FUNK DF Series Manual
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FUNK DF Series Manual

Transmissions (analog)
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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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Summary of Contents for FUNK DF Series

  • Page 1 DF Series 150 and 250 Transmissions (ANALOG) Funk Manufacturing Company CTM147 (16JUL98) LITHO IN U.S.A. ENGLISH...
  • Page 2 DF Series 150 and 250 Transmissions (Analog) CTM147 (16JUL98)
  • Page 3 IMPORTANT: Important warns of possible damage to transmission. NOTE: To make special mention of or to record in writing useful information about the transmission. YZ,CTM147,IFC -19-05MAY98 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=3...
  • Page 4 Contents Page DF Series 150 and 250 Group 05—Safety messages Group 10—General Information Group 15—Transmission Mounting Group 20—Torque Converter Group 25—Charge Pump Group 30—Front Cover Group 35—Control Valve Group 40—Main Case Front Housing Group 45—Gear Ratio Group Group 50—Main Case Rear Housing Group 55—Brake Group...
  • Page 5 Contents CTM147 (16JUL98) DF Series 150 and 250 160798 PN=237...
  • Page 6 Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. DX,FIRE2 -19-03MAR93 00-05-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=4...
  • Page 7 Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. DX,LOWER -19-04JUN90 00-05-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=5...
  • Page 8 If you do not have an exhaust pipe extension, open the doors and get outside air into the area. DX,AIR -19-04JUN90 00-05-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=6...
  • Page 9 Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. DX,TORCH -19-03MAR93 00-05-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=7...
  • Page 10 Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. Disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine. DX,SERV -19-03MAR93 00-05-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=8...
  • Page 11 Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. DX,DRAIN -19-03MAR93 00-05-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=9...
  • Page 12 Make sure rotating shields turn freely. Wear close fitting clothing. Stop the engine and be sure PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment. DX,PTO -19-12SEP95 DX,BYPASS1 -19-10MAR98 00-05-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=10...
  • Page 13 Safety messages 00-05-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=11...
  • Page 14 Constant mesh, in line, high contact ratio ground gears. Up to eight speeds forward and four speeds reverse. • DF-150/250 Hydraulic transmission fluid. • DF-150/250 Filter Remote mounted spin-on type filter. Continued on next page 00-10-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=12...
  • Page 15 1758—1965 kPa (255—285 psi) Valve Pump Flow 87—102 L/min (23—27 gpm) Clutch Pressure 1655—1931 kPa (240—280 psi) Lube, In Pressure 138—414 kPa (20—60 psi) Weights will vary depending on installed options. YZCTM147,10,SPC-19-05MAY98 00-10-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=13...
  • Page 16 The exact location varies depending on installed options and model number. Earlier version of the DF series transmission had three lines of information. Later DF series transmission will have four lines of information on identification plate. All information on identification plate is needed when contacting FUNK concerning transmission.
  • Page 17 Lubrizol 9990 meet one of the following: John Deere Standard JDM J20 C John Deere Standard JDM J20 D HY-GARD is a registered trademark of Deere & Company. YZ,CTM147,10,3 -19-05MAY98 00-10-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=15...
  • Page 18 • Stop the stall procedure when oil temperature is in the normal operating range. Do not allow oil temperature to exceed 121˚C (250˚F) at anytime. YZ,CTM54,10,19 -19-07MAY98 00-10-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=16...
  • Page 19 Use higher viscosity grades (Refer to AIR TEMPERATURE RANGE chart) for: • Ambient temperatures consistently above 30˚C (86˚F). • Frequent stop-and-go driving in hot weather. • High grade climbing in hot weather. YZ,CTM147,10,3A-19-05MAY98 00-10-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=17...
  • Page 20 • Fill transmission to the full mark on dipstick with engine running at idle speed. • Check oil level again when the transmission has reached normal operating temperature 38—93˚C (100—200˚F). YZ,CTM147,10,2 -19-05MAY98 00-10-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=18...
  • Page 21 NOTE: Engage park brake before checking oil level. OIL LEVEL IMPORTANT: The DF series transmission should always be in the neutral position before starting the engine, or when the vehicle is parked and the engine is running.
  • Page 22 • Change filter at every 500 hours, change filter and oil every 1000 hours of transmission operation. YZ,CTM147,10,4 -19-05MAY98 00-10-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=20...
  • Page 23 If the temperature does not lower, trouble is indicated. • Correct overheating problem before the vehicle is operated again. YZ,CTM54,10,18 -19-05MAY98 00-10-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=21...
  • Page 24 YZ,CTM54,10,17 -19-05MAY98 PUT TRANSMISSION IN STORAGE This procedure applies to those transmissions and components that have been tested according to Funk Manufacturing test specifications and have had the oil drained from them prior to shipment. The following actions will help protect the unit and...
  • Page 25 • Remove covers or tape from all openings. • Drain transmission completely. • Tag transmission to indicate it needs to be filled with oil after installing in vehicle. YZ,CTM147,10,6 -19-10MAR98 00-10-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=23...
  • Page 26 Remove the transmission and check previous assembly steps to determine the problem. Take corrective action before proceeding. YZ,CTM147,10,7 -19-05MAY98 00-10-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=24...
  • Page 27 2-Converter Drive Plate Group 7-Housing Spacer (as required) 3-Converter Pilot Sleeve 8-Flywheel End Stop 4-Engine Crank Shaft 9-Flywheel Shoulder Stop 5-Engine Flywheel 10-Pilot Sleeve End Stop 11-Pilot Sleeve Shoulder Stop YZ,CTM147,10,37-19-05MAY98 00-10-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=25...
  • Page 28 If the above dimensions check out, the assembly can continue. CHECK THE FOLLOWING ENGINE AND TRANSMISSION DIMENSIONS TO ASSURE 7. Check the engine crankshaft endplay. It should PROPER INSTALLATION: comply with the engine manufacturer’s tolerance. YZ,CTM147,10,32-19-05MAY98 00-10-15 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=26...
  • Page 29 2-11 1/2 UN ....160 ... . 120 SUGGESTED WRENCHING TORQUE FOR TAPERED PIPE THREAD charts meet Funk Engineering Procedures Manual Torque Specifications FEP 14.4.
  • Page 30 UN ....217 ... . 160 NOTE: Torque tolerance is + 15% -20%. SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS chart meets Funk Engineering Procedures Manual Torque Specifications FEP 14.3. CTM147,10,40...
  • Page 31 38.10 ..1.500 ..-24 ... 2-12 ..217 . . 160 ..17.0 ..12.5 NOTE: Torque tolerance is +15 -20%. 04T,90,K67 -19-01AUG94 00-10-18 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=29...
  • Page 32 IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings. TX,90,DH1559 -19-01AUG94 00-10-19 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=30...
  • Page 33 Tighten toothed or serrated-type lock nuts to the full torque value. DO NOT use these values if a different torque value METRIC BOLT AND CAP SCREW TORQUE VALUES chart meet Funk Engineering Procedures Manual Torque Specifications FEP 14.1. CTM147,10,42 -19-07MAY98...
  • Page 34 Tighten toothed or serrated-type lock nuts to the full torque value. 7/8-9 7/8-14 1199 1-12 1312 UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES chart meet Funk Engineering Procedures Manual Torque Specifications FEP 14.2. CTM147,10,43 -19-07MAY98 00-10-21 CTM147 (16JUL98) DF Series 150 and 250 160798...
  • Page 35 General Information 00-10-22 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=33...
  • Page 36 DX,LIFT -19-04JUN90 TRANSMISSION LIFTING PROCEDURE Use a lift sling similar to (A). It should hold the transmission level without bending the lift hangers (B). YZ,CTM147,15,3 -19-05MAY98 00-15-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=34...
  • Page 37 Model DF150 = 545 Kg (1250 lbs). Model DF250 = 703 Kg (1550 lbs). Actual weights depend on the options included. YZ,CTM147,15,1 -19-05MAY98 MOUNTING DF SERIES TRANSMISSION TO REPAIR STAND NOTE: See Group 99, “Special Tools” for Assembly Stand Plate drawings.
  • Page 38 Accidental • Make sure tapped holes in adapters and slippage may result in personal injury. transmission are clean and not damaged. YZ,CTM147,15,2 -19-05MAY98 00-15-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=36...
