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JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 30

Section F

Transmission

Section F

120 - 3

Powershift Gearbox

120 - 3

Removal and Replacement (cont’d)

A401320

9803/3280

Issue 1

Section F

Transmission

Section F

120 - 4

Powershift Gearbox

120 - 4

Removal and Replacement (cont’d)

Replacement

Replacement is a reversal of the removal procedure but note

the following:

Before replacing the gearbox remove circlip 5 and

withdraw the pump driveshaft 6 together with its

bearing 7 approximately 50 mm (2.0 in). The shaft can

then be engaged after the gearbox has been fitted,

making replacing the gearbox easier. Remember to

engage the pump drive shaft, refit the bearing and

circlip after the gearbox has been fitted.

Set the torque converter as described in Torque

Converter, Removal and Replacement.

Align the Torque Converter

It is vitally important that the torque converter is

fitted at the gearbox and engine flywheel correctly.

Failure to locate the converter correctly will result in

damage to the gearbox oil pump on engine start up.

Proceed as follows:

Make sure that the torque converter drive dogs 1 are

correctly engaged with the pump 2 on the gearbox.

Temporarily tie the converter onto the gearbox. Use

wire tied at a drive plate bolt hole to a convenient point

on the outside of the gearbox.

Take note of the flywheel and drive plate fixing hole

phasing. The heads of the bolts 3 will foul the flywheel 4

if phasing is incorrect.

Before bolting the torque converter housing to the

engine make sure the mating faces are fully together

(DO NOT USE FORCE). The drive plate 8 should also

be mated close to the flywheel. Do not force the

components together with the fixing bolts.

Make sure that the torque converter is free to rotate

A396460

slightly within the clearance of the location bolt holes. If

you cannot rotate the converter it is trapped either by

bolt heads 3 or by incorrectly located pump drive

dogs.Make sure that all is well before tightening the

bolts.

Fill the gearbox with the specified amount and type of

oil (see Section 3, Routine Maintenance). Leave hose

N off until the filling operation is complete. After filling

refit hose N.

Torque Settings

Item

kgf m lbf ft

4.5

237

175

J,T

A396900

9803/3280

Issue 1

Section F

Transmission

Section F

125 - 1

Powershift Gearbox

125 - 1

A395250

A395260

A395540

9803/3280

Issue 1

Section F

Transmission

Section F

125 - 2

Powershift Gearbox

125 - 2

Dismantling

Note: The Dismantling, Inspection and Assembly

procedures in this manual illustrate and describe the 6x4

gearbox. Procedures for the 4x4 version of the gearbox are

indentical in most respects. Where there are differences

procedures are identified under the heading ‘4x4 Gearbox’.

With the gearbox removed from the machine, place suitable

wooden blocks to securely support the assembly.

Cleanliness is of the utmost importance when servicing the

gearbox. All precautions to prevent any ingress of dirt, grit

etc. must be taken. To this end wash the exterior of the

gearbox assembly as follows;

Make sure that all open ports and orifices are effectively

plugged. Remove any deposits of dirt, grit and oil from the

outer casings using a suitable degreaser and water. Dry the

casings.

Remove the Main Hydraulic Pump and Driveshaft

a If the main hydraulic pump has not already been

removed proceed as follows. Support the pump, undo

the 2 bolts 1a. Draw the pump away from the gearbox,

disengaging the drive shaft. Lift the pump clear.

b Remove the circlip 1b followed by bearing 1c.

Withdraw the driveshaft 1d. Remove the sealing ring

1e.

Remove the Solenoid Control Valve Block

a Undo the 8 socket head cap screws 2a and lift off the

valve block assembly 2b. Do not use a screwdriver to

lever the block, the sealing faces will be damaged. If

the block is difficult to remove, lightly tap the manifold

block with a soft faced hammer.

Note: Some gearboxes are fitted with a valve block sub-

base plate. Be sure to retrieve the plate. The plate is thin,

make sure it is not damaged when removing. Take care not

to damage the surfaces of the plate.

b Remove and discard the valve block sealing gasket.

