TM-9-2520-249-34-P

• DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL AND REPAIR PARTS AND SPECIAL TOOLS LISTS (INCLUDING DEPOT MAINTENANCE ALLOWANCES) FOR TRANSMISSION W/ CONTAINER, ASSEMBLY
• WARNING
• Table of Contents
• Table of Contents-continued
• CHAPTER 1. INTRODUCTION
• Section II. DESCRIPTION AND DATA
• Table 1-1. Specifications and Data
• Table 1-1. Specifications and Data-continued
• CHAPTER 2. DESCRIPTION AND OPERATION
• Input Pressure Pump
• Fluid Velocity-Type Governor
• Low-Range Planetary Gearing
• Reverse-Range Clutches, Left and Right
• Steer Planetary Gearing, Left and Right
• Output Drive Clutches, Left and Right
• Brake Coolant Pump Assembly
• Main Control Valve Body Assembly
• Lubrication Regulator Valve Body Assembly.
• Section II. OPERATION OF HYDRAULIC SYSTEM
• Oil Filter Assembly
• Cooler Bypass Valve and Converter-out Circuit
• Manual selector value
• Lubrication Circuit (green)
• Figure 2-3. Hydraulic system, first gear, straight travel operation-schematic view.
• Second Gear, Straight Travel Operation
• Third Gear, Straight Travel Operation.
• Fourth Gear, Straight Travel Operation
• Pitot Pressure Circuit.
• Reverse-1 Gear, Straight Travel Operation
• Reverse-2 Gear, Straight Travel Operation
• First Gear, Normal Left Steer Operation
• Second Gear, Normal Right Steer Operation
• Second Gear, Pivot Right Steer Operation
• Operational Circuits
• Reverse- 1 Gear, Pivot Left Steer
• Output Components
• Section III. TORQUE PATHS THROUGH TRANSMISSION
• Neutral Torque path
• Straight Travel Torque Paths
• Second Gear-Straight Travel
• Third Gear--Straight Travel
• Fourth Gear--Straight Travel
• Reverse-1 Gear-Straight Travel
• Reverse-2 Gear--Straight Travel
• Normal (land) Steer Operation
• Second Gear, Normal Right Steer
• Third Gear, Normal Left Steer
• Fourth Gear, Normal Right Steer
• Reverse 1 Gear, Normal Right Steer
• Reverse 2 Gear, Normal Left Steer
• Pivot (water) Steer Operation
• Second Gear, Pilot Left Steer
• Third Gear, Pivot Right Steer
• Fourth Gear, Pivot Left Steer
• Reverse-1 Gear, Pivot Left Steer
• Reverse-2 Gear, Pivot Right Steer
• CHAPTER 3. PARTS, SPECIAL TOOLS AND EQUIPMENT FOR DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
• Table 3-1. Special Tools and Equipment for Direct Support and General Support Maintenance
• Table 3-1. Special Tools and Equipment for Direct Support and General Support Maintenance-continued
• Table 3-2. Improvised Tools and Equipment for Direct Support and General Support Maintenance
• Table 3-2. Improvised Tools and Equipment for Direct Support and General Support Maintenance-continued
• CHAPTER 4. TROUBLESHOOTING
• Troubleshooting-XTG 250-1A Transmission Removed from Vehicle
• Table 4-1. TROUBLESHOOTING-continued
• RANGE SELECTOR CONTROL WILL NOT MOVE.
• VEHICLE TRAVELS IN FIRST GEAR, BUT STALLS IN ALL OTHER GEARS, AND IS FREE IN NEUTRAL.
• VEHICLE PULLS TO LEFT IN SECOND, THIRD, AND FOURTH GEARS WHILE NOT STEERING.
• VEHICLE MOVES IN NEUTRAL (ENGINE SPEED 1000 RPM OR ABOVE).
• CHAPTER 5. PRELIMINARY INSTRUCTIONS FOR TRANSMISSION REPAIR
• Bushings, Bushing-type Bearings, and Thrust Washers.
