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Regal Velvet Drive 71L Series Service Manual

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Marine Transmission
Service Manual
71L & 72L Series
A Regal Brand

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Summary of Contents for Regal Velvet Drive 71L Series

  • Page 1 Marine Transmission Service Manual 71L & 72L Series A Regal Brand...
  • Page 3 Models Covered In This Manual Transmission Ratios Transmission Family Assembly Group Forward Reverse Comments Number 3007000M01 1.10:1 MANUAL SHIFT 3007000E01 1.10:1 ELECTRIC SHIFT 3008000M01 72LV 1.50:1 1.65:1 MANUAL SHIFT V-DRIVE (FRONT MOUNT) 3008000M02 72LV 1.25:1 1.37:1 MANUAL SHIFT V-DRIVE (FRONT MOUNT) 3008000M03 72LV 2.00:1...
  • Page 4 Table of Contents SEGMENT A: 71L & 72L / 71LV & 72LV SEGMENT C: 72LH & 72LHP Section Page Section Page Description Overhaul Introduction Assembly Theory of Operation Installation Inspection Specification General Propeller Shaft Alignment Scheduled Inspection Rebuild Kits Maintenance General Lubrication Troubleshooting...
  • Page 5 Table of Contents Title Page List of Tables Technical Specifications Models 3007, 3008, 3011, 3018 & 3019 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Technical Specifications Models 3009 &...
  • Page 6 SEGMENT A 71L & 72L / 71LV & 72LV 71L AND 72L 72LX 71L AND 72L 72LX 71LV AND 72LV The following international symbols are used in this service manual. WARNING This symbol warns of possible personal injury CAUTION This symbol warns of possible damage to transmissions . Original Equipment Manufacturer (Boat/Engine Manufacturer) ®...
  • Page 7 Section I Description ID TAG ID TAG ID TAG 71L AND 72L 72LX 72LH AND 72LHP 3007 & 3019 3011 3010 & 3009 ID TAG ID TAG 71LV AND 72LV 71LVTS AND 72LVTS 3018 & 3008 3018 & 3008 Figure 1. 71L & 72L Transmission Assembly INTRODUCTION (see figure 1) reverse .
  • Page 8 Section I Description The transmission oil pump is driven by the input shaft . Reverse: The reverse clutch is applied hydraulically It supplies oil pressure to operate the clutch packs, when the shift level is placed in the reverse position lubricate parts, and provide cooling .
  • Page 9 Section I Description Hydraulic Circuit: Oil from the sump enters the pump Selector Valve: The selector valve shifts the transmis- suction passage and is directed to the pump (see figure sion from neutral to forward or reverse . When selector 5) .
  • Page 10 Section II Inspection GENERAL SCHEDULED INSPECTIONS (see table 2) The transmission, cooler, cooler lines, and control link- The following recommended inspection intervals are age should be inspected at regular intervals . Regular based on normal operating conditions . Intervals should inspections will ensure proper operation and help be adjusted for extremes of temperature or other detect minor problems that can be corrected before...
  • Page 11 Section III Maintenance GENERAL Maintenance to the transmission will normally consist of NOTE: Oil level must be checked immediately after the following items . engine shut-down to prevent an incorrect reading . Oil drains back into transmission from the cooler and •...
  • Page 12 Section III Maintenance • Place selector lever in neutral . Run engine for five NOTE: Particles of rubber can indicate cooler line wear . minutes at 1500 RPM . Shut down engine . Each line should be inspected for cracks or fraying and should be replaced if damaged .
  • Page 13 Section IV Troubleshooting GENERAL • Excessive engine RPM (over the rated RPM) . This can Before troubleshooting the transmission, do the fol- indicate a slipping clutch . The slipping clutch will usu- lowing . ally squeal . WARNING: Do not operate trans- WARNING •...
  • Page 14 Section IV Troubleshooting Problem Cause Correction LEAKS 1. At pump or output shaft seal Faulty seal Replace Misalignment Correct Rough shaft Replace 2. Between seal and bore Rough housing bore Replace seal 3. At gasket(s) Loose bolts Torque bolts properly Defective gaskets Replace gaskets Face(s) not flat...
