Maintenance and Service Manual 24000 | Ssxgy Powershift i Pe Transmission & R-HR & LFHR MODEL B 3 SPEED LONG DROP (LOCK-UP & FREEWHEEL) COMPONENTS CLARIC-HURTE> E AHR & LHR24-3 LO 12.92Service Publications 1-77 at 1-40, Rt. 18, Box 38 Statesville, NC 28677 TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the NOTE: If the transmission has 4 wheel drive, rear wheels off the ground or disconnect the disconnect both front and rear drivelines. driveline to avoid damage to the trans- Because of the design of the hydraulic ion during towing. system, the engine cannot be started by pushing or towing, (©Copwiht Clark Eapmont Company, 1981, 1892 ‘Unpubished matte igh roseeod No par of te werk may be reproauces nary frm under dy means without det writen parmsson of Ca Equipant CompanyFOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the CLARK-HURTH COMPONENTS product. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only Clark- Hurth Components-approved parts as listed in the applicable parts manual should be used. Use of “will‘it” or non-approved parts may ‘endanger proper operation and performance of the equipment. Clark- Hurth Components does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design ...... Converter and Transmission Case Group Converter Group Three Speed Clutch and Gear Group ........... Clutch Group Control Valve Assembly Charging Pump and Regulating Valve Group . External Plumbing and Pressure Check Points Assembly Instructions. Speed Sensor Installation .......... DISASSEMBLY OF TRANSMISSION . REASSEMBLY OF TRANSMISSION CLEANING AND INSPECTION SERVICING MACHINE AFTER TRANSMISSION OVERHAUL ...... TOWING OR PUSH STARTING SPECIFICATION AND SERVICE DATA LUBRICATION .... ‘TROUBLE SHOOTING GUIDE CLUTCH AND GEAR ARRANTEMENT ..............05 POWER FLOW... ELECTRIC SOLENOID CONTROL ... CONTROL WIRING DIAGRAM DRIVE PLATE INSTALLATION... TRANSMISSION TO ENGINE INSTALLATION PROCEDURE R MODEL SECTION LHR SECTION 0.2.0.0... sceeeeeeeeeee eee NOTE: Metric Dimensions Shown in Brackets [ ]. Fig. Fig. 8 Fig. C Fig. D Fig. E Fig. F - Fig. - Fig.H Fig. | Fig. J . 51 52 53 53 54 55 56-57 58 59 60 61 . 63HOW THE UNITS OPERATE The transmission and hydraulic torque portion of the power tra engine power to the driving wheels. In order to properly m to first understand their function and how they operate. enacts an important role in transmitting ain and service these units it is important The transmission and torque converter function together and operate through a common hydraulic system. It is necessary to consider both units in the study of their function and operation. To supplement the text below, and for reference use therewith, the following illustrations are provided: ‘SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Fig. A ‘Convertor and Transmission Case Group Fig. B Converter Group Fig. Three Speed Clutch and Gear Group «..... Fig. Clutch Group Fig. Control Valve Assembly Fi. F Charging Pump and Regulating Valve Group . - Fig. G Extemel Plumbing and Pressure Check Points Fig. H ‘Assembly Instructions... Fig. Speed Sensor Installation 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 engine. The MHR version is @ 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 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 oll under pressure to the desired directional and speed clutch. A provision is made on certain models to neutralize the transmission when the brakes are applied. This is accomplished through use of a brake actuated shutoff valve. The speed and direction cluich assem- blies are mounted inside the transmission case and are connected to the output shaft of the converter either by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction. rectly on the side of the converter housing or front ‘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.With the engine running, the converter charging pump draws cil from the transmission sump through the removable oil suction screen and directs it through the oil filter and the pressure regulating valve. The pressure regulating valve maintains pressure to the transmission control caver 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 a closely fitted bore. The valve spool is spring loaded to hold the valve in a closed position. When a specific pressure is achieved, the valve spool works against the spring until @ port is exposed along the side of the bore. This sequence of events provides the proper system pressur 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 oll 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 oil then gravity drains to the transmission sump. The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com- ponent which starts the oil flowing to the other components which results in torque multiplication. This el- fement