Professional Documents
Culture Documents
Manual de Servicio Clark 32000 H&HR
Manual de Servicio Clark 32000 H&HR
FOREWORD
This manual has been prepared to provide the customer and the maintenance
personnel with information and instructions on the maintenance and repair of the
SPICER OFF-HIGHWAY product.
Extreme care has been exercised in the design, selection of materials and
manufacturing of these units. The slight outlay in personal attention and cost
required to provide regular and proper lubrication, inspection at stated intervals,
and such adjustments as may be indicated will be reimbursed many times in low
cost operation and trouble free service.
In order to become familiar with the various parts of the product, its principle of
operation, trouble shooting and adjustments, it is urged that the mechanic study
the instructions in this manual carefully and use it as a reference when
performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only SPICER
approved parts as listed in the applicable parts manual should be used. Use of
"will-fit" or non-approved parts may endanger proper operation and performance
of the equipment. SPICER OFF-HIGHWAY does not warrant repair or
replacement parts, nor failures resulting from the use of parts which are not
supplied by or approved by SPICER OFF-HIGHWAY.
TABLE OF CONTENTS
TRANSMISSION ASSEMBLY
The transmission and hydraulic torque portion of the power train enacts an important role in transmitting engine power
to the driving wheels. In order to properly maintain and service these units it is important to first understand their
function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system. It is
necessary to consider both units in the study of their function and operation,
To supplement the text below, and for reference use therewith, the following illustrations are provided:
Basic Design Silhouette
Converter Group
Converter and Transmission Case Group
3 & 4 Speed Clutch and Gear Group
Regulating Valve, Charging Pump and Filter Group
Control Valve Assembly (Mechanical & Electric Shift)
Mechanical Parking Brake
Assembly Instruction
Ring Gear Installation
Clutch and Gear Arrangement
Shielded Bearing Installation
3 & 4 Speed Power Flow
External Plumbing
4 Speed Section
The R, HR, and MHR Model Transmissions are of three basic designs.
The R Model consists of a separate torque converter, mounted to the engine with the powershift transmission remotely
mounted and connected to the torque converter with a drive shaft.
The HR Model consists of a torque converter and powershifted transmission in one package mounted directly to the
engine.
The MHR version is a mid-mount torque converter and transmission assembly connected to the engine by means of a
drive shaft. (See Fig. A for basic design silhouette,)
The shift control valve assembly may be mounted directly on the side of the converter housing or front transmission
cover, or remote mounted and connected to the transmission by means of flexible hoses. The function of the control
valve assembly is to direct oil under pressure to the desired directional and speed clutch, A provision is made on
certain models to neutralize the transmission when the brakes are applied. This is accomplished through use of a brake
actuated shutoff valve. The speed and direction clutch assemblies are mounted inside the transmission case and are
connected to the output shaft of the converter either by direct gearing or drive shaft. The purpose of the speed or
directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction.
An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can be disconnected
or connected by manual shifting.
With the engine running, the converter charging pump draws oil from the transmission sump through the removable oil
suction screen and directs it through the pressure regulating valve and oil filter.
The pressure regulating valve maintains pressure to the transmission control cover for actuating the direction and
speed clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil
is directed through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication.
This regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring
loaded to hold the valve in a closed position, When a specific pressure is achieved, the valve spool works against the
spring until a port is exposed along the side of the bore. This sequence of events provides the proper system pressure.
After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits
in the passage between the turbine shaft and converter support. The oil then flows out of the converter to the oil cooler,
After leaving the cooler, the oil is directed to a fitting on the transmission. Then through a series of tubes and passages
lubricates the transmission bearings and clutches. The oil then gravity drains to the transmission sump.
The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque.
The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This
element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing
to the other components which results in torque multiplication. This element can be compared to a centrifugal pump in
that it picks up fluid at its center and discharges at its outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque
converter. This element receives fluid at its outer diameter and discharges at its center, Fluid directed by the impeller
out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque
converter multiplies torque.
The reaction member of the torque converter is located between and at the center or inner diameters of the impeller
and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and
change its direction to allow correct entry for recirculation into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at
zero RPM, Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing.
The shift control valve assembly consists of a valve body with selector valve spools, A detent ball and spring in the
selector spool provides one position for each speed range. A detent ball and spring in the direction spool provides three
positions, one each for forward, neutral and reverse.
With the engine running and the directional control lever in neutral position, oil pressure from the regulating valve is
blocked at the control valve, and the transmission is in neutral. Movement of the forward and reverse spool will direct
oil, under pressure to either the forward or reverse direction clutch as desired.
When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the
direction selector spool. The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hydraulically
actuated piston. The piston is "oil tight" by the use of sealing rings, A steel disc with external splines is inserted into the
drum and rests against the piston, Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated
until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A Hub with
O.D. splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase
in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position, This allows oil under
pressure to flow from the control valve, through a tube, to a chosen clutch shaft. This shaft has a drilled passageway for
oil under pressure to enter the shaft. Oil pressure sealing rings are located on the clutch shaft. These rings direct oil
under pressure to a desired clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The
discs, with teeth on the outer diameter, clamping against discs with teeth on the inner diameter, enables the hub and
clutch shaft to be locked together and allows them to drive as a unit.
There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston is released.
FIG. A
Figure B
ITEM DESCRIPTION
QTY.
ITEM DESCRIPTION
QTY.
