05

2-SPEED POWERSHIFT TRANSMISSION
Specifications .......................................................................................... 5 1
Description ............................................................................................... 5 2
Torque Converter ...................................................................................... 5 2
Transmission ............................................................................................ 5 3
Power Flow ............................................................................................... 5 4
Control Valve ............................................................................................ 5 5
Main Regulator Valve ................................................................................ 5 5
Hydraulic Controls .................................................................................... 5 6
5
Speed Selector System ............................................................................ 5 8
Control System ......................................................................................... 5 9
Removal and Installation ...................................................................... 5 10
Torque Converter .................................................................................... 5 12
Disassembly ............................................................................................. 5 12
Inspection ................................................................................................. 5 13
Reassembly .............................................................................................. 5 16
Transmission ............................................................................................ 5 18
Disassembly ............................................................................................. 5 18
Inspection ................................................................................................. 5 27
Reassembly .............................................................................................. 5 31
Control Valve ............................................................................................ 5 39
Disassembly ............................................................................................. 5 39
Inspection ................................................................................................. 5 40
Reassembly .............................................................................................. 5 41
Main Regulator Valve ............................................................................. 5 42
Disassembly ............................................................................................. 5 42
Inspection ................................................................................................. 5 42
Reassembly .............................................................................................. 5 42
Adjustment ............................................................................................... 5 43
Stall Speed Measurement ......................................................................... 5 47
10 m (33 ft) Start Acceleration Test ........................................................... 5 48
Automatic 2-speed/Fixed 1st Speed Test ............................................. 5 49
Troubleshooting ...................................................................................... 5 50
Service Data ............................................................................................. 5 55
Specifications
Truck Model
DP100 DP115 DP135 DP150
Item
Type 3-element, 1-stage, 2-phase
Torque converter Model MI 16
Stall torque ratio 2.88
Direction control: Electric, column shift

Control
Speed control: Automatic
1st: 1.556
Transmission Forward
2nd: 0.685
Gear ratio
1st: 1.556
Reverse
2nd: 0.685
5-1
Description
Torque Converter
7 5
2
From oil pump

4
1
8
To oil cooler
200550
1. Pilot boss 4. Turbine assembly 7. Pump (impeller)

2. Flexible plate 5. Stator 8. Stator shaft
3. Drive cover 6. Freewheel 9. Input shaft (transmission)
Oil for the operation of the torque converter is from the They allow the engine to turn fast while the truck
oil pump. It goes through outlet passage in the stator wheels are turning slowly. Thus, a high torque can be
shaft to the oil cooler, from which it goes to the applied, and the truck can accelerate. As the truck
transmission lubrication circuit. comes up to speed, the turbine begins to catch up the
The torque converter consists essentially of three pump (to cause the torque converter to act as a fluid
fundamental members: namely, the pump, turbine and coupling). When this happens, the oil leaving the
stator (reaction member). trailing edges of the turbine vanes is moving at about
the same speed as the pump. Now, the oil could pass
The pump is attached to the drive cover which in turn is
directly into the pump in a helping direction, without
driven by the engine through flexible plates. The
being given an assist by the stator. Under these
turbine is splined to the input shaft (of the
conditions, the stator vanes are in the way. The oil
transmission). The stator is attached to the stator shaft,
begins to hit the back sides of the stator vanes. To
with freewheel in between.
allow the stator vanes to move out of the way, the stator
The purpose of the stator is to cause the torque is mounted on a freewheeling mechanism (one-way
converter to multiply torque when the pump is turning clutch) that allows the stator to turn freely, or
faster than the turbine. This speed difference and freewheel, in only one direction.
increase in torque have the same effect as a low gear in
the manual transmission.
5-2
Transmission
9
8
7
2
R2 R1 6
3
F2 F1
207500
1. Flexible plate 4. Countershaft 7. Pump idler gear

2. Torque converter assembly 5. Output shaft 8. Pump drive gear
3. Input shaft 6. PTO drive gear 9. Pump case
The transmission is the powershift type and has two speeds

forward and two speeds reverse. It has four hydraulic
clutches of the disc type.
5-3
Power Flow
Figures in ( ) indicate number of gear teeth.

Forward 1st Reverse 1st
(39)
(60)
(52) (36)
(29)
(42)
(36)
(52)
(50) (56)
Forward 2nd Reverse 2nd
(54)
(52)
(54)
(52)
(37) (37)
205460B
Speed Gears engaged Gear ratio

52 56
1st x 1.556
52 36
Forward
52 37
2nd x 0.685
52 54
56
1st 1.556
36
Reverse
37
2nd 0.685
54
60 39
PTO gear x 0.929
42 60
5-4
Control Valve
2 5
A A
Section A A
4
3
Section B B
B B
C C
Section C C
205461
1. Accumulator valve 3. Inching valve plunger 5. Travel speed (1st/2nd)

2. Direction valve 4. Inching valve valve
Main Regulator Valve
10 9 8
7 6 5 4 3 2 1
200554A
1. Bolts 5. Spool 9. Main pressure port

2. Cover 6. Body 10. Torque converter inlet
3. O-ring 7. Spring pressure port
4. Slug 8. Drain port
5-5
Orifice: Diam. 0.8 mm (0.031 in.) Solenoid valve
(direction selection) Orifice: Diam. 0.8 mm (0.031 in.)
Last chance filter 230 Last chance filter 230
Torque converter
Hydraulic Controls
Solenoid valve
(speed selection)
Chassis area
Diam. 6 mm Solenoid valve

(0.24 in.) Orifice: Diam. 0.8 mm (direction selection)
Oil cooler (0.031 in.)
Last chance filter

230
Oil filter
Torque converter bypass orifice:
Diam. 4.0 mm (0.157 in.) Oil filter for
forward/
reverse
5-6
Pc clutches
Torque converter inlet relief valve Pc (particle size 95 )
Setting: 0.05 to 0.49 MPa Response
(0.5 to 5.0 kgf/cm 2) Tap (plug) for (inching) valve
[7 to 71 psi] torque converter Setting: 0 to 0.22
inlet pressure MPa (0 to 2.2
(marked T) kgf/cm 2)
Pp [0 to 31.3 psi]
Lubrication relief valve Tap (plug) for
Setting: 0.02 to 0.15 MPa main pressure
(marked M) Main orifice: Diam. 2.0 mm
(0.2 to 1.5 kgf/cm 2) (0.079 in.) Accumulator valve
[3 to 21 psi] Pressure at start of
charging: 0.21 MPa
Main regulator valve (2.1 kgf/cm 2) [30 psi]
Lubrication
line Setting: 1.08 to 1.37 MPa
Pressure at end of
(11.0 to 14 kgf/cm 2)
Oil pump charging: 0.71 MPa
[156 to 199 psi]
Capacity: 70 liters (7.2 kgf/cm 2) [102 psi]
(18.5 U.S. gal.)/min
at 2300 rpm
Transmission oil reservoir

Suction strainer with magnet
100 mesh (particle size 220 )
205923
Oil Pressure Taps
PM
PT
PC
PP
210658
PM: Main pressure tap PP: Solenoid valve pilot pressure tap
PT: Torque converter inlet pressure tap PC: Clutch pressure tap
5-7
Speed Selector System
Travel speed select switch
1st speed clutch

Electronic Control Unit Travel speed
Output (solenoid) valve
(ECU)
gear 2st speed clutch
Electric signal
Travel speed sensor
0.5 mm Hydraulic pressure signal
(0.02 in.) Transmission case
Control system
Electronic Control Unit

