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DF Series
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FUNK DF Series Manual
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Table Of Contents
242
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242
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242
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Introduction
Contents
Safety Messages
Handle Fluids Safely-Avoid Fires
Prepare for Emergencies
Avoid High-Pressure Fluids
Support Machine Properly
Wear Protective Clothing
Service Machines Safely
Work in Ventilated Area
Work in Clean Area
Remove Paint before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Use Proper Lifting Equipment
Practice Safe Maintenance
Use Proper Tools
Dispose of Waste Properly
Live with Safety
Stay Clear of Rotating Drivelines
General Information
Specifications
Identification and Serial Number Plates
Recommended Lubricants
Ambient Air Temperature Chart
Cold Weather Startup
Stalling the Torque Converter
Cold Weather Operation
Alternate Warm-Up Procedure
Hot Weather Operation
Fill the Transmission with Oil
Check and Service Transmission Regularly
Check the Oil Level Daily
Oil Level
Intervals for Changing Transmission Oil and Filters
First Oil and Filter Change
Routine Oil and Filter Maintenance
Oil Analysis
Oil Temperature Warning Signal
Towing the Vehicle
Put Transmission in Storage
Install Transmission to the Engine
Converter-To-Engine Flywheel Dimensions
Engine to Torque Converter Specifications
Suggested Wrenching Torque for Tapered Pipe Thread
Tapered Pipe Thread with Sealant Chart
Tapered Pipe Thread Without Sealant Chart
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
Angle Fitting
Straight Fitting or Special Nut Torque Chart
Service Recommendations for Flat Face O-Ring Seal Fittings
Flat Face O-Ring Seal Fitting Torque
Check Oil Lines and Fittings
Metric Bolt and Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Use Proper Lifting Equipment
Transmission Lifting Procedure
Transmission Repair Stand
Mounting Df Series Transmission to Repair Stand
Safety Precautions
Torque Converter
Specifications
Remove Torque Converter and Drive Plate Assembly
Other Material
Disassemble and Assemble Drive Plate Group
Disassemble Drive Plate Group
Assemble Drive Plate Group
Remove Front Cover
Remove and Install Bearing in Front Cover
Remove Turbine Assembly
Remove Stator Assembly
Disassemble and Assemble Fixed Stator Assembly
Disassemble Fixed Stator Assembly
Stator Front and Back Side Identification
Assemble Fixed Stator Assembly
Disassemble and Assemble Free Stator Assembly
Disassemble Free Stator Assembly
Assemble Free Stator Assembly
Free Stator Clutch Assembly
Disassemble Converter Impeller
Assemble Converter Impeller and Hub
Assemble Stator to Impeller
Assemble Turbine to Stator
Assemble Front Cover to Turbine and Impeller
Other Material
Specifications
Disassemble Suction Tube Group
Remove Suction Tube Assembly
Assemble Suction Tube Group
Install Suction Tube
Charge Pump Group
Remove Charge Pump Group
Remove Driven Gear and Bearing Assembly
Disassemble Auxiliary Pump Drive Disconnect
Assemble Auxiliary Pump Drive Disconnect
Install Charge Pump to Front Cover
Other Material
Specifications
Disassemble Front Cover Group
Remove Front Cover and Input Assembly
Disassemble Input Assembly
Disassemble Front Cover
Remove and Disassemble Driven Gears
Assemble Driven Gears and Bearings
Remove Idler Gears and Disassemble
Assemble Idler Gears
Remove Magnetic Pickup
Assemble Input Assembly
Install Oil Seal and Ball Bearing
Install Idler Gears and Bearing Assemblies
Install Idler Shafts
Alternate O-Ring Installation Procedure
Install Driven Gear Assembly
Assemble Front Cover Group
Assemble Converter Input Shaft and Stator Tube
Install Front Cover Assembly to Main Case Front Housing
Remove and Install Wiring Harness
Remove Wiring Harness
Install Wiring Harness
Specifications
Remove Control Valve Group
Disassemble and Assemble Control Valve
Install Control Valve Group
Cap Screw Tightening Sequence and Torque Specifications
Piping Diagram, Converter Driven Transmission, (Without Wet Brake)
Pressure and Temperature Check Ports (Without Wet Brake)
Operating Conditions
Main Case Front Housing
Remove and Install Dipstick Assembly
Remove Output Yoke
Remove Internal Disconnect
Disassemble and Assemble Ground Driven Pump
Disassemble and Assemble Front Housing
Install Bore Sleeves
Remove Lube Relief Valve
Install Lube Relief Valve
Remove Bearing Cup
Install Bearing Cup
Remove Oil Seal
Install Oil Seal
Install Front Housing to Rear Housing
Remove Magnetic Pickup from Rear Housing
Specifications
Remove Output Group
Disassemble Output Group (no Disconnect) and Oil Trough
Disassemble and Assemble Output Group (with Internal Disconnect)
Disassemble Output Group with Internal Disconnect
Remove All Clutch Stage Assemblies
First Stage Shaft Assembly
Second Stage Clutch Assembly (Df150)
Third Stage Clutch Assembly (Df150)
Fourth Stage Clutch Assembly
Fifth Stage Clutch Assembly
Disassemble Clutch Stage Assembly
Sizing Seal Rings
Install Stage Assemblies into Rear Housing
Gear Ratio Group
Install Output Group (no Disconnect) and Oil Trough
Install Output Group and Oil Trough
Specifications
Rear Housing Component Identification (Df250)
First Stage Cover Group
Remove First Stage Cover Group
Install First Stage Cover Group
Remove Bearing Retainer
Setting End Play of Output Group
Install Output Yoke
Disc Brake Group
Disassemble Disc Brake
Assemble Disc Brake
Special Tools Used in this Manual
Assembly Stand Plate
Front Cover Lifting Tool
Suction Leak Test
Solenoid Valve Operation
Clutch Solenoid Voltage Requirements
Test Solenoids
Df Power Flow Forward Speeds
Df Power Flow Reverse Speeds
Troubleshoot Transmission System Malfunctions
Transmission Control Unit
Trouble Shooting Introduction
Theory of Operation
System Components
Required Components
Component Functions
Basic Components
Transmission Control Unit (TCU)
Engine Speed Magnetic Pickup
Cylinder Magnetic Pickup Sensor
Connector Pinouts
Output Speed Magnetic Pickup Sensor
Connector Pinouts
Bump Shift Handle
Calibration
Reasons to Calibrate
Clutch Calibration Four Forward Speeds and Four Reverse
Clutch Calibration Eight Forward Speeds and Four Reverse
Gear/Diagnostic Indicator
Inching Pedal
Park Pressure
Park Brake
System Requirements
J1 Connector
J2 Connector
J3 Connector
Function of Proportional Valves
Proportional Valves
System Errors
Analog Error Codes
Glossary
Abbreviations Used in Tcu Group
Index
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DF Series
150 and 250
Transmissions (ANALOG)
Funk Manufacturing Company
CTM147 (16JUL98)
LITHO IN U.S.A.
ENGLISH
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Transmissions (analog) (242 pages)
This manual is also suitable for:
Df150
Df250
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