[/elvet Drive’ amare oe “DM Taansmisstons Rev-1 March 1,1995. , Division of Regal-Beloi Rev-2 Feruary 3, 1998 71C-72C V-Drive (All Ratios) 200 Theodore Rice Blvd. New Bedtord, Telephone: | Industrial Park Massachusetts 508/979-4800 02745-1290 Fax: 508/998-1579 |FOREWORD PURPOSE. This service manual presents maintenance instruction for the Velvet-Drive 72C V-Drive marine transmissions. The next page contains a model chart listing the part numbers covered in this manual. Be sure one of these assembly part numbers is on the transmission identification plate before using these instructions. ‘SCOPE. This service manual presents information of value to maintenance personnel familiar with hy- draulic transmissions. The information is organized as shown in the Table of Contents. INTERNATIONAL SYMBOLS. The following international symbols are used in this service manual. These symbols are printed in red to emphasize their importance. A CAUTION: This symbol warns of possible damage to the transmission. WARNING: THIS SYMBOL WARNS OF POSSIBLE PERSONAL INJURY. ABBREVIATIONS. The following symbols and abbreviations are used: * OEM - Original Equipment Manufacturer (Boat/Engine Manufacturer). * SAE - Society of Automotive Engineers. + RPM - Revolutions Per Minute. ‘* ATF - Automatic Transmission Fluid UNITS OF MEASURE. United States standard units of measure are used in this manual. The metric equivalent follows in ( ). The following terms are used: Foot-Pounds (FT-LB). Inch-Pounds (IN-LB) . - Newton Meters (Nm) - Newton Meters (Nm) Pounds per Square Inch (PSI)........... Kilopascal (kPa) Pounds (Ibs) ...... teeeesessseses Kilograms (K) Inches (in.) . Millimeters (mm) Farenheit (F).. Centigrade (C) IMPROVEMENTS. A Reader's Comment Card is located in the back of this manual. Please take a mo- | ‘ment to answer the questions and return the card.71C MODEL CHART TRANSMISSION TRANSMISSION V-DRIVE RATIO ASSEMBLY * PORTION GEAR BOX (in fwd.) 10-04-000-002 10-04-410-001 13-08-410-002 1.99:1 10-04-000-003 10-04-410-001 13-08-410-003 1.98:1 10-04-000-004 10-04-410-001 13-08-410-004 2.50:1 10-04-000-005 10-04-410-001 13-08-410-005 2.49:1 10-04-000-006 10-04-410-001 13-08-410-006 3.10:1 10-04-000-007 10-04-410-001 13-08-410-007 3.141 10-04-000-008 10-04-410-001 13-08-410-008 0.97:1 10-04-000-009 10-04-410-001 13-08-410-009 0.96:1 10-04-000-010 10-04-410-001 13-08-410-010 1.53:1 10-04-000-011 10-04-410-001 13-08-410-011 1511 10-04-000-012 10-04-410-001 13-08-410-012 1.201 10-04-000-013 10-04-410-001 13-08-410-013 1.204 72C MODEL CHART TRANSMISSION TRANSMISSION V-DRIVE RATIO ASSEMBLY * PORTION GEAR BOX (in fwd.) 10-05-000-002 10-05-410-001 13-08-410-002 4.99:1 10-05-000-003 10-05-410-001 13-08-410-003 1.98:1 10-05-000-004 10-05-410-001 13-08-410-004 2.50:1 10-05-000-005 10-05-410-001 13-08-410-005 2.49:1 10-05-000-006 10-05-410-001 13-08-410-006 3.10:1 10-05-000-007 10-05-410-001 13-08-410-007 3.141 10-05-000-008 10-05-410-001 13-08-410-008 0.97:1 10-05-000-009 10-05-410-001 13-08-410-009 0.96:1 10-05-000-010 10-05-410-001 13-08-410-010 1.53: 10-05-000-011 10-05-410-001 13-08-410-011 1.51:1 10-05-000-012 10-05-410-001 13-08-410-012 1.214 10-05-000-013 10-05-410-001 13-08-410-013 1.21:1 * This part number appears on transmission identification plate. PyTABLE OF CONTENTS Section DESCRIPTION A. Introduction B. Direction of Rotation ©. Theory of Operation INSPECTION. .. . A. General B. Scheduled Inspections MAINTENANCE. ‘A. General B. Lubrication. . . TROUBLESHOOTING. A. General B. Guidelines, OVERHAUL A. General B. Disassembly . C. Cleaning D. Inspection E. Repair... cece eee eeeeee F. Assembly - Forward & Reverse Transmission INSTALLATION . ILLUSTRATED PARTS LIST (FORWARD AND REVERSE TRANSMISSION) VIDRIVE GEARBOXES... 60... eee eens A. Description B. Assembly ILLUSTRATED PARTS LIST (V-DRIVE GEARBOX) SPECIAL TOOLS. SPECIFICATIONS SERVICE NOTES 12 12 12 12 12 13 13 29 30 37 37 37 48 51 52 54LIST OF FIGURES Title 71C AND 72C Transmission Assembly Direction of Rotation Typical installation. Transmission Power Flow Hydraulic Cirouit Schematic Bushing Installation Shift Cable Adjustment Outlet Oil to Cooler Coupling Alignment oe 10. 71C and 72C V-Drive Transmission Assembly 11. V-Drive Assembly 12. Output Shaft Shim Fixture 13, Intermediate Shaft Shim Fixture ©PNODAoONs LIST OF TABLES Title 1. Technical Specifications 2. Scheduled Inspections 3. Troubleshooting 4, Bolt and Fastener Torques 5. Spring Dimensions 6. Test Pressures. . 7. Cooler Flow... Page 582 52 53 53DESCRIPTION COOLER OUTLET BREATHER (GEE FIGURE ~N 1 NEUTRAL: Bf SWITCH TRANSMISSION IDENTIFICATION FORWARO PLATE” voRIVE AND REVERSE i ‘TRANSMISSION EARBOK~. (CURRENT) ‘output sHarT ‘COUPLING cooLer RETURN 148268 Figure 1. 71C and 72 C V-Drive Transmission Assembly Table 1. Technical Specifications DESCRIPTION MODEL 71C MODEL 72C ‘Speeds ‘One Forward ‘One Forward. One Reverse One Reverse Dry Weight (Approximate) 190 Ib. (86 kg) 203 Ib. (92 kg) Maximum Operating Temperature 190 Degrees F 190 Degrees F (88 Degrees C) (88 Dearees C) Type of Hydraulic Oil Dexron III Dexron III (See details on Page 6.) | (See details on Page 6.) Effective Downangle 15° 15°A. INTRODUCTION (See Figure 1). The 71C and 72C V-Drive transmissions consist of a planetary gear set and multiple disc clutches. Hydraulic pressure is provided by a crescent type pump. The pump is driven at engine speed by the input shaft. Oil from the pump is sent to the control valve. The control valve positions are forward-neutral-reverse. An internal regulator valve controls system pressure. Oil discharged by the regulator valve is sent to the oil cooler. The V-Drive gearbox contains a set of spiral bevel gears and drive gears (or drive chain). B, DIRECTION OF ROTATION (See Figure 2). Gear Drive. The output shaft on all gear driven, model 1004- and 1005- V-Drive transmissions rotate in the same direction as the engine with the shift lever placed in forward, toward the engine. Chain Drive. The output shaft on all chain driven, model 1004- and 1005- V-Drive transmissions rotate in the opposite direction as the engine with the shift lever placed in forward, toward the engine. The shift lever on all model 1004- and 1005- V- drive transmissions must be placed in forward, toward the engine, when moving forward. INPUT SHAFT AND (GHIFTLEVERIN ‘STARBOARD PROPELLER. CLUTCH ASSEMBLY EAR DRIVE, ny PORT PROPELLER. (CHAIN DRIVE s4e27e Figure 2. Direction of Rotation for Typical Installation©. THEORY OF OPERATION. The following information is for the forward and reverse transmission only. Refer to page 37 for details of operation of V-Drive gearbox. Forward is direct drive. A planetary gear set ( to 1.0 ratio for 71C, and 1.1 to 1.0 ratio for 72C) used to obtain reverse. The transmission oil pump is driven by the input shaft. It supplies oil pressure to operate the clutch packs, lubricate parts, and provide cool- ing. ‘A damper plate is bolted to the engine flywheel. The damper plate is splined to connect to the in- put shaft. The damper plate reduces torsional vi- brations to the transmission from the engine (See Figure 3). COUPLING FORWARD ANO REVERSE ‘TRANSMISSION v.DRIvE GEARBOX 148284 Figure 3. Typical installation Forward. The forward clutch is applied hyrauli- cally when the shift lever is placed in the forward position. This connects the input shaft to the