Maintenance and Service Manual | ee 32000 Powershift & Transmission & R & HR MODEL 4 SPEED LONG DROP a COMPONENTS CLARICHURTE> : 31198.246 — SIHAHAIZ-ALD 1294TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the NOTE: If the transmission has 4 wheel drive, rear wheels off the ground or disconnect the disconnect both front and rear drivelines. driveline 1 avoid damage 10 the trans: Because ci the design of the hydraulic mission during towing. system, the engine cannot be stared by pushing or towing, copyrere Cure Eouipmect Caray, 1905 LUrpstitshed matenal Al hu eakived Umi Deans sua prt ot tv work nye terosuced ary form under (Sv moans wihout are ian permanoe ct Clee augment ComaeryFOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the CLARK-HURTH COMPONENTS 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 trauble free service. In order to become familiar with the variaus parts of tha product, its principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use itas a reference when performing maintenance and repair operations, Whenever repair or replacement af component parts is raquired, only Clark- Hurth Components-appraved parts as listed in the applicable parts manual should be used. Use of “will-fit” or non-approved parts may endanger praper aperation and performance of the equipment, Clark- Hurth Components does not warrant repair or replacement parts, nor failures resulting from the use of parts which ara not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Silhouette Converter Group Converter and Transmission Case Group. Reverse and 3rd and Forward and 2nd Clutch Group. Low, ath and Qutput Group: Fiagulating Vaive, Charging Pump end Filter Group Control Valve Assembly Aexle Disconnect and Machanical Parking Brake Assembly Instruction llustratian DISASSEMBLY OF TRANSMISSION CLEANING AND INSPECTION REASSEMBLY OF TRANSMISSION ....... SERVICING MACHINE AFTER TRANSMISSION OVERHAUL SPECIFICATION AND SEAVICE DATA LUBRICATION .00......cee ceeeeee TROUBLE SHOOTING GUIDE RING GEAR INSTALLATION (16 SCREW TYPICAL FOUR SPEED POWER FLOW... EXTERNAL PLUMBING DIAGRAM RING GEAR INSTALLATION (32 SCREWI REMODEL SECTION ..0000.00.e20. CLUTCH AND GEAR ARRANGEMENT _ SHIELDED BEARING INSTALLATION .. CONVERTER DRIVE PLATE INSTALLATION NOTE: Metric Dimensians Shown in Brackets | ag.49 BB 64,TRANSMISSION ASSEMBLY The sansmission and hydravlic torque portion of the pawer train gmagts an important role in transmitting engine power to the driving wheels. in order to properly ma to first understand their functien and how they operate. tain and service these units it Is important The transmission and terque converter function together and operste through « common Bydrauile system, in necessary to consider both unis ia the study of their function and operation. To supplement the text below, and for reference use therewith, the following illustrations are provided: Basic Design Shouatte Converter Group Converter and Transmission Case Group Reverse and 3rd, Forward and 2nd Clutch Group Low, ath and Qutput Group Regulating Valve, Charging Pump and Filter Group Control Valva Assembly Axle Disconnect and Mechanical Parking Brake ‘Assembly Instruction Ring Gear Installation Clutch and Gear arrangement Shigitled Bearing Installation Four Speed Power Flow External Plumbing The R, HR, and MHR Model Trans ions are of three basic designs The R Modal consists of # separate torque converter, mounted to the engine with the powershift trans- mission remotely mounted and connected to the torque converter with 3 drive shaft. The KR Medel consists of a torque converter and powershifted transmission in one packas® mounted directly to the onaine, The MHR version is a mid-mount torque converter and transmistion assembly connected to the engine by meant of & drive shaft, (See Fig. A for basic design sithouetie.) ‘The shift control valve aszembly may be mounted direcily on the side of the converier housing or front transmission cover, oF romote mounted end connecied to the transmission by means of Mexible hoses. The function ef the control valve essembly is to direct cil under pressure to the desired directional and speed dutch. A provision is made on certain models 