30
31
32
Impeller..................................................................................1
33
34
Impeller Hub..........................................................................1
35
36
37
38
Reaction Member..................................................................1
10
39
11
40
12
41
Turbine. .................................................................................1
13
42
14
43
15
44
16
45
Impeller Cover.......................................................................1
17
46
18
Turbine Shaft...................................................................... 1
47
19
48
20
49
21
50
22
51
23
52
24
53
Plain Washer......................................................................16
25
54
26
55
27
56
28
oil Baffle.............................................................................. 1
57
29
58
Figure C
Pipe Plug............................................................................ 1
Converter Housing & Tube Assembly. ............................. 1
Converter Housing to Front Cover Screw Lockwasher.. 12
Converter Housing to Front Cover Screw....................... 12
Tube Sleeve....................................................................... 1
Tube Sleeve....................................................................... 1
8
9
10
11
12
13
14
15
16
17
18
19
20
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
21
22
rd
ITEM DESCRIPTION
QTY,
46
Tube Sleeve....................................................................... 1
47
Low Speed Clutch Pressure Tube. ................................... 1
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
Hose Fitting........................................................................ 1
Hose Assembly.................................................................. 1
Hose Fitting........................................................................ 1
Converter Housing to Transmission Case Gasket ........... 1
Converter Housing to Transmission Case Spacer ........... 1
Oil Distributor Retainer Ring.............................................. 1
83
84
85
86
87
88
89
90
91
Figure D
ITEM
DESCRIPTION
ITEM
DESCRIPTION
43
44
45
46
47
48
49
50
51
2ndGearBearing ................................................................ 1
10
52
11
53
12
54
13
55
OTY.
OTY.
14
56
15
57
16
58
17
59
18
Reverse&3rdClutchDrum .................................................. 1
60
19
61
20
62
End Plate............................................................................ 1
21
63
22
64
23
65
24
66
25
67
26
Spring Retainer.................................................................. 1
68
27
69
28
Spring Retainer.................................................................. 1
70
29
71
30
72
31
73
32
74
33
75
34
Spring Retainer.................................................................. 1
76
35
77
36
Spring Retainer.................................................................. 1
78
37
79
38
80
39
81
40
82
41
42
3rd Gear............................................................................. 1
Figure D
R OR HR32000 SHORT DROP 3 & 4 SPEED CLUTCH & GEAR GROUP (continued)
ITEM
DESCRIPTION
QTY.
ITEM
DESCRIPTION
QTY.
83
125
84
126
85
127
86
128
87
129
88
130
89
131
90
Output Flange.....................................................................1
132
91
133
92
134
93
135
94
136
95
137
96
138
97
139
98
140
99
2nd Gear.............................................................................1
141
100
142
101
143
End Plate............................................................................ 1
102
144
103
145
104
146
105
147
106
148
107
149
108
150
109
151
110
152
111
153
112
154
113
155
114
156
115
157
116
158
117
159
Bearing Spacer................................................................... 1
118
160
119
161
120
162
121
163
122
164
123
124
Figure E
ITEM DESCRIPTION
QTY.
ITEM
DESCRIPTION
QTY.
26
27
28
29
30
32
33
34
10
35
11
36
12
37
13
38
14
39
15
40
16
41
17
Valve Piston.......................................................... 1
42
18
43
19
44
20
46
21
47
22
48
23
49
24
50
25
NOTE:
Speed selector spacers (items 13 and 22) and
the declutch valve (item 26) are not included
when the control valve housing assembly (item
14) is ordered
When ordering the control valve housing
assembly (item 14) from the Service Parts List
also order the spacer or spacers listed as items
13 and 22 and the declutch valve, spool and
spring needed
NOTE: Some valves will require no spacers,
some valves will require 1 spacer and some will
require 2 spacers
Figure F
ITEM
DESCRIPTION
OTY.
ITEM
DESCRIPTION
OTY.
22
23
24
25
Oil Seal................................................................. 1
26
27
Stop Plug.............................................................. 1
28
Detent Ball............................................................ 3
29
30
Glyd Ring.............................................................. 1
10
Detent Ball............................................................ 1
31
Piston ................................................................... 1
11
32
Piston Housing...................................................... 1
12
33
Oil Seal................................................................. 1
13
34
Band Seal............................................................. 1
14
35
"0"Ring" ................................................................ 1
15
16
44
17
45
18
46
19
47
20
48
21
49
50
Figure G
ITEM
DESCRIPTION
QTY.
ITEM
DESCRIPTION
QTY.
