SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 1

SECTION 21 – TRANSMISSION SYSTEMS

Chapter 5 – SHUTTLE COMMAND (MECHANICAL TRANSMISSION)

CONTENT

Section Description Page

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 114 Mechanical Transmission Housing Removal – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15
21 114 Mechanical Transmission Housing Removal – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
21 114 Mechanical Transmission Housing Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
21 140 Mechanical Transmission Housing Removal – Installation 5th Speed Gear . . . . . . . . . . . 35
21 130 Speed and Range Control Rail Assembly Removal – Installation . . . . . . . . . . . . . . . . . . . 40
21 160 Creeper Gears Removal – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
21 160 Creeper Gears External Control Lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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2 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

21 000 –SPECIFICATIONS – TIGHTENING TORQUES – SPECIAL TOOLS – SECTIONAL

VIEWS – DESCRIPTION AND OPERATION – TROUBLESHOOTING

SPECIFICATIONS
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–speed with constant–mesh gears and
synchronisers on all speed gears
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helically toothed
Range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 forward ranges and 4 reverse ranges
for a total of 20 forward and 16 reverse
speeds
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helically toothed
– Reduction ratios:
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 15) : (46 x 55) = 1 : 7.03
Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 26) : (46 x 40) = 1 : 2.95
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 29) : (46 x 37) = 1 : 2.45
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Speed and range shift controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . independent, by two hand levers
located at the operator’s right side
Speed and range gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . forced–fed by a gear pump (same as
the power steering circuit pump)
Speed driven gear (10, page 8) inner diameter . . . . . . . . . . . mm 60.060 to 60.090
Bush (11) outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 59.981 to 60.000
Gears to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.109
Speed output shaft (13) diameter . . . . . . . . . . . . . . . . . . . . . . . mm 49.375 to 49.391
Bush (11) inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.400 to 49.430
Shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.009 to 0.055
Range (8) driven gear inner diameter . . . . . . . . . . . . . . . . . . . mm 60.060 to 60.090
Bush (9) outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 59.981 to 60.000
Gears to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.109
Range output shaft (7) diameter . . . . . . . . . . . . . . . . . . . . . . . . mm 49.375 to 49.391
Bush (9) inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.400 to 49.430
Shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.009 to 0.055

(to be continued)

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 3

(continued)
PTO drive shaft (3, page 8) diameter (at the bushings) . . . . mm 31.950 to 31.975
Press–fit bush (1) inner diameter . . . . . . . . . . . . . . . . . . . . . . . mm 31.990 to 32.085(o)
PTO drive shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . mm 0.015 to 0.135
Speed input shaft rear bearing (2) thrust washer . . . . . . . . . mm 2.950 to 3.000
Range input shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . see page 33
Range input shaft (4) adjust shims . . . . . . . . . . . . . . . . . . . . . . mm 1.70 –1.75 – 1.80 –1.85 – 1.90 –1.95 –
2.00 – 2.05 – 2.10 – 2.15 – 2.20 – 2.25
– 2.30 –2.35 – 2.40 – 2.45 – 2.50 –
2.55 – 2.60 – 2.65 – 2.70 – 2.75 – 2.80
– 2.85 – 2.90 – 2.95 – 3.00 – 3.10 –
3.20 – 3.30
Range output shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . see page 33
Range output shaft (5) adjust shims . . . . . . . . . . . . . . . . . . . . mm 1.70 –1.75 – 1.80 –1.85 – 1.90 1.95 –
2.00 – 2.05 – 2.10 – 2.15 – 2.20 – 2.25
– 2.30 –2.35 – 2.40 – 2.45 – 2.50 –
2.55 – 2.60 – 2.65 – 2.70 – 2.75 – 2.80
– 2.85 – 2.90 – 2.95 – 3.00 – 3.10 –
3.20 – 3.30
Implement pressure regulating valve spring (8, page 11):
– Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 127
– Compressed length under a load of 278 to 304 N (28.4 to 31 kg) 102.5
Implement working pressure . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 16.7 to 17.6 (17 to 18)
Lubrication pressure regulating valve spring (7, page 11):
– –Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 42
– Compressed length under a load of 84 to 90 N (8.6 to 9.2 kg) 24.5
Lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 6.8 to 8.3 (7 to 8.5)

(o) Final dimension to be obtained without reaming.