(ECU)
Travel speed
select switch
Solenoid
valves
Travel speed sensor
210351
Location of components
The speed selector system is made up of an Electronic Unit: km/h (mph)

Control Unit (ECU), a travel speed sensor and a travel Travel speed
speed (solenoid) valve. Select switch
position (mode) DP100, DP135,
The selection of two modes Automatic 2-speed and DP115 DP150
Fixed 1st speed is done manually by means of the travel 0 to 10 0 to 9
speed select switch. 1st
Automatic (0 to 6.2) (0. to 5.6)
2-speed 10 to 26 9 to 27
2nd
(6.2 to 16.1) (5.6 to 16.8)
0 to 12 0 to 13
Fixed 1st speed
(0 to 7.5) (0 to 8.1)
5-8
Control System
R 8
N
F
1
2
10
7
4
5
6 3
210352
1. Transmission shift lever 6. Inching valve plunger

2. Inching bracket 7. Inching lever
3. Control valve 8. Inching cable
4. Travel speed (solenoid) valve 9. Electronic Control Unit (ECU)
5. Direction (solenoid) valve 10. Inching pedal
5-9
Removal and Installation

To remove the transmission assembly from the truck,
remove it together with the engine. Refer to GROUP 4
POWER TRAIN.
Transmission removal
(1) To separate the transmission from the engine, put the
engine on a stable stand, and support the transmission
with wood blocks.
(2) Remove the hydraulic pump from the transmission.
(3) Fasten a hoist to the transmission and lift the
transmission just enough to take the weight of the
transmission. To lift the transmission, tie a sling
around the torque converter housing and install an eye
bolt to the transmission cover, hitching a chain with
lever block to the eye bolt as shown.
(4) Remove the bolts that hold the flexible plates through
the access hole in the torque converter housing.
(5) Separate the transmission from the engine by lifting it
with a hoist.
205464
Torque converter removal

Remove the torque converter as an assembly from the
transmission by separating the stator shaft from the
transmission input shaft
NOTE
Remove the drain plug of the torque converter and
drain the oil.
5-10
Torque converter installation

(1) Couple the torque converter to the transmission. Make
25 mm (0.984 in.)
sure that the distance between the end face of the
torque converter housing and the mating face of the
flexible plate is 25 mm (0.984 in.). If this distance is
more than 25 mm (0.984 in.), it is an indication that
spline engagement between the torque converter stator
shaft and transmission input shaft is improper; re-
couple the torque converter to the transmission.
(2) Lift the transmission, and couple it to the engine.
(3) Make sure that the clearance between the flywheel and
flexible plates is 0 to 2 mm (0 to 0.08 in.) when the
transmission is coupled to the engine.
(4) Tighten the bolts that hold the flexible plates to the
flywheel through the access hole in the torque 200557
converter housing. The bolts should be tightened
evenly in a crisscross pattern. When tightening those
bolts, turn the torque converter with a heavy-duty
screwdriver put to the bolts.
(5) Install the hydraulic pump to the transmission.
(6) Mount the transmission harness.
Travel speed
Connect the travel speed sensor at the connector side, solenoid valve (S1)
and connect the thermounit at the terminal side.
Connect the F and R changeover solenoid valves
respectively to the terminals with F and R
identification marks at their roots.
Connect the travel speed solenoid valve to the terminal
which has no mark. The remaining terminal is for
grounding.
Solenoid Valve Harness Wire Color

Travel speed S1 RY R solenoid valve F solenoid valve
206064
F LgR
Transmission shift lever
R Br
PVC-R tape
NOTE
The transmission harness is common for the 2nd and
3rd speed transmissions. Travel speed Harness A
sensor side side
When the transmission harness is used for the 2nd
speed transmission, ensure that the terminal marked 2 Tie branch wire Cover the terminal
is not covered. (Refer to the illustration shown at onto truck cable. portions fully.
right.) 206250
(7) Pour in the torque converter oil.

5-11
Torque Converter
Disassembly
6
3
7
3
4
205626
Sequence
1. Bolts, Washers, Plate 5. Thrust washers, Thrust bearing
2. Flexible plates, Pilot boss, O-ring, Bolts, 6. Stator, Rollers, Hub, Springs, Spring caps,
Washers Thrust washers
3. Bolts, Drive cover, Ball bearing, Plug, Gasket, 7. Ball bearing, O-ring, Pump boss, Pump
Washers (impeller), Snap ring, Bolts, Washers
4. Spacer, Turbine
5-12
Suggestion for Disassembly

To remove the stator assembly, slightly force the stator just
like turning it counterclockwise to prevent the rollers from
falling and pull the stator together with the hub by sliding
the splines.
204530
Inspection
1. Pump (impeller)
(1) Check for cracks.
(2) Check for oil leaks due to looseness of the bolts holding
the boss to the pump, or defective O-ring.
(3) Check the face of the pump boss in contact with the oil
seal for wear.
(4) Check the face of the pump boss in contact with the
seal ring for wear.
Oil seal O-ring

Seal ring
200561
5-13
2. Stator
(1) Check the blades for cracks. Also check the fit of the
stator on the clutch cam.
(2) Check the clutch hub and cam for wear or flaws.
(3) Check the springs for damage. Also check the spring
caps for wear or distortion.
(4) Check the rollers for flaws, distortion or flat spots due
to wear.
(5) Check the clutch hub splines for defects.
(6) Check the thrust washers for wear or other defects.
A: Standard value B: Repair or service limit