The gasket may disintegrate on removal, make sure all

traces are removed and discarded. Gearboxes fitted

with a sub-base plate have two gaskets, one each side

of the plate.

Remove the Layshaft Cover

Note: Unless the casings are to be renewed, or the gearbox

oil has been contaminated it is not necessary to remove the

cover.

a Undo the 6 bolts 3a and lift off the cover 3b.

9803/3280

Issue 1

Section F

Transmission

Section F

125 - 3

Powershift Gearbox

125 - 3

A396090

A395230

A395240

A395330

9803/3280

Issue 1

Section F

Transmission

Section F

125 - 4

Powershift Gearbox

125 - 4

Dismantling (cont’d)

Using suitable lifting equipment locate the gearbox in a work

cradle (892/01082) as shown at A. Clamp the gearbox in

position at the 3 clamping points on the rear casing as

shown at B. DO NOT ATTEMPT TO DISMANTLE THE

GEARBOX FURTHER UNLESS IT IS SAFELY LOCATED IN A

SUITABLE WORK CRADLE.

Remove the Torque Converter Housing

a Undo the bolts 4a^†. Note that 2 bolts are located on the

outside of the housing just above the oil filter mounting.

Lift off the housing. Retrieve the sealing ‘O’ ring 4b.

^†Early gearboxes feature a total of 18 bolts while late

gearboxes have 23 bolts

Remove the Gearbox Hydraulic Pump

a Undo the 4 fixing bolts 5a and lift the pump assembly

5b off the input shaft. Retrieve the 4 sealing washers 5c

and pump sealing ring 5d.

Note: A pump which is worn or damaged may have caused

further damage to the gearbox. Dismantle and inspect the

gearbox fully. For details of dismantling and inspecting the

pump, see Powershift Gearbox - Inspection.

Remove the 4WD Clutch Assembly

a Using service tool 892/00812 hold the output yoke 6a

and at the same time undo the bolt 6b. The bolt is very

tight, the help of an assistant will be required.

b Remove the thick washer 6g and yoke 6a. Undo the 8

bolts 6c and lift off the cover 6d, be sure to retrieve the

bearing outer cup from inside the cover. Remove the

output shaft oil seal 6b. Take care not to damage the

seal housing.

c Lift the clutch and shaft assembly 6f from the housing.

Retrieve the inner bearing outer cup from the casing.

For 4WD clutch dismantling and assembly procedure see

4WD Clutch - Dismantling and Assembly in this section.

9803/3280

Issue 2*

Section F

Transmission

Section F

125 - 5

Powershift Gearbox

125 - 5

A395210

A396120

10f

10g

10h

10c

10b

10a

10e

10d

9803/3280

Issue 2*

Section F

Transmission

Section F

125 - 6

Powershift Gearbox

125 - 6

Dismantling (cont’d)

Remove the Torque Converter Relief Valve

a Undo the plug 7a and remove the sealing washer 7b,

spring 7c and poppet 7d. Note that some gearboxes

are fitted with a ball instead of a poppet.

Remove the Pressure Maintenance Valve

a Undo the plug 8a, remove spring 8b and valve spool

8c.

Separate the Front and Rear Casings

a Remove the 4WD clutch oil pipe 9a.

b Undo the 17 casing bolts 9b.

c Using suitable lifting equipment carefully lift off the front

case 9c. Be sure to retrieve all the shaft bearing outer

cups. The cups may be left on the bearings, or inside

the front case. Keep the cups with their associated

bearings.

d Remove and discard the 3 sealing ‘O’ rings 9e from the

front case.

Note: The 3 oil transfer pipes 9f, 9g and 9h located inside

the front case need not be removed unless they are

damaged, or the gearbox oil has been contaminated. If they

are to be removed see Powershift Gearbox - Inspection.

4x4 Gearbox: pipe 9h not fitted.