CREEPER GEARS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . epicyclic spur gears
Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 : (20+100) = 1:6
Control type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through a lever located at the
operator’s left side
Thickness of thrust washers (6, page 8) between driven gears
and creeper support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.465 to 1.535

SHUTTLE GEARS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, with helically toothed
gears, assembled as a standard
Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through a synchroniser
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (43 x 37 x 39) : (37 x 39 x 44) = 1 : 1.02
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever in right hand console
Driven gear bearing adjust shims (12, page 10) . . . . . . . . . . mm 2.55 – 2.60 – 2.65 – 2.70 – 2.75 – 2.80
– 2.85 – 2.90 – 2.95 – 3.00 – 3.05 –
3.10 – 3.15
Driven gear bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 31

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4 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

TIGHTENING TORQUES
Torque
DESCRIPTION Thread size
Nm kgm
Bolts and nuts, speed clutch/transm housing to engine . . . . . . . . . (see C and C, page 2, Sec. 18)
Bolts, speed clutch/transm housing to rear axle housing . . . . . . . . M14 x 1.5 176 18
Setscrew, clutch release fork lever (C1, page 4) .............. M16 x 1.5 157 16
Bolts, transmission housing cover (C2) . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Screws, range rear bearing retaining plate (C3) . . . . . . . . . . . . . . . M10 x 1.25 49 5
Nut, range output shaft (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M47.5 x 1.5 294 30
Screw, solenoid valve pin (C5) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 47 to 54 4.8 to 5.5
Screw, solenoid valve (C6) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 5.4 to 8.1 0.55 to 0.83
Screws, range and transmission control lever support (C7) . . . . . . M10 x 1.25 49 5
Fitting, transmission control lever support inlet (C8) . . . . . . . . . . . . M22 x 1.5 83 8.5
Plug, lubrication pressure regulating valve(C9) . . . . . . . . . . . . . . . . M18 x 1.5 49 5
Screws, creeper gear fixed plate (C10) . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 54 5.5
Screws, clutch housing front cover (C11) . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4
Nut, transmission output shaft (C12) . . . . . . . . . . . . . . . . . . . . . . . . . M45 x 1.5 490 50
Bolts, transmission input shaft support cover . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4
Screws, range rear bearing support plate . . . . . . . . . . . . . . . . . . . . . M14 x 1.5 142 14.5
Bolts, cab to rubber mounts SILENT BLOCK . . . . . . . . . . . . . . . . . . – 340 to 420 34.7 to 42.8
Bolts, cab support bracket (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 114 to 148 11.6 to 15.1
Bolts, cab support bracket (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 250 to 309 25.5 to 31.5

(*) Apply a couple of drops of New Holland Thread Sealant 82995768.

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SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 5

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6 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

SPECIAL TOOLS X 293808 Output shaft retaining tool

CAUTION 292313 Reverse idler gear pin puller adapter
Operations described in this Section of the Manual 292927 Slide hammer
must be performed using the following ESSENTIAL 292176 Range input and output shaft end play
tools marked with the identification code (X). test tool (use with tools nos. 50013
To work safely and achieve the best technical results and 50018)
with additional savings of time and effort, these 291051 Range input shaft bearing and gear
mandatory tools should be used in conjunction with puller
the suggested special tools listed below and
X 293869 Output shaft bearing installer
integrated with the self–made ones for which you will
find the necessary construction drawings and X 293992 Installer for assembling bushes on the
specifications directly on this Manual. PTO drive shaft (use with tool no.
293800)
List of special tools necessary to carry out the X 293993 Installer for assembling the shuttle
different operations described in this Section. input shaft to PTO shaft seal (use with
291215 Range control lever spring hook tool no. 293800)
290090 Overhaul rotary stand 293800 Handle
297471 Tractor splitting kit 294000 PTO drive shaft bush puller
293971 Transmission overhaul front bracket 295049 Range output shaft retaining tool
(use with tool no. 290090) X 297396 Range input and output shaft bearing
293972 Transmission overhaul rear bracket adjustment tool. (Prior number
(use with tool no. 290090) NH21–102 and similar to 50018 ). Also
includes Part A of Dealer made tool
293343 Output shaft nut spanner 50013.
X 293805 Input shaft puller (use with tool no.
50062) or output shaft retaining tool

