28000 3 Spd SD 0004 SPICER OFF-HIGHWAY COMPONENTS Rae ban re A 31190-2866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 manutacturing 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 Principte of operation, trouble shooting and adjustments, itis urged thal the mechanic study the instructions in this manual carefully and use itas a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only Clark- Hurth Compenents-approved parts as listed in the applicable parts manual should be used. Use of “WwilLfit” or non-approved parts may endanger proper operation and performance of the equipment. Clark- Hurth Components does not warrant repair or replacement parts, nor ‘ailures resulting {rom the use of parts which are not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and mode! number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Slihouene . Converter Group . Converter and Transmission Case Group « 8 Speed Clutch and Gear Group , Cluteh Group. Regulating Valve, Charging Pump and Filter Group . Control Valve Assembly eee eee ee Mechanical Parking Brake... eee ‘Assembly Instruction Drawing ........ External Plumbing Diagrem 22.2.2... --... 2. DISASSEMBLY OF TRANSMISSION .....-.-....-.... CLEANING AND INSPECTION .....0.020 20.00 0502065 REASSEMBLY OF TRANSMISSION 2002.22.22... SERVICING MACHINE AFTER TRANSMISSION OVERHAUL SPECIFICATION AND SERVICE DATA... ..-. =. 22-222. LUBRICATION .......... TROUBLE SHOOTING GUIDE -.-.... 22.22.2222 HA MODEL TYPICAL THREE SPEED POWER FLOW... CLUTCH AND GEAR ARRANGEMENT 2.2.2... SHIELDED BEARING INSTALLATION cece RING GEAR INSTALLATION ......20.. 0... SPEED SENSOR BUSHING INSTALLATION ..... 2.2... DRIVE PLATE INSTALLATION 0.00000. 0000ccecceeee NOTE: Metric Dimensions Shown in Brackets [ wees 8496-26-37 we 38TRANSMISSION ASSEMBLY “The transmission and hydraulic tarque portion of the power troin enacts on important role in transmitting angine pawer ta ‘the driving whoeic. In order to properly maintain and sorvice these Units it is important to first uncierstand thait function and hhow they operate, ‘The transmission and torque converter function tagsther and operate through a;common hydraulic system. f ‘consider both units in the study af their function and operation. yeouseary ta To supplement the taxt below, and for reference: use therewith, the following illustrations are provided: ‘Basie Design Sihouette ‘Gonwerter Assembly ‘Converter and Transmission Case Group ‘Three-Speed Case and Clutch Group ‘Cuuteh Group. Repulnting Vohe, Charging Pump and Fite Gaoup ‘Contol Valve Mechanical Parking Brake ‘Typical 28000 Cross Section External Plumbing Diagram ‘Typical Three Speed Power Flaw (Clutch and Gear Arrangement ‘Ring Gear Inctalation ‘Shialded Bearing tnetallation ‘The f, HR, and MHR Model Trangmistions are of three basic designs. ‘The R Model consists of a separate torque converter, mounted to the engine with the powmrshift transmission remotely ‘mounted end connected ta the torque converter with a drive shaft ‘The HF Model consists of » torque converter and powershifted transmission in one package mounted directly to the engine. ‘The MHR version ia. a mi-mount torque converter and trenemission assembly connected to the engine Ihy rheans af a drive shaft. (See Fig. A tor basic design sithoustte.| “Tho shift control valve assembly may be mounted direetly on the side of the converter rousing or front trensmission cover, or remote mounted and consectod we the transmission by moans.of flexible hoses. The funetion af the control valve seeambly is tordirect oil under pressure to the desired directional and speed clutch. A provision ts mede on certain models to neutralize the transmission when the brakes ore epolied. This js accomplished through use of « brake actuated shutoff valve. The speed land direction clutch assemblies ace mounted inside the transmission case and are connected to the outgut shaft of the ‘carverter tithes by direct gearing or dive shaft, The puraost of the speed or directional clutches is to direct the power flovr through the gear train to provide the disited speed range and direction,HOW THE UNITS OPERATE With the engine running, the converter charging pump draws oll 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 mainisins pressure to the transmission comtvol caver for actuating the direction and speed clutches. This fequiras & small portion of the tots! volume of oll used in-tha system. The remaining volume of oil is directed through the torque converter cirewit to the oil cooler and returns to the transmission for positive lubrication. This requiator valve consists of a hardened valve spool opereting in a closely fitted bore, The valve sncol fs spring loaded to held the velve in 2 cloged position. When 2 specific pressure is achieved, the valve spool works against tha spring until a port is exposed along tha side of the bora. This sequence of evants provides tha proper system presuira, ‘Alter entering the converter housing the oit is directed through the stator support to the exavertar blade cavity and exits in the passage between the turbine shaft and converter support. The eit then flows out of the converter to the oll cooler. After leaving the cooler, the oil is directed 20 a fitting on the transmission. Then through a series of tubes and passapes lubricates the transmission bearings and clutches. The oil then gravity drains to the teansmission sump. The hydraulic torque corwerter consists basically of thrae elements and their related parts to muttiply engine torque, The engine power is wansmitted from the engine Aywhee! to the impeller elament through the impallar caver. This element is the BUMB Portion of the hydraulic torque corwerter and ir the primary component which starts the oil flowing to the sther ‘components which results in torque multiplication, This element can be compared to a centrifugal pump in that it pieles up fhuid at its center and oischarges at its outer dismeter ‘The torque converter turbine is mounted opposite the impeller snd ls connected 10 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 hydreulic torque corwerier ‘muttiplies torque ‘The resction marber of the torque converter is located between and at the center or inner diameters of the impeller ant turbine laments. Its function is to take the fluid which is-exhaucting from the inner pertion of the turbine ang change itz direction to allow correet entry Ter recirculation into the impelter element, The torque converter will multiply ongine torque ta its designed maximum multiplication ratio when the output shaft ist zero RPM. Therefore, we can say thet 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 speing in the selector 5900! provides one position for each sperd range. A detent ball and spring in the direction spool provides three positions, ene ‘ach for forward, nowteal and reverse. With the engine running and the directional contro! lever in nautral position, ofl pressure from the regulating valve is blocked at the cantrol valve, and the trenamvission is in nowtral. Movement of the forward and reverse spool weil direct oil, uncer Drosure to either tho forwerd or revarse direction clutch as desired, When either directional clutch is selocted the opposite clutch is relieved of pressure and vents bock through the direction stlector spool, The same procedure is used in the spoet salector. “Tho direction or spond clutch assembly consists af drum with internal splines and a bote to receive « hydraulically actuate piston, The piston is “oil tight” by tho ust of sealing rings. A see! disc with extarnal splines is inserted into the