Repair of the Balkankar automatic loader box
Troubleshooting
* Slipping or dragging gear changes
* Increased noise or vibration during operation
*Transmission fluid leak
* Burnt oil smell
* Fault codes displayed on the instrument panel
Required tools and materials
* Transmission repair kit
* Transmission fluid
* Pan gasket
* Transmission filter
* Diagnostic scanner
Repair procedure
1. Preparation
* Place the forklift on a level surface.
* Stop the engine and let it cool.
* Remove the oil filler cap.
* Drain the transmission fluid into a previously prepared container.
2. Removing the transmission pan
* Remove the bolts securing the pan to the gearbox.
* Carefully remove the pan, keeping an eye on the gasket.
* Clean the pan and its surface of old gasket and fluid.
3. Installing a new gasket and filter
* Apply sealant to the new gasket.
* Install the gasket to the pan and transmission.
* Tighten the pan bolts according to the torque specified in the repair manual.
* Install a new transmission filter.
4. Disassembling the gearbox
* Drain the torque converter fluid.
* Remove the torque converter.
* Disassemble the gearbox following the repair manual.
* Inspect and replace worn or damaged parts.
5. Gearbox assembly
* Reassemble the gearbox in reverse order.
* Install the new torque converter and tighten the bolts to the specified torque.
6. Filling with transmission fluid
* Fill with new transmission fluid according to the repair manual.
* The fluid level should be at the “Hot” mark on the dipstick.
* Install the oil filler cap.
7. Testing and adjustment
* Start the engine and warm it up to operating temperature.
* Shift through all gears to check transmission operation.
* Check the gearbox fluid level and top up if necessary.
* Clear trouble codes using the diagnostic scanner if they were displayed.
Adviсe
* Use only original spare parts or high-quality analogues.
* Observe the sequence and tightening torques during assembly.
* Check that the transmission fluid level and condition are correct.
*Service the transmission according to the manufacturer’s recommendations.