2
Tool to be fabricated for range input and output shaft bearing adjustment (Mark tool with no. 50018 –
Dimensions in mm).
Fabricate tool using Aq 42 material.
NOTE: Dealer made tool 50018 can also be
purchased as Tool Number 297396

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 7

Tool to be fabricated for range input shaft bearing

assembly (Mark tool with no. 50060 – Dimensions in
mm).
Fabricate tool using UNI C30 material.

107
53

60

3
Tool to be fabricated for input shaft bearing
removal(Mark tool with no. 50062 –
Dimensions in mm).
Fabricate tool using UNI Fe 42 C material.

25849

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8 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

Tool to be fabricated for range output shaft bearing

assembly (Mark tool with no. 50061 – Dimensions in
mm).
Fabricate tool using UNI C30 material.

6
Tool to be fabricated for range input shaft taper bearing assembly (Mark tool with no. 50013 – Dimensions in mm).
Fabricate tool using UNI C40 material. – Use only part (a)

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 9

7
Tool to be fabricated to adapt the transmission overhaul front bracket (tool no. 293971). (Mark tool with no.
50110 –Fabricate tool using UNI Fe 42 C material.

8
Tool to be fabricated for location and alignment during engine/transmission housing installation. (Mark tool with
no. 50117 – Dimensions in mm). Fabricate tool using UNI C40 material. Make 2

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10 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

9
Longitudinal Views – 40 KPH Transmission with 5th Speed and Creeper Gears
1. PTO shaft centring bushes 7. Range output shaft
2. Transmission input shaft rear bearing thrust washer 8. Range driven gears
3. PTO drive shaft 9. Range driven gear bushes
4. Range input shaft bearing adjust shims 10. Speed driven gears
5. Range output shaft bearing adjust shims 11. Speed driven gear bushes
6. Thrust washers between driven gears and creeper 12. Shuttle driven gear bearing adjust shims
gears support 13. Transmission output shaft

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 11

10
Longitudinal View – 40 KPH Transmission with 5th Speed and Range Gears
1. Seal 16. High and medium–high range engagement
2. Seal synchroniser
3. O ring 17. 1st and 2nd gear synchroniser
4. Circlip 18. 3rd and 4th gear synchroniser
5. Circlip 19. Spacer
6. Needle Bearing bearing 20. Shuttle driven gear
7. Shuttle synchroniser 21. Circlip
8. Circlip 22. Transmission output shaft
9. Circlip 23. Needle bearing
10. Gear 24. 5th speed driven gear
11. Transmission input shaft 25. 5th speed drive gear
12. Seal 26. 5th gear synchroniser
13. Range input shaft 27. Circlip
14. Range output shaft 28. Shuttle input shaft
15. Low and medium–low range engagement sleeve

NOTE: During installation apply sealant on surfaces marked with an X as detailed on page 30.

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12 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

25853

11
Transmission Control Lever Support Longitudinal Views and Transmission Cross Sections
1. Shuttle control fork 8. O ring
2. Shuttle control inner lever 9. O ring
3. O ring 10. Range control idler lever
4. Fork detent (1) 11. Speed control idler lever
5. Retaining ring 12. Actuating balls and springs
6. Reverse pin 13. Actuating balls and springs
7. Shuttle reverse idler gear

NOTE: During installation apply sealant on surfaces marked with an X as detailed on page 30.

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 13

12
Speed and Range Control Lever Support Cross Section and Solenoid Valve Arrangement
1. PTO brake solenoid control valve 7. Lubrication pressure regulating valve spring
2. PTO solenoid control valve 8. Implement pressure regulating valve spring
3. Diff lock solenoid control valve 9. Solenoid valve pin
4. Inlet fitting 10. Solenoid valve
5. Implement pressure regulating valve 11. FWD engagement solenoid valve.
(16.7 to 17.6 bar – 17 to 18 kg/cm2)
6. Lubrication pressure regulating valve
(6.8 to 8.3 bar – 7 to 8.5 kg/cm2).