can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque. The reaction member of the torque converter is located between and at the center or inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. The torque converter will multiply engine torque to its designed maximum mul ratio when the out- put shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque ‘multiplication is increasing. The shift control valve assembly consists of 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 regulat- 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. When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector spool. The same procedure is used in the speed selector. The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hy- draulically actuated piston. The piston is “oil tight” by the use of sealing rings. A steel dise with external splines is inserted into the drum and rests against the piston. Next, a friction dise 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 Hubwith 0.D. splines is inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direc- tion as long as no pressure is present in that specific clutch.To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows oil under pressure to flow from the control valve, through a passageway, to a chosen clutch shaft. This shaft has a drilled passageway for oil under pressure fo enter the shaft. Oil pressure sealing rings are located on the clutch shaft. These rings direct oil under pressure to a desired clutch. Pressure of the oil forces the piston inst the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against the hub and clutch shaft to be locked together and allows and dises dises with teeth on the inner diameter, enabl them to drive as a uni ‘There are bleed balls or bleed orifices, depending upon the model, in the clutch piston which allow quick ‘escape for oil when the pressure to the piston is released. Figure AITEM evonsens " 12 B “4 15 16 v7 18 19 20 2 23 24 25 7 28 29 30 31 32 33 CONVERTER AND TRANSMISSION CASE GROUP DESCRIPTION Pipe Plug Air Breather . Pipe Plug Pipe Plug Converter Housing Sleeve Clip... Clip Screw Lockwasher ..... Clip Screw Clip Screw wees Clip Serew Lockwasher . lip Converter Housing Sleeve . .. Pipe Plug Converter Housing to Transmieion Case ‘Screw Lockwasher. Converter to Transmission Case Screw Pipe Plug Plug Hole Plug Gasket Case Assembly Hole Plug Converter Housing Screen Assembly Gasket . Screen Assembly .. Converter Housing to Transmission Case Gasket Converter Housing to Case Dowel Pin Cluteh Pressure Tube “O” Ring .... Lube Tube Sleeve ....... Tube Sleeve Cluteh Pressure Tube “O" Ring . Clutch Pressure Tube “O" Ring Tube Sleeve Clutch Pressure Tube “0 Ring Tube Sleeve Clutch Pressure Tube “0” Ring . ary 34 35 36 7 38 39 40 a 42 43 44 45 46 7 BSISRLBRI8ESE BIRZREBWLVL’B Figure B ITEM DESCRIPTION Transmission Case Assembly Tube Sleeve . Clutch Pressure Tube “O” ing . Rear Cover to Transmission Case Gasket Transmission Case to Rear Cover Dowel Pin Rear Cover Pipe Plug - Rear Cover Rear Cover to Case Screw Reor Cover to Case Screw Lockwasher Transmission Case to Rear Cover Dowel Pin Pipe Plug Pipe Plug . Magnetic Drain Plug Oil Battie Tube Clip . Clip Screw Lockwasher Clip Serew Suction Line Assembly “O" Ring ‘Suction Tube Assembly ‘Screw Lockwasher... ‘Suction Line Screw Clutch Lube Tube 3rd Speed Tube .. Low Speed Clutch Pressure Tube Speed Sensor Hole Plug ‘Speed Sensor Plug “0” Ring ‘Speed Sensor Adjuster Bushing ‘Speed Sensor Hole Plug Speed Sensor Plug "0" Ring Speed Sensor Adjuster Bushing . Speed Sensor Adjuster Bushing ‘Speed Sensor Plug "0" Ring Speed Sensor Hole Plug Dipstick Tube Assembly Dipstick PH AEMAS SAHA peo Ewa RBs oo aryFigure CITEM 1 2 3 4 5 6 7 8 9 10 " 12 13 14 15 16 v7 18 19 20 aa 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38 40 CONVERTER AND PUMP DRIVE GROUP DESCRIPTION Bearing Support Screw and Lockwasher. Idler Gear Bearing Locating Ring. .... Idler Gear Bearing Retaining Ring . Pump Drive Idler Gear. Idler Stub Shaft Bearing Boaring Retaining Ring Bearing Locating Ring. . Bearing Support Screw and Lockwasher. Bearing Locating Ring, Pump Drive Bearing Support Boaring Retaining Ring Pump Drive Gear Bearing . .. Bearing Locating Ring Pump Drive Gear Idler Gear Stub Shatt. 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 Auxiliary 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 Idler Shaft Lockball . : Reverse Idler Gear Bearing Thrust Pate. Reverse Idler Gear Bearing Assembly .... Reverse Idler Gear. ary. a 42 43 44 45 48 a7 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 74 75 76 7 78 79 Figure C ITEM DESCRIPTION Roverse Idler Gear Bearing Thrust Plate Bearing Retaining Plate Nut Turbine Retaining Ring Turbine to Hub Screw : od Turbine Hub Ring... Turbine Turbine Hub... : Impeller to Cover “0” Ring. . Impeller Cover . Turbine Hub Bearing Impeller Cover to Bearing Cap "0" Ring. Turbine Hub Bearing Retaining Ring Turbine Retaining Ring . Impeller Cover Bearing Cap Drive Plate Assembly. Drive Plate Drive Plote Backing Ring Drive Plate Mounting Nut. cesses Drive Plate Mounting Stud Lockwasher........ 