  • Page 15 Section IV Troubleshooting Problem Cause Correction MALFUNCTION IN FORWARD OR REVERSE 1. Clutch drags or does not release Warped clutch plate Replace defective parts Mechanical failure Replace defective parts Tight pack clearance Increase clearance to specification 2. Clutch does not apply Low pressure See low oil pressure Defective parts...
  • Page 16 Section V Overhaul GENERAL INSPECTION Before removal and disassembly, review the following Case. Inspect for cracks . Check sealing surfaces for procedures . Use the proper hand tools, slings, or hoists nicks, scratches, or burrs that can cause leaks . Inspect for the job .
  • Page 17 Section V Overhaul • Inspect assemblies pressed together for proper fit PIPE PLUGS and position . BREATHER • Check that each snap ring is fully engaged in groove . BEARING • Threaded plugs, screws and bolts should be tight- ened to the torques shown in Table 4 . NOTE: The following procedures are correct for most transmissions .
  • Page 18 Section V Overhaul STEP 5. Starting with a friction clutch plate, alternately STEP 6. Install clutch plates and pressure plate in ring gear . stack friction clutch plates and steel clutch plates . Friction clutch plates are designed with 3 missing teeth 120°...
  • Page 19 Section V Overhaul STEP 9. Lubricate clutch spring bearing ring and piston STEP 11. Place clutch Belleville (dish) spring inside rim sealing ring with vasoline . of forward clutch cylinder . Spring is dished . The inside of the spring should be lower than the outside . Install clutch spring bearing ring in groove of piston .
  • Page 20 Section V Overhaul STEP 13. Remove clutch assembly from press . Install to clutch end play chart . More than one snap ring may snap ring in groove of ring gear . (Snap ring 4822) be required . CAUTION: Several different snap CAUTION Clutch End Play Chart rings are used to assemble the...
  • Page 21 Section V Overhaul STEP 16. Install selected snap ring(s) in groove of ring Place complete assembly in press . Press bearing into gear . If selected snap ring does not result in proper end drive gear assembly until seated against shoulder . play, repeat this step .
  • Page 22 Section V Overhaul STEP 21. Install clutch and drive gear assembly in case . STEP 23. Install three dowel pins and eleven pressure plate springs in case . Rotate clutch and drive gear assembly back and forth to engage ring gear teeth with pinion gear teeth . Spring and Dowel Pin Installation STEP 24.
  • Page 23 Section V Overhaul STEP 25. Install reverse clutch pressure plate in case NOTE: Be sure O-ring is not twisted, cut or distorted . with three half moons aligned with dowel pins . Be sure Replace if damaged . all springs are seated in their holes . If removed, install dryseal plug in adapter .
  • Page 24 Section V Overhaul STEP 29. Install adapter on case and align bolt holes . STEP 31. Install driven gear in pump body . Thread four capscrews into case . Tighten in a criss-cross NOTE: Pump gear should be installed the same side pattern to final torque specified in Table 4 .
  • Page 25 Section V Overhaul STEP 33. Install pump assembly on top of adapter and STEP 36. Install valve cover as follows: align bolt holes . Apply thread locker to bolts - apply Position gasket on case . Place valve cover over gasket Loctite 242 or equivalent .
  • Page 26 Section V Overhaul STEP 38. Slide coupling on output shaft . Thread nut on output shaft . Tighten nut to torque shown in Table 4 . COUPLING Coupling Installation STEP 39. Install dipstick in side of case . Turn handle until snug .
  • Page 27 Section VI Installation Read OEM manual for complete installation instructions . CAUTION: After a transmission fail- CAUTION ure, the cooler should be replaced and all lines flushed. Connect oil line to oil to the cooler outlet . See Figure 7B . Align input shaft spline with damper plate .
  • Page 28 Section VI Installation ELECTRIC SHIFT 45 46 VELVET DRIVE 72 73 © VELVET DRIVE Figure 8. 71L and 72L Transmission Assembly ® T R A N S M I S S I O N S...