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14 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

DESCRIPTION AND OPERATION

The 40 KPH option transmission is fitted with range The range lever shifts through the low and
and shuttle gears and provides a total of 20 forward medium–low ranges by means of a
and 16 reverse speed gears or ratios. When the non–synchronised engagement sleeve and through
creeper option is installed 40 forward and 32 reverse the high and medium–high ranges by means of a
speed ratios are available Transmission controls synchronised sleeve.
consist in three different levers, as follows: The shuttle lever selects the direction of movement
The main shift lever selects five speed gears or of the tractor.
ratios through a synchronised engagement sleeve. NOTE: With the 5th speed gear engaged, an
interlock device prevents the shuttle lever to be
moved to the reverse position.

TROUBLESHOOTING – TRANSMISSION AND RANGE GEARS

Problem Possible Cause Correction
Noisy operation with range lever 1. Input and output shaft support Remove transmission housing and
in neutral and main lever bearing misadjusted adjust bearings (see page 48).
engaged.
2. Failed or defective inner Remove housing, overhaul
component transmission and replace faulty
parts.
3. Internal component seizure Overhaul transmission and top up
due to poor lubrication oil to correct level.
Noisy operation with tractor 1. Faulty clutch plate springs Replace clutch plate.
stationary, idling engine and
transmission in neutral
Self–disengagement of speed, 1. External linkage and levers Adjust correctly.
range and shuttle gears misadjusted.
2. Failed control rail retaining Replace springs.
springs
3. Damaged synchroniser Remove transmission housing and
engagement teeth replace synchroniser.
4. Partial engagement travel Correct reasons for problem and
restore full travel.
Difficult engagement of speed, 1. External linkage and levers Adjust correctly.
range and shuttle gears misadjusted.
2. External levers or linkage stiff Check pivot points and lubricate.
or seized.
3. Central clutch drags See page 4, Section 18.
4. Faulty synchroniser Remove transmission housing and
replace synchroniser.
5. Internal control items (rails, Overhaul control items
forks and sleeves) slide with
difficulty

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 15

MECHANICAL TRANSMISSION HOUSING

Removal – Installation (Op. 21 114 10)

DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity.
Ensure that units or parts are supported by suitable
slings or hooks.
Ensure that no–one is in the vicinity of the load to be
lifted.

1. Detach the negative cable (1) from the battery

and insulate.

13
2. Detach and remove the range and speed control
cables (1) from the rails (2) and brackets (3).

14
3. Detach all connectors from the solenoid valves in
the range and speed control assembly.
NOTE: Before detaching connectors from the control
assembly, mark each connector and respective
solenoid valve.

15

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16 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

4. Detach the shuttle control cable (1) and bracket.

16
5. Remove cab as described in Section 90.
6. Drain and remove fuel tanks.
7. Remove engine as described in Section 10.
8. Disconnect all relevant hydraulic pipework
between transmission, rear axle and hydraulic
pump.
9. Ensure rear axle is fully supported using tractor
splitting kit 297471 or suitable stands positioned
beneath front and rear of rear axle.
WARNING
Do Not attempt to disconnect rear axle from
transmission until the rear axle is adequately
supported.

10. Loosen two bolts from the transmission housing

top cover (1), screw in two eyebolts, secure two
cables and keep them tensioned using a hoist.
11. Loosen the transmission housing to rear axle
housing attaching bolts and remove the housing.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS. 17

12. Fix the transmission housing on the rotary stand

tool no. 290090 using front and rear brackets,
tools nos. 293971 (1) and 293972 (2),
respectively.

18

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 17

20270

19
Pattern for application of sealant during installation of the speed clutch–transmission housing to rear axle housing.
Installation
1. Install the transmission housing to the rear axle
housing and engine observing the following:
– nstallation follows the removal procedure in
reverse.
– Before reassembling housings, supports
and covers, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown above.
– Tighten all bolts to correct torques as detailed
on page 4.