  • Page 39 Transmission Mounting 00-15-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=37...
  • Page 40 3. Place torque converter assembly on work surface with drive plate assembly up. 4. Place support blocks under torque converter impeller to prevent tipping. YZ,CTM147,20,3 -19-05MAY98 00-20-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=38...
  • Page 41 2. Remove ring (B) and drive plate assembly (C). 3. Inspect for wear or damage. Look closely at drive plate (C) for signs of fatigue, cracks or elongated bolt holes. YZ,CTM147,20,4 -19-05MAY98 00-20-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=39...
  • Page 42 1. Install drive plate assembly (A) and ring (B). 2. Install cap screws (C) and tighten evenly. Alternating front to rear and side to side. 3. Tighten to 40 N·m (30 lb-ft). YZ,CTM147,20,26-19-05MAY98 00-20-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=40...
  • Page 43 3—Front cover 7—Turbine assembly 12—O-ring 17—Washer (12 used) 4—Bearing 8—Converter stator 13—Seal ring 18—Cap screw (12 used) 5—Thrust washer (5 used) 9—Retainer ring (2 used) 14—Gasket O-ring 19—Shipping plug YZ,CTM147,20,28-19-05MAY98 00-20-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=41...
  • Page 44 20—Washer (12 used) 4—Bearing 10—Converter stator 16—Seal ring 21—Cap screw (12 used) 5—Thrust washer (5 used) 11—Outer clutch race 17—Gasket O-ring 22—Shipping plug 6—Needle thrust washer (3 12—Sprag clutch assembly used) YZ,CTM147,20,27-19-05MAY98 00-20-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=42...
  • Page 45 4. Install new bearing. YZ,CTM147,20,6 -19-05MAY98 REMOVE TURBINE ASSEMBLY 1. Remove thrust washer (A). 2. Remove needle thrust bearing (B). 3. Remove turbine assembly (C) and inspect . YZ,CTM147,20,7 -19-05MAY98 00-20-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=43...
  • Page 46 OR A “FIXED STATOR ASSEMBLY” DEPENDING ON APPLICATION. THIS MANUAL ILLUSTRATES AND DESCRIBES BOTH STATOR TYPES. YZ,CTM147,20,9 -19-05MAY98 DISASSEMBLE AND ASSEMBLE FIXED STATOR ASSEMBLY A—Retaining ring (2) B—Stator C—Fixed stator hub YZ,CTM147,20,35-19-05MAY98 00-20-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=44...
  • Page 47 DISASSEMBLE FIXED STATOR ASSEMBLY 1. Remove retainer ring (A). 2. Remove fixed stator hub (B). 3. Turn stator (C) over. 4. Remove retainer ring (D). 5. Inspect parts for wear or damage. YZ,CTM147,20,10-19-05MAY98 00-20-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=45...
  • Page 48 The “FRONT” of the stator casting is identified by the vanes being thicker (A) on this side. The “BACK” of the stator casting is identified by the vanes being thinner (B) on this side. YZ,CTM147,20,11-19-05MAY98 00-20-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=46...
  • Page 49 3. Turn stator over. NOTE: Stator hub (B) may be installed with either side 4. Install fixed stator hub (B) into stator (C). 5. Install retaining ring (D) into groove. YZ,CTM147,20,12-19-05MAY98 00-20-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=47...
  • Page 50 Torque Converter DISASSEMBLE AND ASSEMBLE FREE STATOR ASSEMBLY A—Retaining ring (2) C—Stator E—Clutch sprag assembly F—Inner clutch race B—Clutch retainer (2) D—Outer clutch race YZ,CTM147,20,34-19-05MAY98 00-20-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=48...
  • Page 51 NOTE: Clutch retainer (B) will slide out of stator when turned over. 6. Turn stator (C) over. 7. Remove retaining ring (A). 8. Remove clutch retainer (B). 9. Inspect parts for wear or damage. YZ,CTM147,20,13-19-05MAY98 00-20-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=49...
  • Page 52 1. Position stator with “BACK” side up. 2. Install retaining ring (A) into groove. 3. Turn stator, position “FRONT” side up. 4. Install clutch retainer (B) with slotted face down. YZ,CTM147,20,14-19-05MAY98 00-20-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=50...
  • Page 53 8. Install inner clutch race (D) to about one half its depth into the sprag clutch (B). 9. Push all parts together. 10. Install assembled parts into stator. 11. Compare the assembly to the “free stator clutch assembly” photograph. YZ,CTM147,20,15-19-05MAY98 00-20-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=51...
  • Page 54 The cage flange of the sprag clutch assembly (B) is up. YZ,CTM147,20,16-19-05MAY98 12. Install clutch retainer (A) slotted face up. 13. Install retainer ring (B) into groove. YZ,CTM147,20,17-19-05MAY98 00-20-15 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=52...
  • Page 55 3. Remove seal ring (C). 4. Remove twelve cap screws (D) and washers. 5. Turn impeller over. 6. Remove impeller hub (E) and 0-ring (F). 7. Inspect splines, seal and bearing surfaces. YZ,CTM147,20,18-19-05MAY98 00-20-16 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=53...
  • Page 56 NOTE: There are two bolt hole patterns in the impeller hub. Be certain all holes are aligned. 4. Align holes in impeller hub (B) with holes in impeller (C). YZ,CTM147,20,19-19-05MAY98 00-20-17 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=54...
  • Page 57 IMPORTANT: Seal ring ends must be hooked together. 8. Install seal ring (B) into groove on impeller hub (C) and lock ends. LOCTITE is a trademark of the LOCTITE Corporation. YZ,CTM147,20,20-19-05MAY98 00-20-18 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=55...
  • Page 58 NOTE: If Stator is installed improperly it will not turn freely on thrust bearing. 7. Rotate stator assembly several turns to be sure it is properly seated on the thrust bearings. YZ,CTM147,20,21-19-05MAY98 00-20-19 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=56...
  • Page 59 NOTE: Thrust washers (A) and (C) are identical parts. 5. Install turbine assembly (D). 6. Rotate turbine assembly several turns to be sure it is properly seated on the thrust bearings. YZ,CTM147,20,22-19-05MAY98 00-20-20 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=57...
  • Page 60 4. Lubricate new gasket O-ring (C) with clean transmission fluid. 5. Install new gasket O-ring (C), in groove in impeller (D). Be certain the gasket O-ring is not twisted and is laying flat in the groove. YZ,CTM147,20,23-19-05MAY98 00-20-21 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=58...
  • Page 61 9. Install hex nuts (D). 10. Tighten cap screws to 35 N·m (26 lb-ft), alternating front to rear and side to side. YZ,CTM147,20,24-19-05MAY98 00-20-22 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=59...
  • Page 62 *John Deere part number reference. YZCTM147,25,OTH-19-05MAY98 SPECIFICATIONS Item Measurement Specification Charge pump-to-front cover cap Torque 115 N·m (85 lb-ft) screws. Suction Manifold-to-Front Cover cap Torque 25 N·m (18 lb-ft) screws. YZCTM147,25,SPC-19-05MAY98 00-25-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=60...
  • Page 63 Charge Pump DISASSEMBLE SUCTION TUBE GROUP A—O-ring fitting (2 used) C—Suction screen assembly E—Gasket G—O-ring B—Suction tube D—Cap screw (2 used) F—Suction manifold YZ,CTM147,25,14-19-05MAY98 00-25-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=61...
  • Page 64 5. Loosen nut (C) connecting tube to suction manifold. 6. Remove two cap screws (D) from suction manifold. 7. Remove suction manifold and O-ring in groove on back of manifold. 8. Remove suction tube (E). YZ,CTM147,25,12-19-05MAY98 00-25-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=62...
  • Page 65 Charge Pump ASSEMBLE SUCTION TUBE GROUP A—O-ring fitting (2 used) C—Suction screen assembly E—Gasket G—O-ring B—Suction tube D—Cap screw (2 used) F—Suction manifold YZ,CTM147,25,19-19-05MAY98 00-25-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=63...
  • Page 66 6. Tighten nuts (B) and (C) at both ends of suction tube (E) to 190 N·m (140 lb-ft). 7. Install suction screen assembly (F). 8. Connect wiring harness (A) to magnetic pickup. YZ,CTM147,25,9 -19-05MAY98 00-25-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=64...