Remove the Clutch/Shaft Assemblies

a Carefully lift out the clutch/shaft assemblies in the

following order:

10a - 6 speed clutch shaft (not fitted to 4x4 Gearbox)

10b - Reverse clutch unit

10c - Forward/Input clutch shaft

10d - Layshaft clutch

10e - Mainshaft clutch

b Retrieve the bearing outer cups from the rear case 10f

and centre of the transfer gear 10g. Note that the

layshaft bearing cup 10h can not be removed until the

transfer gear/output shaft has been removed, see step

11. Keep the cups together with their associated

bearings.

9803/3280

Issue 2*

Section F

Transmission

Section F

125 - 7

Powershift Gearbox

125 - 7

11c

11d

11b

11r

11g

11h

11j

11p

11m

11k

11f

11e

11a

A395280

9803/3280

Issue 1

Section F

Transmission

Section F

125 - 8

Powershift Gearbox

125 - 8

Dismantling (cont’d)

11 Remove the Transfer Gear

b Using service tool 892/00812 hold the output yoke 11b

and at the same time undo the bolt 11c. The bolt is very

tight, the help of an assistant will be required. Remove

the bolt, thick washer 11d followed by the yoke.

c Remove and discard the oil seal 11g. Take care not to

damage the seal housing.

d Support the transfer gear/shaft assembly 11a.

Withdraw the gear from inside the casing. The

assembly will lift away complete with the inner taper

roller bearing 11e and spacer 11f.

e Remove the outer taper roller bearing 11h.

Remove circlip 11j followed by bearing double outer

cup 11k.

Note: The inner and outer taper roller bearing assembly

(comprising double outer cup 11k, inner bearing 11e, spacer

11f and outer bearing 11h) is a matched set. Keep all the

components together in their original relationships.

Components from another set are not interchangeable. If

any components are worn or damaged the whole assembly

must be renewed as a complete matched set.

g Retrieve the layshaft bearing outer cup 11r from the

rear casing.

h If the speed sensor 11m is to be removed, undo bolt

11p and withdraw the sensor together with its sealing

‘O’ ring.

9803/3280

Issue 1

Section F

Transmission

Section F

126 - 1

Powershift Gearbox

126 - 1

Inspection

A395290

A395210

A395110

9803/3280

Issue 1

Section F

Transmission

Section F

126 - 2

Powershift Gearbox

126 - 2

Inspection

Before assembling the gearbox, make sure that a thorough

b If the existing pump is to be re-installed proceed as

inspection of all components is carried out. Remember that

follows;

although a failed component may be easy to identify, the

Undo the security screw 4a and separate the pump

cause of that failure may be less easy to trace. It is also

body. Carefully inspect the gear teeth, white metal

possible that a failed component may have caused damage

bearing and gear/body mating faces for signs of wear

to other areas of the gearbox.

and damage, (If either is evident, the pump must be

renewed).

Cleaning

Carefully remove and discard the oil seal 4b. Take care

not to damage the seal housing. Fit a new seal and

a Carefully remove all traces of gasket or gasket

then re-assemble the pump.

compound from the following components:

c Make sure that pump the mating face on the gearbox

Note: When removing gasket compound use a gasket

front cover is clean and free from surface damage.

removal product such as Loctite Chisel. Take care not to

damage the mating faces. Clean the faces with a fine

Oil Transfer Pipes

carborundum paper. Use a solvent cleaner and a clean cloth

to finally remove all traces of oil or debris.

The front case incorporates oil transfer pipes 5a, 5b and 5c.

If the pipes are damaged or if the gearbox has been

Front and rear casing mating faces.

contaminated, the pipes must be removed for cleaning or

Front casing and torque converter housing mating

renewal.

faces.

4x4 Gearbox: pipe 5c not fitted.

Main hydraulic pump and rear casing mating faces.

Solenoid control valve manifold and casing mating

a Using a ‘crows foot’ type spanner and a ratchet wrench

faces.

undo the pipes from the adaptors in the casing. Unless

4WD casing mating faces.

pipes are being transferred to a new casing it will not

Layshaft cover and rear casing mating faces.

be necessary to remove the pipe adaptors.