10 Impeller Cover Stud. - 10 Impeller to Cover Screw... ....sseereereeens 24 Impeller to Cover Screw Lockwasher Retaining Ring . Froowhoe! Outer Race Snap Ring Freewheel Assembly Reaction Member. Impeller to Hub Bearing Spacer. Impeller to Hub Screw ... Impellor to Hub Serew Lock Tab Impeller... Impeller Hub “0” Ring Impeller Hub Gear Impeller Hub Gear Bearing - Idlor Shaft “O” Ring . Reverse Idler Shaft Oil Baifle Retaining Ring, Oil Battle Oil Seal : Oil Baffle Seal RingFigure DCLUTCH AND GEAR GROUP ITEM DESCRIPTION 1. Forward Shaft Pilot Bearing 2 Spring Retainer Snap Ring. 3. Spring Retainer 4 Piston Return Dise Spring 22.21.2121. 5 Piston Return Spring Spacer . 8 Forward Shaft, Drum & Plug Assembly” 7 Piston Ring Expander Spring 8 Forward Shaft Piston Ring 9. Piston Ring Sieove Retaining Ring 10 Piston Ring Sleeve 11 Forward Shaft Rear Bearing 12. Reverse & 2nd Shaft Piston Ring, 12A_ Piston Ring Expander Spring 13° Front Bearing Retaining Ring 14 Front Bearing Snap Ring . 15 Reverse & 2nd Shaft Front Bearing 16 Front Bearing Retaining Ring .. 17 Clutch Driven Gear Bearing 18 Bearing Retaining Ring... 19 Clutch Driven Gear Bearing Spacer 20 Reverse Clutch Gear 21 Baffle ing 22 Bearing Retaining Fing 23 Clutch Driven Gear Bearing |. 24 Spring Retaining Snap Ring 25 Spring Retainer 26 Piston Return Dise Spring 27 Piston Return Spring Spacer 28 Reverse & 2nd Shaft Drum & Plug Assombiy 29 Piston Return Spring 30 Spxing Retainer 31 Spring Retainer Snap Ring, 32 Reverse & 2nd Shatt Rear Bearing 33 Retainer Locating Ring. 34 Retainer Ring Retainer 35 2nd Clutch Oise Hub Retaining Ring 36 Battle Ring . . 37 nd Clutch Dise Hub * 38 Piston Return Spring 39. Spring Retainer 40 Spring Retainer Snap Ring” 41 3rd Shatt Plot Bearing 42 43 44 45 48 31d Clutch Dise Hub 47 31d Shaft Piston Ring | 447A Piston Ring Expander Spring 48 Front Bearing Retaining Ring 49 Front Bearing Snap Ring 50 3rd Shaft Front Bearing » 51 3rd Clutch Shatt, Drum & Plug Assombiy « 2 Front Bearing Cap Screw Lockwasher 53. Frong Bearing Cap Screw 54 Range Nut 85 Flange Washor 6 Hange“O" Ring 57 Front Outout Flange ary 58 59 60 61 8 Figure D Tem DESCRIPTION Front Bearing Cap Oil Seal Front Bearing Cap Bearing Cap Shim . * Front Bearing Cap "O" Ring Front Bearing Cup Front Bearing Cone Forward Shaft Gear : Goar Retainer Ring : Low Speed Clutch Shalt Front Bearing Front Bearing Spacor a Low Speed Shatt Rear Bearing Low Speed Gear Bearing Locating Ring Low Speed Gear Searing Spacer Low Gear Hub Batfle Ring .- Low Speed Gear Bearing tcaina Ring © Low Speed Gear Bearing Belleville Washer Retainer Spring Retainer Snap Ring Piston Retum Dise Spring Piston Return Spring Spacer Low Clutch Shaft Drum & Blood Valve Assembly Low Speed Shaft Rear Beating Spacer Low Speed Rear Beating . ‘Low Shaft Bearing Retainer Ring Low Shatt Piston Ring Bearing Cap Gasket Bearing Cap "0" Ring Bearing Cap Plug Rear Bearing Cap Bearing Cap Screw Lockwasher Boaring Cap Screw += = Idler Shaft Front Bearing» Idler Shaft Idler Shaft Rear Bearing Idler Shaft Rear Bearing Lock Ball Rear Bearing Locating Ring ......... Idler Shaft Nut Idler Shaft Bearing Cap Gasket Idler Shaft Bearing Cap... Idler Shaft Bearing Cap Screw Lockwasher Idler Shaft Bearing Cap Serew ‘Output Shaft... Output Gear Spacer ‘Output Shaft Geer Rear Bearing Cone Fear Bearing Cup . Rear Beering Cap "0" Ring Rear Beering Cap "0" Ring Rear Bearing Cap Rear Bearing Cap Screw Lockwasher Rear Bearing Cap Screw Roar Bearing Cap Oil Seal Rear Output Flange Flange “O” Ring Flange Washer Flange Nut Rear Bearing Cap Screw Fear Bearing Cap Screw LackwasherFigure EItem oon ITEM Bon rem Item evoaunan CLUTCH ASSEMBLY - 1ST DESCRIPTION ary iTem Backing Plate Retaining Ring ..... 6 Clutch Dise Backing Plate .......... 7 Cluteh Inner Dise 8 Clutch Outer Dise.........+ -10 Clutch Piston 1 DESCRIPTION Clutch Piston Ring - Outer. Clutch Piston Ring Inner... Low Clutch Shaft Drum & Bleed Valve Assembly. CLUTCH ASSEMBLY - FORWARD DESCRIPTION ary ITEM Backing Plate Retaining Ring ..... 5 Clutch Dise Backing Plate ..........2.1 6 Cluteh Inner Dise . 112 7 8 Clutch Outer Dise 12 CLUTCH ASSEMBLY - 3RD DESCRIPTION ary iTem rd Clutch Shaft Drum & Plus 5 ‘Assembly - asaeieiV Clutch Piston Seal - Inner e Clutch Piston Seal - Outer 1 7 Cluteh Piston Assombly.........00.061 8 DESCRIPTION Clutch Piston... Clutch Piston Seal - Outer Clutch Piston Seal - Inner ...... Forward Shaft, Drum & Plug Assembly DESCRIPTION Clutch Outer Dise. Clutch Inner Disc. Clutch Disc Backing Plate. .. Backing Plate Retaining Ring. ... CLUTCH ASSEMBLY REVERSE - 2ND DESCRIPTION ary Tem Backing Plate Retaining Ring - 1 9 Clutch Disc Backing Plate ..........