (cont'd)

33

End Float Checking - Forward/Reverse Unit

Measure end float of forward/reverse unit shaft which

*

should be 0.01 to 0.16 mm (0.0004 to 0.006 in).

Note: Rotate shaft whilst measuring to seat bearings fully.

Position pointer of dial test indicator (DTI) on the chamfer of

the shaft, not the end face. This will ensure a constant

reading is given.

The forward/reverse shaft and its associated

components are manufactured using a ‘Setright’

system. Provided components are assembled correctly

the end float will be within the limits given above.

S221201

If there is no float, or too much end float, separate the

casings and check that the bearings inner and outer

cups are fitted correctly. If the forward/reverse shaft

and clutch assemblies have been dismantled check that

the assembly has been carried out correctly.

34

End Float Setting - Mainshaft

A

If the mainshaft, output shaft and/or associated

bearings have been renewed, the shaft end float must

be reset.

a Remove the torque converter housing and position

the gearbox to gain access to setting ring A.

b Using service tool 892/01079 tighten the setting ring

to 25 Nm

(18.4 lbf ft) whilst at the same time

rotating the shaft via the output yoke (a gear must

be engaged). Do not over tighten the ring.

Y

Overtightening will damage the bearings.

A

c Undo the ring a small amount to obtain a shaft end

float of 0.03 to 0.08 mm (0.001 to 0.003 in). To

measure the endfloat screw in a bolt (or service tool

892/01078) at the threaded hole in the end of the

X

shaft. Set up a DTI with the probe on the chamfer of

the shaft. Zero the DTI. Rotate the shaft and at the

same time pull up on the bolt, noting the reading on

the DTI. Screw the ring in or out until the end float is

correct.

d When the correct setting has been obtained, stake

the setting ring to the casing as shown at Y (see the

Z

note below). Note that once staked the setting ring

can not be used again. If the ring is disturbed it must

be discarded and a new one used to re-set the end

float.

Note: If the slots in the setting ring fall close (within zone Z)

to the staking position Y, stake at position X instead. In this

event the ring must also be folded on one side at position Y,

fold on the side furthest away from the slot in the ring. This is

important as the ring will otherwise restrict the flow of

lubrication oil.

X

A396640

9803/3280

Issue 2*

Section F

Transmission

Section F

112 - 10

Synchro Shuttle Gearbox

112 - 10

Assembly (cont'd)

35

End Float Setting - Layshaft

If the layshaft and/or its bearings have been renewed,

the shaft end float must be reset.

A

a Fit the torque converter housing and stand the

gearbox on the housing.

b Using service tool 892/01079 tighten the setting ring

A to 25 Nm

(18.4 lbf ft) whilst at the same time

rotating the shaft via the output yoke (a gear must

be engaged). Do not over tighten the ring.

Overtightening will damage the bearings.

c Undo the ring a small amount to obtain a shaft end

float of 0.03 to 0.08 mm (0.001 to 0.003 in). To

measure the endfloat screw in a bolt (or service tool

892/01078) at the threaded hole in the end of the

shaft. Set up a DTI with the probe on the chamfer of

the shaft. Zero the DTI. Rotate the shaft and at the

same time pull up on the bolt, noting the reading on

the DTI. Screw the ring in or out until the end float is

correct.

d When the correct setting has been obtained, stake

the setting ring to the casing as shown at the two

positions Y (see the note below). Note that once

staked the setting ring can not be used again. If the

ring is disturbed it must be discarded and a new one

used to re-set the end float.

Y

Note: If the slots in the setting ring fall close (within zone Z)

A

to the staking positions Y, stake at position X instead. In this

event the ring must also be folded on one side at the two

positions Y, fold on the side furthest away from the slot in

X

the ring. This is important as the ring will otherwise restrict

the flow of lubrication oil.

Y

e Using a new gasket, refit the layshaft bearing cover.