Unit: mm (in.)
A 67.97 to 67.951
Outside diameter of (2.6760 to 2.67523)
clutch hub 1
B 67.8 (2.669)
10.185 to 10.2 3 4 1 2 5 6 7
Diameter of clutch A (0.40098 to 0.402)
rollers 2
B 10.1 (0.398)
A 4.95 to 5
Thickness of thrust (0.1949 to 0.197)
washer 3
B 4.8 (0.189) 200724
A 3.95 to 4
washer 4
B 3.8 (0.150)
A 2.9 to 3
washer 5
B 2.8 (0.11)
A 4.9 to 5
washer 6
B 4.8 (0.189)
A 4.95 to 5
washer 7
B 4.8 (0.189)
5-14
3. Turbine
(1) Check the vanes for cracks.
(2) Check the fit of the turbine boss in the turbine.
(3) Check the turbine boss splines for wear or other
defects.
4. Pilot boss
Check the surface in contact with the pilot bearing for wear
or other defects.
A: Standard value B: Repair or service limit 1
Unit: mm (in.)
0.007 0.00028
Diameter of portion in A 20 0.020 (0.79 0.00079 )
contact with engine
flywheel 1 B 19.85 (0.7815)
200411
5-15
Reassembly
1 10
13
11
4
2
9
3
7 12
13
5
205643
Sequence
1. Pump (impeller) 8. Thrust washer
2. Pump boss, O-ring, Bolts, Washers 9. Thrust bearing, Thrust washers
3. Ball bearing, Snap ring 10. Turbine
4. Stator assembly 11. Drive cover, O-ring, Bolts, Washers
5. Springs, Spring caps 12. Spacer, Ball bearing, Pilot boss, O-ring, Bolts,
6. Rollers Washers
7. Hub 13. Flexible plates, Plate, Bolts, Washers
5-16
Suggestions for Reassembly
1. Stator assembly 5 5
(1) Put hub 7 in the stator as shown. Put spring 5 and
spring cap 5 in each hole, and press in roller 6 while
pushing the spring cap.
6
(2) Install a total of ten rollers, and restore the hub to its
original position.
(3) After having assembled the stator, turn the hub by
hand, making sure that it rotates in only one direction.
7 202885A
2. Selection of spacer
Measure the dimensions A, B and C. Select a spacer equal
to the clearance (dimension D) and put it in position.
A
Part number Thickness of spacer
92322 - 14700 2.9 mm (0.114 in.)
92322 - 14800 3.0 mm (0.118 in.)
92322 - 14900 3.2 mm (0.126 in.) B
D C
92322 - 06600 3.4 mm (0.134 in.) 204534
92322 - 06700 3.5 mm (0.138 in.)
A 26.3 (1.035)
Standard dimensions B 19 (0.75)
mm (in.)
0 0
C 4 0.1 (0.16 0.004 )
3. Flexible plate
After having installed the flexible plate, measure the face
runout of the plates with a dial indicator. Replace the
plates if the runout has exceeded the service limit.
Unit: mm (in.)
A 0.2 (0.008)
Face runout of flexible
plate (in free state)
B 0.5 (0.020)
205922
5-17
Transmission
Disassembly
1. Control valve and external parts
6
10 4
9
2
5
12
3
13
11
18
14
17
15
8
16
210353
Sequence
1. Inching bracket, Spring, Bolts, Washers 11. Bracket, Bolts, Washers
2. Breather 12. Bracket, Bolts, Washers
3. Oil level gauge, Plug 13. Travel speed sensor cover,
4. Oil pipe, Eye bolt, Gaskets Travel speed sensor, Bolts, Washers
5. Oil pipe, Eye bolts, Gaskets 14. Thermounit
6. Oil pipe, O-rings, Bolts, Washers 15. Drain plug, Gasket
7. Oil pipe, O-rings, Bolts, Washers 16. Oil filter
8. Oil pipe, Eye bolt, Gaskets 17. Cover, O-ring, Bolts, Washers
9. Control valve, Gasket, Bolts, Washers 18. Magnet strainer assembly
10. Main regulator valve, Gasket, Bolts, Washers
5-18
2. Transmission cover and shafts
12
13
11
14
10
5
9
4
3
1
2
207501
Sequence
1. Transmission cover subassembly, Gasket, 8. Input shaft subassembly
O-rings, Bolts, Washers 9. Baffle plate, Bolts, Washers
2. Oil seals 10. Output shaft
3. Ball bearing 11. Travel speed sensor gear, Lock plate, Bolts
4. Output gear 12. Ball bearing
5. Snap ring 13. Output gear
6. Baffle plate, Bolts, Washers 14. Snap ring
7. Countershaft subassembly
5-19
Suggestions for Disassembly
1. Transmission cover subassembly 1 removal

Bolts (jack bolts)
Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25
holes in the cover evenly until the cover is approximately
25 mm (1 in.) apart (the bearings get out of place). Then
remove the cover, taking care not to damage the seal rings
of the input shaft and countershaft. Do not attempt to
remove the lubrication line relief valve from the cover.
Special tool needed
Bolt 67284 - 15400

205479
2. Output gear (outside) 4 removal

Remove the output gear together with ball bearing 3 with a Output gear
gear puller.
Sliding hammer
3. Input shaft subassembly 8 and countershaft
subassembly 7 removal
Tap the rear end of the input shaft subassembly 8 to push it
forward. This will also cause the countershaft subassembly
to come off. Remove the countershaft subassembly by
turning it aside the input shaft subassembly. Then remove 205480
the input shaft subassembly.
4. Output shaft 10 removal

Turn a sliding hammer in the M10 x 1.25 hole in the end of
the output shaft, and remove the shaft together with the
output gear, ball bearing and travel speed sensor gear.
5-20
3. Stator shaft and oil pump
20
21
22
19
27
23
16 15 32
26
17
33
18
17
29
28
30
31
25
24
34
205679
Sequence
15. PTO cover, O-ring, Bolts, Washers 25. Oil seal
16. Snap ring 26. Idler gear shaft
17. Pump drive gear, Seal rings 27. Roller bearing
18. Ball bearing 28. PTO drive gear
19. Pump case, O-ring, Bolts, Washers 29. Ball bearing
20. Pump plate, O-ring, Gasket, Bolts, Washers 30. Ball bearing
21. Internal gear 31. Stator shaft, Seal ring, Bolts, Washers
22. Pump gear 32. Pump idler gear
23. Ball bearing 33. Roller bearing
24. Torque converter housing, Gasket, Bolts, 34. Transmission case, Dowels
Washers
5-21
1. Torque converter housing 24 removal

holes in the housing evenly until the housing is
approximately 18 mm (0.7 in.) apart (the PTO drive gear
ball bearing gets out of place). Fasten a hoist to the housing
and remove the housing.
Special tool needed
Bolt 67284 - 15400
2. Oil pump removal

Remove the oil pump as a subassembly including pump
case 19, pump plate 20, internal gear 21 and pump gear 22.
3. Idler gear shaft 26 removal

Turn the Shaft Puller (special tool) in the shaft hole. Install
the sliding hammer (used in removing output shaft 10) to
M20 1.5
this Puller and remove the shaft.
M10 1.25
Special tool needed
26
Shaft puller To be made by dealer
204852
4. PTO drive gear 28 removal

Grip ball bearing 29 with a gear puller. Put a protective
plate on the end of the stator shaft and remove the gear 28
together with two ball bearings
205483
5-22
5. Stator shaft 31 removal

holes in one end of the shaft evenly or hit the other end by
using a protective plate.
Special tool needed
Bolt 67284 - 15400
6. Roller bearing outer race removal

Do not remove the outer race of roller bearing 33 for idler
gear 32 unless it has a defect.
5-23
4. Input shaft subassembly
12
5
13
15
4
3
2 14
1
16
14
15
13
12
11
10
1
6
11 7
11
8
9
10
11
207502
Sequence
1. Seal rings 10. Snap rings, Pressure plates
2. Ball bearing 11. Friction plates, Mating plates
3. Thrust washer 12. Snap rings, Retainers
4. Gear (R2 drive), Needle roller bearing 13. Clutch springs
5. Thrust washer, Snap ring 14. Clutch pistons, Steel balls, Screws,
6. Ball bearing Piston seals
7. Thrust washer 15. Seal rings
8. Gear (R1 drive), Needle roller bearing 16. Input shaft
9. Thrust washer, Snap ring
NOTE
Do not attempt to remove the screws from the input
shaft. It is not necessary to disassemble clutch pistons
14 if the balls move freely in the pistons when the
pistons are shaken.
5-24
1. Input shaft ball bearing 6 removal

Use the special tools to remove ball bearing 6 from the
1
input shaft.
Special tools needed
Ref.
Tool name Part No. Q'ty
No.
Puller 91268 - 13810 2

4 2 3
Plate 91268 - 13820 1 207503
! Bolt F1035 - 10020 2

Unit: mm (in.)
"
Gear puller T-24 1
1 4 11 (0. 2
[BANZAI make] (0.43)
47
)
87)
(7.
200
6
55 ) (0.24)
17
(2.
2 ) ) 2
08 .60 (0. 5
(0. (12 98
)
320 54 )
(3.
90 44)
(2.
62
6
(0.24)
21
(0.83) 1 2 M10 1.25
203541
2. Input shaft disassembling

