712000 3-4-6 Speed Long Drop 0120 SPICER OFF-HIGHWAY COMPONENTSFOREWORD This manual has been prepared to provide the customer and the maintenance personnel with intormation aftd instructions on the maintenance and repair of the CLARK-HURTH COMPONENTS product Extrame cate 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 principle of operation, troubleshooting, and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use if as a reference when performing maintenance and repair eperations. Whenever repair or replacement of component parts is required, only Clark-Hurth Components-approved parts as listed in the applicable parts manual should be used. Use-o! “wil-fi” or non-approved parts may endanger proper operation and Performance of the equipment, Clark-Hurth Components does nat warrant repair or replacement parts, nor failures resulting from the use af parts which are not supplied by or aporoved by Clark-Hurth Components, IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS ‘T2000 TRANSMISSION ASSEMBLY HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION ‘Transmission Case and Plate Group _. Fig. A Converter Group oe. eee Fig. 8 Forward - Reverse, 3rd and 4th - High Clutch Group Fig. G Low (Ist), 2nd and Ouiput Shaft Group... Fig. O Output Sheff Group with Disconnect . Central Valve Group~Dual Modulation ........ Fig. F Control Valve Group—Single Modulation, Mechanical Inching . - Fig. G Assembly Instructions... Fig Het WL, DISASSEMBLY OF TRANSMISSION ...., 4 REASSEMELY OF TRANSMISSION se 58 CLUTCH ENGAGEMENT (POWER FLOW) 3 SPEED . 2 CLUTCH ENGAGEMENT (POWER FLOW] 4 AND 6 SPEED. 7a DRIVE PLATE INSTALLATION 00.0... ceeccceeeeecae 1% TRANSMISSION TO ENGINE INSTALLATION PROCEDURE....... 75 SPECIFICATIONS AND SERVICE DATA. . 78 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL. ..... 77 EXTERNAL PLUMBING AND PRESSURE CHECK POINTS 78, 73 CLEANING AND INSPECTION. . feet ees 80 PARIKING BRAKE SERVICE feet cee ai TROUBLESHOOTING GUIDE cee BR CONVERTER STALL PROCEDURE feces BB ELECTRIC SOLENOID CONTROL WIRING DIAGRAM .......... 84, 85 NOTE: Metric Dimensions Shown in Brackets { |Tr2000 TRANSMISSION ASSEMBLY The transmission and hydraulic torque converter partion of the power train enacts an important role in transmit: ting engine power to the driving wheels. In order to properly maintain and service these units it is important to first understand their function and how they operate. The transmission and torque converter function together and operate through a common hydraulic system. It is necessary to consider both units in the study of their function and operation The electric shift contral valve is incated in the vehicle's operator compartment. The function of the control is to energize the selected solenoid vaives thus directing the oil under pressure to the selected directional and range (gear) clutches. The purpose of the range or directional clutches is ta direct the power flow through the gear train 19 provide the Gesired speed range and direction An axle disconnect is optional and is located on the cutput shaft. The drive to the front axle can be disconnected or connected by manual, pneumatic; or hydraulic shifting. When either directional clutch is selected the opposite cluteh is relieved of pressure and vents back through the direction selector solenoid to the oll sump. The same procedute is used in the speed selector The direction or speed clutch assembly consists of a drum with slots and a bore to receive @ hydraulically ace tuated piston. The piston is “oll tight’’ by the use of sealing rings. A steel disc with external tangs is inserted into the drum and rests against the piston, Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A bub with QD, splines is inserted inte the splines. of discs with teeth on the inner dlameter The discs and hub are Iree to increase in speed or rotate in the opposite direction as lang as na pressure is present in that specitic clutch. To engage the clutah, the electric shift contral lever is placed in the desired pasitinn. This energizes the selected direction and range (gear) solenoids allowing the oil under pressure to flew through tubes and passages to the selected cluteh shafts. Oil sealing rings are lacated on the clutch shaft. These rings direct ail uncer pressure through a drilled passageway in the shall to a desired clutch, Pressure of the oil forces the piston and dises against the heavy nack-up plate. The discs with tangs on the auter diameter clamping against discs with teeth on the inner diameter enables the hub and clutch shalt to be locked together and allows them to drive as: a unit ‘There are bleed balls in the clutch piston or clutch drum which allow quick escape far cll when the pressure to the piston is releasedHOW THE UNITS OPERATE With the engine running, the transmission charging pump draws ail from the transmission sump through the ail suction tube and screen and directs it through the pressure regulaling valve and oil filter, The pressure regulating valve maintains pressure to the transmission solencid valves for actuating the direction land speed clutches. This regulator valve consists of a hardened valve spaol operating in a closely fitted bore, The valve spool is spring loarted to hold the valve in the closed position. When a specific pressure is achieved, the valve spool works against the spring until an exhaust port is exposed along the side of the bore. This sequence of events provides the proper sysiem pressure. This requires a small portion of the total volurme of oil used in the system. The remaining volume of oil is directed out through an extemal oil cealer and into the lube inlet port. From the lube inlet port oll goes thraugh the forward-reverse shaft, ubricating the forward and reverse clutches, with the re- mainder going to the tarque converter After entering the converter, the oll Is divected through the converter blade cavity and exits in the passage between the turtsine shaft and impetler hub, The ol then lubes the impeller hub bearing with the remainder going to the ard- hammer will compress springs and seat retainer ring. Be sure ring is in full position in groove. Figure 94 Install piston return disc springs. First spring with large diameter of bevel toward wear plate, Alternaie five (5) springs. NOTE: See page 71 “eg Figure 97 Install first steel (outer) cluteh disc. Figure 98 Install first friction {inner} clutch disc, Alternate stee! Figure 95 and friction until five (5) steel and five (8) friction discs, ion return spring ring retainer on clutch shaft ae in position -17-Figure 102 Press needle bearings in clutch gear and disc hub, being certain bearings are pressed flush with face of gear on both sides. Install the clutch gear in the Glutch assembly by aligning te clulch hub teeth with Figure $9 the clutch inner discs. Be sure the clutch hub: is in full Install clutch disc and plate. positien in ihe cluich assembly. Oe not toree this operation * ; Figure 100 Figure 103 Install end plate retainer ring. Position thrust bearing inner washer on clutch shaft, Position thrust bearing on clulch shalt against inner theust bearing washer. Install euter thrust bearing ‘washer against bearing, Figure 101 Position thrust bearing inner washer on clutch shaft, Install outer thrust Bearing washer against thrust bearing. Position thrust bearing on clutch shatt Figure 104 against inner theust bearing washer Install thrust washer retainer ting - 1BoO as Figure 108 Install rear bearing inner race an elutch shat with Figure 105 beating race shoulder down. install cluteh shaft gear locating ring y Figure 106 Install clutch shaft eutput drive gear on clutch shatt Figure 109 with long hub of gear up. clutch piston outer seal ring REASSEMBLY OF LOW (1ST) CLUTCH (See cleaning and inspection page} Figure 107 Install Ste driven gear on clutch shatt with lang hub af Install inner clutch piston seal ring. Size inner ring as gear up. explained in Figure 95Figure 114 Position piston in tow clutch drum as shown. Use caution as not to damage inner and ovier piston sealing rings Figure 112 Position clutch piston wear plate on piston Figure 113 Install piston return disc springs. First spring with larga diameter of bevel teward wear plate, Alternate seven (7) springs. NOTE: See page 71, —20- Figure 114 Positlon return spring ratainer an clutch shaft Figure 115 Start ring an shate with snag ring pliors