WUE el rie eot Tae alte UCC TTeL) Powershift Transmission 3-4-6 Speed Short Drop Se lor te) gaa lal Loree Ee)1) 2) 3) 4) 5) 8) 8) 10) TABLE OF CONTENTS Foreword Safety precautions, cleaning and inspection Technical specifications ~ identification of the unit ~ weight, oil capacity = pressure and temperature specifications Maintenance - oil specification - maintenance inter - servicing machine after components overhaul Installation details = converter drive coupling = components to engine installation ~ external plumbing Operation of the unit ~ hydraulic diagram ~ power flows + electrical wiring Troubleshooting - stall procedure - check points - See page 5-3 Sectional views and parts identification Assembly instructions Disassembly and Reassembly of unitsFOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainte- nance and repair of the SPICER CLARK-HURTH OFF-HIGHWAY COMPONENTS DIVISION 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 prin- ciple 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 Spicer Clark-Hurth Components-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. Spicer 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 Spicer Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.SAFETY PRECAUTIONS To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed. Proper service and repair are important to the safety of the service technician and the safe, reliable operation of the machine. If replace- ment parts are required the part must be replaced with one of the same part number or with an equivalent part. Do not use a replace- ment part of lesser quality. The service procedures recommended in this manual are effective methods of performing service and repair. Some of these procedures require the use of tools specifically designed for the purpose. Accordingly, anyone who intends to use a replacement part, service procedure or tool, which is not recommended by Spicer Clark-Hurth Components, must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the replacement part, service procedure or tool selected. It is important to note that this manual contains various ‘Cautions’ and ‘Notices’ that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the unit or render it unsafe. It is also important to understand that these ‘Cautions’ and “Notices’ are not inclusive, because it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions. aCLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid. it is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned. A CAUTION: Care should be exercised to avoid skin rashes, fire hazards, and inhalation of vapours BEARINGS Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles Of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process. HOUSINGS Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evap- oration of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaners. A CAUTION: Care should be exercised to avoid inhalation of vapours and skin rashes when using All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft, lint- less absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping compound. INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressad. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date. BEARINGS Carefully inspect all rollers, cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed. 22OIL SEALS, GASKETS, ETC. Replacement of spring load oil seals, O-rings, metal sealing rings, gaskets, and snap rings is more eco- nomical when unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. When assembling new metal type sealing rings, same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assem- bly of mating members. Lubricate all O-rings and seals with recommended type Automatic Transmission Fluid before assembly. GEARS AND SHAFTS If magna-fiux process is available, use process to check parts, Examine teeth on all gears carefully for ‘wear, pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is wor through or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are true. HOUSING, COVERS, ETC. inspect housings, covers and bearing caps to be certain they are thoroughly clean and that mating sur- faces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures. LEGEND SYMBOLS ca Disassombly of assembly groups Renew at each