Pressure maintenance valve bore (front case)

6x4 Gearbox Only: If the adaptors are to be removed,

adaptor 5e must be removed last.

b Clean the inside of the casings using a suitable

degreasing agent.

b If the adaptors have been removed make sure that the

sealing rings are renewed and fitted correctly.

General Inspection

6x4 Gearbox Only: Position the lock nut 5f on adaptor

5e as shown and then fit the adaptor to the case.

a Carefully inspect all gears, bearings and shafts for signs

Screw in until the locking nut reaches the case. Do not

of excessive wear or damage. If wear or damage is

tighten the locking nut down at this stage.

evident, components must be renewed.

All Gearboxes: Fit the adaptors. Torque tighten to

70 Nm.

Note: The transfer gear shaft inner, outer bearing and

spacer assembly is a matched set. If any of the components

c Make sure the pipes are clear and free from debris

are damaged or worn the complete assembly must be

before refitting. Loosly fit the pipes 5a and 5b. Make

renewed. Components are not interchangeable between

sure they are fitted at the correct adaptors as shown.

bearing sets.

6x4 Gearbox Only: Loosly fit the pipe 5c, rotate

adaptor 5e so that the pipe is not strained. Torque

b Make sure that all oil way cross drillings are clear and

tighten down the lock nut 5f to 70 Nm.

free from debris. Blocked oil ways are a common cause

All Gearboxes: Torque tighten the pipes to 30 Nm.

of bearing failure. If necessary use an air line to blow

through the oil ways.

Casings

Clutch Units

If the gearbox casings are to be renewed, be sure to fit

blanking plugs and adapters as required. Inspect the original

a If clutch failure is suspected see the relevant clutch

casings and identify the blanking plug and adapter positions.

dismantling and assembly procedure in this section.

Transfer the plugs and adapters to the new casings. Apply

JCB Threadlocker and Sealer to the threads.

Gearbox Hydraulic Pump

a If tests have shown the pump performance to be

Note that new plugs may be supplied with a sealant ‘patch’,

unacceptable, the pump must be renewed as a

in which case sealant need not be applied.

complete unit.

Note: Early gearboxes feature a ‘18 bolt fix’ torque converter

housing. It is strongly recommended that a new ‘23 bolt fix’

housing and matching front case is fitted on assembly of the

gearbox. A compatible torque converter relief valve will also

be required.

9803/3280

Issue 3*

Section F

Transmission

Section F

127 - 1

Powershift Gearbox

127 - 1

11f

A396070

A395280

9803/3280

Issue 1

Section F

Transmission

Section F

127 - 2

Powershift Gearbox

127 - 2

Assembly

Checking Transfer Gear/Output Shaft

Using suitable lifting equipment locate the gearbox rear

casing in a work cradle. Clamp the casing in position at the 3

Assembly End Float

clamping points as shown at A.

DO NOT ATTEMPT TO ASSEMBLE THE GEARBOX UNLESS

The transfer gear/output shaft and its associated

IT IS SAFELY LOCATED IN A SUITABLE WORK CRADLE.

components are manufactured using a ‘Setright’ system.

Measure the rolling torque at the yoke 1h. Provided

Where ‘oil’ is referred to, use new, clean transmission oil of

components have been assembled correctly the torque will

the correct specification for the gearbox. See Section 3,

be between 0.6 and 2.2 Nm (0.5 and 1.6 lbf ft).

Lubricants and Capacities.

Assemble the Transfer Gear/Output Shaft

Note 1: Before fitting the transfer gear/output shaft assembly

1d, fit the layshaft outer bearing cup to the casing (shown at

E).

Position the casing as shown at D.

Note 2: The inner and outer taper roller bearing assembly

(comprising double outer cup 1a, inner bearing 1c, spacer 1e

and outer bearing 1f) is a matched set. Keep all the

components together in their original relationships.