20
Forward Spool..................................................... 1
21
22
24
25
26
10
27
11
28
12
29
Housing Gasket................................................... 1
30
13
Solenoid ............................................................ *5
31
14
O Ring............................................................. *5
32
15
O Ring............................................................. *5
33
16
O Ring............................................................. *5
34
Washer............................................................*5
17
35
Set Screw........................................................*5
18
36
19
37
Washer............................................................*5
38
Coil .................................................................*5
39
Figure H
View "R"
NOTE:
Metric
dimensions
shown In brackets [ ]
THREAD SIZE
LB-FT
[Nm]
1" - 20
150- 200
[203.4- 271,1]
1/4
200- 250
[271 ,2 - 338,9]
1/2
300- 350
[406,8 - 474,5]
3/4
400- 450
[542.4 - 610,1]
1 " - 18
1 " - 18
1 " - 12
GRADE 8
SIZE
FINE THREAD
lbf.ft
[N.m]
COARSE THREAD
lbf-ft
[N.m]
FINE THREAD
Ibf.-ft
[N.m]
COARSE THREAD
Ibf-ft [N.m]
.2500
9-11
[12-151
8-10
[11-141
11-13
r15-181
9-11
[12-151
-3125
16-20
[22-27]
12-16
[16-22]
28-32
[38-43]
26-30
[35-41]
.3750
.4375
.5000
.5625
26-29
41-45
64-70
91-100
[35-39]
[56-611
[87-95]
[123-136]
23-25
37-41
57-63
82-90
[31.34]
[50-561
[77-85]
[111-1221
37-41
58-64
90-99
129-141
[50-56]
[79-87
[122-134]
[174-1911
.6250
128-141
[174-191]
113-124
[153-168]
180-198
.7500
223.245
[302-332)
200-220
[271-298]
315.347
Figure H
33-36
52-57
80-88
115.127
[45-49]
[71-771
[108-1191
[156-1721
[224-268]
159.175
[216-237]
[427-470]
282-310
[382-420]
ITEM
DESCRIPTION
QTY .
ITEM
DESCRIPTION
QTY .
Return Spring.................................................. 2
10
11
Rivet ..............................................................20
12
13
Figure I
Figure 8
Remove pump adaptor bolts and pump adaptor.
Figure 5
Figure 9
Figure 6
Figure 10
Remove impeller cover bearing cap.
Figure 14
Figure 12
Figure 15
Figure 13
Remove impeller cover and turbine as an assembly.
Figure 16
Remove reaction member and spacer.
Figure 17
Remove converter housing to engine housing spacer ring.
Figure 20
Remove impeller assembly.
Figure 18
Figure 21
Figure 19
Figure 22
Using pry slots in converter housing, pry oil baffle and impeller
from housing.
NOTE: Impeller, oil baffle and impeller hub gear are removed as an
assembly.
Figure 26
Figure 23
Remove converter housing to transmission housing bolts.
Figure 27
Figure 24
Figure 28
Figure 25
Remove pump drive gear bearing support bolts.
Figure 29
Use a spreading type snap ring pliers to spread the ears on forward
clutch front bearing retainer ring. Remove forward clutch with pry
bar.
Figure 32
Remove output flange nut, washer and "0" ring.
Figure 30
Figure 33
Remove output flange.
Figure 34
Remove low clutch bearing cap. Note oil sealing ring.
Figure 31
Remove 2nd clutch pilot bearing.
Figure 38
Remove output shaft and low clutch rear bearing locating ring.
Figure 35 Remove output shaft bearing cap.
Cut and remove low clutch rear bearing retainer plate bolt
lockwire. Remove low clutch shaft oil sealing ring.
Figure 39
Remove rear cover bolts. Using pry slots provided, pry cover from
transmission housing tapping on low clutch and output shaft to
allow cover to be removed without shaft binding.
NOTE: The use of alignment studs will facilitate cover removal.
Figure 40
Remove bearing lock balls.
Figure 43-A
A Timken bearing cup, No.29520 must be used with the above
bearing puller.
Figure 41
Remove low clutch double bearing cup, outer cone bearing and
spacer.
Figure 42
CAUTION: Outer cone bearing, double bearing cup, spacer and
inner cone bearing are replaced as a set only.
Figure 44
Remove 2nd gear ring retainer snap ring.
Figure 43
Remove low clutch inner bearing cone.
NOTE: To remove the inner cone bearing without damage. a
special bearing pulier must be made (see diagram Fig. 43-A) or the
outer cage and rollers may be pulled trom the bearing inner race
and the inner race can be removed after the low clutch assembly
has been removed trom the transmission. See caution in Figure 42.
Figure 45
Remove 2nd gear retainer ring retainer.
Figure 48
Remove output shaft assembly. (3 speed output shaft shown.)
Figure 46
Remove 2nd gear retainer ring.
Figure 47
Remove 2nd gear.
NOTE: On the 4 speed transmission there is a bearing end plate
between the 2nd gear and bearing.
Figure 49
Remove low speed drive gear retainer ring and drive gear.
Figure 50
Remove reverse and 3rd clutch assembly.
Figure 51
Remove low clutch assembly.
Figure 56
Remove impeller hub, "0" ring and impeller hub screw backing ring.
Figure 53 Remove impeller hub gear.
Figure 56
NOTE: Each disc
spring assembly is
made up of selected springs to precisely match each part within this
assembly. Failure to replace all piston return springs can result in
unequal deflection within the spring pack. The result of this
imbalance may adversely affect overall life of springs.
The disc spring packs are to be used as complete assemblies and
care should be taken not to intermix the individual disc springs with
disc springs in another clutch or disc spring pack.
CLUTCH DISASSEMBLY
Figure 54
Lift oil baffle and oil seal assembly from impeller.
10
Figure 60
Figure 57
Remove low clutch shaft front bearing race.
Remove low speed gear and outer taper bearing. Remove low
clutch taper bearing spacer.
Figure 61
Remove clutch end plate retainer ring. Remove clutch end plate
and inner and outer clutch discs.
Figure 58
Remove low speed gear taper bearing retainer ring retainer.
Figure 62
Remove low gear inner taper bearing.
Figure 59
Remove low speed gear taper bearing retainer ring.
11
Figure 66
Remove clutch shaft piston rings and expander springs.
See page 67 for proper piston ring and expander spring installation.