  • Page 29 Section VI Installation Item Part Qty. Number Description 30-07-065-M01 MAIN CASE MANUAL SHIFT 30-07-065-E01* MAIN CASE ELECTRIC SHIFT 30-00-140-001* SOLENOID 10-00-238-002 SCREEN 3000188001 THREAD REDUCER (SAE J1926-8 FITTING) 3/4-16 THD 4885B THREAD REDUCER (3/8-18 DRYSEAL THD) 4915 MAGNET 30-07-036-001 OIL BAFFLE 10-00-043-031 DOWEL PIN 71-97...
  • Page 30 Section VI Installation Item Part Qty. Number Description 103340 FLAT WASHER (5/16) 108579 LOCK WASHER (5/16) 9418892 HEX NUT (5/16-24) 10-16-162-001 RING GEAR 71-6 RING GEAR (3018 AND 3019 MODELS ONLY) 4806J SEALING RING 4495 SNAP RING 10-16-179-001 CLUTCH HUB (3007 AND 3008 MODELS ONLY) 3011090001 CLUTCH HUB 3011 MODEL ONLY 71-40...
  • Page 31 Section VI Installation Item Part Qty. Number Description 3000166001 CLUTCH PRESSURE PLATE 3000166001 ASSY - INNER CLUTCH PLATE (MODEL 3007 AND 3008) 3000166001 ASSY - INNER CLUTCH PLATE (MODEL 3018 AND 3019 ONLY) 3009166001 PAPER CLUTCH PLATE MODEL 3011 ONLY 10-16-166-001 PLATE - OUTER CLUTCH 5L-67...
  • Page 32 Section VI Installation NOTE: The following kits are available for Model 71L and 72L transmissions . Index numbers shown match the index numbers on the exploded view, Figure 8 . Forward Clutch Kit (Models 3007 & 3008 Only) Index Part Qty.
  • Page 33 Section VI Installation Gasket, Sealing Rings, O-Ring and Oil Seal Kit (Model 3011 Only) Index Part Qty. Number Description 3011410001 GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT 3006045003 GASKET, CASE/ADAPTOR 71-14 PRV VALVE COVER GASKET 1000044014 INPUT SHAFT PUMP SEAL 3007044001 OUTPUT SHAFT SEAL 4805A...
  • Page 34 Section VI Installation Gasket, Sealing Rings, O-Ring and Oil Seal Kit (Model 3007 Only) Index Part Qty. Number Description 3007420001 GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT 3006045003 GASKET, CASE/ADAPTOR 71-14 PRV VALVE COVER GASKET 1000044014 INPUT SHAFT PUMP SEAL 3007044001 OUTPUT SHAFT SEAL 4805A...
  • Page 35 Section VI Installation Gasket, Sealing Rings, O-Ring and Oil Seal Kit (Model 3019 Only) Index Part Qty. Number Description 3019420001 GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT 3006045003 GASKET, CASE/ADAPTOR 71-14 PRV VALVE COVER GASKET 1000044014 INPUT SHAFT PUMP SEAL 3007044001 OUTPUT SHAFT SEAL 4805A...
  • Page 36 Section VII Specifications CAUTION: Threaded plugs, screws, bolts and coupling nuts must be tightened to torque CAUTION shown in this table to prevent premature failure of transmission or reduction unit. Recommend using Thread Locker Loctite 242 or equivalent to all fasteners. Table 4.
  • Page 37 Section VII Specifications Table 7. Test Pressures: 71L, 72L, 72LX (Models 3007, 3008, 3011, 3018 & 3019) Typical Range Typical Range Pressure Tap Engine RPM 1275 Neutral 2000 NOT USED NOT USED NOT USED NOT USED Line 3500 NOT USED NOT USED NOT USED NOT USED...
  • Page 38 Section VII Propeller Shaft Alignment & Flange PROPELLER SHAFT ALIGNMENT The term “Propeller Shaft Alignment” is really a mis- nomer because we are really not aligning the prop shaft . We are aligning the engine and transmission as an assembly . We can reposition the prop shaft axially, but we cannot move it latterly .