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18 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

MECHANICAL TRANSMISSION
OVERHAUL

Removal–Installation of Speed and Range

Gears (Op. 21 114 85)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

1. Fix the transmission housing on the rotary stand

tool no. 290090 using front and rear brackets,
tools nos. 293971 (1) and 293972 (2),
respectively.

20
2. Loosen retaining bolts and remove upper cover
(1).

21
3. Loosen the cover (1) retaining bolts, position tool
no. 295049 (2) on the transmission housing,
loosen the output shaft locknut using spanner
tool no. 293343 (3) and retrieve cover (1).

22

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 19

4. Remove retaining screws and detach the range

input and output shaft rear bearing support (1).

23
5. Using puller tool no. 291051 (1) and a suitable
insert (2) remove the gear (3) along with the
bearing and bush. Take care to keep the input
shaft bearing off.

24
6. Loosen the plugs (1) and retrieve the actuating
balls and springs. Remove plug (2).

25
7. Withdraw roll pins (1) securing the low and
medium–low range control fork. Withdraw the roll
pins (7) from the two range selector dogs.

23383

26

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20 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

8. Remove the fork (1) along with the engagement

sleeve, slide out the rail (2) and retrieve the
selector dog (3).

27
9. Slide out the control rail (1) and safety pin (2) of
both rails (1) and (2, Figure 28).

28
10. Slide out the medium–low and medium–high
range gears (1 and 2, respectively) along with the
inner bushes and thrust pad (3).

29
11. Remove synchroniser (1) along with the control
fork and output shaft (2).

30

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 21

12. Remove the range input shaft (1).

31
13. Assemble tool no. 293805 (1) using two 20 mm
shims (2) to support the transmission input shaft.

32
14. Withdraw the bearing spring retainer (1) (on both
sides).

33
15. Retrieve clutch engagement bearing (1).

34

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22 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

16. Loosen the screw (1) attaching the fork to the

lever.

35
17. Withdraw the control lever (2) and retrieve the
fork (1).

36
18. Loosen all cover (1) retaining bolts (2).

37
19. Screw in three of the screws (1, Figure 37) into
the threaded holes to separate the cover (1) from
the transmission housing.

38

604.55.111.00 – 06 – 2002
 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 23

20. Loosen the plug (1) and retrieve springs and

actuating pawl.

39
21. Partially punch out the roll pin until releasing the
control lever (3) from the fork (1). Remove control
lever and fork.

40
22. Using a puller withdraw the bearing (1) from the
shuttle input shaft.

41
23. Loosen retaining screws and remove cover (1).
Slide out circlip, seals and locating dowel from
the shaft.

42

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24 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

24. Remove circlip (1), seals and locating dowel.

43
25. Remove the circlip and using adapter tool no.
292313 (1) and slide hammer tool no. 292927
remove the reverse idler gear pin. Leave gear in
place.

44
26. Using a brass punch, push on the rear of reverse
control gear.

45
27. Withdraw the input shaft (1) along with the
reverse gear and shuttle synchroniser from the
front side.

46

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 25

28. Remove circlip (1) from the transmission input

shaft.

47
29. Remove tool no. 293805 from rear side, set the
housing upright and withdraw the input shaft (1).
Retrieve the gear (2), reverse idler gear and
bearing.

48
30. Remove bolts(1).

49
31. Loosen the stop plugs (5), slide out both selector
dog (6) roll pins and the fork internal retaining
spring pin.

50

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26 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

32. Slide out the rails from rear side and retrieve
forks and selector dog.

51
33. Remove the safety pawl (1).

52
34. Loosen the fitting and retaining screw, remove
the output shaft lubrication tube (1).

53
35. Install tool no. 293808 (1) on transmission output
shaft and insert a spanner (2) to hold the shaft in
place.

54

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 27

36. Unstake the transmission output shaft locknut

(1).

55
37. Loosen the transmission output shaft locknut
and retrieve the bush.

56
38. Using an aluminium punch from the front side,
release shaft from bearing.

57
39. Position the transmission housing upright,
withdraw the output shaft (1) and retrieve the
group of gears.