Figure 64
Remove clutch piston return disc spring retainer ring. A sleeve with
a portion removed is recommended for removing the clutch piston
return spring washers and retainer ring. Sleeve shown is a common
pipe, with a 1-1/2 x 1 [39,0 x 26,0 mm] opening. The pipe is 6 x 31/4 x 2-3/4 [155,0 x 85,0 x 78,0 mm]. Compress disc springs
washer. Through opening, remove retainer ring. Release tension on
washers. Remove spring retainer ring.
Figure 65
Remove disc springs and spacer. Turn clutch over and tap clutch
shaft on a block of wood to remove clutch piston. NOTE: Disc
springs in the low clutch are different than disc springs in the
forward and reverse clutch. Do not mix low clutch springs with
forward and reverse springs. See page 40 for spring identification.
Figure 68
Remove spacer and bearing. Caution: Do not lose lock ball.
12
FORWARD AND 2ND CLUTCH DISASSEMBLY
Figure 69
Figure 72
Pry front bearing inner race from shaft. Caution: Do not damage
bearing roller surface.
Figure 70
Figure 73
Figure 71
Figure 74
Remove end plate.
13
Figure 78
Compress spring retainer washer. Through opening remove spring
retainer snap ring. Release tension on spring retainer.
Figure 75
Remove inner and outer clutch discs.
Figure 79
Remove snap ring and snap ring retainer.
Figure 76
Remove inner bearing.
Figure 80
Remove disc spring washers.
NOTE: Non-modulated clutches will have a piston return spring in
forward & reverse. See note in Figure 65.
Figure 77
Remove hearing locating ring.
14
Figure 81
Remove clutch piston.
CAUTION: Care should be exercised to avoid skin rashes. fire
CLEANING
HOUSINGS
Clean interior and exterior of housings, bearing caps, etc.
thoroughly. Cast parts may be cleaned in hot solution tanks with
mild alkali solutions providing these parts do not have ground or
polished surfaces. Parts should remain in solution long enough to
be thoroughly cleaned and heated. This will aid the evaporation of
the cleaning solution and rinse water. Parts cleaned in solution
tanks must be thoroughly rinsed with clean water to remove all
traces of alkali. Cast parts may also be cleaned with steam
cleaner.
CAUTION: Care should be exercised to avoid inhalation of
vapors and skin rashes when using alkali cleaners.
AII parts cleaned must be thoroughly dried immediately by using
moisture-free compressed air or soft, lintless absorbent wiping
rags tree of abrasive materials such as metal filings,
contaminated oil or lapping compound.
15
Figure 82
Figure 85
Install 2nd disc spring washer with large diameter of bevel up.
Install balance of washers, quantity (1) seven alternating bevel.
Figure 83
Insert clutch piston in clutch drum.
Figure 86
Install disc spring snap ring retainer and snap ring. Compress
washers and snap ring retainer, install snap ring in lower snap ring
groove. Install bearing locating ring. See page 40, Figure A.
Figure 84
Install 1 st disc spring washer, large diameter of bevel down as
shown. NOTE: Do not mix forward clutch disc spring washers with
low clutch washers. See NOTE in Figure 65.
16
Figure 87
Insert one steel disc.
Figure 91
Install clutch driven gear inner bearing.
Figure 88
Install one friction disc. Alternate steel and friction discs until the
proper amount of discs are installed. First disc next to the piston is
steel, last disc installed is friction.
Figure 92
Install clutch driven gear into clutch drum. Align splines on clutch
gear with internal teeth of friction discs. Tap gear into position. Do
not force this operation. Gear splines must be in full position with
internal teeth of all friction discs.
Figure 89
Install end plate.
Figure 93
17
Figure 94
Figure 97
Figure 95
Install front bearing inner race.
Figure 98
Install hearing retainer ring.
Figure 96
Install front bearing and outer race.
18
Figure 99
Install piston rings and expander springs as explained on page 67.
Figure 102
Position piston return disc spring washer snap ring. Compress
washers and install snap ring.
Figure 100
Install new clutch piston inner and outer sealing ring. Insert piston
into clutch drum using caution as not to damage seals. Position
inner spring retainer, piston return spring, outer spring retainer and
retainer snap ring retainer and snap ring. Compress spring and
retainer and install snap ring. See page 40, Figure B.
Assemble clutch discs and end plate as previously explained.
Figure 103
Install snap ring retainer.
Figure 101
Install new clutch piston inner and outer sealing ring. Insert piston
into clutch drum using caution as not to damage seals. Install piston
to disc spring washer spacer.
See NOTE in Figure 65.
Install disc spring washers. First washer with large diameter of
washer toward spacer. Alternate (5) five washers.
See page 40, Figure C.
19
Figure 104
Install low gear inner taper bearing. Install one steel disc. Install one
friction disc. NOTE: The friction discs in the low clutch has 8 higher
co-efficient rating than the friction discs in the other clutches,
therefore the discs must not be mixed. The low clutch inner disc
can be identified by an "X" stamped on one side of the inner teeth.
The low clutch inner disc also has a strip of non-soluble yellow paint
sprayed on the outer edge of the disc. Alternate steel and friction
discs until the proper amount of discs are installed. First disc next to
the piston is steel, last disc installed is friction.
Figure 105
Install end plate and retainer ring.
Figure 108
Install low gear outer taper bearing.
