Transmission Planetary. Thickness of five new friction discs and of four new plates. Apply 9S-3263 Thread Lock Compound to the threads of the plugs

Specifications 784C, 785C and 785C HAA Off-Highway Truck/Tractors Power Train

Media Number --06

Publication Date -01/12/2004

Date Updated -10/12/2004

Transmission Planetary

SMCS - 3030 Part Number - 3T-0036

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Illustration 1	g00294372

Table 1
Table For Speed Selector
Speed	Engaged Clutches
Neutral-1	3
Neutral-2	1
Reverse	1 and 6
First Gear	1 and 5
Second Gear	2 and 5
Third Gear	1 and 4
Fourth Gear	2 and 4
Fifth Gear	1 and 3
Sixth Gear	2 and 3

(1) No. 1 clutch

Thickness of five new friction discs and of four new plates ... 54.72 ± 0.72 mm (2.154 ± 0.028 inch)

Thickness of one new 6Y-7220 Friction Disc ... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)

Thickness of one new 6Y-2441 Plate ... 6.73 ± 0.08 mm (0.265 ± 0.003 inch)

(2) No. 2 clutch

Thickness of four new friction discs and of three new plates ... 42.43 ± 0.56 mm (1.671 ± 0.022 inch)

Thickness of one new 6Y-7220 Friction Disc ... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)

Thickness of one new 6Y-2441 Plate ... 6.73 ± 0.08 mm (0.265 ± 0.003 inch)

(3) No. 3 clutch

Thickness of four new friction discs and of three new plates ... 42.43 ± 0.56 mm (1.671 ± 0.022 inch)

Thickness of one new 6Y-7220 Friction Disc ... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)

Thickness of one new 6Y-2441 Plate ... 6.73 ± 0.08 mm (0.265 ± 0.003 inch)

(4) No. 4 clutch

Thickness of three new friction discs and of two new plates ... 30.14 ± 0.40 mm (1.187 ± 0.015 inch)

Thickness of one new 6Y-7219 Friction Disc ... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)

Thickness of one new 9N-4333 Plate ... 6.73 ± 0.08 mm (0.265 ± 0.003 inch)

(5) No. 5 clutch

Thickness of five new friction discs and of four new plates ... 53.20 ± 0.72 mm (2.095 ±0.028 inch)

Thickness of one new 6Y-7218 Friction Disc ... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)

Thickness of one new 9N-4332 Plate ... 6.35 ± 0.08 mm (0.250 ± 003 inch)

Thickness of one new 9N-4331 Plate ... 6.35 ± 0.08 mm (0.250 ± 0.003 inch)

Note: 9N-4331 Plate is the second plate from the piston.

(6) No. 6 clutch

Thickness of six new friction discs and of five new plates ... 65.11 ± 0.88 mm (2.563 ± 0.035 inch)

Thickness of one new 6Y-7218 Friction Disc ... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)

Thickness of one new 9N-4332 Plate ... 6.35 ± 0.08 mm (0.250 ± 0.003 inch)

Thickness of one new 9N-4331 Plate ... 6.35 ± 0.08 mm (0.250 ± 0.003 inch)

Note: 9N-4331 Plate is the third plate from the piston.

(7) Install the baffle with 7M-7260 Liquid Gasket on the face of the bolt.

(8) Torque for 16 bolts ... 115 ± 7 N·m (85 ± 5 lb ft)

(9) Torque for 16 bolts ... 115 ± 7 N·m (85 ± 5 lb ft)

(10) Torque for 17 bolts ... 410 ± 50 N·m (302 ± 37 lb ft)

(11) Lubricate the bore with a small amount of the lubricant that is being sealed.

(12) (13) (14) 4J-1386 Springs

Quantity for No. 1 clutch (12) ... 16

Quantity for No. 2 clutch (13) ... 16

Quantity for No. 3 clutch (14) ... 10

Length under test force ... 35.81 mm (1.41 inch)

Test force ... 110.3 ± 8.9 N (24.8 ± 2.0 lb)

Free length after test ... 43.69 mm (1.72 inch)

Outside diameter ... 19.61 mm (0.772 inch)

(15) (16) (17) 8J-6704 Springs

Quantity for No. 4 clutch (15) ... 12

Quantity for No. 5 clutch (16) ... 6

Quantity for No. 6 clutch (17) ... 6

Length under test force ... 42.06 mm (1.656 inch)

Test force ... 127.2 ± 10.2 N (28.6 ± 2.3 lb)

Free length after test ... 62.51 mm (2.46 inch)

Outside diameter ... 14.22 mm (0.560 inch)

(18) 4M-5016 Springs

Quantity for No. 5 clutch ... 6

Length under test force ... 68.07 mm (2.68 inch)

Test force ... 124.55 ± 9.96 N (28.00 ± 2.24 lb)

Free length after test ... 83.31 mm (3.28 inch)

Outside diameter ... 14.27 mm (0.562 inch)

(19) 2P-5755 Springs

Quantity for No. 6 clutch ... 6

Length under test force ... 86.87 mm (3.42 inch)

Test force ... 113.0 ± 9.0 N (25.4 ± 2.0 lb)

Free length after test ... 123.44 mm (4.86 inch)

Outside diameter ... 14.27 mm (0.562 inch)

(20) Install the gasket with the rubber face against the slinger.

(21) Torque for the six plugs ... 15 ± 3 N·m (11 ± 2 lb ft)

Note: Apply 9S-3263 Thread Lock Compound to the threads of the plugs.

Table 2
Planetary Dimensions
Location	Shaft Diameter	Gear Bore	Carrier Bore
A	42.395 ± 0.006 mm (1.6691 ± 0.0002 inch)	58.298 ± 0.010 mm (2.2952 ± 0.0004 inch)	42.418 ± 0.010 mm (1.6700 ± 0.0004 inch)
B	42.395 ± 0.006 mm (1.6691 ± 0.0002 inch)	51.948 ± 0.010 mm (2.0452 ± 0.0004 inch)	42.418 ± 0.010 mm (1.6700 ± 0.0004 inch)
C	54.417 ± 0.005 mm (2.1424 ± 0.0002 inch)	75.885 ± 0.010 mm (2.9876 ± 0.0004 inch)	54.440 ± 0.010 mm (2.1433 ± 0.0004 inch)
D	47.193 ± 0.008 mm (1.8580 ± 0.0003 inch)	66.274 ± 0.010 mm (2.6092 ± 0.0004 inch)	47.216 ± 0.010 mm (1.8589 ± 0.0004 inch)