dary and rests against the piston. Next, a friction dige with splines at the inner diametor is inserted, Discs ae slternated until the raquited total is achiewsd. A heavy beck-up plate then inserted and socured with 2 snap ring. A hub with O.D. spines is inertad into the splines of dies with tooth on the inner dlameter, The dises and hub are free to inereass in weed or rotate in ‘the opposite direction as long aso pressure Is present in that specific clutch. ‘To engage the clutch, as previously ciated, the control valve is placed in the desired position. This allawe oil under pressure to flow fram the control valve, through a tube, to @ chosen clutch shaft. This shaft has 9 drilled pasageway for oil under pressure to enter the shaft. Oil pressure sealing rings are located on the clutch shaft, These sings direct ail under pressure to 3 esired clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The discs, with teeth on the ‘outer dimerar, clamping againat diss with Teeth of the inne’ diameter, enables the huby and cluteh ghatt to be locked ‘together and allows them to drive as unit, ‘There are blevd balls in the elutch piston which allow quick escape for oll when the pyessure to the plston ix releused.HR 28000 (SHORT DROP) (ourPuT) R 28000 HR 28000 MHR 28000 FIGURE AHR 28000 CONVERTER GROUP teen Desorption any. wen Description 1 Bearing Support Screw oo. <6 | 32 Impeller Hub - 2 Bearing Support Screw: Lockwasher <6 | 33 Impeller Hub O-Ring oe Driving Gear Snap Ring <3 | 34° Impeller... 4 Drive Gear Bearing 3 | 38 Oil Battie Retainer Ring . 5 Drive Gear Bearing Supports... ...2. 0.2.63 | 38 OW Battle... . B Drive Gear ses ees eves e eee sc3 | 37 OW Battie Soe! Ring... - . 7 Snap Ring {internal = See itern 8] -1 | 88 Betent Spring... Drive Gear Hub Sleeve and Snap Ring 39° Detent Ball a - Asvembly — lic, items 7 and 9.6.0... 2 021 40 Valve to Converter Gasket... 9 Snap Rng (External — See item & ' 41 Control Valve Housing Assembly 10 Valve Body te Converter Housing Gasket... 42. Valve to Converter Housing Screw 11 Valve Body ta Converter Housing O-Ring . Lackwasher esc. cce eee ses 12 Valve Body te Converter Housing O-Ring 43° Valve to Converter Housing Serew . 12 Valve Body to Converter Housing O-Ring 44° Turbine Hub Screw Washer . 14 Regulator Valve, Charging Pune end 45 Turbine Hub Serew 2... Fier ABBEMBIY eee eee e eel 46° Hing Gear Screw eee eee 18 OWSeDI ceed 47° Ring Gear Screw Plain Washer . 16 Impeller Hub GAS e ees 1 48° Flywheel Ring Ge: ce 17 Impeller Hub Gear 1 rs Soap fing 49° Wnpeller Cover Sleeve 18 Stetor Olt Seating ceed Seppe 3 Res 50 Impallor Caver to Impeltar Serew and 19 Seuling Ring Expander Spring... .... 1 LOCKWABIEE eee vce essen 20 Stator SupRE ee eee | BT Ipater COM ee 21 Turbine Shaft boss vecseest | 52. Impetor Cover Beating... 22 Turbine Shatt Geer... ---1 | 83. inmpetor Cover Bearing Retsiner Ring 23. Turbine Shaft Geat Retainer Ring ...........1 | 54 tmpetioe Caver O-Ring . 24° Converter Housing and Tube Asscmbly 1 | 88 Turbine Retainer Ring oe 26 Turbine Shaft Bearing 1 | 56 Turbine 26 Turbine Shaft OW Sealing Rig wees vereT | BF TIME MUD ec cee 27 Stator Support Screw Lackwasher ........-6 | 6@ Turbine Lacsting Ring... 28 Stator Suppart Screw . . -..6 | 50 Renetion Member Rotsiner Ring 29° Hub ta Impetiey Screw cos... | 60) Rewetion Member... . 3O Hub ta Impeller Serew Washor .. .- & | 61 Reaction Mambar Spacer 31 Impoltor Hub Bearing - a 1 | 62. impetior Hub Bearing Retainer Ring a |HA 28000 CONVERTER AND TRANSMISSION CASE GROUP = re a | omen m= 2 comutosngn tiie tty ot | a bate nw Ong. 3 Tube Sleeve . - seeeeeeee 1 39° Suction Tube Spacer Ring .. - on ‘4 Tube Sleeve... - os 1 40° Suction Tube Retainer Screw Lockwasher .... 1 Converter Housing Sleeve -.-..-.- 1 41 Suction Tube Retainer Screw . . sewed @ coumrnngaentoas ly | Sf Saae Rae Argan ssonecere et + momnmansacee cometawaney oy | M2 MARGIE @) cama ouing Stet une ny ; tt onan Tee Oconee enaoee oot ore Horas Tin 10 comm tnnaty Seen tone tower 1 | ag cae N comnewtiaty sees tay sce Tenn tb coun tent anne 1 | oe tonne tan enue tone ooo 13° Breather... .... : 1 47 Transmission Case ta Converter Housing en S acces IS | ae tammmunene enon 16° Tube Sleeve... baee . a3 Housing Screw . - 10 Ne Rana cose | ay MeN eee pcan te rwamesen i pean dueve tar Gn www wemmataare ara | Sf peommmencienecon cme nt 18 Convertr Hogs to Troramisnon 4 | 82 Tranemiesion Case Rear Cover we Ua nee Bear to ev torn knoe one enes ia | o meemmenane. " 1, coma tanatye twsrion os nowtnnoere. a Housing Screw coer ot 56 Rear Cover to Transmission Case Stud Nut - 2 22 Labs Tike Ressining Basew -- .- - ' 57 Rear Cover to Transmission 24 Valve Oil Supply Tube... =. 1 | 5a Tube Sleeve O-Ring - . weet 26 3rd Speed Tube Asrernbly «= - --- . 1 BO Transmission Case to Rear Cover Stud . fo acc Sow isowaine a | St oma Sonnet 30) Lube Tube Assembly... eee weal 83 Boreen Assembly Gesket ....... aa 31 Lube Tube Retainer Screw Lockwasher .... 5.1 84 Screen. Asonmbly - ot 32 Lube Tube Res w Screw . . wt G5 Suction Tubs Assembly « vel 33° Reverse Tubs O-Ring 4 | 66 Pipe Plug wees ae 2 oe one be sey SoS) | ey Resinuee ingssocssccsescnna eee o) | te senntae name wa28000 THREE-SPEED CASE AND CLUTCH GROUP (Short Drop Output! tem Deseroton ay | te Descrnion on 1 Revaree & ard Clutch, Shaft Piston fing ......3 | 69. Front Beuring Retin Ring... 1A Piston fing Expander Spi 23 |S Forwars & 2na Shaft Piston Ping 2 Front Beating Ratene’ Rng 111 | 4A Piston fing Enpander Spring 3 Reverse & rd Shatt Front B Ti | $5 Low Saeed Clutch Shaft Pot Bearing 4 4 Front Bearing Ratanar Ring. (1 | 58 2nd Gear Bearing Sos 5 Shielded Orivan Gear Boaring-Shiats Out 1 | 87 Low Geer Bearing Retsine: Ring 1 8 Clvich Driven Gear Beating Snap Ring 1 | 58 Low Geer Bearing oe) 7 Clutch Driven Gear sv: Viva | 88 Low Gear Bearing Locating Fing 1 8 Clutch Hub Oil Battle Ring» SE | 60 Low Geos. a 1 8 Chich Driven Geer Beating Snap Fing 1 | 61 Low Gear Gi Battle ting na 10 Clutch Driven Gear Bearing . 1 62 Low Gear Baaring Lecating Ring a 11 Return Spring Retciner Saao Ring 1 | 63. Low Gest Bearing Poa 42. Spring Retainer Soap Ring Retaines tt | ea Lew Gee Besring Retaining ing. : 13 Spring Retainer... veces eae ceed ‘65 Return Spring Retainar Snap Ring . . « weal 14 Piston Return Spring: sete cena ad ‘86 Saving Retainer Snap Ring Retainer. weed 18 Spring Petainer «= « seceeel | 67. Return Spring Retainar. nt 16 Reverse & 3rd Chich Shot & Dum ss 1 | gg Remen eoine ce 17 Boring Retainer «<2... 5 6:1 | 69. Return Spring Retainer : ‘18 Piston Return Spring aa . oS FO Low Speed Clutch Shaft & Drum... 1 18 Spring Retainer 5.» « rod 71 Bearing Cap Screw . ae 20. Spring Retainer Snap Ang Retaines | t 72 Bearing Cop Screw Lockwasher coe 21 Return Spring Retainer Soaq Ring St | 3b Reertove toe Pup nn St 2 ve St | ra rive Geer Retainer Ring 1 : st 198 Low Speed Drive Gear. Sony 3 Shree Bb . ot 76 Output Rear Bearing Lock Ball . 1 26 Srd Geor Bearing Spacer). Tig | 72. bow Shaft Rear Bearing = ot 27a Gear Bearing Snap Rng |= LL | 28 Lew St ear naang Beene ng << -1 20 Grd Gear Bearing — Shield Out. - Tia] 28. bow Shaft Piston Ring 28° Reverse & 3rd Shaft Rear Bearing al ‘¢ - 28 Reverse 8 Bearings 1 | gy pear Bearing Cap Gasket 31) Clutch Hub Oil Baffle Ring wees weed 82 Reon Beering Cop 0-Fing . - 32 2od Gear Retaines Rings = Liq | 84 Low Shatt Rear Bearing Cap... 33 Return Spring Retainer Snap Ring . 