• Repair Standards
• CHAPTER 6. DISASSEMBLY OF TRANSMISSION INTO SUBASSEMBLIES
• Remove control valve body assembly separator plate
• Remove  steer valve body assembly
• Remove oil transfer plate
• Remove lockup regulator valve body assembly
• Remove lubrication regulator valve body assembly
• Remove input oil pump assembly
• Attach lifting sling
• Apply pressure to stator assembly
• Position torque converter housing
• Remove high-range clutch package
• Remove turbine output shaft 1
• Remove snapring
• Remove pump gear key
• Remove output housing
• Install handle and adapter
• Remove brake apply rotating cam
• Remove retainer assembly
• Attach sling
• Position output housing assembly
• Install handle and adapter
• Remove rotating cam
• Remove reverse-range clutch apply disk
• Remove sump cover
• Place bevel gear housing
• Remove left cross shaft bearing retainer
• Remove right cross shaft bearing retainer assembly
• CHAPTER 7. REPAIR OF SUBASSEMBLIES
• Section II. TORQUE CONVERTER ELEMENTS-REPAIR
• Assembly
• Table 7-2. Repair Standards (Torque converter elements)
• Section IV. CONVERTER HOUSING ASSEMBLY AND CONVERTER GROUND SLEEVE ASSEMBLY-REPAIR
• Section V. TORQUE CONVERTER OUTPUT SHAFT ASSEMBLY-REPAIR
• Section VI. HIGH-RANGE CLUTCH ASSEMBLY-REPAIR
• Assembly
• Section VII. INTERMEDIATE-RANGE CARRIER AND LOW-RANGE SPUR GEAR ASSEMBLY-REPAIR
• Inspection and Repair
• Table 7-6. Repair Standards (Intermediate-range Carrier, Low-range Spur Gear)
• Section VIII. LOW- AND INTERMEDIATE-RANGE CLUTCH SPACER ASSEMBLY-REPAIR
• Section X. LOW-RANGE PLANTARY CARRIER ASSEMBLY-REPAIR
• Assembly
• Section XI. RIGHT AND LEFT CROSS-SHAFT BEARING RETAINERS-REPAIR
• Section XII. BEVEL GEAR HOUSING ASSEMBLY-REPAIR
• Section XIII. BEVEL DRIVEN GEAR AND CROSS-SHAFT ASSEMBLY-REPAIR
• Table 7-11. Repair Standards (Bevel Driven Gear, Cross Shaft)
• Section XIV. BEVEL DRIVE GEAR ASSEMBLY-REPAIR
• Figure 7-20. Loosening pinion bearing support.
• Assembly
• Table 7-12. Repair Standards (Bevel Drive Gear)
• Section XV. STEER COOLANT CHECK VALVE RETAINER ASSEMBLY-REPAIR
• Disassembly
• Figure 7-28. Installing spindle into reverse-range planetary carrier.
• Table 7-13. Repair Standards (Reverse-range Planetary Carrier)
• Section XVII. STEER PLANETARY CARRIER AND OUTPUT SHAFT ASSEMBLY-REPAIR
• Assembly
• Figure 7-32. Installing double-row ball bearing onto output shaft.
• Table 7-14. Repair Standards (Steer Planetary Carrier, Output Shaft)
• Section XVIII. RIGHT AND LEFT BRAKE AND STEER CLUTCH-REPAIR
• Table 7-15. Repair Standards (Right, Left Brake, Steer Clutch)
• Section XIX. RIGHT AND LEFT OUTPUT CLUTCH ASSEMBLIES-REPAIR
• Assembly
• Figure 7-41. Installing output clutch piston return spring.
• Table 7-16. Repair Standards (Right, Left Output Clutch Assemblies)
• Section XX. RIGHT AND LEFT OUTPUT HOUSING ASSEMBLY-REPAIR
• Assembly
• Figure 7-47. Dimensions for installing screw thread inserts and insert staking pins.
• Table 7-17. Repair Standards (Right, Left Output Housing)
• Assembly
• Section XXII. RIGHT OUTPUT END COVER ASSEMBLY AND SPEEDOMETER DRIVE COVER-REPAIR
• Section XXIII. OUTPUT OIL PUMP ASSEMBLY-REPAIR
• Table 7-20. Repair Standards (Output Oil Pump)
• Section XXIV. OIL FILTER ASSEMBLY-REPAIR
• Repair Standards.
• Assembly
• Section XXVI. LUBRICATION REGULATOR VALVE BODY ASSEMBLY-REPAIR
• Section XXVII. INPUT OIL PUMP ASSEMBLY-REPAIR
• Assembly
• Section XXVIII. BRAKE COOLANT PUMP ASSEMBLY-REPAIR
• Table 7-24. Repair Standards (Brake CooIant Pump)
• Section XXIX. MAIN CONTROL SELECTOR VALVE BODY ASSEMBLY-REPAIR
• Table 7-25. Repair Standards (Main control Selector Valve body)
• Section XXX. STEER VALVE BODY ASSEMBLY-REPAIR
• Figure 7-58. Removing for installing) steer shaft assembly
• Figure 7-59. Steer valve adjustment
• Table 7-26. Repair Standards (Steer Valve Body)
• Section XXXI. OIL TRANSFER PLATE ASSEMBLY-REPAIR
• Assembly
• Figure 7-62. Removing (or installing) brake apply shaft.
• Table 7-27. Repair Standards (Right, Left Brake Apply body Bevel Gear Housing Cover)-Continued
• Table 7-27. Repair Standards (Right, Left Brake Apply body Bevel Gear Housing Cover)-Continued
• CHAPTER 8. ASSEMBLY OF TRANSMISSION FROM SUBASSEMBLIES
• Determining Actual Shim Between Bevel Drive Gear Support and Carrier
• Figure 8-4. Nominal shims for bearing retainers.
• Figure 8-5. Checking backlash of bevel gears.