Figure 109
NOTE: Retainer ring is selected at assembly for proper thickness. A
snap ring kit is available. Select the thickest of the three rings in the
kit that can be fitted into the snap ring groove to assure s proper
taper bearing tightness. Check ring as shown for tight ring to
bearing fit.
Figure 106
Install low clutch taper bearing spacer.
NOTE: When installing the 3rd gear in the 3rd speed clutch a
bearing spacer is used between the inner and outer 3rd gear
bearing also.
Figure 110
Figure 107
Install low gear into crutch drum. Align splines on low gear with
internal teeth of friction discs. Tap gear into position. Do not
force this operation. Gear splines must be in full position with
internal teeth of all friction discs.
20
Figure 114
Install low clutch assembly from rear of transmission case.
Figure 111
Install low speed gear taper bearing retainer ring retainer.
Figure 115
Install reverse and 3rd clutch assembly from the front of the
transmission.
Figure 112
Install low clutch shaft front bearing inner race with large diameter
of race down.
Figure 116
Figure 113
21
Figure 120
Install output shaft assembly in housing. (3 speed shown).
See caution in Figure 42.
Figure 117
Press output gear on output shaft. Install output gear washer in
undercut of gear. (3 speed shown).
Figure 121
Install low clutch inner taper bearing.
NOTE: Heat bearing in hot oil prior to installation.
Figure 118
Press inner taper bearing on output shaft. Insta!! double taper
bearing spacer, double taper bearing cup and outer taper bearing.
(3 speed shown).
Figure 122
Install bearing spacer and double bearing cup.
Figure 119
Output shaft assembly. (3 speed shown).
22
Figure 126
Install low clutch shaft oil sealing ring.
Figure 123
Install outer taper bearing.
NOTE: Heat bearing in hot oil prior to installation.
Figure 127
Install alignment studs and new gasket. Place lock balls in low shaft
and idler shaft. A light coat of grease will hold lock balls in place.
Position shafts so lock balls align with notches in rear cover.
Figure 124
Install bearing retainer plate, inner diameter chamfer toward
bearing.
Figure 128
Tap cover in place and secure with bolts and lockwashers.
Figure 125
Install bolts. block gears to prevent turning. Tighten bolts to
specified torque. Lockwire bolts to prevent loosening.
23
Figure 129
Figure 132
Install new "0" ring and gasket on low clutch bearing cap.
Position cap over clutch shaft, use caution as not to damage oil
sealing ring.
Figure 130
Install the output shaft and low clutch shaft rear bearing locating
ring. Be certain ring is in full position in ring groove.
Figure 133
Install bolts and washers, tighten to specified torque.
Figure 131
Coat outer diameter of oil seal with Permatex No.2 and press seal
in the output shaft bearing cap with lip of seal in. Position new
gasket on bearing cap. Install bearing cap on transmission housing.
Install bolts and lockwashers, tighten to specified torque.
Figure 134
Install output flange on output shaft.
24
Figure 138
Install 2nd speed gear retaining ring retainer .
Figure 135
Install the output flange "0" ring, washer and flange nut. Block
output flange to prevent from turning. See elastic stop nut torque
chart, Figure H.
Figure 140
Install transmission case gasket and "0" rings. Install housing
spacer.
NOTE: Housing spacer is used with 12 plate clutch modulation
only.
Figure 137 Install 2nd speed gear retainer ring.
25
Figure 144
Install (12) impeller hub special screws to approximately .06 inch
[1,5] of seated position. With a calibrated torque wrench, tighten
screws to 40-45 Ibs. ft. [54,3-61,0 N.m] torque. NOTE: Assembly of
impeller to impeller hub must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with
coating which begins to harden after installation in the impeller hub
holes. If not tightened to proper torque within the fifteen minute
period, insufficient screw clamping tension will result. The special
screw is to be used for one installation only. If the screw is removed
for any reason it must be replaced.
The compound left in the hub holes must be removed with the
proper tap and cleaned with solvent. Dry hole thoroughly and use a
new screw for reinstallation.
Figure 141
Install housing spacer gasket and "0" rings. See R-Model section
for front cover installation.
Figure 142
Clean impeller hub mounting surface and tapped holes with solvent.
Dry thoroughly being certain tapped holes are dry and clean. Install
new "0" ring on impeller hub. Position impeller hub screw backing
ring.
Figure 145
Apply a light coat of Permatex No.2 on the outer diameter of the oil
baffle seal. Press seal in oil baffle with lip of seal down.
(NOTE: When baffle is positioned on impel!er. lip of oil seal wil! be
up.)
Figure 143
Align holes in impeller hub with holes in impeller and backing ring.
26
Figure 149
Secure impeller hub gear with retainer ring.
Figure 146
Install a new oil baffle seal ring.
Figure 150
Install new turbine shaft piston ring.
Figure 147
DRIVE GEAR
RETAINING RING
TURBINE SHAFT
27
Figure 155
Install right pump drive gear.
Figure 152
Support converter housing with chain faJI. Spread forward clutch
front bearing retainer ring and tap fo~ard and 2nd clutch assembly
into transmission case assembly. Be certain snap ring is in full
position in ring groove.
Figure 156
Align holes in pump drive gear bearing supports with holes in
converter housing. Install bolts and washers and tighten to specified
torque.
Figure 153
Position center pump drive gear.
Figure 157
Install 2nd speed clutch pilot bearing.
Figure 154
Install left pump drive gear.
28
Figure 161
Install stator support bolts and tighten to specified torque.
Figure 158
Install alignment studs and position converter housing on studs.