+41 10 Clutch inner Dise : 12 " Clutch Outer Dise 12 Clutch Piston - Reverse 13 Clutch Piston Seal - Outer .. 1 14 Clutch Piston Seal- Inner ......2..0.01 18 Reverse dnd Shaft Drum & Pug Assembly Bazan Figure E DESCRIPTION Clutch Piston Seal - Inner Clutch Piston Seal - Outer .. Clutch Piston Assembly - 2nd.......- Clutch Outer Dise Clutch Inner Disc . Clutch Disc Backing PlateCONTROL VALVE ASSEMBLY ITEM Elbow . DESCRIPTION Forward Pressure Tube Assembly Elbow . os Valve Plug ...--.- seeteeeees Forward & Reverse Shift Spool . Spool Position Spring. ... : Forward & Reverse Shift Spool .... Ground Wire Harness 9 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....-..--+ Control Valve Housing ........+. 00+ Pipe Plug ...........00220 Shuttle Valve to Electric Control Gasket. Port Plug. Spool Stop...... High-Low Shuttle Spool... Shuttle Spool Spring........... Shuttle Valve Body Pipe Plug ........+ 4 een Valve Mounting Screw Lockwasher. aA & Se wi ow Nua eeaoan ITEM 28 29 30 31 32 33 34 35 36 37 38 39 40 a 42 43 44 45 46 47 48 49 50 51 52 Note: DESCRIPTION Valve Mounting Screw Valve Mounting Screw Lockwasher. ... . Valve Mounting Screw ....... feeeees Shuttle Valve Solenoid . . Solenoid Coil . a Shuttle Valve Solenoid “O” Ring. . Shuttle Valve Solenoid “O” Ring Shuttle Valve Solenoid “O” Ring. ‘1st Speed Shift Spool. . Spring... Plug Stop . Spool Stop... Shift Spool . ‘Spool Position Spring. Bore Plug “O” Ring Valve Housing Spool Bore Plug.......+ Piston Housing Assembly Stop Plug. Plug “O” Ring Piston “O" Ring. Glyd Ring........ Piston... Piston Housing. . . Ring... Items 53 thru 56 are various options. Figure F ease aoanaaean ary. declutch.CHARGING PUMP & VALVE ASSEMBLY GROUP ITEM DESCRIPTION Valve Stop Roll Pin ......-.. Valve Stop... Spring ... Os os CORN Ball... aca Valve Stop "0" Ring .... Valve Piston .......00.00+ nea 19 8 Valve Spring - Inner Valve Spring - Outer... . Regulating Valve & Filter Adaptor Carve Hkono 10 Pump Mounting Stud Lockwasher 11 Pump Mounting Stud Nut 12 Filter Assembly. . 13 Valve to Pump Capscrew. . . 14 Valve to Pump Capscrew Lockwasher .. 15 Valve to Pump Capscrew. 16 Valve to Pump Screw Lockwasher . 17 Valve to Pump Gasket... 18 Thrust Plate & Bearing Assembly...... 19 Pump Driven Shaft Assembly ......... 20 Thrust Plate & Bearing Assembly. 21 Wave Spring... ary. a~NRO n NN2NS2448 ITEM DESCRIPTION 22 Thrust Plate Seal .......... 23 Pump Drive Shaft Assembly .. 24 Pipe Plug. . . 25 Pump Mounting Stud. . 26 Pump Drive Gear Oil Seal 27 Pump Mounting Screw Lockwasher. 28 Pump Mounting Screw 29 Safety Valve Spacer...... 30 Safety Valve Poppet... 31 Safety Valve Seat........ 32 Safety Valve Spring 33 Safety Valve Retainer.......... 34 Pump Assembly to Converter Housing Gasket. 35 Pump Body...... 36 Velve Mounting Screw. . : 37 Valve Mounting Screw Lockwasher.... 38 High Clutch Pressure “O” Ring........ 39 Valve to Converter Housing Gasket... . 40 Control Valve Assembly 41 Valve Mounting Screw Lockwasher.... 42 Valve Mounting Screw. ........00++ Figure G aaorese asCONVERTER LOCK-UP ‘OPTION Hoat Exchanger ‘Ghodk Poin A Heat Exchanger Outlet Temparature Port HR-MODEL pu—Resr Output Parking Grake—Option Broathor Airy Pump Ove ou SE NOTE ch Z SRE NOTE 7 Pork" “ye Pon's Proteus Chet Pon" Pressure Check Point ‘Chock Point “Cc Heat Exchanger Desice Inet Temperature et Clutch Pressure ‘Check Point Check Point *8-0" Hest Exchanger iit Pressure y ‘Ground Driven Emergency S ‘Soona Pump Orie & Mountng-Option Port "x" Port {be Pressure Check Point 15:25 PSI [108-172 kPa} 1 2000 APM and 180°-200°F, [52"-93°C} at Comertor Out REAR VIEW brain Pugs or Sptonal Yendor pst Pons FRONT VIEW Figure HCharge Pump for emote Filter Option Cheek Point for Forward Modulates Ciuten Notes Hose Line Operating Requirements: 1. Prosoure Lines Sultabla for operation trom ambient to 250°F. [121°C] continuous operating temperature. Must withstand 200 PSI [2068 KPa} Continuous pressure, wih 600 PSI [4157 kPa intermittent surges. Rel, SAE. Spec. No. S517, T0ORT Hyraulo Hose Specticaions 2, See Lubrication Spociations. Al hose lines used must conform to SAE. Spee. No. J 1019 Tests and Procedures for High ‘Temperature Wansmission Oil Hosa. Port *L"—Converter Outlet Temperature Pot isto be used for Conver Outlot. ‘Temperature pick-up. Gauge Isto be located In the Operator Compartment. Soe Oi Temperature Gauge Specifications, nt "M'"—Converter Outlet Pressure Pressure must be measures during normal ‘hice "Production Line” lest. Cmertr ‘utlet pressure equals tho total pressure ‘drop of the Heat Exchanger, Heat Exchanger tings and back pressure of the tranemiseon lubrication sytem Port Foard