  • Page 39 Section VIII Propeller Shaft Alignment & Flange Specifications THE COUPLER AND/OR FLANGE FACES ARE NOT BENT SHAFT PERPENDICULAR TO THE SHAFT Symptoms may include: Knocking noise, leaking stuff- Symptoms may include: Knocking noise, leaking stuff- ing box, leaking transmission rear seal, loose transmis- ing box, leaking transmission rear seal, loose transmis- sion output shaft nut, broken transmission shaft at sion output shaft nut, broken transmission shaft at...
  • Page 40 Section VIII Propeller Shaft Alignment & Flange Specifications FIVE INCH FLANGE Velvet Drive five (5) inch flanges conform to the requirements of SAE 510 specifications . There are two features that make this flange unique to the industry . The female pilot bore is in the transmission flange and the bolt circle is a 4 ¼...
  • Page 41 SEGMENT B V-DRIVES The following international symbols are used in this service manual. WARNING This symbol warns of possible personal injury CAUTION This symbol warns of possible damage to transmissions . Original Equipment Manufacturer (Boat/Engine Manufacturer) ® T R A N S M I S S I O N S...
  • Page 42 I-V Assembly VIEW PART VIEW PART DESCRIPTION DESCRIPTION NUMBER NUMBER 30080650C1 CASE- FRONT HALF 3000133001 REAR INPUT GEAR BEARING 30080650C2 CASE - BACK HALF 3000133002 REAR INPUT GEAR BEARING 3008031001 OUTPUT FLANGE 3000133007 REAR OUTPUT GEAR BEARING 4775L LOCK NUT 3000133006 REAR OUTPUT GEAR BEARING 3008085001...
  • Page 43 72 LVTS ® T R A N S M I S S I O N S...
  • Page 44 72 LVTS 72LVTS V-DRIVE VIEW PART VIEW PART DESCRIPTION DESCRIPTION NUMBER NUMBER 30080650C1 CASE- FRONT HALF 3000133002 REAR INPUT GEAR BEARING 3008065TC3 CASE - BACK HALF 2000133073 REAR OUTPUT GEAR BEARING 3008031T01 OUTPUT FLANGE 2000133072 REAR OUTPUT GEAR BEARING 3008039T01 OUTPUT SEAL PLATE 3008085001 INPUT GEAR 1.5 RATIO...
  • Page 45 71LV and 72LV Kits V-Drive Gasket and Seal Kit (Front Mount Coupling Only) Index Part Qty. Number Description 3008420003 V-DRIVE GASKET AND SEAL KIT MODEL 3008 AND 3019 MODELS ONLY 3008045001 GASKET 3005044002 OUTPUT SEAL 3005044001 INPUT SHAFT SEAL V-Drive Gasket and Seal Kit (Thru Shaft Coupling Only) Index Part Qty.
  • Page 46 SEGMENT C 72LH & 72LHP The following international symbols are used in this service manual. WARNING This symbol warns of possible personal injury CAUTION This symbol warns of possible damage to transmissions . Original Equipment Manufacturer (Boat/Engine Manufacturer) ® T R A N S M I S S I O N S...
  • Page 47 Section I Assembly STEP 1. If removed, install the following parts in case . Install orfis in back of housing under rear bearing . Press bearing into case and retain with retainer ring . Install all plugs and fittings into top of housing . See chart for torque specs .
  • Page 48 Section I Assembly STEP 5. Starting with a friction clutch plate , alternately STEP 6. Install Clutch plates and pressure plate in ring stack friction clutch plates and steel clutch plates . gear . Steel clutch plates are designed with 3 missing teeth 120°...
  • Page 49 Section I Assembly STEP 9. Lubricate clutch spring bearing ring and piston STEP 11. Place clutch Belleville (dish) spring inside rim sealing ring with vasoline . of forward clutch cylinder . Spring is dished . The inside of the spring should be lower than the outside . Install clutch spring bearing ring in groove on piston face .