NOTE: Turn output shaft to align clutch disc hub in clutch. Do not
force this operation.
Figure 159
Figure 162
Grease stator support piston ring, oil baffle oil seal and seal ring to
facilitate reassembly. Install impeller and oil baffle assembly in
converter housing.
Figure 160
Install new sealing ring expander spring and oil sealing ring on
support. NOTE: Expander spring gap to be 180 from sealing ring
hook joint. Position support on turbine shaft, turn support to clear
pump drive gear. Align support holes with converter housing.
Figure 163
Position oil baffle in housing. Secure with oil baffle retainer ring,
being sure ring is in full position in ring groove
29
Figure 164
Install reaction member spacer with tang facing out. Install reaction
member.
Figure 165
Figure 168
Position new impeller to impeller cover "0" ring on impeller. Install
turbine and impeller cover.
Figure 169
Install impeller cover bolts and torque to specifications.
Figure 166
Position turbine in impeller cover.
Figure 167
30
Figure 170
Install new "0" ring seal in impeller cover bearing cap.
Figure 174
Figure 171
Install bearing cap and bolts, torque to specifications.
Figure 175
Install pump assembly on studs. NOTE: Pump assemblies may
vary.
Figure 172
Position auxiliary pump adaptor on housing. Install adaptor bolts
and washers, tighten to specified torque. (Adaptors may vary.)
31
Figure 176
Tighten pump stud nuts to specified torque.
Figure 179
Position valve plate to control valve gasket and control valve on
studs.
Figure 180
Position new control valve to solenoid valve housing gasket and
solenoid housing on studs .
Figure 177
Position a new modulator to housing gasket and modulator valve
assembly on aligning studs.
Figure 181
Install control valve assembly to converter housing bolts and
washers. Tighten to specified torque.
Figure 178
Position modulator valve opening plate gasket and plate on studs.
32
Figure 182
Install converter housing to engine flywheel housing spacer.
33
Recheck all drain plugs, lines, connections, etc., for leaks and
tighten where necessary.
TORQUE IN (LBS.-FT.)
BOLTS, CAPSCREWS, STUDS AND NUTS
LUBRICATED OR PLATED
Grade 5
Grade 8
Nominal
Fine Thread
Course Thread
Fine Thread
Course Thread
Size
.3125
16-20[21.7-27.1]
12-16 [16.3-21.7]
28-32 [38.0-43.4]
26-30 [35.3-4O.7]
.3750
26-29 [35.3-39.3]
23-25 [31.2-33,9]
37-41 [50.2-55.6]
33-36 [44.7-48.8]
.4375
41-45 [55.6-61.0]
37-41 [50.2-55.6]
58-64 [78.6-86.8]
52-57 [70.5-77.3]
.5000
64- 70 [86.8-94.9]
57-63 [77.3-85.4]
.5625
91-100 [123,4-135.6]
82-90 [111.2-122.0]
34
8O-88 [108.5-119.3]
115-127[156.0-172.21
CONVERTER OUT
PRESSURE
OIL FILTRATION
LUBRICATION
RECOMMENDED LUBRICANTS FOR CLARK-HURTH
COMPONENTS POWER SHIFTED TRANSMISSION AND
TORQUE CONVERTERS
Prevailing Ambient Temperature
TYPE OF OIL
CAPACITY
CHECK PERIOD
NORMAL *
DRAIN PERIOD
Temperature
Range 2
Temperature
Range 3
Temperature
Range 4
Temperature
Range 5
(a).*Dexron
(b) .*Dexron II D
(a) MILL46167
(b) MILL46167 A
(a) Conoco High Performance Synthetic Motor Oil Spec No 6718
PREFERRED Oil VISCOSITY Select highest oil viscosity
compatible with prevailing ambient temperatures and oil application
chart
Temperature ranges 2" and "3" may be used to lower ambient
temperatures when sump preheaters are used
Temperature range "4" should be used only in ambient temperature
range shown
MOOULATED SHIFT TRANSMISSIONS T12000 18000 24000
28000 & 32000 series transmissions with modulated shift use only
C-3 0, temperature range 3 items (a) & (b) *Dexron D *Dexron
II D SEE CAUTION BELOW
3000 4000 5000 6000 8000 16000 & 34000 series transmissions
with modulated shift use only C3 D, temperature range 3 item (a)
only *Oexron D Do NOT use *Dexron II D SEE CAUTION BELOW
(a) C2 Grade 30
(b) C3 Grade 30
(c) Engine Oil Grade 30 AP-CD/SE or CD/SF
(d) MILL2104C Grade30
(e) MILL2104DGrade 30
.*Dexron
is a registered
trademark of General
Motors Corp.
* Normal drain periods and filter change intervals are for average environmental and duty-cycle conditions. Severe or sustained
high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination. For
extreme conditions judgment must be used to determine the required change intervals.
35
MECHANICAL CHECKS
Prior to checking any part of the system from ii hydraulic
standpoint, the following mechanical checks should be made:
HYDRAULIC CHECKS
Before checking on the torque converter, transmission, and allied
hydraulic system for pressures and rate of oil flow, it is essential that
the following preliminary checks be made:
the converter. Where the former means is impractical, the latter means
should be employed as follows:
Engage shift levers in forward and high speed and apply brakes.