10 novivalize the transmission when the brakes are applied. This is accomplished through use of @ brake actuated shutoff valvo, The «peed and direction clutch assem- 2 are mounted inside the transmissi -:289 and are connected fo the output shaft af the canverter 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 end rection. ‘An axle disconnect is optional and Is located on the oulput shaft, The drive to the front or rear axle ean bbe ditconnected or connected by manual shifting.HOW THE UNITS OPERATE ‘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 ol filter, The pressure rogulating valve maintains pressure to the transmission control cover for actuating the dirse- tion and speed clutches. This requires » small portion of the total volume of cil used in the system, The remaining volume of oil is directed through the torque converter circuit to the will cooler and returns ta the for positive lubrication, This regulator valve consists of @ hardened valve spool operating in a closely fitted bore, The valve spool is spring loaded to hold the valve in a closad position. When a spotifie prossure is achlaved, the valve speol works against the spring until a port is exposed slong the side of the bore. This sequence of events provides the proper system pressure, seni si ‘After entering the converter hausing the cil is directed through the stater 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 converier fo the oll cooler. After leaving the cooler, the oil iz di 19 on the transmission, Then through a series of tubes and passages lubricates the transmission bearings and clutches. The oil then gravity deains to the teensmission. sump, ed 10.3 The hydraulic torque converter consists basically of three elements and their related parts to multiply engine Yorque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element the pump portion of the hydraulic torque canvarier and Is the primary eom- ponent which starts the oil flowing to the other components which results in torque multiplication. This el- ‘emeni can be compared to « ceririfugal pump in that it picks up fluid at Its center and discharges at its outer meter. ‘The torque converter turbine is mounted opporite the impeller and ic connected to the outpur shaft of the: torque converter. This clement receives fluid at Its outer diameter and discharges al it cantar. Fluid directed by the impeller out inte the partievlar design of blading in the turbine and eeection member is the means by which the hydraulic torque converter multiplies torque. ‘The reaction mamibar of the torque converter is located between end at the center or inner diameters of the Impeller and wrbine elements. its function is to take the fluid which is exhausting from the inner portion of the turbine and change its di ction ta allow correer entry for raeireulation into the irspaller element. The torque converter will multiply engine torque to its designed maximum multiplication ratio when the out- put shaft is et zero RPM. Therefore, we can say that as the output shaft Is decreasing in speed the torque mutiplication is increasing. The shift control valve assembly consists of a valve body with ealoctor valve spools. A detent ball and spring in the selector spool provides one position for each speed ange. A detent ball and spring in the direction spool provides thres positions, one each far forward, neutral and reverse. With the engine running and the directional control lever in neutral position, ell pressure from the regula ing valve is blocked at the control valve, and the transmission is in neutral roverse spocl will direct oil, under pressure to either # Movement of the forward and forward or reverse diveetion 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 It used in the speed selector. The direction or spead clutch assembly consists of a deem with internal splines and a bore to receive a hy- on is “oil tight” by the use of sealing draulieally actwated giston, The a. A steel disc with external pliner i inserted into tho drum and rests against the piston. Next, a frleion disc with splines at the inner cneled until the required total i achiaved. A heavy back-up ol diameter is inserted. Discs ore al fe