A
Using the Piston Tool A (special tool) or an arbor press,
compress clutch spring 13 and retainer 12, and remove
snap ring 12.
Special tool needed
Piston tool A 92267 - 00300
207504
5-25
5. Countershaft subassembly
5 12
13
15
4
14
3 16
2
1
14
15
13
12
11
10
6
7
11
11 8
9
10
11
207505
Sequence
1. Seal rings 10. Snap rings, Pressure plates
2. Ball bearing 11. Friction plates, Mating plates
3. Thrust washer 12. Snap ring, Retainer
4. Gear (F2 drive), Needle roller bearing, Spacer 13. Clutch springs
5. Thrust washer, Snap ring 14. Clutch pistons, Steel balls, Screws,
6. Ball bearing Piston seals
7. Thrust washer 15. Seal rings
8. Gear (F1 drive), Needle roller bearing 16. Countershaft
NOTE Suggestion for Disassembly
Do not attempt to remove the screws from the For disassembly, make reference to the disassembly of
countershaft. It is not necessary to disassemble the input shaft.
clutch pistons 14 if the balls move freely in the
pistons when the pistons are shaken.
5-26
Inspection
1. Oil pump
(1) Put the internal gear and pump gear in the pump case,
and measure top clearance 2.
(2) Using a dial indicator, measure side clearance 1
between the gears and pump case.
Unit: mm (in.)
0.040 to 0.078
A 2
(0.00157 to 0.00307)
Side clearance 1
B 0.09 (0.0035) 1
205486
0.3 to 0.345
A
(0.0118 to 0.0136)
Top clearance 2
B 0.35 (0.0138)
2. Stator shaft
(1) Check the splines for wear or damage.
(2) Check the oil passages for clogging.
3. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact, warpage or
excessive wear.
4. Clutch drums
(1) Check the mating plate sliding surfaces for wear or
damage.
(2) Check the clutch piston sliding surfaces for wear or
damage.
5-27
5. Gears
7,8
(1) Check the gear and splines for wear or damage.
(2) Check the gear surface in contact with the needle roller
bearings for wear or damage.
Unit: mm (in.)
2.30.07
A
Thickness of mating (0.0910.0028)
6 2 1 3
plate 1
B 2.1 (0.083)
4
2.60.1
A
Thickness of friction (0.1020.004)
plate 2
B 2.2 (0.087) 5
Free movement of 0.10 to 0.30 207514

A
friction plate on gear 3 (0.0039 to 0.0118)
0.01 0.0004
A 4 0.03 (0.16 0.0012 )
Width of piston seal
ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 )
Width of piston seal
ring groove in piston 5
B 4.5 (0.177)
Free length of clutch 62.9 (2.48)

A
spring 6 k = 39.1 (3.992) [223.5]
Spring constant:
k = N/mm (kgf/mm)
B 60 (2.36)
[lbf/in.]
2.50.05
A
Width of clutch piston (0.0980.0020)
seal ring 7
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch piston
seal ring groove 8
B 3.0 (0.118)
5-28
6. Input shaft and countershaft

(1) Check the seal rings, shaft and case for wear or damage.
Unit: mm (in.)
2.50.05
A
Width of piston seal ring (0.0980.0020)
for input shaft 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of piston seal ring
groove in input shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of stator A 35 0 (1.38 0 )
shaft in contact with seal
ring 3 B 35.2 (1.386)
2.50.05
Width of seal ring for A
(0.0980.0020)
input shaft and
countershaft 4
B 2.0 (0.079)
+ 0.2 + 0.008
Width of seal ring groove A 2.5 + 0.1 (0.098 + 0.004 )
in input shaft and
countershaft 5 B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of A 35 0 (1.38 0 )
transmission cover in
contact with seal ring 6 B 35.2 (1.386)
4,5
1,2
6 3
207506
Remarks: The input shaft is shown. Items other than 1, 2 and 3 are common to the input shaft and countershaft.

(3) Check oil passages for clogging.
5-29
7. Gears
Check each gear for worn teeth or splines.
8. Magnet strainer assembly

Disassemble and clean the strainer. Replace the strainer if
defective.
9. Transmission cover and torque converter housing

oil seals
Replace the oil seals with new ones.
5-30
Reassembly
1. Input shaft subassembly (countershaft subassembly)
6 5 10 9 8 7 4 7 8 4 9 10 5
13
16 6
17 14
15
21
20 19
18 2 3 2 11 12 21 1
207507
Sequence
1. Input shaft or countershaft 12. Needle roller bearing
2. Sealing rings, Piston seals 13. Gear (R1 drive)
3. Pistons 14. Thrust washer
4. Springs 15. Ball bearing
5. Retainers 16. Thrust washer, Snap ring
6. Snap rings 17. Needle roller bearing
7. Mating plates 18. Gear (R2 drive)
8. Friction plates 19. Thrust washer
9. Pressure plates 20. Ball bearing
10. Snap rings 21. Seal rings
NOTE
The countershaft subassembly is similar in reassembly
sequence and suggestions to the input shaft, the only
difference being that the portion carrying the F2 drive
gear is long and has needle roller bearing and spacer
and that the torque converter side does not extend
beyond the ball bearing.
5-31
1. Piston installation
When putting pistons 3 in the clutch drum, apply ATF
(automatic transmission fluid) to their seal ring contact
surfaces.
2. Return spring installation A

Using the Piston Tool A (special tool) or an arbor press,
compress springs 4 and retainers 5, and install snap rings 6.
Special tool needed
Piston tool A 92267 - 00300
207504
3. Friction and mating plate installation Mating plate

(1) Make sure that the position and number of the plates are Friction plate
correct. Install the plates while applying ATF to them.
When replacing the friction plates, replace the mating
plates as a set.
207516
(2) Thrust washer installation

Install thrust washers 11, 14, 16 and 19 with the side
that has oil grooves toward the gear.
203800
4. Piston testing
After having assembled the clutch, apply air pressure of
approximately 690 kPa (7 kgf/cm2) [100 psi] to the oil hole
to make sure that the piston moves freely without any sign
of air leaks.
5-32
2. Stator shaft and oil pump
15 16
12
17
18
19 20
14 3
13 9
1
10
5 11 205680
Sequence
1. Transmission case, Dowels 8. Idler gear shaft 15. Pump plate, O-ring,
2. Roller bearing 9. Roller bearing Gasket, Bolts, Washers
3. Idler gear 10. Oil seal 16. Ball bearing
4. Stator shaft, Seal ring, 11. Torque converter housing, 17. Pump drive gear,
Bolts, Washers Gasket, Bolts, Washers Seal rings
5. Ball bearing 12. Pump case, O-ring, 18. Ball bearing
6. PTO drive gear Bolts, Washers 19. Snap ring
7. Ball bearing 13. Internal gear 20. PTO cover, O-ring,
14. Pump gear Bolts, Washers
NOTE
The dowels fitted into the transmission case have not
been removed. These dowels are for locating the pump
case, torque converter housing and transmission cover
subassembly for installation.
5-33
1. PTO drive gear 6 installation

Install ball bearings 5 and 7 to PTO drive gear 6. Install
the gear to stator shaft 4.
2. Oil seal 10 installation Unit: mm (in.)

Replace the oil seal with a new one. To install the new oil
seal, use the Installer (special tool).
98.5 (3.88)
140 (5.51)
Special tool needed
Oil seal installer To be made by dealer
40 (1.57)
13 (0.51) 8 (0.31)
150 (5.91)
205491
3. Oil pump assembling

Put internal gear 13, pump gear 14 and pump plate 15 in
pump case 12. Apply oil to the internal gear and pump
gear. Do not forget to install the O-ring.
4. Oil pump subassembly installation

Be sure to place the gasket and the O-ring for the oil hole
when installing the oil pump subassembly.
5. Pump drive gear 17 installation

Install ball bearing 16 on pump drive gear 17. Install two
seal rings in position and apply oil to these seal rings. Then
drive the gear assembly into the transmission case with the
splines in alignment with those of pump gear 14.
6. Ball bearing 18 installation

Unit: mm (in.)
2 13 (0.51)
When installing ball bearing 18 in pump case 12, hold the
pump drive gear with the Pump Drive Gear Holder (special
15
tool), or have someone press the gear with a copper bar or

4(
6.0
the like, in order to prevent the gear from coming off.