1 84 Low Shaft Rear Bearing Cop Plug . . « 4 Spring Futine Snap Rng Retina a 8 Rear Bowring Cap Olt Seal... 4... - 3 Spring Rotainer ses seve sees e + TIT | 88 Ras Bessing Cap Serer sree 25 Piston Retainer... CUTIES) | 7 nar Bearing Cap Sereyy Leckivashars 000. Fee tere °] |) 28 Outaut Shait Bearing Cop vss sssvcssee ct ‘BO Formard & 2nd Clutch Shaft & Onur Sia] 8 Ostou Sate Gearing Gap Gases 66-1 38° Spring Retainer . ceeeeee Ma sat Bearing Spader ss ee esse ny AQ. Piston Return Spring so. s ccc sees Lr | 2 Rear Bearng Lorating Ring | AY Spring Rataingr vss esses oa put Shaft Rear Beoring : 42. Spring Retaines Soap Ring Retaines + | 93° Output Shaft Geer... soa 43° Retuen Spring Retainer Snap Ringo... ses 84 Output Shaft Geor Retaining Ring 1 44 Gluteh Driven Gear Bearing... 1 98 Output Shatt - ceed 5 Clutch Driven Gear Besring Snup Fing | 11 | 86 Ovtpur Shaft Front Besring ce 46 Clutch Hub Oi Bottle Ring - : + | 87 Bearing Locating fing : 1 AT Clutch Driven Gear... . 1 38 Bearing Retaining Ring - 1 48° Chitch Driven Gear Beating Snap Fing | a 99 Transmission Case Assembly . 1 49 Shiaided Oriven Gear Besring Shield Out 1 | 760 output Companion Flange 1 50. Front Bearing Reteiner Ring : + | 101 ange O-Ring i 51 Front Bearing Locating Rings... cs.0.7 | 702. lenge Nut Washer « boos 1 52. Ferward & 2nd Shaft Font Gearing Sy n03 risnge Nut oe TTTLOW CLUTCH GROUP Dewription 1 End Plate Retainer Ring « fetes tereteeyreeeetseteeeeeceee 2 End Plate «2... ceneee cove eceeeeeeeeeetpeseteeee 1 2 Gluteh Inner Disc. cee eee eee 3 4 CW tet OWE DIRE sce ce eee eee eee tent e eters cee cneet etree cee ay 5 (Clutets Piston , weed 6 (Clute Piston Quter Seat Ring ceed 7 Cluteh Pistan tnner Seal Ring coeteteeseenes ceeeeee a (Lover Spsed Clutch Drum and Shaft... seceeeeteeererseteeetsseesee REVERSE AND 3rd CLUTCH GROUP hem Description ow. 1 End Plate Retainer Ring... 0.0.00. cecsecceceeeeceeceeeee coe cece? 2 End Plate cee eceeeeceesesseecessescesceseeceuseveeccceessescccseecrsereteneaverse 2 a Clutch Inner Disc cece ces cccseceesceeeecesccesescsceesseerstecsecsereerereseeee IZ 4 Clutoh Outer Die eee ee wove besecteceeteseeee cove veeeveeveeeesree IZ 5 Clute ston 6... cece cece cee cesses ceveeetsecesveeeeeeteerersreeee 6 (Clutch Piston Outer Seal Ring... 260. ees ecco . cove vcteevstreeneseeee® 7 (Chuteh Piston trner Seal Ring... 2c. : . ceeeee cee? 8 Rovorse and 3rd Clutch Drum and Shaft. wobec eco eeeeeeetecseeeeee sed FORWARD AND 2nd CLUTCH GROUP tera Description avy End Plate Rerainer Ring cecceeeee End Pate Chutch timer Disc. Clutch Outer Dise . Chuteh Piston eee ‘Clutch Piston Quier Seal Ring... eeeeecee ‘Clutch Piston tnner Seal Ring... .- Forward and 2nd Clutch Brum and ShattPRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP tem Description ay. | tem Desesinton Oty. 1 Charging Pump Drive Steeva..... 1 | 26 Valve ta Housing Stud Lockwasher 2 Pump Sloeve Snap Ring... <1 | 27 Valve to Housing Stud Nut. Valve te Housing Gasket... 28 Thnust Plate & Bearing Assembly . 4) Valve Body O-Ring =. 1 | 28° Wave Spring... . 5 Valve Begy O-Ring ===. 1 | 30. Pump shaft Seat - oe 6 . 1 | 31. Pump to Filter Adaptor Screw Lockwasher. - 7 cece 1 | 32. Pump ta Fiker Adeptor Screw , a 8 ‘ 1 | 33° Pump Brive Shit Assembly - © Safety Valve Plunger 2... -1 | 34 Pump Drive Shot OB Seat... 10. Setety Valve Spring... <1 | 38 Pressure Reguistor Velve . 11 Vetve Stop O-Ring... <1 | 36 Valve Body Roll Pin - 12° Valve Stop <1 | 37 Valve Body O-Ring woes 13 Valve Stop Roll Fin... 21 | 38) Pump to Fitter Gasker wees 14 Valve Stop Roll Pin. . : 1 | 39) iter Adaptor oe eee eee ee 18 Valve Stop - - 1 | 40. ritter Adsptor Plug... 16 Valve Stop O-Ring... oe 1 | 41) By-Pass Fitter Disc Spring 2... eee 17 Vatve Picton 42 By-Pass Fitter Disc 2 18 Valve Spring — Inner... 1 | 43. By-Pass Fiter Disc Seat . . 18 Valve Spring ~ Outer cee <1 | 4d Fiiter Seat Retainer Ring . . 20° Valve to Converter Housing Stud 4 | 45. Filter Housing O-Ring... . 21 Valve Body to Pump Gasket... - -.1 | 46° Gil Fier Element Assembly cece 22 Pump Body Snap Ring... +. 1 | 47 OW Fiker clement Spring... 23° Thrust Plate & Bearing Assembly a 24 Pump Driven Shaft Ausembly 1 | 49) Pipe Plug... coe 25 Charging Pump Housing <1 | 50 Optional Adaptor for Remote FilterHYDRAULICALLY OPERATED CONTROL VALVE FIGURE GCONTROL VALVE ASSEMBLY aveription ay. weareanrenw 0 " 2 1B “ 16 18 wv 18 0 20 a 88 Valve Sp00! Oi Seat. Valen Spool Oil Seal Retainer Ring... Valve Spool Oi Seal Washer... Forward ond Reverse Wave Spool... Control Valve Assembly ~ Incl. teats I thru 9, 15, 16 aed 18 thru 20. ‘Neutral Switch Detent Bait Neutral Sites Valve Housing Fug - Valve Housing Plug “O" Ring « Overshift Spacer... Devent Spring Prog HOptONAL) 2. eee ce cee eee ece eee eetee estes event Soring Plug Washer Optional}... Devant Spring (Optional) Detent Bell (Optional). Overshift Spacor . Valve Spool Oi Seal Washer... ‘Valve Spool OF! Soat Retainer Ring Valve Saoo! Gk! Seal Hydraulic Pistan Housing Assembly... NOTE: tterns 22 thru 25, 32, 33 and 537 are various declutch options. Adaptor to Converter Housing Screw ee eee - cee ‘Adleptar to Converter Housing Scrow Lockwasher Valve Adaptor Housing .. Converter Housing to Valve Adaptor Housing Gasket ===... eee eeeeeeeee ‘Aduptor Housing to Converter Housing Serew . . ‘Adaptor Housing to Adaptor Plate Gasket. Valve Adaptor PlatoMECHANICAL PARKING BRAKE term Dazeripton ‘ow. 1 Backing Ptave Ascombiy . 1 2 ‘Actuating Levir « 3 Brake Shoe and Lining 2 4 GRORE FUND oes esceeceseeseereestetentsacneennenecanvenseareerersesnnssecansaasessenee 1 5 Brake Drum . wl 8 Brake Drum to Flange Soraw Lockwasher 6 7 Brake Drum to Flange Screw 2.2.2. 6 8 Rewrn Spring... 2 2 Brake Shoe (See iter 3}. - 10 Broke: Lining 2 " Rivet Ey 12 Backing Plate Screw... es 4 ” Backing Piste Screw Lackwasher . 4 FIGURE #FIGURE |‘To COOLER FRGN CONVERTER, INSTALL GAUGE IN THIS LINE FOR CONVERTER “OUT” PRESSURE* ‘CLUTCH PRESSURE ‘CHECK POINT** OWL LEVEL FROM COOLER TO CHEEK PORT ‘TRANSMISSION LUBE- DISTRIBUTOR OWL SUCTION SCREEN 28000 SERIES PLUMBING DIAGRAM TWEE “a" FILTER USE REPLACEMENT ELEMENT 215502. INSTALL GAUGE IN THIS: DG NOT SUBSTITUTE LINE FOR CONVERTER "QUT" PRESSURE* ‘CLUTCH PRESSURE CHECK POINT" OM LeveL, FROM COOLER TO 1 “CHECK POINT TRANSMISSION ‘ gi Wee DISTRIBUTOR ai NOTE: ALL TYPE “A” FILTERS USE CLARK FILTER REPLACEMENT = ELEMENT PART NO. 215502 ‘CHARGING PUMP OIL DO NOT SuestruTe SUCTION SCREEN 28000 SERIES PLUMBING DIAGRAM (WITH REMOTE FILTER) 23°00,F" CL TRANSMISSION IN NEUTRAL “CONVERTER GUT CONVERTER GUTLET om TEMP, 190°-200°F PRESSURE OPERATING SPECIFICATIONS: 25 P.S.L [172.4 kPa] MINIMUM PRESSURE AT 2000 A.P.M, ENGINE SPEED AND A. MAXIMUNE OF 70 P-S.I, |482,6 kPa] OUTLET PRESSURE WITH ENGINE OPERATING AT NO-LOAD GOVERNED SPEED, 240-280 PSI {1854.8 . 1930.5 kPa] WITH PARKING BRAKE SET ISEE NOTE). OIL TEMPERATURE 80-200" F, [82,2 93,3° C.J, ENGINE ATIDLE (400 TO GOORPMI, SHIFT THRU DIRECTIONAND ‘SPEED CLUTCHES. ALL CLUTCH PRESSURE MUST BE EQUAL YuITHI 8 PSI. [34,6 kPa] IF CLUTCH PRESSURE VARIES IN AMY ONE CLUTCH MORE THAN 5 PSI. [34,6 kPal REPAIR CLUTCH, “CLUTCH PRESSURE NOTE: NEVER USE SERVICE GRAKES WHILE MAKING CLUTCH PRESSURE CHECKS. UNITS. HAVING BRAKE ACTUATED DECLUTCHING IN FORWARD AND/OR REVERSE WILL NOT GIVE A TRUE READING. ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS, FIGURE JMAINTENANCE AND SERVICE ‘The instructions contained herein cover the disassembly CAUTION: Cleantiness is of extcome importance and an fend reewsambly of the wansmission in a sequence that absolute must in the repair and overhaul of this unit. Before would normally be followed ster the unit has been atternpting any repairs, the exterior of the anit must be removed from the machine and is to be completely throughly cleaned t0 prevent ihe possibilty of dirt and overhauled. It must also be understood that this isa basic foreign matter entering the mechanism. ‘28000 transmission with many optians. Companion tages and output shirts with and without disconnect assemblies ‘may vary on specific models. The units are very simile 10 trouble shoot, disassemble, repair, and resssam ble, DISASSEMBLY Figere a ‘Side view ef Sspeed short drop output power shift Remove cherging pump to regulating valve stud mut, Tesnamission. Remove pump and filter adaptor. cS cal eh Figure? lu Remove filter housing and filter element, Remove pressure regulating valve assembly. NOTE: See lubscstion section for fiter cartitge change interval.Fequre S Figure {etal tare bolts in threaded notes 180° apart tarameve cover from impel. NOTE: Some units may have pry slots instaad of threaded holes. Fiquees Remave control valve bolts and washers, Remove control valve. Use caution se not to lose detent springs and balls Figure 8 Figure 7 Romove impeller cover bolts. 11 impeller cowie bearing & to be replaced, remove retainer ring. Pry bearing from pocket.Figure 12 Figura 15 Remove turbine and hub saamly. NOTE: For special tine REMOVE rection member and spacer. Figure 13, Remove turbine locating ring,Figure 17 Using pry slots in converter housing, pry oll baffle and impeller from housing, NOTE: Impelier, oi! battle and impalter ub goar ore removed at an assemaly. Figure 21 Mowe center gear toward the reer of carverter housing. Remove pump drive gear on the right, Figure 18 Figure 19 Remove stator support. Figure 22 NOTE: Suppert must be turned to clear pump drive gear. FRernouw purmp drive gear an the left.ge Figure 20 Figure 26 shoves forward & 2nd elutets lacating ring with Finere 25 forsracd and 2nd clutch in position, Figure 24 Remova batts securing conwerter housing to transmission hpwsing, If eluteh remained in eonwerter housing, spread housing. ‘ears en snap ting as exptained in Figura 26 and remove ‘chutch. If clutch assembly remained in transmission case remnowe samme by pulling straight ox Figure 25, Support converter housing with @ chain fall. Using spreading type snap ring pliers, spread eats on lorward clutch front bearing retsining ring. Holding snap ring open Figure 28 pry converter housing from transmission housing. Remove turbine shaft gear retainer ring and gearFigure 20 . Figure 32 From rear of somverier hovsing tp turbine shaft and bearing fram housing. Remave inetier bub gee. Ss 2 Figure 30 | eqwmas Flemove turbine shaft and bearing from converter housing _ Lift oll baffie and il seal assembly frorm impelir. 388s Figuee 31 Figure 3a Remove impetier bub gear retainer ring. lemnove impeller to hub bolts,Figure 35 [Remove impeller hub O-Ring. Figure 38 Remove output flange nut, washer sad O-Ring. Figure a Remove output flange. Figure 38 Remove 2rd guar retaining ring snel 2nd gear. NOTE: 14 perking brate iz used, remove drake drum and ange, upper and lower brake shoe return springs, Brake shows, and setuator arm. Remove brake backing pate bolts and backing plate Figure 97 Figure 4 Remove 2nd speed elutch shaft pilot bearing Remove low shaft bearing eap bolts and bearing cap.Figure 42 Remove tow shaft rear bearing locating ring, Figure 43 Remove output shaft rear bearing locating zing, Figure a8 Remave rear cover bolts. Using pry slots provided, pry cover from transmission housing tapping on low clutch end ‘output shatt to. allow cover to be removed without shaft binding. CAUTION: Do not lose output shaft rear bearing Jock bolt. Figure 45 Remove low shaft rear bearing Figere a5 Remove tow clutch rear bearing.Figure so Remove output shaft assembly from housing. Figure 47 Figure 51 Remove tow clutch assembly from housing. CLUTCH DISASSEMBLY NOTE: Twro cliches are shown being duassembled. The low clutch, and the forwmid andsacond. Allclulches are disansam Figure 48 bled ina similar manner, The quantity af clutch discs will differ ‘betwen the low clutch and the forveard, reverse, sacond and third, Donot mix the friction dizer inthe low chutch with the trie ‘ton discs of any of the other clutches. (Sae now, Figure 86.) LOW CLUTCH DISASSEMBLY # “| =a —_— i Figure 49 From the front of the transmission housing, tap the output Figure 52 shalt, gar and bearing from pilot location in ease. Remove low clutch shaft rear beoring.Figure 54 Remove low speed gear and outer bearing, Remnave clutch end plate retainer ring Figure 56 Remove clutch end plate and inner and ourer catch cise. ‘See Note Figure 86, Figure 57 ‘Remove tow gear inner bearing, a Figure 5 Remove elutch piston return spring, A sleeve with a portion Fimoved & recommended for removing the clutch piston retura spring, washer, and retainer ring. Steeve shown is 3 common pipe, with a TeB/2" wide x 1" high (29,026,0mm) opening. The pipe is 6" long, 3-4/4" 0.0, 2.3/8" 1.0, (185,0x85,0x78.mm). Compress spring retainer washer, Through opening remove spring retainer snap cing, Releaie tension on spring retainer. Remove soring Tetainet and spring, Turn eluteh ever and tap elutch shaft fon a block af wood to remove eiuteh piston. 0FORWARD & 2ND CLUTCH DISASSEMBLY 062 Figure 59 FRornove clutch shatt piston rings and «pander springs. Figare 63: FRemave clutch driven gear and outer bearing. Figure 61 Figure 64 Remove tront bearing Remave inner bearing,Figure 65 Remove end plate retainer ring. Figure: Relieve spring compression. Remove retainer ring, retainer Ss and spring. % Figure 68 Remove end plate, Figure 6 Remove inner and outer clutch discs. Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston. CLEANING AND INSPECTION CLEANING ‘Clean all parts thoroughly using solvent type cleaning It is recommended that parts be immersed in cleaning flvict ‘and moved up and down slowiy until all old lubricant and ‘foreign material ik. dissolved and parts are thoroughly cleaned, Siipynannitly Yee: a CAUTION: Care should be exercised 10 avoid inhalation of + oF sgpore and skin rashes wher ssing alkali cleaners. Figure 87 Bearings ‘Compress return spring retsner, Remove retsiner ring from Remove beerings from leaning fluid and st roo, | block of wood to dislodge sol ” ‘at against ied porticles of lubricant.lenmerse apgin in cleaning fluid to flush out particles, Flepest above operation until bearings are thoraughly clean. DDry bearings using moisture-free compressed sir. Be-coreful te diract air stream across besring to avoid spinning, Bo nat spi bearings when drying. Bearings may be rotated slowly bby hand to facilitate drying process. ‘Suction Scrosn: Remove suction screen located at the lower left hand side ‘of the transmission outing. Clean screen thoroughly or replace if necomary. AFTER housing ir clesned, reinstall sereen ancl gsket Housings: ‘Clean interior and exterior of housings, bearing caps, ete.. ‘thoroughly. Cast parts may be cleaned in hot solution tanks ‘with mild elkali solutions providing these paris do not have ‘ground oF polished surfaces. Posts should remain in solution long enough io. be thoroughly cleaned and heated. This will aid the evaporation of the elegning 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 eleaner CAUTION: Care should be exercised 10 avoid inhalation of \apors and skin rashes when using afkali cleaners. All parts clesned must be thoroughly dried immediately by using moisture-frae compressed aie ar soft, lintless absor: bent wiping rags free of abrasive materials such as metal {iliogs, contaminated oll or lapping compound. INSPECTION ‘The importanoe of careful and thorough inspection of all parts connot be overstressed, Replacoment of ll parts showing indication of wear or stress will eliminate costly