Heavy-Duty Torque Converter Repair for Industrial Vehicles

All Automatic provides specialist heavy-duty torque converter repair, rebuilding and reconditioning for selected industrial vehicles and plant machinery.

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We support gearbox specialists, forklift engineers, plant repair workshops, fleet operators and industrial vehicle maintenance teams across the UK and Europe.

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Our engineers rebuild worn and damaged torque converters to OEM standards or better, where possible. This can help you return vital equipment to service without the cost or delay of sourcing a new unit.

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Heavy-duty torque converters often work under demanding conditions. They must handle high loads, long working hours and regular stop-start use. They must also manage the heat created during low-speed work and repeated changes of direction.

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A fault within the torque converter or transmission system can cause poor drive, excess heat and loss of power. Early inspection can help prevent further damage and reduce equipment downtime.

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Whether you need a forklift torque converter repair, refuse vehicle torque converter repair or support with compatible plant machinery, our team can check the transmission details and advise on the next step.

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Industrial and Heavy-Duty Torque Converter Support.

A torque converter transfers engine power to an automatic or powershift transmission. It allows the engine to keep running while the vehicle is stationary. It also helps the machine move smoothly when carrying or pushing heavy loads.

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Industrial converters often face greater strain than units used in standard road cars. Forklifts, loaders and refuse vehicles may spend much of the day working at low speeds. This can create high temperatures within the transmission oil.

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High loads and repeated direction changes do not always cause a fault on their own. A correctly specified and maintained machine should be designed for this type of work.

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Problems are more likely when the oil level is low, the cooling system is restricted or the oil supply is weak. Internal wear can also reduce the converter’s ability to transfer power.

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Heavy-Duty Torque Converter Applications We Support

We repair and rebuild torque converters from selected industrial vehicles and plant machinery.

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The machine must use an automatic or powershift transmission fitted with a hydrodynamic torque converter. Not every model within an equipment category uses this type of transmission.

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Verified applications include:

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• Engine-powered counterbalance forklifts fitted with torque-converter transmissions

• Rough-terrain forklifts fitted with torque-converter drive

• Telehandlers using torque-converter powershift transmissions

• Refuse collection vehicles fitted with torque-converter automatic transmissions

• Large wheel loaders and loading shovels with torque-converter powershift systems

• Articulated dump trucks fitted with torque-converter transmissions

• Backhoe loaders using torque-converter powershift or autoshift transmissions
   

Some machines within these categories use hydrostatic drive, CVT systems, automated manual transmissions or electric drivetrains instead.

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Before sending a unit, please provide the machine make, model and transmission number. Converter part numbers and clear photographs can also help us confirm the application.​

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Confirming Your Torque Converter Application

The type of machine does not always confirm which transmission is fitted. Manufacturers may offer several transmission options within the same model range.

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For example, one forklift may use a torque-converter transmission, while another may use hydrostatic or electric drive. Telehandlers and wheel loaders can also be supplied with different transmission systems.

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Our team can check the details before the converter is removed or sent to our workshop.

Please provide:

• Machine manufacturer

• Machine model

• Serial number, where available

• Transmission manufacturer and model

• Torque converter part number

• Photographs of identification plates and markings

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This helps us confirm that the unit contains a torque converter and is suitable for our repair service.

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Forklift Torque Converter Repair

​Forklifts often work for long periods while carrying heavy and changing loads. Many also make hundreds of forward and reverse movements during a working day.

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This places regular demand on the torque converter and transmission. The system relies on the correct oil level, pressure, flow and cooling performance.

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A forklift torque converter repair may be needed when the truck is slow to move or loses pulling power under load. Other signs may include excess heat, unusual noise or poor performance once the forklift is warm.

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The fault may be inside the converter. It may also come from another part of the transmission system.

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For this reason, the converter should not be treated as the cause until the wider system has been checked.

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Signs of Forklift Torque Converter Failure

​Forklift torque converter failure can cause several symptoms. These may include:

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• Slow or delayed movement after selecting forward or reverse

• Reduced drive when lifting or carrying a load

• High engine speed with limited vehicle movement

• Loss of power on slopes or ramps

• Shuddering or vibration during operation

• Whining, grinding or other unusual noises

• Excess transmission temperature

• Burnt or discoloured transmission oil

• Oil leaks near the converter or transmission

• Performance that becomes worse as the forklift warms up

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These signs do not always confirm a failed torque converter.

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Similar symptoms can be caused by low oil, a weak charging pump, worn transmission clutches or a blocked oil cooler. Control valves, hoses and internal oil leaks may also affect performance.