  • Page 67 Charge Pump CHARGE PUMP GROUP THE CHARGE PUMP IS NOT REPAIRABLE. THE DEFECTIVE. THE AUXILIARY PUMP DRIVE PUMP MUST BE REPLACED IF FOUND DISCONNECT PARTS MAY BE SERVICED. YZ,CTM147,25,4 -19-05MAY98 00-25-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=65...
  • Page 68 3. Remove O-ring (C). YZ,CTM147,25,2 -19-05MAY98 REMOVE DRIVEN GEAR AND BEARING ASSEMBLY 1. Remove driven gear and bearing assembly (A) from charge pump. 2. Inspect for wear and damage. YZ,CTM147,25,3 -19-05MAY98 00-25-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=66...
  • Page 69 I—Detent shift block M—Oil seal B—O-ring F—Disconnect sleeve J—Disconnect fork N—Inner ring bearing C—Shipping plug G—Disconnect shift arm K—Roll pin O—Spring Plunger D—Cap screw H—Disconnect lever shaft L—Roll pin YZ,CTM147,25,11-19-05MAY98 00-25-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=67...
  • Page 70 6. Inspect parts for wear or damage. 7. Remove oil seal (E). 8. Remove inner ring bearing (D). 9. Remove spring plunger (F). 10. Inspect parts for wear and damage. YZCTM147,25,15A-19-05MAY98 00-25-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=68...
  • Page 71 4. Apply LOCTITE #262 to threads of spring plunger (C). 5. Install spring plunger (C) into charge pump. 6. Install disconnect lever shaft (D) through inner ring bearing (A). YZ,CTM147,25,5 -19-05MAY98 00-25-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=69...
  • Page 72 11. Install disconnect sleeve (C). 12. Rotate disconnect shift arm (A) away from pump opening to hold sleeve on pump shaft. CTM147,25,13A -19-05MAY98 00-25-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=70...
  • Page 73 NOTE: Driven gear and bearing assembly is a slip fit into the charge pump. Driven gear and bearing assembly can be install into the front cover first. • Install driven gear assembly (A) onto charge pump. YZ,CTM147,25,7 -19-06MAY98 00-25-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=71...
  • Page 74 2. Install charge pump (B) into front cover. 3. Install three cap screws (A) through charge pump into front cover. 4. Tighten cap screws to 115 N·m (85 lb-ft). YZ,CTM147,25,8 -19-05MAY98 00-25-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=72...
  • Page 75 Charge Pump 00-25-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=73...
  • Page 76 Front Housing Cap Screws. Magnetic Pickup-to-Main Case Front Torque 10 N·m (8 lb-ft) Housing Cap Screws. Front Cover Assembly-to-Main Case Torque 87 N·m (64 lb-ft) Front Housing Cap Screws. YZCTM147,30,SPC-19-05MAY98 00-30-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=74...
  • Page 77 K—Hex cap screw, 8x50mm N—Cap screw (2 used) C—Gear, 43T H—Hex cap screw, (7 used) O—Deflector D—Converter input shaft 12x280mm (4 used) L—Shipping plug E—Cotter pin I—Hex cap screw, 12x172mm (3 used) YZ,CTM147,30,26-19-05MAY98 00-30-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=75...
  • Page 78 Front Cover REMOVE FRONT COVER AND INPUT ASSEMBLY 1. Position transmission with front cover up. 2. Remove seven bolts (A). YZ,CTM147,30,1 -19-05MAY98 3. Install lifting device. YZ,CTM147,30,23-19-05MAY98 00-30-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=76...
  • Page 79 YZ,CTM147,30,24-19-05MAY98 5. Remove 43 tooth gear (A). 6. Remove needle bearing and thrust race (B). 7. Remove O-ring (C). 8. Remove seven bolts (D) and deflector (not shown). YZ,CTM147,30,12-19-05MAY98 00-30-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=77...
  • Page 80 Front Cover 9. Remove stator support tube (A). 10. Remove converter input shaft. YZ,CTM147,30,29-19-05MAY98 00-30-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=78...
  • Page 81 H—Bearing (3 used) M—O-ring (2 used) R—Lock washer (2 used) D—Idler gear (2 used) I—Bearing N—Magnetic pickup sensor S—Washer (2 used) E—Oil seal J—Snap ring O—Magnetic pickup cover T—Hex socket plug YZ,CTM147,30,27-19-05MAY98 00-30-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=79...
  • Page 82 4. Remove two O-rings from bottom of idler shaft bores. 5. Inspect idler shaft for wear or damage. YZ,CTM147,30,2 -19-05MAY98 6. Use a driving tool to remove oil seal and bearing from front cover. YZ,CTM147,30,3 -19-05MAY98 00-30-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=80...
  • Page 83 . 4. Remove spacer and driven gear assembly (C). YZ,CTM147,30,4 -19-05MAY98 5. Use puller to remove bearings (A) from gear (B). 6. Inspect bearings and gears. YZ,CTM147,30,7 -19-05MAY98 00-30-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=81...
  • Page 84 4. Press top bearing through idler gear, removing both bearings. 5. Inspect bearings and gears for wear or damage. YZ,CTM147,30,9 -19-05MAY98 00-30-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=82...
  • Page 85 1. Remove two cap screws, two lock washers and two flat washers (A). 2. Remove magnetic pickup cover (B). 3. Remove magnetic pickup sensor with O-ring (C). NOTE: Install magnetic pickup after installing driven gears. YZ,CTM147,30,11-19-05MAY98 00-30-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=83...
  • Page 86 H—Bearing (3 used) M—O-ring (2 used) R—Lock washer (2 used) D—Idler gear (2 used) I—Bearing N—Magnetic pickup sensor S—Washer (2 used) E—Oil seal J—Snap ring O—Magnetic pickup cover T—Hex socket plug YZ,CTM147,30,30-19-05MAY98 00-30-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=84...
  • Page 87 NOTE: If outside diameter of oil seal is not already ® coated with a sealer apply LOCTITE #620. 3. Position input housing with converter side down. 4. Install new ball bearing (D) into front cover. YZ,CTM147,30,14-19-05MAY98 00-30-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=85...
  • Page 88 2. Position idler gear assembly into its cavity beside auxiliary pump port. 3. Install idler gear assembly (B) into charge pump port and place into cavity. YZ,CTM147,30,15-19-05MAY98 00-30-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=86...
  • Page 89 3. Use grease to hold O-ring (C) to the bottom of the idler shaft during installation. ALTERNATE O-RING INSTALLATION PROCEDURE 3a. Position O-ring (C) at the bottom of the shaft bore in the input housing. YZ,CTM147,30,16-19-05MAY98 00-30-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=87...
  • Page 90 4. Use bolt to align thru hole in idler shaft with threaded hole in the input cover. 5. Push idler shaft (D) through idler gear assembly into input housing. 6. Install the other idler shaft in this same manner. YZ,CTM147,30,17-19-05MAY98 00-30-15 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=88...
  • Page 91 1. Install driven gear assembly with the snap ring up. 2. Rotate idler gear (A) to align teeth with driven gear (B). 3. Push idler gear bearing into bore in input housing. YZ,CTM147,30,21-19-05MAY98 00-30-16 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=89...
  • Page 92 Front Cover 4. Install bearing spacer (C). CAUTION: Wear eye protection when installing snap rings. 5. Install snap ring into groove. YZ,CTM147,30,22-19-05MAY98 00-30-17 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=90...
  • Page 93 3. Push magnetic pickup sensor into front cover. 4. Install magnetic pickup cover (B). 5. Install cap screws and lock washers (C). 6. Tighten cap screws to 10 N·m (8 lb-ft). YZ,CTM147,30,13-19-05MAY98 00-30-18 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=91...
  • Page 94 K—Hex cap screw, 8x50mm N—Cap screw (2 used) C—Gear, 43T H—Hex cap screw, (7 used) O—Deflector D—Converter input shaft 12x280mm (4 used) L—Shipping plug E—Cotter pin I—Hex cap screw, 12x172mm (3 used) YZ,CTM147,30,31-19-05MAY98 00-30-19 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=92...
  • Page 95 It also must not interfere with installing the input housing over the stator tube. 4. Install cap screws (B) and deflector (C). 5. Tighten cap screws to 37 N·m (27 lb-ft). YZ,CTM147,30,18-19-05MAY98 00-30-20 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=93...