Components from another set are not interchangeable. If any

components are worn or damaged the whole assembly must

be renewed as a complete matched set.

a Make sure that you have fitted the layshaft outer bearing

cup, see Note 1 above. Fit the bearing double outer cup

1a into the casing. Note the correct way up of circlip 1b,

with the chamfer uppermost. Make sure that the circlip

A395580

locates fully in its groove as shown at B. The tangs of

the circlip must not overhang the inner diameter of the

bearing cup 1a. An incorrectly located circlip can foul

and damage the outer bearing.

b Push the inner bearing 1c onto the transfer gear/shaft

1d followed by spacer 1e.

d Locate the transfer gear assembly in the casing from

inside. Using service tool 892/01083 retain the gear in

position (shown at C). If the gear is not held in position

the bearings may be damaged during assembly.

c Using service tool 892/01084 push on the outer bearing

1f. Using service tool 892/01085 fit a new oil seal 1g.

Make sure the seal is pushed square to the housing.

e Fit yoke 1h followed by thick washer 1j and bolt 1k. Hold

the yoke using service tool 892/00812 and torque

tighten the bolt to 400 Nm (295 lbf ft).

If applicable fit the speed sensor 11f. Make sure that the

sealing ‘O’ ring is correctly located and then torque

A396090

tighten the bolt to 28Nm (20 lbf ft).

9803/3280

Issue 1

Section F

Transmission

Section F

127 - 3

Powershift Gearbox

127 - 3

A396050

A395060

A395620

A335160

A395210

9803/3280

Issue 1

Section F

Transmission

Section F

127 - 4

Powershift Gearbox

127 - 4

Assembly (cont’d)

Fit the Clutch/Shaft Assemblies

a Fit the bearing outer cups at their correct locations in the

rear case 3a and centre of the transfer gear 3b.

b Carefully fit the clutch/shaft assemblies in the following

order:

Note: When fitting the layshaft clutch take care not to

damage the rear bearing on the transfer gear teeth.

Note: Before fitting the input clutch shaft make sure that the

4 sealing rings (shown at A) are in good condition and

lubricated with oil.

3c - Mainshaft clutch

3d - Layshaft clutch

3e - Forward/Input clutch shaft

3f - Reverse clutch unit

3g - 6 speed clutch shaft (not fitted to 4x4 Gearbox)

c Make sure that the sealing rings on the ends of the

clutch shafts 3c, 3d, 3f and 3g are in good condition and

lubricated with oil.

4x4 Gearbox: clutch 3g (6 speed) not fitted.

Assemble the Front and Rear Casings

a Make sure that the 3 off ‘O’ rings 4a are correctly fitted

to the rear case.

b Apply a thin bead of JCB Multigasket to the rear casing

mating face as shown at B.

c Make sure that the shaft bearing outer cups are correctly

located in the front case 4b and then carefully lower the

case over the clutch shafts until it mates with the rear

case. Do not use excessive force when fitting the case.

d Fit the 17 casing bolts 4c and progressively torque

tighten to 56 Nm (41 lbf ft).

9803/3280

Issue 1

Section F

Transmission

Section F

127 - 5

Powershift Gearbox

127 - 5

A335160

9803/3280

Issue 1

Section F

Transmission

Section F

127 - 6

Powershift Gearbox

127 - 6

Assembly (cont’d)

Checking the Clutch Shaft End Floats

Provided components are assembled correctly the end float

will be within the limits given. Check that the shafts can be

rotated by hand (turn the input shaft and output yoke). The

shafts should rotate smoothly. The end floats can be checked

to confirm correct assembly.

End float for all shafts will be within the range 0.02 mm to

0.16 mm (0.0008 to 0.0063 in).

All shafts except the Input Shaft:

Shaft 5a - Mainshaft

Shaft 5b - Reverse clutch unit

Shaft 5c - Layshaft

Shaft 5d - 6 speed shaft (not fitted to 4x4 gearboxes)

a Remove the plugs X and Y from the front casing.