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The complete system should be inspected before a repair is agreed.

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What Causes Forklift Torque Converter Failure?

Forklift torque converter problems are often linked to poor oil flow, excess heat or internal wear.

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A low transmission oil level can reduce the supply of oil to the converter. This may cause low pressure, poor lubrication and higher operating temperatures.

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A worn or weak charging pump can create similar problems. If the pump cannot provide enough oil, the converter may struggle to transfer power or control heat.

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Blocked oil coolers and restricted return lines can prevent hot oil from leaving the converter. This may cause the oil and internal parts to overheat.

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Air can also enter the oil supply through a damaged hose, loose connection or failed seal. This can disrupt oil flow and reduce hydraulic pressure.

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Internal causes may include:

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• Worn sealing rings

• Damaged bearings

• Excess internal oil leakage

• Worn converter components

• Damage caused by continued overheating

• Contamination from worn transmission parts

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Prolonged operation at or near converter stall can also create excess heat. This may happen when power is applied but the forklift cannot move.

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For example, an operator may continue applying power while pushing against a fixed load. A similar problem can occur if the forklift is held on a slope with the accelerator instead of the brake.

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Contaminated or degraded oil may also increase wear. Fine metal particles can circulate through the converter and transmission. Debris may also block filters, oilways or cooler lines.

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When a rebuilt converter is fitted, the oil cooler, pipes and transmission system should be cleaned as required. The cause of the original fault should also be found and corrected.

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Refuse Vehicle Torque Converter Repair

Refuse collection vehicles have a demanding working cycle. They make regular stops and often operate at low road speeds. Their load also changes throughout the working day.

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This type of use can create high transmission temperatures. It can also place continued demand on the torque converter, cooling circuit and oil supply.

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A failing converter may cause:

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• Delayed drive

• Slow acceleration

• Reduced performance when loaded

• Transmission overheating

• Slipping or loss of power

• Vibration during operation

• Unusual noise from the transmission area

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Our refuse vehicle torque converter repair service supports fleet operators, local authority contractors and commercial vehicle workshops.

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Where suitable, we rebuild the vehicle’s existing converter. This helps retain the correct fit, specification and operating characteristics for the vehicle.

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We understand that a refuse vehicle that is off the road can affect collection routes and operating costs. Our team works to keep turnaround times short while completing the repair to the required standard.

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Torque Converter Repairs for Compatible Plant Machinery

We repair torque converters from selected plant machines fitted with torque-converter powershift transmissions.

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These applications can include large wheel loaders, loading shovels, articulated dump trucks, backhoe loaders and some telehandlers.

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Not every plant machine uses a torque converter. Compact loaders may use hydrostatic drive, while other equipment may use CVT, electric or automated manual systems.

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The transmission type must therefore be confirmed before a repair is booked.

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A worn converter may reduce the amount of power transferred from the engine to the transmission. The machine may still move, but it may feel weak or slow when working under load.

Operators may notice:

• Poor pushing or climbing power

• Slow machine travel

• Delayed engagement

• Excess transmission heat

• Higher engine speed than normal

• Shuddering or vibration

• Reduced performance after the machine warms up

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Please send us the machine and transmission details so we can confirm whether the unit is suitable for rebuilding.

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Industrial Torque Converter Brands We Repair

Industrial transmissions can vary between manufacturers, models and applications.

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Some converters are fitted to several types of machine. Others are made for one vehicle, transmission or operating requirement.

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All Automatic specialises in reconditioning industrial transmission torque converters associated with major brands, including:

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• Brockhouse

• JCB

• Jungheinrich

• Caterpillar and CAT

• Toyota

• Graziano

• Warner and BorgWarner

• Fichtel & Sachs

• ZF

• Allison

• Aisin Warner

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We can also assess converters from other industrial and specialist applications.

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The manufacturer name, transmission model and converter number can help us identify the unit. Machine details can also be useful.

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Where an identification plate cannot be read, send us clear photographs of the converter and any visible markings.

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Support depends on the exact unit, its condition and the availability of suitable parts.

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Contact All Automatic Today:​

To discuss a repair, call All Automatic on 01543 467716 or click 'Get In Touch' below.

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Please include the machine make, model, transmission details and any part numbers shown on the converter. A short description of the fault and clear photographs of the unit will also help our team assess the job.

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We will confirm whether the converter is suitable for rebuilding and advise you on the next steps.

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Make All Automatic your partner in excellence for industrial automatic transmission torque converter rebuilding in the UK.