  • Page 96 8. Install new needle thrust bearing (D). 9. Install new O-ring (E) flat against front housing. 10. Install 43 tooth gear (F). 11. Rotate gear to be sure it is centered and seated on bearings. YZ,CTM147,30,19-19-05MAY98 00-30-21 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=94...
  • Page 97 NOTE: Be sure the input housing goes down completely and sits flat on the front housing. 3. Install seven cap screws (A). 4. Tighten cap screws to 87 N·m (64 lb-ft) YZ,CTM147,30,25-19-05MAY98 00-30-22 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=95...
  • Page 98 2. Disconnect all electrical connectors. 3. Remove bracket (A) and harness. 4. Inspect wiring and connectors. INSTALL WIRING HARNESS 1. Install bracket (A) and harness. 2. Connect all electrical connectors. YZ,CTM147,35,1 -19-05MAY98 00-35-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=96...
  • Page 99 1. Tag and disconnect all electrical leads to control 4. Remove gasket (C). valve. 5. Remove plate (B). 2. Remove cap screws (F), (G) and (J). 6. Remove gasket (A). 3. Remove valve assembly (D). YZ,CTM147,35,6 -19-05MAY98 00-35-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=97...
  • Page 100 E—Main Regulator Assembly I—O-ring L—Proportional Solenoid (12 used) F—Steel Ball 9/32 (4 used) J—O-ring Plug C—Proportional 12 or 24 Volt G—Hex Socket Plug 9/16-18 Valve (7 used) (2 used) YZ,CTM147,35,7 -19-05MAY98 00-35-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=98...
  • Page 101 5. Install cap screws (F), (G) and (J) and washers 1. Install gasket (A). (E). Observe tightening sequence and torque specifications given in this section. 2. Install plate (B). YZ,CTM147,35,12-19-06MAY98 00-35-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=99...
  • Page 102 2. Repeat step 1. represented by call outs. CONTROL VALVE CAP SCREW TORQUE 1. First rotational sequence tighten all cap screws to SPECIFICATIONS..40 N·m (30 lb-ft) 40 N·m (30 lb-ft). YZ,CTM147,35,10-19-05MAY98 00-35-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=100...
  • Page 103 Control Valve PIPING DIAGRAM, CONVERTER DRIVEN TRANSMISSION, (WITHOUT WET BRAKE) NOTE: Piping diagram for converter driven or direct drive DF series transmission without wet brake option (Digital Valve Shown). A—Charge pump 91 lpm C—Heat exchanger Maximum D—Main control valve for 2—...
  • Page 104 • Pump flow 87—102 L/min (23—27 gpm) at 1655—1931 kPa (255—280 psi). • Lube 40—60 psi In gear • Lube 20—40 psi In neutral, “Converter In” pressure should always be higher than Lube pressure. YZ,CTM147,35,8 -19-05MAY98 00-35-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=102...
  • Page 105 • 3 and 4 are reverse clutches. Ports marked A, B, C and D are Speed Clutch Ports. NOTE: All check ports are 7/16-20 UNF SAE O-ring, unless otherwise specified. YZ,CTM147,35,3 -19-05MAY98 00-35-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=103...
  • Page 106 Solenoid Capscrews Torque 25 N·m (18 lb-ft) Thin Stop Nut-to-Coil on Output Torque 5 N·m (50 lb-in) Disconnect Group. Ground Driven Pump-to-Front Torque 87 N·m (64 lb-ft) Housing Capscrews. YZCTM147,40,SPC-19-01APR98 00-40-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=104...
  • Page 107 3. Install 1/4 inch hose (A) from valve to dipstick tube 3. Remove dipstick tube assembly. assembly (C). 4. Remove gasket. 4. Tighten cap screws (D) to 25 N·m (18 lb-ft). YZ,CTM147,40,13-19-05MAY98 00-40-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=105...
  • Page 108 2. Remove pin and coil assembly (A). YZ,CTM147,40,17-19-05MAY98 NOTE: Behind the core assembly (A) inside of the solenoid cap (B) you will find solenoid spool, solenoid plunger, and spring solenoid. 3. Remove core assembly (A). YZ,CTM147,40,19-19-05MAY98 00-40-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=106...
  • Page 109 Main Case Front Housing 4. Remove cap screws (A). YZ,CTM147,40,20-19-05MAY98 5. Remove solenoid cap.(A). YZ,CTM147,40,21-19-05MAY98 00-40-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=107...
  • Page 110 Main Case Front Housing 6. Remove gasket (A). YZ,CTM147,40,22-19-05MAY98 7. Remove cap screw (B). 8. Remove piston (A). YZ,CTM147,40,23-19-05MAY98 00-40-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=108...
  • Page 111 Main Case Front Housing 9. Remove lip seal (A) from piston (B). YZ,CTM147,40,24-19-05MAY98 10. Remove disconnect return spring (A). 11. Remove cap screws. YZ,CTM147,40,25-19-05MAY98 00-40-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=109...
  • Page 112 Main Case Front Housing 12. Remove cylinder housing. YZ,CTM147,40,26-19-05MAY98 00-40-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=110...
  • Page 113 Main Case Front Housing INSTALL INTERNAL DISCONNECT 1. Install cylinder housing (A) and cap screw (B). 2. Tighten cap screws 25 N·m (18 lb-ft.) YZ,CTM147,40,27-19-05MAY98 00-40-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=111...
  • Page 114 Main Case Front Housing 3. Install disconnect return spring (A). 4. Install lip seal (A) onto piston (B). YZ,CTM147,40,28-19-05MAY98 00-40-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=112...
  • Page 115 8. Tighten cap screw 25 N·m (18 lb-ft.). LOCTITE is a trademark of the LOCTITE Corporation. YZ,CTM147,40,29-19-05MAY98 NOTE: Place small hole in gasket over small hole in cylinder housing. 9. Install gasket (A). YZ,CTM147,40,30-19-05MAY98 00-40-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=113...
  • Page 116 14. Tighten core assembly. YZ,CTM147,40,31-19-05MAY98 15. Place pin and coil assembly (A) onto core assembly. 16. Install thin stop nut. 17. Tighten to 5 N·m (50 lb-in). YZ,CTM147,40,32-19-05MAY98 00-40-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=114...
  • Page 117 Main Case Front Housing DISASSEMBLE AND ASSEMBLE GROUND DRIVEN PUMP A—Shipping Plug E—Hex Cap Screw (3) B—O-ring F—Adapter C—External Retaining Ring G—Bearing D—Bearing H—Gear I—O-ring YZ,CTM147,40,34-19-05MAY98 00-40-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=115...
  • Page 118 Main Case Front Housing 1. Remove three cap screws (A). 2. Remove ground driven pump assembly (B). YZ,CTM147,40,35-19-05MAY98 DISASSEMBLE GROUND DRIVEN PUMP 1. Remove external retaining ring (A). YZ,CTM147,40,36-19-05MAY98 00-40-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=116...
  • Page 119 3. Start bearing (F) onto gear (C) and press bearing 3. Discard bearings (D) and (F). into adapter (A). 4. Install external retaining ring (B) into groove in gear (C). YZ,CTM147,40,37-19-06MAY98 00-40-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=117...
  • Page 120 YZ,CTM147,40,38-19-05MAY98 INSTALL GROUND DRIVEN PUMP 1. Install ground driven pump onto main case front housing. 2. Install cap screws (A). 3. Torque cap screws to 87 N·m (64 lb-ft). YZ,CTM147,40,39-19-05MAY98 00-40-15 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=118...
  • Page 121 A—Hex cap screws C—Bore Sleeve (4 used) F—Bearing Cup I—Bracket 12x120mm (18 used) D—Input Bushing G—Plug with O-ring (2 used) B—Front Housing (DF250) E—Dowel Pin (2 used) H—Lube Relief Valve Assembly YZ,CTM147,40,18-19-05MAY98 00-40-16 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=119...
  • Page 122 Main Case Front Housing REMOVE FRONT HOUSING 1. Remove cap screws from front housing. YZ,CTM147,40,2 -19-05MAY98 00-40-17 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=120...
