Removing and Reinstalling the Transmission on a Champion 740 Grader

[MikePhua]

Champion’s Grader Heritage and the 740 Series
Champion Motor Graders, originally founded in Canada in the early 20th century, built a reputation for rugged, operator-friendly graders tailored to municipal and contractor use. By the 1980s and 1990s, Champion’s 700 Series—especially the 740—had become a staple in road maintenance fleets across North America. The 740 model featured a six-wheel drive configuration, torque converter transmission, and hydraulic circle control, making it ideal for snow removal, gravel shaping, and rural road grading.
After Volvo Construction Equipment acquired Champion in the late 1990s, many of the design principles from the 740 were carried into Volvo’s G700 series. Despite the transition, thousands of Champion 740 graders remain in service today, especially in smaller municipalities and private fleets.
Terminology Annotation

• Circle: The rotating assembly beneath the grader’s moldboard that allows blade angle adjustment.
  
• Torque Converter: A fluid coupling between engine and transmission that multiplies torque and allows smooth gear changes.
  
• Transmission Jack: A specialized hydraulic lift used to support and maneuver heavy transmissions during removal or installation.
  
• Comealong: A hand-operated winch used to pull or position heavy components with precision.
  

Preparing for Transmission Removal
Removing the transmission from a Champion 740 grader is a labor-intensive task that requires careful planning and proper equipment. The process begins with elevating the machine to create sufficient clearance beneath the cab. Operators typically raise all six wheels onto 12-inch blocks, achieving a minimum of 52 inches between the frame and ground—enough space to maneuver the transmission safely.
Before removal:

• Disconnect all hydraulic hoses and electrical connectors.
  
• Remove driveshafts and inspect universal joints for wear.
  
• Swing the circle assembly to the side to create access to the transmission tunnel.
  
• Secure the blade with safety supports to prevent accidental movement.
  

In older units, counterbalance valves may not hold the blade in position, leading to creep. Always verify hydraulic lockout before working beneath the machine.
Lifting and Extracting the Transmission
Once the transmission is exposed, a two-ton transmission jack is positioned beneath it. A sling is looped around the input yoke and attached to a truck-mounted crane or overhead hoist. Additional slings are secured to the rectangular lifting ears on the transmission housing, connected to a comealong for horizontal control.
Steps for extraction:

• Loosen and remove transmission mounts.
  
• Lower the transmission gradually using the jack.
  
• Tighten the comealong to pull the unit forward and clear of the frame.
  

Experienced technicians report that removal typically takes 2 to 2.5 hours, while installation may require 3 to 3.5 hours due to alignment challenges and reattachment of components.
Transmission Variants and Compatibility
Champion graders used several powertrain configurations over the years. Some units were equipped with torque converters, while others had direct-drive transmissions. Identifying the correct variant requires referencing the grader’s serial number, which determines compatibility with replacement units and rebuild kits.
In one case from Ontario, a technician discovered that a replacement transmission sourced from a salvage yard had incompatible input splines. The issue was resolved by swapping the input shaft from the original unit—a reminder that Champion’s modular design sometimes masks subtle differences between models.
Common Failure Points and Rebuild Considerations
Transmission failures in Champion 740 graders often stem from clutch pack wear, fluid contamination, or solenoid malfunction. In the 1990s, clutch durability was a known issue, prompting many rebuilds after 4,000–6,000 hours of operation.
Signs of impending failure include:

• Sluggish gear engagement.
  
• Transmission overheating.
  
• Unusual whining or grinding noises.
  
• Fluid discoloration or burnt odor.
  

During rebuilds, technicians should inspect:

• Clutch discs and pressure plates.
  
• Valve body and solenoids.
  
• Torque converter seals and bearings.
  
• Transmission cooler and lines.
  

Using OEM-grade parts and verifying tolerances with dial indicators and feeler gauges ensures longevity. Some operators opt for remanufactured units, which can reduce downtime but may lack the precision of a custom rebuild.
Safety and Efficiency Tips

• Always chock wheels and engage parking brakes before lifting.
  
• Use jack stands rated for heavy equipment, not automotive-grade.
  
• Label all connectors and hoses during disassembly to avoid confusion.
  
• Replace transmission mounts if rubber shows signs of cracking or delamination.
  
• Flush transmission lines before reinstalling to prevent contamination.
  

A municipal fleet in Alberta reported a 30% reduction in transmission-related downtime after implementing a standardized rebuild protocol and training technicians on Champion-specific procedures.
Recommendations for Fleet Managers

• Maintain a service log with transmission hours and fluid changes.
  
• Stock critical components like solenoids and seals for rapid response.
  
• Train operators to recognize early symptoms of transmission distress.
  
• Schedule preventive inspections every 1,000 hours or annually.
  
• Partner with rebuild shops familiar with Champion legacy equipment.
  

Closing Reflections
The Champion 740 grader remains a testament to durable engineering and field-serviceable design. While transmission removal and replacement demand skill and patience, the process is manageable with proper tools and planning. As these machines continue to serve in demanding environments, understanding their mechanical intricacies ensures they remain productive assets rather than maintenance liabilities. Whether in snow-covered roads or dusty rural lanes, a well-maintained 740 grader still earns its keep—one pass at a time.