58

604.55.111.00 – 06 – 2002
28 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

Installation
1. Reinstall the mechanical speed and range gears
into the transmission housing observing the
following:
– Reinstallation follows the removal procedure
in reverse, from step 39 back to step 1.
– Refer to figures on pages 10 to 13 for correct
orientation of the different parts.
– Ensure the housing is thoroughly cleaned
(especially inner compartments).
– Check seals and replace if damaged.
– Before reassembling housings, supports
and covers, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the
figure on page 30
– Tighten to correct torques as detailed on
page 4.
– Consider the following operations and
perform adjustments as detailed on pages 31
to 43.
2. After removing the circlip and thrust washer,
disassemble the transmission input shaft
bearings using tools nos. 293805 (1) and. 50062
(2) (see on page 7). Heat the bearings, reinstall 59
them and settle using a brass punch.
3. Mount retaining tool no. 293808 (1) on the
transmission output shaft and insert a spanner
(3) to hold it in place. Support tool (1) using tool
no. 293805 (2) attached to the housing.

60
4. Install front bearing (2) on to the transmission
output shaft using tool no. 293869 (1).

61

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 29

5. Withdraw the PTO shaft seal using puller tool no.

294000 (2) and slide hammer (1).

62
6. Install the seal using tool no. 293993 (3) and
handle tool no. 293800 (1).

63
7. Withdraw the bush (3) as per step 44. Install the
bush (3) using tool no. 293992 (2) and handle
tool no. 293800 (1).

64
8. Remove the range input shaft bearing (2) using
two suitable pullers and an insert (1).

65

604.55.111.00 – 06 – 2002
30 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

9. Heat and Install the bearing (3) on to the input

shaft using tool no. 50060 (2) shown on page 6.
Using tool no. 50013 (1) (see on page 7), keep
the bearing properly seated during cooling.

66
10. Heat and Install the bearing (1) on to the output
shaft using tool no. 50061 (2) shown on page 6.
Using tool no. 50018 (3) (see on page 5) keep the
bearing properly seated on the gear during
cooling.
NOTE: Remove tools nos. 50060 (2, Figure 67) and
50061 (2, Figure 68) when bearings (1 and 3) have
completely cooled down.

67
Pattern for application of sealant during
installation of control rail support (1), upper
cover (2) and front cover (3) to the transmission
housing

68

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 31

MECHANICAL TRANSMISSION HOUSING

Shuttle Gear Bearing Adjustment

WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

Proceed as follows:
1. Remove the circlip (5) and slide out adjust shim
(4), front bearing (3), spacer (2) and rear bearing
(1).

69
2. Reassemble all parts without the adjust shim.
Ensure the assembly is bottoming. Measure
distance (L1) from the top of gear (2) to the
bearing outer race (1).
L1

70
3. Place the gear on a suitable bush (1) to raise the
inner assembly. Ensure also the circlip is raised.

71

604.55.111.00 – 06 – 2002
32 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

4. Measure distance (L2) from the top of gear (2) to

the bearing (1) outer race. Adjust shim (2,
Figure 72) to be added is given by:
S = L1 – L2 – 0.05 mm
where:

L2
S = Adjust shim(2).
L1 and L2 = Readings on the gear
0.05 mm = Decrease necessary to compensate
for bearing increased load deriving from
tightening of the transmission output shaft
locknut.
If necessary, round off the value (S) to the
previous 0.05 mm.
Example: 72
Reading L1 = 10.25 mm.
Reading L2 = 7.33 mm.
Adjust shim:
S = 10.25 – 7.33 – 0.05 = 2.87 mm.
Adjust shim to be assembled is 2.85 mm.
NOTE: Available adjust shims for the shuttle driven
gear are listed on page 3
5. Remove circlip (1), assemble adjust shim (2) as
previously found and lock the assembly
reinstalling circlip (1).

73

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 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 33

MECHANICAL TRANSMISSION HOUSING

Range Input and Output Shaft Taper Bearing

Adjustment
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

Proceed as follows:
1. Install cover (2) without the adjust shim. Install
tool no. 50013 (1) (see page 8) on to the input
shaft.