Clutch Pressure Port“ Reverse Clutch Pressure REMOTE FILTER OPTION __-_-! Por “F Fegultor Valve Pressure 240-280 PSI [1655-1931 KP] ven Modulated Reverse Cluich Pressure Porton Modultor Valve ‘04 Tomnperatur Gauge Specifications: 4. Normal Operating Temperature: 180-250°F. e2-121°C] 2. Rd Lined Tomporaturo: 250°F. [121°C] “ost Conditions: 1) Converter Outlet Oi Temperature 190-220°F. {6210420 2, Tanamieion in Neutral Operating Spectcations "1-25 PSI [73 kPa) Min. prossure at 2000 RPM engine speed and a may. of 70 PSI [485 kPel oul prossure at ‘a noroad governed speed. — saa ae These pots can be used for Held “Touble Shooting” oF vehi “Production Line” tts Ports “F" "U" and °M" ‘These ports are To bo usod as check points for normal vehicle "Production Line” test Port "FClutch Pressure Itis recommended that clutch pressure ‘be montored by a gauge having an ineator lal range of 0 Yo 400 PS! [0 t0 2758 kPa) and located inthe Operator Compara. Ports "G" and "H'-Backup Warning “These ports are provided for installation cof Backup Pressure Switch for Warning ght or Hor,MECHANICAL DISCONNECT Front Shown Rear Avaliable MECHANICAL DISCONNECT WITH SPEEDO Figure |‘Assomblo oll iter and tighton 20 to 25 Lba Ft. [27,2-38,8 N'm] AA Toten ss st bn sa6d por ‘Must be loose intemal ft bearing with a No.3 etohed on the bearing, s0-outer steel plates, 10ciner ction plates. ‘Altematoly ascombe, starting wih ‘utor stool pate. Souter staal plates, inner ‘nition plates. ‘Atemately assombio, starting with ‘Suter steal pate ‘Bouter ste! plates, 12:nnertrction plates. ‘Atematoly assemble, stating with ‘outer steel pate. AX Damien 200 t0 250 Lbs.Ft (271,2:998,9 Nm] ‘Special bearing loacing notches ‘opposite snap ring, end lack tabe afer tightening ‘cap crows to proper torque, Da Tetonsiscom an Torsten Taeto9 Nm DX to Foret and Revere Chich Spring ncave ie oft Bao sing bo paced aga hac pe Fomang em sng tea cn 19 Ee tucke aferly versed as shown. ‘Shim output shat beerings to reduce 6 0 8 Lbs. in. [0,68-0,00 Nm] preload. Clean mounting sutaces and tapped holes wih solvent. Dy thoroughly, being certain tapped holes are ry and clean. See text for proper installation Tighton 200-260 Lbs. Ft. [271,2-398.9 Nm] and sake nut securely Into shaft nich A A ‘Stator support screw assembly: (View "5" 1. Glan stator suppor mounting surface and tappee holes with sovet. Dry thoroughly, ‘boing cortain lapped holes are clean and dry. 2, Intl 6 special stator support sorews. Tighton sorows 12 10 16 Lbs. FL. (163216 Nim torque. tos ‘Al loadin chamters for ol seals, plston Fings, and "O" rings must be smooth and ‘ree trom burrs. inspect at assembly. Lubricate all piston ring grooves and ‘O" rings witn oll befor assem ‘Aoply a thin coating of grease between ‘seal ips on lip type seals prior to assembly. ‘Apply a very ight coat of Permatex No. 2 12 1D. ofa ot coals and boro plugs Botore asey. ‘Apply a ight coat of Loctite No. 82 tal plug threads. ‘Apply a light coat of Permatex No.2 to ‘ata bolo stud thraade ‘After assembly of pars using Loctite or Permatex, there must not be any tree for excess material which might enter the of eeu viene view sr Z REVERSE IDLER Enlaged vow of stator suppor piston ang & expander ne =r) pander 99910 be fppron 160" tem 9 hook Jot to ad assemby 1st (om) caution: ‘Assombly of stator support to converter housing must Be completed within a 15 ‘minute period from start of screw Inatallation. The special scraw isto be ‘Used for one instalation only I screw is removes for ary roason, It must be replaced. The Locte fet inthe oles ‘must be removed with the proper tp ‘and cleaned with sovert. Dry hole ‘thoroughly and use @ new scraw for rovnstalaion.| view “s" See Sauton Torque Speciation fr Lbicated Grade 5 €) "oy Ped Srew tones Grade 8 G2 Ton] Fe Tr ARSE TER Fie TIRED CoMEE TREND Se] on my | NS weet LE a Se cee | baer [ee ps ata | oa [Lona [oe ae] ae a) S| wee | asso [ares Tie ane | art [fee enal [ae Lf Sm[ are | tweet [are | [ata esq) | wee [pr ma | se [pes Se aes ae [ees aca | aoa | op Sees| “orioo | hesecase [apa [ries teeg) || ioe | frag snnal [ser | feo. va See{ tarsi wss- total [via toe 1 ena ens I| To oe| tatoos) | too rs | saa Seb ns | peasosea | 0 aeo_[ torte asst || aise [ per -eroat | ease | fas a0 Figure |SECTION S-S Auxiliary Pump Drive viEWR “Two longer bolts at this location ‘Apply a light coat of Loctite No. 262 to all rear cover bolts ELECTRIC SOLENOID CONTROL, Charge Pump & Fier Assemble Speed Sensor Bushing in housing to specie’ ‘mension with Loco 262 and stake (3) ee places Stake 3 places approx Alter curing of Loot, peed sonar bushing rust be secure with 40 Ftp {582 Nm torque ad Liszer say 1385 (3813), ew -Apply Loctite No. 262 to this bolt only before intaling.MAINTENANCE AND SERVICE The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence that would ‘normally be followed after the unit has been removed from the ‘machine and is to be completely overhauled. It must also be ‘understood that this is a basic HR24000 3 speed long drop ‘output transmission with many options. The units are very similar to trouble shoot, disassemble, repair and reassemble. DISASSEMBLY Figure 1 Side view of the HR24000 3 speed long drop transmission, with electric control valve and front output capped. Figure 2 Remove two control valve cover bolts. Install two aligning studs in housing and remove remaining valve to housing bolts. 