TM-5-3805-254-14-P-2
TRUCK, DUMP, 20 TON, 6X4, ON-OFF HIGHWAY 71,000 GVW, IHC MODEL F-5070 (CCE)
TECHNICAL MANUAL; OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT, GENERAL SUPPORT AND DEPT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE INSTRUCTIONS)
JUNE 1980
TM-5-3805-254-14-P-2 - Page 834 of 894
SHIFTER HOUSING FRONT CONTROL
DISASSEMBLY:
1. Shift auxiliary into neutral. Remove retaining cap
screws (K-2) and lock washers (K-5).
Separate cover
(R-2) from case (G-1) and gasket (K-I) and lift straight
up.
2. Remove plug (R-7) from poppet ball hole and tip
shifter housing to remove poppet spring (R-6), poppet
plunger (R-5) and poppet ball (R-4) from housing.
3. Place shifter housing in a vise so that shift forks
are facing out and end of shift rods (R-11 and R-8) are
pointing to the right.
4. Remove screw (R-14) in shift forks (R-9 and R-
12). Remove screw (R-14) from shift fork (R-12) and use
brass drift to tap shift rod free of underdrive shift fork (R-
12). If models 8031-P or Q are being worked on remove
stop sleeve (R-13) behind fork (R-12). If model R8031-R
is being worked on remove long stop sleeve (R-13) in
front of fork (R-12).
5. Remove screw (R-14) from direct and overdrive
shift fork (R-9). Use brass drift to tap shift rod forward
and free of fork. Use
caution
as shift rod is pulled free of
front boss to prevent loss of interlock (R-10) and poppet
ball (R-4). Use magnet or tip shifter housing over to
remove poppet plunger (R-5) and spring (R-6) from cross
bore in front boss of shifter housing.
6. If shift rod oil seals (R-3) are to be replaced then
remove from housing at this time. Remove old gaskets
from sealing surface and clean housing for inspection
prior to reassembly.
7. Clean and inspect all shifter housing parts for
wear or damage before reassembly.
ASSEMBLY
FRONT CONTROL:
1. To reassemble shifter housing it may be placed
on edge in a vise with inside of housing facing out and
shift rod oil seal openings to the right. Or, if desired,
housing may be placed upside down on a bench.
2. Check fit of shift rods (R-8 and R-11) in shift
forks (R-9 and R-12) as well as in their proper position in
housing to make sure the parts assemble properly and
slide freely. Remove shift rods and apply a light coat of
grease to all bores in housing and to the rods as they are
assembled in the housing.
3. If shift rod oil seals (R-3) were removed, use a
light coat of gasket cement on O.D. of seals and use 12 "
tubing or proper tools to press seals into housing.
4. Assemble shift rod poppet spring (R-6), poppet
plunger (R-5) and poppet ball (R-4) into lower end of
interlock and poppet cross hole in front boss of shifter
housing. Use poppet assembly tool to preload poppet,
ball and spring during assembly of shift rod.
5. Select the shortest shift rod (direct and overdrive
speed shift rod R-8) and enter it through the lower oil seal
(R-3) and into bore of housing. Position shift rod so that
three poppet notches are down and will align with poppet
ball.
6. Tap shift rod (R-8) through first boss to dislodge
poppet assembly tool. Slide shift rod through bore and
with long hub of shift fork to the left.
Assemble direct and
overdrive shift fork (R-9) to rod.
7. Locate shift fork (R-9) in its proper position and
secure to shift rod with screw (R-14). Torque screw to 40
50 lbs. ft.
8. Locate direct and overdrive shift rod in its neutral
position and drop interlock (R-10) into interlock and
poppet cross hole of front boss. Make sure interlock
seats in neutral notch of shift rod (R-8).
9. Select longest shift rod (underdrive rod R-11)
and enter through upper oil seal (R-3) and through front
boss of shifter housing. Position shift rod so that two
poppet notches are up.
10. Slide shift rod into housing. With long hub of shift
fork to the right, assemble underdrive shift fork (R-12) to
rod. If reassembling cover for R8031-P or Q model,
assemble stop sleeve (R-13) in back of fork (R-12). If
reassembling cover for R8031-R assemble long stop
sleeve (R-13) on shift rod before assembling fork (R-12)
on rod.
11. Pass shift rod through rear boss and locate shift
fork in its proper position on rod. Secure fork to rod with
screw (R-14) torque to 40-50 lbs. ft.
12. Assemble poppet ball (R-4), poppet plunger (R-
5) and poppet spring (R-6) through threaded hole on top
outside of shifter housing. Secure with poppet hole plug
(R-7).
13. Use large screwdriver and move underdrive shift
fork out of neutral position. If interlocks are in place and
operative then direct and overdrive shift fork (R-9) will be
locked in the neutral position.
14. Return underdrive rod to neutral. Check shifting
of both shift rods in and out of neutral to make sure they
travel freely and completely into all shift positions. Shift
rod back into neutral position.
825
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