i Figure 116 Use a sleeve with the proper inner diameter to fit aver shaft and against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring. Be sure ring i in tull position in groove.Figure 117 Install first steel (outer) eluteh dises, Figure 118 Install fist trietion (inner) cluten disc. Alternate steet and trietion until ten (1D) and ten (10) friction discs are in pasition Figure 119 ‘end plate. Figure 120 Install end plate retainer ring. Figure 121 Low (1st) clutch pack musi be checked for c clearance. Stand the clutch assembly on and as shown Measure the distance between the clutch end plate and the end plate retainer ring by inserting a feoler gauge or taper gauge through the slots in the cluich drum The required clearance is .080-,135 [2,08-3,43). If the clearance is greater than .195 [9.43], add one ‘Steel disc under the end plate. ye 3 Figure 122 ion thrust bearing inner washer on clutch shalt. ion thrust bearing on clutch shaft against inner thrust bearing washer. Install cuter thrust bearing washer against bearing,a Figure 123 Press bearings in clutch gear and disc hub, being certain bearings are pressed flush with face ef gear on both sides. Install the clutch gear in the clutch assembly by aligning the elutch hub teeth with the clutch inner discs. Be sure the clutch hub is in full position in the clutch assembly, Do not terce this operation Figure 124 on inner thrust washer on shatt. Position thrust 9 on shaft. Position outer thrust washer an shaft Figure 125 Install clutch shaft front bearing, NOTE: Bearing has shield in it. This shield must be up. Figure 126 Install front bearing retainer ring. A Figure 127 Install clutch shaft oll sealing rings. Grease rings to facilitate reassombly into trent housing DISASSEMBLY AND REASSEMBLY OF SAD AND 4TH (HIGH) CLUTCH 4TH GLUTGH USED ON 4&6 SPEED MODELS ONLY DISASSEMBLY Figure 128 ft oil sealing rings. Remove cluteh si4TH CLUTCH (HIGH) DISASSEMBLY Figure 129 Figure 132 Using a gear puller as shawn, remove front bearing Remove outer thrust washer retainer ring. Figure 130 Figure 133 Remove clutch gear Remove outer thrust washer, thrust bearing. and innet ‘hnust washer. ‘. Ve es ii Figure 131 Figure 134 Remove clutch gear lacating ring. For 3 speed Remove clutch gear and disc hub. Remove bearings models, proceed to Figure 14d. and spacer trom clutch gear.Figure 138 Remove clutch discs, Figure 135 Remove outer thrust washer, thrust bearing, and inner thrust washer. Z So Figure 136 Remove and plate retainer ring Figure 139 ‘Compress disc springs and remove retainer ring. Figure 137 Remove end plate:Figure 141 98. NOTE: See page 71 Remove disc sp: Figure 142 Remove clutch piston wear plate. Figure 143 Remove clutch piston, DISASSEMBLY OF (3RD) CLUTCH Figure 144 Remove 3rd clutch rear bearing retainer ring Figure 145 Figure 146 Remove outer thrust washer, thrust bearing, and inner trust washer 25& a Figure 147 Figure 150 Remove ard gear anc gear bearings Remove end plate. _ ae vs % Figure 148 Remove auter thrust washer, thrust bearing, and inner thrust washer Figure 151 Remove clutch discs ~~) © ! i Figure 149 Figure 152 Remove end plate retainer ring, Compress dise springs and remove retainer ting, ~25-Figure 153 Remove retainer ring retainer. Figure 154 Remove aise springs, NOTE: See page 71 Figure 155 Remove cluteh piston wear plate -27- Figure 156 Remove clutch piston, REASSEMBLY OF 4TH (HIGH) CLUTCH (See cleaning and inspection page} {For 3 speed, proceed to Figure 177) a Figure 187 ‘Clutch piston bleed ball must be clean and free of any foreign material Figure 158 Install inner and guier eluich piston seal rings. Size inner ring as explained in Figure 91. Install clutch piston in clutch drum. Use cautian as not to damage sealing ringsFigure 159. Install clutch piston wear plate. Figure 162 Start ring on shalt with snap ring pllers Figure 160 Install piston return dise springs. First spring with large diameter of bevel toward wear plate. Alternate Figure 163 ‘ivo (8) springs. NOTE: Sae page 71 Use a sleeve with the proper inner diameter to tt aver shaft and against retainer ring. A sharp blow with @ soli hammer will compress springs and seat retainer ing. Be sure ring is in full position in groove, Figure 161 Figure 164 jon return spring ring retainer en clutch shat. Install first stee! (outer) cluteh disc. —28-Figure 165 Instail frst friction (inner) clutch disc. Alternate steel and friction until six (6) steel and six (6) friction discs are in pesitan. Figure 166 Install clutch dlise end alate. Figure 167 stall end plate retainer ring. -23- thrust bearing washer again: Figure 168 NOTE: 4th (high) clutch pack must be checkd for dutch dise clearance ‘With the clutch assembly on end, the clutch dlises will tall 19 the piston, Measure the distance belwoen the clutch end plate and thé end plate retainer ring by inserting a fecler gauge oF taper gauge trough the slots in the clutch ‘cru, ‘The required clearance is 048-108 [1,22-2, It the clearance is greater than 108 [2,74], add one steel dise under the end plate: Figure 169 Position thrust bearing inner washer on cl Position thrust bearing an clutch shalt. Install outer ch shaft thrust bearing,es Figure 170 Press one bearing in clutch gear. Install bearing spacer nex! fo bearing. Press second bearing in gear being certain bearings ate pressed flush with face of gears on both sides. install the clutch gear in the clutch assemnly by aligning the clutch hub teeth wilh ‘ha clutch inner discs. Be sure the clutch hub is in full position in the clutch assembly. Do not force this ‘oparation. oe Figure 174 Position inner thrust washer on shalt. Position thrust bearing on shalt. Position outer thrust washer over shrust bearing. Figure 172 Install thrust washer retainer ring. Figure 173 Install clutch shait gear locating ring. Figure 174 Position gear on clutch shattFigure 178 install inner and outer cluteh piston seal rings. Size inner ring as explained in Figure 91. Install clutch Figure 175 piston in clutch drum. Use caution as not to damage Install cluteh shalt front bearing. NOTE: Bearing has a seahng rings. shield in it, This shield must be up. AY Figure 176 Figure 179 ‘clutch shatt olf sealing rings. Grease rings 10 Install eluteh piston wear plate facilitate reassembly into front housing a, 3RD CLUTCH REASSEMBLY g Figure 180. Figure 177 Install piston return disc springs. First spring with Clutch piston bleed ball must be clean and free of any large diameter of bevel tawaré wear plate, Alternate foraign material five (5) springs. NOTE: See page 71.Figure 181 n-reluen spring ring retainer on clutch shat. 2% © i Figure 182 Stan tin with snap ring pliers = Figure 183 sleeve with the proper inner diameter to fit over shaft and against retainer ring, A sharp blow with & soft hammer will compress springs and seat retainer fing. Be sure ring is in full position in groove, Use Figure 184 Install fitst steel (outer) clutch dise a Figure 185 ner) clulch disc. Alternate steel and friction util frve (5) steel and five (5) friction discos are in position Install first ériction ( Figure 185 Install clutch dise: end plate.Figure 187 Install end plate retainer ring. Figure 190 Position thrust buaring inner washer on clutch shaft * Position thrust bearing on shaft against washer. Install Figure 188 Pasition thrust bearing i washer on clutch shaft. Position thrust bearing against inner washer. Install outer thrust washer on fhrust bearing ° Figure 191 ti Ho: ida aaa Up Figure 189 Press bearings in clutch gear and dise hubs, being certain bearings are pressed fiush with face of gear on both sides. Install the clutch gear the chute assembly by aligning the clutch hub teeth with the clutel inner discs. Be sure the clutehy hub is in position in the cluteh assembly. Oo not force this Figure 192 operation Insiall bearing retainer ting, -33-DISASSEMBLY AND REASSEMBLY OF FORWARD AND REVERSE CLUTCHES NOTE: A 3 speed transmission will not have external = gear feeth on the forward and raverse clutch dum, ~~ REVERSE CLUTCH BEING DISASSEMBLED ee, Figure 196 Remove end plate retainer ring. Figure 193 Remove outer thrust washer, thrust bearing, and inner thrust washer. ‘ Pi Figure 197 Figure 194 Remove end plate. Remove bearings and spacer trom clutch gear. Figure 195 = Remove outer thrust washer, thrust bearing, and inner Figure 198 thrust washer. Alemove clutch discs 34Figure 199 Compress dise springs and remove retainer ring. Figure 200 Rlemove retainer ring retainer. Figure 201 Remave disc springs. NOTI a5 — Figure 202 Flemove clutch piston wear piate. Figure 203 Remove clutch piston DISASSEMBLY OF FORWARD CLUTCH ~ igure 204 Remove clutch shalt oil sealing ring,Figure 205 Remove outer thrust washer, thrust bearing, and inner thrust washer, nm Figure 208 Remove end plate retainer ring Figure 206 Remove bearings and spacer from elutch gear. Remove end plate. Figure 207 Remove outer thrust washer, thrust bearing, and inner Figure 210 thrust washer. Remove clutch ~ 36 cs.Figure 2114 Compress dise springs and remove retainer ring Figure 212 Remove retainer ring retainer Figure 213 Remove dise springs. NOTE: See page 71 Figure 214 Remove clutch piston wear plate. Figure 215 Remove elutch piston REASSEMBLY OF FORWARD CLUTCH (See cleaning and inspection page) igure 216 Clutch piston bleed orifice must be clean and tree of any foreign material. Install innet and outer piston seal ings. Size inner ring as explained in Figure 91Figure 217 Figure 220 Install clutch piston in cluteh chum. Use caution as not Position retucn spring ring retainer on clutch shaft te damage sealing rings. 1 Figure 221 7 Start ring on clutch with snap ring pliers. ~ Figure 218 Inetall clutoh piston wear plate * Figure 222 Figure 219 Use a sleeve with the proper inner diameter to fit over Install piston reiuen disc springs. First spring with shaft and against retainer ring. A sharp blow with a large diameter of bevel taward wear plate. Alternate soft hammer will compress springs and seat retainer five (5) springs. NOTE: See page 71 ring. Be sure ring is in full pasitian in groove, ~38-Figure 226 Install end plate retainer ring, Figure 223 uter} clutch dise Install first stee! : ay ’ t Figure 227 NOTE: Forward clutch pack must be checked for Clutch dise clearance. Figure 224 and the end plate retainer ring by inserting a tealer friction until six (6) steel and six (6) friction discs: drum. 2 in position. The required jearance is 048-108 [1,22-2,74] H the clearance is greater than .108 [2,74], add one stael dise under the and pial Figure 228 Positon thrust bearing on clutch shalt against inner ‘thrust Dearing washer. Position thrust baaring inner Figure 225 washer on clutch shaft. Install outer thrust bearing Install clutch disc enc plate. washer against thrust bearing.Figure 229 Fress one bearing in clutch goar, flush with face of gear. Install bearing spacer next to bearing. Press second bearing in gear, flush with face of gear. Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner dises. Be sure the clutch hub is in full position in the clutch assembly. Do noi force this operation. tis, Figure 230 Positian inner thrust washer on shatt. Position thrust bearing on clutch shaft against inner thrust bearing washer, Position auter theust washer on shaft F Figure 231 Install clutch shaft oil sealing rings. Grease rings to facilitate reassembly inta front housing, REVERSE CLUTCH REASSEMBLY Figure 232 Gich piston beed erifice must He clean and tee ef any foreign material Figure 233 install inner and outer cluteh piston seal rings. Size inner ring as explained in Figure 91. Install clutch piston in clutch drum. Use caubon as nat to damage sealing rings Figure 234 Install clutch pision wear plate.Figure 235 Install piston return dis¢ springs. First spring with large diameter of bevel toward wear plate. Alternate five (Bt springs. NOTE: See page 71 Figure 236 Positian return spring ring retainer on clutch shaft Figure 237 Start ring on shaft with snap ring pliers. Figure 298 Use a sieeve vith the proper inner diameter 10 fit over shalt and against retainer ring, A sharp blow with a solt hammer will compress springs and seat retainer ring. Be sure ring is in Tull positon in groove Figure 239 Install first stee! {outer} clutch dise. Figure 240 Install first friction (inner) clutch disc. Alternate stasl and frietion until six (6) steel and six (8) friction dises are in position.Figure 241 Install eluteh dise: end plate Hi install end plato rel Figure 243 NOTE: Reverse cluich pack mi cluich disc clearance. be checked for Stand the clutch assembly on end as shown Measure the distance between the cluich end plate and the end plate ratainer ring by inserting a fesler gauge er taper gauge through the slots in the clutch drum, The required clearance is .048-.108 [1 22-2,74] H the clearance is greater than .108 [2,74], add one steel disc under the end plate. —42— Figure 244 Position thrust bearing inner washer on clutch shaft Position thrus! bearing on clutch shaft against inner thrust bearing washer. Install outer thrust bearing washer against bearing, ai ERI Figure 245 Press one bearing in clutch gear, flush with face of gest. Install bearing spacer next to Dearing. Press second bearing in gear, flush with face of gear, Install the clutch gear in the clutch assembly by aligning the ‘clutch hub teeth with the clutch inner discs. Be sure the clutch hub is in full position in the eluteh assembly, Do nat force this operation Figure 246 Position inner thrust washer on shaft. Position thrust bearing on shaft, Position outer thrust washer an shat.REGULATOR VALVE DISASSEMBLY AND REASSEMALY DISASSEMBLY Figure 250 Install pressure requiator valve spring and regulator valve pision as an assembly into requlator valve sleeve. Figure 247 Tap pin from reguister valve sleeve, Use caution as valve Spool is under spring pressure, Figure 251 Compress valve spring and valve and install pin inta requiator valve sinave. ~ DISASSEMBLY AND REASSEMBLY OF DUAL MODULATED VALVE ASSEMBLY Figure 248 : inching Flemove reguistor valve piston and pressure regulator Far single madulation and mechanical inching sea rah page 86, valve spring DISASSEMBLY REASSEMBLY {See cleaning and inspection page) : Figure 249 Figure 252 Position pressure requiator valve spring into regulator Remove inner, middle, and outer spring and stop pin valve piston rom modulation housing sleeve. Reference Figure 53 4aREASSEMBLY (See cleaning arid inspection page) Figure 253 Ramewe accumulator sa00l. Reterence Figure 54. Figure 256 Install soring spacer in spring retainer. Figure 257 Figure 254 Install spring in spring retainer Remove cross pin from sleeve. NOTE: Some units will have two cross pins the same ‘ength. Some units will have twa pins of diferent lengths. The longest pin goes in the bettom holes Figure 255 Figure 258 Remove regulator spool, spring, retainer spring, and (Check orifies in regulator spool to ba free and clear of spacer spring from housing sleeve. any foreign material nageFigure 259 Figure 262 Install spring relainer, spring, and regulator valve in From opposite end, position accumulatar spool in sleeve against inner cross pin. sieeve ag shown. Figure 260 Compress regulator speal and spring in sieeve tar enough to install eross pin Figure 263 ‘install outer accumulator spring. Figure 261 Figure 264 Install crass pin, See note after Figure 254, Install mide spring -4g=DISASSEMBLY AND REASSEMBLY ‘OF SPACER PLATE DISASSEMBLY Figure 265 Install inner spring. Figure 268 Remove reverse idler gear end plate eapscrew and he washer, ; Figure 266 Install step pin in inner spring. Figure 269 1d dowel pin. Figure 267 If charging pump oF pump drive gear are Ie be Figure 270 replaced, remove relainer ring and drive gear, Remove reverse idler gear. —46—Figure 274 Idlor shaft and locating ring removed Figure 271 Romove reverse idler gear bearing, Figure 275 Remove locating ring trom iver shat Figure 272 Flemove idles gear tanged thrust washer. Figure 273 I reverse idler shatt is 10 be replaced, supsert spacer plate around idler shaft opening ard press idler shatt Figure 276 spacer. Do not drive on idler shalt as daing so Flemove stator support oil sealing ring and expander use damage to spacer plate. ring, -ayeFigure 280 It support bushing oF bearing is to be replaced, Figure 277 remove fram stator suppart, The stator support is held in place by twa retaining rings. Remove converter end retainer ring trom groowe. Remove thrust washer. i“ Figure 281 Compress converter safety valve spring and remave Figure 278 retaining washer. Remove safely valve spring. Turn Push support toward vansmission side far enough ta spacer over and remove safely valve popoet expesa relainer ring. Rameve retainer ring REASSEMBLY OF SPACER PLATE (See cleaning and inspection page} Figure 282 Figure 279 From transmission side of spacer plate, position From canverler end, remove stator support, converter safely valve poppet in bore in spacer 4gFigure 283 Tum spacer over and position safely valve spring on poppet. Compress spring and install ooppet retaining washer. NOTE: End of spring must go in recessed side of washer. Figure 284 If stator support bushing was removed. install bushing in support. i 1 fila Figure 285 Install needia bearing in stator support, Figure 286 Install stator support through spacer plate —40- Figure 267 Install stator support locating ring, Figure 268 Push support back through spacer until locating ring shoulders in support bore. Turn spacer plate over and install impeller nub gear washer and support retaining ting.Figure 292 Turn spacer plate over and position tanged thrust Figure 289 washer on shaft, being certain tang in washer is in Install stator support oil sealing ring expander ring notch in spacer plate. Install oil sealing ring on expander ring. MOTE: Expander spring gap to be 180 degrees tram sealing ring hook joint Figure 290 - Install locating ring on reverse idler shaft Figure 293 Position idler gear needle bearing on shalt. Lubricate beating Figure 291 Support spacer plate and press reverse idler shaft into Figure 294 position and tight against lacating ring, Position idler gear on bearing 50FRONT OUTPUT FLANGE DISASSEMBLY AND REASSEMBLY (FLANGE USED WITH FRONT DISCONNECT) DISASSEMBLY NOTE: Unless disconnect front and rear flange bushings are ta be replaced, DG NOT remove ‘bushing or expansion plug. Figure 295 Position idler gear end plate and rall pin on idler shatt, aligning roll pin with hole in idler shart Figure 296 Remove flange to bearing retainer ring, Figure 296 ingtall and plate capscrew and washer. Figure 297 Tighten capscrew to specified torque. See tarque Figure 299 chart, Using @ bearing puller as shown, remove bearing. —51-Figure 300 Bearing removed. Figure 303 Remove ail seal retainer ring fram outpul flange: Figure 304 Tap: expansion plug from flange. (See note al top of page 51) Figure 301 ll seal sleeve and °O" ring removed. ey Figure 302 Figure 305 Remove oil seal ‘rom sleeve Remove output bushing, (See note at top af page $1.) —5e-REASSEMBLY (See cleaning and inspection page) Figure 306 Install new inner and auter flange bushings te dimensions shawn in Figure 307B. NOTE: Bushings used enly with frant disconnect. Figure 307 ‘Apply a light coat of Loctite #577 ta the outer edge of expansion plug. Install plug in flange. NOTE: See Figure 307A for expansien plug in: n tool fabrication. it is imperative plug be installed property to prevent il leakage. Figure 3078 -53- ‘Apply Loctite 877 ar Loctite HVV $71 To Plug OD. Prior Ta Installation Remave Excess Material Chamler Of Piug Must Be tn Must be Secure And Cal Tight Figure 2078 Figure 308 Position retainer ring on output flange. Figure 309 Apply a wory light coal of Permatex #2 to the outer diameter of the output flange oll seai. Press oil seal in oll Seal sleeve. Oil Soal must ba flush with ane side of face of oll Seal sieve, and lip of seal must be in.REAR OUTPUT FLANGE DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 310 Install new “CQ” ring an oll seal sleeve. Position cil seal sleeve assembly on output flange. NOTE: Recessed portion of oil seal and sleeve must be up, with lip of seal up. This leaves a space between oll seal and output bearing, Figure 313 Using a bearing puller as shown, remeve bearing Figure 311 Press bearing on output flange. Figure 312 Figure 314 Install bearing ta flange retainer ring Bearing removed.Figure 315 ‘Oil seal sleeve and “Gr ring removed Figure 316 Fiemove oll seal from sleeve. Figure 917 Remove ail seal retainer ring from output flange. REASSEMBLY (See cleaning and inspection page) Figure 318 Position bearing retainer ring on autpur flange. Figure 319) Apply a very fight coat of Permatex #2 to the outer diameter of the Output flange oil seal. Pres oil seal in oil seal sieeve. Oil seal must be tlush with one side of face of oil Seal sieeve, and lip of seal must be in Bb Figure 320 Install new “G" ring on oll seal sieeve. Position all seal sleeve assembly on outpul flange. NOTE: Recessed portian of oil seal and sleeve must be up, with lip of Seal up. This leaves a space between ail seal and ‘output bearingFigure 324 Figure 321 Press bearing an output flange. DISASSEMBLY AND REASSEMBLY OF CONVERTER HOUSING DISASSEMBLY Figure 325 Remove converter housing plug. (High and Srd Cluich Shai) Remove oil distributor siseve set screw. = Figure 322 Remove torque converter bearing. Figure 326 Figure 323 Using a hammer puller as shown, remove cil Remove ail distributor and "O" rings. distributor sleeve. (High and ed.)Figure 327 Figure 330 install naw “O" rings an canverter heusing ail sistributer. Install oll distinuler in convarter housing REASSEMBLY OF CONVERTER HOUSING with long hub toward oil seal (See cleaning and inspection page) Sleeve removed, Figure 331 OO A ee Figure 328 Make gure pr#ssure regulator check ball assembiy is clean and free of foreign matertal. Figure 332 Figure 329 Install high-ded cluteh shaft ail distributor sleeve in Apply @ very light coat of Permatex #2 te the outer converter housing with inside diameter chamfer up diameter of the converter housing oll seal. Press seal and the noich in the distributer aligned up with the iv housing with lip of seal in retaining set screw hele in the converter housing,Figure 333 Apply Loctite #243 to threads of (NOTE: This cet screw has a hole in it. Use caution as not to allaw any Loctite to piug hole.) Install set screw in converter housing and in ail Figure 334 Install sot screw plug. REASSEMBLY OF TRANSMISSION (See cleaning and inspection page) Figure 335 Install forward-reverse gil distributor sleeve in transmission case with inside diameter chamfer out, (toward front of transmission), and the neich in the distributor aligned up wath the retaining set screw hole in the transmission case, 58 - Figure 336 Install set screw in transmission case and in oil Cistributer sieeve. Install set screw plug, Figure 337 Install reverse and forward clutch shaft rear bearing in tansmigs‘on ease. Figure 338 Position supply tube and screen assembly in transmission case sumpFigure 339 Figure 342 Push supply tube through opening in ease and install Install output shaft inner bearing lacating ring in rear Of transmission case. Figure 340 Install supply tube clip and screw and lackwasher in case and tighten to specified torque. See torque chart, Figure 343 in ease against locating ring. Figure 341 Position output gear in transmission case with long Figure 344 hub of gear toward front of case. Install new "OF ring on rear oil seal sleeve,Figure 945 Apply a very light coat of Permatex #2 to the outer iametor of the output flange oll seal. Press oil seat in oil seal sleeve, Oil seal must be flush with one sits of Figure 348 face of oil seal sleeve and lip of seal must be in. Install output shaft to output gear retainer ring. . NOTE: If disconnect to the front is nol used, proceed Pasition oil seal sleeve in transmission case with 10 Figures 350 and 351 recessed portion of oil seat toward output bearing. This leaves @ space between oil seal and output bearing. Figure 349 Pogttien shitt hub on eutput shaft Figure 347 Install rear output flange and shaft through output oi! seal. Align splines of shaft with splines on output gear. Install shalt thraugh gear. Use caution as not to Figure 350 damage oil seal, Tag shaft into pasition install front output shatt bearing locating ring -60-Figure 351 Fosition front outout lange and bearing assembly output shaft, Using snap ring pliers as shawn squeeze snap ring ends tegether and tap flange embly into case until snap ring can seat in snap ring gronve. Hhtransmission is less disconnect, proceed to Figure S58. Apply Permatex #2 te outer diameter of shift rail ail seal Install seal in case vath ip of seal in rd Figure 953 shit fork in shilt hub on autput shatt Figure 354 Install shift fork to rail lockscrew. Tighten securely and lockwire to prevent loosening. Figure 355 Pasition detent ball, spring. and o shown, as Figure 356 ‘With new “O" ring in oosition, install detent piug.Figure 360 Figure 357 Position forward and raverse clutch in top bore, Tighten plug securely. Figure 358 Position 4th high and 3rd clutch assembly in center bore in transmission case. NOTE: 3 speed trans- mission will only have 3ed clutch Figure 361 g Position new tanemission ease te converter housing else gaskel on transmission casa. A light coal of grease Figure 359 will hold gasket in position, NOTE: The use of aligning Position ‘Ist and 2nd clutch assembly in bottom nore studs will facilitate spacer plate te tansmission case in transmission case installation, —62-Figure 364 With roll pin in position in pump idler shaft, install inner washer and shatt in spacer aligning pin with hole in washer and spacer. Figure 362 Install spacer plate assembly on transmission aligning cluteh shafts with opening in spacer plale Use caution as nat to damage oil sealing rings. ‘Spacer plate must be tab against transmission case Do not use bolts to pull spacer plate and case together. Tap spacer plate inta position al dovrel gins Install spacer plate fo transmission case capscrews. Figure 365 Position needle bearing on shatl. See "NOTE" on Figure J for proper capscrew Figure 366 installation and torque Install ole gear on bearing 63ELECTRIC CONTROL VALVE REASSEMBLY ‘A bore plug is used in the canter hole nn 3 speed only. Figure 367 Align hole in outer washer with pin in shalt and install ‘washer, Figure 370 Figure 368 Install solenoid cartridges as explained above, Position impeller hub gear on stator support Figure 369 Position spacer to converter housing gasket on Figure 371 spacer, A ight coat of grease mil hold gasket in place. Tighten cartridges 16-20 IbMft torque [21.7-27,1 Nem]Figure 372 Install new °O" rings on cartridges. Figure 375 Tighten cartridge nut per assembly drawing struction Figure 373 Position salenoid coll on eartridgo. Figure 376 The use of aligning studs will facilitate converter housing fo spacer installation. The transmission could be lad down to align the and of the clutch shafts inte sealing ring sleeves in canverter housing. Do not force this operation. Ganverter housing must be light agains! transmission spacer, NOTE: De not use bolts to pull converter housing in place, Figure 374 Install converter housing te transmission case screws With new “O" ring in gosition, install coil ta cartridge and lockwashers. See Figures J and K far proper rut. screw lacation and installation.Tighten belts to specitied torque. See Figures J and lor proper serew location and installation Figure 378 Pasition new °O" rings and gasket on the Ist and 2ad luich shat oi distributor cap. Figure 373 Install distributor cap on clutch shaft Use caution as not ta damage clutch shaft oll sealing rings. Instatl capscrews and washers. Tighten to specified torque. See torque chart Figure 380 Install eorverter locating ring on turbine shat Figure 381 Position converter assembly on stator suppart and jurbing shaft, Figure 382 Install converter assembly retainer ring, 86Figure 383 Figure 385 With naw “O° ring in place, install bore plug in il charging pump 19 converter housing bolts and converter assembly. ‘hers. and tighten to specified torque. See torque chart Figure 284 Install bore plug retainer ring Figure 387 It auxiliary punto is used, it is not necessary te install the permanant pump hole caver. With new gasket in place, install pump hole caver on charging pump. install bolts and washers and tighten te specified torque. See torque chart Figure 385 . With new gasket in place, install charging pump in Figure 988 converter housing. Install regulator sleeve assembly in converter housing. ~87-Using a special tool as shawn in Figure 389A, tighten sleove to 45-50 bie [61,1677 Nem} Figure 390 Install oi iter on regulating valve, Tighten fiter to 20-26 lott [27-4 Nem] INSTALLATION GF DUAL MODULATION For single modulation and mechanical inching see page 86. FL ELD Figure 391 Figure 3898 Install modulation diverter in transmission case, 6aFigure 395 Install havsing over sleeve and spring assembly and lighten securely. Figure 392 Position a new *O" ring on lower end of the modu- lation valve sleeve and spring assembly, Install “O" ring on other valve sleeve, parking beake is not used, proceed to Figure 490 Figure 396 Position parking brake dis on output flange. Install CapScreWs and washers and tighten to specified Figure 393 torque. See torque chart. Install valve oF values in transmission case. Figure 394 Figure 397 Position a new °O" ring on modulator valve housing. Position caliper brake assembly on brake cise.Figure 398 Install caliper brake mounting serew through brake assembly and through lacknut. Apoly Loctite #262 to threads and install screw in transmission case. Figure 400 See special section an page 74 for drive plate installation Figure 398 Mounting screws to be installed to allow tree movement of caliper pads to dise. Tighten jam nut See torque chart, See page 81 for beake informaton. -70-Note: The disc spring packs are to be used as complete assemblies and care should be taken not to intermix the individual disc springs with disc springs in another clutch or disc spring pack. Service replacement assemblies are banded together and must be replaced as assembly. NOTESCLUTCH ENGAGEMENT CLUTCH ENGAGEMENT FOR 3 SPEED 712000 POWER SHIFT TRANSMISSION FORWARD SPEED. CLUTCH eto [ae] [a | REVERSE SPEED CLUTCH SHIFT | DIRECTION SPEED | CLUTCH -72-CLUTCH ENGAGEMENT CLUTCH ENGAGEMENT FOR 4 SPEED 712000 POWER SHIFT TRANSMISSION FORWARD binecTION | SPEED CLUTCH | CLUTCH DIRECTION | SPEED cLUTeH | CLUTCH | c D E CLUTCH ENGAGEMENT FOR 6 SPEED 712000 POWER SHIFT TRANSMISSION REVERSE DIRECTION CLUTCH DIRECTION CLUTCH 7aDRIVE PLATE INSTALLATION Measure the “A” dimension (Bolt Circle diameter! and arder Orive Plate Kit listed belo Nate two (2 kits have two (2h intermediate drive plates and one (1) drive plate ond weld nut assembly, Two (21 kits with three intermediate drive pietes, 2) NTERMEDIATE DAVE PLATES, BACKING RIG 'A” Dimension (Bolt Circle Diameter) 11.380" [288,900 mm] Diameter kit Ne, 802501 13.125" [333,38 mn] Dameter Kit No. anzaza 13.500" [342.90 mm! Diameter Kit No, 802425 Esch Kit wall include the following parts: 2 Intermediate Drive Plates 1 Drive Plate andl Weld Nut Aasambiy: 1 Backing Ring. 8 Mounting Screws, 6 Lock Washers. 1 Instruction Sheet. ‘TO FACILITATE ASSEMBLY, ALSGN SMALL HOLES IN DRIVE PLATES, ‘ALIGNMENT HOLES (pene pute an f- ‘WELD NUT ASSEN Y . UNTER MEDIATE Oeive Pures BACKING Fae “&” Dimension (Bolt Circle Diameter! 11.980" [288,900 mm] Diamoter Kit No. 802543 13.125" [339,38 mm| Diameter Kit Ne. 802426 13.800" |342,90 mm| Diameter Kit No, 802427 Kit will include the following parts: 3 Intermediste Ds 1 Backing Ring, 5 Mounting Screws. 6 Lock Washers 1 Instruction Sheet. Plates. SEE RLUSTHATION ABOVE — ALAGNMENT HOLES. Position drive plate and weld nut assembly on torque converter assembly with wold nuts toward converter. Align fermediaté Unive pistes and backing ring with holes in torque converter assembly, NOTE: Twi dimples 130° apart in backing ring must be out award engine flywheel. install capscrews and washers, Tighten 28 10.25 ft lb. torque [35 - 39 Mm -744 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE Remove all burs from fywhoel mounting face and nse pilot bore. Clean dive plate surfice with solvent, Check engine flywheel & housing for conformance to standard SAE No, 3 per SAE 927 ana J1033 tolerance specifications tor pilot bore size, pilot bore Funout and mounting face flatness. Measure and facord engine crankshaft end ply. install two 2.80 163,500 mm! long tansmission to ‘lywhee! housing guide studs in the engine flywheel hhousing as shawn, Rotate the engine flywheel to align 4 drive plite mounting screw hole with the flywhee! housing access hole Install a 4.00 [101,60 mm) tong drive plate locating Stud 3750 - 24 fine thread in a drive plate nut. Align the locating stud in the drive plate with the flywteel dive plate mounting screw hole positioned in step No. 3 Rotate the transmission torque conwerter to ali locating stud in the drive plate with the fywhoc! plate mounting S¢zw hole positioned in siap No. 3 Locate transmssion on flywheel housing ‘Alegning drive plate to thwheel and transmission to flywheel housing guide studs, install taneméssion 10 fhywhee! mousing screws. Tighten sctews to specifiod torque, Remove transmission to engine guide stud. Install remaining screws and tighten te speciied toca Hemave drive plate locating stud, Install drive plate attaching screw and washer. Snug screw but do not tighten. Some engine fiywneal housings have 3 hole incated on the tlywines! Rousing sircurforence in line wilh the-drive plate screw accest: hole. A screwdriver or pry bar used 1 hold ihe sive: plate against the thwheel wil faciitats installation of the drive piate screws. Rotate the engine Flywheel and install the rérnaining seven (7) thywhosl to drive plate attaching serews, Snug screws but do not tighten. After afl eight (6) scree are mstaled torque each ono 26 10 20 Uff torque [35-39 Nim), This will roquiee tightening ‘each screw and rotating the engine tlywhee! until the {ull amount of eight (8) screws have been tightened to specified torque Masaure engine crankshaft end play after transmission has been completely installed en-engine flywheel. This ‘valle must be within 1109 10,025 mm) af the end play recotdod! in step Mo. 2. “Does not apply tou 2 intermediate drive plates, See Fig. 4 BT ea y fe Rae aware veygueee pg eng mu ERE ‘ Shi 7 f 30h nas 75 -SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION AND TORQUE CONVERTER: TRANSMISSION. With iransimission outiat ol temperature, 1802 OUT PRESSURE . 200" F. [a2.3° - 23° C] and trancmission in NEUTRAL. Operating spetinestions 25 PSI. [173 kPal minimum pressure at 2000, OIL FILTRATION Full tow Sher saiey yan asa strainer sever sguma at oto af trramision case cuuToH 18S PS, (1275.5 KPa] minimum — wath peeing PRESSURE brake so 8 note), al tempacanurn 180° 200° F AAPL engine epaod AND a maximutn af 100 fae naar] enrear ae aioe Reta) P.S.L (BD KPa) ousiet pressure with engine Sh tira direc ard speed canes, AK clutch ‘operating al novead governed speed Presaure must ba equal wittn PSI. [34,5 KPa} CONTROLS: {chien presture vanes n ary.one clutch mee ha Speed Selection — Ehectic: SPS. [45 KPal reper cltch CLUTCH TYPE Muti decs, Rydrauelly actasied, spring Noted operating pressure 240-280 PS.) feleased, automate wear Eompensaian, 28.90 [1854.8 - TODS MPa at 2000 APM, fadusiment Allchuichee of cooted are idan ato NOTE: Never use seeviea brakes while making eure ‘itch pressure checks. Units having Brake ae INNER DISC Friesen, \woted deelutceng in forward anator reverse wil cute rot give # true reading. QUIER DISC Se! ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS. LUBRICATION TYPEOF OR See Lube Chart. RECOMMENDED LUBRICANTS FOR CLARK-HURTH POWER capaciry (Consult Gperatce's Manual on aopbcable actin SHIFTED TRANSMISSION AND TORGUE CONVERTERS rogel for system capacity. Tommie Covers rarer, an alo mera sytem Must Be coneitaea as 8 whele to Soto copay CHECK PERIOD Chock level DAILY wen engin running at 600 "400 PAM anal il at 180" to 200" F [82.2 56.3°G), Marta ol evs ta FULL par. “NORMAL Every 1000 hours, change of ser ORAM PERIOD Ewer} 1008 nous, Gan and rol oye as wo Drain wat 180" 19 200%, f,.8°-95.3" C} (a) Drain vnervssion. (b) Oot romeo and ace nets rw ae is) Rott rangmisson 1g LOW pen 46) Fam engine a §00-600 FFM, ro grime con verer ahd Ines (e)Racheck toa! kit erga running at 00-600 RPM. atta a rg nua 29 LOW pon, When of temperate is hot 119" 200° Fy [822% 58." C] mate final clues chook ‘BRING OIL LEVEL TO FULL PORT. ote: Hs recommended that ofl filter be changed ‘afer 80 and 100 hours of opeeation on new el ‘ebuil ar repaited uni **Narmal rain periods ana ol iter enanige intervals art for aver: age environmental and duty-cyele conditions. Severe or sustained Nigh operating temperstures oF very dusty atmonsherie conetions ‘wal cause acelersted deterioration and contamunatiga, Foe extrrne coneitions judgment must be used te determine the required change intervals, Prevailing Ambiont Temperature (908 vee a0 Tengeee “9 HOC nee rR Gn a . ur APEDGE & COS? O82 ae . OCC at . Sy ML ziedde Tengecure 2" HMC? dr 1 2 mg coe e (2.03 aoe '0 : tages O-rat : rin 229 Bn incerta Fe 6 Fempentin at vee ene Bh-Oenon » ‘Son Caen Boi ‘pata abi? ULL ASIN? A. tomo Aigetocinneee Sets ty De — Si M8 ciated tadomarh of ‘Generel Watcre Corperattn, Salect nohest ail vscaaty expt ng aie erganatunee ang eh speteatan aha. Temparm.rerngns2" ard" ru oe Une a tor ambien amperes lahan aug protease Tope ange oul ual ny amber epee ang HM. MODULATED SHIFT TRANSWESSIONS: T7200, ton, 24009, 22000, 8 32000 sie ranemasions wih Mexualed Muse oly Coe omeentare ‘anges tame stat) ‘Sowrunce "Caser © SEE EAUTION BELOW 3200 {003.10 6000, SIC6, E00 & SECC sara nara meh moc fh umeony © ar terperaewavange Siem atenly “Decor De NOT une "Sime I'S. SEE CAUTION BELOW. CAUTION: *Dexron I bs not compatible with gaptic cach pate tres ‘gn mil URCESE IT MEETS Te APPROVED C2 SPECHIEA TIONS. “Dearon lt cannot be sea inthe 3000, «000, S000, #000, 3400, 4000, 2 24100 series pomer shit ranamlasions, of the HAZED00 & HRS2008 ova ivan ceemere oes-up, or fhe G20 weve carvers avn ek Gp UNLESS IT MEETS ThE APPROVED €-a SPECIFICATIONS. [Any eatin trom thes Charl must have wniien approval tam the ap: ficabian apartment ofthe Clam Mur Cemponemts Engineer ans Marketing Beporinent to i PREFERED OM. vssCOSIT fs i with —76—SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and its hydraulic system are important links in the driveline be- ween the engine and the wheels. The proper operation of either unit depends greatly on the condition and ‘peration of the other; therefore, whenever repair or ‘overhaul of ane unit is performed, the balance of the system must be considered before the job can be con- sidered complete. After the everhauled or repaired transmiesion has necting hydraulic system must be thoroughly cl This can be accomplished in Several manners and a degree of judgment must be exercised as to the method employed, The following are considered the minimum steps fo be taken: 1. Drain entire system thoroughly, 2. Disconnect and clean all hydraulic fines. Where feasible, nydraulic lines should be removed from machina for cleaning. 3. Replace olf titer elements, cleaning out fitter cases thoroughly, 4. Theil conler must’be thoroughly cleaned. The cooler should be "back flushed!” with ail and -T7- ‘compressed air until all foreign material has bean removed. Flushing in direction of narmal ‘il flow will not adequately clean the cooler. If necessary, cooler assembly should be removed ‘rom machine for cleaning, using ci, comprassed ar, and steam cleaner for that purpose, DO NOT ‘use flushing compounds for cleaning purposes, Reassemble all components and use only type ‘il recommended for lubrication section. Fill transmission through filler opening until fluid comes up to LOW port on transmission. Remove LOWER check plug, fill until oll runs from LOWER oil hole, Replace filler and level plug. Fun enging two minutes at 500-600 R.PM. 10 prime torque converter and hydrau! 8. Recheck level of fl in transmission with engine running at idle (500-600 F.PM.). ‘Add quantity necessary to bring fluid level to run {freely from LOWER oll level check plug hale. In- stall oll level plug. Recheck with hot oil (180-200° F) (82, 2-99, 3° C}. Bring oil level to FULL port to run freely from UPPER ail level plug hole, Recheck all drain plugs, lines, connections, etc,, for leaks and tighten where necessary.PORT IS TO BE USED FOR “OIL TO COOLER” TEMPERATURE PIGK-UP GAUGE 18 TO BE LOCATED IN THE OPERATOR COMPARTMENT. SEE OIL TEMPERATURE GAUGE SPECIFICATION (PRESSURE MUST BE MEASURED DURING NORMAL VEHICLE TEST PROCEDURE, TEST CONDITIONS 1 "TO COOLER” DIL. TEMPERATURE 160. 220°F [n2.104°C} 2. TRANSMISSION IN NEUTRAL OPERATING SPECIFICATIONS: 1. 28 psi [173 kPa] MINIMUM PRESSURE AT 2000 ¢pm ENGINE SPEED AND ‘A MAXIMUM OF 100 PSI [690 kPa] OUTLET PRESSURE AT NO_LOAD GOVERNED SPEED port Gi) — CLUTCH PRESSURE 17 IS REGOMMENDED THAT GLUTCH PRESSURE BE MONITORED BY A GALIGE LOCATED IN THE OPERATOR COMPARTMENT. NORMAL OPERATING PRESSURE 240.280 PSI [1655- 1930 kPa) at 2000 RPM 5) and @) — sackur waRNInG THIS PORT 1S PROVIDED FOR INSTALLATION OF BACKUP PRESSURE SWITCH FOR WARNING UGHT OR HORN. OIL TEMPERATURE GAUGE SPECIFICATIONS: 1 NORMAL OPERATING TEMPERATURE: 165: 250°" (e2-teVC) 2,RED LINED TEMPERATURE: 250° [121°F) Port FORARD CLUTER von REVERSE CLUTOW PRESSURE ~~ OPTION - REMOTE FILTER rom ©) emmeccue 22 AECULATED CUTE PRESSURE Bp € FILLER HOLE OIL %3 COOLER, TOP VIEW Hear ExcHANCER wear ExcHan’ Hear exchanger INLET TEMPERATURE, ce 7 PRESSURE L / ron) TOCOGLER / REAR VIEW See Pages 94 through 87 for Hydraulic Diagram. 783, 4 & 6 Speed FRONT VIEW check POAT GuumTE "SSPEED: 16r 4 SPEED {5T a, HECK PORT CLT | 6 SFEED FWD 3D 4TH, REY 20, roe) [aL Fron coi MAGNETIC DRAWN SLUG, rom {7 SHE PORT FoR Stine rabesiee See Pages 84 through 97 lor Hydraulic OagTe™. EET SIDE VIEW { | —19CLEANING AND INSPECTION CLEANING Glean all parts thoroughly using salvent type clean- ing fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down stowly until all old lubricant and foreign material is dissolved and parts, are thoroughly cleaned CAUTION: Care should be exercised ta avoid skin rashes, fire hazards, and inhalation of vapors when us- ing solvent type cisaners. Bearings Fremove bearings trom cleaning fluid and strive flat against a block af wood to dlisindge saliditied particias cof lubricant, Immerse again in cleaning fluid w flush out particles, Repeat above aperation until hearings are thoroughly clean. Dry bearings using moisture-tree compressed ait Be careful ta direct air stream across bearing fo avaid spinning. Do net spin bearings when drying. Bearings may be rotated slowly by hand to facilitate crying process Housings Clean interior and exterior of housings, bearing caps, etc;, horoughly. Cast parts may be cleaned in not solution tanks: with mild alkalt solutions proviging these parts de not have ground oF polished surtaces, Parts should remain in solution long enough to be thoraughiy leaned and heated, This will aid the evaporation af the laaning solution and rinse water, Parts cleaned in solu- tion tanks must be thoroughly rinsed with clean water 10 remove all traces of alkali, Cast parts may also be cleaned with steam cleaner. CAUTION: Care shauid be exercised to avoid inhalation of vapors and skin rashes when using alkali cleaners. All parts cleaned must be thoroughly dried im- mediately by using moisture-tree compressed air or sot, lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping com- pound, -50- INSPECTION ‘The importance of careful and tharough inspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear ar stress will eliminate costly and avoidable failures at a later date Bearings Carefully inspect all rollers: cages and cups tor wear, chipping, or nicks to determine fitness of bearings for further use. Do not replace a bearing cone or cup individually vrithout replacing the mating cup or cone at the same time. Alter inspection, dip bearings in Automatic Transmission Fluid and wrap in elean lintiess cloth or paper to protect them until installed. Oil Seals, Gaskets, Ete. Replacement af spring load oil seals, “0” rings, metal sealing rings, gaskets, and snap rings is more economical when unit is disassembled than premature everhaul to replace these pans at a future time. Fur- ther loss of lubricant through a worn seat may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, par ticularly when being installed. Gutting, scratching. ar curling under of lip of seal seriously impairs its etficien- ‘ey, Apply a thin coat of Permatex No. 2 on the outer diameter of the oil seal to assure an oil tight ft into the retainer, When assambiing naw metal type sealing ‘ings, same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members. Lubricate all “O" rings and seals with recommended type Automatic Transenis sion Fluid befara assembly. Gears and Shafts Imagna-flux process is available, use process to check paris. Examine teeth on all gears carefully for woar, pitting, chipping, nicks. cracks, or scores. If gear teeth show spots where case hardening is worn through ‘or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are net sprung, bent, or splines ‘twisted, and that shafts are true, Housing, Covers, etc. Inspect housings, covers, and bearing caps to be ‘certain they are thoroughly clean and that mating sur- faces, bearing bores, elc., are free from nicks or burrs. ‘Check all parts carefully for evidence of cracks or con- «dition which would cause subsequent of leaks or failures.12000 CALIPER BRAKE ASSEMBLY QUANTITY HOUgIAg. evens Lining : re Spring : Cam Plate Bal Capscrew Body (Module) NouLEn= aes ine ITEM & 9 10 " 12 19 14 DESCRIPTION QUANTITY Lever ceeeeeee Nut... between . Beligville Spring... . Retainer Retainer Ring : Piston : Capscrew PARKING BRAKE LINING AND PISTON REPLACEMENT PROCEDURE DISASSEMBLY 1 JLoosen and remove lever rataining nut (item 9} fram brake module and piston assembly (tem 13). Remove lever (tern 8), 2. Depress retainer (item 11) and remove retaining ring {item 12) trom lever end af brake module (item 7). Remove retainer (item 11) and tive (5) Delleville springs (item 10) from pisten (item 13) 4.Remave piston (item 13), twa cam plates (tem 4), and three balls (em 5) from brake module (item 7). REASSEMBLY 5. Lubvicate three: new bails (tem 5) with high compres: sion grease and place in ramps of new cam plates item 4) 6. Install new cam plates (tem 4) in brake module: (tem 7] making sure locking lugs-are aligned property in brake module item 7) 7-nstal piston (heen 13) in brake module item 7) making sure piston aligns properly on cam plates (item 4), 8. Install five (5) belleville springs fitem 10) and retainer {item 11) on lever end of piston (item 13) 9. Depress retainer (item 11) and install retaining ring {item 72) in groove on piston (item 13) 10. Install brake madule assembly {item 7) on housing item 7) ~at— 14,Positizn lever (item 8) in a convenient location tor ‘actuation rod, Install lever (item 8) and laver retaining nut {item 9} on brake module assembly (item 7) Shug lever retaining nut (item 9). 12. Adjust brakes per instructions PARKING BRAKE ADJUSTMENT (Mechanical Applied) With the brake assembiedon the transmission with & free fioating operstion of the caliper, adjust caliper as follows: NOTE: Do nat use operating lever (item 8) as a means to turn the madule bady (item 7). To use the lever will cause the piston to extend and cause a false setting, Module capscrams (item 14) must be loose before brake adjustment 1. Serew brake module (item 7} in until linings contact disc. Back module (item 7} off until a flat on module lines up with capscrewr {item 14). Torque capscrews (item 14) 8-10 oft [14-14 Nem). 2. Remove lever retaining nut (item 9). Remove lever (item 8) 3, Reposition lever (item 6) to desired angle of operation 4. Install retaining nut (item 9) and tighten to 10 Ibttt torque [13,6 Nem]‘TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION The following information is presented as an aid 1a isolating and determining the specific problem arsa in @ transmission that is not functioning correctly. ‘When troubleshooting a “transmission” problem, it should be kept in mind that the transmission is only ‘he central unit of a group of related powertrain com ponents. Proper operation of the transmission depends ‘on the condition and correet functioning af the other com ponents of the group, Therefore, ta property diagnose a Suspected problem in the transmission, its necessary to consider the transmission fluid, chargng pump, lorque converter, ransmission assembly, of cooler, filter, con- necting lines, and controls, including the engine, as a complete system. By analyzing the principles of operation together with the information in this section, it should be possible 10 identity and correct any malfunction which may oc cur in the system. 712000 TRANSMISSION ‘712000 (powarshift with torque converter transmis sion troubles fal nic two general eategories: mechanical problems and hydraulic problems). In addition to the mechanical components, all of whieh must be in the proper condition and functioning correctly, the correct functioning of the hydraulie citcutt is most important. Transmission fluid is the “tif blood” of the transmission. It must be supplied in an adequate quantity and delivered to the system al the correct pressures to ensure converter operation, to engage and hold the clutches from slipping, and to coal and lubricate the working components TROUBLESHOOTING PROCEDURES Stall Test: Use a stall test to identity transmission, con- verter, or engine problems. ‘Transmission Pressure Checks: Transmission problems: can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine ifthe sllopage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmis- sion lubrication pressure may also be measured, Mechanical Checks: Prior to checking any part of the system for hycraulic function (pressure lesting), the follwing mechanical checks should be made: There ar only two mechanical linkages available on the transmission. 