reeserbiy Ci Reassemble to from assembly Group P| nemove obsructon pars x, Unlock, lock e.g. split pin, locking plat otc. Lock - adhere (liquid sealant) Reinstall - remount parts which had Guard against material damage, damage obstructed disassembly * ° to pans ‘Mark before disassembly, observe marks ‘Attention! Important notice ae cnnine Check - adjust e.g, torque, dimensions, is Filing - topping up - refiling e pressures ing water, ete, oll, coo! T= Special tool P= Page Drain of cl, lubricant Tighten - clamp: tightening a clamping 12 direction of instabation Note direction of instal am Visuel inspection ‘Apply prossuro into hydraulic circuit Possibly stil serviceable, renew if novessary Toclean Oi ||| | a] E> | 88 DIE HADI |S ay 23TRANSMISSION IDENTIFICATION NAMEPLATE LOCATION ON REAR LEFT LOWER CORNER OF TRANSMISSION CASE A. IDENTIFICATION OF THE UNIT 1, Model and type of the unit 2. Serial number REAR VIEWTRANSMISSION DRY WEIGHT - LB [Kg] PUMP BIDIRECTIONAL ISC PTO LB 1540 50 40 25 20 (Kal [698.5] (23) (19) [12] [10] 32WE OF Ot ‘CHECK PERIOD NORMAL * DRAIN PERIOD A See Lube Chat. Consult Opernr’s Manus! on spoteabe machine ‘move or system copay. Terave Conver, ‘Traremiscon ao leg yaa yate must be Conaidered se 2 whole 10 determine eapachy (heck eve! DAILY wit engine runing at ‘500600 RPA and la 180 to 200" F-1822 “833° CL Malnaln of eval to FULL Mas. vary $00 hous, change oft seman. Every 1000 how, dan and oll Syterna5 fellows: Drain with a 150° to 200° F156 sasect NOTE: 1 i recommended that Stor ‘laments be changed afer 80 and 100 hours ‘of operation on new and rebuilt or repaired, ‘ni (2) Drain wansmiasion and remove sump screen. Clean screen thoroughly ana replace, using new goskete. Drain ol fiers, remove and discard fer slaments Ciean fier shee and Refit wanamission to LOW mark ‘Run engine at 500.600 RPM to prime Recheck level with engine running st 1500600 RPM and edd ol to bring lev! fo LOW mark, When ol temperature thot 180200" F) 1022.83." Cl make final ‘llevel check. BRING OIL LEVEL TO FULLMARK LUBRICATION RECOMMENDED LUBRICANTS FOR CLARK POWER SHIFTED TRANSMISSION "AND TORQUE CONVERTERS. Prevaling Ambient Temperature ll + Sper hm so unenses cost eran te = DER Emre “Normal drain periods and filter change intervals are for average environmental and duty-cycle conditions. Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination. For extreme conditions judgment must be used to determine the required change intervals. 4SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and its allied hydraulic system are important links in the drive line between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other; therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the job can be considered completed. After the overhaul or repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned, This can be accomplished in several manners and a degree of judgement must be exercised as to the method ‘employed. The following are considered the minimum steps to be taken: 1. Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning. 3. Replace oil fiter elements, cleaning out filter cases thoroughly. 4, The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil and compressed air until all foreign material has been removed. Flushing in direction of normal oil flow will not adequately clean the cooler. lf necessary, cooler assembly should be removed from machine for cleaning, using oil, compressed air and steam cleaner for that purpose. Do not use flushing compounds for cleaning purposes. 5, Reassemble all components and use only type oil recommended in lubrication section. Fill transmission through filter opening until fluid comes up to LOW mark on NOTE: If the dipstick is not accessible. Oil level check plugs are provided. Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug. Run engine two minutes at idle to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine run- ning at idle. ‘Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install oil level plug or dipstick. Recheck with hot oil (180 - 200 degrees F) [82,2 - 93,3 degrees C]. See hydraulic checks for warm up procedure. 6. Recheck all drain plugs, lines, connections, etc, for leaks and tighten where necessary. 