is then inserted an secured with 2 snap ring, A Hub with O.D. splines is inserted it toath en the inner diameter The discs and heb are free to incroase ir te the splines of discs with speed oF rotate in the opposite direc- tien ax long as no pressure is present in that specific clutch. To engege the clutch, as previously stated, the control valve i placed in the desired position. This allows oll under pressure ta Flaw from the control valve, through a tubs, to # chosen lutch shaft, This sheft haz a drilled passageway for eil under pressure to enter the shaft. Oil pressure sealing rings are located on the clutch shaft, These rings direct oil under pressure te a desired clutch, Prossure af the ell forces the piston and dises ainst the heavy back-up plate. The dises, with teeth on the outer jameter, clamping against dises with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows thom 10 drive as a unit. There are blead balls in the clutch piston which allow quick escape for ail when the pressure to the piston is released. R-32000 HR-32000 MHR-32000 FIG. AHR32000 CONVERTER GROUP ITEM DESCRIPTION ary. ITEM DESCRIPTION 1 Bearing Support Screw .....-. 6 30° Hub to Impeller Screw.... 2 Bearing Support Serew Lockwasher... 6 31. Impeller Hub Screw Backing Ring 1 a Drive Gear Snap Ring .. 3 32) Impeller. 1 4 Pump Drive Gear Bearing . 3 33. Impeller Hub “O" Ring 1 5 Pump Drive Bearing Support. 3 34 Impeller Hub. 1 6 Pump Drive Gear... 338. Impeller Hub Bearing. .. 1 7 Turbine Shaft Gear... 1 36 Beering Snep Ring... 1 Turbine Shaft Gear Snap Ring . 1 37 Reaction Member Spacer 1 9. Charging Puro Drive Sleeve... 1 38 Reaction Member... eeccecce 10 Pump Sleeve Snap Ring......... 1 39 Reaction Member Snap Ring 1 11 Valve to Housing Gasket wee 7 40) Turbine Hub 1 12° Valve Body "O" Ring eee 7 Bl Turbine 00. ccc eee 1 43. Valve Body “O" Ring. sc. cece 1 42. Turbine Hub Backing Ring 1 14 Charging Pump & Oil Filter Assembly . 1 43 Turbine Hub Screw seaae a 15 Valve Body “0” Aing - 1 44 Impeller to Cover “Q" Ring. ...... 1 16 Turbine Shaft Bearing ......... ved 45° impeller Cover . od 17 Turbine Shaft Piston Ring... 1 46. Impeller Cover Bearing... i 18 Turbine Shaft - 1 47 Bearing Cap to. Impeller Cover 1 19. Stator Support . o 1 4B Bearing Washor ..........--. wed 20. Stator Support Screw Lockwasher,.,. 6 4% Bearing Snap Ring....... 4 21. Stator Support Screw. 6 50. Impeller Cover Bearing Cap... 1 22 Piston Ring........ 1 51 Impeller Caver Sleeve - 1 23. Piston Ring Expander Spring . 1 82 Ring Gear Screw .. 118 24 Impeller Hub Gear Snap Ring 1 53. Plain Washer... . 26 Impeller Hub Gear... i 54 Flywheel Ring Geer... 26 Oil Baffle Oil Seal 1 5S Bearing Cap to impeller Cover Screw 27. Oil Baffle Seal Ring 1 36 Bearing Cap to Impeller Cover 28 Oil Baffle... seed Serews Lockwashar aa 24 Git Baie Retaince ing 1 57. Impeller to Cover Serew . 24 58 Impellerte Cover Screw Lackwasher... 241 Figure G.iTem 2B a at 35 28 a7 2B 23 31 2 3 35 38 2 38 a aa a5 46 ay an a9 HR32000 CONVERTER & TRANSMISSION CASE GROUP DESCRIPTION cary. Pipe PUG cscs eects oe 1 Converter Housing Aswernoly |. 1 Converter Housing ta Frant Cover ‘Ser Lockwasher ry Converter Housing to Front Cover Screw 2 Tune Sloove Tube Sleeve Converter Housing Sleeve... Converter Housing Slave Lock Ganverter Housing Slesive Sere Lackiasher Converter Housing Sleeve Sera 1 1 1 1 1 Converter Housing Sleeve Screw 1 Converter Housing Sloeve Screw Lackmusher ... 1 Converter Housing Sleeve Lock 1 Converter Housing Sleeve. 1 Breathe 1 Sireet Ell 1 Breather Rectucing Wushing...... 1 Tube Slenue a Pas Plus, 1 Converter Housing te Transmission Housing Screw Lackwasher - 4 Converter Housing te Tranemigeiea Mousing Screws 4 Converter Housing te Transimisasan Housing Lackwasher - 4 Conwartar Hovsing to Transmissian Housing Screw ren 4 Lsbe Tube Retaining Serew Lockwasher 1 Lube Tube Retaining Serew: Suction Tube "0" Flog 1 Suction Tube Spacor Ring ve 1 Suction Tube Aesembly. 1 Sustion Tube Retainér Serevr Lackwesher 1 1 Sustion Tue Retainer Screw Tube Clip Serer Tube Cip Ser Loekwauner Tube Crp. oo 1 Reverse Tubs Azssmbiy. Fevers Tubs "0" Ring 1 Lube Tubs Retainer Screw 1 Lutes Tubu Ratainee Scraw Lackwashar. 