Accelerate engine half to three-quarter throttle
Remedy
3. Replace pump.
(R-32000 only)
4. Replace pump.
2. Replace.
NOISY CONVERTER
1. Worn coupling gears.
1. Replace.
2. Replace.
3. A complete disassembly will be necessary to determine what
bearing is faulty.
LACK OF POWER
1. Low engine RPM at converter stall.
36
DESCRIPTION
ITEM
QTY
DESCRIPTION
QTY.
Regulator Spool....................................................................2
10
11
12
13
Accumulator Valve.................................................................... 2
14
Plug ........................................................................................... 2
15
37
38
THEORY OF OPERATION
39
FIG.A
.061 -.067
[1.55 -1.70]
FIG.B
FIG.C
.046 -.053
[1.18 -1.34]
LOW (1st)
CLUTCH
FIG.D
(4 SPEED ONLY)
40
1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
2. Check engine flywheel and housing or housing adaptor for conformance to standard S.A.E. No.3 -SAE J927 and J1033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.
3. Install torque converter ring gear as shown.
NOTE; Assembly of the ring gear must be completed within a fifteen minute period from start of screw
installation. The screws are prepared with an epoxy coating which begins to harden after installation in the
flywheel mounting holes. If not tightened to proper torque within the fifteen minute period insufficient screw
clamping tension will result.
4
Install backing ring and sixteen (16) special screws to approximately 06 inch 11,5 mm 1 of seated position It is permissible to use
a power wrench for this installation phase. With a calibrated torque wrench tighten screws 30 to 33 pounds feet of torque [40, 7 44,7 Nm].
To obtain maximum effectiveness of the special screw's locking feature, a minimum time period after screw installation of twelve (121 hours is suggested
before engine start-up
The special screw is to be used for ONE installation only If the screw is removed for any reason it MUST BE REPLACED It is recommended that the
epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use a NEW screw for re-installation
Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws This may require more than one trial to match the drive gear teeth Pulling the converter into position with housing attachment bolts is not
recommended.
Measure engine crankshaft end play after assembly of torque converter This value must be within one thousandth (.001) of an
inch 10.0254mm] of end play recorded (in Paragraph #21 before assembly of torque converter
802554
1
16
1
1
16
1
1
249341
236288
802555
243767 Backing Ring not included in 802553 Ring Gear Kit Must be Ordered Separately
Dimensions are in inches
Dimensions in [ ] are mm
41
42
44
45
46
47
48
View "R"
View "S"
Forward & Reverse Clutch Return
Springs Concave side of first belleville
washer tu be placed against clutch piston
Remaining 3ix washers of each ciutch to
be stacked alternately reversed as shown
NOTE:
Metric
dimensions
shown In brackets [ ]
THREAD SIZE
LB-FT
[Nm]
1" - 20
150- 200
[203.4- 271,1]
1/4
200- 250
[271 ,2 - 338,9]
1/2
300- 350
[406,8 - 474,5]
3/4
400- 450
[542.4 - 610,1]
1 " - 18
1 " - 18
1 " - 12
GRADE 8
SIZE
FINE THREAD
lbf.ft
[N.m]
COARSE THREAD
lbf-ft
[N.m]
FINE THREAD
Ibf.-ft
[N.m]
COARSE THREAD
Ibf-ft [N.m]
.2500
9-11
[12-151
8-10
[11-141
11-13
r15-181
9-11
[12-151
-3125
16-20
[22-27]
12-16
[16-22]
28-32
[38-43]
26-30
[35-41]
.3750
.4375
.5000
.5625
26-29
41-45
64-70
91-100
[35-39]
[56-611
[87-95]
[123-136]
23-25
37-41
57-63
82-90
[31.34]
[50-561
[77-85]
[111-1221
37-41
58-64
90-99
129-141
[50-56]
[79-87
[122-134]
[174-1911
.6250
128-141
[174-191]
113-124
[153-168]
180-198
.7500
223.245
[302-332)
200-220
[271-298]
315.347
33-36
52-57
80-88
115.127
[45-49]
[71-771
[108-1191
[156-1721
[224-268]
159.175
[216-237]
[427-470]
282-310
[382-420]
50
Figure 186
Remove outer bearing.
Figure 183
Remove clutch shaft oil sealing rings.
Figure 187
Figure 184
Figure 188
Pry 4th gear up to accommodate gear puller. Remove 4th gear.
Figure 185
Pry front bearing to accommodate bearing puller.
51
Figure 189
Remove bearing spacer.
Figure 192
Install piston. and piston return spring. See page 40. Fig. D. Install
inner and outer discs as explained in Fig. 87 & 88. Install 4th speed
gear inner bearing.
NOTE: Bearing Part Number must go down. See Figure 195.
Figure 190
Remove 4th gear inner bearing. Remove end plate retainer ring and
end plate. Remove inner and outer clutch discs. Compress spring
retainer washer. Remove spring retainer snap ring. Release tension
on spring retainer. Remove snap ring, spring retainer, return spring
and clutch piston.
Figure 193
Install bearing spacer between inner and outer 4th speed gear
bearings. Instal14th speed gear into clutch drum. Align splines on
clutch gear with internal teeth of friction discs. Tap gear into
position. Do not force this operation. Gear splines must be in full
position with internal teeth of all friction discs.
Figure 191
If rear bearing, shaft or output gear and clutch drum are to be
replaced, press shaft from rear bearing and output gear.
52
Figure 194
Figure 197
Install 4th speed gear outer bearing. NOTE: Bearing Part Number
must go up. See Figure 195. It is recommended a rubber band be
used to hold outer bearing rollers in position when installing
bearing.