  • Page 123 1. Use four threaded holes (A) in front housing to attach lifting tool. NOTE: Use only high grade fasteners for holding the lifting tool to the front cover. 2. Attach lifting tool (B) onto front housing. YZ,CTM147,40,3 -19-05MAY98 00-40-18 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=121...
  • Page 124 CAUTION: Front housing weight is approximately 265 lbs. 3. Lift front housing (A) from rear housing (B). YZ,CTM147,40,4 -19-05MAY98 DISASSEMBLE FRONT HOUSING A—Lube relief valve B—Bore sleeve (4) C—Bearing cup YZ,CTM147,40,11-19-10MAR98 00-40-19 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=122...
  • Page 125 DF 150 Series Transmission has a shoulder in the bore. NOTE: See group 99, special tools. 2. Remove bore sleeves from front side of front housing. YZ,CTM147,40,5 -19-05MAY98 00-40-20 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=123...
  • Page 126 2. Place bore sleeve (A) onto driving tool (B) with outside diameter chamfer of bore sleeve to end of tool. NOTE: See group 99, special tools. 3. Install bore sleeve flush with shoulder. YZ,CTM147,40,6 -19-05MAY98 00-40-21 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=124...
  • Page 127 1. Position front housing with bearing bore side down. 2. Install new lube relief valve (A). NOTE: See group 99, special tools. YZ,CTM147,40,8 -19-05MAY98 REMOVE BEARING CUP 1. Remove bearing cup. YZ,CTM147,40,9 -19-05MAY98 00-40-22 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=125...
  • Page 128 1. Remove oil seal (A). YZ,CTM147,40,12-19-05MAY98 INSTALL OIL SEAL NOTE: Apply LOCTITE #242 or equivalent to outside diameter of oil seal before installation. 1. Install new oil seal flush with shoulder. YZ,CTM147,40,14-19-05MAY98 00-40-23 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=126...
  • Page 129 1. Attach lift tool to front housing. NOTE: Refer to remove front housing for information on attaching lifting tool. 2. Install new gasket onto rear housing. 3. Install front housing (A) to rear housing (B). YZ,CTM147,40,15-19-07MAY98 00-40-24 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=127...
  • Page 130 Main Case Front Housing 4. Install cap screws. 5. Tighten cap screws to 87 N·m (64 lb-ft). YZ,CTM147,40,16-19-05MAY98 00-40-25 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=128...
  • Page 131 Main Case Front Housing 00-40-26 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=129...
  • Page 132 2. Remove cover (B), note position of cut out in cover. 3. Pull out magnetic sensor (C) with O-ring (D). A—Cap screws and washers B—Cover C—Magnetic sensor D—O-ring YZ,CTM147,45,3 -19-05MAY98 00-45-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=130...
  • Page 133 1. Remove two cap screws (A) from oil trough assembly (B). YZ,CTM147,45,1 -19-06MAY98 CAUTION: Approximate weight of output group is 75 lbs. 2. Remove output group and oil trough. YZ,CTM147,45,2 -19-06MAY98 00-45-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=131...
  • Page 134 1. Remove bearing cones (A). IMPORTANT: Do not attempt to remove gear from shaft. This is a permanent assembly. Assemble Output Group Damage to parts will result. 1. Install new bearing cones (A). YZ,CTM147,45,13-19-05MAY98 00-45-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=132...
  • Page 135 35—Thin stop nut 8—Thrust race 17—Shift fork assembly 26—Solenoid cap 36—Pin and coil 12 or 24 9—Shift collar 18—Cylinder housing 27—Cap screw (2 used) volt assembly 10—Snap ring (external) YZ,CTM147,45,41-19-05MAY98 00-45-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=133...
  • Page 136 Gear Ratio Group DISASSEMBLE OUTPUT GROUP WITH INTERNAL DISCONNECT 1. Remove oil trough (A). 2. Remove shift fork. YZ,CTM147,45,8 -19-05MAY98 00-45-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=134...
  • Page 137 Gear Ratio Group 3. Remove output disconnect shaft (A). YZ,CTM147,45,9 -19-05MAY98 4. Remove thrust race (B). 5. Remove thrust bearing (A). YZ,CTM147,45,10-19-05MAY98 00-45-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=135...
  • Page 138 6. Remove shift collar (B). 7. Remove bearing cone (A). YZ,CTM147,45,11-19-05MAY98 ASSEMBLE OUTPUT GROUP WITH INTERNAL DISCONNECT NOTE: See group 99 for special tool (B). 1. Install bearing cone (A). YZ,CTM147,45,12-19-05MAY98 00-45-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=136...
  • Page 139 Gear Ratio Group 2. Press sleeve (A) into output disconnect shaft. YZ,CTM147,45,44-19-05MAY98 3. Install new bearing cone (A). 4. Install shift collar (B). YZ,CTM147,45,45-19-05MAY98 00-45-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=137...
  • Page 140 Gear Ratio Group 5. Install new thrust bearing (A). 6. Install new thrust race (B) YZ,CTM147,45,46-19-05MAY98 7. Install output disconnect shaft (A). YZ,CTM147,45,47-19-05MAY98 00-45-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=138...
  • Page 141 Gear Ratio Group 8. Install shift fork assembly (A) with threaded end up. YZ,CTM147,45,48-19-05MAY98 9. Install oil trough (A) with bolt holes down. YZ,CTM147,45,49-19-05MAY98 00-45-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=139...
  • Page 142 1. Install lift tool (A). 2. Lock holders (B) into place. 3. Install bolt (C) into sixth stage assembly. 4. Lift all clutch stage assemblies from rear housing. YZ,CTM147,45,5 -19-05MAY98 00-45-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=140...
  • Page 143 5. Place stages on work table. CAUTION: Place clutch stage assemblies in 6. Remove lift tool from clutch stage assemblies. center of work table to prevent personal injury. YZ,CTM147,45,6 -19-05MAY98 00-45-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=141...
  • Page 144 NOTE: Refer to Sizing Seal Rings in this group. 3. Remove and discard Bearing (D). 4. Inspect first stage shaft assembly (C). 3. Install new seal ring (A). ASSEMBLE FIRST STAGE ASSEMBLY YZ,CTM147,45,17-19-05MAY98 00-45-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=142...
  • Page 145 E—Clutch Gear K—Clutch Separator Plate O—Lube Shutoff Washer (2 Assembly F—Bearing (2 used) (20 used) used) T—Clutch Gear G—O-ring (2 used) L—Retainer Ring (2 used) P—Clutch Piston (2 used) YZ,CTM147,45,16-19-05MAY98 00-45-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=143...
  • Page 146 D-O-ring M-Clutch Plate Retainer E-Piston Outer Seal N-Snap Ring F-Clutch Piston O-O-ring G-Lube Shutoff Washer P-Bearing H-Clutch Return Spring (6 used) Q-Clutch Gear I-Snap Ring Retainer R-Bearing S-Retaining Ring YZ,CTM147,45,38-19-05MAY98 00-45-15 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=144...
  • Page 147 F—Bearing (2 used) (DF-150 20 used) N—Lube shutoff piston (2 T—Bearing G—Snap ring (2 used) J—Clutch separator plates used) U—Bearing H—Clutch plate retainer (DF-250 22 used) O—Clutch piston (2 used) YZ,CTM147,45,40-19-05MAY98 00-45-16 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=145...
  • Page 148 Q—O-ring (2 used) used) used) M—Clutch retainer spring (12 R—4th and 5th stage shaft F—Bearing (2 used) J—Clutch separator plate used) assembly G—Snap ring (2 used) (DF-150 20 used) YZ,CTM147,45,39-19-05MAY98 00-45-17 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=146...
  • Page 149 Gear Ratio Group DISASSEMBLE CLUTCH STAGE ASSEMBLY All clutch stage assemblies in the DF series transmission assemble and disassemble in the same manner. In this manual we show the disassembly and assembly of the second stage clutch. 1. Remove three teflon seal rings.
  • Page 150 Gear Ratio Group 2. Install bearing removal tool (A). 3. Install gear puller (B) onto bearing removal tool. 4. Remove bearing (C) from shaft assembly. YZ,CTM147,45,19-19-05MAY98 00-45-19 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=148...
  • Page 151 Gear Ratio Group 5. Remove snap ring (D) from shaft assembly. 6. Install gear puller. 7. Remove clutch gear (E). YZ,CTM147,45,20-19-05MAY98 00-45-20 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=149...