1 Lube Tube Assembly 3 Tube Chip Serew ced Tube Clip Screw Loekwasner 1 Tabe Clip. 1 Sid Speed Tube ciceeeee 1 i ' : 1 3rd Speed Tube "O Ring Valve OW SPY THBE sss csecceeeees Catch Pressure Tube “OF Ring, Tabe Steere Low Speed Ghutgh Pressure Tube Transmission Case to Converter Housing Screw Lotkwasher 9 ‘Tranumisgion Case to Converter Housing Serew iren 50 31 3 DESCRIPTION Rest Cover Dawal Pin Fest Cover uo 1 Rast Cover ta Traramigtion Case Screw Lockwaeh Fest Cover ta Tranamission Case Screw 13 Rear Cover Poe Plug voces Rear Caver ta Case Stud Nut Ress Cover to Caze Stud Lackwasher Clutch Pressure Tube "O” Ring. ‘une Sieve Rear Cover to Transmission Case Gasket ear Cover te Case Stud - Magnetic Orein Plt. Oil Lavel Plug OO Lavel Plog Tranemission Cone Ansombly Seraen Assambly 6 Serger AEEUMBWY ees eee 011 Destritwtor Retainer Ring 4h Clutch Front i Distributor Pressurg Tuo “O° Ring . Sh Speed Pressure Tube THe EWE eee cee cee Pressure Tubs "0" Ring Tube Slave... dith Speed Clutch Lube Tube Oil Distributor Retainer Ring Locking Bait vee Suction Tube. Suetion Tube Clip Washer Suction Tube Clip Suistion SoA oes sy Suction Line Screg Suction Line Washer Suction Ling “0” Ring, a Converter Hausing ta Transmssion Cone Dawel Fin Suction Tube Clip Rivet Comenter Hausing ta Transmission Cae Cache 1 OW Battle ' Comener Hausing Adapter Ring se. ...ee ce. 1 duh Speed Pressure Tube “0 ing Law Spec! Pressure Tube "Ql Rina 1 Convertor Kausing to Transmission Case Gasket - Comrerter Hausing to Tramemiesion Case Spocer - Front Gover Gi $63.0 e eevee Convener Having Frant Cover Converter Hausing Frant Gower Gasket Hove Fring Hse Assemby Maze Fitting «=.=Figure DROR HR32000 REVERSE & 3RD & FORWARD & 2ND CLUTCH GROUP TEM DESCRIPTION ary ITEM DESCRIPTION ory 1. Reverse & rad Clutch Shatt Piston Ring . 47 Low Clute Ovive Gear. cee 1A. Preton Ring Expander Springs 88 GrarRetaiing Ping ees ssc: . 2 Front Bearing Retainer Rina . 49 Ind-Gone . 3 Reverand Shaft Front Searing End Plate 50 Clutch Hubs Ou Sette Rip vot teeeeee 4 Riaverse & Sed Shatt Bearing End Piste Bal : 51 QretGeer Retainer Ring... . S Reverse & Sid Sha Front Bearing 2.2. c csc sese 52. re Geor Retsiner Ring Retainer Front Baaring Retainer Ring... : 53 2nd Gear Retainer Ring Retainer Snap Ring... 7 Clutch Driven Gear Bearing - Shield in : 54 8 Cluteh Driven Gear Bearing Snap Ring 5... 5 55 § Clutch Drivan Gear... see seeeeese ous 10 Clutch Hub Oi Battle Ring 11 Spring Resines Sap Fag o 12 Clutch Driven Gear Bearing Snap Ring 1% Gutch Driven Gear Bearing - 1 Spring Retainer Snap Fira : vee 15 Spring Retainer Snap Ring Retainer oo 16 Spring Retainer... - 17 Piston Retum Spring botnets 18 Spring Retainer... 0... . 49 End Pate Retainer Ring - oe 20 End Plote-ReversoCWtGh os ssesevseereeeeee 21 Clutch Outer Di - Reverse Clutch 5-2. 22 Glutchlnmer Disc -Reverse Clutch... 23 Guteh stan AssombW- Reverse Clutch . 24 Clutch Piston Outer Soa! 25. Clutch Piston Inner Seal - : 36 Reverse & ard Gutch Brum . ‘Spring Retainer Snap Ring... : Spring Raina’ Snap Ring Retainer - BE Spring Raina oo cc eeeecveveeeese 57 Fiston Ratum Spring ...... fine 88 Spring Retainer 89 End Plate Retainer ing... : a) End Pinte-2nei Ciutet @1 Clutch Gute Disc Bnd Clutch 62 Clutch Inner Dise -2raCluteh 63 Clutch Peston Asgeribly -2ne Clutch e 6 8 a 68 69 ‘Clutch Piston Outer Seat - ‘Clute Piston lana Saal... +5 coe Forward & 2nd Ciutch Drom - ‘Clutch Piston laner Seal - CCutch Pistoa Outer Saal, « en Coch Paton Assembly - Forward Gch FO Clutch Outer Desc» Forward Chtcht . Fi Clutch inner Dise Forward Chacha 72 End Plate -Forware Clutch... 74 End Plate Retwinoe Ring . Be ee ee ee eee eee 27 Cluteh Piston loner Seal. 74 Spring Retanar Snap Ring. 28 Clutch Piston Outer Ses! - : 78 Spring Retainer 29° Gluten Piston Bd Chae : - 78 Piston Return Soving = : 30 Chuteh inner Bice - Se Clutch - TF Spring Retainer .. be 31 Ghutch Outer Dise -Bra Cruteh bene FR Spring Retainer Sogo Ring Betaines = B2 Ene Plate Bred Cute ee - 28 Soxing Retainer S36 Ri votes - 33. End Plate Retainer Ring. ee 80 Chach Driven Geor Bearing 34 Spring Retainer - 81 Clutch Oriven Geer Braving Snap Ring =... 