• Assembly Pictorial Steps
• Position the bevel gear housing on blocks
• Install proper shims
• Position bevel gear housing
• Install eight 3/8-16x1 3/4-inch, selflocking bolts
• Place bevel gear housing
• Install splined spacer
• Install six internal-splined disks
• Position left output housing assembly
• Insert eyebolt
• Install two 3/8-16 x 1 3/4-inch bolts
• Install left output driven gear
• Install  steer  coolant  check  valve  retainer assembly
• Install reverse-range clutch apply disk
• Install 12 steel balls
• Insert eyebolt
• Attach lifting sling
• Install output driven oil pump assembly
• Install Woodruff key
• Install lifting bracket
• Install converter output shaft and bearing
• Hold the pitot tube in place
• Install bearing
• Install ten 3/8-16 x 2 1/4-inch bolts
• Install bearing retainers
• Install turbine assembly
• Install square sealring
• Attach sling
• Install the proper spacer or spacers
• Install three antirotational pins
• Install splined washer
• Install gasket
• Install gasket
• Install two gaskets
• Install three 3/8-16 x 21/1-inch bolts
• Remove the guide bolts
• Install gasket
• Position converter housing assembly
• CHAPTER 9. TESTS AND ADJUSTMENTS
• Figure 9-1. Test data log sheet
• Oil Pressure Readings
• Figure.9 2. Transmission oil pressure check points front view.
• Figure 9-3. Transmission oil pressure check points-rear
• Adjustments
• Shift Control Linkage.
• APPENDIX A. REFERENCES
• APPENDIX B. DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
• Maintenance  code
• Special Information
• GROUP 07-TRANSMISSIONS
• GROUP 0708-TORQUE CONVERTER-Continued
• GROUP 0710-TRANSMISSION ASSEMBLY
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0710-TRANSMISSION ASSEMBLY-continued
• GROUP 0713-RANGE CLUTCHES
• GROUP 0713-RANGE CLUTCHES-continued
• GROUP 0713-RANGE CLUTCHES-continued
• GROUP 0714-CONTROL VALVE
• GROUP 0714-CONTROL VALVE-continued
• GROUP 0714-CONTROL VALVE-continued
• GROUP 0714-CONTROL VALVE-continued
• GROUP 0714-CONTROL VALVE-continued
• GROUP 0714-CONTROL VALVE-continued
• GROUP 0714-CONTROL VALVE-continued
• GROUP 0721-OIL PUMPS
• GROUP 0721-OIL PUMPS-continued
• GROUP 0721-OIL PUMPS-continued
• GROUP 0721-OIL PUMPS-continued
• GROUP 2604-SPECIAL TOOLS
• Section IV. NATIONAL STOCK NUMBER AND PART NUMBER INDEX
• National Stock Number Cross-Reference to Figure and Item Numbers-Continued
• National Stock Number Cross-Reference to Figure and Item Numbers-Continued
• National Stock Number Cross-Reference to Figure and Item Numbers-Continued
• National Stock Number Cross-Reference to Figure and Item Numbers-Continued
• National Stock Number Cross-Reference to Figure and Item Numbers-Continued
• National Stock Number Cross-Reference to Figure and Item Numbers-Continued
• National Stock Number Cross-Reference to Figure and Item Numbers-Continued
• Part Numbers Cross-Referenced to Figure and Item Numbers
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• Part Numbers Cross-Referenced to Figure and Item Numbers-continued
• INDEX
• INDEX-continued
• INDEX-continued
• INDEX-continued
• INDEX-continued
• INDEX-continued
• INDEX-continued
• Foldout 1. Model XTG 250-1a transmission-cross-section view.
• Foldout 2. Model XTG 250-1A transmission hydraulic system-schematic view.
• Foldout 3. Lockup clutch, torque converter, converter housing, and related parts-exploded view.
• Foldout 4. High-range clutch, intermediate- and low-range clutches and planetaries, and related parts-exploded view.
• Foldout 5. Cross shaft, bevel gears, bevel gear housing, and related parts-exploded view.
• Foldout 6. Left reverse-range clutch and planetary, brake cams, and steer planetary-exploded view.
• Foldout 7. Left brake disks, steer clutch, output clutch, output housing. Transfer gears, and end cover exploded view.
• Foldout 8. Right brake disks, steer clutch. Output housing, transfer gears, and end cover-exploded view.
• Foldout 9. Reverse-range clutch and planetary, brake cams, and steer planetary-exploded view.
• Foldout 10. Oil filter screen. Main-pressure regulator, lubrication regulator, and oil, and oil filler tube exploded view.
• Foldout 11. Input oil pump, brake coolant pump, and related parts-exploded view.
• Foldout 12. Control, steer valve assemblies, and separating plates-exploded view.
• Foldout 13. Oil transfer plate, bevel gear housing cover, and brake apply components-exploded view.
• Foldout 14. Special tools and equipment.
• Foldout 15. Sequence for tightening transmission top bolts.
• THE METRIC SYSTEM AND EQUIVALENTS
• TM-9-2520-249-34-P
• Blank Page
• Distribution
• RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
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• RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS

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