Apply JCB Threadlocker and Sealer to the fixing

Z

bolts and tighten to 56 Nm (42 lbf ft).

X

Z

A396630

9803/3280

Issue 1

Section F

Transmission

Section F

112 - 11

Synchro Shuttle Gearbox

112 - 11

Assembly (cont'd)

36

Place new pump sealing ring in position. Make sure that

the charge pump drain hole is clear before fitting a new

36

oil seal to the pump housing.

37

15

37

Install pump taking care to align mounting holes. Apply

JCB Threadlocker and Sealer to bolts and, using new

sealing washers, tighten to 28 Nm (21 lbf ft).

A388140

38

Apply a bead of JCB Multigasket to the mating face of

the gearbox cover as shown at A. Refit the torque

converter housing. Apply JCB Threadlocker and Sealer

to the 12 bolts and tighten to 56 Nm (42 lbf ft).

A

A388020

38

221260

9803/3280

Issue 2*

Section F

Transmission

Section F

112 - 12

Synchro Shuttle Gearbox

112 - 12

Assembly (cont'd)

39

Fit torque converter pressure relief valve assembly 39a;

Fit the valve ball and spring. Ensure that larger diameter

of spring is located securely over the spigot on the plug.

Use a new sealing washer, apply JCB Threadlocker and

Sealer to the plug, then tighten.

Fit the torque converter pressure regulating valve

41

assembly 39b; Fit the spool and spring. Apply JCB

Threadlocker and Sealer to the plug, then tighten.

40

Using a new gasket mount pressure maintenance valve

onto casing. Apply JCB Threadlocker and Sealer to

bolts and tighten to 10 Nm (7.4 lbf ft).

44

Note: To avoid contamination of sealant printed on gasket

face keep in protective wrapper until needed.

39b

41

Assemble pressure maintenance valve spool and spring

into adaptor block. Apply JCB Threadlocker and Sealer

to plug, fit and tighten. Do not overtighten as damage

to the aluminium housing could result.

39a

42

Fit new ‘O’ rings around ports on mating face of

solenoid valve. Mount solenoid valve onto pressure

maintenance valve, ensuring that port 'P' aligns with

metering orifice in the pressure maintenance valve

body. Apply JCB Threadlocker and Sealer to capscrews

and tighten to 5Nm (3.7 lbf ft).

A387980

43

Fit the 4 wheel drive solenoid valve. Fit the hydraulic

pipe 43a.

43a

43

42

A388260

9803/3280

Issue 1

Section F

Transmission

Section F

112 - 13

Synchro Shuttle Gearbox

112 - 13

Assembly (cont'd)

44

If the gear lever turret assembly has been dismantled,

apply grease liberally to the working surfaces before

assembling. Assembly is the reverse of the procedure

A

detailed in Gearbox - Dismantling, Step 1, but note the

following:

B

a Be sure to locate the slots in the levers A with the

*

pegs B in the housing E.

b After fitting spring C, rotate it so that the end of the

bottom coil butts with the the spigot D in the

housing E.

B

D

C

A

E

A397010

45

Locate a new gasket (not shown) on the casing followed

by the gear lever turret baffle plate. Make sure the plate

is the correct way round.

45

A388270

46

Locate a second gasket and then fit the turret

assembly.

Apply JCB Threadlocker and Sealer to mounting bolts

and tighten to 56 Nm (42 lbf ft). Check for gear

selection.

46

9803/3280

Issue 2*

Section F

Transmission

Section F

112 - 14

Synchro Shuttle Gearbox

112 - 14

Assembly (cont'd)

Note: It is recommended that a 75 micron (0.075mm)

service suction strainer (892/00970) is fitted to clean the

system after a major overhaul.

Remove the service strainer and fit a production strainer

after the first 100 hours operation. Renew the oil.

47

Using a new gasket, install suction strainer. Apply JCB

Threadlocker and Sealer to bolts and tighten to 10 Nm

(7 lbf ft).