35 Piston Return Spxing vobcstavtsteneenenes 82 Clutch Hub Oi Baffle Ring - : 36 Spring Retainer - 83. Ferword Gluten Driven Gear 31 Spring Retainer Snap fing Retainer = 84 Clutch Divan Goar Bearing Seap Ring 38. Spring Retsiner SED RIND... .ses see 85 Clutch Driven Gear Bering “Shield I csv 39 rd Gear Basing « - - 85 Front Bearing Retainer Ring... . 40. 3rd Geer Bearing Snap Ring. woe 7 Fron Bearing Locating Ring “41 Clutch Hub Oi Bafto Ring BB Forward & 2nd Shalt Front Boating ev eeeee 42 antGear : . 183. Forward & 2nd Shaft Bearing End Plate Ball... 4% 3rd Gear Hearing Spacer cs 20 Forward & 2nd Stat Front Bearing End Plote 44 3tel Gear Bearing Shan Ring... BT Front Bearing Retsinet RIAD. ces essen 45 Brel Gear Bearing Shioid Out - 82 Forward & 2nd Shaft Piston Ring : 4b evens B-3rd Sheft Reor Besritny <2. ccc 2A Piston Ring Expander Springs -R OR HR32000 LOW, 4TH & OUTPUT GROUP ITEM DESCRIPTION S8sesaars Low Sooo Clutch Shaft Pitot Beesing ‘2nd Gear Basing End Piste - nd Gear Beating Bearing Retaining Ring Retainer Low Speed Guar Booring Rit Lom Speed Geo Boing Assembly Low Speed Gear Clutch tnd Ol Bato Ring « Scxing Ratainer Ring Rotainoe Scxing Retaining Ring : Piston Rotum Dice Springs Piston to Dise Spring Spacer Ere Pate Rep Fing End Pate eas : Clutch inne O56 : Clutch Outer Bice Clureh Piston. Clutch Aston Gunar Sant Ring Clutch Feston Inet Seal ing Law Speed Clutch Deum. Low Sheed Sash Rear Bearing... Bearing Lockbat Fea Bearing Retsine Plato Fiat Bearing Retwiner Fata Sorow Fea: Bearing Gop Gaskat Fieai Hearing Cap Rear Boarina Cap Screw Lackwaster Rar HearinayGan Screw Rear Bearing Cap Prag. Roar Bearing Cap "0" Ring Gutth Sash Piston Ring low Speed Shalt Rear Besting Locating Hing. Bearing Cap Screw Lockwathsr Bearing Cap Screw BBesring Gap Sctew Lackwasher | Baring Cap Screw ler Shatt Beating Cap ‘lay Shaft Basting Cap Gasket ‘Ber Shaft Nut - Ilar Shaft Washer rear Beoring Locating Ring Idler Shaft Rese Beuring Lock Ball Idler Shaft Rear Bear Fler Bearing Cepscrew far Beating Capeorn Lackwashor Fear Beating Cap Rear Baaring Cup. Rear Bearing Cone ary ee eee ITEM 52 53 seae HISBRLERLSSLSSS Sodeegag eee eSesesaeaesse ‘Output Shaft Gear ‘Output Shaft Gear Spacer : ‘Ouput Shaft... : Front Baring Gone 2... esse Front Bearing Cup Front Beoring Cap Bes Front Seeing Cap Front Beering Cap Ohi S Front Besring Cap Screw. DESCRIPTION Front Besring Gap Screw Lockwnsner 4th Geor Pisin Ring “4th Gear Frort Bearing Snap Ring Idee Shaft Front Beoring «4th Gear Bearing Snap Ring 4th Gear Boating - Ath Gear Spaces” th Gear tn Gaat Beating oc Bearing Soo Ring ms Spring Retainer Fiston Return Spring Spina Retainer 04 Battie Ring Backing Plate Sra Ring Clutch Oise Backing Plate - Clutch inner Dise Clutch Outer Bios: Clutch Piston : Cute Piston Guitar Seal Ring lutch ston Inner Seal Rog sah Clutch Drum Locating Ring at Gluten Bue Idee Shaft : Idler Shaft Gear Key. lolor Snaft Gant oe. Bore Plug Dizcorwaecy Assenibty Oil Seal.. Output Fang Output Fange “O° Ring. ‘utout Flange Washer : urput Flange Nut Speedo Driva Gear eer Bearing Cap FReer Beoring Cap Lociwasher Rear Bearing Cap Scrow ‘Sps6do Drivan Gear Sprodo Tube Nut - Rea Bearing Cap Screw ‘ear Bearing Cap Screw Lockwash: CapShIM eee cece cess ary ody g ee BePRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP ITEM DESCRIPTION 1 oo bk ow 10 W 12 13 4 18 16 v7 18 19 20 24 22 23 24 26 Charging Pump Drive Sleeve Pump Sleeve Snap Ring... Valve ta Housing Gasket. Valve Body “O” Ring Valve Body “O" Ring Pipe Plug. : Safety Valve Seat Safety Valve Spacer... Safety Valve Plunger Safety Valve Spring - Valve Stop “0” fing ....----- Valve Stop. Valve Stop Roll Pin Valve Stop Roll Pin Valve Stap........5 o Valve Step “O" Ring . Valve Piston . Valve Spring - Inner Valve Spring - Quter Valve to Converter Housing Stud Valve Body to Pump Gasket... Pump Body Snap Ring. . Thrust Plate & Bearing Assembly Fump Driven Shaft Assembly... Charging Pump Housing . ITEM. DESCRIPTION 26 27 28 29 30 31 az 33 a4 35 36 37 38 39 40 a4 42 a3 4a 45 46 47 48 49 50 Valve ta Housing Stud Lockwasher Valve to Housing Stud Nut Thrust Plate & Bearing Assembly Wave Spring. Pump Shaft Seal ce Pump to Filter Adaptor Screw Lockwaster... Pump to Filter Adaptor Serew. Pump Drive Shaft Assembly