and avoidable failures a a later date. Besrings ‘Carefully inspect all alters, cages and cups for wear, chipping or nicks 10 determine fitness of bearings tor further use, Do not replace = bearing cone or cup Individually without replacing the mating cup oF cone at the same time. After inspection dip bearings in recor: mended type Automatic Transmission Fluid and wrap in clean intess cloth or paper to protect them until installed. Oil Seals, Gaskets, Ete. Replacement af sing load oil seals, O-Alings, metal se rings, gaskets and sap rings iz mare economical wiv unit | disassembled than premature averhaul to replace these parts at a future time. Further loss of tubricant through Worn soa! may result in failure of other more expensive parts of the assembly, Seating members showid bbe handled carefully, particularly when: being instalied. Cutting, seratehing, oF curting under of fig of seat seriously impairs its efficiency. Apply a thin coat of Permatex No. 2 om the outer diameter of the oil seal to assure an oil tight fit into the retainer. When assembling new metal type staling rings, same should be lubricated with cast of chassis grease to stabilize rings in their grooves for case of sesembly of mating members, Lubricate all O-Rings and seals with recommended type Automatic Transmission Fluid betore aseerbly. Gears and Shafts If magna-tlox process 's available, use process. to check parts. Examine teeth on all gears caretully far wear, pitting, chipping, nicks. cracks or scores. IY gear teeth show spats where case hardening is worn through or cracked, replace with few eit, Small nicks may be removed with sultable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are tu Housing, Covers, Ete. Inspect housings, coversand bearing caps to be cortain they ‘are thoroughly cleaned and that mating surfaces, bearing bores, #tc., ane free from nicks or burrs. Check all parts carefully fr evidence of cracks or condition which would ‘cause subsequent gil leaks or failuras, REASSEMBLY FORWARD & 2ND CLUTCH REASSEMBLY Figure 70 Install new ehetch piston inner and owtar sealing rings. Figure 3 losert eluteh piston in elutch drum. Use Caution as not to damage seating ing. 2Figure 72 Install clutch piston retum spring, spring retainer and retainer snap ring. Insert one steel disc Figure 73. Inatall eluich piston return spring, epcing retainer and retainer sep ring. Insert one sie! disc, NOTE: i Terward and reverse Gltehas are modulated, assemble piston return dee springs me shown in Figura A on pape 31 Figure 74 Install end Plate. “ Figure 75 Install end plate retainer ring. Figure 78 [nstall cluteh driven gear inner Bearing. Figura 77 Install clutch driven gear into clutch drum. Align splines on clutch gear with internal teeth of friction dise. Tap gear into position, Do not foree this operation, Gear splines must be ‘in full position with internal teeth of all friction dic,Figure 78 Install driven gear outer bearing. (See page 32 for proper ‘Shielded Bearing installation.) Fur 70 ‘nstall front bearing locating ring. Figure 68 natal Froot Bearing. NOTE: Snap ring groove In front bescing mutt be down. » Figure 82 Install clutch shaft oil sealing Finge.and expander springs [par instructions on page 39. LOW CLUTCH REASSEMBLY i ae Faure #3 treat new cuch plate ner Sd outer sang sng Inert piston Ire ‘dutch drum usin caution os not te ebmoge wean" Posiion piston relurn toring, aig retsinty ae revine up ring Compress sping ar tetamner aa stlFigure 84 Install lew gear inner bearing. Fig Install one friction die, NOTE: The friction alse in the low clutch has 2 higher coefficient rating than the frietion dict in the other ‘clutches, therefore che des musi not be mixed, Alternate steel end friction discs until the proper amount of dises aro Installed. First disc next to the piston is steel, last disc installed Is friction, yu" we Figure 87 Instat end plate and re:ainer ring. Install low gear into clutch drum. Align splines on low gear with Internal teeth of friction discs. Tap gear into pas! Do not force this operation. Gear splines rust be ie Full position with internal teeth of all friction discs. "yom ww Figure 88 Anetall love gear outer bearing. NOTE: Viner instating Ue rd gear in the 3rd speed clutch 2 bearing spocer is used between the inner and outer 3rd ‘ear bearing:Foqure 80, Install love gear retainer ring. a0 Figuce 81 Figure 94 natal oer ehateh shaft reer bearing, Fram the frent of we transmission housing install the reverse and 3rd ehetch assambly.install low clutch reor wi ring rit roave 10 Figure 90 ara Fee Bee wih beri oe Topten ro cover tlt sectid tora. ae Figure 104 Figure 97 From front of tension 380 tap love latch and output Install love clutch rear bearing retainer ring, shaft to roar. This will allow clearsnee to install reer Beating snapring, Install low clutch rear bearing locating ring, Figure Position 9 new garket on rear tranenission ease, Align lock, ballin output shaft rear bearing with notch in rear ‘vansmission cover. Tap eover in place and secure with bolts Figure 101 and lockwaehors Install output shatt rear baaring locating ring.Figure 102 Install output shaft tear bearing spacer oF speedometer drive gear on output shaft, Position new gasket on rear cover. Oil ole in gasket must align with oil return hole in rear cover. Install output bearing cap and stcure with bolts and watchers, NOTE: ff mechanical parking brake is used refer to Figures 108 and 108 before installing ourpur baaring cap. Figure 103 Install low clutch shaft piston rings. Install newr goskat and (O-Ring on low shaft bearing cae, Figure 104 Install beering cap and secure with lockwashers and bolts. ‘Tighten to specified torque. Figure 105 Hf mechanical parking brake is used, instal output bearing ‘cap and brake hacking plate, Install bolts and washers anch tighten te specified torque, Pasition actuating arm anct locate brake shoes. Install upper and lower brake shoe retwn springs. Install brake drum and ‘lange, If parking take is not Used install companion flange, Figure 108 Figure 107, Position 2nd speed clutch shaft pilot bearing in low speed ‘clutch shaft,DRIVE GEAR RETAINER RING }-——TURBINE SHAFT NOTE: LONG HUB OF DRIVE GEAR TOWARD RETAINER RING Figure 114 ‘At the rear of the converter housing install turbine shaft (eer and retainer ring #3 shown, Fiquee 108 Install 2nd speed gear on low clutch shaft and secure with retainer ring. ak Figure 132 From the front of the trancmission case, install the forward and Zed clutch assembly. Inner diss in clutch must be fully engaged with splines on 2nd gear. Fiqure 109 Position new turbine shaft piston ring on shott. Figure 113, ‘Spread forward clutch front bearing retainer ring. Position ‘converter housing to trancmiccion case assembly. Use 2 heavy coat of grease to cemer clutch shaft seating rings. Tap Figure 110 housing into place using caution as not to damage any cf ‘Tap turbine shaft and besring in converter housing, ‘the sealing rings.Figure 14 Sscure converter housing to transmission ease with bolts ‘and washers, Tightan to specified torque, Figure 115 Position center purnp drive gear, Install left pump drive gear n igore 117 {netall right purnp drive gear Figure 118 ‘Align holes in purrp drive gear bearing supports with holes in converter housing. lnstall bolts and washers, Tighten 10 specified ts Figuee 14 Install now sealing ring expander spring and oil sealing ring ‘on support. NOTE: Expander spring gap to be TBO° fram fing ring hak jeint, Position support on turbine shaft to ump drive gear, A\ign support holes with eanverter 2Figure 123 Figure 120 Inntall a new