74
2. Screw installer tool no. 292176 (2) on tool no.
50013 (3). Place a dial indicator (1) with the
stylus touching the bearing inner race. Turn the
shafts to settle the bearing rollers, reset gauge to
zero ensuring that the assembly is bottoming.
Through the lever of installer tool no. 292176 (2),
bring the assembly to touch the cover (4) and read
the travel (L) on the dial indicator.
Adjust shim to be added is given by:
S = L– (0 to 0.06 mm)
where:
S = Adjust shim.
L = Travel reading.
0 to 0.06 mm = input shaft bearing end play. 75
NOTE: Available adjust shims for the range input
shaft bearings are listed on page 3.
3. Dismantle tools (2 and 3), remove cover (4),
assemble the shim as previously found, reinstall
cover (4) and tools (2 and 3). Repeat step 2 to
check end play is to specification, 0 to 0.06 mm.
Remove tools (2 and 3).

604.55.111.00 – 06 – 2002
34 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

4. Install disc (1) with a test shim (Sp). Remove

output shaft lubrication plug.Assemble tool no.
50018 (4) (see on page 6), installer tool no.
292176 (3) and dial indicator (2). Ensure the
indicator stylus is located on the bearing inner
race.

Turn the shafts to settle the bearing rollers and

reset gauge to zero ensuring that the assembly
is bottoming.
Using the lever of installer tool no. 292176 (3)
bring assembly to touch the disc (1) and read
travel (H) on the dial indicator.
Shim to be added is given by: 76
S1 = H + Sp – (0 to 0.06 mm)
where:

S1 = Adjust shim.
Sp = Test shim.
H = Travel reading.
0 to 0.06 mm =Output shaft bearing end play.
NOTE: Available adjust shims for the range output
shaft bearings are listed on page 3.
5. Dismantle tools (3 and 4), remove disc (1),
replace test shim (Sp) with adjust shim (S1),
reinstall disc (1) and tools (3 and 4). Repeat step
4 to check end play is to specification, 0 to 0.06
mm. Remove tools (3 and 4) and screw in the
output shaft lubrication plug.

604.55.111.00 – 06 – 2002
 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 35

MECHANICAL TRANSMISSION HOUSING

Removal–Installation of 5th Speed Gears

(Op. 21 140 14)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

To overhaul the 5th speed gears, it is necessary to

remove the transmission housing following the
procedure detailed on pages 15 to 27. Then proceed
as follows:
1. Fix the transmission housing on the rotary stand
tool no. 290090 using front and rear brackets,
tools nos. 293971 (1) and 293972 (2),
respectively.

77
2. Loosen the retaining bolts and remove the upper
cover (1).

78
3. Slide out the bearing spring retainer (1) (on both
sides)

79

604.55.111.00 – 06 – 2002
36 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

4. Retrieve the clutch engagement bearing (1).

80
5. Loosen the screw (1) attaching the fork to the
clutch control lever.

81
6. Withdraw the control lever (2) and retrieve the
fork (1).

82
7. Loosen all cover (1) retaining bolts (2).

83

604.55.111.00 – 06 – 2002
 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 37

8. Screw in three of the screws (1, Figure 84) into

the threaded holes to separate the cover (1) from
the transmission housing.

84
9. Loosen the screw (1) and retrieve spring and
actuating ball.

85
10. Withdraw the bearing (1) from the shuttle input
shaft using a puller.
11. Remove the control and safety selector dog roll
pins from the 5th speed rail. Withdraw the control
fork along with the rail from the front side.
Retrieve selector dogs.

86
12. Remove circlip (1).

87

604.55.111.00 – 06 – 2002
38 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

13. Retrieve the synchroniser assembly (1), the 5th

speed drive gear along with thrust washer and
seal.

88
14. Loosen the fitting and retaining screw, remove
the output shaft lubrication tube (1).

89
15. Install tool no. 293808 (1) on to the transmission
output shaft and insert a spanner (2) to hold the
shaft in place.