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 possibilty of dirt and foreign ‘matter entering the mechanism. NOTE: For R-Model remote mounted) front cover removal, service and installation on ‘transmission see page 63. For lock-up see page 89. Fig Remove valve cover and gasket. Figure 4 Remove control valve assembly, and gasket.Figure 5 Figure 8 Remove oilfilter element. Itis recommended a small pan be Remove drive plate screws and washers. NOTE: Some used to catch remaining oil in element, units may have stud nuts and washers Figure 6 Remove pressure regulating valve and charging pump Figure 9 screws, stud nuts and washers. Remove drive plates and backing ring Figure 10 Figure 7 Pry impeller cover bearing cap from cover. NOTE: Some Remove regulating valve, pump assembly and gasket, units will have studs through bearing cap holes.Figure 11 Figure 14 Remove bearing cap and "0" ring. Remove impeller cover and turbine as an assembly. Figure 12 Figure 15 Remove turbine hub to turbine shaft retainer ring. Remove turbine hub to impeller cover bearing retainer ring. (ii Figure 13 Figure 16 Remove impeller cover to impeller screws and washers. ‘Tap turbine and hub from impeller cover —3—Figure 17 Remove turbine and hub assembly from impeller cover. Figure 19 Install bearing in impeller cover. Figure 18 Remove impeller cover bearing. See clea 1g and inspection page. If the turbine or turbine hub was replaced or dis- assembled, this procedure must be used for reassembly. Figure 20 Install turbine assembly in impeller cover bearing, 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 clean, 2. Install backing ring and special screws to approximately .06 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. NOTE: Assembly of turbine hub must be completed within a fifteen minute period from start of screw installa- tion. The screws are prepared with a coating which begins to harden after installation in the hub holes, If not tightened to proper torque within the fifteen minute period, insut- ficient screw clamping tension will result. The special screw is to be used for one installation only. Ifthe sorew 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 @ Figure 21 new screw for reinstallation, Install turbine hub to impeller cover bearing retainer ringFigure 22 Remove the turbine locating ring from turbine shaft. Figure 23 Remove reaction member retainer ring, Figure 24 Remove reaction member. NOTE: Some units will have a fixed reaction member and some units will have a free- wheeling reaction member. The fixed is a one piece and the freewheeling is an assembly. Remove as an assembly. Figure 25 Remove reaction member spacer. Figure 26 Figure 27 Remove oil baffle retaining ring,igu 5 Pry oil baffle from housing. NOTE: A resistance will be Figure noted because of the heavy oil sealing ring, Remove pump drive gear bearing support bolts.(e Figure 34 Support converter housing with a chain hoist. Remove converter housing to transmission case bolts, Figure 37 Spread reverse clutch front bearing locating ring. Pry reverse and 2nd clutch from housing, Figure 35 Separate converter housing from transmission case Unclinch lock nut by straightening upset metal in notch in assembly. NOTE: Reverse, second and third clutches will idler shaft. Remove idler shaft nut. remain in the converter housing, Figure 36 Spread 3rd speed clutch front bearing locating ring. Pry or Figure 39 tap clutch from housing. Remove nut spacer.Figure 40 Remove idler gear and outer taper bearing from idler shaft. Figure 41 Remove bearing spacer. Figure 42 Remove inner taper bearing —e— Figure 43 Remove bearing spacer. Figure 44 Remove idler shaft, use caution as not to lose shaft lock ball Figure 45 Using spreading type snap ring pliers, spread turbine shaft bearing locating ring. Tap turbine shaft and bearing from stator support.Figure 46 If stator support is to be removed, remove screws and support Figure 49 Remove front oil sealing ring sleeve retainer screw and, washer. Remove sleeve lock. Figure 47 Remove impeller hub bearing from stator support as shown, Remove support sealing ring and sealing ring expander spring, Figure 50 OIL SEALING RING SLEEVE REMOVAL Using a sleeve puller like the one shown, remove