oll battle seal rina, Install stator support bolts and tighten to specified torque, 4, fhe Figure 121 NOTE: See page 33for 13 inch special impeller hub bearing and ‘12 bolt sevembly instructions, Figure 126 Install nsw *O” ring on impeller hub. Align holes in impeller Install oil baffle on impeller assembly. Use caution as not to ‘nub with holes in impeller. Install bolts snd ghee to epweiied §—— damage oil seal, {orqus. Lockwive In pairs to provent loosening. Figure 122 ‘Apply 2 light coat of Permatex No, 2 0a the outer diameter of the oil baffle seal. Press sea! in wil beltle with lip af seal Figure 928 down, Install impeller Hub gear.Figure 126 ‘Secure impeller hub guar with retainer ring Figure 127 Grease stator support piston ring. oil beffle oll seal and! seat ring to facilitate reaisembly. Inetatl Impeller and oi! battle sauembly in convertar housing. Figuee 128 Position oil baffle in housing. Secure with oil baffte retainer ing, being sure ring isin Fut! position in ring groove Figure 129 Install reastion member spacer with tang of spacer out Install reaction mambar. NOTE: Castsd knob on reaction ‘member must be positionad between the 3 Be o'clock loca- ‘on on support, preferably between 4.& 5 o'clock, Figure 130 Install rewetion member retainer ring, Fiqure 134 Install urbine locating ring om turbine shaft.Figure 138 ‘Secure vaive with bolts and washers. Tighten to specilied torque. Install pump drive sleeves. Figure 140 Position new gasket and O-Rings on pressure regulator valve, Install-vaive-on studs. Fi With new valve body fo pump gasket in position insert pump drive shaft through valve body. Use caution as nat to damage vahe body oil seal. It may be secessary: to turn impeller one way o¢ the other to align puenp shaft witty ‘drive sleeves, CS Figura 142 natal new O-Ring in fiter adaptor hausing. neta filter element land housing. Tighten fitter housing 20 10 25 ft. ls. torque (27,2-88,8 Nem.) SEE aTSERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and its allied 5 hydraulic system are important links in the drive line berween the engine and the wheels. The ‘oper= ston of either unit depends greatly on the nd operation of the ether: therefore, vehenev' ‘or overhaul of ene unit is performed, the balance of the system must be considered before the job can be considered completed. After the overhauled or rep: ‘been installed in the machine, the oil cosler, and con- necting hydraulic system must be thoroughly cleaned. & This can be accomplished in several manners ond a de- joree of judgment must be exercised as io the method ‘employed. The foll be taken: 1. Drain entire system thorough 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from. machine for cleaning. 3. Replece oil filter elements, cleaning out filler ‘eases thoroughly. are considered the minimum steps. te 4. The oll cooler must be thoroughly elesned. The cooler should be “back flushed with oil and ‘compressed aie until all foreign material has been removed. Flushing in direction of normal oil flow ‘will not sdequately clean the cooler. Hf neces sary, cooler assembly should be removed from machine for cleaning, using wil, compressed and steam eleener for that purpose. DO Use flushing compounds for cleaning purposes. ‘On remote mounted torque converiers remove drain plug from torque converter and inspect inert of converter housing, gears, ot.” presence of considerable foreign material is noted, it will be necessary that converter be re bor; howaver, uch laber it a minor cast compared fo cost of ‘difficulties whieh Reassemble all components and use enly type il recommended in lubrication section, Fill tranumission through filler opening until fluid rnernission dipstick. ‘accessible cil level check pluge are provided, Remave LOWER check plug, fill until off runs from LOWER cil hole. Replace fillor and level plea. Run engine two minuies at 500-600 RPM 10 prime torque converter and hydraulic lines Re- heck level of tlvid in transmission: with engine. running at idle (500-600 RPA) ‘Ada suantiny necemary 0 bring fluid vel to LOW mark on cor runs freely from LOWER oil level check plug hole. Install off level plug or dipstick. “Recheck with hot oil (180:260"°F) (62, 2.93, 3° ¢] Bring oll level to FULL mark on dipstick or runs froely from UPPER cit level plug. plugs, lines, connections, ete., and tighten where necessary. TORQUE IN (LBS—FT.) BOLTS, CAPSCREWS, STUDS AND NUTS Grade § Identification, 3 Radial Doshes 120° Apart on Head of Bolt Grade @ Identification, 6 Radial Dashes 60° Apart on Heod of Bolt Laoreanes “aus Sct ot 5 Ht Sn tat arace 8 2) Eira re caine pes || eal (es. a |[ 8 [eo ep [Tes- a] eee teas [aiaaual_|[ caro (ea a] : ae (oa a | a fons | eet tea Segoe [ase [hasan] Co psa 2at | Geeta [eee pne-ae, Jo -20 featconvesren our Pats contaans cures TRE euros nen ove SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION ‘AND TORQUE CONVERTER Conver out of tmp. 180" 200° F ma ae. Treinen m MEAFTAAL ‘pecs. Sn 172A Ml memes puesta 200% RPM. wae seo AND maior 75H 2 ePaper th ng psn soled guaract soe Ferm a Rewer Moret Sees Sacinn Morn Maia dics taemeay acceso omnes ‘haces ecole ind haven Herd oF ott capac, Noman = BeAIN RIOD. Normal drain periods and filler change intervals are fer average environmental and FuTaATON LUBRICATION fee lube Chart Conta Operators stanval en spplicable fytam must be emnidered 44 4 hala So Geter pect j (Chek it tava! DAILY S000 Wk ued ila 180" te 200" Flea rar ch alsin ot eval vo UL) fe | OTE iy ered tt eae bbe changed shor 3B and 160 hows af ap- (stint tow nnd tobe or paled vn (8) Dinin rameniion and remove, sme fowee, Clnem seen thoroughly ord ‘apace ung new gusts (Co) ain ot iter, remove and sacar ‘ner stmants“Capn tba shale and San new sloment at waneaon te LOW mark, fon sine at SOD RP fe ana (0) Agger tein retina 360660 BP aed add lt ing ye te LOM rah a pare ‘ore shot (180200" F) [872.033 C) ‘sete tal it eval hack "BRING OF eve 9 Fu Ae ge Severe of sustained high operating tomperatures or very dusty ated deterioration and contamination. For extreme conditions judgment must be used to determine, the required change Intervals 5 ro tna samy pe ses aaa sven ‘sume stom a eanmnioncn eae 200: Opa TEE. TOaLe Ua! Ws owe ala ove tof trom TR" 2H 122°" HAGEL wa eo 99420, Preaie oat beste Spe BAS Aah Gate ese aes re uth a fs 05 4a ap ch OTE Mover une sevice abes whe ming ‘hatch prosture checks. Unis Raving beak me ‘oe aeetnehng ia Femara edi bevareg rot give a rue eon [RUMavrs USE PARKING BRAKE WHEN MAK ut CLUTCH PRESSURE CHECKS. conditions, imospheric conditions will cause accaler-TROUBLE SI HOOTING GUIDE Fer The R and HR Model, 26000 Transmission ‘The following dats is pravented as an sid to locating the source of difficulty in 2 malfunctioning unit. It is necessary to consider the torque sanverier charging pump, tranamitsion, ail eoeler, and connecting lines a complowe aysiem when sunning down the source cf trouble cince the proper operation of any unit there- le-deperds greatly en the condition and operations of the others. By studying the princlples of operation togethte with date in this section, it moy be possible 10 correct ary malfunetion which may ‘occur In the systeen. TROUBLE SHOOTING PROCEDURE BASICALLY CON- SISTS OF TWO CLASSIFICATIONS: MECHANICAL AND HYDRAULIC. IMECHANICAL CHECKS Prior te checking any part of the system from & hhydreviie standpeint, the following mechanical checks. should be ened 1, A check should be made to be sure all contro! lever linkage i properly connected and edjusied at all ‘connecting points. 