the best repair manual

1. SERVICE REPAIR
S40FT S50FT S60FT S70FT S55FTS [F187]

2. 1300 SRM 1129 General
General
This section has the repair procedures for the transmission.
SERIAL NUMBER
The transmission serial number is located on the
right side of the transmission control valve directly
below the floor plate. See Figure 1.
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
Figure 1. Transmission Serial Number
Location
Confidential/Proprietary - Do Not Copy or Duplicate 1

3. Charge Pump Repair 1300 SRM 1129
Charge Pump Repair
REMOVE
NOTE: The charge pump can be removed from the
transmission while it is still in the lift truck but,
for the sake of clarity, the following procedures are
shown with the transmission removed from the lift
truck.
Remove four mounting capscrews, washers, trans-
mission charge pump, and gasket from the torque
converter housing. Discard the gasket. See Figure 2.
INSPECT
Inspect the splines on the shaft of the transmission
charge pump for damage or worn areas that could
affect the operation of the pump. If the splines are
damaged, replace the transmission charge pump.
INSTALL
Install new gasket, transmission charge pump, four
mounting capscrews, and washers in the torque
converter housing. Tighten capscrews to 19 N•m
(168 lbf in).
NOTE: THE TRANSMISSION IS SHOWN REMOVED
FROM THE LIFT TRUCK FOR CLARITY.
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
1. CAPSCREW
2. CHARGE PUMP
3. GASKET
4. TORQUE CONVERTER HOUSING
Figure 2. Transmission Charge Pump
2 Confidential/Proprietary - Do Not Copy or Duplicate

4. 1300 SRM 1129 Torque Converter Replace
Torque Converter Replace
REMOVE
WARNING
Make sure the engine and transmission are
held in position so that they will not fall and
cause an injury and damage to the equipment.
CAUTION
Be careful that you do not damage parts of
the torque converter or transmission when
the transmission is separated from the engine.
Keep the transmission and engine in align-
ment until they are completely separated so
parts of the transmission are not damaged.
Use a crane or lifting device to separate the
transmission from the engine.
1. Remove the engine and transmission as a unit
from the lift truck. See the section Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) lift trucks, and Frame 100 SRM
1120 for S30FT, S35FT, S40FTS (E010); H1.6FT,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
CAUTION
Use care when disconnecting the wiring har-
ness connectors from electrical connectors on
the transmission and control valve. The con-
nectors on the transmission and control valve
are easily damaged.
NOTE: When disconnecting wiring harness connec-
tors during disassembly, tag each connector to aid in
connecting the wiring harness during reassembly.
2. Put the engine and transmission on solid blocks
on a work surface. Disconnect the connectors of
the transmission wiring harness from the control
valve and transmission. Remove the transmis-
sion wiring harness from the transmission. See
Figure 3.
WARNING
Make sure that the engine/transmission assem-
bly is stable before attempting to rotate the en-
gine.
Use a flashlight to see the bolts as they are ro-
tated into view through the access hole. Do not
use your fingers to check for alignment of the
bolts with the access hole.
3. Move each bolt into view through the access hole
of the flywheel housing by rotating the crank-
shaft. Remove the four capscrews that attach the
flywheel to the torque converter. See Figure 4.
4. Remove the access cover from the torque con-
verter housing. Install a lifting eye bolt into the
rear access cover bolt hole, and connect a lifting
device to the eye bolt. Remove the 10 capscrews
that hold the torque converter housing to the fly-
wheel housing on the engine. Carefully separate
the transmission from the engine.
NOTE: The torque converter cannot be repaired and
must be replaced as a unit, if damaged.
5. Carefully remove the torque converter from the
stator support. See Figure 5.
6. Remove the plug, suction screen spring, and suc-
tion screen from the torque converter housing,
and drain the oil from the transmission.
7. Remove the transmission charge pump and
transmission oil filter from the torque converter
housing.
NOTE: Step 8, Step 9, and the NOTE below ap-
ply to early lift truck models except H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) models.
8. Remove the dipstick from the dipstick tube,
and disconnect the vent tube assembly from the
transmission housing.
NOTE: The dipstick tube must be removed before the
torque converter housing can be removed from the
front cover housing.
9. Remove the dipstick tube from the torque con-
verter housing.
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5. Torque Converter Replace 1300 SRM 1129
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
1. GM 2.4L ENGINE
2. CAPSCREW
3. TRANSMISSION WIRING HARNESS
4. TRANSMISSION
5. CAPSCREW
6. ACCESS COVER
7. CONTROL VALVE
Figure 3. Engine-Transmission Combination
4 Confidential/Proprietary - Do Not Copy or Duplicate

6. 1300 SRM 1129 Torque Converter Replace
Figure 4. Torque Converter Bolt Access
Confidential/Proprietary - Do Not Copy or Duplicate 5

