JLG 3507 Service Manual page 58

Transmission:
6.5.1 Transmission Removal
WARNING:
injury. NEVER lift a transmission alone; enlist
the help of at least one assistant or use a
suitable hoist or overhead crane and sling.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in the
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Remove the engine cover to allow easier access to
the transmission.
5. Remove the belly pan from under engine.
6. Disconnect the (+) positive and (-) negative battery
cables and remove the battery.
7. Thoroughly clean the transmission and surrounding
area, including all hoses and fittings, before
proceeding.
8. Place a suitable receptacle under the transmission
drain plug (1). Remove the transmission drain plug
and allow the transmission oil to drain into the
receptacle. Repeat drain procedure with the drop
box (2).
1
9. Transfer the used transmission oil into a suitable,
covered container, and label the container "Used
Oil". Dispose of used oil at an approved recycling
facility. Clean and reinstall the transmission drain
plug.
10. Remove the drive shafts. Refer to Section 5.4.3,
"Drive Shaft Removal."
11. Remove the air cleaner unit and intake tubes.
6.4
Risk of severe personal
MZ1380
2
12. Remove the hydraulic pump. Refer to Section 8.7.3,
"Pump Replacement."
13. Label and disconnect the transmission temperature
switch connector and shift solenoid wiring harness
connectors.
14. Label, disconnect and cap the transmission oil
cooler inlet and outlet hoses at the transmission. The
transmission oil cooler outlet hose, routed to the
lower radiator fitting, is located on the top of the
transmission. the transmission oil cooler inlet hose,
routed to the upper radiator fitting, is located on top
of the transmission.
15. Remove the access plug from the side of the engine
bell housing. This will allow access to remove the
eight bolts holding the flex plate to the engine
flywheel.
16. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Remove
them one at a time.
17. Wipe up any spilled hydraulic and transmission oil.
18. Connect a lifting strap or chain to the lifting eye at
the top of the transmission, and to a suitable hoist or
overhead crane. Operate the hoist or crane to
remove slack from the chain, but DO NOT raise the
transmission at this time.
19. Place blocks under the rear of engine for support
BEFORE transmission mounts are removed.
20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.
22. Remove the ten bolts and washers holding the
transmission to the engine.
23. Remove the four capscrews and four lockwashers
securing each rear transmission mount to the
transmission.
24. Remove the two transmission mount from the
machine.
25. Inspect the rubber mounts. Replace the mounts if
damaged.
26. Carefully remove the transmission from the machine.
Avoid causing damage to the transmission or
surrounding parts.
27. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
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