out- put shaft. The transmission then transmits power at a 1 to 1 speed ratio in the same direction of ro- tation as the engine (See Figure 4). Reverse. The reverse clutch is applied hydrauli- cally when the shift lever is placed in the reverse Position. The applied clutch holds the ring gear. The input shaft and sun gear, drive the pinion gears, which drive the carrier output shaft. The output shaft turns opposite to engine rotation at a 1 to 1 speed ratio for 71C models, and 1.1 to 1 speed ratio for 72C models (See Figure 4). FORWARD REVERSE 148204 Figure 4. Transmission Power Flow Hydraulic Circuit. Oil from the V-Drive sump en- ters the pump suction passage and is directed to the pump. The pump supplies oil under pressure through passages to the control and regulator valves (See Figure 5). Oil pressure on the end of the regulator valve moves the valve, compressing the spring. This movement allows oil to flow to the cooler. Selector Valve. The selector valve shifts the transmission from neutral to forward or reverse. When selector valve is placed in the forward po- sition, oil is directed to the forward clutch. When selector valve is placed in reverse position, oil is fed to the reverse clutch. When one clutch is en- gaged the other is exhausted by a slot in the se- lector vaive.‘ExnaU TST Se woe q 4 sxscron wun” Genrer} i 45 A \ iC. seerceearaets 7 146906 Figure 5. Hydraulic Circuit SchematicINSPECTION A. GENERAL. The transmission, cooler, cooler lines, and con- trol linkage should be inspected at regular inter- vals. Regular inspections will ensure proper operation and help detect minor problems that can be corrected before they cause a transmis- sion failure. B. SCHEDULED INSPECTION (See Table 2). THESE INSPECTIONS AT REQUIRED INTERVALS CAN RESULT IN INJURY TO PERSONNEL OR PREMATURE FAILURE OF TRANSMISSION. " WARNING: FAILURE TO PERFORM The following recommended inspection intervals are based on normal operating conditions. Inter- vals should be adjusted for extremes of tempera- ture or other severe operating conditions. Inspection intervals are defined as follows: WEEKLY - Once a week before transmission is operated. PERIODIC - Once a month or 100 hours, which- ever comes first. SAFETY - Annually or 1,000 hours, whichever comes first. Table 2. Scheduled Inspections INSPECTION TASK INSPECTION INTERVAL WEEKLY | PERIODIC | SAFETY cooler lines must be replaced. details. tails. See page 6 for details. damage, or looseness. housings and bolts. ment replace breather, Check mount torque specified in OEM manual. has exceeded 190 degrees or alarm sounds, oil in transmission, cooler, and i CAUTION: If transmission temperature Check oil level. Add oil to proper level. See page 6 for x Remove dipstick. Check oil for signs of water or other x ‘contaminants. Check (smell) for signs of burnt oil (overheating). If found, replace oil. See page 6 for de- ‘Change oil in transmission, cooler, and cooler lines. x Inspect control linkage and shift lever for operation. x There should be no sticking, binding, or looseness. Inspect cooler, lines, and connections for leakage, x x Inspect transmission for signs of leakage around x x Inspect breather. Check movement of cap. If no move- x bolts for tightness. If loose, tighten to xMAINTENANCE A. GENERAL. Transmission maintenance normally requires performing the following tasks ‘+ Checking Oil level. The proper oil level can prevent damage to the transmission. ‘* Changing Oil. Regular scheduled oil changes are an important part of transmission mainte- nance. WARNING: SHIFT LINKAGE MUST BE ADJUSTED FOR PROPER OPER- ATION OF TRANSMISSION. * Adjusting control lever and shift linkage. For details refer to page 29 or the OEM manual + Tightening transmission mounting bolts. Tighten only to torque specified in OEM manual B, LUBRICATION. Type of Oil. TRANSMISSION FLUID. General Motors Dexron Ill, Ford Mercon, Daimler-Benz 236.6 or any SAE 10 hydraulic oil that meets Allison C3, Caterpillar TO-2 or equivalent specification is recommended. NOTE: Because of the continuous development of oil formulation, some high performance applications may result in foaming and leakage from the transmission’s vent. Under these circumstances, Velvet-Drive suggest using oils meeting Allison C3 or Caterpillar TO-2 specifications. In addition, it may be necessary to experiment with the fluid level in these applications. Do not mix different brands or types of cil. If the transmission oil temperature has exceeded 190 degrees Fahrenheit or ifthe transmission alarm sound, the oil must be changed. Any changes or modifications to the transmission cooling system will require the oil level be readjusted. Any additions to the boat which will change the installation angle of the transmission at rest (such as extra fresh water tanks, fuel supply, etc.) will require and oil level adjustment. Oil Level Check. Due to the various installation angles and oil cooler set-ups, it may be necessary to adjust the transmission oil level. Transmission oil level can be checked either warm or cold using the follow- ing procedures. Always clean around dipstick with a lint-ree cloth to remove dirt and grease. Small particles of dirt can damage internal components and cause valves to stick. Warm Oil Level Check. A Before making a warm oil level check note the following. * Place control lever in neutral. WARNING: DO NOT REMOVE DIP- STICK WITH ENGINE RUNNING. HOT OIL CAN CAUSE BURNS. * Start engine and let transmission reach nor- mal operating temperature (190 degrees F max) Oil expands when heated and will change the oil level reading. + Check oil level immediately after engine shut- down. Oil drains into transmission from cooler and cooler lines, and will change the oil level reading, + Shut-down engine. Remove dipstick, wipe end with a lint-ree cloth, * Immediately install dipstick in transmission un- til seated, then remove it. * Read oil level on dipstick. Oil level should be at dipstick mark * Add or remove oil if necessary. If required, re- peat this checking procedure until oil is at dip- stick mark.Cold Oil Level Check. A cold oil level mark can be added to the dipstick for ease in checking oil level before starting the engine. Use the following procedure to mark cold oil level on dipstick. * Set oil level according to Warm Oil Level Check (page 6). * Let boat sit overnight. * Remove dipstick and wipe end with a lint-free cloth. * Install dipstick in transmission until seated, then remove it ‘* Mark dipstick at the cold oil level reading. * Install dipstick in transmission. Use the cold oil level mark to check oil before starting engine. If oil level adjustment is needed, add oil to the new mark. Changing A * Place control lever in neutral. Run engine for five minutes at 1500 RPM. Shut-down engine. WARNING: DO NOT REMOVE DIP- STICK WITH ENGINE RUNNING. HOT OIL CAN CAUSE BURNS. * Clean area around cooler line with a lint-free cloth, + Remove cooler return line from transmission. Drain oil from transmission, cooler, and cooler lines into a suitable container. * Check oil for the following foreign matter. Note the following, Metal Particles. A few small particles are normal. However, large metal chips are an early sign of transmission failure. The transmission should be disassembled and inspected for internal dam- age. Rubber Particles. These indicate