  • Page 50 Section I Assembly STEP 13. Remove clutch assembly from press . Install STEP 15. The following instructions are for the 72C snap ring in groove of ring gear . (Snap ring 4822) models . Clutch pack clearance is not adjustable on 71C models .
  • Page 51 Section I Assembly STEP 16. Install selected snap ring(s) in groove of ring gear . Repeat step till proper clutch end play is achieved . Bearing Installation STEP 19. Install snap rings in grooves of drive gear assembly and forward clutch cylinder . Snap Ring Assembly STEP 17.
  • Page 52 Section I Assembly STEP 21. Install clutch and drive gear assembly in case . STEP 23. Install three dowel pins and eleven pressure plate springs in case . Rotate clutch and drive gear assembly back and forth to engage ring gear teeth with pinion gear teeth . Spring and Dowel Pin Installation STEP 24.
  • Page 53 Section I Assembly STEP 25. Install reverse clutch pressure plate in case NOTE: Be sure O-ring is not twisted, cut or distorted . with three half moons aligned with dowel pins . Be sure Replace if damaged . all springs are seated in their holes . If removed, install dryseal plug in adapter .
  • Page 54 Section I Assembly STEP 29. Install adapter on case and align bolt holes . STEP 31. Install driven gear in pump body . Thread four capscrews into case . Tighten in a criss-cross NOTE: Pump gear should be installed the same side pattern to final torque specified in Table 4 .
  • Page 55 Section I Assembly STEP 33. Install pump assembly on top of adapter and STEP 35. Lubricate control valve O .D . Slide valve align bolt holes . assembly into side of case . CAUTION: Position pump housing STEP 36. Install valve cover as follows: CAUTION with cast arrow at top pointing in the same direction as engine...
  • Page 56 Section I Assembly STEP 37A. Electric Shift: Be sure cartridge screen is clean. Insert cartridge into port and torque to spec in Table 4. Slide coils over cartridge stem. Be sure you have the spacer washer between the 2 coils. Position coils as needed and tighten nut to spec in Table 4.
  • Page 57 Section II Installation CAUTION: After a transmission fail- Adjust the shift cable so the holes in the shift lever are CAUTION ure, the cooler should be replaced centered over the detent ball at each selector location . and all lines flushed. See figure 7A .
  • Page 58 Section II Specifications 72LHP and 72LH (Models 3009 and 3010) Pressure Readings Pressures should read as follows with transmission temperature of 120° – 130°F. Mainline Mainline Neutral Reverse Reverse Forward Cooler Flow Cooler Flow Engine Line Clutch Pressure Pressure Reverse Forward MIN.
  • Page 59 Section II Installation ® T R A N S M I S S I O N S...
  • Page 60 Section II Installation Item Part Qty. Number Description 3009065MC1 MAIN CASE MANUAL SHIFT 3009065ECI* MAIN CASE ELECTRIC SHIFT 3009065MC6 MAIN CASE MANUAL SHIFT MERC 6 BC 3009065EC6 MAIN CASE ELECTRIC SHIFT MERC 6 BC 3009140001* SOLENOID 413281 1/4-18 NPTF PIPE PLUG 3008052002 PIPE PLUG 4804M...
  • Page 61 Section II Installation Item Part Qty. Number Description 3006039001 VALVE COVER 433648 SCREW 3006239005 CONTROL VALVE 3006141001 O-RING 3006139001 SNAP RING 71-79B SHIFT LEVER 103340 FLAT WASHER (5/16) 108579 LOCK WASHER (5/16) 9418892 HEX NUT (5/16-24) 5L-67 REAR CLUTCH PRESSURE PLATE 4768 RING - SHIM (SELECTIVE FIT) 4768A...
  • Page 62 Section II Installation Item Part Qty. Number Description 10-16-166-001 PLATE - OUTER CLUTCH (MODEL 3009 ONLY) 10-16-166-001 PLATE - OUTER CLUTCH (MODEL 3010 ONLY) 10-00-044-014 OIL SEAL 20-00-183-005 BOLT, HEX - 5/16-18 X 1 3/8 71C-60 FRONT PUMP HOUSING 3-61 PUMP GASKET 3009043001 DOWEL MODEL 3009 ONLY...