90
16. Unstake the transmission output shaft locknut(1)

91

604.55.111.00 – 06 – 2002
 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 39

17. Loosen the transmission output shaft locknut

and retrieve the 5th speed driven gear.
NOTE: If it is necessary to disassemble the entire
transmission and range gears refer to Page 18.
18. Reinstall the 5th speed gear assembly into the
housing observing the following:
– Reinstallation follows the removal procedure
in reverse, from step 17 back to step 1.
– Refer to figures on pages 8 to 11 for correct
orientation of the different parts.
– Ensure the housing is thoroughly cleaned
(especially inner compartments).
– Check seals and replace if damaged. 92
– Before reassembling the 5th speed gear
assembly, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the
figure on page 30.
– Tighten to correct torques as detailed on
page 4.

604.55.111.00 – 06 – 2002
40 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

SPEED AND RANGE CONTROL RAIL

ASSEMBLY

Removal – Installation (Op. 21 130 30)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the mechanical speed and range control rail

assembly as follows:
1. Detach the negative cable (1) from the battery
and insulate.

93
2. Raise rear tractor, place a stationary stand (1)
under the right hand final drive case and remove
right hand wheel.

94

3. Disconnect speed and range control cables (1)

from rails (2) and supports (3).

95

604.55.111.00 – 06 – 2002
 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 41

4. Detach all electrical connectors (1) from solenoid

valves and sensors.
NOTE: Before detaching connectors from the control
assembly, mark each connector and respective
solenoid valve as well as each connector and
respective sensor to assist reassembly and avoid
reversal of connections.

96
5. Loosen all lines (1) from the speed and range
control rail assembly.

97
6. Loosen two retaining screws and insert two
alignment pins (1) into the holes. Loosen all
retaining screws and remove control assembly.
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

7. Reinstall the mechanical speed and range

control rail assembly to the transmission housing
observing the following:
– Reinstallation follows the removal procedure
in reverse, from step 7 back to step 1.
– Before reassembling the speed and range
98
control rail assembly thoroughly clean and
degrease mating surfaces and apply a 2 mm.
bead of sealant following the pattern shown
in the figure on page 30.
– Tighten to correct torques as detailed on
page 4.

604.55.111.00 – 06 – 2002
42 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

CREEPER GEARS

Removal – Installation (Op. 21 160 50).

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

1. To overhaul the creeper gear assembly it is

necessary to remove the transmission housing. 1
2
2. Fix the transmission housing on the rotary stand
tool no. 290090 using front and rear brackets,
tools nos. 293971 (1) and 293972 (2),
respectively.
3. Remove the circlip (1).

24519

99
4. Retrieve the driven gear assembly (1).

24520
1
100

24521

101

604.55.111.00 – 06 – 2002
 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5 43

5. Loosen retaining screws and remove the creeper 1

gear housing (1).
WARNING
Always use suitable tools to align holes. DO NOT
USE HANDS OR FINGERS.

6. Reassemble the creeper gear assembly

observing the following:
– Reassembly follows the disassembly
procedure in reverse, from step 5 back to
step 1.
– Refer to figures on page 10 to 13 for correct 24522
orientation of different components.
102
– Tighten to correct torques as detailed on
pages 4.
– Ensure the creeper housing (1, Figure 102)
does not disturb the input shaft bearing
cover.
– After reassembling the transmission housing
to the rear axle housing, but before installing
the fuel main tank, carry out the following
adjustment:

CREEPER GEAR ASSEMBLY

Creeper External Control Lever Travel

Adjustment
1. Prior to this adjustment, it is necessary to reinstall
the transmission housing to the rear axle
housing, but the fuel main tank should not be
installed.
Then proceed as follows:
2. Loosen the locknut (1) and loosen the bolt (2) 1
almost completely. Move the external lever (3)
backwards to end of travel. 2
3. Tighten the screw (3) until touching the external
lever (1). Then, screw it in a further 1 1/2 turn and
lock using the locknut (2).
Loosen the locknut (4) and screw in the screw (5) 3
until obtaining a distance (L) = 57 mm between 24523

this screw and screw (3). Tighten the locknut (4). 103

5
2

4
3
24524

104

604.55.111.00 – 06 – 2002
44 SECTION 21 – TRANSMISSION SYSTEMS – CHAPTER 5

NOTES

604.55.111.00 – 06 – 2002