2. Chick shift levers and rod foe Binding or restrie- tions in (aval that would prevent full engagement Shift lawers by hand at contol valve, if full engage- rent cannot be obtained, difficuly mey be in control cover and valve assembly, HORAULIC CHECKS Before checking on the tarque converter, iransmis- sion, and allied hydraulic system for pressures and rate of oil flow. its essential that the following pre: Tinninary checks be made ‘Cheek oll level in. ransmission. This should be done with il wempecatures of 180 to 200° F.[87,2-93,9° Cl. DO NOT ATTEMPT THESE CHECKS WIH COLD OW To bring the wil remperarure ta this specification Ht is mecessery fo sither wark #he smashing of “stall” out the converter, Where the Former means the larier means should be employad s follows: Engage shift levers in forward and ‘high spend snd apply brakes. Accelerate engine half 10 three quarter threttle Hold stell until desived converiar outlet temperatare lg reached. CAUTION: FULL THROTTLE STALL SPEEDS, FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER. impractical, LOW CLUTCH PRESSURE cove Low Clutch pretiure regulating valve apo! stuek open Faulty charging prnp Broken or wern clutch sheft or piston sesling Clutch pitten bleed valve stuck open. i tevel Remedy Fil te proper level Clean valve spool and housing. 08 pomp. Replace sealing rings Clean bleed valves thoroughly. 1 2 2 5. LOW CONVERTER CHARGING PUMP OUTPUT 1. Low ei leval 1. Fill to proper love 2. Suction scroan plugged. 2. Clean wetion exraen. 3. lr leaks at pump intake hase and connections oF 3. Tighten all connections ar replace hoe if necessary. callansed hose. |F-28000 oniy) 4. Detective oll pump. 4. Replace pump. OVERHEATING form oil sea . 1. Remove, disassemble, and rebuild convertor essem= 1. Worn oi! saaing rings fer 2. Woen oil pumo. 2. Replace, 3. Low oil level 2. Fill te proper fevel. 4. Pump suction line taking air. (F-28000 only) A. Check oil Tine connections and lighten securely, NOISY CONVERTER Worn coupling gears. Worn. ail pump. Worn or damaged bearings. sambly will be necessary Ve deter Faulty. LACK OF POWER Low engine RPA at converter See “Overhesting” and make same checks. 1. Tune engine check governor, 2. Make corvections as explained in “Overhoating.”| COLOR KEY mean 157 (LOM), Eo EE an (nh) 3 SPEED TRANSMISSION28000 SERIES -3 SPEED CLUTCH & GEAR ARRANGEMENT (SHORT DROP OUTPUT)FIG.A MODULATED FWD. ‘& REV. CLUTCHES 2nd & 3rd & NON- MODULATED FORWARD & REVERSE CLUTCHES LOW (181) CLUTCH FIG.D (4 SPEED ONLY)ney, BEARING SHIELD (MUST FACE IN BEARING shi AUST FACE OUT 00] ok nen BEARING shteID beakING suet MUST FACE OUT SHIELDED BEARING INSTALLATION‘TURBINE HUB BACKING RING 8-TURBINE HUB. SCREWS EFERENCE - 12 IMPELLER HUB SCREWS ON 13° CONVERTERS. MUST BE LOOSE INTERNAL FIT BEARING. SEE PARTS LIST IMPELLER HUB, TURBINE HUB AND BACKING RING WITH SPECIAL SCREWS 1. CLEAN HU8 MOUNTING SURFACE AND TAPPED HOLES WITH SOLVENT. DRY THORQUGHLY BEING (CERTAIN TAPPED HOLES ARE DAY AND CLEAN, 2. INSTALL BACKING RING AND SPECIAL SELF-LOCKING SCREWS 10 APPROXIMATELY. 06 INCH [1,5] OF SEATED POSITION. WITH A CALIBRATED TORQUE WRENCH, TIGHTEN SCREWS 40 TO 45 LBS. FI a3. B12 Nir] TOEaU jOTE- ASSEMBLY OF HUS 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, IF NOT TIGHTENED TO PROPER TORQUE WITHIN THE FIFTEEN MINUTE PERIOD, INSUFFICIENT SCREW CLAMPING TENSION WiLL RESULT, THIS SPECIAL SCREW IS TO.BE USED FOR ONE INSTALLATION ONLY. iF THE SCREW IS REMOVED FOR ANY REASON iT MUST BE REPLACED. THE EPOXY LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER TAP AND CLEANED WITH SGLVENT DRY HOLE THOMOUGHLY AND USE A NEW SCREW FOR REINSTALLATION ASSEMBLY INSTRUCTIONS FOR 28000 CONVERTER: WITH SPECIAL APPLICATION IMPELLER HUB BEARING.16 SCREW RING GEAR INSTALLATION PROCEDURE (Non-Asbestos Ring Gear) 1. Rerrove all burs hom flywheel mounting lace and pilot bores. Clean the torque converte ing gear tlywhesl mounting surtace and the ring gear screw tapped holes with solvant. Dry thaeaughly, beeng certairing gear screw Molus ae dry and eles. 2. Check engine fiywheel and housing or housing adaptor for conformance ia siondard SME. No. 3 — SAE J927 and 1033 tolarans spacifiestons for plot boves sien, pilot bores eccentricities and mounting face Gavislions, Measure and record engine ‘urankshatt'end play. 3 Install torque convenr ting gaat as shown, NOTE; Assembly af the ring gear must be completed within a fifteen minute Period ‘rem start of screw installation. The screws aie prepared wth an epoxy Casting which begins 10 harden after installation inthe lhywhee! mounting holes. H not lightaned to proper tarque within the fitegs minute pesiad insuficient screw clameing tersion will sult Install backing ring and sisiewn (161 spel ee Oo apprenimatety 06 inch (1,5 ml ol ake positon, Mis permissible to uae {powers wrench for this installation phase. With calibrated torque wwanch given screves.30 10 38 pounds feet of torque a0. 7 7 Nini To abiain maximum etiectivencss of the special scrow's focking feature. a minimum tne paiod atte screvr instalation of ‘wolve [12] haurs i suggested before engine startup The special sciew is to be used for ONE installsion only. Hf the screw ig removed for nay season it MUST BE REPLACED. iis recermended that the epexy left in the tywhee! hole be removed with the Reaper tap and cleaned with solvent, Dry hole thoroughly and uce a NEW screw for reinezalstion. 5. Angamble torque converter to engine thywwiod by sing conver ina pasion by hand blore festering housing amtachment cre. This may require more than on ial 0 match the dive geae Tove Pulley ve converter int postion with Raueng sttachenent bolts is nat ieconwmendod, 6. Measure engine crankshaft end play after aasembly of torque conver, This value must be waihin one thousandth (1001) wt an inch (0,0254ew] of end play recarde Gm Paragraph #2) belore aceembly of torque coneren (502869 1.5 INCH (38.1 16 SCREW RING GEAR KIT S25 1.5 INCH EE. 16 SCREW RING GEAR KIT $ ABEH Torque Cormenon Feng ow 1 papa we Gores Fing Ge 16 RRB rng Ge Sevew 1.5 Hh 2871 16 OBB fy Cie Set 1 PN 1 RIDES eta frase Shot a ee 1 MRE raat ltracon Sheet [BE3767 Ragnar) Rwy not sclnkad BCE Fra Gur ie Ms Ue nated Sia Dimensions are in ches — Gimensins in {om ‘SEE PAGE 35 FOR INSTALLATION ILLUSTRATIONS, SEE PAGE 36 FOR 32 BOLT INSTALLATIONBACKING RING. ENGINE FLYWHEEL TORQUE CONVERTER RING GEAR RING GEAR SCREW fama GEAR SCTE ENGINE FLYWHEEL SEE PAGE 34 FOR INSTALLATION. PROCEDURE AND POLT TORQUE BACKING RING 263767 = ‘TORQUE CONVERTER RING GEAR 249341 =32 SCREW RING GEAR INSTALLATION PROCEDURE (Non-Asbestos Ring Gear} 11. Remave all burs trom Tywheel mounting faoe and pilot bores. Clean the torque converter ring gear tlywtvee! mounting surface land the ring gear serew tapped holes with solvent. ry thoroughly, being certain rng gear screw holes are dry and clean. 