42HR 36000 Series Transmission Converter Drive Plate INSTALLATION INSTRUCTIONS Proper Identification by Bolt Circle Diameter dimension (Bolt Circle diameter) and order Drive Plate Kit listed below Measure the *A" Dimension Bott Crete Oiamoted A" Dimenslon (Bot Cele Diamoten) 16.00" [881,000 mn] ameter 16.07 406,400 ren] chameter ato, 002587-10mm, HatNo, 202504 WO Nuts 16.00" [406 400 mm] ameter ‘ER No. 602558-10rne 16.00" [408,400 men clameter Ht No. 602800-711620, 416.575 (620,625 rn] clametor *# fat No, 802800-7/16:20, 117.00" [431,800 men clametor Ot No, 802508-10rmm Each hit wi include the folowing pats: ‘tetermadiato Drive Paton 117.0" [431,800 mm] clametor 1 Backing Piao et No, 802662-711620 +14 Delve Pato Mounting Capscrews leatrucion Sheet ach tt wil aclude the following parts: '5 ltormodiats Drive Plates NOTE: Assembly of fexpalos must be completed 1 Drive Plate Assombly ‘wktin 018 minute period from start of scrow 1 Backing Plato [Rstallaton, the screw la removed fr any reason “14 Drive Pale Mounting Capecrewe must be replaced. The adhesive left in the tapped {nstuction Shoot ‘nolos met bo removed with he proper tap and **'t pe. Ove Pala Mounting Spacers ‘loaned with solvent. ry the hole thoroughly and Included ia ft No, 802800. : {se a new screw tor relnstalation. Position drive plate and weld nut assembly on Impeller cover with weld nuts toward caver. Align intermediate drive plate and backing ring with holes in impeller cover. NOTE: Two dimples 180° apart in backing ring must be out (toward engine fiywhee)). Install capscrews. Tighten cap- screws 62 - 67 fibs torque [70.4 - 77.1 Nm}. olTRANSMISSION TO ENGINE INSTALLATION PROCEDURE |. Remove all burrs from flywheel mounting face and nose pilot bore. Clean drive plate surface with solvent. Dry thoroughly. LLL . Check engine flywheel and housing for conformance to standard SAE. #3 - S.AE. J-927 and J-1039 tolerance specifications for pilot bore size, pilot bore runout and mounting face flatness. Measure and record engine crank- shaft end play. N N N Install two 3.50 [88,90 mm} long converter to flywheel hous- ing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole. . Install a 4.00 [101,60 mm long drive plate locating stud in a drive plate nut. Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in Step No. 3, Locate converter on flywhee! housing aligning drive plate to flywheel and converter to flywheel housing. Install converter to flywheel housing screws. Tighten screws to specified torque. Remove converter to engine guide studs. Install remaining screws and tighten to specified torque. 3. Remove drive plate locating stud. Install drive plate attaching screw. Snug screw but do not tighten. Some engine flywheel housings have a hole locat- ed on the flywheel housing circumference in line with the drive plate screw access hole. A screwdriver or pry bar used to hold the drive plate against the flywheel will faciitate installation of the drive plate screws. Rotate the engine fly- ‘whee! and install the remaining seven (7) flywheel to drive plate attaching screws. Snug screws but do not tighten. Afterall eight (8) screws are installed, tighten each cap- screw to the following torque: M-10 capscrews 48 ibs torque {60.65 N:m.] This will required rotating the engine ‘lywheel until the full amount of eight (8) screws have been tightened. |. Measure crankshaft end play after converter has been completely installed on engine flywheel. This value must be within .001 {0,025 mm] of the end play recorded in Step No. 2. 52HR 36000 6 SPEED FULL POWER SHIFT SHORT DROP - PLUMBING ve SEB Betat tie prema (@- 4375-20 8AE "0" ANG PORT @-s0zs-19sae-orrnapont PO" @.- s.a125:2:8a8 “RING FORT \ .2 @-vner 08) @ oO Ed Sa Fre, pen Ol-—er Converter Outet alo Port "Aa! eons" @ @ ‘Temperature Pickup Conver Out ‘CLUTCH PRESSURE igspeed cute pressure © {taspeed Sr opoed 13 20 speed | 53Port "J" - Converter Outlet Temperature Portis to be used for Converter Outlet ‘Temperature Pick-up. Gauge is to be located in the Operator Compartment. See Oil Temperature Gauge Specification. Port “s" - Converter Outlet Pressure Test Conditions: Warm Transmission to normal operating temp- erature and stabilize Converter Outlet Oil Temperature at 180° - 200°F [82,2" - 933°C}. Operating Specifications: 25 PSI [172.4 kPa] minimum