Figure 198
Figure 195
Figure 196
Figure 199
53
Figure 200
Install output shaft and 4th speed clutch assembly in transmission
housing. Refer to Figure 121 for remainder of transmission
reassembly.
54
REAR VIEW
55
1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface and the ring gear screw
tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
2. Check engine flywheel and housing or housing adaptor for conformance to standard S.A.E. No.3 -SAE J927 and J1033 tolerance specifications for pilot
bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine crankshaft end play.
3.
4.
Install backing ring and thirty-two (32) special screws to approximately .06 inch [1,5 mm] of seated position It is permissible to use a power wrench for this
installation phase. With a calibrated torque wrench tighten screws 23 to 25 pounds feet of torque [31,2 33,8 N.m]
To obtain maximum effectiveness of the special screw's locking feature, a minimum time period after screw installation of twelve (12) hours is suggested
before engine start-up
The special screw is to be used for ONE installation only If the screw is removed for any reason it MUST BE REPLACED. It is recommended that the
epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use a NEW screw for re-installation
5 Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment screws. This may require more
than one trial to match the drive gear teeth Pulling the converter into position with housing attachment bolts is not recommended
6. Measure engine crankshaft end play after assembly of torque converter This value must be within one thousandth 1.0011 of an
inch [0,0254mml of end play recorded (in Paragraph #2) before assembly of torque converter
1
32
1
1
32
1
249265
243970
802550
249265
244903
802550
802548
1
32
1
249265
240318
802550
249265
237153
802550
1
32
1
249265
4200097
802550
236937 Backing Ring Not Included in Ring Gear Kit Must be Ordered Separately
NOTE: The initial installation drive gear mounting kit includes a converter air breather. This breather is used on C & CL 2701C &
CL 320 converters only and is not required for the HR & LHR 280001HR & LHR 32000 applications
56
57
R-MODEL SECTION
58
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
23
Input Shaft.....................................................................1
24
25
Flange"0"Ring ............................................................... 1
26
27
28
29
30
31
10
32
11
33
12
34
13
3rdSpeedTubeAssembly................................................ 1
35
Detent Ball.....................................................................1
14
Tube Clip....................................................................... 2
36
Detent Ball.....................................................................1
15
37
Pipe Plug.......................................................................1
16
38
17
39
18
Breather ........................................................................ 1
40
19
41
20
42
21
43
22
Sleeve Lockscrew.......................................................... 2
59
R-32000
ASSEMBLY INSTRUCTION ILLUSTRATION
60
61
DISASSEMBLY
Figure 3
Remove front cover plug.
Figure 1
Remove control valve bolts and washers. Remove control valve.
Use caution as not to lose detent springs and balls.
Figure 2
Remove companion flange nut, washer and "0" ring.
Figure 4
Remove bolts securing front cover to transmission housing.
62
RETAINER RING
INPUT SHAFT
Figure 8
Input shaft, rear bearing, drive gear and snap ring.
Figure 6
Use a spreading type snap ring pliers to spread the ears on forward clutch front bearing retainer ring. Remove forward clutch
with pry bar .
Figure 7
If input shaft is to be removed, tap on threaded end of shaft,
remove input shaft, gear and bearing.
Figure 9
Install input shaft into front bearing.
Figure 10
Support converter housing with chain fall. Spread forward clutch
front bearing retainer ring and tap forward and 2nd clutch assembly
into transmission case assembly. Be certain snap ring is in full
position in ring groove.
63
Figure 11
Install 2nd speed clutch pilot bearing.
Figure 14
Support front cover with a chain fall. Install alignment studs in
transmission case. Position front cover assembly on aligning studs.
Turn output flange to align clutch disc hub in clutch. Do not force
this operation. With front cover in position against the transmission
case install cover to case bolts. Tighten to specified torque.
Figure 12
Install transmission case gasket and "0" ring seals.
Figure 15
Install front cover plug.
Figure 13
Install housing spacer, gasket and "0" ring seals. NOTE: Housing
spacer is used with 12 plate clutch modulation only.
Figure 16
Install companion flange, flange "0" ring, washer and nut. Torque
nut to specified torque. (See elastic stop nut torque chart).
64
Figure 17
Locate detent balls and springs in control valve. Position new
gasket. Secure valve with bolts and washers. Tighten to specified
torque.
65
66
PROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS NOTE: NOT ALL
TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS
1. Fill the oil sealing ring grooves with a good grade of grease, this will help stabilize the teflon ring and expander spring in the ring groove for installation
2. Position the expander spring in the inner groove of the new piston ring, with the expander spring gap 180 o from the hook joint gap of the piston ring.
3. Carefully position the piston ring and expander spring on the clutch shaft in the inner most ring groove. Hook the piston piston ring joint.
4. Repeat steps 1, 2 and 3 for the remaining ring or rings making certain all hook joints are fastened securely.
5. Apply a heavy coat of grease to the outer diameter of the rings and clutch shaft. Center the piston ring's in the ring groove.
6. Before installing the clutch assembly in the transmission case it is recommended a piston ring sleeve PN's 241309,237576, or 235314 be used to center all of the
piston rings in their respective ring grooves. Use extreme caution to not damage piston ring when installing the clutch shaft in the transmission case, or when
installing the converter housing or front cover on the clutch shafts.
28000, 32000
SERIES
67
Measure the "A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below
68
69