cooler line wear. Each line should be inspected for cracks or fraying. Damaged lines should be replaced. * Install cooler return line in transmission. NOTE: The amount of oil will vary based on length of cooler lines. Use an amount equal to about three-fourths the quantity removed. ill transmission with new oil * Install dipstick. Remove dipstick and check against cold level mark. Add oil to the proper level. NOTE: If a cold oil level mark is not shown use the procedure described in Warm Oil Level Check to set oil level. * Start engine and allow to idle. Check transmis- sion, cooler, and cooler lines for leaks.TROUBLESHOOTING A. GENERAL. Before troubleshooting the transmission, check the folowing: * Oil level and condition of oil. See page 6 for details, * Transmission, cooler, and cooler lines for dam- age or leakage. Correct any problem. ‘+ Engine, damper plate, or drive train alignment. Refer to page 29 or OEM manual for drive train alignment requirements. B, GUIDELINES. Perform all pressure checks at normal operating temperature. Refer to page 53 for details. Pres- sure gages used should have a range of 0-200 or 0-300 psi and must be accurate. Shift into each selector position to determine when noise or problem occurs. Determine which parts are moving. This will help pinpoint the cause. Use the following information as a guide to common problems. Damper Plate. Some transmission problems are damper plate related. Check and/or replace damper plate when the following problem occurs. ‘* Transmission “knocks” at idle or low RPM, then stops at 1,000 RPM or higher. NOTE: If the damper plate springs are too soft the sides of the windows will wear. If the springs are too hard the splines will wear. Consult engine OEM for damper plate recommendations. Clutches. Check and/or replace clutches if the following problem occurs. + Excessive engine RPM (over the rated RPM). This can indicate a slipping clutch. The slipping clutch will usually squeal. A WARNING: DO NOT OPERATE ‘TRANSMISSION IF THE FOLLOWING CONDITION IS SUSPECTED BE- CAUSE TRANSMISSION CAN NOT BE DISENGAGED. * Transmission overheating with squealing clutch. A slipping clutch will normally overheat. This can result in warped clutch plates. In severe overheating clutch plates can weld together. This will cause a tie up condition in the transmission when the other clutch is applied Table 3. Troubleshooting 2. Between seal and bore. 3. At gasket(s) Loose bolts. Rough housing bore. Damaged gaskets. Face(s) not flat. PROBLEM CAUSE CORRECTION LEAKS: 1. At pump or output shatt | Faulty seal Replace seal oa Misalignment. Correct alignment. Rough shatt Replace shaft. Polish bore and replace seal. Tighten bolts to proper torque. Refer to Table 4 (page 52). Replace damaged gaskets. Replace damaged parts.Table 3. Troubleshooting (Continued) PROBLEM CAUSE CORRECTION LEAKS: (Cont.) 4, Loss of oil with no trace of missing oil 5. Oil out of breather. Oil leaking from cooler or cooler lines. Oil has been overheated. (Lost anti-foam additive.) High or low oil level. Water in oil Cooler too small Cooler lines not properly con- nected. Replace damaged cooler or cooler lines. Replace oil Correct oil level. Change oil. Replace cooler with larger cooler. Connect cooler lines to correct ports. (Refer to page 29.) Incorrect oil Replace oil with correct type. MALFUNCTION IN BOTH FORWARD AND REVERSE: 1. Low oil pressure. Regulator valve jammed. Clean and polish valve 2. No oil pressure. 3. High oil temperature. 4, Damper plate noise. 5. No line pressure. 6. Noise in Forward and Re- verse. 7. Hydraulic noise or buzz. 8. Gear noise in forward and/ or reverse. Internal leakage. Low oil level. Pump damaged, Regulator valve jammed, Regulator valve jammed, ‘Worn or incorrect damper plate Heavy weight oil. Misalignment of damper plate with engine, or misalignment of output shatt coupling, Low oil level or air in hydraulic circuit. Regulator valve sticking. \-Drive bevel gears not prop- erly meshed or gear tooth dam- age. Replace damaged sealing rings. Add oil Replace pump. Clean and polish. Clean and polish. Replace damper plate. Replace oil with correct type. Align drive train components. Check oil level. Fill if low. Run engine in neutral at 1200 RPM to remove air. Clean and polish regulator valve. ‘Check tooth contact pattern. Shim as required to obtain proper mesh or replace dam- aged parts.Table 3. Troubleshooting (Continued) PROBLEM CAUSE CORRECTION MALFUNCTION IN FORWARD OR REVERSE: 1. Clutch drags or does not release. 2, Clutch does not apply. 3. Harsh engagement. 4. Soft engagement. 5. Won't move or sluggish Warped clutch plate. Mechanical Failure. Tight pack clearance. Low pressure. Damaged parts. High pressure - regulator valve sticking. Engine idle too fast. Linkage binding or misad- justed. Low pressure. Forward clutch seized. Worn or broken sealing rings. Replace damaged parts. Replace damaged parts. Increase clearance to speciti- cation. See low oil pressure. Replace damaged parts. Clean and polish valve. Adjust engine idle. Repair as required and adjust to OEM measurement. See low oil pressure. Replace damaged parts. Replace damaged parts. MALFUNCTION IN NEUTRAL: 1. Drives in forward direction. 2. Drives in reverse direction. 3. Noisy in neutral only. Broken sealing rings or bush- ings. Warped forward clutch plates or mechanical failure of clutch. Exhaust blocked in control valve. Shift linkage improperly ad- justed Warped reverse clutch plates or mechanical failure of clutch. Exhaust blocked in control valve. Shift linkage improperly ad- justed Low oil pressure - Pump gears worn Low oil level. Replace damaged parts. Replace damaged parts. Clean control valve. Adjust shift linkage. Replace damaged parts. Clean control valve Adjust shift linkage. Replace pump. Add oil 10Table 3. Troubleshooting (Continued) PROBLEM CAUSE CORRECTION TRANSMISSION OVER- HEATING: Oil level high. Adjust oil level. Oil level tow. Adjust oil level Cooler or lines too small Low oil pressure - Pump gears worn, Clutches slipping. Internal leakage bypassing cooler. ‘Temperature sensor damaged Incorrect type or poor quality ol Regulator valve sticking, Replace with larger cooler and or cooler lines. Lines should have a minimum 19/32" 1.D. Check pump pressure. If low, inspect pump. Replace pump it worn or damaged. Check sealing rings. Replace if damaged. Locate and fix leak. Replace sensor Drain, flush, and replace with correct type oil Clean and polish "OVERHAUL A. GENERAL. A WARNING: KEEP WORK AREA, TOOLS, AND TRANSMISSION CLEAN. WIPE UP ANY SPILLED TRANSMISSION OIL TO PREVENT ACCIDENTS. AS REQUIRED, WEAR SAFETY GLASSES, SAFETY SHOES, AND A HARD HAT TO PRE- VENT PERSONAL INJURY. Before removal and disassembly, review the fol- lowing procedures. Use the proper hand tools, slings, or hoists for the job. Refer to the OEM manual for specific removal procedures. Refer to page 37 for overhaul of V-Drive gearbox. B. DISASSEMBLY. + The transmission can be disassembled follow- ing the order of index numbers on the exploded- view (page 31). * Do not remove suction tube or bearings unless replacement or cleaning is required. * Do not disassemble pressed parts unless re- placement of parts is required. * Remove O-rings, sealing rings, and oil seals carefully to prevent damage if they must be re- used. It is recommended these parts be