pressure at 2000 RPM engine speed and a maximum of 70 PSI [482,6 kPa] outlet pressure with engine at no load governed speed. Ports “Rr, ‘y", “S” and “AR” are used for field ‘Trouble Shooting” or Production Tests. Clutch Pressure Recommond that the clutch pressure be monitored by a gauge having an indicator cial range of 0-400 [0,2758 KPa}. Gauge isto be located in the operators compartment, Ciuich pressure range 240-310 PS| [1655-2137 kPa). PORT CHART FROM TO. PORT PORT REMARKS AD AC PUMP TO FILTER AB AH REGULATE VALVE HEAT ‘CONVERTER OUT TO AQ EXCHANGE | HEAT EXCHANGER HEAT AH HEAT EXCHANGER TO EXCHANGE. TRANSMISSION LUBE FILTER, PART NO. CARTRIDGE 234777 ‘SPIN-ON 246787 OIL TEMPERATURE GAUGE SPECIFICATIONS. 1. Normal Operating Temp. Range: 180° Red Lined Temp.: 250°F [121,1°CV] Pep Chart - Oil Temp. Gauge: to 250°F (82,2" to 121,1°C] Maximum Operating Temp.: 300°F (148,9°C] °X" DIM. PART NO. 144.00 [3657.6] 234033) 48.00 [1219,2) 234034 4HOW THE UNITS OPERATE With the engine running, the converter charging pump draws oil from the transmission sump through the removable oil suction screen and directs it through the pressure regulating valve and oll filter. The pressure regulating valve maintains pressure to the transmission control cover for actuating the direction and speed clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of cil is directed through the torque converter circuit to the oil cooler and retums to the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating in a closely fitting 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 pressure. After entering the converter housing the oll 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 fitting on the transmission. 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 elements through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element 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 t its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and the 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 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 designated maximum multiplication ratio when the output 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 a valve body with spool type solenoid cartridge valves which are controlled electronically. eaWith the engine running and the directional control lever in neutral position, oil pressure from the regulating valve is blocked at the control valve, and the transmission is in neutral. Selection of forward or reverse will direct oil, under pressure to either the forward or reverse directional clutch as desired. When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selectional spool. The same procedure is sued in the speed selector. the direction or speed clutch assembly consists of a drum with intemal splines and a bore to receive a hydraulically actuated piston. the piston is “oil tight” by the use of sealing rings. A stee! disc with external splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A hub with O.D. splines is inserted into the splines of disc with teeth on the inner diameter. The disc and hub are {ree to increase in speed or rotate in the opposite direction as long as no pressure is present in theat 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 tubed, to the chosen clutch shaft. Oil pressure sealing rings located on the clutch shaft direct oil under pressure to pass thru a drilled passageway in the clutch shaft to enter the piston cavity. Pressure of the oil forces the piston and disc against the heavy back-up plate. The disc, with teeth on the outer diameter, clamping against disc with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows them to drive as @ unit ‘There are bleed balls in some of the clutches which allow quick escape for oil when the pressure to the piston is released. 