48

Fit a new filter:

a Smear seal with transmission oil.

b Screw the filter on until it just contacts the filter

head.

c Turn the filter at least another 3/4 of a turn.

49

Install dipstick/oil filler tube (not shown) as follows:

48

a Fit nut to tube followed by seal.

b Insert tube fully down bore in casing. Engage nut

47

and tighten down loosely onto seal.

c Tighten nut fully after tube has been correctly

phased.

See 2/4 Wheel Drive Clutch for hydraulic 4WD

dismantling and assembly procedures.

50

Fit a new sealing ring 50a to the pump drive shaft. Insert

the pump drive shaft followed by bearing 50b and

circlip 50c.

Note: The main hydraulic pump may be fitted at this stage,

or, after the gearbox has been refitted to the machine.

50

50a

50b

50c

A388040

9803/3280

Issue 1

Section F

Transmission

Section F

113 - 1

Synchro Shuttle Gearbox

113 - 1

Reverser Unit - Dismantling

1

Carefully remove piston ring seals.

Note: If the piston ring seals are excessively worn then

check for burrs or damage on the shaft grooves. If necessary

1

remove burrs with a fine grade abrasion paper and oil.

S232720

2

Remove the taper bearing using pullers.

*

2

S232720

*

3

Remove the thrust bearing and thrust washers.

4

Withdraw the gear and splined hub assembly 4 with the

*

needle roller bearing and spacer. Note the location of

3

the spacer to ensure it is returned to its original position

on re-assembly.

4

S407220

*

5

Remove the thrust bearing and thrust washers.

6

Remove the clutch friction/counter plates retaining

5

circlip.

7

Remove pressure (end) plate.

6

7

S407250

9803/3280

Issue 2*

Section F

Transmission

Section F

113 - 2

Synchro Shuttle Gearbox

113 - 2

Reverser Unit - Dismantling (cont'd)

8

Remove the clutch friction/counter plates. Keep them

together in sets, DO NOT mix the plates with those from

other clutches.

8

9

Remove last counter plate.

*

10

Remove disc spring.

9

10

S232741

11

Position clutch assembly in press to compress piston

spring then remove circlip.

11

12

Lift off spring retaining plate.

12

*13

Remove spring and oil baffle.

13

S145000

S407190

14

Knock the clutch shaft on a piece of aluminimum (or

wood) to remove the piston.

Note: If the piston does not loosen when the clutch shaft is

knocked on aluminimum, then hand pump air down the shaft

oil inlet hole.

S145010

*

15

Remove and discard piston and shaft ‘O’ rings.

16

Repeat steps 2 to 15 to dismantle the opposite clutch.

*

Note that a spacer is not fitted on the opposite

(Forward) clutch. Refer to step 4.

15

S407200

9803/3280

Issue 2*

Section F

Transmission

Section F

113 - 3

Synchro Shuttle Gearbox

113 - 3

Reverser Unit - Assembly

1

Fit new 'O' rings onto the piston and shaft, lubricate

with oil then press piston fully into bore of clutch

housing.

1

S407200

*2

Install the oil baffle and piston spring, make sure the

spring seats in the piston.

4

3

Fit the spring retaining plate.

3

4

Compress spring and secure with circlip.

2

S145000

S407190

5

Fit the disc spring assembly. Fit the assembly so that

the outer diameter curves away from the clutch piston.

7

6

Firstly, fit one counter plate.

7

Fit one friction plate followed by one steel counter plate.

6

8

Continue fitting alternate friction and plain steel plates,

finishing with a friction plate.

5

S232741

9

Fit the pressure (end) plate. Make sure that the

10

chamfered face is fitted facing the clutch pack as

shown at A. Make sure that the prongs on the pressure

A

plate DO NOT locate in the large grooves in the hub (the

10

ones with drilled holes).

9

10

Fit the clutch friction/counter plates retaining circlip.