2. Chack engine flywhee! and housing or housing adaptor far canformance to standard SALE No. 3 — SAE J927 and 103 ‘olerance specifications lor plat bores sie, plot hores eccentricities and mounting lace deviations. Measure and record engine crankshaft end play, 3, stall torque converter ring gat a shown. NOTE: Ascembly of the ring gear must be completed within 9 fifteen minute pefiod from start of sere installation. The screws are prepared ith an epoxy Easting which bagina to hardan aftr instalation in the flywheol maunting holes. Hf rot tiphiened to proper torque within the fifteen minute period insufficient screw elarnomng terion wil result 4. natal backing ring and thirty-two (923 special screws te approximately 06 inch 1,5 roma of seated position. ts permissible to use @ power wwranch fo# Bis installation phase. With 2 calibrated torque-wronch tighinn srrews 23 to 25 nownds feat a torque (31,2 - 338 Nim. ‘To. obtain maximum effecsiveness of the cpecial screw’s lacking fepture, » minimum time paesiod after scrow instalation of twelve (12) hours is suggested before engine stertu, “The special screw is 9 besa for QREE instalaion ary. it the scxew is removed for any reason it MUST BE REPLACED. itis recommended that the epoxy lelt in the tlynhes! hole be removed with the proper tap and cleened with solvent. Gry hole ‘thoroughly and use # NEW screw fer reinstallation 5. Assemble torque converter ta angine Rywhee! by sliding converter ito position by hand before fastening housing attachment ‘straws, The may fequte move than one Wal 1o match the drive goar teeth, Pullng the convertor into postion with Rousing anachment bolts is not recommended 6. Meacura engine crankshaft end play after assembly of torque converter. The value must be within one thousandth 1001) of an inch (0)0254enm! of end play recorded lin Paragraph £23 belare assembly of torque converter. 02546 = 15 INCH 138.1) 32 SCREW RING GEAR KIT ‘2647 — 25 CH (63.5132 SCREW RING GEAR KIT 124085 Tengu Converter ny Gat 1 GDK5 Torque Converter feng Gear 2470 Hing Gear Screw 15 Inch 36.1 $2 THM} Rlng Ge Screw 25 Inch (835) 1 BIBBED—stlision Inaction Sheet YB ation Itrocbs Suet 02645 — 1,75 INCH 108.4) 32 SCREW RING GEAR KIT naste 30 WWeH 76.2] 32 SCREW RING GEAR KIT 1 248268 Targus Carvarie ing Gest 249265 Teque Converter Aina Goa 2 2eel02 Rng Gear Scrow 18 Inch 'a,4) 28838 Ring Geo Scew 3 ich 782) 1 BLEED Installation instruction Bheet BIESEO—nvaloton Instruction Sheet a546 — 2.0 INCH ISO.) 32 SCREW RING GEAR KIT 207549 — B22 SCREW RING GEAR KIT 1 2AB2EE Tague Converter ing Geat a MONE ang Gaye Seve 20 em OH) 3220007 Ring Gear Scr IMB» 8251 1 BagBHO nals irasacton Stet 1} -HOISED metalation mamctian SieUr {238057 Backing féva Alot edule in Ring Gaur Kt Mest be Onda Senseatey NGTE: Tho inital instnltion chive aor mounting kt includes a cemvarter sir breather. This breather is used on G 6 CL 270°C & (CL 320 converts ony and is pot required forthe HIM B LH ZB000°NR & LHR 32000 applications. SEE PAGE 37 FOR INSTALLATION ILLUSTRATIONSBACKING RING ENGINE FLYWHEEL TORQUE CONVERTER RING GEAR RING GEAR SCREW ENGINE FLYWHEEL, FING GEAR SCREW _\ 4 (32) 243970 1 600 (38,11 (321 244903 1.750 [44,41 (3) 240318 2.000 (60:8) - (32) 237153 2.500 163,51 or ‘SEE PAGE 36 (33) 236038 3.900 [76.21 + FOR INSTALLATION (32) 4200097 IMB x 1.251 PROCEDURE AND BOLT TOROUE \ Key BACKING RING Besar TORQUE CONVERTER RING GEAR 2492651.060 007 [26.94.17] Stake 3 places approx equally spaced | Atter curing of Loctite, speed sensor bushing must be secure with 40 FL Lb. [54.2 Nm] torque. 1.880.007 [35.32.17] ‘Assemble Speed Sensor Bushing in housing to specified REAR VIEW dimension with Loctite 262 and stake (3) three places. SPEED SENSOR BUSHING INSTALLATIONPROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS NOTE: NOT ALL TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS Fl the oil sealing sing grooves with a good grads of grease. this will help stabilize the tellon ring and! expander sping in the ring ‘of06We fo inatllation, Position tha expander spring in the Inner groove ofthe new piston ring, withthe expancier apring ep 180° from the hack joint gash fof the piston ring. Carefully potion the piston ring and expander spring on the clutch shaft n the inner most ring groove. Hook: the picton piston ring joi. Repeat steps 1, 2 and 3 foe the reshaning ring of | js making certain all hook joints ace fastened securely. ‘Aaply a heavy coat of grease to the outa’ diameter of the rings and clutch shaft, Cente the piston Hing’ in the ring groove, Before instaling the clutch assernbly In the front caver ar converter housing tis recommended a piston ring sleeve PM's 241309, 237876 ot 234286 be used 12 cantor all of the pistan rings in their roepoctive ring grooves. Use extreme eaution 1 net domoge piston rings whan instating the clutch shat inthe front trasnmission cover or convertor housing. USED FOR POSITIONING — PISTON fing, OF PISTON RINGS SLEEVE 234285 BEARING (CLUTCH SHAFT |_— Beanina PISTON RINGS' PISTON RINGS Ba sure thet Head in chamfer and infersection of lead in chamfer fa piton ring bore ts trea of burs and nicks, 248424 SPRING SPRING GAP AND RING GAP ‘car ARE 180" APARTDRIVE PLATE INSTALLATION ‘SUBJECT: 20000722000 Sorlos Transmission and C-270C-320 Series Converter Drive Plate Kits REASON FOR BULLETIN: Proper Identification by Bolt Circle Diameter Measure the "A dimension (Bolt Cicle diame: and onder Drive Pie Kit sted below, sore vu DRIVE PLATE AND ad WELD MT ASEM ‘pane Bates 7 Ld ae ae Tiacxes s "A" Dimension {Balt Circle Diameter 13.128" [999.375 mm| Diaenater Vit No, 802335, 13,50" [242,900 mm Giarneter Kit No, 89233 17.00" [431,800 ment Diameter it Ne 802464 Each kit wall nckude the fetioming parte: 4 intermediate trive Plates 11 Bhive Plots ancl Weld Nut Assembly. 7 Backing Fing. 1D Screw and Lockwasher Assembly. 1 Inetrction Sheet TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN ORIVE PLATES ~ SEE ILLUSTRATION ABOVE Postion dive plate and weld nut assembly on implies cover wih weld ruts toward cover. Align intermediate drive plage and backing ring with holes in impeller cover. NOTE: Two dines 180" apart in backing ring must be out (azward engine Fywheel Install copacrews and washérs. Tighten 23 to 25 f.Ibs. toraue [91,2 - 33.8 Nm). SEE PAGE 41 FOR TRANSMISSION TO ENGINE INSTALLATION PROCEDURE2. 3 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE Romave all burrs from flywheel mounting faga and ‘nase pilot bore. Clean drive plate surface with solvent ‘Check engine flywheel and housing for conformance to sandud SAE £2 - SAE J827 tolerance tions for pilot hore size, pilot bore runout and mounting face flatness. Messure and record engine ‘ranikshatt end play. Install wo 3.50 188,90 mm} long ansmission to ‘lywheel housing guide studs in the engine fiywheel ‘housing es shown. Rotate the engine flywheel to align 2 drive plate mounting screw hole with the flywheel ‘housing aocess hole. Install 8 4:00 {101.80 mm long drive plate locating ‘stud .3750-24 fine thread in 2 drive plate nut. Align the locating stud in the dive plate with the flywhoel drive plats mousing screw hole positionad instep No. 3, Locaté transmission on fiyrhee! housing aligning drive plate to flywheel and transmission to flywheel howsing. Install transmission to _flywheet housing screws. Tighten screws to specified torque. Remove trans: mission to engine guide studs. Install remaining ‘screws and thahten to specified torque, Remove drive plate tocating stud Install drive plate attaching screw and washer, Snug screw but do- not tighten. Some engine fiywheel housings have 6 hole loceted on the flywheel housing -crcurnference in line with the drive plata screw access hole. A screwdriver or pry bar used to hold the drive plate against the flywheel wil facilitate instalation of the drive plate screws. Rotate the engine flywheel and install she rerraining éoven (7) flywheel to drive pl attaching screws, Snug screws but da not tighten, Aer all eight I) screws are installed torque each one 25 to 30 ft. Ibs. torque [33,9 - 40,6 Num.) This will to ‘quire torquing e8ch screw and rotating: the engine flywheel until the full amount of eight (BI scrows have been tightened. Measure engine crankshaft end play after trang mission has been. completely installed on engine flywheel, This valve must be within 001 [0,025 mm} af the end play recorded in step No. 2 aNOTESNOTESNOTESNOTESAPPLICATION POLICY