sleeve. NOTE: The following photos are not of the HR Converter Housing but the sleeve removal procedure is identical. Figure 51 Sleeve being removed. Figure 48 Remove clutch front bearing locating ring See cleaning and inspection page.CONVERTER HOUSING REASSEMBLY NOTE: When installing @ new sleeve itis recommended 8 press or a driver be used to prevent damage to the sleeve and be sure the notch in the sleeve is aligned with sleeve lock notch. Figure 52 Install new sealing ring expander spring and oil sealing ring fon 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. Figure 53 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 N.m] torque. NOTE: Assembly of stator support to converter housing must be completed within @ 18 minute period from start of screw 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 a new screw for reinstallation Figure 54 Position charging pump drive get housing, Figure 55 Install support screws and tighten to specified torque. (See torque chart) Figure 56 Position auxiliary pump drive gear, bearing and support in, housing, Install support screws and tighten to specified torque. (See torque chart)Figure 57 Position pump drive idler gear and bearing on idler gear stud shaft. Install gear to shaft retainer ring Figure 60 Install reverse idler shaft spacer. Figure 58 If beating was removed, press turbine shaft bearing into position. NOTE: Bearing outer diameter ring groove must bbe down. Install bearing washer and retainer ring. Install new turbine shaft oil sealing ring, Figure 61 Install inner taper bearing on shaft with large diameter of taper down, Spread ears on turbine shaft bearing retainer ing located in reaction member support. Tap turbine shaft and bearing into position, being certain bearing snap ring is in full position in snap ring groove. ley df Figure 59 With new “0” ring on shaft, position idler shaft and lock ball Figure 62 inconverter housing. Tap shaft into position. Note lock ball Position bearing spacer on shaft. —neFigure 63 Figure 66 Position idler gear on bearing with hub of gear up. Ingtall retainer nut. Figure 64 Install idler gear outer taper bearing with large diameter of Figure 67 taper up. Tighten nut 200 - 260 ft. Ibs. torque [271,2-338,8 N.m} Figure 65 Figure 68 Position outer spacer on shaft. Stake nut securely in shaft notch =12—Figure 69 Figure 72 Remove 2nd speed clutch disc hub snap ring retainer outer Remove rear output flange nut, washer and “O" ring, fing and retainer, Remove output flange. Figure 73 Figure 70 Remove 1st speed clutch rear bearing cap bolts and Remove disc hub retainer ring and disc hub. washers, Figure 71 Repeat procedures Figure 69 and 70 to remove 3rd speed Figure 74 clutch disc hub. Remove bearing cap and gasket, =13—Figure 75 Figure 78 Remove idler shaft rear bearing cap bolts and washers, Pry bearing cap from case. Figure 78 Figure 78 Ramavebeaing cop ond ska Remove booting cap, “Ong ond ol ea TY Figure 77 Figur 80 Remove rear output sah bearing cap bots and washers. Remove Tat sped cut er beating locating rng eoFigure 84 Figure 81 Rear cover removed. NOTE: Aligning studs were used to Remove idler shaft rear bearing locating ring facilitate removal. Remove gasket. Figure 82 Remove rear cover bolts. NOTE: The top two bolts are Figure 85 longer than the other cover bolts. Use caution as not to lose idler shaft rear bearing lock ball Figure 83 Using pry slots provided, pry cover from transmission case. Using 9 soft hammer tap on the low clutch and idler shaft to Figure 86 prevent cover from binding. Remove output shaft assembly =15—Figure 87 Figure 90 Remove oil sump oil baffle. Remove bearing spacer. Figure 88 Figure 91 Remove Ist clutch rear bearing retainer ring. Remove idler shaft assembly. Figure 89 Figure 92 Remove rear bearing, Remove 1st speed clutch assembly. —16—Figure 93 Remove forward clutch gear retainer ring and gear. (See Figure 95 Figure 93-A), Remove forward clutch oil piston ring sleeve retainer ring. - Figure 96 Figure 93-A Remove piston ring sleeve. Figure 94 Figure 97 From the front remove the forward clutch assembly. Remove forward clutch rear bearing =7-OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 98 Remove front output shaft bearing cap bolts and washers, Figure 101 Remove rear taper bearing. i. Figure 99 = Remove bearing cap and shims. Le ae Figure 100 Figure 102 Remove output front taper bearing cup. Remove output gear. 18a Figure 103 Remove gear spacer. Figure 104 Remove front taper bearing, See cleaning and inspection page. OUTPUT SHAFT REASSEMBLY a! ee Figure 105 Install front output taper bearing with large diameter of taper down. 19 Figure 106 Position gear spacer on shaft. Figure 107 Position output gear on shaft with long hub of gear up Figure 108, Install rear taper bearing on shaft with large diameter