62co HYDRAULIC DIAGRAM 36000 - 4 SPEED SPICER CLARK-HURTH WILL NOT SUPPLY ITEMS MODULATION MODULATION INDICATED WITH * REV36000 SIX SPEED TRANSMISSION (FORWARD | \ REVERSE} ={SECONt Low cs FWO HIGH—{THIRD BASIC DESIGN oa36000 POWER FLOW SIX SPEED TRANSMISSION WL \ reverse {secon Low (1836000 POWER FLOW SIX SPEED TRANSMISSION J A - (FORWARD | REVERSE {SECON ‘rorward 3rd Forward 4th — — — ——— — Tt Low (1936000 POWER FLOW SIX SPEED TRANSMISSION A ! (FORWARD | ! D E REVERSE PSEC LOW (181) c 1, bros hana FE ine Forward Sth ————__—- | Forward 5th | Forward 6th Forward 6th = — — — — — — o736000 POWER FLOW SIX SPEED TRANSMISSION || Fonwano) | ‘REVERSE FHSECOND Low (189 Reverse ist Reverse 2nd — Reverse 3rd — —— — —— — —36000 FOUR SPEED TRANSMISSION WE FORWARD} Hino } REVERSE F={SECo! Low (189) 6936000 POWER FLOW FOUR SPEED TRANSMISSION A » fi Ss B 2 ————————_— { fronwano} ano | D E io, evens {seo Low (1) i ce = Fou to : F Forward 3d —$ $$$ Forward 4th — — — — — -36000 POWER FLOW FOUR SPEED TRANSMISSION A ih ° ! FORWARD} ‘THIRD | D E nevense } {8250 tow oe 1 F c 7 = Fou 1 4 136000 POWER FLOW FOUR SPEED TRANSMISSION A . Fi B = (FORWARD! ‘THIRD’ LA D E a evense} HGED0 vow — i c = Reverse 1st36000 THREE SPEED TRANSMISSION rofw JF Low (1s) (THIRD —36000 Forward 1st Forward 2nd Forward 3rd — —— — —— — — POWER FLOW THREE SPEED TRANSMISSION A I Cc cp . Shi peas ; D E REVERSE LOW (188) c 1 3 | fos — - TS at Forward Forward 3rd.36000 POWER FLOW THREE SPEED TRANSMISSION A ry \ = I | 1 D E EVERSE IND LOW (tst)’ Reverse 1st Reverse 2nd — Reverse 3rd — —- — —— — —Bl eam eoon g GAL PUC SGA INVHOVIG ONIMIM IOULNOD GIONI10S DMLIF1S Pu’ NOISSIWSNVUL Gaads &Z]_va e-c| ey 3ONVEO 8 8-£-5 | 2Y NMOUS t a-2-9-y | ama 9 e-z| oN Na3uD: g 9 vd MOTIBA , - i t a-9| ed ne z 8-9-9| za UHM 3 8-9-S-b td 3009 0109 [on aim] [oaziousna aaadS ‘GAbZ PUL DGAZL INVHDVIG ONIYIM 1OULNOD GION310S onuloaig pue NOISSINSNVEL dS &(aaads 9) JOULNOD GIONS 91HL9373 oreGAPE PUP OCAZL - NWHDVIC ONIMIM TOULNOD saceemad GIONTOS DIULOITS NOISSINSNVUL ‘dds 936000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED FULL POWERSHIFT ronwano toa O O | souenoro Siow O I ss FORWARD LOW ENGAGED 62036000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED FULL POWERSHIFT FORWARD Low SOLENOID SUPPLY "LOT PRESSURE LUTCH PRESSURE ERR venr SS FORWARD HIGH ENGAGED 62136000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED VERSION FORWARD REVERSE #228 cuuten pressure PILOT PRESSURE 88888 ven 3RD SPEED REVERSE ENGAGED 22FORWARD —} REVERSE——} 36000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED VERSION [ 2ND SPEED REVERSE ENGAGED o23 #8885 c.urcn pressure PILOT PRESSURE 8888 ventREVERSE 36000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED VERSION 1ST SPEED FOWARD ENGAGED 624 S@BecLuTCH PRESSURE $2938 PLOT PRESSURE V8Bvenr36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT Rev. 4th =] Clutch Pressure Pilot Pressure Vent36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT FWD 4th [ Clutch Pressure Pilot Pressure 7 Vent36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 3rd (4 SPEED) Ly We © 2 5 a a 2 a = S 2 2 oO Pilot Pressure Vent e2736000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 2nd (4 SPEED) Clutch Pressure Pilot Pressure Vent36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 1st (4 SPEED) IIA |] Clutch Pressure ES Pilot Pressure 62936000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 3rd (3 SPEED) CULL: WML o £ 5 a a o 2 a = Ss 2 2 oO Ley LLL Ley VILLE Vent 630TROUBLESHOOTING GUIDE FOR THE HR36000 TRANSMISSION ‘The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly. When troubleshooting a “transmission” problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components. Proper operation of the transmission depends ‘on the condition and correct functioning of the other components of the group. Therefore, to properly diag- nose a suspected problem in the transmission, it is necessary to consider the transmission fiuid, charging pump, torque converter, transmission assembly, oil cooler, fiter, connecting lines, and controls, including the engine, as a complete system. By analyzing the principles of operation together with the information in this section, it should be possible to identify and correct any malfunction which may occur in the system. HR96000 TRANSMISSION HR36000 (power shift with torque converter transmission) troubles fall into three general categories: ‘mechanical, hydraulic and electrical problems. In addition to the mechanical and electrical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit is most important, Transmission fluid is the “Ife blood” of the transmission. it must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, t0 engage and hold the