Pump Drive Shaft Oil Seal . Pressure Regulator Valve. ... Valve Body Roll Pin a Valve Body “O" Ring Pump to Filter Gasket Filtor Adaptor cteeeee es Filter Adaptor Plug By-Pass Filter Disc Spring, By-Pass Filter Disc. By-Pass Filter Disc Seat Filter Seat Rat ar Ring. . Filter Housing “O" Ring. Oil Filter Element Assembly ‘Oj! Filter Element Spring. . Filter Housing , a Optional Adaptor for Remote Filter ary. 4 4DEcICH ruc | Ce g | “J noc & CONTROL VALVE ABSEMULY tan oeciute™) FigureITEM Naoko 10 u 12 13 14 15 16 7 18 19 20 21 CONTROL VALVE ASSEMBLY DESCRIPTION Olt Seal Oil Seal Retainer Ring Oil Seal Retainer Washer Forward & Reverse Valve Spool... Contral Valve Gasket... ., Detent Spring... 6s... Detent Spring Detent Ball Neutral Switeh oo... Detent Balt os Valve Housing Plug Valve Housing Plug "0" Ring ‘Overshift Spacer (Not on all models). Control Valve Housing bees Detent Spring Plug Detent Spring Plug Washer Detent Spring Value ta Adaptor Housing Serew ‘Valve to Adapter Housing Screw Lockwasher. - Speed Selector Spaol Plug. Speed Selector Spaol ary. Tem 22 23 24 25 26 27 28 29 30 3t 32 33 co 35 Figures A-B-C & D a4 45 46 a7 438 49 50 DESCRIPTION ‘Overshift Spacer [Not an all models). Oil Seal Retsiner Washer Oil Seal Retainer Ring. errr Oi Seal cee Piston Housing Assembly Stop Plug Plug “O" Ring Piston “O” Ring Glyd Ring Piston... Piston Housing Oil Seal... “O° Ring. . Adaptor Screw . Adaptor Screw Lockwasher Valve Adaptor Valve Adaptor Gasket Adaptor Screw... Adaptor to Plate Gasket ....., Valve Adaptor Plate ary. us declutch options. 4 4MECHANICAL PARKING BRAKE Figure Hrem AXLE DISCONNECT DESCRIPTION ary. Disconnect Housing Capscrew on 4 Disconnect Housing Capserew Lockwasher 4 Disconnect Housing Disconnect Housing Plug Shift Hub Shift Fork. Shift Fork Lockserew: MECHANICAL PARKING DESCRIPTION Backing Plate Assembly... Actuating Lever Brake Shoe and Lining Brake Flange Brake Drum Brake Drum to Flange Screw Lockwasher Brake Drum to Flange Screw ime 8 9 10 n 12 3 4 rem W 12 13 DESCRIPTION Disconnect Shi Detent Ball Detent Spring Shift Rai Shift Rail Oil Seal Bearing Retainer Ring Bearing .... Bearing Retainer Ring BRAKE DESCRIPTION Return Spring 2 Broke Shoe (see item 3). Brake Lining .... 2 RIVE oeeernenn nen ne) Backing Plate Serew .... Backing Plate Screw Lockwasher ...ASSEMBLY INSTRUCTION ILLUSTRATION Figure |2 impo fab unc Turbine Hub Asseenty ah aching Reva on Spatial Sell Lecring Seles 4. Clsan hub guriing pyrtaee anc lgped hoses om sserent Dry toraughly bing cen Isopec Flew ara dry 8 clean 2 Insta backer) ng ae Souci st asxing {Tighten eoraye a0 to 45 Loe, Pe §543510 No) Nene Riaernbiy of hu must be eomalata Winn & Teen ruts pana fom stat ste IO Ine Toe spectalsevaw fy @ bo used for on ffolatin only. W e-teren 9 remove for any Feason i muai be replaces The epony Wii Ihe fat holes must be suMcoc Wth Ie BrOBRY 1 (ad Seana wth aceon, Ory Rete nero and ee 8 now screw for tension 2S Seo to be apse medec wat fang hue \emgih to te ice 2X Trwee ciusches,S-outes siee! plaies.S.ioner bition | plas Aasernble alterna, Steet ele Ay See Einne stp at Torque Cat DS cow cuter cue ste! ates. oener ction Dlates assomone seersaeip sizing woh ater Sec asi 2, Swe Binstic Stop Mut Torque Chart EY nim gutzut sna eearnge to prosuoe 6 ua 8 Loe « In 10,98,0,90 Horn preteoa, AX Tightsn a1 secon ses'y, 10 1 15 Lo (13.620. remy View "O" 2 Pieces oaauition ory Low Gltch Return Serre ‘Consaiva saa ot rat aetevile woe" 19 be plneod quiet eit patan. Reenaining faut ‘ere fo ba sached altserasely reversed as stun. Fanard & Reverse Clutch Rature Sprogs Concave side of frat belie wastes Oy bt paced agains clutch platen, Hemsnng 2 frasharg OF each euigh 1p be slackuo Steraiey teverseg sa shor = AX steat noes wushing 200° F* BIC} Delowe ane, Of Busting #9 coe BB ea sik BUT on peed teh, Bang mes team ark ov 2 santos one eral brig, ho sn ane’ wena 2d 012 Pte Medutsian) Two clutches t2auter steal pases, Zinnes Inchon plates. Asser bie slarnatery, Sling oth autor sea pla Notes, A Use Bormann & Crime Seater only where Spocted 1B. Al foaa in chamie for al sea, piston rings & ‘O" Feigy mugl be smooth to trom aus inupect at aay (C.