replaced with new parts during assembly. * Keep matched parts and sets together. Do not reverse or mix them. C. CLEANING. A WARNING: CLEANING SOLVENTS CAN BE TOXIC, FLAMMABLE, AN IR- RITANT TO THE SKIN, OR GIVE OFF HARMFUL FUMES. AVOID PRO- LONGED CONTACT, INHALATION OF VAPORS, OR SMOKING. * Rinse all metal parts in cleaning solvent to re- move dirt, grease, and transmission oil. * Take special care to remove cleaning solvent from all internal passages and cavities. * Air dry clutch plates. * If O-rings, sealing rings, and oil seals are to be reused, air dry them. D. INSPECTION. ‘* Inspect case for cracks. Check sealing sur- faces for nicks, scratches, or burrs that can cause leaks. Inspect output shaft bores for signs ‘of wear on one side. This can indicate misalign- ment of drive train components. * Inspect gears for unusual wear patterns, chipped, cracked or broken teeth. ‘+ Inspect bearings for chips, cracks, galling, or missing bearings. Check for signs of discolor- ation due to overheating * Inspect threaded parts for stripped, damaged threads, or burrs. * Inspect springs for distortion, cracks, or other damage. Check dimensions of each spring. Re- fer to Table 5 (page 2) for details.E. REPAIR. ‘+ Remove minor scratches, burrs, or surface de- fects with very fine emery cloth. * Retap threaded holes using the same size tap. Do not make the hole larger. * If parts cannot be repaired, they must be re- placed. F. ASSEMBLY OF FORWARD AND REVERSE TRANSMISSION. A CAUTION: Threaded parts, screws, bolts, and coupling nuts must be tightened to the torques shown in Table 4 (page 52) to prevent prema- ture failure of transmission. NOTE: The following procedures are correct for most transmissions. Minor differences may be found on some models. * Anew coupling nut must be used at assembly. * Prior to assembly, dip or coat internal parts with transmission oil. Let excess oil drain off. ‘* Inspect assemblies pressed together for Proper fit and position. ‘* Check that each snap ring is fully engaged in groove. * Assemble the transmission using the following procedures. Refer to Figure 10 (page 31) for an exploded-view of the transmission. Numbers in ( )refer to item numbers on the exploded-view. If \-Drive gearbox was disassembled refer to page 37 for assembly details. A CAUTION: Transmissions manutac- tured prior to September 1978 used bushings instead of sealing rings. If bushings were removed from the case, they must be installed before assembly of transmission. Refer to Figure 6 for details. [ASSENBLED IN CASE BORE TO DIMENSIONS aT HOLES IN BUSHING MUST ALIGN WITH HOLES IN CASE AS SHOWN. ~ EACH BUSHING TO BE Teac NOTE: THE 71.26C SERVICE BUSHING REPLACES THE ORIGINAL 71-268 BUSHING Figure 6. Bushing Installation 146514STEP 1. If removed, install the following parts in case (81). Tighten threaded parts to torque shown in Table 4 (page 52). Install breather (72) into top of case (81). Press suction tube (71) into case (81), Apply loctite #92, or equivalent, to threads of pipe plugs (74, 75, and 76) and thread into top of case (81). On early models: Apply loctite #592, or equiva- lent, to threads of dipstick tube (2) and thread into side of case (81). This is used instead of pipe plug (76). NOTE: The plastic shipping plug (73) should be installed hand-tight. STEP 2. Place thrustwasher (70) on face of bearing bore. Notch in thrustwasher (70) must align with notch in case (81) STEP 3. If removed, press bushings (68) into pinion carrier (69). A CAUTION: Do not block pressure holes in pinion carrier with bush- ings. 14 PIPE PLUGS SUCTION TUBE pipstick ‘TUBE OR PLUG 1146924 Case Assembly Thrustwasher Installation CARRIER BUSHINGS a6 | 138/68 Toit grooves AND OIL HOLES MUST BE (EM pLaceo as sHowN 146944 Bushing InstallationSTEP 4. Lubricate sealing rings (67) and bush- ings (68) with vaseline. Install sealing rings (67) in grooves of pinion car- rier (69). Compress each sealing ring (67) until it locks in place. Install pinion carrier (69) in case (81). STEP 5. Install pressure plate (58) in ring (60). Late production ring gears for 72C transmis- sions have 3 large oil drain holes 120° apart. Early production ring gears have 4 small 3/16 holes 90° apart. Either ring gear can be used successtully in marine applications, STEP 6. Starting with a friction clutch plate (57), alternately stack friction clutch plates (57) and steel clutch plates (56), Friction clutch plates are now designed with 3 missing teeth 120° apart. When installed in a late designed ring gear, they should be installed with the missing teeth aligned with the 3 large drain holes as shown in detail *C’. Early and late friction plates can be mixed indis- criminately when installed in an early 72C ring gear or in any 71C ring gear. 15 SEALING RINGS: PRESSURE. HOLES 146354 Pinion Carrier Assembly aL ‘PRESSURE, DRAIN HOLES Aina 3 ean Teel. CLUTCH PLATE FRICTION, STEEL. REACTION PRESSURE PLATE PLATE Forward Clutch Pack Arrangement FIGURE “B”STEP 7. Install clutch plates (56 and 57) and pressure plate (55) in ring gear (60). STEP 8. Install snap ring (54) in ring gear (60). NOTE: Snap ring will locate on top of internal teeth. Do not attempt to seat snap ring in under- cut relief groove. STEP 9. Lubricate O-ring (50) lightly with vase- line and install in groove of forward clutch cylin- der (48), 16 ctuTcH, PLATES, 118514 Forward Clutch Pack Assembly 118524 ‘Snap FORWARD o-nIN cLurcH CYLINDER 118394 O-Ring InstallationSTEP 10. Lubricate clutch spring bearing ring (62) and piston sealing ring (51) with vaseline. Install clutch spring bearing ring (62) in groove on piston (49) face. Install piston sealing ring (51) in outer groove of piston (49). NOTE: Check that piston sealing ring is not twisted, cut, or deformed. Replace if damaged. STEP 11. Install piston (49) in forward clutch cylinder (48). STEP 12. Place clutch belleville (dished) spring (53) inside rim of forward clutch cylinder (48). ‘Spring is dished. The inside of the spring should be lower than the outside. 7 CLUTCH SPRING BEARING FING. PISTON PISTON ‘SEALING RING +2681 Clutch Rings Installation FORWARD CLUTCH eee CYLINDER 118954 Piston Installation ‘CLUTCH BELLEVILLE ‘SPRING (DISHED) FORWARD: CLUTCH CYLINDER 118964 Clutch Spring AssemblySTEP 13. Install ring gear (60) over forward clutch cylinder (48), with piston (49) and spring (53) facing up. Press ring gear (60) down over forward clutch cylinder (48). Remove clutch assembly from press. A CAUTION: Check to see that clutch spring bearing ring is still seated in groove of clutch piston. STEP 14. Install snap ring (59) in groove of ring gear (60) NOTE: Several different snap rings are used to assemble clutch group. They have different thicknesses. Be sure correct snap ring is used, STEP 15. Place ring gear (60) in press with ex- ternal splines facing down. Press forward clutch cylinder (48) against snap ring (59). Remove clutch assembly from press. NOTE: Assembly tool should support the ring gear only. The forward clutch cylinder should not be touching the assembly tool. 18 RING. GEAR EXTERNAL ‘SPLINES. FORWARD CLUTCH CYLINDER 326524 Forward Clutch Cylinder Installation 11898 RING GEAR TRIM OF by cuter Je] CYLINDER ASSEMBLY TOOL 118974 Compressing Clutch Pack* STEP 16. Push down, by hand, on clutch plates. Measure snap ring gap. Select proper thickness ‘snap ring (59) or combination of snap rings (59) to set clutch pack clearance. Refer to chart be- low. More than one snap ring may be required. 