6)
Special tool needed

4
1
0(
24
Pump drive gear 9)

1
1.5
.9
To be made by dealer 0.3 1)

80
holder (
(4.
10 (0.3
7)
(7.
91
8
09
7)
)
)
0.39 28 0)
10( (1.
1
205492
5-34
3. Shafts and transmission cover
29
30
34
25
33 32 31 26 28 21 22 27 23 24
207508
Sequence
21. Output shaft 29. Input shaft subassembly
22. Snap ring 30. Countershaft subassembly
23. Output gear 31. Output gear
24. Ball bearing 32. Ball bearing
25. Travel speed sensor gear, Lock plate, Bolts 33. Oil seals
26. Snap ring 34. Transmission cover subassembly, Gasket,
27. Baffle plate, Bolts, Washers O-rings, Bolts, Washers
28. Baffle plate, Bolts, Washers
5-35
1. Output shaft 21 assembling and installation

Assemble output shaft 21, snap rings 22 and 26, output
gear 23, ball bearing 24 and travel speed sensor gear 25 in
a subassembly. Install the subassembly in the transmission
case. Use a new lock plate for the bolts that hold the travel
speed sensor gear.
2. Input shaft subassembly installation

Install a total of four seal rings, one on the front side and
three on the rear side. Apply oil to these rings when
installing them.
3. Oil seal 33 installation

Replace two oil seals with new ones. To install these seals, Transmission cover
apply grease to their lips and install them with the Oil Seal
Installer (special tool) with their main lips toward inside.
205494
Special tool needed

Unit: mm (in.)
1 (0.04) chamfer
Oil seal installer To be made by dealer
68.5 (2.70)
94.5 (3.72)
108 (4.25)
(1.57)
40
10 (0.39) 28 (1.10)
170 (6.69)
1.5 (0.06)
205495
5-36
4. Transmission cover installation

Install hooks in the jack bolt holes in the transmission cover
and hitch slings to these hooks. Put the gasket on the
transmission case. Hoist the cover and install it in position.
Apply oil to the servo cases formed of the cover when
installing the cover. Do not forget to put the O-rings in the
oil holes
205496
5-37
4. Control valve and external parts
18
13
9
15
10
17
14
7
16
12
1 5
2 4
11
3
210354
Sequence
1. Magnet strainer assembly 10. Control valve, Gasket, Bolts, Washers
2. Cover, O-ring, Bolts, Washers 11. Oil pipe, Eye bolt, Gaskets
3. Oil filter 12. Oil pipe, O-rings, Bolts, Washers
4. Plug, Gasket 13. Oil pipe, O-rings, Bolts, Washers
5. Thermounit 14. Oil pipe, Eye bolts, Gaskets
6. Travel speed sensor cover, 15. Oil pipe, Eye bolt, Gaskets
Travel speed sensor, Bolts, Washers 16. Plug, Oil level gauge
7. Bracket, Bolts, Washers 17. Breather
8. Bracket, Bolts, Washers 18. Inching bracket, Spring, Bolts, Washers
9. Main regulator valve, Gasket, Bolts, Washers
5-38
Control Valve
Disassembly
1
1
2 3
5
9
14 8
2
10
4
11
14
3 13
15
1 6
12
11
11
10 205473
Sequence
1. Solenoid valves, O-rings 8. Inching valve, Spring, Slug 12. Oil seal
2. Speed valve, Solenoid spring 9. Roller bearing, Plug, O-ring 13. Oil filter
3. Springs, Direction valve 10. Plate, O-ring, Bolts, Washers 14. Plugs, O-rings
4. Plug, O-ring, Roller bearing 11. Accumulator piston, 15. Valve body, Gasket
5. Oil filter, O-rings Spring guide,
6. Stopper pin, O-ring Springs (outer and inner)
7. Inching valve plunger, Spring
CAUTION
Slowly loosen each bolt and solenoid valve so that
the spring and plunger do not suddenly jump out.
5-39
Suggestion for Disassembly
Stopper pin 6 removal

Turn a screw in the M4 x 0.7 hole in the stopper pin 6 and
carefully remove the pin because removal of the stopper pin
will cause inching valve plunger 7 to fly out.
Inspection
(1) Check the oil holes in the valve body for restriction.
(2) Check each plunger for wear or damage. Make sure the
plunger moves freely.
(3) Check the orifice in the inching valve for restriction.
Also check the inching valve spring for damage.
Measure free length.
(4) Replace oil seal 12 with a new one.
200220
(5) Replace filter 13 with a new one.
(6) Wash filter 5, or replace it with a new one.
Unit: mm (in.)
Free length of speed valve 87.5 (3.44)
A 1
spring 1 k = 3.88 (0.396) [22.1]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 85 (3.35)
2
Free length of direction valve 32.5 (1.26)

A
springs 2 k = 8.61 (0.8786) [49.2]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 31.5 (1.24)
2
3
Free length of inching valve 39 (1.53)
A
spring 3 k = 2.12 (0.217) [12.1] 4
Spring constant:
6
28 (1.10) 5
Free length of return spring 4 A
k = 0.478 (0.0488) [2.73]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] 205699
B 26.5 (1.04)
Free length of accumulator 109.5 [4.31]

A
valve outer spring 5 k = 6.38 (0.651) [36.4]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 107.5 [4.23]
Free length of accumulator 154 (6.06)

A
valve inner spring 6 k = 6.86 (0.6998) [38.6]
Spring constant:
5-40
Reassembly
1 15
14
13 A A
Section A A
13
12
11
10
3
8
7
Section B B 9 B
B
16
C C
6 4
Section C C 5
210192
Sequence
1. Valve body 9. Spring, Inching valve plunger
2. Oil filter 10. Stopper pin, O-ring
3. Oil seal 11. Oil filter, O-ring
4. Plate, O-ring 12. Spring, Direction valve
5. Accumulator piston, Springs (inner and outer), 13. Solenoid valves
Spring seat 14. Plug, O-ring, Roller bearing
6. Plate, O-ring 15. Spring, Travel speed valve, Solenoid valve
7. Plug, O-ring, Roller bearing 16. Plug, O-ring
8. Inching valve, Spring, Slug
Start by:
Clean the oil passages in the control valve thoroughly and
make sure they are not restricted.

(1) Replace oil seal 3 with a new one.
(2) Apply ATF (automatic transmission fluid) to the valves
and plungers when installing them in the valve body.
5-41
Main Regulator Valve
Disassembly
5
2
6 4 3
210180
Sequence
1. Cover, O-ring, Bolts, Washers 4. Spring
2. Slug 5. Cover, O-ring, Bolts, Washers
3. Spool 6. Body
CAUTION
Slowly loosen bolts 1 so that the spring, spool
and slug do not suddenly jump out.
Inspection Reassembly
(1) Check the oil holes in the valve body for To reassemble, follow the reverse of disassembly
restriction. sequence.
(2) Check the valve spool for wear or damage. Make
sure the spool moves freely. Suggestion for Reassembly
(3) Check the spring for damage. Measure the free
Apply oil to the spool and slug when putting them in
length of the spring.
the body.
Unit: mm (in.)
Free length of main 112 (4.41)
A
regulator valve spring k = 4.99 (0.5087) [28.5]
Spring constant:
k = N/mm (kgf/mm)
B 109 (4.29)
[lbf/in.]
5-42
Adjustment
Brake pedal and inching pedal adjustment

Adjust the brake pedal before adjusting the inching pedal.
1. Brake pedal adjustment
190 mm (7.5 in.)