  • Page 152 Gear Ratio Group 8. Remove bearing (A). CTM147,45,20A -19-05MAY98 9. Remove o-ring (A). 10. Inspect for wear and damage. CTM147,45,20B -19-05MAY98 00-45-21 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=150...
  • Page 153 Gear Ratio Group CAUTION: Wear eye protection when removing snap ring. 11. Remove snap ring (A). YZ,CTM147,45,21-19-05MAY98 12. Turn shaft assembly over. Remove all clutch and separator plates. YZ,CTM147,45,15-19-05MAY98 00-45-22 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=151...
  • Page 154 Gear Ratio Group 13. Turn shaft assembly over. 14. Install puller. 15. Remove ball bearing and discard bearing. YZ,CTM147,45,22-19-05MAY98 00-45-23 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=152...
  • Page 155 Gear Ratio Group 16. Place shaft assembly on press. 17. Use press tool (B) to compress clutch return springs. NOTE: See group 99 for special tools. 18. Remove snap ring (C). YZ,CTM147,45,23-19-05MAY98 00-45-24 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=153...
  • Page 156 IMPORTANT: Pay attention to the assembly of the clutch return springs. They must be reassembled in the same way. 19. Lift out snap ring, retaining ring, and clutch return springs. 20. Remove lube shutoff washer. YZ,CTM147,45,24-19-05MAY98 00-45-25 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=154...
  • Page 157 21. Apply air pressure through oil passage to force piston from shaft assembly. 22. Remove piston from cylinder. 23. Remove O-ring and piston outer seal from piston. 24. Inspect all parts. YZ,CTM147,45,25-19-05MAY98 00-45-26 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=155...
  • Page 158 Gear Ratio Group ASSEMBLE CLUTCH STAGE ASSEMBLY 1. Install new O-ring (A). 2. Install new piston outer seal (B). 3. Install clutch piston (C). 4. Install lube shutoff washer (D). YZ,CTM147,45,26-19-05MAY98 00-45-27 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=156...
  • Page 159 Use the photograph as a guide. 5. Install clutch return springs (A). 6. Place press tool (B) over shaft. 7. Place snap ring retainer (C) and retaining ring (D) over shaft. YZ,CTM147,45,27-19-05MAY98 00-45-28 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=157...
  • Page 160 Continue until all plates are installed. 11. Install clutch separator plate (A). 12. Install clutch plate (B). Repeat steps 11 and 12 until all plates are installed. YZ,CTM147,45,29-19-05MAY98 00-45-29 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=158...
  • Page 161 Gear Ratio Group 13. Install clutch plate retainer (A). CAUTION: Wear eye protection when installing snap ring. 14. Install snap ring (B). YZ,CTM147,45,30-19-05MAY98 00-45-30 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=159...
  • Page 162 16. After aligning clutch plates remove gear and hub assembly. IMPORTANT: Seal side of bearing goes toward the clutch plates. 17. Install new bearing with seal side of bearing toward clutch plates. YZ,CTM147,45,31-19-05MAY98 00-45-31 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=160...
  • Page 163 NOT press bearing below snap ring groove in shaft. Pressing bearing too far into gear will preload bearing. This will cause the bearing to fail. 21. PARTIALLY install bearing into gear and hub assembly. YZ,CTM147,45,32-19-05MAY98 00-45-32 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=161...
  • Page 164 24. Press only on snap ring. Press until snap ring slips into snap ring groove. NOTE: Check clutch gear for end play. It must have at least .25 mm (.010 in) end play. YZ,CTM147,45,33-19-05MAY98 00-45-33 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=162...
  • Page 165 Gear Ratio Group 25. Install new outer bearing (D). YZ,CTM147,45,34-19-05MAY98 00-45-34 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=163...
  • Page 166 1. Twist seal ring into a tight circle, approximately 3/4 inch in diameter. 2. Install three seal rings in the ring grooves in the shaft assembly. YZ,CTM147,45,35-19-06MAY98 00-45-35 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=164...
  • Page 167 2nd and 3rd clutch stages. Three holes in end of 4th assemblies are installed into the stage shaft. When working on a transmission in a reverse order. YZ,CTM147,45,50-19-05MAY98 00-45-36 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=165...
  • Page 168 Gear Ratio Group 1. Arrange stage assemblies. 2. Install lifting tool. YZ,CTM147,45,36-19-05MAY98 3. Secure all stage assemblies to lifting tool. YZ,CTM147,45,14-19-05MAY98 00-45-37 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=166...
  • Page 169 5. Move locks (B) away from shaft grooves and remove bolt (C) from lifting tool (A). 6. Remove lifting tool carefully from stage assemblies to avoid damage to seal rings. YZ,CTM147,45,37-19-05MAY98 00-45-38 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=167...
  • Page 170 Gear Ratio Group INSTALL OUTPUT GROUP (NO DISCONNECT) AND OIL TROUGH A—Bearing cone (2 used) B—Seventh stage output C—Oil Trough Assembly D—Cap Screw M8x12 8.8 (2 shaft gear assembly used) CTM147,45,42A -19-05MAY98 00-45-39 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=168...
  • Page 171 (remove bearing cup). 1. Install seventh stage assembly into main case rear housing. YZ,CTM147,45,42-19-05MAY98 2. Install two cap screws (A). 3. Tighten cap screws (A) to 25 N·m (18 lb-ft). YZ,CTM147,45,43-19-06MAY98 00-45-40 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=169...
  • Page 172 Bearing Retainer-to-Main Case Rear Torque 25 N·m (18 lb-ft) Housing cap screws. Yoke-to-Output Shaft cap screw. Torque 215 N·m (159 lb-ft) Output Shaft. End play 0± .051 mm (0± .002 inch) YZCTM147,50,SPC-19-05MAY98 00-50-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=170...
  • Page 173 L—Cap Screw M6x20 8.8 (2 O—Magnetic Pickup Sensor C—Elbow H—Magnetic Pickup Sensor used) P—Plug (If Magnetic Pickup D—Identification Plate I—Cover M—Snap Ring Sensor Not Used) E—Drive Screw (2 used) J—Washer (2 used) YZ,CTM147,50,14-19-05MAY98 00-50-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=171...
  • Page 174 Main Case Rear Housing FIRST STAGE COVER GROUP A—O-ring B—First stage cover C—Lift hanger D—Cap screw (6 used) YZ,CTM147,50,15-19-05MAY98 00-50-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=172...
  • Page 175 1. Remove cap screws (C). A—Lift hanger C—Cap screw (5) D—Oil seal E—O-ring B—Cover 2. Remove lift hanger (A), cover (B) and O-ring (E). 3. Remove oil seal (D). YZ,CTM147,50,1 -19-05MAY98 00-50-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=173...
  • Page 176 3. Align cover (B) with bolt hole pattern in rear housing. 4. Install cap screws (C). 5. Install lift hanger (A) over cover (B). 6. Tighten cap screws to 87 N·m (64 lb-ft). YZ,CTM147,50,2 -19-05MAY98 00-50-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=174...
  • Page 177 Main Case Rear Housing REMOVE BEARING RETAINER A—O-ring C—.18 shim (as required) E—Bearing retainer G—Oil seal B—.51 shim (as required) D—.13 shim (as required) F—Cap screw M8x60 8.8 (6 used) YZ,CTM147,50,17-19-05MAY98 00-50-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=175...
  • Page 178 Main Case Rear Housing 1. Position rear housing with bearing retainer up. 2. Remove cap screws (A) from bearing retainer (B). YZ,CTM147,50,13-19-06MAY98 00-50-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=176...
  • Page 179 Main Case Rear Housing IMPORTANT: Keep shims together for reassembly. 3. Remove bearing retainer and shims. YZ,CTM147,50,18-19-05MAY98 DISASSEMBLE BEARING RETAINER • Remove oil seal (A) and O-ring (B). YZ,CTM147,50,6 -19-05MAY98 00-50-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=177...
  • Page 180 Rear housing bore is a light fit for setting end play of the seventh stage assembly. 2. Install new bearing cup into rear housing 1/4 inch past flush. YZ,CTM147,50,5 -19-05MAY98 00-50-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=178...