4x4 Gearbox: plug Y not fitted.

b Fit a bolt to the threaded hole in the end of the shafts.

Pull up on the bolt to detect excessive end float.

Remove the bolt.

c Apply JCB Threadlocker and Sealer to the plugs X and

Y as applicable. Torque tighten the plugs to 102 Nm

(75 lbf ft).

Input Clutch Shaft:

a Pull on the input shaft 5e to detect excessive end float.

9803/3280

Issue 1

Section F

Transmission

Section F

127 - 7

Powershift Gearbox

127 - 7

A395240

A395570

A405220

A395230

9803/3280

Issue 3*

Section F

Transmission

Section F

127 - 8

Powershift Gearbox

127 - 8

Assembly (cont’d)

Fit the 4WD Clutch Assembly

a Fit the 4WD clutch oil feed pipe 6a at the casing.

b Make sure the shaft bearing outer cup is correctly

located in the front casing (not shown) and then locate

the clutch and shaft assembly 6b in the the housing.

c Make sure that the front and 4WD casing (6c) mating

faces are clean and undamaged. Apply a 3 mm bead of

Loctite 509 to the front casing as shown at A. Note that

the bead is applied near the inner or outer edge of the

flange as applicable at positions Y. Make sure that the

shaft bearing outer cup (not shown) is correctly located

inside the 4WD casing and then fit the casing. Fit 8 off

bolts 6e and progressively torque tighten to 56 Nm

Check the 4WD clutch shaft end float:

Provided components are assembled correctly the end float

will be within the limits given. Rotate the shaft by hand, it

should rotate smoothly.

The end float can be checked to confirm correct assembly.

End float must be within the range 0.01 mm to 0.16 mm

(0.0004 to 0.0063 in).

d Fit a bolt to the threaded hole in the end of the shaft. Pull

up on the bolt to detect excessive end float.

e Fit a new oil seal 6f. Make sure the seal is pushed

square to the housing.

Fit the output yoke 6g, followed by thick washer 6h and

bolt 6j. Hold the yoke using service tool 892/00812 and

at the same time torque tigten the bolt to 400 Nm (295

lbf ft).

Fit the Torque Converter Relief Valve

Note: The torque converter relief valve may be of a ball type

(shown at B), or poppet type (shown at C).

a Fit the ball or poppet (see note above) 7a followed by

the spring 7b. Using a new sealing washer fit plug 7c.

Fit the Pressure Maintenance Valve

a Oil the spool 8a and fit to the casing. Fit spring 8b. Apply

JCB Threadlocker and Sealer to the plug 8c. Using a

new sealing washer fit plug.

Fit the Gearbox Hydraulic Pump

a Make sure that the pump is fitted with a new oil seal 9a,

see Powershift Gearbox, Inspection, step 4.

Fit a new sealing ring 9b. Locate the pump over the

input shaft aligning the bolt holes. Apply JCB

Threadlocker and Sealer to bolts 9c. Fit the bolts

together with new sealing washers 9d. Progressively

torque tighten the bolts to 28 Nm (20 lbf ft).

b Pour some clean, new, oil into the pump at position X.

9803/3280

Issue 3*

Section F

Transmission

Section F

127 - 9

Powershift Gearbox

127 - 9

A396130

A402660

9803/3280

Issue 2*

Section F

Transmission

Section F

127 - 10

Powershift Gearbox

127 - 10

Assembly (cont’d)

Fit the Torque Converter Housing - Gearboxes with

18 bolt fix only

*Important Note: Only the specified sealant can be used.The

10c

machine MUST NOT be operated for at least 6 hours after

sealant has been applied and the converter housing

10c

assembled. This is to allow time for the sealant to cure.

a Make sure that the front case and torque converter

housing

(10a) mating faces are clean, dry and

undamaged. Apply a 3 mm wide bead of Bondloc B574

sealant to the front casing as shown at A (pump not

shown for clarity). Make sure that sealant is applied

between all the port channels as shown. Take extra

10a

special care in the area X as sealing is critical in these

areas. Be sure not to block galleries with sealant. Fit a

new ‘O’ ring 10d to the housing 10a.