Bring the roller 1 of the brake pedal into contact with the 1
pedal 2 of the brake control valve 2 by means of the
adjusting bolt 4. Under this condition, the top height of the 4
3
pedal from the floor level will be approximately 190 mm
(7.5 in.).
NOTE: The set angle (391.5) of the brake valve must be 2

kept unchanged. 210611
2. Inching pedal adjustment 6 mm

(0.24 in.) 4
(1) With the clutch valve plunger 1 pushed in all the way
3 1 2
[6 mm (0.24 in.) allowed for protrusion], attach the
transmission side return spring 2 to the inching lever 3
and inching bracket 4.
5
(2) Connect the inching cable 5 to the inching bracket 4,
then attach the clevis 6 to the inching lever 3.
6 210612
(3) Attach the pedal side turnbuckle 7 to the inching pedal

12
arm 8 and vehicle body side inching lever 9. Be sure
190 mm (7.5 in.)
11
that turnbuckle clevis pin holes are approximately 272
A
mm (10.7 in.) apart center to center.
(4) Attach the return spring 10 between the vehicle body 13
14
side inching lever 9 and seat frame. 8 7 10 9
(5) Tilting the inching pedal 11, adjust the clearance A
between cam follower 12 and brake pedal valve 13 to
14.5 mm (0.571 in.), then hold the inching pedal 11 in
that position with the adjusting bolt 14. Under this
condition, the top height of the inching pedal 11 from
the floor level will be approximately 190 mm (7.5 in.). 272 mm (10.7 in.)
210613
5-43
(6) Attach the inching cable 15 to the vehicle body side 9 mm

inching lever 9 and bracket 16. (0.35 in.)
12 1
(7) With the clearance A set at 14.5 mm (0.571 in.)
A
between cam follower 12 and brake valve pedal 13,
adjust the protrusion of clutch valve plunger 1 to 9 mm
(0.35 in.) with the turnbuckle 7. 13 7
9
16
15
210614
(8) Depress the inching pedal 11 and make sure that the
protrusion of clutch valve plunger 1 is 11.50.5 mm 11.50.5 mm
(0.4530.020 in.) when the cam follower 12 touches (0.4530.020 in.)
11 1
the brake valve pedal 13. If the 11.50.5 mm
(0.4530.020 in.) cannot be obtained, adjust the length 12
of the turnbuckle 7.
13
210615
(9) Depress the inching pedal 11 all the way and make sure
that the protrusion of clutch valve plunger 1 is 19.51 19.51 mm
(0.7680.039 in.)
mm (0.7680.039 in.). Then, tighten the lock nut of
1
the turnbuckle 7 and adjusting bolt 14.
11
14
210616
5-44
Oil Pressure Measurement
NOTE
Front tires rotate during the measurement. Build a
fence around the vehicle to prevent access to it.
NOTE: Always perform pedal adjustments before oil

pressure measurement.
1. Main oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure
Main pressure
gauge to the main oil pressure outlet of the regulator tap (M)
valve.
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17713 210617
NOTE: Parts marked with an asterisk (*) are included

in the gauge kit 64309 - 17701.
(2) Idle the engine and check that the transmission oil is up
to the specified level.
(3) Warm up the engine to raise the transmission oil
temperature.
(4) Keep the engine idling (at between 1000 and 1500
rpm).
(5) Under the above condition, perform the oil pressure
measurement.
A: Standard value
Main oil pressure 1.08 to 1.37 MPa

(with engine idling at A (11 to 14 kgf/cm2)
1500100 rpm) [157 to 199 psi]
NOTE: Monitor the idling speed through engine

tachometer during measurement.
5-45
2. Clutch Oil Pressure Measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure
Clutch pressure tap (Pc)
gauge to the clutch oil pressure outlet port of the
selector valve.
NOTE: Use the same special tools as used for main oil
pressure measurement.
(2) Lift the front tires off the floor by either of the
following methods.
210618
(a) The front axle housing is jacked up.
(b) The mast is tilted all the way backward first. With
a wooden block applied under the outer mast, the
mast is tilted forward to lift the front tires. Then,
an appropriate stand or square timber is placed
under the frame to keep the front tires lifted.
(3) Put scotch blocks under the rear tires.
(4) Implement the steps (2) through (4) of main oil pressure
measurement. End face of control valve body
(5) Place the transmission shift lever into the FORWARD

position, then release the parking brake.
(6) Depress the inching pedal gradually to pull out the
clutch (inching) valve plunger pushed all the way in.
Record pressure fluctuations with plunger stroke in the
meantime and make sure that the oil pressure change
patterns as shown at the left.
B
Reference data A
MPa (kgf/cm2) [psi]
1.23
Pedal height (from frame top surface 190 mm
Clutch pressure,
(12.5)
to uppermost end of pedal) (7.5 in.) [178]
0.22
(2.2)
Clearance between inching cam 14.5 mm 10.5 7 [31]
(0.41) (0.28)
follower and brake valve (0.571 in.)
0
15 10 5 2
Plunger protrusion A when inching 9 mm (0.59) (0.39) (0.20) (0.08)
pedal is not depressed (0.35 in.) Clutch valve plunger stroke, mm (in.)
210619
Plunger protrusion B when brake 14 mm
begins to work (0.55 in.)
5-46
3. Torque converter inlet oil pressure measurement

Torque converter
(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure inlet pressure tap (T)
gauge to the torque converter inlet oil pressure inlet
port of the regulator valve.
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731

210620
*Gauge 64309 - 17713
NOTE: The parts marked with an asterisk (*) are

included in the gauge kit 64309 - 17701.
(2) Idle the engine and check that transmission oil is up to

the specified level.
(3) Warm up the engine to raise the transmission oil
temperature.
(4) Keep the engine idling (at between 1000 and 1500
rpm), measure the torque converter inlet oil pressure.
A: Standard value
Torque converter inlet

oil pressure 0.05 to 0.49 MPa
A (0.5 to 5 kgf/cm2)
(with engine idling at
1500100 rpm) [7 to 71 psi]
NOTE: Monitor the idling speed through engine

tachometer during measurement.
Stall Speed Measurement

(1) With the engine running at low idle, check to make sure
that the oil level is correct in the transmission case.
(2) Warm up transmission oil.
(3) Block the front and rear wheels, and apply the parking
brake.
(4) Run the engine at low idle.
5-47
(5) Move the transmission shift lever to the forward

position, and gradually depress the accelerator pedal all
the way. Under this condition, measure the stall speed
with an engine tachometer.
Stall speed
1760 rpm
(tolerance: 100 rpm)
CAUTION
Do not attempt to depress the inching pedal. Do
not continue operation in stall condition for more
than 30 seconds. A failure to follow this
precaution would result in destruction of the
torque converter.
(6) Similarly measure the stall speed for reverse drive.
NOTE
(a) Any stall speed within 100 rpm tolerance of the
specification is satisfactory.
(b) If the engine or torque converter is changed, the
stall speed will vary since the stall speed is
determined by the combination of engine and
torque converter.
10 m (33 ft) Start Acceleration Test

(1) Stand ready to start with the engine running at low idle,
the transmission shift lever in the neutral position and
the travel speed select switch in Automatic 2-speed
position.
(2) At the signal, move the transmission shift lever to the
forward position and, at the same time, depress the
accelerator pedal fully.
(3) Measure the time required for the truck to travel 10 m
(33 ft) with a stopwatch.
(4) Conduct the same test for reverse travel, too.
Travel time (no load) 5 seconds, maximum
5-48
Automatic 2-speed/Fixed 1st Speed