10-04 bronze pack clearance: 10-05 bronze pack clearance: 10-04 paper pack clearance: 10-05 paper pack clearance: 0.018 - 0.053 in (0.46 - 1.35 mm) 0.035 - 0.055 in. (0.89 - 1.40 mm) 0.018 - 0.053 in. (0.46 - 1.35 mm) 0.021 - 0.046 in. (0.53 - 1.17 mm) PART ‘SNAP RING THICKNESS NUMBER inch mm 4768 0.050-0.054 | 1.3-1.4 4768A 0.074-0.078 | 1.9-2.0 47688 0.096-0.100 | 24-25 10-00-139-018 | 0.062-0.066 | 1.6-1.7 10-00-139-048 | 0.033 -0.037 | 0.84 -0.94 10-00-139-049 | 0.050- 0.054 | 1.27-1.37 STEP 17. Install selected snap ring(s) (59) in groove of ring gear (60). 19 118408 Snap Ring Selection SNAP RING GROOVE s1es1a Snap Ring AssemblySTEP 18. If removed, install woodrutf key (65) in drive gear assembly (66). Slide forward clutch hub (64) on drive gear assembly (66) and align with woodruff key (65). Press forward clutch hub (64) on drive gear assembly (66) and against shoulder. Install snap ring (63) in groove of drive gear as- sembly (66) Lubricate sealing rings (62) with vaseline and in- stall in grooves of drive gear assembly (66). Compress each sealing ring (62) until it locks in place. STEP 19. Install drive gear assembly (66) in clutch assembly. Slide bearing (47) down drive gear assembly (66). Place complete assembly in press. Press bearing (47) into drive gear assembly (66) until seated against shoulder. STEP 20. Install snap rings (45 and 46) in grooves of drive gear assembly (66) and forward clutch cylinder (48). 20 DRIVE GEAR ‘ASSEMBLY 126958 Sealing Ring Installation sa292n Bearing Installation SNAP RINGS: RING GEAR 192898 Snap Ring InstallationSTEP 21. Apply vaseline to bronze thrust washer (61). Install over end of shaft and against face of gear. STEP 22. Install clutch and drive gear assembly in case (81). Rotate clutch and drive gear assembly back and forth to engage ring gear teeth with pinion teeth. STEP 23. Install thrustwasher (43) on face of clutch cylinder. Check clearance as follows: Position case (81) vertically as shown. Measure from face of case (81), without gasket (33), to face of clutch cylinder. ‘When dimension is 0.433 inch (11.0 mm) or less, use 71-158 thrustwasher. When dimension is greater than 0.433 inch (11.0 mm), use 10-16-193-001 thrustwasher. 2 FACE OF CLUTCH CYLINDER CASE 126594 ‘Thrustwasher InstallationSTEP 24, Install one bronze reverse clutch fric- tion plate (40) in case (81). STEP 25. Install three dowel pins (42) and eleven pressure plate springs (41) in case (81). STEP 26. Install one steel clutch plate (39) in case (81) with large part of tab to left of dowel pin (42). Alternately stack remaining friction clutch plates (40) and steel clutch plates (99) in case (81). REVERSE CLUTCH FRICTION PLATE 126544 DOWEL PINS swearal Spring and Dowel Pin Installation LARGE, ‘SIDE OF ‘TAB HERE DOWEL PIN Reverse Clutch Pack instalSTEP 27. Install clutch pressure plate (38) in case (81) with three half moons aligned with dowel pins (42). Be sure all pressure plate springs (41) are seated in their holes. STEP 28. Lubricate sealing ring (36) with vase- line and install in groove of reverse clutch piston (35). NOTE: Be sure sealing ring is not twisted, cut, or distorted. Replace if damaged. STEP 29. If removed, press needle bearing (31) into adapter (29). Needle bearing (31) must be stalled flush (even) with back face of adapter (29). Lubricate O-ring (37) with vaseline and install in groove of adapter (29). NOTE: Be sure O-ring is not twisted, cut, or dis torted. Replace if damaged If removed, install dryseal plug (34) in adapter (29). Tighten plug (34) to torque shown in Table 4 (page 52). 23 Pressure Plate Installation REVERSE CLUTCH PISTON SEALING FING 119828, Sealing Ring Assembly SEALING NEEDLE BACK FACE RING BEARING OF FORWARD AND. REVERSE ADAPTER 126984 Sealing Ring InstallationSTEP 30. Install reverse clutch piston (35) in adapter (29) Lightly coat gasket (33) with vaseline and place on adapter (29). STEP 31. Install adapter (29) on case (81) and align bolt holes. Thread four capscrews (30) into case (81). Tighten capscrews (30) in a criss-cross pattern to final torque specified in Table 4. Lightly tap woodrutf key (28) into place in drive gear with a soft-taced mallet. STEP 32. Press cil seal (26) into pump body. CAUTION: Oil seal must be installed dry on the outside diameter. Lubri- cants can damage rubber coating. STEP 33. Install driven gear in pump body. NOTE: Pump gear should be installed the same side down as removed. ‘FORWARD AND. REVERSE REVERSE ADAPTER, CLUTCH PISTON 126998 Reverse Clutch Piston Assembly FORWARD AND ‘CAPSCREWS REVERSE ADAPTER s20ata 126584 PUMP. ORIVEN GEAR 12659 Pump Driven Gear AssemblySTEP 34. Lubricate pump gasket (27) with vase- line and install in groove of adapter (29). Install pump drive gear onto drive gear assembly (66). Check that pump drive gear locates freely on woodruff key (28) and drive gear assembly (66), STEP 35. Install pump assembly (24) on top of adapter (29) and align bolt holes. with cast arrow at top pointing in the same direction as engine rotation. CAUTION: Position pump housing ‘Thread four bolts (25) into adapter (29). Tighten bolts (26) in a criss-cross pattern to final torque specified in Table 4 (page 52). Pump Assembly Installation (Non-automotive rotation engine) 25STEP 36. Assemble control valve assembly (17), Lubricate O-ring (22) with vaseline and install on ‘end of control valve assembly (17) NOTE: Gap in snap ring must be aligned with notch in control valve. STEP 37. Lightly lubricate O.D. of control valve assembly (17) with vaseline. Slide control valve assembly (17) into side of case (81). STEP 38. Install switch cam (15) on end of con- trol valve assembly (17). Be sure tab on switch cam (15) sets in notch of control valve assembly (17), O-RING contro. “ vawe Tok SPRING RETAINER AN eaison ‘snap. ee VALVE 126998 Control Valve Assembly ‘CONTROL. VALVE ASSEMBLY NoTcH ALIGNED ( With THs BOLT HOLE, | Control Valve Assembly Installation ‘Switch Cam installation 26STEP 39. Install valve cover (12) as follows: Position gasket (16) on case (81). Place valve cover (12) over gasket (16) and align bolt holes. Thread three bolts (13) with lockwashers (14) into case (81). Tighten bolts (13) in a criss-cross pat- tern to final torque specified in Table 4 (page 52) If removed, lubricate O-ring (11) with vaseline and install in groove of neutral switch (10) Thread neutral switch assembly (9) into valve cover (12). Tighten neutral switch assembly (9) to torque specified in Table 4 (page 52). STEP 40. Install shift lever (3) as follows: Lubricate poppet spring (8) and hole in case (81) with grease, Shell Alvania #2, or equivalent Place poppet spring (8) and stee! ball (7) in case (81), Slide shift lever (3) over end of control valve as- sembly (17) and against steel ball (7). Rotate s! lever (3) to engage steel ball (7) in hole of shift lever (3). Hold shift lever (3) against steel ball (7). Install washers (5 and 6) and thread nut (4) on control valve assembly (17). Tighten nut (4) to torque specified in Table 4 (page 52). STEP 41. If removed, apply loctite #270 to threads of studs (78). Thread studs (78) into back of case (61). Tighten studs (78) to torque speci- fied in Table 4 (page 52). Lubricate gasket (79) with vaseline and install on back of case (81) over studs (78). 