  • Page 63 Rebuild Kits FORWARD CLUTCH KITS FORWARD CLUTCH PACK KIT (3009 MODEL ONLY) Item Part Qty. Number Description 3009410002 PAPER FWD CLUTCH PACK KIT (3009 MODEL ONLY) 3009062001 CLUTCH PRESSURE PLATE 10-16-166-001 STEEL CLUTCH PLATE 3009166001 FRICTION CLUTCH PLATE (PAPER) 5L-67 REAR CLUTCH PRESSURE PLATE FORWARD PAPER CLUTCH PACK KIT (3010 MODEL ONLY) Item...
  • Page 64 Rebuild Kits REVERSE CLUTCH KITS HIGH PERFORMANCE REVERSE CLUTCH Item Part Qty. Number Description 3009410003 PAPER REVERSE CLUTCH KIT (3009 & 3010 MODELS) 3009166002 PAPER REVERSE CLUTCH 72-176 STEEL PLATES HEAVY DUTY REVERSE CLUTCH Item Part Qty. Number Description 3000410008 HEAT TREATD BRONZE REVERSE CLUTCH KIT (3009 &...
  • Page 65 Rebuild Kits GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT MODEL 3009 AND 3010 ONLY Item Part Qty. Number Description 3009420005 GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT MODEL 3009 AND 3010 ONLY 3006045003 GASKET, CASE/ADAPTOR 71-14 PRV VALVE COVER GASKET 3009045001 OIL PAN GASKET 1000044014...
  • Page 66 Rebuild Kits GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT MODEL 3007 ONLY Item Part Qty. Number Description 3007420001 GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT MODEL 3011 ONLY 3006045003 GASKET, CASE/ADAPTOR 71-14 PRV VALVE COVER GASKET 1000044014 INPUT SHAFT PUMP SEAL 3007044001 OUTPUT SHAFT SEAL 4805A...
  • Page 67 Rebuild Kits GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT MODEL 3019 ONLY Item Part Qty. Number Description 3019420001 GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT MODEL 3011 ONLY 3006045003 GASKET, CASE/ADAPTOR 71-14 PRV VALVE COVER GASKET 1000044014 INPUT SHAFT PUMP SEAL 3007044001 OUTPUT SHAFT SEAL 4805A...
  • Page 68 Rebuild Kits GASKET, SEALING RINGS,O-RING AND OIL SEAL KIT MODEL 3019 ONLY Item Part Qty. Number Description 3009420001 DANA 1480 COUPLER KIT 3009031001 COUPLING 3009047001 PILOT SPACER 3009183021 BOLT 1/2-20 X 1.25 LG Item Part Qty. Number Description 3009420003 DANA 1350 COUPLER KIT 3009031002 COUPLING 3009047001...
  • Page 69 Rebuild Kits SOLENOID SERVICE KITS MODELS 3009 AND 3010 ONLY COIL KITS (COILS ONLY) Item Part Qty. Number Description 3009140101 10 VOLT COILS 3009140241 24 VOLT COILS SOLENOID O-RING AND SEAL KIT MODELS 3009 AND 3010 ONLY Item Part Qty. Number Description 3009420006...
  • Page 70 Rebuild Kits MERC 6 ADAPTOR KIT FOR MODEL 3009 ONLY Item Part Qty. Number Description 3009420002 MERC 6 ADAPTOR KIT CONSIST OF 3009045002 GASKET 3009172001 MERC 6 ADAPTOR 3009183003 BOLT 3/8-16 X 7/8 LG 3009146001 STUD 7/16-14 X 4-1/8 LG 179858 BOLT 7/16-14 X 1"...
  • Page 72 Transmissions (VDT) has been a leader in the marine industry for over 50 years. Founded in 1948, VDT ® has been a Regal company since its purchase from Borg Warner in 1995. VDT products feature quiet, smooth operation and are manufactured using the highest quality industry standards. Applications include tournament ski boats, inboard cruisers, sport fishing boats, sailboats, trawlers, center consoles, runabouts, yachts and high performance boats.

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