*

Using an air line, blow air down the shaft oil inlet hole

and check the piston and clutch pack is free to operate

9

smoothly.

A402700

S217580

9803/3280

Issue 3*

Section F

Transmission

Section F

113 - 4

Synchro Shuttle Gearbox

113 - 4

Reverser Unit - Assembly (cont'd)

11

Using a dial test indicator as shown, measure the end

float of the pressure (end) plate, which should be 3.2 to

4.4 mm (0.126 to 0.173 in). If necessary, fit shim

between the retaining circlip and pressure (end) plate to

correct end float inaccuracies.

*

S217590

12

Fit the thrust bearing and thrust washers.

12

S407240

13

Fit gear and splined hub assembly.

15

Note: Prior to fitting gear, align teeth of clutch plates using a

thin rod (screwdriver).

*

14

Fit the spacer followed by the needle roller bearing.

14

Note: Ensure that the spacer is fitted first.

*

*

15

Fit the thrust bearing and thrust washers.

13

S407220

16

Smear the clutch end bearing with JCB HP Grease and

press the bearing onto shaft.

*

17

Fit piston ring seals, refer to Piston Ring Seals - Fitting

17

Procedure.

18

Repeat steps 1 to 16 for the opposite clutch. Note that

*

16

a spacer is not fitted on the opposite (Forward) clutch.

Refer to step 14.

S232720

9803/3280

Issue 2*

Section F

Transmission

Section F

114 - 1

Synchro Shuttle Gearbox

114 - 1

Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON)

Y

B

9803/3280

Issue 2*

Section F

Transmission

Section F

115 - 1

Synchro Shuttle Gearbox

115 - 1

Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON)

9803/3280

Issue 1

Section F

Transmission

Section F

115 - 3

Synchro Shuttle Gearbox

115 - 3

9803/3280

Issue 1

Section F

Transmission

Section F

116 - 1

Synchro Shuttle Gearbox

116 - 1

Pressure Testing the 2/4WD Clutch

1

Assemble the 2/4 wheel drive clutch, as described in

‘Assembly’.

2

Check the clutch pack end float and adjust as required

(see Assembly).

3

Using special tool 993/59300, insert the adaptor A into

the oil gallery in the end of the 2/4 wheel drive clutch

shaft as shown. Hold the adaptor in position with

clamp B.

4

Use a hand pump to pressurise the clutch assembly

until gear, item 5 can be turned by hand. Note the

pressure gauge reading - DO NOT EXCEED 200 lb/in²

(13.8 bar).

5

If the pressure gauge reading is between 125 - 135

lbf/in² (8.6 - 9.3 bar) then the clutch is operating

correctly and can be fitted in the transmission.

6

If however the pressure gauge reading is above 135

lbf/in² (9.3 bar) then check the clutch for assembly

defects, especially the clutch pack end float (the shim

may not be to the correct thickness). -test after

checking for (and rectifying) assembly defects.

B

A

S185720

9803/3280

Issue 1

Section F

Transmission

Section F

117 - 1

Synchro Shuttle Transmission

117 - 1

Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure

1

Wind the PTFE piston ring seal around your finger as

shown, so that the seal forms a 'coil'.

157250

2

Smear the seal with grease and then fit the seal to the

shaft.

Make sure that the seal sits below or flush with the

outer diameter of the shaft. If necessary, use finger

pressure as shown to make the seal flush with the shaft.

CAUTION: If the seal is not set below or flush with the outer

diameter of the shaft, then the seal will 'cut' when the shaft is

fitted to its mating component.

157260

9803/3280

Issue 1

Section F

Transmission

Section F

120 - 1

Powershift Gearbox

120 - 1

Removal and Replacement

c

R

M

N

J

K

T

R

d

P

S

L

H

H

d

c

X

F

G

b

a

G

E

a

b

Z

Y

D

B

A401320

9803/3280

Issue 1

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