  • Page 181 4. Tighten cap screws but do not tighten to final torque. NOTE: Refer to group 45 to install gear ratio group into rear housing. NOTE: Refer to group 40 to install front housing to rear housing. YZ,CTM147,50,8 -19-06MAY98 00-50-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=179...
  • Page 182 IMPORTANT: Check end play with dial indicator on cap screw. 4. Place dial indicator on cap screw. 5. Use pry bars under yoke to check end play. A—V-ring seal B—Yoke C—O-ring D—Yoke washer E—Cap screw YZ,CTM147,50,9 -19-05MAY98 00-50-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=180...
  • Page 183 7. Remove bolts from bearing retainer. 8. Remove bearing retainer from rear housing. 9. Remove or install correct amount of shims to reach a 0 ± .002 amount of end play. YZ,CTM147,50,10-19-05MAY98 00-50-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=181...
  • Page 184 11. Install cap screws. 12. Tighten cap screws to 25 N·m (18 lb-ft). 13. Install yoke, O-ring, washer and cap screw. YZ,CTM147,50,11-19-05MAY98 14. Tighten cap screw to 215 N·m (159 lb-ft). YZ,CTM147,50,12-19-05MAY98 00-50-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=182...
  • Page 185 Main Case Rear Housing 00-50-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=183...
  • Page 186 F—Brake disc J—Cap screw (6 used) M—Mount pin (2 used) C—Cap screw G—Cap screw (6 used) K—Caliper assembly N—Cotter pin (4 used) D—V-ring seal H—Hex nut (6 used) YZ,CTM147,55,1 -19-05MAY98 00-55-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=184...
  • Page 187 3. Remove caliper assembly (C) from brake bracket. YZ,CTM147,55,2 -19-05MAY98 4. Remove cap screw (A). 5. Remove yoke washer (B) and O-ring (C). 6. Remove yoke flange with brake disc (D) from output shaft (F). YZ,CTM147,55,3 -19-05MAY98 00-55-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=185...
  • Page 188 7. Remove cap screw (A), Hex nut (B) and lock washer (C) six places. 8. Remove brake disc (D) from yoke flange (E). 9. Inspect brake disc and yoke flange splines for wear or damage. YZ,CTM147,55,4 -19-05MAY98 00-55-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=186...
  • Page 189 4. Install yoke flange with brake disc (D) on output shaft. 5. Install O-ring (C) yoke washer (B) and cap screw (A). 6. Tighten cap screw to 215 N·m (159 lb-ft). YZ,CTM147,55,5 -19-05MAY98 00-55-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=187...
  • Page 190 7. Install caliper assembly (C) on brake bracket. 8. Tighten cap screws 87 N·m (64 lb ft). 9. Install mount pins (B) two places. 10. Install new cotter pins (A) two places. YZ,CTM147,55,6 -19-05MAY98 00-55-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=188...
  • Page 191 Brake Group 00-55-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=189...
  • Page 192 Transmission Repair Stand. Transmission Stand Mounting Brackets. Clutch Return Spring Compression tool. Front Housing Lifting tool. Front Housing Relief Valve tool. Contact FUNK Manufacturing for measured drawings. Funk Manufacturing Company Industrial Park, Highway 169 North P.O. Box 577 Coffeyville, Kansas 67337-0577...
  • Page 193 F—2.362 in. (59.994mm) O—7x 11/16 Drill Through G—8.79 in. (223.26mm) P—.69 in. (17.52mm) H—4.625 in. (117.475mm) Q—3.77 in. (95.75mm) R— 2.992 in. (75.996mm) For use with OTC stand P/N 1735 YZ,CTM147,99,2 -19-05MAY98 00-99-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=191...
  • Page 194 O—17/64 Drill Through as Shown G—2.362 in. (59.994mm) P—1.46 in. (37.08mm) H—6.48 in. (164.59mm) Q—2.992 in. (75.996mm) I—2.25 in. (57.15mm) R— 3.00 in. (76.2mm) For use with OTC stand P/N 1735 YZ,CTM147,99,3 -19-05MAY98 00-99-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=192...
  • Page 195 P-1.46 in. (37.08mm) G-1.44 in. (36.5mm) Q-2.992 in. (75.996mm) H-.47 in. (12mm) R- 3.00 in. (76.2mm) I-.71 in. (18.11mm) NOTE: Used for lifting main case front housing. J-2.88 in. (73.17mm) YZ,CTM147,99,4 -19-05MAY98 00-99-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=193...
  • Page 196 2. Install a 21 bar (2068 kPa) (300psi) pressure gauge in the pressure port. 6. Drain the transmission to proper level. YZ,CTM147,100,2-19-05MAY98 00-100-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=194...
  • Page 197 SOLENOID VALVE OPERATION Before troubleshooting the electric circuit of the valve, the chart shows what solenoids are charged when that gear is selected. DF SERIES EIGHT SPEEDS FORWARD AND FOUR REVERSE DF 8/4 Gear Engage Solenoid Charged F 8th ....2 and D F 7th .
  • Page 198 RESISTANCE 14 OHMS 53 OHMS ± 3% ± 3% * This coil must be used with a Funk approved electronic control module. All checks must be made at the valve. YZ,CTM147,100,6-19-10MAR98 TEST SOLENOIDS IMPORTANT: If a solenoid is removed from the 1.
  • Page 199 Test and Troubleshooting 4-4 DF POWER FLOW FORWARD SPEEDS 1st Gear - 1A, 2nd Gear - 2A 3rd Gear - 1B, 4th Gear - 2B YZCTM147,100,10-19-05MAY98 00-100-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=197...
  • Page 200 Test and Troubleshooting 4-4 DF POWER FLOW REVERSE SPEEDS R1 Gear - 3A, R2 Gear - 4A R3 Gear - 3B, R4 Gear - 4B YZCTM147,100,11-19-05MAY98 00-100-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=198...
  • Page 201 Test and Troubleshooting 8-4 DF POWER FLOW FORWARD SPEEDS 1st Gear - 1A, 2nd Gear - 2A 3rd Gear - 1C, 4th Gear - 2C YZCTM147,100,12-19-05MAY98 00-100-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=199...
  • Page 202 Test and Troubleshooting 8-4 DF POWER FLOW FORWARD SPEEDS (CONTINUED) 5th Gear - 1B, 6th Gear - 2B 7th Gear - 1D, 8th Gear - 2D YZCTM147,100,13-19-05MAY98 00-100-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=200...
  • Page 203 Test and Troubleshooting 8-4 DF POWER FLOW REVERSE SPEEDS R1 Gear - 3A R2 Gear - 3C YZCTM147,100,14-19-05MAY98 00-100-8 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=201...
  • Page 204 Test and Troubleshooting 8-4 DF POWER FLOW REVERSE SPEEDS (CONTINUED) R3 Gear - 3B R4 Gear - 3D YZCTM147,100,15-19-05MAY98 00-100-9 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=202...
  • Page 205 Low (One or Two Gears) for external leakage, Remove control valve. Inspect or replace gasket (See group 35) Leakage in clutch piston or seal Air check to confirm leak. ring. Continued on next page 00-100-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=203...
  • Page 206 Fault code problem Check fault codes to define problem. Voltage to wrong solenoids on Check wiring and connecters. control valve. (See schematic.) Converter damage. Rebuild converter. Continued on next page 00-100-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=204...
  • Page 207 Restricted transmission pump Remove and clean screen (See suction screen. Group 25) Leak in transmission control valve Remove valve and inspect gaskets or gasket (See Group 35). Continued on next page 00-100-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=205...
  • Page 208 Transmission pressure checks Converter sprag clutch damaged or Disassemble and inspect converter. okay, but has no power and installed wrong. possibly overheating. Converter relief valve broken. Replace relief valve. YZ,CTM147,100,1-19-05MAY98 00-100-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=206...
  • Page 209 No power to solenoid, solenoid Check for electric power to solenoid disengage. inoperative. - check wiring and connecters if O.K., replace solenoid. Check valve installed backwards. Install check valve properly. YZ,CTM147,100,9-19-05MAY98 00-100-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=207...
  • Page 210 TCU is • Gear/Diagnostic indicator very remote. • Transmission control valve • Transmission hydraulic system (pump, relief valves, lines, etc.) • Transmission mechanical system (clutches, gears, shafts, seals, etc.) CTM114,105,1 -19-05MAY98 00-105-1 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=208...