10c

10b

b Carefully locate the torque converter casing on the front

case. Fit new 10.9 grade bolts as follows:

M10 bolts 10b (15 off). Note that spacers are fitted

under bolts at positions 10 and 14.

M8 bolts 10c. (3 off)

Progressively torque tighten the bolts in the sequence

shown. Note that the bolt at position 1 is re-torqued

after tightening the bolt at position 15.

Sequence

Bolt Position

Torque

(shown at B)

lbf ft

1 - 9

57.5

44.25

11 - 13

57.5

44.25

57.5

1 (Re-torque)

57.5

17 - 19

10d

A401250

9803/3280

Issue 3*

Section F

Transmission

Section F

127 - 11

Powershift Gearbox

127 - 11

A404970

10a

M8 x 45 mm

M8 x 25 mm

A404980

9803/3280

Issue 2*

Section F

Transmission

Section F

127 - 12

Powershift Gearbox

127 - 12

Assembly (cont’d)

Fit the Torque Converter Housing - Gearboxes with

23 bolt fix only

Important Note: Only the specified sealant can be used. The

10a

machine MUST NOT be operated for at least 6 hours after

sealant has been applied and the converter housing

assembled. This is to allow time for the sealant to cure.

a Make sure that the front case and torque converter

housing

(10a) mating faces are clean, dry and

undamaged. Apply a 3 mm wide bead of Loctite 509

10d

sealant to the front casing as shown at A (pump not

shown for clarity). Make sure that sealant is applied

between all the port channels as shown. Take extra

special care at positions X as sealing is critical in these

areas. Be sure not to block galleries with sealant. Fit a

new ‘O’ ring 10d to the housing 10a.

b Carefully locate the torque converter casing on the front

case. Fit new 10.9 grade bolts (shown at B) as follows:

A401250

M10 x 35 mm bolts (21 off). Note that on some

gearboxes spacers are fitted under bolts at positions Y.

M8 x 25 mm bolt at position 22.

M8 x 45 mm bolt at position 23.

Progressively torque tighten the bolts in the sequence

shown.

Sequence

Bolt Position

Torque

(shown at B)

lbf ft

1 - 21

57.5

22 - 23

35 - 40 26 - 30

9803/3280

Issue 2*

Section F

Transmission

Section F

127 - 13

Powershift Gearbox

127 - 13

11b

11a

A390510

13a

12b

13b

12a

12c

A395260

12d

9803/3280

Issue 1

Section F

Transmission

Section F

127 - 14

Powershift Gearbox

127 - 14

Fit the Solenoid Control Valve Block

a Fit two guide studs at the valve interface on the front

case. Locate a new valve block sealing gasket 11a as

shown at C. Care is needed as the gasket is thin.

Gearboxes fitted with a sub-base plate have two

gaskets, one each side of the plate.

b Fit the 8 socket head cap screws and washers 11b. The

screws must be progressively torque tightened.

Gradually tighten all the screws to 35 Nm (26 lbf ft).

Fit the Main Hydraulic Pump Driveshaft

a Fit a new sealing ring 12a to the shaft 12b. Apply clean

oil to the sealing ring and fit the shaft inside the gearbox.

b Apply clean oil to the ball bearing 12c. Fit the bearing

followed by circlip 12d.

Fit the Layshaft Cover

a If applicable fit the layshaft cover 13a. Make sure the

casing mating faces are clean and undamaged. Apply a

thin bead of JCB Multigasket to the rear casing and fit

the cover. Fit bolts 13b and progressively torque tighten

to 56Nm (41 lbf ft).

Note: The main machine hydraulic pump can be fitted at this

stage. However, it is easier to fit the gearbox to the machine

and then fit the pump. See Section E, Main Hydraulic

Pump, Replacement.

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