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Installation of The Power Take-Off

This document provides instructions for installing a power take-off (PTO) on a transmission. Key steps include measuring the oil pump shim thickness, installing shims to achieve a 0-0.08mm gap between the thrust plate and transmission housing, installing the oil pump components, applying oil and installing the PTO assembly, and connecting air and electrical lines. Torque specifications and notes about component orientations are also provided.

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James Trott
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45 views

Installation of The Power Take-Off

This document provides instructions for installing a power take-off (PTO) on a transmission. Key steps include measuring the oil pump shim thickness, installing shims to achieve a 0-0.08mm gap between the thrust plate and transmission housing, installing the oil pump components, applying oil and installing the PTO assembly, and connecting air and electrical lines. Torque specifications and notes about component orientations are also provided.

Uploaded by

James Trott
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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2.12.2 Installation of the Power Take-Off


Install as follows:
Required Tools:
Depth gauge
Strip Clamps (2) W 000 589 59 63 00
NOTE: If any of the components that affect the spacing for the oil pump are being changed, or
the Power Take-Off (PTO) is being installed for the first time, the oil pump shim thickness must
be measured.
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1. If the oil pump drive shaft is still in the transmission, install a bolt in the end, as a
handle, and remove the shaft.

2. Clean the mating surfaces of the transmission and PTO housing.


3. Install two Strip Clamps, tool W 000 589 59 63 00, on the transmission, to close any
gaps between the thrust plate and pump houisng. Torque to 10 N·m (88.5 lb·in.).
4. Check the depth at the top and bottom of the oil pump pocket, where the shim is
supported by the transmission housing.
5. Measure and record the gap between of the raised edge of the oil pump thrust plate
and the surface of the transmission housing. There must be 0.0 to 0.08 mm (0.0 to 0.0031
in.) gap, between the transmission housing and the surface of the thrust plate. If the
measured value is 0.0 mm (0.0 in.), confirm the thrust plate is not protruding from the
pocket by measuring from the plate edge to the transmission housing.
6. Remove the thrust plate and pump assembly. The shim is between the transmission
housing and the back of the pump.
7. Measure the original shim thickness and add or subtract the gap measurement to find
the shim size that would make the gap 0.0 mm (0.0 in.).

Determining Shim Thickness to Achieve Zero Gap


Example 1: The gap measurement is too large.
Original Shim 0.90 mm (0.0354 in.) + Gap 0.12 mm (0.0048 in.) = Maximum New Shim
1.02 mm (0.04 in.).
The available shim equal or smaller than the calculated dimension is 1.00 mm (0.039 in.).
Example 2: The gap measurement is too small (the thrust plate protrudes from the face of
the transmission housing).
Original Shim 0.85 mm (0.033 in.) - Gap 0.02 mm (0.0007 in.) = Maximum New Shim
0.83 mm (0.032 in.).
The available shim equal or smaller than the calculated dimension is 0.80 mm (0.031 in.).

8. Install the pump housing and shim, into the transmission housing.
9. Install the oil pump hub and rotor, confirming the dots on both are visible.
NOTE: The pump cover plate must be installed with the dished surface against the PTO
or the pump will not work.
10. Install the thrust plate.
11. If a new shim was required, install the clamps and recheck the thrust plate gap.

NOTE: If there are missing teeth on the driven end of the oil pump drive shaft, this
feature is intended to improve ease of installation. When placed in the nine o'clock
position, the missing teeth will allow the shaft to pass by the planetary gear more easily.

12. Install the oil pump drive shaft.


13. If not already in place, install guide studs in the back of the transmission.
14. Install the O-ring into its position on the face of the PTO and the gasket into position
on the transmission.

15. Apply some transmission oil to the outer bearing race, on the pump driveshaft, and
the bearing pocket in the PTO and install the PTO assembly. Replace the guide studs and
torque the PTO fasteners to 50 N·m (37 lb·ft).
16. Connect and secure the air and electrical harnesses to the PTO.
17. Fill the transmission with oil, with the level even to the bottom of the fill plug.
18. Fit a new fill plug seal, and torque the fill plug to 60 N·m (44 lb·ft).

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