clutches from slipping, and to cool and lubricate the working components. ‘TROUBLESHOOTING PROCEDURES Stall Test: Uso a stall test to identity transmission, converter, or engine problems. ‘Transmission Pressure Checks: ‘Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping ‘clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmis ion lubrication pressure may also be measured. Mechanical and Electrical Checks: Prior to checking any part of the system for hydraulic function (pressure testing), the following mechani- cal and electrical checks should be make: ‘© Check the parking brake for correct adjustment. ‘* Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points. ‘© The controls are actuated electrically. Check the wiring and electrical components. ‘* Be sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission. Air clean the radiator, if necessary. * The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and maximum no-load governed speed specifications. ™Hydraulic Check: ‘Aiso, before checking the transmission clutches, torque converter, charging pump, and hydraulic circult for Pressure and rate of oi flow, itis important to make the following transmission fluid check. ‘Check oil level in the transmission. The transmission fluid must the at the correct (ful level). All clutches and the converter and its fluid circuit lines must be fully charged (filed) at all times. See NOTE below. AX sore: rnevwasson tis mtn opeingerguane 82-89 6980-2007 x spunea nso apna nan To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at “stall”. (Refer to converter stall procedure.) AX, carn: so at nto vise oust nov reece wen oun ‘engine and converter at stall R.P.M. ‘A. CONVERTER STALL PROCEDURE 1. Put the vehicle against a solid barrier, such as a wall, andlor apply the parking brake and block the wheels. 2. Put the directional control lever in FORWARD (or REVERSE, as applicable). 43, Select the highest speed. With the engine running, slowly increase engine speed to approximately one-half throttle and hold Lunt transmission (converter outlet) oil temperature reaches the operating range. AX csnore conten ye eer sean gran 9 anes a shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached. Excessive temperature (120° C) 250° F maximum) will cause damage 72HR36000 CONVERTER GROUPrem 10 " 2 HR36000 CONVERTER GROUP DESCRIPTION Bearing Support Serew Bearing Support Lockwasher Drive Gear Snap Ring Pump Drive Gear Bearing Pump Drive Gear Bearing Support Pump Drive Gear Converter Housing Charging Pump and Pressure Regulator Valve Turbine Shaft Rear Bearing Turbine Shaft Front Bearing Bearing Washer 4 16 16 7 18 19 20 a1 22 23 26 25 26 2 Turbine Shaft Oi! Sealing Ring Converter inlet Tube Stator Support ‘Stator Support Sealing Ring Turbine Shaft Bearing Locating Ring ‘Stator Support Screw Lockwasher Stator Support Screw Turbine Hub Turbine Locating Ring Reaction Member Retaining Reaction Member Reaction Member Spacer Dowel Reaction Member Spacer Impeller Hub Bearing Retaining Ring Impeller Hub Bearing QTy wee eee ess rvnoon rem 8B 1 BREBKRE 7 Sseaesse et FR PERS 1 SRLBR a2 DESCRIPTION Impetter Hub Impeller Hub to Impeller “O” Ring Impeller Hub Screw Backing Ring Impeller Hub Sorew il Baffle Retaining Ring Oil Baffle il Baffle Seal Ring il Baffle Ol Seal Impeller Hub Gear Impeller Hub Gear Snap Ring Turbine ‘Turbine Hub Screw Lock Tab Turbine Hub Screw Impelior Cover to Impeller “O" Ring Impetier Cover Impelior Cover Bearing Impeller Cover Bearing Cap *O” Ring \Impelier Cover Bearing Washer Impeller Cover Bearing Washer Snap Ring ‘Turbine Hub to Turbine Shaft Retaining Ring Impeller Cover Bearing Cap Drive Plate Assembly Drive Piate Drive Plate Backing Ring Drive Plate Mounting Capscrew Impeller Cover to Impeller Screw ‘Screw Lockwasher ary " 14 24 24TRANSMISSION CASE & CONVERTER HOUSING ASSEMBLYTRANSMISSION CASE & CONVERTER HOUSING ASSEMBLY Tem DESCRIPTION 1 Modulator Bypass Tube 2 Tube Retaining Screw ‘3. Tube Retaining Sorew Lockwasher 4 Tube Cip 5 4th Spoed Pressure Tube 6 Tube “0” Ring 7. Srd Speed Pressure Tube {8 Tube Rotaining Sorew 9 Tube Retaining Screw Lockwasher 10 Tube lip 11 Forward Pressure Tube 12 Tube °O" Ring 18 Valve Oil Supply Tube 14 Port Plug 18 Port Plug "0" Ring 16 Port Plug 17 Port Plug "0" