Maintenance and Service Manual 24000 Powershift i Transmission HR MODEL 4 SPEED LONG DROP E COMPONENTS CLARICHURTE> | ‘SM HR24-4LD (Rev. 12-87)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 Power Shift Transmission. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the transmission, its principal of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only Clark Components International-approved parts as listed in the applicable parts manual should be used. Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment. Clark Components International does not warrant repair or replacement parts, nor failures resulting from the use thereof, which are not supplied by or approved by Clark Components Intemational. IMPORTANT: Always furnish the Distributor with the transmission serial and model number ‘when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design. Fig, A Converter and Transmission Case Group Fig. B Converter Group .....-+.- ses Fig © Four Speed Clutch and Gear Group . a ° Cluteh Group. Fig. E Control Valve Assembly... ee Fig. F Charging Pump and Regulating Valve Group. .. Fig. G External Plumbing and Pressure Check Points Fig. H ‘Assembly Instructions Fig. 1 HR24000 Typical Cross Section......2..cc6eseeteseeseesseerees Figs DISASSEMBLY OF TRANSMISSION ......2..00000000000 1 REASSEMBLY OF TRANSMISSION. .....2.026.2000000eeeeeee veya #2 CLEANING AND INSPECTION syguageserqvevesnvvoesa 60) SERVICING MACHINE AFTER TRANSMISSION OVERHAUL, - 60 TOWING OR PUSH STARTING «0.0.0. 20eseceecees * senvuees OO) ‘SPECIFICATIONS AND SERVICE DATA. cecteeseesteessesees 61 LUBRICATION 2... 208 eae M1 TROUBLE SHOOTING GUIDE... -26.2..es cevtteeteessseses 62 CLUTCH AND GEAR ARRANGEMENT. 63 POWER FLOW scien COTEHE) HERE 64 ELECTRIC SOLENOID CONTROL puatenacaanenntves ony 67 CONTROL WIRING DIAGRAM... 68 DRIVE PLATE INSTALLATION ...2..es0eceeeeees oun 6 ‘TRANSMISSION TO ENGINE INSTALLATION PROCEDURE. 70 NOTE: Metric Dimensions Shown in Brackets [ ].CLARK HOW THE UNITS OPERATE ‘The transmission and hydraulic torque portion of the power train enacts an import engine power to the di role in transmitting ing 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. I is necessary to consider both units in the study of their function and operation. To supplement the text below, and for reference use therewith, the following illustrations are provided: ‘SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Fig. A Converter and Transmission Case Group : o. Fig. B Converter Group... essere ceeeee Figh © Four Speed Clutch and Gear Group it Fig. D Clutch Group. Fig. € Control Valve Assembly. races ober Fig. F Charging Pump and Regulating Valve Group. Fig. G External Plumbing and Pressure Check Points ......... Fig. H Assembly Instructions Fig. 1 HR24000 Typical Cross Section...... Fig. J The R, HR, and MHR Model Transmissions are of three basic designs. ‘The R Model consists of a separate torque converter, mounted to the engine with the powershift trans mission remotely mounted and connected to the torque converter with a drive shaft. ‘The HR Model consists of a torque converter and powershifted transmission in one package mounted directly to the er ‘The MHR version is a mid-mount torque converter and transmission assembly connected to the engine by means of a drive shaft. (See Fig. A for basic design silhouette.) The shift control valve assembly may be mounted directly on the side of the converter housing or front transmission cover, or remote mounted and connected to the transmission by means of flexible hoses. The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutch. A provision is made on certain models to neutralize the transmission when the brekes are applied This is accomplished through use of a brake actuated shutoff valve. The speed and direction clutch assem- blies are mounted inside the transmission case and are connected 10 the output shaft of the converter either by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction. ‘An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can bbe disconnected or connected by manval shifting.CLARK With the engine running, the converter charging pump draws oil from the transmission sump through the removable oll suction screen and directs it through the oil filter and the pressure regulating valve. The pressure regulating valve maintains pressure to the transmission control cover for actuating the direc- tion and speed clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil is directed through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating in @ closely fitted bore. The valve spool is spring loaded to hold the valve in a closed position. When a specifie pressure is achieved, the valve spool works against the spring until a port is exposed along the side of the bore. This sequence of events provides the proper system pressure. After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to a lubricating fitting on the transmission and through a series of tubes and passages lubricates the transmission bearings and clutches. The oll then gravity drains to the transmission sump. The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com- ponent which starts the oil flowing to the other components which results in torque multiplication. This el fement can be compared to « centrifugal pump in that it picks up Fluid at its center and discharges ais outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the forque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque. ‘The reaction member of the torque converter is located between and at the center or inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. jon ratio when the out- ing in speed the torque The torque converter will multiply engine torque to its designed maximum multi put shaft is at zero RPM. Therefore, we can say that as the output shaft is decre multiplication is increasing. The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring in the selector spool provides one position for each speed range. A detent ball and spring in the direction spool provides three positions, one each for forward, neutral and reverse. With the engine running and the directional control lever in neutral position, oil pressure from the regul ing valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and reverse spool will direct oil, under pressure to either the forward or reverse direction clutch as desired. red of pressure and vents back through the direction selector spool. The same procedure is used in the speed selector. ‘The direction or speed clutch assembly consists of a drum with internal splines and a bore to recei draulically actuated piston. The piston is “oil tight" by the use of sealing rings. A st splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at th diameter is inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with » snap ring. A Hubwith O.D. splines is inserted into the splines of discs wi teoth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direc- tion as long as no pressure is present in that specific clutch.CLARK To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows cil under pressure to flow from the control valve, through @ passageway, to a chosen clutch shaft. This shaft 1d passageway for oil under pressure to enter the shaft. Oil pressure sealing rings are loc the clutch shaft. These rings direct oil under pressure to a desired clutch. Pressure of the cil forces the and discs against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping a discs with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows them to drive a8 a unit, There are bleed balls or bleed orifices, depending upon the model, in the clutch piston which allow quick ‘escape for cil when the pressure to the piston Is released. has a FIGURE AFigure BCONVERTER AND TRANSMISSION CASE GROUP ITEM DESCRIPTION ary. item DESCRIPTION ary. 1 Pipe Plug. ....- 2 33 Clutch Pressure Tube “O” Ring ....... 1 2 Air Breather. .. 1 34 Tube Sleeve ..... bere 1 3 Pipe Plug. .......se00 1 36 Clutch Pressure Tube “O” Ring ....... 1 4 Pipe Plug. 2 36 Tube Sleeve .............005 1 5 Converter Housing Sleeve ot 37 Clutch Pressure Tube “O” Ring .a 6 Clip feces TV 38 Transmission Case Assembly . 1 7 Clip Screw Lockwasher . 1 39 Tube Sleeve eeees 1 8 Clip Screw... .sesseeeeees 1 40 Clutch Pressure Tube “0” Ring 1 9 Clip Screw. 1 41 Rear Cover to Transmission Case Gasket. 1 10 Clip Screw Lockwasher. 1 42 Transmission Case to Rear Cover 11 Clip vo vvvvttettttttteeeee 4 Dowel Pin....... ceed 12 Converter Housing Sleeve. . .. 1 43 Rear Cover Pipe Plug... i 13 Pipe Plug........ os wea 2 44 Rear Cover... a 14 Converter Housing to Transmission 46, Rear: Cover-toCana Saretw..-.0- «= 2-22 20 Case Screw Lockwasher............. 17 46 RearCoverto Case Screw Lockwasher... 20 15 Converter to Transmission 47 Transmission Case to Rear Cover Case Screw........-- see 7 Dowel Pin.....seeeeeeeeeeeeeeeeeee 1 16 Pipe Plug 2 48 Pipe Plug....... 17’ PUG ossises os va ore Q 1 49 Pipe Plug....... 18 Hole Plug Gasket..........2.5 1 80 Magnetic Drain Plug 19 Case Assembly Hole Plug... 1 51 Oil Baffle......... 20 Converter Housing.........++ 1 52 Tube Clip......... 2... 21 Screen Assembly Gasket... 1 53 Clip Screw Lockwasher ... 22 Screen Assembly ..........+ 1 5A Clip Screw.........ceeeee 23 Converter Housing to Transmission 55 Suction Line Assembly “O” Ring... Case Gasket ... : : 6 Suction Tube Assembly. 24 Converter Housing to Case Dowel Pin... 1 G7: ScieW Lookwasherss 25 Clutch Pressure Tube “O” Ring ....... 1 58 Suction Line Screw 26 Lube Tube Sleeve 1 59 Clutch Lube Tube... 27 Tube Sleeve ....... 1 60 3rd Speed Tube ... 28 Clutch Pressure Tube 1 61 High Speed Clutch Pressure Tube 29 Tube Sleave ....... 1 62 Low Speed Clutch Pressure Tube. 30 Clutch Pressure Tube 1 63 Dipstick Tube Assembly ....... 1 31 Tube Sleeve .... 4 64 Dipstick....... eee 1 32 Clutch Pressure Tube 1Figure CITEM CONVERTER & PUMP DRIVE GROUP DESCRIPTION Bearing Support Screw & Lockwasher . Idler Gear Bearing Locating Ring. Idler Gear Bearing Retaining Ring Pump Drive Idler Gear Idler Stub Shaft Bearing Bearing Retaining Ring Bearing Locating Ring. o Bearing Support Screw & Lockwasher Bearing Locating Ring. Pump Drive Beating Suppor Bearing Retaining Ring. Pump Drive Gear Bearing... Bearing Locating Ring. Pump Drive Gear Idler Gear Stub Shaft. . Stub Shaft Lock Ball Piston Ring Expander Spring Piston Ring. Stator Support Bearing Snap Ring. Piston Ring. Bearing Retaining Ring Bearing Locating Washer Turbine Shaft Bearing Turbine Shaft Baffle Ring .. ‘Stator Support Screw . Auslisry Pump Drive Bearing Suppor Bearing Retaining Ring Pump Drive Gear Bearing .... Bearing Locating Ring. ‘Auxiliary Pump Drive Gear ... Pump Mounting Cover Gasket Pump Mounting Cover. : Pump Mounting Cover Capscrew Lockwasher Pump Mounting Cover Capscrew Ieler Shaft Lockball Idler Gear Bearing Thrust Plate Idler Gear Bearing Assembly Idler Gear ary. ph CRASS HAD SSH de eee eee Tem 4 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 87 58 59 60 61 62 63 64 65 66 67 68 69 70 n 72 73 4 6 76 7 78 79 20 DESCRIPTION Reverse Idler Gear. Idler Gear Bearing Thrust Plate Bearing Retaining Plate Nut. . Turbine Retaining Ring Turbine to Hub Sorew. Turbine Hub Ring. . Turbine Turbine Hub Impeller to Cover “O" Ring... Impelier Cover Turbine Hub Bearing Impeller Cover to Bearing Cap “0” Ring. Turbine Hub Bearing Retaining Ring Turbine Retaining Ring... Impeller Cover Bearing Cap . late Assembly. . Drive Plate Drive Plate Backing Ang Drive Plate Mounting Nut. Drive Plate Mounting Stud Lockwasher Impeller Cover Stud, Impeller to Cover Serew . Impeller to Cover Serew Lockwasher Retaining Ring, Froewheo! Outer Race Retainer Ring. Freewheel Assembly Reaction Member cee Impeller to Hub Bearing Spacer. Impeller to Hub Screw Drive Impeller to Hub Screw Lock Tab Impetter. Impeller Hub “O" Ring Impeller Hub Gear : Impeller Hub Gear Bearing. Idler Shaft “O" Ring... Idler Shaft . Oil Baffle Retaining Ring Oil Baffle Oil Seal Oil Batfle Seal RingITEM DESCRIPTION Forward Shaft Plot Bening Spring Retainer Ring : Spring Retainer ecaoievee Piston Retum Spring Bellville Washer Piston Return Spring Spacer Forward Catch Shat, rum f Plug Assomely Paton Ring Expander Spring... +++ Forward Shaft Piston Ring Piston Ring Steeve Retsining Fing Piston fing Sleeve Forward Shaft Rese Bearing Reverse @ 2nd Shaft Piston Ring Front Bearing Retuning Ring, Front Beating Snap Fina Reverse & 2nd Shatt Front Bearing Front Bearing Retaining Ring Cteh Daven Gear Bearing Assembly. Revaroe Cutch Gear & Hub Assembly Batle Ring. : Spring etsining Snap Ring. Spring Retainer Piston Return Spring Bellevile Wash Piston Return Spring Spacer oo Reverse 2nd Clutch Brom & Plug Assembly. Piston Ratu Spring. Spring Retainer Spring Retainer Snep Ring. Retainer Locsting Ring Retaining Ring Retain 2nd Clutch Ose Hub Retaling Ring... Bate Ring : Reverso @ 2nd Shalt Roar Bearing 2nd Clutch Diee Hub. 41a @ 4th Shaft. Drum & Pug Assembly Paton Return Spring - 3rd Clutch. Spring Retainer... Spring Retainer Snap Ring ‘ra Outen Dic Hub Reining Ring Bate Ring . 31d 4th Shaft Rest Basing 53rd cluteh Oe Hud Clutch Osven Gear Bearing Specer 4th Gear & Hub Asserby " Clutch Driven Gear Bearing ear Oren Gear Thrust Washer “These Wacher Lock Bal : “Tast Washer Locating Ring. Spring Retainer Snap Ring Spring Retainer. ee Piston Return Spring . 4th Shat Piston Ring Front Bearing Retaining Ring f Front Bearing Snap Rings. .++- 4th Clutch Shaft Front Beating Front Orven Gese Theat Washer ‘Thnst Wather Lock Bal Clutch Oxven Gear Bearing Front Bearing Cap Screw Lochwasher Front Bearing Cap Screw ange Nut Flange Wash Fiange “0” Ring me Front Output Flange : Front Bearing Cap Oi Sea. CLUTCH AND GEAR GROUP. ary. 1 1 3 2 1 3 1 1 1 1 7 1 1 1 1 1 1 4 1 1 1 1 3 1 1 1 4 4 1 1 1 ITEM DESCRIPTION ary. 101 102 103 108 105 106 108 308 0 m nz na ns 16 18 119 120 121 12 123, 124 125 126 AR Front Bearing Cap i Bearing Cap Shim cece AR Forward Shaft Gear f Gear Retaining Ring ==. ‘ ‘at Shand Clutch Shot Front Bearing... 1 1 1 1 1 tat Speed Gear Bearing Lacatng Ring a 1 ‘st Speed Gear Bearing Spacer : 1 Tet Gear & Hob Assembly 1 Bata Ring 1 Low Speed Geer Bearing Locating Ring... 1 Low Speed Gear Bearing 1 Batol Washer Retainer. : 1 Spring Retainer Snap Ring 1 Beleite Washer, 7 Bellevile Washer Spacer 1 ‘st Clutoh Shaft Drum & Bleed Vale Assembly 1 1st Speed Shalt Rear Bearing Spacer, 1 {et Speed Shaft Rae Boring 1 1st Shaft Bearing Retainer Ring 1 ‘et Shaft Paton Ring 1 Bearing Cap Gasket 1 Bearing Cap “0” Ring 1 Bearing Cn Plus. 7 1 Rear Boating Cap... 1 Baring Cap Ser Lociaunsher 4 essing Cop Serew 4 Ie Shaft Front Bearing, 1 tata shat, 1 1 1 1 1 4 1 1 1 1 1 lar Shaft Rear Bearing lol Shaft Rear Bearing Lock Ball Rear Bearing Locating Ring Pump Drive Sloeve lao Shot Mut anata later Gear Spacer. later shat Gear laer Shot Gear IalerShst Gearing Cap Gasket . later Shat Bearing Cap. lalor Shot Bosring Cap Screw Lockwasher later Shaft Bearing Cap Serow. . r Opt Shot . coven ‘Output Gear Spacer. Output Shatt Geer 7 Rear Bearing Cone. Rear Bearing Cup. Rear Gessing Cop "O° Ring Bescing Cap “0” Ring . Flange “O° Ring . ange Nut. oeoo. . Rear Baaring Cap Screw. ‘ Rear Bsaring Cap Screw Lockwasher = As Requiredrem Rone ITeM Ron ITEM BY 2a oON trem eyvoannen CLUTCH ASSEMBLY - 1ST DESCRIPTION ary. ITEM —_DESCRIPTION ary. Backing Plate Retaining Ring... 1 5 Clutch Piston ........0eceeeeee 1 Clutch Disc Backing Plate ...... 1 6 Clutch Piston Seal - Outer 1 Clutch Inner Disc. +10 z Clutch Piston Seal - Inner ...... 1 Clutch Outer Dise +110 8 1st Clutch Drum Assembly...... 1 CLUTCH ASSEMBLY - FORWARD DESCRIPTION ory. ITEM DESCRIPTION ary. Backing Plate Retaining Ring... 1 5 Clutch Piston .. 1 Clutch Disc Backing Plate .. 1 6 Clutch Piston Seal - Outer...... 1 Clutch Inner Disc... . 12 7 Clutch Piston Seal - Inner ...... 1 Clutch Outer Disc 12 8 Forward Clutch Drum Assembly... 1 CLUTCH ASSEMBLY 4TH & 3RD DESCRIPTION ary. ITEM DESCRIPTION ary. Backing Plate Retaining Ring.... 1 9 Clutch Piston Seal - Inner ...... 1 Clutch Disc Backing Plate 1 10 Clutch Piston Seal - Outer. . 1 Clutch Inner Disc.......++ 6 W Clutch Piston - 3rd... 1 Clutch Outer Disc ........22.5. 6 12 Clutch Outer Disc ........ 6 Clutch Piston - 4th 1 13 Clutch Inner Disc. 6 Clutch Piston Seal - Outer. 1 14 Clutch Disc Backing Plate 1 Clutch Piston Seal - Inner ...... 1 15 Backing Plate Retaining Ring.... 1 4th & 3rd Clutch Drum Assembly... 1 CLUTCH ASSEMBLY - REVERSE - 2ND DESCRIPTION ary. ITEM DESCRIPTION ary. Backing Plate Retaining Ring. ... 1 9 Clutch Piston Seal - Inner 1 Clutch Disc Backing Plate ...... 1 10 Clutch Piston Seal - Outer . 1 Clutch Inner Disc. . 12 " Clutch Piston - 2nd... ‘i Clutch Outer Disc . 12 12 Clutch Outer Dise . . 6 Clutch Piston - Reverse . .. 1 13 Clutch Inner Disc. . rn) Clutch Piston Seal - Outer...... 1 14 Clutch Dise Backing Plate ...... 1 Clutch Piston Seal - Inner ...... 1 15 Backing Plate Retaining Ring.... 1 Reverse & 2nd Clutch Drum AssemblyITEM eres oNnH " 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 CONTROL VALVE ASSEMBLY DESCRIPTION Elbow Forward Pressure Tube Assembly Elbow Valve Plug : 7 Forward & Reverse Shift Spool . Spool Position Spring. ..... 66. ...e 005 Forward & Reverse Shift Spool Ground Wire Harness ......... Receptacle Mounting Screw . Receptacle & Wire Assembly.......... Dust Cover Mounting Stud Lockwasher. Dust Cover Mounting Stud Nut Grommet, Dust Cover Dust Cover Seal...... Dust Cover Mounting Stud... Valve Spool Stop........ 666. Control Valve Housing Pipe Plug...... 3 aabeea at alate Shuttle Valve to Electric Control Gasket. Spool Stop. : High-Low Shuttle Spool ....... Shuttle Spool Spring... Shuttle Valve Body Pipe Plug ..... Valve Mounting Screw Lockwasher. fms ae et ee ee Nw tee ee ene enssanne ary. ITEM 28 29 30 31 32 33 34 35 36 37 38 39 40 a1 42 43 44 45 46 47 48 49 50 51 52 Note: DESCRIPTION Valve Mounting Screw Valve Mounting Screw Lockwasher. Valve Mounting Screw ..... Shuttle Valve Solenoid Solenoid Coil..... Shuttle Valve Solenoid “O" Ring....... “O" Ring....... Shuttle Valve Solenoid “O” Ring. . 1st Speed Shift Spool............ SPHNQ. eee eee eee e ee eeeeee ee eeeeee Shuttle Valve Solenoid sas aaaaaeen Plug Stop .. Roll Pin Spool Stop Shift Spool Spool Position Spring. Bore Plug “O” Ring. Valve Housing Spool Bore Plug. . Piston Housing Assembly.........+ Stop PIG... ce eee eeeeee eee Plug "0" Ring . Piston “0” Ring Glyd Ring........ PION os wezones « Piston Housing. . . . “O" Ring. ..... Items 53 thru 56 are various declutch options.FIGURE GCHARGING PUMP & VALVE ASSEMBLY GROUP ITEM DESCRIPTION ory. item DESCRIPTION ary. 1 Valve Stop Roll Pin 1 22 Thrust Plate Seal .......0.000eeeeeee 2 2 Valve Stop... 1 23 Pump Drive Shaft Assembly 1 4) SiHIE Lge ox ge emewes oc mae 1 24 Pipe Plug........ 1 Be Ballewoevanor on nosnie 1 25 Pump Mounting Stud... 2 5 Valve Stop “0 Ring .. 1 26 Pump Drive Gear Oil Seal . 1 6 Valve Piston ..........006+ 1 27 Pump Mounting Screw Lockwasher.... 3 7. Valve Spring = Inner.......+ 1 28 Pump Mounting Screw . 3 8 Valve Spring - Outer 1 29 Safety Valve Spacer 4 a 9 Regulating Valve & Filter Adaptor 30 Safety Valve Poppet.........csese008 1 ‘Aasemhy ai ' 31 Safety Valve Seat... .......seseees 1 10 Pump Mounting Stud Lockwasher..... 2 52° Safaty’ Valve’ Spring « 1 11 Pump Mounting Stud Nut........ 2 33 Safety Valve Retainer. ......- 4 TRIP Assarnbly. ! 34 Pump Assembly to Converter Housing 13 Valve to Pump Capscrew. . 2 Gasket. 1 14 Valve to Pump Capscrew Lockwasher 2 35 Pump Body .. 1 15 Valve to Pump Capscrew. 1 36 Valve Mounting Screw. seems & 16 Valve to Pump Screw Lockwasher..... 1 37 Valve Mounting Screw Lockwasher.... 4 17 Valve to Pump Gasket... . 1 38 High Clutch Pressure “O” Ring. . 1 18 Thrust Plate & Bearing Assembly 2 39 Valve to Converter Housing Gasket.... 17 19 Pump Driven Shaft Assembly ... 1 40 Control Valve Assembly........... 1 20 Thrust Plate & Bearing Assembly 2 41 Valve Mounting Screw Lockwasher 5 21 Wave Spring......+++++ 2 42 Valve Mounting Screw. ........ 5CONVERTER LOCK-UP OPTION Heat Exchanger ‘Check Point wa" Heat Exchangor cee. |v Pent "A" HR-MODEL utpur—Resr Parking Brake—Option Brosther Por ‘SEE NOTE, Part“ SEE NOTE , Port" oy « y ‘Comerir Inlet Port Ports reser Check Point ‘Gheck Point "6-c" ° Heat Exenangor Dipstick Init Temperature 494 Clutch Pressure Check Poi Check Point "88" f Hest Exchanger | Outlet Prossure [F ceround oriven Emergency Steering Pump Onve & Port" Udbe Pressure Check Polat 15:25 PSI [100-172 KPa) ‘at 2000 RPM and 180° 200°F, {82°.93°0} at Comertor Out. FRONT VIEW Figure HCLARK —— Charge Pump foe emote Fat Option check Point for Forward Moculatea Guten Notes Hese Lino Operating Requirements: sure Linos_ Sulable fr operation from ambient to 250°F. [121°C cominuous operating Temperature. Must wiistans 300 PSI [2068 is) ontnuous prassure, with 600 PSI [4157 Kal Imermitnt Surges. Abt SA.E. Spec. No 517, 100R Hydraulic Hose Specticatons ‘S00 Lubrication Specications {Ale lines used must contorm 10 SAE, Spec. No. J 1018 Toss and Prosedures fr High Tommperature Tanemission Ol Hose. Pod "L"—Conertar Out Temperature Fortis tobe used for Converter Outlet Temperature pickup. Gauge Ist be located In the Operator Compartment See Ol! Temperature Gauge Speciications. Pott "M"—Converter Out Pressure Pressure must be measured curing normal venice "Procucton Line” test. Conorter ‘ute pressure equals the total pressure top of Heat Exchange, Hoa! Exchanger {nee ana back pressure of tho anemision lubreaion eystom, Fi 1a | (| REMOTE FILTER OPTION — Port “F* Fogulator Vane Pressure 240-280 PSI (1655-1851 4Pat Port “6 Forward Clutch Pressure papi ovoree Clutch Pressure Modules Reverse Clutch Pressure Prt on Modutor Valve (il Temperature Gauge Specications: 1, Normal Operating Tomperature: 180280°F.J82-121*C] 2. Red Lined Temperature: 250°F, [121°C] Test Condon: 1. Converter Outlet i Temperature seoz20"r.fs2-104°C), 2. Transmission in Neva Operating Specifications: "25 PSI [7S kPs) Min. prossure at 2000 FRPW engine soced and a max. of 70 PSI [683 kPa) allt preseure at a noload governed speed Ports" ang ou ‘These pots can bo usod for flé "Touble Shooting” or wohise "Production Line" toes. Ports "FU" and ‘These pots are 10 be Used as check points foromal woncle "Praduston Line" test. Port “F"-ciuton Preseure This recommended that lich pressure ‘be monitored by a gauge having an indicator lal range of Oo 400 Pst [0 0 2758 4Pa) land located inthe Operator Compartmant Ports “@" and “H-Backup Warning “Those ports are provided for installation ‘of Backup Preseure Switch for Warning tigate Hor: igure H6 phate catch ‘hietses Bearing 23183) MECHANICAL DISCONNECT MECHANICAL DISCONNECT Front Shown WITH SPEEDO Rear Available Rear Shown Figure |Assomble ol filer and tighten 20 to 25 Lbs Ft, [27.2008 Nm] AA Teton sas most eas poet a ‘Must be loose internal ft bearing with @ No.3 tened on the besring. 10-0uter stool pate, 10:iner friction plates. [Atomately assemble, stating with ‘uter ste! plate ‘utr stool plates. Ginner friction plates. ‘Aternately ascomle, starting with ‘uter sie! plate, 12outer ste plates, 12iner friction plates, Aternately assemble, starting wth ute stet plate DA Maton 200 0 250 Los [271 2.8989 Nm) ‘Special bearing foadlng roiches ‘opposite snap tng. Bend look tabs afer ightning ‘2p screws to proper traue, Tighten ol screen assy 10to T8 Lost [136-203 Nm) Low, Forward and Reverse Clutch Springs - Goncave ide of et Bolovile spring tobe placed against utc piston. Femalning sh springs of each clutch to be stacked atornatolyrovorsed as shown, ‘Shim output shat bearings to produee 6 108 Lbs. In [0,68-0,90 Nm] pretoad, Clean mounting surfaces and tapped holes with solvent. Dry thoroughly, being certain tapped holes are {ty and clan. See text for proper int Tighton 200-250 Lbs. Ft. [271,2:338,8 Nm) ‘and ‘stako nut socuely ito stat notch. tion. A ‘Stator suppor serow assembly: (Viow “S") 1. Clean stator support mounting surface and {tapped Polos wih solvnt. Ory thoroughly, bong corlan lapped hol ar clean and dry. 2 Insal 6 special stator suppor screws. Tighion ‘screws 12 0 16 Lbs. FL. [162.216 Nm] forave, Notes ‘Allied in chamfos for ol seal, piston Fings. and "O'rings must be smoath and free trom burrs. Ingpoct at assembly. Lubricate all piston ring groavos and rings with ol botore assombly. ‘Apply a thin coating of grouse botwot se ips on lip type seas pio to assembiy ‘Apo a very ligt coat of Permatex No. 216 (010. of allo seals and bore pluge batore ay. ‘ABBY aight coat of Loctite No. 92 ‘oral plug tveads. ‘Apply alight coat of Permatex No. 2t0 alliva hole stud threads. ‘After assembly of parts using Loctite or Permatex, there must not be any foe for excess material which might enter the of cru view “7 Z REVERSE IDLER Enlargad vow of slater supp baton expander Ercan gp tom LT) ppt 100% ten fg hook ito aid esse 3st (om Caution: ‘Assembly of stator support to converter housing must be completed within 85 ‘minute pecod fom sat of secon instalation. The special serow sto bo teed for one Insalabon only I scr” is removed for any reason, it must be replaced. The Lacie lt inthe holes must be removes withthe prope tap Gnd cleaned win satan. Ory hole ‘thoreughly and use a new screw for reinstatiaton, Ser Sauten, view “s" Tora Spacieaon fr Lbicaed Grados CQ “5 og Seow Pease Grace 8 NOW] —__ FINE THREAD COARSE THREAD ENE THREAD ‘COARSE THREAD Se et cabaret weet et Fa ee sa} pena | Paes seg [eos | fogs sam |p are | tee eas soos | foe sas sts | Pose ei [ar et | feos s6a) || ae | far eo | sar | Pro Som| orto | Terese [eres ora ang) [ooo | fens eeay | oo on | foes 9. as] at T00 | ase-Tosg [ee ao | firie tea || an-var | vag tors] | vas [ [a0 eal feeo| ionsver[ restora) [asa vee reas soon] | vo toa | oto. aons] | 9s sear Soo -tessas | ess asem[ aon-zeo [ents eee ][ate-a | wentarest | en ato | Teo Figure |MAINTENANCE AND SERVICE ‘The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence thet ‘would normally be followed after the unit has been femoved from the machine and is to be complotely tvorhauled. It must also be understood thet this is @ basic 24000 4 speed long drop output transmission with many aptions, The units are very similar to trouble shoot, disassemble, repair and reassemble. CAUTION: Cleanliness is of extreme importance and an absolute must in the repair and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and 39 matter entering the mechanism, DISASSEMBLY Side view of the HR24000 4 speed transmission with ‘electric control valve and modulation. Figure 2 ‘Remove ou titer element. itis recommended a small pan be Used to catch re ing oil in element. Figure 3 Remove pressure regulating val screws, stud nuts and washers. fe and charging pump Figure 4 Remove regulating valve and pump essembly.Figure 11 Figure 14 Remove drive plate sttaching cap screws. Some units will Remove turbine hub to turbine shaft retainer ring. have stud nuts and washers. Figure 12 Figure 15 Remove drive plate and backing ring. Remove impeller cover to impeller cap screws. Figure 13 Figure 16 Remove impeller cover bearing cap. Remove impeller cover and turbine as an assembly.Figure 17 Remove turbine hub to impeller cover bearing retainerring, Figure 18 ‘Tap turbine and hub from impeller cover. Figure 19 Remove impeller cover bearing. IMPELLER COVER AND TURBINE REASSEMBLY (See cleaning and inspection page.) Figure 20 Install impeller cover bearing in cover with bearing locating ring up. If the turbine or turbine hub was replaced or di ssembled, this procedure must be used for reassembly. TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS 1. Clean hub mounting surface and tapped holes with solvent. Dry thoroughly being certain tapped holes are dry and cle 2. Install backing ring and special screws to approximately 08 inch [1,5] of seated position. With a calibrated torque wrench, tighten screws 37 to 41 Ibs. ft. torque [50,2-55,6 N.m.J. NOTE: Assembly of turbine hub must be completed within 9 fifteen minute period from start of screw installation. The screws are prepared with 2 coating which begins to harden after installation in the hub holes. If not ‘tightened to proper torque within the fifteen minute period, insufficient screw clamping tension will result. The special screw is to be used for one installation only. If the screw is removed for any reason it must be replaced. The compound left in the hub holes must be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use @ new screw for reinstall Figure 21 Position turbine assembly in impeller cover.& Figure 25 Figure 22 Remove reaction member. NOTE: Some units will have @ Install turbine hub to impeller cover bearing retainer ring. fixed reaction member and some units will have @ free- wheeling reaction member. The fixed is a one piece andthe freewheeling is an assembly. Remove as an assembly. Figure 23 Remove turbine locating ring from turbine shaft ae Remove reaction member spacer. Figure 24 Figure 27 Remove reaction member retainer ring. Remove impeller and hub assembly.Figure 31 Seperate converter housing from transmission case ‘assembly. NOTE: Reverse, second, third and fourth clutches will remain in the converter housing. Figure 28 Remove oil baffle retainer ring. Figure 29 Figure 32 Pry oil baffle from housing. NOTE: A resistance will be Remove 3rd speed clutch dise hub snap ring, retainer outer noted because of the heavy oil sealing ring. ring and retainer. (Q) Figure 30 ‘Support converter housing with a chain hoist. Remove Figure 33 converter housing to transmission case bolts. Remove dise hub retainer ring and disc hub.& Figure 34 Remove 2nd speed clutch disc hub snap ring, retainer outer Figure 37 ‘ing and retainer. Remove the low clutch and idler shaft rear bearing cap bolts Figure 35 Remove disc hub retainer ring and disc hub. Figure 38 Remove low clutch rear bearing cap. Figure 36 Using an impact wrench (ifavailable), if nota flange retainer ‘bar must be used to hold the companion flange from ‘uring, loosen output flange nut. Remove nut, washer, “0” Figure 39 ring and flange, Remove idler shaft bearing cap.Figure 40 Remove the rear output flange nut, washer, “O" ring and flange. @ Figure 41 Remove output shaft rear bearing cap bolts. FO Figure 42 Remove bearing cap. Figure 43, Remove flange spacer or speedometer drive gear. 2 * i | Figure 44 Remove the 1st clutch rear bearing locating ring s Figure 45 Remove the idler shaft rear bearing locating ring,CLARK : es J & s ee / 1 Figure 62 Figure 55 Remove besring spacer. Remove idler shat front bearing Figure 63 Figure 56 Remove idler shaft assembly. Remove oil sump oil baffle. Figure 57 Figure 64 Remove forward clutch drive gear retainer ring and driv Remove 1st speed clutch assembly. gear. See Figure 57-A. —10—Figure 57-A. Figure 60 Remove sealing ring sleeve. Figure 58 Figure 61 Remove forward clutch assembly. Remove forward clutch rear bearing, Figure 59 Figure 62 Remove output shatt front bearing cap bolts and washers. Remove sealing ring sleeve retainer ring, auFigure 63 Figure 66 Remove bearing cep and shims. Unelinch lock nut by straightening upset metal in notch in idler shaft. Remove shaft nut Figure 64 Remove output shaft front taper bearing cup. Figure 67 Repest procedure in Figure 66 for reverse idler shaft. CONVERTER HOUSING DISASSEMBLY iP Figure 65 ‘Spread reverse clutch front bearing locating ring. Pry clutch Figure 68 ‘assembly from housing. Remove bearing spacers. —12—Figure 69 Remove reverse idler gear and outer taper bearing. Remove taper bearing and thrust plate. Remove shaft. Use Yes caution as not to lose lock ball Figure 70 With the help of an assistant, spread the 4th speed clutch front bearing locating ring and pry clutch from converter housing while the assistant removes the idler gear and outer taper bearing, Figure 73 Repeat procedures in Figures 71 and 72 for idler shaft removal Figure 71 Figure 74 sing e soft bar, drive reverse idler shaft from taper bearing Spread the turbine shaft bearing locating ring. =13—Figure 75 Figure 78 Holding ring open, tap turbine shaft from stator support. Remove pump idler gear retainer ring. Figure 76 Figure 79 Remove turbine shaft, Remove idler gear. Figure 77 Figure 80 used, remove auxiliary pump drive gear cover and gasket. Remove the charging pump drive gear support bolts. agFigure 84 If stator suppor is to be replaced, remove support screws and tap support from housing Figure 81 Remove drive gear and support assembly. See Figure 333 for oil ‘1st CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY Pe Figure 82 Remove the auxiliary pump drive gear support bolts Figure 85 Remove front bearing. ity s Figure 83 Figure 86 Remove auxiliary pump drive gear. Remove bearing spacer. —15—e % Figure 96 Figure 93 Remove piston return spring (Belleville washer) retainer ring retainer. Figure 94 Remove return spring retainer ring, > Figure 95 springs. (Belleville washers). NOTE: Belle- vile washers in the 1st clutch are diferent then washers in the forward and reverse clutch. Tst clutch washers have () four holes in them (for identification ony). Do not mix ‘st clutch wa washers. Remove piston spacer. Figure 97 ‘Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston, (See cleaning and inspection page.) 1st CLUTCH REASSEMBLY -W7- Figure 98 Install clutch piston outer seal ring. NOTE: Ring must be sized before installing in clutch drum. Sizing is best accomplished by rotating piston while holding @ round object against the new seal ring as shown. Rotate piston Until seal ring is flush with outer diameter of piston.Figure 99 Install clutch piston inner seal and size as explained in Figure 98. Figure 100 Position piston in 1st clutch drum as shown. Use caution as. not to damage inner and outer piston sealing rings. Figure 101 Position piston return spring spacer over clutch shaft. Figure 102 Install Belleville washers (piston return springs}. S in Figure 95. First washer with large diameter spacer. Alternate seven (7) washers. See Figure 105-A, Figure 103, Install piston return spring (Belleville washers) rot con clutch shaft. ~ Figure 104 Using a sleeve with the proper inner diameter, drive the Belleville washer ring into position. NOTE: Be certain retainer ring is in full position in ring groove. =iFigure 107 i Install one friction disc. NOTE: The friction discs in the low Figure 105 clutch has a higher co-efficient rating than the friction discs Position ring retainer washer over retainer ring inthe otherclutches, therefore the discs must not be mixed. ‘The low clutch friction disc has a yellow mark of nonsoluble paint on the outer diameter for permanent identification, Alternate steel and friction discs until the proper amount of, discs are installed. First disc next to the piston is steel. last disc installed is friction, Figure 105-A, Cross section of 1st clutch. Figure 108 Install clutch disc end plate. eE™ uc = = Figure 108 Figure 109 Install one steel dis. Install end plate retainer ring. —19—CLARK Figure 110 Install clutch gear inner bearing, NOTE: This bearing does rot have shield in it. Figure 111 Position bearing spacer on clutch shaft. ~ Figure 112 Install low clutch driven gear and hub into clutch drum, align splines on clutch hub with internal teeth of friction, discs. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction dises. Figure 113 Install clutch gear outer bearing. NOTE: Outer bearing has a shield in it, this shield must be up. Figure 114 Position front bearing spacer on clutch shaft. Figure 115 Install front bearing, —20—REVERSE AND 2nd CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY (Reverse being disassembled) Figure 116 Remove clutch shaft oil sealing rings. Figure 117 Remove front bearing retainer ring, Figure 118 Remove front bearing. aa Figure 119 Remove clutch gear bearing retainer ring. Figure 120 Pry reverse gear from clutch assembly far enough to use @ ‘gear puller. Figure 121 Remove reverse gear and bearing spacer.Figure 125 Remove inner reverse gear taper bearing Figure 126 Figure 123 Compress piston retum springs (Belleville washers) Remove end plate. Remove return spring retainer ring end ring retainer. Figure 124 Figure 127 Remove inner and outer clutch discs. Remove piston retum springs. (Belleville washers.) —22-Remove piston spacer. ~ a, Po Figure 129 Remove clutch piston, DISASSEMBLY OF 2nd SPEED CLUTCH Figure 130 Remove end plate retainer ring Figure 131 Remove end plate Figure 132 Remove inner and outer clutch dises. Figure 133 Compress piston return spring retainer. Remove retainer ring.Figure 134 Figure 137 Remove spring retainer and return spring. Install clutch piston in clutch drum. Use caution as not to damage seal rings. ‘> ~ Figure 135 Remove clutch piston. Figure 138 {See cleaning and inspection page.) Position piston return spring ‘and spring retainer on clutch shat. 2nd CLUTCH REASSEMBLY ¥ “ « Figure 136 Install clutch piston outer and inner seal rings. Size rings as Figure 139 explained in Figure 98. Compress spring and install retainer 24Figure 140 Figure 143 Install one steel disc Install end plate retainer ring. REVERSE CLUTCH REASSEMBLY ™~ Figure 141 Install one friction dise. Alternate steel and friction dises ‘ntl the proper amount of dises are installed. First disc next Figure 144 to the piston is steel, last disc installed is friction, Install clutch piston outer and inner seal rings. Size as ‘explained in Figure 98. & Figure 145 Figure 142 Install clutch piston in clutch drum. Use caution as not to Install clutch dise end plate. damage seal rings. —25—Figure 146 Figure 149 Install one steel dise. Install end plate retainer ring. Figure 147 Install one friction disc. Alternate steel and friction discs Until the proper amount of discs are installed, First disc next Figure 160 to the piston is steel, last disc installed is friction. Position piston return spacer over clutch shaft. Figure 181 Install Belleville washers. First washer with large diameter Figure 148 toward spacer. Alternate seven (7) washers. See Figura Install cluteh dise end plate. 152-8. ~26—Figure 149 Install clutch dise end plate. Figure 150 Install end plate retainer ring, Figure 151 Install new piston ring expander springs per instructions on page 50, -27— Figure 152 Install piston rings on clutch shaft per instructions on page 50, (each on standard converter, 4 each with lockup converter REVERSE AND 2ND CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY (2nd clutch being disassembled) Figure 153, Remove end plate retainer ring. me + Figure 154 Remove end plate,CLARK Figure 187 Install front bearing retainer ring, Figure 160 Remove front bearing retainer ring. —— Figure 158 Install clutch shaft oil sealing rings. Grease rings to facilitate reassembly into front housing. 3rd AND 4th SPEED CLUTCH DISASSEMBLY AND REASSEMBLY Figure 161 Remove front bearing. DISASSEMBLY (4th being disassembled) Figure 162 Remove clutch shaft oil sealing rings. Remove gear front thrust washer. —28—CLARK ~& > ue RX , Figure 163 Remove thrust washer lock ball 3 Figure 164 Figure 167 Remove clutch gear and disc hub. Remove inner bearing Figure 165 Figure 168 Remove clutch gear outer bearing Remove gear rear thrust washer. —29—Figure 169 Remove thrust washer lock ball. 5 ! Figure 170 Remove thrust washer locating ring. ~~“ Figure 171 Remove clutch disc end plate retain Figure 172 Remove end plete, Figure 173 Remove inner and outer clutch discs. Figure 174 Remove clutch disc return spring retainer ring. —30—XQ : Figure 175 Figure 178 Remove spring retainer and spring. Remove end plate. % Figure 176 Remove eluteh piston. Figure 179 Remove inner and outer clutch dises. DISASSEMBLY OF 3rd SPEED CLUTCH — an Figure 177 Figure 180 Remove end plate retainer ring Remove return spring retainer ring a3CLARK Figure 181 Remove spring retainer and spring. ae be Figure 182 Remove clutch piston. (See cleaning and inspection page.) REASSEMBLY OF 3rd SPEED CLUTCH Figure 183 Install clutch piston outer and inner explained in Figure 98. rings. Size as Figure 184 Install clutch piston in clutch drum. Use caution as not to damage seal rings. Figure 185 Position return spring and spring retainer on clutch shat. Figure 186 Compress return spring and install spring retainer ring —32—Figure 187 Figure 190 Install one steel disc. Install end plate retainer ring. REASSEMBLY OF 4th SPEED CLUTCH Figure 188 Install one friction disc. Alternate steel and friction discs Until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction. Figure 191 Install clutch piston outer and inner seal rings. Size as explained in Figure 98. Figure 192 Figure 189 Install cluteh piston in clutch drum. Use caution Install end plate. damage seal rings. not to —3—Figure 193 Position return spring and spring retainer on clutch shaft. Figure 194 Compress return spring and install spring retainer ring. Figure 195 Install one steel disc. —34— Figure 196 Install one friction disc. Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction. cs ™~ Figure 197 Install end plate, = % Figure 198 Install end plate retainer ring.Figure 199 Figure 202 Install inner thrust washer locating ring. Install clutch gear inner bearing. Pte = € Figure 200 Position lock ball in hole in shaft. A small amount of g Figure 203 will hold ball in place. Install bearing spacer. Figure 201 Position inner thrust washer on shaft aligning notch in Figure 204 Washer with lock ball. Install outer bearing. —35—: a Figure 208 Install clutch shaft front bearing, NOTE: Bearing outer diameter locating ring groove must be up. Figure 205 Install clutch driven gear and hub into clutch drum. Align splines on clutch hub with internal teeth of friction discs. Figure 209 Figure 206 Install bearing retainer. Position lock ball in hole in shaft. ae Figure 210 Install clutch shaft oil sealing rings. Grease rings t© facilitate reassembly into front housing. Figure 207 Position outer thrust washer on shaft aligning notch in washer with lock ball —36—FORWARD CLUTCH “ DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 214 Compress piston return springs (Belleville washers), Remove retum spring retainer ring and ring retainer. Remove clutch disc end plate retainer ring, Figure 215 Remove piston return springs. (Belleville washers) Figure 212 Remove end plate ‘~ors Figure 213 Figure 216 Remove inner and outer clutch dises. Remove piston spacer —37—Figure 217 Remove clutch piston. Remove clutch shaft ol sealing rings Figure 220 and expander springs. Position piston return spring spacer over clutch shaft. {See cleaning and inspection page.) FORWARD CLUTCH REASSEMBLY 7 S Figure 221 Install Belleville washers. First washer with large diamete! toward spacer, Alternate seven (7) washers, See Figure igure 218 222-8, Install clutch piston outer and inner seal rings. Size as ‘explained in Figure 98. Figure 222 Install piston return spring retainer ring retainer and Figure 219 retainer ring on clutch shaft. Compress return springs and Install clutch piston in clutch drum. Use caution as not to install retainer ring. Be sure ring is in full position in damage seal rings. retainer —38—PISTON Figure 222-A Figure 223 Install one steel disc. Figure 224 Install one friction dise. Alternate st Until the proper amount of discs are to the piston is steel, last disc installed is friction. Figure 225 Install clutch disc end plate, and friction discs led. First disc next —39- Figure 226 Install end plate retainer ring. Install new expander springs ‘and clutch shaft oil sealing rings. OUTPUT SHAFT DISASSEMBLY Remove rear taper be:OUTPUT SHAFT REASSEMBLY Figure 228 Figure 231 Remove output gear. Install output shaft front taper bearing, large diameter of taper down. Figure 229 Figure 232 Remove gear spacer. Position gear spacer on output shaft ¢ » Figure 230 Remove front taper bearing. mr Figure 233 (See cleaning and inspection page.) Position output gear on shaft with long hub of gear up —40—at F pene Figure 237 Install output shaft rear teper besring, large dlameter of igure taper down. per bearing, Ira Remove small idler gear. NOTE: Some special ratio unite will ave onty one idler geet. IDLER SHAFT DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 238 Remove large idler gear. Figure 235 Remove idler shaft bearing retainer nut. Pry idler shaft rear bearing up far enough to use a bearing puller. er a> 7 Figure 236 Figure 239 Remove rear bearing. Remove gear spacer. —a1-cleaning and inspection page.) j IDLER SHAFT REASSEMBLY m (se Figure 243 Install idler shaft rearbearing, outer locating ring groove up, Install bearing retainer nut, tighten nut 200 to 250 ft. Ibs, torque [271,2 - 338,9 N.m}. Figure 240 (See cleaning and inspec Position gear spacer on shat. n pag REASSEMBLY OF TRANSMISSION Figure 241 Figure 244 orion large ilar gear on shat with long hub on gor init forward chsh rear Bearing wth beating locating tg toward font of tanariscon cae ia Figure 242 Figure 245 Position small ier gearon shat wth long hub of gar Agncutchoilseting ing sleeve with notch in case Tap Po sles ito poten —42—Figure 246 Figure 248-A Install sleeve retainer ring * Figure 247 Position forward clutch assembly into sleeve, use caution Figure 249 1s not to damage oil sealing rings on clutch shaft. Install idler shaft front bearing, Figure 248 Position forward shaft gear on rear of clutch shaft with long hub of gear toward bearing. Install gear retaining ring. See Figure 250 figure 248-4 Install 1st clutch assembly in case. —43—eure 251 Figure 254 igure Install bearing cap capscrews and washers, tighten to Install idler shaft assembly into front bearing. specified torque. (See torque chart te. Al Figure 252 Figure 255 Install output shaft front bearing taper bearing cup with Position oil baffle in transmission sump. large diameter of taper in Figure 253 Coat outer diameter of ol seal with Permatex #2 and press SO s0al in bearing cap with lip of seal in, Remove any excess Figure 256 sealant, Install new "0" ring on bearing cap. Install front Position output shaft assembly in front bearing bore, use bearing cap and shims. caution as not to damage front oil seal —4a-CLARK Figure 260 Position a new gasket and “O" ring on rear of housing. A light coat of chassis grease will hold the gasket in place, Install two aligning studs in housing, this will facilitate alignment of rear cover to housing. Figure 257 Install 1st clutch rear beating spacer. Figure 258 Install 1st clutch rear bearing, NOTE: Bearing loceting ring Figure 261 groove must be out. Position lock ballin idler rear bering. Figure 262 Align lock ball in idler shatt rear bearing with notch in rear transmission cover. Tep cover in place and secure with Install bearing retainer ring. bolts and washers, Remove aligning studs. Figure 259 —45—Figure 266 Figure 263 install bolts and washers and tighten to specified torque. Tighten cover bolts to specified torque. (See torque chart (See torque chart) Figure 267 Figure 264 From the front, tap the idler shaft to the rear until the rear Position speedometer gear on output shaft. (Optional - not bearing locating ring groove is exposed. Install locating used on all models.) ring, Figure 265 With rear taper bearing cup in rear beering cap, apply @ very, Figure 268 light coat of Permatex #2 to the outer diameter of the rear From the front, tap the 1st clutch to the rear until the rear ‘output oil seal. Press seal in bearing cap with lip of sea in. bearing locating ring groove is exposed. Install locating With new “O" ring in position, install bearing cap. ring. —as—OUTPUT SHAFT ROLLING TORQUE PROCEDURE (Bearing Preload) Figure 269 Position new "0" ring and gasket on 1st clutch rear bearing Figure 272 a ‘Tap output shaft front and rear to seat taper bearings. Loosen front bearing cap bolts. Using an inch Ib. torque wrench, determine the rolling torque of the output shaft and record. Tighten front bearing cap bolts to specified torque, Check rolling torque with bolts tight. Torque must be 6 to 8 inch Ibs. [0,68 - 0,90 N.mj more than when bearing cap loose. Add or omit shims on the front bearing e the proper preload, Figure 270 Install capserews and washers, tighten to specified torque. (See torque chart) Figure 273 Install output flange, new "0" ring, washer and nut. Figure 271 Figure 274 Position new gasket on idler shaft bearing cap. Install Using a flange retainer to prevent output shaft from turning, bearing cap, bolts and lockwashers, tighten to specified tighten flange nut 200 to 260 ft. bs. torque. [271,2 - 338,9 torque. (See torque chart.) Nam. —47—Figure 275 Install front output flange, “O" ring, washer and nut, Tighten as explained in Figure 274, mS ° @x. Figure 276 Figure 279 Position the 3rd clutch disc hub on the idler shaft. Install Install the 2nd clutch disc hub on the 1st clutch shaft, disc hub retainer ring, Install dise hub retainer ring. Figure 277 Figure 280 Install dise hub retainer ring retainer. Install retainer ring retainer, —a8—Figure 281 Install retainer retainer ring. Figure 282 Position new "0" rings and gasket on front of transmission housing. A light coat of chassis grease will hold “O” rings and gasket in place. (See cleaning and inspection page.) CONVERTER HOUSING REASSEMBLY Figure 283 Install new sealing ring expander spring and oll sealing ring ‘on support. Expander spring gap to be 180° from sealing ring hook joint. Press support bearing into position. NOTE: Bearing part number must be up. Clean stator support mounting surface and tapped holes with solvent. Dry thoroughly, being certain tapped holes are clean and dry. —49— Figure 284 Position support in converter housing aligning holes in support with holes in housing. Tap support into position, STATOR SUPPORT SCREW ASSEMBLY: Install 6 special stator support screws. Tighten screws to 12-16 Ibs. ft. [16,3-21.6 Nm] torque. NOTE: Assembly of stator support to converter housing must be completed within a 15 minute period from start of strew installation. The special screw is to be used for one installation only. If the screw is removed for any reason it ‘must be replaced. The Loctite left in the holes must be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use @ new screw for reinstallation. Figure 285 Position auxiliary pump drive gear, bearing and support in housing. =a. Figure 288 Align holes in bearing support with holes in housing. Install support screws and washers. Tighten to specified torque. (See torque chart)