- Lubreate all aision fing roawss & "O° sin. ‘ah tore ay. Reply tory bg coat ot Permatex No.2 10 0.0: ff allot seals betere assy Ale asain of pars wang Permatex ct ‘Crane sealer, Were Must ote ary Be oF snbos2 malar! Wat ud enter Uw OF cls F.- Apply bgt coat o” Crane Sealer ta st pipe plugs G.- Apel 8 tin coating of grease metween gel Tig 09 op type sot pra to ace. «App igi oa oF Perrone Mo. tn all thea ile ae rene NOPE. The friction dae sn thew chic has ahigher cowffcant rateg than tha Sion ‘ges 9 me ather elvtenes, neva the ‘hess rues ot be ried. Ths kc le bs fee dsc cane Geraedbyan Xam ged con anesie oftnainnsr wath. Tha law ule inne eae alga hae 2 pp af non-sotubie Yellow pre sprayed on Ue our ee ot Ihe aise. op : Enlarged vinw e! Pisin Ring & Expander Nate Expander gap 10 Be apatex. 120" fom ng eos ein ot Hing accom, __tasnie sro wur roroue dimensions shown Ve mm - cende 5) Tae Eoetaion tran “COARSE THREAD a ee iam || west uy | est wom) ma iaa | erm | as way | us ar | tao al sees pars ss ie. me | [ions a0 aa pee in wear te a EEE ea ase Soe pes ma] Sasa opt ea] sop ee teat Figure!NOTESMAINTENANGE AND SERVICE The instructions contained heroin cover the disassembly and agegembly of the transmission equence that would noxrally be folowod after the unit has been ternawed feo th machina and is ta br completely everhaulad. i must alco be ndarstood that this is # busie 32000 tansmisson with many options. Camparion flsngés and output shafts with and without disconnect assembly may vary on specific mode's. The wi ‘ae very similar to tauble shoot, disssemble, repsix, anid reassemble. CAUTION: Cloariiness i of exveme importance and an absolute must in the repair and oveihaul of this unit. Bafore teriting any repeirg, the axterior of tho unit must be tBoroughly clesrad to prevent sha possibilty of dit and foreign ‘matter entering the mechanism, See page 2 for Rhode! emote mounted) transmission front cover section, DISASSEMBLY Figure 7 Sideview of teansmission. a Figure 2 ter housing and filter stemant, NOTE: Some units wil have 8 double pump—procesd to figure 3. Remove ks em Figure 3 Remove chaiging pump to reguisting valve stud nuts. Remove pump andi iileer adapter, or double pamp assembly, Figure 4 Remove pressure regulating valve assembly,i bape ae Figure 5 Figure 8 Remave pump drive sleeves, Remove modulator valve adaptor plate and alignment studs igure 6 Remove twa valve te conweriar housing capse-ews. Install two slighing studs as shown. Remave remaining 250° 211%] cortecoc parang iimcsratae, Ral SAE, Sose Na. ISTTIOOAY Rjcrauna Hare Spore non 4 All Hage Lines ice must concen to SAE, Spon: Na. sna Tout Prowse ty High Temp. Wansmisice O1 Hee 6 See Lunriation speeiteatonsPROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS NOTE: NOT ALL TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS Fill the oil sealing ring grooves with « good grade of arcace, this will help stabilie the tafion ring and expander spring in the ring groave for installation, Position the expand spring i the inner groove of the new pizzon ring, with the expand 5 ‘ofthe piston sing, ing gap» 180° from the heok joint gap Carefully position the pistan ving and oxpander spring on the cluich shaft in the inner most ring groues. Hook the pistan piston ring, iin. [Repeat steps 1, 2 and 3 for the remaining ring or tings making certain all hook joints ate fastened securely. Apply 8 heavy cpat of grease ta the outer diameter of the rings and clutch shalt, Cantar the piston cing's in the ring groove. Bafore installing the: cluich assembly in the Htont gover or converter housing itis tecommendes! a piston ring sieeve PIN's 241.308, 237676 oF ZH265 be used to center ail of te piston rings in thelr 1aspectve ring grooves. Use extreme caution to not damage Piston rings when inetalling the clutch shaft av the frent asneission eovsr OF converter hausing USED FOR POSITIONING — PISTON RING, PISTON RING OF PISTON RINGS SLEEVE 254205 SLEEVE 2erg09_OF 237576 J | BEARING Nd Quran su € a vsrou mes Bo sure thal lad in chamfer and Intersection of lead in. hamlet to. piston fing bow is tree of burrs and nites. ; Reason sr - BEARING PISTON RINGS: ogy ne he oawaoa Fiston Ring i oe NN dy ‘ey { | | YX sens ff) Exmander Bing Se