27 switch vooeasen | BOUT 126624 Valve Cover installation LockWasHER FLATWASHER 148904] Shift Lever Assembly stuos casKeT 146408 Stud InstallationSTEP 42. On early models, install dipstick (1) in side of case (81). Turn handle until snug. Do not overtighten. STEP 43. Slide coupling (80) onto output shaft of transmission. Align splines of coupling (80) with input shaft of \V-Drive and slide V-Drive against back of trans- mission. Thread new nuts (77) onto studs (78). Tighten nuts (77) in a criss-cross pattern to final torque specified in Table 4 (page 52) Rotate V-Drive coupling several times to be sure coupling (80) is not binding. pIPstick, 40st Dipstick Installation LOCK NUTS, vDRIVE GEARBOX TRANSMISSION 140424 \V-Drive InstallationINSTALLATION CAUTION: After a transmission fail- * Connect propeller shaft to gearbox. Check A ure the cooler and cooler lines must —_ alignment of coupling halves (See Figure 9). be flushed to remove contaminated transmission oil and metal/rubber particles. Failure to comply can re- MAINLINE > PRESSURE TAP sult in premature wear or failure of verhauled transmission. REVERSE CLUTCH a over ae = * Align input shaft spline with damper plate. * Assemble transmission to engine, and then in- y Nee a stall bolts. Do not use bolts to draw transmission Rx against engine. WARNING: CHECK THE SHIFT LEVER POSITION AT THE HELM TO =) fa SEE THAT FORWARD POSITION IS. RED SHIPPING PLUG) ALSO FORWARD POSITION AT THE TRANSMISSION SHIFT LEVER. 127850, (TRANSMISSION SHOULD NOT BE S RUNNING IN REVERSE WHEN BOAT Figure 8. Oll Outlet to Cooler IS GOING FORWARD.) ‘* Adjust shift cable so holes in shift lever are centered over the detent ball at each selector lo- 203 \ cation (See Figure 7). * For complete installation instructions refer to OEM manual. * Connect oil line to oil cooler outlet (See Figure 8) SHIFT LEVER DETENT BALL CENTERED INHOLE FORWARD, NEUTRAL, AND REVERSE Posmrions N PROPELLER TRANSMISSION ‘SHAFT ourpur ‘COUPLING 146744 FLANGE FLANGE 146498 ™ Figure 7. Shift Cable Adjustment Figure 9. Coupling Alignment 29ILLUSTRATED PARTS LIST A. GENERAL. The Illustrated Parts List is a breakdown of as- semblies, subassemblies, and detail parts of the 71C and 72C transmission. Explanation of columns in illustrated parts list INDEX NUMBER COLUMN: The index numbers key the parts list to the related illustration. The in- dex numbers are arranged in sequence and re- flect the order of disassembly. An index number followed by a letter indicates a multiple listing of that item. PART NUMBER COLUMN: This column contains the Velvet-Drive part number for each item. When “NO NUMBER” appears in this column it indicates the item is not serviced separately (NSS). It is only available as part of the Next Higher Assembly or a service kit. Service kits and special notes are listed at the end of the parts list, DESCRIPTION COLUMN: This column identifies the items being listed. The assemblies, detail parts, and attaching parts are indented to show their relationship to the assembly. Parts unique to a specific model will have this information noted in( ), such as: (10-04 ONLY). Symbols appearing in this column are explained at the end of the parts list. ' QTY COLUMN: This column indicates the num- ber of parts required for assembly. Some parts, such as shims and snap rings, are used as re- quired to obtain the proper fit or clearance. B. ORDERING DATA. Obtain the index number assigned to the item(s) required from the illustration. Refer to the illus- trated parts list for the name and part numbers. Be sure to check if any of the parts are contained in a service or repair kit. Always reference the model and serial numbers on the transmission identification plate. This will help ensure the cor- rect parts are supplied for the transmission NOTE: The illustrated parts list for the V-Drive gearbox is on page 48.Figure 10. 71C and 72C V-Drive Transmission Assembly 31INDEX PART DESCRIPTION ‘ary No. NUMBER Fig. 10 | 10-04-000- * | TRANSMISSION ASSEMBLY (MODEL 71C) 10-05-000- *_ | TRANSMISSION ASSEMBLY (MODEL 72C) 1 | 10-06-559-001 | * DIPSTICK (EARLY) 1 2 — | 10-04-034.002 | * DIPSTICK TUBE (EARLY) 1 3 | 71-798 * SHIFT LEVER 1 4 | satea92 © HEX NUT (5/16-24) 1 5 | 108579 * LOCKWASHER (5/16) 1 6 | 103340 * FLATWASHER (5/16) 1 7 | 453632 * STEEL BALL (5/16) 1 a | 7142 + POPPET SPRING 1 9 | 10-00-640-004 | » NEUTRAL SWITCH ASSEMBLY 1 10 | NONUMBER NEUTRAL SWITCH (NSS) 1 11 | 10-00-141-046 | #* O-RING 1 12 | 10-16-039-001 VALVE COVER 1 13 | 179796 © HEX HEAD BOLT (1/4-20 X 1/2) 3 14 | 103319 * LOCKWASHER (1/4) 3 15 | 10-16-099-001 | » SWITCH CAM 1 16 | 71-14 * VALVE COVER GASKET 1 17 | 71-A244A * CONTROL VALVE ASSEMBLY 1 18 | 4821 ** SNAP RING 1 19 | 71-246 SPRING RETAINER 1 20 | 71-242 VALVE SPRING (BLACK) 1 20A | 72N-242 VALVE SPRING (WHITE) SUPERSEDED BY 71-242 1 21 | 71-243 REGULATOR VALVE 1 22 | 480¢H O-RING 1 23 (| 71-2440 ** CONTROL VALVE 1 24 | 71C-A60 * PUMP ASSEMBLY 1 25 | 10-00-183-021 | « HEX HEAD BOLT (5/16-18 X 1-3/8) 4 26 | 10-00-044-014 | «* OIL SEAL 1 27 | 3-61 * PUMP GASKET 1 28 | 4873 * WOODRUFF KEY 1 29° | 71C-A8 * FORWARD AND REVERSE ADAPTER ASSY 1 30 | 4911 * CAPSCREW (3/8-16 X 1-1/4) 4 31 | 4a400 * NEEDLE BEARING 1 32 | NO NUMBER | ** FORWARD AND REVERSE ADAPTER (NSS) 1 33 | 71-1448 * GASKET 1 34 | 444858 * PIPE PLUG (1/4) 1 35 | 71-35 * REVERSE CLUTCH PISTON 1 36 | 4805A * CLUTCH SEALING RING 1 37 | 4804G * O-RING 1 38 | 71-71 * REVERSE CLUTCH PRESSURE PLATE 1 39 | 72-176 © STEEL CLUTCH PLATE (10-04 ONLY) 1 39A | 72-176 * STEEL CLUTCH PLATE (10-05 ONLY) 2 40 | 72-A66B * FRICTION CLUTCH PLATE (10-04 ONLY) 2 40A | 72-A66B + FRICTION CLUTCH PLATE (10-05 ONLY) 3 41 | 71-97 + PRESSURE PLATE SPRING "1 42. | R6-177 * DOWEL PIN (0.312 DIA X 0.621 LONG) (10-04 ONLY) 3 42A_| 4622E + DOWEL PIN (0.312 DIA X 0.875 LONG) (10-05 ONLY) 3 32INDEX PART DESCRIPTION ‘ary No. NUMBER 43 | 71-158 ‘* THRUSTWASHER + 1 43A | 10-16-193-001 | * THRUSTWASHER + 1 44 | 4822 + SNAP RING 1 45 | REA-7-1/2 ‘* SNAP RING (10-04 ONLY) 1 45A | 4766B ‘+ SNAP RING (10-05 ONLY) 1 46 | 4734 ‘+ SNAP RING (10-04 ONLY) 1 46A | 45598 ‘+ SNAP RING (10-05 ONLY) 1 47 | BI107A ‘* BEARING (10-04 ONLY) 1 47A | 1000-130-016 | * BEARING (10-05 ONLY) 1 48 | 71-70 * FORWARD CLUTCH CYLINDER (10-04 ONLY) 1 48a | 72-70 * FORWARD CLUTCH CYLINDER (10-05 ONLY) 1 49 | 10-16-124-001 | » FORWARD CLUTCH PISTON 1 50 | 5M-122 * O-RING 1 51 | 5L-36 * PISTON SEALING RING 1 52 | 5C-33 * CLUTCH SPRING BEARING RING 1 53 | 3-37 * CLUTCH BELLEVILLE SPRING 1 54 | 4755 * SNAP RING 1 55 | SC-175A + CLUTCH PRESSURE PLATE 1 56 | 1016-166-001 | * STEEL CLUTCH PLATE (10-04 ONLY) 4 56A | 1016-166-001 | * STEEL CLUTCH PLATE (10-05 ONLY) 6 57 | SC-A6GA * FRICTION CLUTCH PLATE (10-04 ONLY) 5 57A_ | SC-AGGA ‘* FRICTION CLUTCH PLATE (10-05 ONLY) o 58 | SL-67 * CLUTCH PRESSURE PLATE 1 59 | 10-00-139-048 | » SNAP RING (0.033 - 0.037 THICK) (10-04 ONLY) 1 59A | 10-00-139-049 | * SNAP RING (0.050 - 0.054 THICK) (10-04 ONLY) 1 598 | 4768 ‘+ SNAP RING (0.050 - 0.054 THICK) (10-05 ONLY) 12 5c | 4768A ‘* SNAP RING (0.074 - 0.078 THICK) (10-05 ONLY) 1 59D | 47688 ‘+ SNAP RING (0.096 - 0.100 THICK) (10-05 ONLY) 1 59E | 10-00-139-018 | * SNAP RING (0.062 - 0.066 THICK) (10-05 ONLY) 1 60 | 71-6 ‘* RING GEAR (10-04 ONLY) 1 60A | 1016-162-001 | * RING GEAR (10-05 ONLY) 1 61 | 71-17 * THRUSTWASHER 1 62 | 4806) * SEALING RING 2 63 | 4495 * SNAP RING 1 64 | 71-40 * FORWARD CLUTCH HUB (10-04 ONLY) 1 64A | 10-16-179.001 | » FORWARD CLUTCH HUB (10-05 ONLY) 1 65218211 * WOODRUFF KEY (10-04 ONLY) 1 65A | 124553, * WOODRUFF KEY (10-05 ONLY) 1 66 | 71C-3A16 + DRIVE GEAR ASSEMBLY (10-04 ONLY) 1 66A | 72C-2A16 * DRIVE GEAR ASSEMBLY (10-05 ONLY) 1 67 — ‘| 48068 * SEALING RING 4 67a | 71-280 * BRUSHING (OLD STYLE, NOT ILLUSTRATED) 2 68 | 71-9¢ * BUSHING 3 69 | 10-17-659-020 | « PINION CARRIER ASSEMBLY 1 (10-04 WITH SEALING RINGS) 69A | 71-1A2A * PINION CARRIER ASSEMBLY 1 (10-04 WITH BUSHINGS) 69B | 10-18-659-014 | PINION CARRIER ASSEMBLY 1 (10-05 WITH SEALING RINGS) 33INDEX PART DESCRIPTION arty No. NUMBER 9c | 72-1A28 ‘* PINION CARRIER ASSEMBLY 1 (10-05 WITH BUSHINGS) 70 | 71-159 + THRUSTWASHER (CASE WITH BUSHINGS) 1 70A | 10-17-193-001 | « THRUSTWASHER (CASE WITHOUT BUSHINGS) 1 71 | 10-04-034.001 | « SUCTION TUBE (10-04 ONLY) 1 71A | 10-05-034-001 | * SUCTION TUBE (10-05 ONLY) 1 72 | A4740a * BREATHER 1 73 | 100-191-059 | « SHIPPING PLUG (3/8-18) 1 74 | 444866 + PIPE PLUG (3/8-18) 1 75 | 444687 © PIPE PLUG (1/8-27) 1 76 | 444752 * PIPE PLUG (3/4-14) (CURRENT) 1 77 — | 9419506 + HEX NUT (7/16-20) 6 78 — | 10-00-146-001 | « STUD 6 79 | 13-08-045-002 | » GASKET 1 80 | 13-08-089-001 | » COUPLING ¢ 1 81 | 10-04-565-005 | » CASE ASSEMBLY @ 1 (10-04 WITH SEALING RINGS) 81A | 10-04-565-002 | » CASE ASSEMBLY ll 1 (10-04 WITH BUSHINGS) 81B | 10-05-565-012 | » CASE ASSEMBLY @ 1 (10-05 WITH SEALING RINGS) 81C | 10-05-565-002 | « CASE ASSEMBLY 1 (10-05 WITH BUSHINGS) 82 | 1017-036-002 | * OIL BAFFLE (Used on 71C) 1 82A_| 1018-036-001 | + OIL BAFFLE (Used on 72C) 1 NSS - NOT SERVICED SEPARATELY, BUY NEXT HIGHER ASSEMBLY. * CHECK MODEL NUMBER ON IDENTIFICATION PLATE AND MATCH WITH MODEL CHART IN THE FRONT OF THIS MANUAL. + mes USE AS REQUIRED TO OBTAIN PROPER AMOUNT OF END PLAY, ASSEMBLY INCLUDES CASE, SUCTION TUBE, AND STUDS. ASSEMBLY INCLUDES CASE, SUCTION TUBE, BUSHINGS, AND STUDS. COUPLING IS NOT SUPPLIED WITH TRANSMISSION OR V-DRIVE GEARBOX AND MUST BE ORDERED SEPARATELY. NOTE: The following kits are available for the 10-04 and 10-05 transmissions. Index numbers shown match the index numbers on the exploded-view, Figure 10 (page 31). INDEX PART DESCRIPTION ‘ary NO. NUMBER ‘A4B67AE FORWARD CLUTCH PACK KIT (10-04 ONLY) 85 | 5C-175A * CLUTCH PRESSURE PLATE 1 56 | 1016-166-001 | ¢ STEEL CLUTCH PLATE 4 57 | 5C-A66A * FRICTION CLUTCH PLATE 5 58__[ 51-67 * CLUTCH PRESSURE PLATE 1 34INDEX PART DESCRIPTION aTy NO. NUMBER ‘A4867AB FORWARD CLUTCH PACK KIT (10-05 ONLY) > 55 | 5C-175A, * CLUTCH PRESSURE PLATE 1 56A | 1016-166-001 | * STEEL CLUTCH PLATE 6 57 | SC-A6GA © FRICTION CLUTCH PLATE 7 58__| 5L-67 * CLUTCH PRESSURE PLATE 1 INDEX PART DESCRIPTION ary NO. NUMBER 10-04-420-052 | NEUTRAL SWITCH KIT - 10-04-539-001 | * SWITCH AND BODY ASSEMBLY 1 9 | 10-00-640-004 | » NEUTRAL SWITCH ASSEMBLY 1 12 | 10-16-039-001 VALVE COVER 1 13 | 0000179796 | » HEX HEAD BOLT (1/4-20 x 1/2) 3 14 |.0000103319 | » LOCKWASHER (1/4) 3 15 | 10-16-099-001 | » SWITCH CAM 1 160 | 71-14 * VALVE COVER GASKET 1 OF 1340 «INSTRUCTION SHEET 1 INDEX PART DESCRIPTION ary NO. NUMBER 10-95-410-002 | SNAP RING SERVICE KIT 4766 ‘+ RETAINING RING Al 18 | 4821 * SNAP RING 1 44 | 4822 * SNAP RING 1 45 | R6A-7-1/2 * SNAP RING (10-04 ONLY) 1 45 | 47668 * SNAP RING (10-05 ONLY) 1 46 | 4734 © SNAP RING (10-04 ONLY) 2 46A | 4559 ‘+ SNAP RING (10-05 ONLY) 1 54 (| 4755 + SNAP RING 1 59 | 10-00-139-048 | * SNAP RING (.033-.037 THICK) (10-04 ONLY) 1 59A | 10-00-139-049 | * SNAP RING (.050-.054 THICK) (10-04 ONLY) 1 59B | 4768 * SNAP RING (.050-.054 THICK) (10-05 ONLY) 2 59C_ | 4768A ‘* SNAP RING (.074-.078 THICK) (10-05 ONLY) 1 59D | 47688 * SNAP RING (.096-.100 THICK) (10-05 ONLY) 1 59E | 10-00-139-018 | * SNAP RING (.062-.066 THICK) (10-05 ONLY) 1 63 | 4495 + SNAP RING 1 4756D * SNAP RING 1 4756E © SNAP RING 1 4816 © SNAP RING 1 47664 SNAP RING 1 35SERVICE NOTES 36V-DRIVE GEARBOXES ‘A. DESCRIPTION. The V-Drive gearbox is mounted on the back of a 71C or 72C transmission. The gearbox is either gear or chain driven and provides various ratios. (See Figure 2, page 2.) The V-Drive gearbox is splash lubricated. B. ASSEMBLY. Refer to page 12 for general maintenance proce- dures on V-Drive gearboxes. Before starting dis- assembly, review the exploded-view shown in Figure 12 (page 48). The V-Drive can be disas- sembled by following the index numbers shown in Figure 12. The following procedures are cor- rect for most V-Drives. Minor differences may be found. Numbers in ( ) refer to item numbers on the exploded-view. 37 CAUTION: Threaded plugs, screws, bolts, and coupling nut must be tightened to torque shown in Table 4 (page 52) to prevent premature V- Drive failure. ‘* Anew coupling nut must be used at assembly. ‘* Bearing cups and cones, bevel gears, and case/cover are matched sets. If one is damaged both must be replaced. ‘* Multi-piece bevel gears are no longer availa- ble. They can be replaced with the one piece bevel gear and shaft. See illustrated parts list for details. * The dipstick has been changed to increase oil capacity in the gearbox. Old style dipsticks (part number 10-06-559-001) should be replaced with the new dipstick. See illustrated parts list for details.STEP 1. Install bearing cups (17 and 27) in case cover (11). It removed, press oil sleeve (38) in case cover (1) STEP 2. Lubricate O-rings (45) with vaseline. In- stall O-rings (45) in groove of bearing caps (43). NOTE: Check that O-ring is not twisted, cut, or deformed. Replace if damaged. STEP 3. Thread bearing caps (43) into case (11) Until lush with outer edge of case (11). 38 BEARING CUPS OWL SLEEVE ‘case Cover 1464 Bearing Cup Installation BEARING CAP ‘O-RING Groove one 14646 (O-Ring Installation case BEARING Bearing Caps InstallationSTEP 4, Install bearing cups (24 and 33) in case (1), 7Y NOTE: Do not install shims under bearing cup. STEP 5. Install bearing (42) and snap ring (41) in case (11). STEP 6. Install one bearing cone and bearing cup (10) in case cover (11). NOTE: If a new bearing is being installed, there may not be a side “A” etched on the bearing cup and one cone. In this instance it doesn’t make any difference which side of the cup each cone is in- stalled. However, the two cones and cup must have the same serial number etched on them. 39 BEARING CUPS a Bearing Cups Installation BEARING SHAPRING 45499 Bearing and Snap Ring Installation 40500 Bearing and Cup InstallationSTEP 7. Slide output shaft (40) through bearing cone and bearing cup (10) in case cover (11). NOTE: See Figure 13 (page 51) for instructions on local manufacture of fixture. Hold output shaft (40) and install fixture using two bolts (7). Install old coupling nut (3) on end of output shaft (40) and tighten. STEP 8. Determine amount of shims required on output shaft (40) as follows: (a) Measure dimension “A” from machined face of case cover (11) to ground face of bevel gear (Measure to the nearest 0.001 inch), (b) Multiply etched dimension on the end of bevel gear by 0.001 inch. (0) If dimension etched on end of bevel gear has plus (+) in front of it, add the dimension in step (b) to measurement obtained in step (a). If dimen- sion etched on end of bevel gear has a minus (-) in front of it subtract the dimension in step (b) from measurement obtained in step (a). (d) Add dimension from step (c) to 14.375 inch. (e) Subtract dimension obtained in step (4) from 20.9343 inch. The difference is the amount of shims required to Igcate the output shaft bevel gear. Remove old coupling nut (3) from end of output shaft (40) Remove output shatt (40) from bearing cone and bearing cup (10) in case cover (11). Remove fixture from case cover (11). 