7. Torque Converter Replace 1300 SRM 1129
Legend for Figure 4
A. GM 2.4L ENGINE
B. MAZDA ENGINE
C. YANMAR ENGINE
D. GM 4.3L ENGINE
E. ILLUSTRATES NEW DIPSTICK AND BREATHER
LOCATION AND NEW FITTING DESIGN USED
ON ENGINE AND TRANSMISSIONS SHOWN
IN ILLUSTRATIONS A THROUGH D, EXCEPT
WHEN D IS USED ON H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) LIFT TRUCK MODELS
F. CUMMINS 4.5L DIESEL ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
1. TRANSMISSION OIL FILTER
2. DIPSTICK
3. DIPSTICK TUBE
4. TRANSMISSION HOUSING
5. VENT TUBE ASSEMBLY
6. TORQUE CONVERTER HOUSING
7. TRANSMISSION OIL TEMPERATURE SENSOR
8. SUCTION SCREEN
9. SUCTION SCREEN SPRING
10. PLUG
11. CAPSCREW
12. WASHER
13. SMALL ACCESS COVER
14. TORQUE CONVERTER
15. TRANSMISSION CHARGE PUMP
16. STATOR SUPPORT
17. PILOT HUB
Figure 5. Torque Converter Removal
6 Confidential/Proprietary - Do Not Copy or Duplicate

8. 1300 SRM 1129 Torque Converter Replace
10. If damaged, remove the small access cover from
the torque converter housing.
NOTE: Perform Step 11 only if repair of the of the
transmission chain drive is required. If the trans-
mission clutch packs are in need of further repair,
see Clutch Packs Repair.
11. Remove 12 capscrews from the transmission
housing and four mounting capscrews from the
front of the torque converter housing. Using
a small pry bar in the designated pry points,
remove the torque converter housing from the
front cover housing. Discard the O-rings and
gasket. See Figure 6 and Figure 7.
INSTALL
1. Install new O-rings and gasket and using four
capscrews, install the torque converter housing
on the front cover housing and 12 capscrews on
the transmission housing. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 7.
2. If removed, install the small access cover on the
torque converter housing. Tighten capscrews to
7.9 N•m (69 lbf in). See Figure 8.
NOTE: The information in Step 3 and Step 4 applies
only to early lift truck models except for H4.0FT5/
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005) models.
3. Clean the surface of the dipstick tube and dip-
stick hole in the torque converter housing. Apply
adhesive (Hyster P/N 264159) to the entire sur-
face of the hole in the housing. Insert the dipstick
tube until the collar bottoms on the housing and
orient the tab against the housing flange.
4. Install the dipstick into the dipstick tube, and
connect the vent tube assembly to the transmis-
sion housing.
5. Install a new transmission oil filter on the torque
converter housing.
6. Install the transmission charge pump on the
torque converter housing. Tighten capscrews to
19 N•m (168 lbf in).
7. Install the suction screen, suction screen spring,
and plug into the torque converter housing.
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
1. PRY POINTS
2. TORQUE CONVERTER HOUSING
3. FRONT COVER HOUSING
4. TRANSMISSION HOUSING
Figure 6. Pry Point Location
8. Install the torque converter onto the input shaft
and stator support of the transmission. Make
sure the splines are aligned and the converter
engages fully.
9. Lubricate the pilot hub on the torque converter
with antiseize compound. See Figure 8.
10. If removed, install a lifting eye bolt into the rear
access cover bolt hole, and connect a lifting de-
vice to the eye bolt. Align the torque converter
housing with the flywheel housing. Make sure
the pilot hub on the torque converter engages the
flywheel.
Confidential/Proprietary - Do Not Copy or Duplicate 7

9. Torque Converter Replace 1300 SRM 1129
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
1. CAPSCREW
2. WASHER
3. TORQUE CONVERTER HOUSING
4. GASKET
5. FRONT COVER HOUSING
Figure 7. Torque Converter Housing
8 Confidential/Proprietary - Do Not Copy or Duplicate

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11. 1300 SRM 1129 Torque Converter Replace
CAUTION
Be careful that you do not damage parts of
the torque converter or transmission when
the transmission is joined to the engine. Keep
the transmission and engine in alignment un-
til they are completely joined so parts of the
transmission are not damaged. Use a crane or
lifting device to join the transmission to the
engine.
11. Install the transmission to the engine. Install
the capscrews that connect the torque converter
housing to the flywheel housing. Tighten the
capscrews to 38 N•m (28 lbf ft). See Figure 9.
CAUTION
Use care when connecting the wiring harness
connectors to electrical connectors on the
transmission and control valve. The connec-
tors on the transmission and control valve are
easily damaged.
12. Install the transmission wiring harness on the
transmission. Connect the connectors of the
transmission wiring harness to the control valve
and transmission. See Figure 9.
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
1. TRANSMISSION OIL FILTER
2. DIPSTICK
3. DIPSTICK TUBE
4. TRANSMISSION HOUSING
5. VENT TUBE ASSEMBLY
6. TORQUE CONVERTER HOUSING
7. TRANSMISSION OIL TEMPERATURE SENSOR
8. SUCTION SCREEN
9. SUCTION SCREEN SPRING
10. PLUG
Confidential/Proprietary - Do Not Copy or Duplicate 9