of taper down.1ST SPEED CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 109 Pry front bearing from clutch shaft far enough to install a bearing puller. Remove front bearing. Figure 110 Remove front bearing spacer. I~ “17% Figure 111 Remove 1st speed gear and outer bearing —20— Figure 112 Remove inner bearing spacer. Figure 113 Pry inner bearing far enough to use a bearing puller. Remove inner bearing. Figure 114 Remove clutch disc end plate retainer ring.ll Figure 115, Remove end plate. E % Figure 116 Remove inner and outer clutch discs. ~ Figure 117 Remove piston return spring retainer ring retainer. Figure 118 Compress return springs and remove spring retainer ring, Figure 119 Remove piston return disc springs. Note: Do not mix disc springs with any other disc springs as they are matched spring packs. 4 Figure 120 Remove piston spacer. —21—Figure 121 ‘Turn clutch over and tap clutch shaft on @ block of wood to remove piston, Figure 124 Install piston return springs. See note in Figure 119. First spring with large diameter of bevel toward spacer. Alternate seven (7) See cleaning and inspection page. Springs (See Figure 1264). 1ST SPEED CLUTCH REASSEMBLY il y f ‘Cae Figure 125 Figure 122 Install clutch piston inner and outer seal ring. NOTE: Ring ‘must be sized before installing in clutch drum. Sizing is best accomplished by rotating piston while holding a round object against the new seal ring as shown. Rotate piston nti seal ring is flush with outer diameter of piston. Install clutch piston in clutch drum. Use caution as not to damage seal rings. 8 Figure 123 Position piston return spring spacer on clutch shaft Position piston return spring (Belleville washer) retainer ring on clutch shaft. Compress washers and instal retainer ring, Install retainer ring retainer washer. —22—|ST (LOW) Figure 126-A Figure 127 Install one steel disc. Install one friction disc, NOTE: The friction discs in the 1st speed clutch has a higher co- efficient rating than the friction discs in the other clutches therefore the discs must not be mixed. The 1st speed 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 128 Install clutch disc end plate Mite, Figure 129 Install end plate retainer ring Figure 130 Install clutch gear inner bearing. NOTE: This bearing does not have a shield in it BR, oo Figure 131 Install inner bearing spacer.igure 132 Install cluteh driven gear into clutch drum. Align splines on Figure 135 clutch gear with internal teeth of friction discs. Tap gear Install 1st speed clutch front beering. into position. Do not force this operation. Gear splines must be in full position with internal teeth of all fiction discs. FORWARD CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 133, Install clutch gear outer bearing. NOTE: Outer bearing has * a shield in it, this shield must be up. Figure 136 Remove clutch disc end plate retainer ring. Figure 134 Figure 137 Position front bearing spacer on clutch shaft, Remove end plate. 24Figure 138 Remove inner and outer clutch discs. Figure 139 Compress piston return springs (Belleville washers), remove spring retsiner ring and ring retainer washer. ea ED Figure 140, Remove piston return disc springs. See note in Figure 119, Figure 141 Remove return spring spacer. Figure 142 Remove clutch piston. Remove clutch shaft piston rings and expander springs. See page 50 for proper piston ring and expander spring installation. See cleaning and inspection page. FORWARD CLUTCH REASSEMBLY Figure 143. Install clutch piston outer and inner seal rings. Size as explained in Figure 122. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.Figure 144 Install piston return spring spacer. = rE x m1 reese reat pt nam soe sin ih ee Sart toward spacer. Alternate seven (7) springs. See note in Figure 119. ~ Figure 146 Install piston return spring retainer ring retainer on clutch shaft. —26— Figure 147 Compress return springs and install retainer ring. Be sure ring is in full position in retainer. Fwb. REV. PISTON Figure 147-8 Figure 148 Install one steel disc. 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 149 Install clutch dise end plate. ee 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 lock-up converter REVERSE AND 2ND CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY (2nd clutch being disassembled) Figure 153 Remove end plate retainer ring, Figure 154 Remove end plateFigure 155 Remove inner and outer clutch discs. i 3 be Figure 156 Compress piston return spring. Remove retainer ring, f Figure 157 Remove return spring retainer and spring, —28— Figure 158 Remove clutch piston. DISASSEMBLY OF REVERSE CLUTCH @) a a Figure 159 Remove clutch shaft piston rings and expander springs. See ‘page 50 for proper piston ring and expander spring installation, wn” = Figure 160 Remove front bearing retainer ring.