see SSS \ senna SPRING GAP_AND RING GAP \ GAP. ARE 180° APART Sp1.0801 + .007 [26.94.17] Stake 3 places approx. equally spaced. APN After curing of Loctite, speed sensor bushing must be secure with 40 Fi. Lb. [54.2 N-m] torque. L 990 ¥ O07 [35.34.17] Assemble Speed Sensor Bushing in housing ta specitied REAR VIEW Gimension with Lociite 282 and stake (3) three places. SPEED SENSOR BUSHING INSTALLATION a2‘OIL SEALING RING SLEEVE REMOVAL NOTE: The following photos are not of the HR Converter Housing but the sieeve removal procedure is identical Figure 4 Figure 1 Figure 5 Steeve being removed. ‘See cleaning and inspection page. NOTE: When installing a new siaeve itis recommended a press orardriver be used to prewerst damage to thesslaeve ancibbesure the natch in te sleeve i aligned with sleeve lack rote. Instill Figuee 2 sleeve lock anil capacrew. Tighten screw to specified torus, Remove ail sealing ring sleeve retainer screw, (See torque chart) Figure 3 Ramave screw and sleave lack. aa—32000 TRANSMISSION CONVERTER DRIVE PLATE INSTALLATION Measure tho “A” dimension (Bolt Circle diame) ars ander Drive Plate Wit listed below, ALIGNMENT LES WED NUT ASSEMBLY ws wTeneDuare ‘BOLE CIRCLE oA TORWE PLATES. BACKING RING “A” Dimension (Bolt Cirele Diameter) 13.128" [333,375 erm] Biareter Ke No, 802335 13.50" [342,900 mm] Disenetor kit No, 802333 17.00" (431,800 enn! Diaeneter Kor No. 802454 Fach kit will include the following parts: 4 Interrmediste Drive Plates 1 Drive Plate and Weld Nut Assen 1 Backing Ring, 10 Screws and Lockwasher Assembly 1 lesirwction Shoot, ‘TO FACIUTATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES — SEE ILLUSTRATION ABOVE, Position divs plata and weld nut assembly an imps cover with wold nuts toward cover. Align intormediats dive plate and backing ring with holes in smpeller caver. NOTE: Two dimples 180° apart in backing ring must be out itoward engine flywheel Install eapserows and washers, Tighten 23 to 26 ft tbs, torque [34,2 » 33,8 Nm] SEE PAGE 65 FOR TRANSMISSION TO ENGINE INSTALLATION PROCEDURETRANSMISSION TO ENGINE INSTALLATION PROCEDURE Remove all burrs irom flywheel mounting face and nose pilot bore, Clasn drive plate surface with solvent. Check engine flywhes! and housing for conformance 1 standard SAE. @3 . SAE 1927 tolerance specifications for pilot bore size, pilet bare runout and mounting face flatness. Measure and record engine crankshaft end play. Install two 3.60 [88,90 mm] tong transmission to fiywheel housing guide studs in the engine flywheel housing 8s shawn. Rotate tho engine flywheel to align 2 drive piste mounting screw hole with the flywheel housing access hole. Instell 2 4.00 [101,60 ml long drive plate locating stud 3750-24 fine thread in a-drive plate nut. Align the locating stud in the drive plate with the flywhoe! drive plata mounting screw hole positioned in step No. 3. Locate transmission on fiywheel housing aligning drive plate 10 flywheel and transmission to fywhee! housing Install transmission to flywheel housing screws. Tighten serews 10 specified torque. Remove trans mission 10 engine guide studs. Install remaining ‘screws and tighten to specified torque. Remove drive plate locating stud Install drive plate attaching screw and washer, Snug screw but de not tighten, Same engine flywheel housings hewe: 9 hole located en tha flywheel housing -circumtoronee in line with the drive plate screw access hole, A, screwdriver or pry bar used to hold the dive plate against the flywhee! wall facilitate installation ot the drive plate scrows. Rotate the engine flywheel and install the cemaining seven (7I flywheel to orive plats attaching screws. Snug strews but do not tighten. ‘Afterall eight (B) scraws are installed forque each one 25 to 30 ft lbs. torque [33,9 - 40,6 Num). This will re ‘quite torquing each screw and rotating the engine flywheel until the full amount of eight (B) screws hove bean tightened. Measure engina crankshaft end play after trans mission har been complistely installed on engine fiywheel. This value must be within .OOT (0,028 mml of the end play recorded in step No. 2, Ae?NOTESCLARIC-HURTE> COMPONENTS Statesville, North Carolina ‘Arco, Italy OHT-0013 PRINTED IN U.S.A,