Test
Move the travel speed select switch mounted on the console
box to each position, and make sure that the speed selector
system functions properly. Move the switch when the truck
is at standstill.
DP100, DP115
(1) In the Fixed 1st speed position, the truck runs at a
maximum speed of 12 km/hr (7.5 mph) and a greater
torque is available.
(2) In the Automatic 2-speed position, the transmission
Travel speed select switch
automatically shifts from the 1st to the 2nd speed when
the travel speed reaches 10 km/hr (6.2 mph) to allow 205698A
the truck to run at a maximum speed of 26 km/hr (16.1
mph).
DP135, DP150
(1) In the Fixed 1st speed position, the truck runs at a
maximum speed of 13 km/hr (8.1 mph) and a greater
torque is available.
(2) In the Automatic 2-speed position, the transmission
automatically shifts from the 1st to the 2nd speed when
the travel speed reaches 9 km/hr (5.6 mph) to allow the
truck to run at a maximum speed of 26 km/hr (16.1
mph).
5-49
Troubleshooting
Engine Poor performance Tune up engine.
Oil level too low Refill.

Air being sucked in on suction side Retighten or replace gasket.
Main regulator valve not operating Repair or replace.
properly
Main regulator valve spring fatigued Replace.
Oil pump gears worn, resulting in Overhaul and check or
Torque
converter reduced capacity replace defective parts.
Magnet strainer clogged Replace.
Seal rings or O-rings worn Replace after measuring oil
pressure.
Stator freewheel seized Replace stator assembly,
hub and roller.
Not enough Blades of running members damaged Repair or replace. Replace
output power or rubbing bearing.
Air being sucked in on suction side Retighten or replace.

Outlet pressure too low to suppress Readjust.
internal foaming
Water in oil Replace oil.
Transmission Main pressure too low, resulting in Readjust after measuring
slipping clutches oil pressure.
Seal rings or O-rings worn Replace after measuring oil
pressure.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.
Wheels High mechanical resistance Check and adjust brake

system.
5-50
Flexible plate broken Replace.

Torque
converter Oil pump drive defective Replace.
Turbine shaft broken Replace.
Main pressure too low Check pump gears for wear
or replace.

Inching pedal link maladjusted Readjust.
Seal rings worn in servo case Replace.
O-rings on input shaft worn Replace.
Plug on input shaft loose or slipped Repair.
No power
flow off, resulting in oil leaks
Clutch seized Replace.
Transmission
Shafts broken Replace.
Clutch drum, particularly snap ring Replace.
groove, defective
Snap ring fitted to clutch drum Replace.
broken
Oil line to clutch piston clogged Clean or replace.
Shaft splines worn Replace shafts.
Power train Broken parts in reduction and Refer to each section.

differential or front axle
Flexible plates broken Replace.

Bearings damaged Replace.
Torque Rubbing vanes of running members Replace.
converter Bolts loose Retighten or replace.
Splines worn Replace.
Oil pump worn Inspect or replace.
Abnormal
noise
Clutch seized and dragging Replace clutch plate.
Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
Splines worn Replace.
5-51
Oil strainer clogged Clean or replace.

Main regulator valve spool defective Wash or replace.
Restriction in oil pipe Replace.
Loud noise
Oil too viscous in cold weather Replace oil. *
Instruments out of order Replace.
Improper oil used Replace oil. *
Abnormal
noise Oil strainer clogged Clean or replace.
Oil pump defective Replace.
Excessive oil leaks
Main regulator valve spring Replace.
defective
Low noise
Main regulator valve spool Repair or replace.
defective
Air being sucked in Retighten or replace
packing.
Leaking oil seals Check lips and sliding surfaces for

wear. Replace seals.
Leaking joint of case Retighten or replace packing.
Leaking pipe connection or joint Repair or replace pipe, gasket and
O-rings.
Leaking drain plug Retighten or replace gasket.
Oil leaks Cracks or blowholes in case Replace.
Oil blowing out of transmission case
Air being sucked in on suction side Replace packing and retighten.
Oil leaks from air breather Repair.
Oil level too high Lower oil level.
* (Refer to Recommended Brands of Lubricants.)
5-52
Oil level too high or too low Keep correct oil level.
Oil strainer clogged Clean or replace.
Rubbing vanes of running members Repair or replace.
Stator freewheel defective Replace stator assembly.
Torque
converter O-ring.
Restriction in oil pipe (resulting in Repair or replace.
reduced circulation flow)
Bearings worn or seized Repair or replace.
Instruments out of order Replace.
Oil
temperature
is too high
Clutches dragging Replace clutch plates.
Transmission Bearings worn or seized Repair or replace.
Control linkage defective Repair or replace.
Truck not operated properly Advice user to drive truck

Others properly.
Others
Cooling fan belt damaged Replace.
Oil cooler clogged Clean or replace.
Brakes grabbing Check and readjust.
Main regulator valve defective Repair or replace valve assembly.

Main pressure is too
high Oil viscosity too high in cold weather Replace oil. *
Improper oil used Replace oil. *
Magnet strainer clogged Clean or replace.

Oil pump defective Replace.
Coil spring defective in main regulator valve Replace.
Main pressure is too Main regulator valve spool defective Repair or replace.
low Air being sucked in Retighten or replace packing.
Control linkage defective Repair or replace.
Inching valve out of order Repair or replace.
* (Refer to Recommended Brands of Lubricants.)
5-53
Magnet strainer clogged Clean or replace.

Oil pump worn or defective Replace.
Coil spring defective in main regulator valve Replace.
Main regulator valve spool defective Repair or replace.
Clutch pressure is too packing.
low
Control linkage out of order Repair or replace.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch seal rings broken Replace.
Lack of engine power if the speed is slightly low in Tune up engine.

both forward and reverse drive
Stall speed out of
specification Stator and freewheel defective if the speed is Replace stator assembly.
excessively low in both forward and reverse drive
Inching pedal linkage defective, or clutch slipping Repair or replace.
if the speed is too high
Travel speed select switch in Fixed 1st speed Move switch to Automatic
position 2-speed position.
Solenoid valve defective Replace.
No automatic shifting
Solenoid valve inlet orifice clogged Clean or replace.
Solenoid valve spool or spring defective Repair or replace.
ECU control box internally defective Check or replace.
Transmission shifts up Harness open Repair.

when travel speed select
switch is in Fixed 1st
speed position Travel speed select switch defective Replace.
5-54
Service Data
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Stall speed (tolerance: 100 rpm) rpm A 1760
Main pressure (engine at 1500100 rpm) MPa (kgf/cm2) [psi] A

1.08 to 1.37 (11 to 14) [156.4 to 199]
Clutch pressure (engine at 1500100 rpm) MPa (kgf/cm2) [psi] A
Torque converter inlet pressure (engine at 1500100 rpm)

A 0.05 to 0.49 (0.5 to 5.0) [7 to 71]
MPa (kgf/cm2) [psi]
Lubrication line pressure (engine at 1500100 rpm)

A 0.02 to 0.15 (0.2 to 1.5) [3 to 21]
MPa (kgf/cm2) [psi]
10 m (33 ft) start acceleration (no load) A 5 seconds, maximum

0 0
A 100 0.035 (3.94 0.00138 )
Diameter of portion in contact with oil seal 1
B 99.85 (3.9311)
Pump boss
200721
0.007 0.00028
A 20 0.020 (0.79 0.00079 )
Diameter of portion in contact with engine flywheel 1
B 19.85 (0.7815)
Pilot boss
1
200411
5-55