1. Mechanical inching from brake pedal to inching valve on transmission 2, Linkage from axle disconnect to disconnect actuator, ‘Check the parking brake and inching pedal for cor- rect adjustment and travel, Be sure the pedal maves freely and returns fully, Be Sure all lever linkage is properly connected and ad- justed in each segment and at all connecting paints. ‘The controls are actuated electrically. Check the ‘wiring and electrical componer Be sure that all components of the cooling system ate in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and trans- mission. Air Clean the radiator, it necessary. ‘The engine must be operating correctly. Be sure that it is Correctly tuned snd adjusted to the correct idte and maximum no-load governed speed specifications. Hydraulic Check: Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic cireuit for pressure and rata of ell flow, itis important 19 make the follawing transmission fluid check: (Check oil evel in the transmission. The transmission ‘fluid must be at the correct (full level), All clutches and ‘the converter and its fluid circuit lines must be fully ‘charged (filled) at all times, See NGTE below NOTE: Tha transmission fluid must be at operating temperature of [82-93° G] 180-200° F to obtain correct fluid level and pressure readings. 0G NOT ATTEMPT TO MAKE THESE CHANGES WITH GOLD OIL. To raise the oll temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at “stall. CAUTION: Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall RPM.‘CONVERTER STALL PROCEDURE 1. Putthe vehicle against a solid barrier, such as awl, andior apply the parking brake and block the ‘wheels. 2. Put the directional control lever i FORWARD (or REVERSE, 5 applicable). 3. Putthe speed contral lever in ded (3 speed) (HIGH) or 6th (6 speed) ‘With the engine running, slowly increase engine speed to approximately one-half throttle and hold un til transmission (converter autlet) off temperature reaches the operating range CAUTION: Do not operate the converter ai stall condition longer than 30-seconds atone time, shift to neutral for 15, seconds and repeat the procedure until desired tempera lure is reached. Excessive temperature ((120° C] 250° F inaximum) will Cause damage to transmission clutches, fluid, converter, and seals. TROUBLESHOOTING GUIDE eter to the following troubleshooting gi for the diagnosis of typical transmission troubles. LOW CLUTCH PRESSURE CAUSE Low oil level 1 REMEDY Fill to proper level 1 2. Cluteh pressure regulating valve stuck open. 2. Clean valve spool and housing, a. Faulty charging pump 3 Replace pump. 4. Broken-or worn clutch shatt or pisten sealing rings. 4. Replace sealing rings. 5. Cluteh piston bleed valve stuck open. 5. Clean bleed valves. thoroughly. LOW CHARGING PUMP OUTPUT 1. Low oil level 1. Fill 10 proper leva! 2. Suction screen plugged. 2 Clean suction pump. J. Detective charging pump. 3. Replace pump OVERHEATING 1. Worn ail sealing rings. 1. Remove; disassemble, and rebuild converter assem. iy 2, Wor charging pump, 2. Replace. 3 Low oil level Fill t proper te 4. Disty oll cooter. 4. Glean cooler. 5, Restriction in cooler lines. 5. Ghange cooler lines. NOISY CONVERTER 4. Worn charging pump, 1. Replace, 2, Worn or damaged bearings. 2. Acomplete disassembly will be necessary to éeter- ie what bearing is faulty. LACK OF POWER Low engine FLPM. al converter stall 1. Tune engine check governor 2. See “Overheating” and make same checks, 2, Make corrections as explained in “Overheating.” 83oasds £ WVHOVIC ONIKIM TOKLNOS CIONSIOS DH L935 75 {YE AnINO W3d LNHUND GBMOTTY TIRING aaivAli wounaaa azu Mos owas WEE 40'NO TYROILIO wOUNTOaG OM HOS | HOLWE 34O°NO WHOIS | ‘ aoM whe Peretti vaga, ‘omam0s 2 Tea PE aaads € gions | 4 ore oig3NNoo. goxavs PF moNaT05, e x08 AVI naan ao a HUA SUM WaZMAGa | NOLIN Ja280719 BLeLNOD_IOYINOD Sy. SQELNOD EVO. anaa3adS 9 ONY PF WYyHOWIC ONIIM TOXLNOD GIONS10S OWLO313 ews me gues 230 aM ue se rt SAWN WIBIIG — HLLOM | Baar newsaienora | | Sao Beaty ob hes aa asus 8 ae seaanae (malSINGLE MODULATION AND MECHANICAL INCHING REMOVAL Figure 4 Femove inching spool. Figure 1 Remove inching valve housing. Figure 5 Remove modulator valve housing and “O" ring. Figure 2 Remove inching return spring, actuator rod, and regu: lator spring, Figure 6 Figure 3 Remove modulator valve outer, middle, and inner springs Remove inching sieeve and "Q" sing, nd spring stop. — 86 —Figure 7 Figure 10 Remove modulation housing sleeve and accumulator Femove modulator valve cuter, middie, and inner springs, ‘spool, and spring stap. Figure 8 Remove shuttle sleeve and speol. DISASSEMBLY AND REASSEMBLY OF Figure 11 SINGLE MODULATOR VALVE ASSEMBLY Remove accumulator spool DISASSEMBLY Figure 9 Figure 12 Remove modulator valve body "Oring Remove modulator sleeve pin 87 —Figure 13 Figure 18 Remove regulator spool assembly retainer ring. Remove regulator spool sleeve assembly. Remove “O" ring. Figure 14 Figure 17 Remove regulater spool stop, spring, and spring and Remove sieeve check ball retainer pin sleeve assembly. Remove regulator spool sleeve retainer ring, Remove check ball,REASSEMBLY (See Cleaning and Inspection Page) 1 = Figure 22 Install sleeve retainer rag. Figure 19 Install a new ring on regulator spool siseve. Postion check ball in sleeve, Install housing sleeve pin Figure 20 Install check ball retainer pin Figure 21 Figure 24 Position sleeve and ball assembly in regulater spool Install regulator spool stop, spring, and regulator spool with check ball retainer pin up. and sleeve assembly in housing sieeve. — 89 —Figure 25 Figure 28 Compress reguiator spool spring and instal retainer ring. Install inching requiator spool spring — ee PN Figure 26 Position new “0” ring on modulation sleave. Figure 29 SINGLE MODULATION AND Install inching aetuator rad aver spring. MECHANICAL INCHING INSTALLATION Figure 27 Install a new "O” ringon inching sleeve, Install inching ‘spool in sleeve, Install spool and sleeve in inching control Figure 30 bore. Install inching return spring — 90 —Figure 31 Figure 34 With new actuator rad oil sealin position and new "©" Wily new “Oring in positon, install modulation housing. ring on inching housing, install housing over actuator —sloove assembly in bore. rod and thread inta inching bore. Figure 32 Figure 35 Tighten inching valve housing to- speciied torque. See Install sccumulster spa! in housing sieeve as shown. assembly instruction drawing, Figure 33 Figure 36 Position shuttle spool in shuttie sleeve, Install spool and Install stop pin, inner, middie, and outer springs in ao- sleeve in modulator valve bore cumulator and housing sieeve. atFigure 37 Figure 38 Position a new ‘“O" ring an modulator vaive housing Tighten modulator vatve housing 10 spectties torque. Thread housing into valve bore Sae-assembly instruction drawing. NOTES:Oude wan TORY Mat WeLSAs NouyouaN NossMswrL SHI 30 3UNSE3Md 2¥B GAY SIN eaONYHONS UVaH HSONWHOMS LH BHLL I owe aunesaua Wwi0l SHI stents 3HASSaNe 199000 OL. L49L B07 NOUSNOOUA. HON “TweNON BNiuna OSuraved 38 Lani SUNSSI Pern 13s CSE SUNEESME ATION OL. BF AMO In.6 aU OME ssunnvesaeat | ‘suouyaUiggds 26000 jS40 TWHOW vneaeWa Wo Anse BOLWEBIG SHL NI GaIVAO 38 Ot BAO NOWWOIMGM How WowyPl aoa 335 Nouvoutads Wo aaon i é =A UOpES07 eg 10) 64 Pu gE saBEy 90g sUNssatid ONY SUIDMINA solr eon wourreen eRSTin Ws cL SL NOILVINGOW WNd HLIM ‘SUNG SHNSTAN GHY SUMIOd NOMOTHNOD WYVYOVIC SIINVHGAH GAAdS E OO0ZE-L i - L- 1 ult a 22H EMBL! Alans 20FT-12000 3 SPEED HYDRAULIC DIAGRAM WITH MODULATION AND INCHING | | [SSREEO SHIFT OIAGRAM Wm | | [eshisghion \ 5 x i DE pe 1 LE xp xp] pepe Sa Bixt | xt | x RH YDRAUL = LENO aE DISCONMEGT OPTION REMOTEFILTEH OPTION —95—T-12000 4&6 SPEED HYDRAULIC DIAGRAM WITH DUAL MODULATION moouLanon wopuuanan abe cr @ LE 0 4,2 Fost no & nai LE ow @ fet 14 J2}3 4] 1]2131 4) ls he Re c x] BMX) 3 wa - een es E [x hx) |x| AIR/HYDRAULIC Ox IX, bs osconmect-GPton Tne ns 6 SPEED SHIFT DIAGRAM Foe REVERSE | ET 1/2/84 5i6|1/243|1 1253 by v REMOTE FILTER OPTION 4 x} x] pe ex xb Ix/x}x |x he Lx ix] lomeo a Ix|x} ix| SOUENOD ENGI — 96 —T-12000 4&6 SPEED HYDRAULIC DIAGRAM WITH MODULATION AND INCHING moouLarion i Ct 1 out ' {@ vat -+ eV ea le Sos FWD LO. fle, — @ [Xi g Pv te TH Me) © alka “| s#0 _ fei @ 8 ‘4 SPEED SHIFT SEER ‘WANS EMERGE] MET 1p 2t3ia/1 aia its B Dxpx DX] c x | | | A [xlalx}x E [XIX] DePX| DCC) Bo IX] LENG AIUHYDRELUC. DISCONNECT -OFTION g weWwy BEMNOTE FILTER - OPTIONONT-0040