40 ‘CASE COVER sour SHAFT ‘COUPLING NUT FIXTURE 140514 “40520 Shim SelectionSTEP 9. Install selected shims (39) on output ourpuT sHIMs) shaft (40). SHAFT 146530 Shim Installation STEP 10. If removed, install gear or sprocket INTERMEDIATE (GEAR (OR SPROCKET) (30) on intermediate shaft (31). a = GEARSPACER If removed, install gear spacer (29) and press bearing cone (28) on end of intermediate shaft (31). NOTE: Do not install bearing cone on other end of intermediate shaft at this time. BEARING CONE 140544 y Gear and Bearing installation STEP 11. Install intermediate shaft (31) in case ADIUSTING INTERMEDIATE cover (11). — jue FxTURE. four NOTE: See Figure 14 (page 51) for instructions Lock - on local manufacture of fixture. CASE COVER WASHER Install fixture on case cover (11) using two bolts (12) and lockwashers (13). Tighten bolts (13) snug. Tighten bolt on fixture so intermediate shaft (31) a does not move. aSTEP 12. Determine amount of shims (35) re- quired on intermediate shatt (31) as follows: {a) Measure dimension “A” from machined face of case cover (11) to ground face of bevel gear (Measure to the nearest 0.001 inch). (b) Muttiply etched dimension on the end of bevel gear by 0.001 inch. (c) If dimension etched on end of bevel gear has a plus (+) in front of it, add the dimension in step (b) to measurement obtained in step (a). If dimen- sion etched on end of bevel gear has a minus (-) in front of it subtract the dimension in step (b) from measurement obtained in step (a). (d) Add dimension from step (c) to 14.472 inch. (e) Subtract dimension obtained in step (d) from 17.8141 inch. The difference is the amount of shims required to locate the intermediate shaft bevel gear. Remove bolts (12), lockwashers (13), and fixture from case cover (11). Remove intermediate shaft (31) from case cover (1), STEP 13. Remove bearing cup (27) from case cover (11) Install selected shims (35) and bearing cup (27) in case cover (11). 42 FIXTURE. ETCHED DIMENSION INTERMEDIATE. SHAFT CASE COVER Shim Selection (CASE COVER. So rm BEARING CUP Shim InstallationSTEP 14. ate shaft a STEP 15, A STEP 16, cover (11 Press bearing cone (34) on intermedi- 1) Install oil seal (5) in bearing cap (6). CAUTION: Oil seal must be installed dry on outside diameter. Lubricants can damage rubber coating. . Install bearing assembly (10) in case ) BEARING PRESS CONE INTERMEDIATE SHAFT 146564 Bearing Cone Assembly BEARING cap OW SEAL 140508 ‘CASE COVER BEARING ASSEMBLY 148608 Bearing InstallationSTEP 17. Lightly coat gasket (9) with vaseline and position on case cover (11). Place bearing cap (6) on case cover (11) and align bolt holes. Be certain oil channel in bearing cap (6) is aligned with oil channel in case cover (11). Thread bolts (7) with lockwashers (8) into case cover (11). Tighten bolts (7) to torque shown in Table 4 (page 52). STEP 18. Install intermediate shaft (31) and out- put shaft (40) in case cover (11) NOTE: Be sure shims are installed on output, shaft STEP 19. Hold output shaft (40) and install cou- pling (4) on end of output shaft (40). Thread old coupling nut (3) onto end of output shaft (40). Tighten coupling nut (3) to torque shown in Table 4 (page 52). 44 BOLT Lock - WASHER BEARING cap 40614 Bearing Cap Installation ‘ourpur SHAFT INTERMEDIATE SHAFT. ‘COUPLING NUT 14665 Coupling Nut InstallationSTEP 20. If required assemble input shaft as fol- lows: Install gear or sprocket (21) on input shaft (20). Slide gear spacer (19) onto input shaft (20). ing cones (17 and 2) on input shaft NOTE: On chain drives it sprocket is smaller than bearing cone, chain must be installed on sprocket before pressing bearing cone on input shaft. STEP 21. Install input shaft (20) in case cover (11). NOTE: Gear drive shown. For chain drive units, chain should be installed on the sprockets. STEP 22. Install oil baffle (36) on case cover (1p. Install screws (3) and tighten to torque shown in Table 4 (page 52). 45 \ GEAR SPACER’ (oR GEAR (ORSPROCKET) Bearing Assembly on BAFFLE case coven 14668 Oil Baffle InstallationNOTE: The adjustment procedure described in STEPS 7 - 13 does not apply to older transmis- sions having an inspection opening and plug (46) shown on Page 48. Use the procedure described on STEP 23 to adjust gear tooth pattern on these models. STEP 23. The procedure outlined in STEPS 7 - 13 does not apply to transmissions identified with the brass plug (46) shown on Page 48, On these mod- els, the transmission must be assembled and the brass plug removed. The contact pattern of the beveled gears are then checked by the following procedure. Coat teeth of bevel gears (31 and 40) with red dy- kem or gear paint. Complete assembly of case cover (11) to case (11). Refer to STEP 24. Rotate coupling (4) several times to develop a contact pattern Remove case cover (11) from case (11). Check contact pattern. If not correct, adjust using the following procedures. TOE CONTACT: Remove shims (35) from inter- mediate shaft (31), HEEL CONTACT: Add shims (39) to intermediate shaft (31), Ht more than 0.010 inch of adjustment is required in intermediate shaft shim pack for proper tooth Pattern, complete the adjustment in the output shaft shim pack. A CAUTION: After contact pattern is correct apply a bead of RTV sealant to back of a new coupling nut. Thread coupling nut onto output shaft and tighten to torque shown in Table 4 (page 52). STEP 24. Lightly coat gasket (14) with vaseline and position on case (11). Place case cover on case (11) and align holes. 46 Insert taper pins (15) through case cover and into case (11). Coat threads of bolts (12) with locktite #92, or equivalent. Thread bolts (12) with lockwashers (13) into case (11). Tap ends of taper pins (15) to set them in case (11). Tighten bolts (12) in a criss- cross pattern to final torque shown in Table 4 (page 52) INTERMEDIATE SHAFT esinco PATTERN TOE CONTACT HEEL CONTACT PATTERN PATTERN UNDESIRED PATTERNS 146078 Tooth Contact Patterns BOUTS case. LOCKWASHER TAPERPIN GASKET Cover InstallationSTEP 25. Coat threads of dipstick tube (2) with loctite #592, or equivalent. Thread dipstick tube (2) into case (11). Tighten dipstick tube (2) to torque shown in Table 4 (page 52). Install dipstick (1) in dipstick tube (2). Turn handle until snug, do not overtighten. NOTE: Early transmissions had dipstick tube and dipstick mounted in transmission. If removed, coat threads of plug (46) with loctite #92, of equivalent. Thread plug (46) into case (11) and tighten to torque shown in Table 4 (page 52). STEP 26. Tighten upper bearing cap (43) to seat bearings. Loosen upper bearing cap (43). Tighten lower bearing cap (43) to seat bearings. Loosen lower bearing cap (43). Tighten bearing caps (43) to torque shown on Ta- ble 4 (page 52). Install spring pin (44) in nearest notch of each bearing cap (43). Drive spring pins (44) into case (11) until flush. 47 CASE, pipsrick TUBE pipstick 146698 Dipstick Installation 146708 Spring Pins Installation