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 0.040 to 0.078 (0.00157 to 0.00307)
Side clearance 1
B 0.09 (0.0035)
A 0.3 to 0.345 (0.0118 to 0.0136)
Top clearance 2
B 0.35 (0.0138)
Oil pump
1 205486
A 67.97 to 67.951 (2.6760 to 2.67523)

Outside diameter of clutch hub 1
B 67.8 (2.669)
A 10.185 to 10.2 (0.40098 to 0.402)
Diameter of clutch rollers 2
B 10.1 (0.398)
A 4.95 to 5 (0.1949 to 0.197)
Thickness of thrust washer 3
B 4.8 (0.189)
A 3.95 to 4 (0.1555 to 0.157)
B 3.8 (0.150)
A 2.9 to 3 (0.114 to 0.118)
B 2.8 (0.110)
A 4.9 to 5 (0.193 to 0.197)
B 4.8 (0.189)
Stator A 4.95 to 5 (0.1949 to 0.197)
B 4.8 (0.189)
3 4 1 2 5 6 7
200724
5-56

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Face runout of flexible plates 1 A 0.2 (0.008)
(in free state) B 0.5 (0.020)
Distance between end face of torque converter
A 25 (0.984)
housing and mating face of flexible plate 2
Flexible 2
plates
1
200725
A 2.30.07 (0.0910.0028)
Thickness of mating plate 1
B 2.1 (0.083)
A 2.60.1 (0.1020.004)
Thickness of friction plate 2
B 2.2 (0.087)
Free movement of friction plate on gear 3 A 0.10 to 0.30 (0.0039 to 0.0118)
0.01 0.0004
A 4 0.03 (0.16 0.0012 )
Width of piston seal ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 )
Width of seal ring groove in piston 5
B 4.5 (0.177)
62.9 (2.48)
Free length of clutch spring 6 A
k = 39.1 (3.992) [223.5]
Clutches Spring constant: k = N/mm (kgf/mm) [lbf/in.]
B 60 (2.36)
6 2 1 3
5
210220
5-57

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
A 2.50.05 (0.0980.0020)
Width of piston seal ring for input shaft 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of piston seal ring groove in input shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of stator shaft in contact with seal A 35 0 (1.38 0 )
ring 3 B 35.2 (1.386)
A 2.50.05 (0.0980.0020)
Width of seal ring for input shaft and countershaft 4
B 2.0 (0.079)
+ 0.2 + 0.008
Width of seal ring groove in input shaft and A 2.5 + 0.1 (0.098 + 0.004 )
countershaft 5 B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of transmission cover in contact A 35 0 (1.38 0 )
with seal ring 6 B 35.2 (1.386)
Width of clutch piston seal ring for input shaft and A 2.50.05 (0.0980.0020)
Input shaft, countershaft 7 B 2.0 (0.079)
countershaft + 0.2 + 0.008
and Width of clutch piston seal ring groove in input A 2.5 + 0.1 (0.098 + 0.004 )
transmission shaft and countershaft 8 B 3.0 (0.118)
cover
4,5 1,2
6 7,8 3
210218
Remarks: The input shaft is shown. Items other than 1, 2 and 3 are common to the input shaft and
countershaft.
5-58
A: Standard value
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Input gear and counter gear 1 A 0.12 to 0.28 (0.0047 to 0.0110)
Forward 1st speed gear and reverse 1st

A
speed gear 2
0.13 to 0.32 (0.0051 to 0.0126)
Forward 2nd speed gear and reverse 2nd
A
speed gear 3
Pump drive gear and idler gear 4 A

0.12 to 0.26 (0.0047 to 0.0102)
PTO drive gear and idler gear 5 A
4 5
3 2
Backlash of
gears R2 R1
F2 F1
2
210217
5-59

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
87.5 (3.44)
A
Free length of speed valve spring 1 k = 3.88 (0.396) [22.1]
Spring constant: k = N/mm (kgf/mm) [lbf/in.]
B 85 (3.35)
32.5 (1.28)
A
Free length of direction valve springs 2 k = 8.61 (0.8786) [49.2]
B 31.5 (1.24)
39 (1.53)
A
Free length of inching valve spring 3 k = 2.12 (0.217) [12.1]
B 38 (1.49)
28 (1.10)
A
Free length of return spring 4 k = 0.478 (0.0488) [2.73]
B 26.5 (1.04)
109.5 (4.31)
A
Free length of accumulator valve outer spring 5 k = 6.38 (0.651) [36.4]
B 107.5 (4.23)
154 (6.06)
A
Control Free length of accumulator valve inner spring 6 k = 6.86 (0.6998) [38.6]
valve Spring constant: k = N/mm (kgf/mm) [lbf/in.]
B 152 (5.98)
2
3
210208
5-60

Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
112 (4.41)
A
Free length of main regulator valve spring 1 k = 4.99 (0.5087) [28.5]
B 109 (4.29)
Main
regulator
valve
1
210181
Inching pedal height (from frame to top end of

A 190 (7.48)
pedal) 1
Clearance between inching pedal cam follower and

A 14.5 (0.57)
brake control valve pedal 2
Protrusion of inching plunger with inching pedal

A 9 (0.35)
released 3
Protrusion of inching plunger when brake starts to

A 14 (0.55), minimum
be applied 4
Inching
pedal
control
2
3
4
210358
5-61

05

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2-SPEED POWERSHIFT TRANSMISSION

Torque converter Model MI 16

Stall torque ratio 2.88

Direction control: Electric, column shift

From oil pump

1. Pilot boss 4. Turbine assembly 7. Pump (impeller)

1. Flexible plate 4. Countershaft 7. Pump idler gear

The transmission is the powershift type and has two speeds

Figures in ( ) indicate number of gear teeth.

Forward 2nd Reverse 2nd

Speed Gears engaged Gear ratio

1. Accumulator valve 3. Inching valve plunger 5. Travel speed (1st/2nd)

Main Regulator Valve

1. Bolts 5. Spool 9. Main pressure port

Last chance filter 230 Last chance filter 230

Diam. 6 mm Solenoid valve

Last chance filter

Transmission oil reservoir

Oil Pressure Taps

Speed Selector System

Travel speed select switch

1st speed clutch

Electronic Control Unit

Travel speed sensor

The speed selector system is made up of an Electronic Unit: km/h (mph)

1. Transmission shift lever 6. Inching valve plunger

Removal and Installation

Torque converter removal

Torque converter installation

Solenoid Valve Harness Wire Color

(7) Pour in the torque converter oil.

Suggestion for Disassembly

Oil seal O-ring

A: Standard value B: Repair or service limit

Suggestions for Reassembly

92322 - 06700 3.5 mm (0.138 in.)

2. Transmission cover and shafts

Suggestions for Disassembly

1. Transmission cover subassembly 1 removal

Bolt 67284 - 15400

2. Output gear (outside) 4 removal

4. Output shaft 10 removal

3. Stator shaft and oil pump

Suggestions for Disassembly

1. Torque converter housing 24 removal

Bolt 67284 - 15400

2. Oil pump removal

3. Idler gear shaft 26 removal

4. PTO drive gear 28 removal

5. Stator shaft 31 removal

Bolt 67284 - 15400

6. Roller bearing outer race removal

4. Input shaft subassembly

Suggestions for Disassembly

1. Input shaft ball bearing 6 removal

 Puller 91268 - 13810 2

Plate 91268 - 13820 1 207503

! Bolt F1035 - 10020 2

2. Input shaft disassembling

Piston tool A 92267 - 00300

NOTE Suggestion for Disassembly

3. Friction plates and mating plates

Puller 91268 - 13810 2