  • Page 211 3. Cylinder Magnetic Pickup Sensor (MPU) 4. Output Speed Magnetic Pickup Sensor (MPU) 5. Shift Lever 6. Temperature Sensor 7. Gear/Diagnostic Indicator 8. Inching Pedal (Optional) 9. Park Pressure 10. Proportional Valves CTM114,105,4 -19-05MAY98 00-105-2 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=209...
  • Page 212 (J1, J2 and J3) and any ground strap from the TCU prior to welding. Disconnection the battery supply alone is not sufficient to protect the TCU from ground voltage feeding back through the wiring harness. CTM114,105,5 -19-05MAY98 00-105-3 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=210...
  • Page 213 Cylinder RPM is calculated by pulses per minute divided by the number of teeth on the cylinder gear. CTM114,105,7 -19-05MAY98 00-105-4 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=211...
  • Page 214 The sixth stage gear is on the same shaft as the sixth stage pinion which drives the output gear. CTM114,105,8 -19-05MAY98 00-105-5 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=212...
  • Page 215 The handle can be moved forward to request a forward gear or moved back to request a reverse gear. The release ring under the handle knob must be pulled up to release the neutral lock. CTM114,105,9 -19-05MAY98 00-105-6 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=213...
  • Page 216 • When to Calibrate? If solenoid valve assemblies are changed. After repairs involving transmission clutches. If TCU is replaced. If shift Quality deteriorates. CTM114,105,34 -19-05MAY98 00-105-7 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=214...
  • Page 217 Transmission Control Unit CLUTCH CALIBRATION FOUR FORWARD SPEEDS AND FOUR REVERSE For Funk Analog Valve DF150 or DF250 Series 6. Move the shift handle to the Forward position. Transmissions Four Forward Speeds and Four Reverse. 7. During the first few seconds of the calibration process, the display will show “---”...
  • Page 218 Transmission Control Unit CLUTCH CALIBRATION EIGHT FORWARD SPEEDS AND FOUR REVERSE For Funk Analog Valve DF150 or DF250 Series 6. Move the shift handle to the Forward position. Transmissions Eight Forward Speeds and Four Reverse. 7. During the first few seconds of the calibration process, the display will show “---”...
  • Page 219 The inching pedal provides the operator with a device percentage of modulation is used to modulate the for controlling modulation of the transmission clutches transmission clutches. when desired. With the pedal fully depressed, the CTM114,105,12 -19-21APR98 00-105-10 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=217...
  • Page 220 The Torque Converter Lockup is controlled by the TCU. CTM114,105,15A -19-05MAY98 00-105-11 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=218...
  • Page 221 FORWARD NOT PARK BAT1 STEER VAGND •Metric-pack 150 series 30 way sealed P2S connector •Packard part number: 12034398 •Terminals: 12103881 •Tighten Connector to TCU 0.8—1.5 N·m (7.1—13.3 in-lb) CTM114,105,35 -19-01APR98 00-105-12 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=219...
  • Page 222 SOL E TCLOC R PTO F PTO •Metric-pack 150 series 30 way sealed P2S connector •Packard part number: 12048455 •Terminals: 12103881 •Tighten Connector to TCU 0.8—1.5 N·m (7.1—13.3 in-lb) CTM114,105,37 -19-01APR98 00-105-13 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=220...
  • Page 223 This moves the main spool to a position where the spring force and clutch pressure increases to match it, holding the main spool in a partially displaced position that provides a proportional pressure to the clutch. CTM114,105,39 -19-16APR98 00-105-14 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=221...
  • Page 224 Transmission Control Unit PROPORTIONAL VALVES CONNECTOR PINOUT DF Series Transmission Eight Speeds Forward and Four Reverse SIGNAL CONNECTOR GEAR ENGAGED SOLENOID CHARGED DESCRIPTION AND PIN F 8th ... 2 and D...
  • Page 225 These codes are available for shift lever may be placed back into a legal forward or future retrieval to aid in the diagnosing of the system. CTM114,105,20 -19-05MAY98 00-105-16 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=223...
  • Page 226 Error: Short to positive in Solenoid 2 circuit from output pin J3-B2 to return pin J3-B3. Error: Open or short to ground in Solenoid B circuit from output pin J3-E1 to return pin J3-E2. CTM114,105,22 -19-05MAY98 00-105-17 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=224...
  • Page 227 Error: Short to positive in Solenoid A circuit from Error: Short to positive in Solenoid D circuit from output pin J3-D2 to return pin J3-D3. output pin J3-F2 to return pin J3-F3. CTM114,105,23 -19-05MAY98 00-105-18 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=225...
  • Page 228 Error: NOT PARK (input pin J1-K1) and NEUTRAL Error: Handle signal is park but PARK PRESSURE (input pin J2-A1) are both passive at TCU. (input pin J2-B3) is passive at TCU. CTM114,105,24 -19-05MAY98 00-105-19 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=226...
  • Page 229 Diagnostic Code: 59 Diagnostic Code: 90 Error: Invalid 5 bit selector code. Error: PARK (input pin J2-B3) and NOT PARK (input pin J1-K1) are both active at TCU. CTM114,105,28 -19-05MAY98 00-105-20 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=227...
  • Page 230 Diagnostic Code: 107 Diagnostic Code: 98 Error: Cylinder speed will not drop below the start count speed. Error: WHEELS-UP (input pin J1-H1) and WHEELS-DOWN (input pin J1-H2) are both active. CTM114,105,30 -19-05MAY98 00-105-21 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=228...
  • Page 231 Error: Clutch L fast fill time exceeds 300 ms. Error: Clutch A fast fill time exceeds 300 ms. Diagnostic Code: 120 Diagnostic Code: 114 Error: Clutch M fast fill time exceeds 300 ms. CTM114,105,33 -19-05MAY98 00-105-22 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=229...
  • Page 232 Error: Pointer in capcom20 gets too big. Error: Analog inching voltage (J1-F3) is too high. Diagnostic Code: 165 Diagnostic Code: 149 Error:Safety FET A failed OFF. Error: Vehicle system voltage (j3-A1) is too high. CTM114,105,6 -19-05MAY98 00-105-23 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=230...
  • Page 233 Error Code: Driver 11 cannot get down to requested current. Error: Group three enable high should be low. Error: Short to positive in circuit from output pin Diagnostic Code: 174 J3-H2 to return pin J3-H3. CTM147,105,45 -19-05MAY98 00-105-24 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=231...
  • Page 234 Error Code: Driver 13 cannot get down to requested into it. current. Error: Short to positive in circuit from output pin J3-J3 to return pin J3-K1. CTM147,105,46 -19-05MAY98 00-105-25 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=232...
  • Page 235 Fault: An abnormal condition which results in a lever between the Forward and Reverse positions. perceived performance change or in a loss of function which may result in performance loss or system damage. CTM114,105,19 -19-05MAY98 00-105-26 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=233...
  • Page 236 CYL: Cylinder RPM: Revolutions Per Minute ENG: Engine REV: Reverse TEMP: Temperature FOR: Forward CAN: Control Area Network NEU: Neutral SOL: Solenoid P: Park POT: Potentiometer DC: Direct Current CTM114,105,19A -19-05MAY98 00-105-27 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=234...
  • Page 237 Transmission Control Unit 00-105-28 CTM147 (16JUL98) DF Series 150 and 250 160798 PN=235...
  • Page 238 Index Page Page Free stator Auxiliary pump drive disconnect Free stator assembly drawing ..00-20-11 Assemble ....00-25-10 Front Cover Disassemble .
  • Page 239 Index Page Page Front housing—Continued Remove bore sleeves ... . 00-40-20 Remove front housing ... . 00-40-17 Remove internal disconnect ..00-40-3 Lubricant, transmission .
  • Page 240 Index Page Page Rear housing—Continued Torque converter 12.75—Continued Install output yokes ....00-50-11 Fixed stator converter drawing ..00-20-4 Remove / install magnetic pickup ..00-45-1 Free stator assembly drawing .
  • Page 241 Index Page Transmission Control Unit—Continued Inching Pedal ....00-105-10 Input Function Switches ..00-105-11 Optional Components ... 00-105-10 Output Speed MPU .

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Df150Df250

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