12. Torque Converter Replace 1300 SRM 1129
11. CAPSCREW
12. WASHER
13. SMALL ACCESS COVER
14. TORQUE CONVERTER
15. TRANSMISSION CHARGE PUMP
16. STATOR SUPPORT
17. PILOT HUB
Figure 8. Torque Converter Installation
13. Rotate the engine crankshaft to position the
flywheel mounting holes in line with the torque
converter mounting holes. Install the capscrews
that hold the torque converter to the flywheel,
after coating the threads with Loctite™ 242,
through the access hole of the flywheel housing.
See Figure 10. Tighten the capscrews to 56 N•m
(41 lbf ft). Remove the lifting eye bolt, and install
the access cover on the torque converter housing.
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
10 Confidential/Proprietary - Do Not Copy or Duplicate

13. 1300 SRM 1129 Torque Converter Replace
B. NEWER LIFT TRUCK MODELS
1. GM 2.4L ENGINE
2. CAPSCREW
3. TRANSMISSION WIRING HARNESS
4. TRANSMISSION
5. CAPSCREW
6. ACCESS COVER
7. CONTROL VALVE
Figure 9. Engine-Transmission Combination
Confidential/Proprietary - Do Not Copy or Duplicate 11

14. Torque Converter Replace 1300 SRM 1129
Figure 10. Torque Converter Bolt Access
12 Confidential/Proprietary - Do Not Copy or Duplicate

15. 1300 SRM 1129 Front Cover Housing and Chain Drive Repair
Legend for Figure 10
A. GM 2.4L ENGINE
B. MAZDA ENGINE
C. YANMAR ENGINE
D. GM 4.3L ENGINE
E. ILLUSTRATES NEW DIPSTICK AND BREATHER
LOCATION AND NEW FITTING DESIGN USED
ON ENGINE AND TRANSMISSIONS SHOWN
IN ILLUSTRATIONS A THROUGH D, EXCEPT
WHEN D IS USED ON H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) LIFT TRUCK MODELS
F. CUMMINS 4.5L DIESEL ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING
WARNING
Make sure the engine and transmission are
held in position so that they will not fall and
cause an injury and damage to the equipment.
14. Install the engine and transmission as a unit into
the lift truck. See the section Frame 100 SRM
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005) lift trucks, and Frame 100 SRM 1120 for
S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT,
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-
3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT
(H40-70FT) (L177) lift trucks.
15. Fill the transmission to the correct level using
the correct transmission fluid and procedure
given in the section Periodic Maintenance
8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
S55FTS) (F187); H2.0-3.5FT (H40-70FT)
(L177) lift trucks, Periodic Maintenance
8000 SRM 1207 for S30FT, S35FT, S40FTS
(E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
H35FT, H40FTS) (F001) lift trucks, and Pe-
riodic Maintenance 8000 SRM 1248 for S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005) lift
trucks.
Front Cover Housing and Chain Drive Repair
REMOVE
WARNING
Make sure the engine and transmission are
held in position so that they will not fall and
cause an injury and damage to the equipment.
CAUTION
Keep the transmission and engine in alignment
until they are completely separated so parts of
the transmission are not damaged. Use a crane
or lifting device to separate the transmission
from the engine.
1. Remove the engine and transmission as a unit
from the lift truck. See the section Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) lift trucks, and Frame 100 SRM
1120 for S30FT, S35FT, S40FTS (E010); H1.6FT,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
CAUTION
To prevent possible damage to the transmis-
sion assembly when placing the assembly on a
work surface, place blocks under the back side
of the transmission housing for additional sup-
port.
CAUTION
Use care when disconnecting the wiring har-
ness connectors from electrical connectors on
the transmission and control valve. The con-
nectors on the transmission and control valve
are easily damaged.
NOTE: When disconnecting wiring harness connec-
tors during disassembly, tag each connector to aid in
connecting the wiring harness during reassembly.
Confidential/Proprietary - Do Not Copy or Duplicate 13

16. Front Cover Housing and Chain Drive Repair 1300 SRM 1129
2. Put the engine and transmission on solid blocks
on a work surface. Disconnect the connectors of
the transmission wiring harness from the control
valve and transmission. Remove the transmis-
sion wiring harness from the transmission. See
Figure 11.
A. EARLY LIFT TRUCK MODELS EXCEPT
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
B. NEWER LIFT TRUCK MODELS
1. GM 2.4L ENGINE
2. CAPSCREW
3. TRANSMISSION WIRING HARNESS
4. TRANSMISSION
5. CAPSCREW
6. ACCESS COVER
7. CONTROL VALVE
Figure 11. Engine-Transmission Combination
14 Confidential/Proprietary - Do Not Copy or Duplicate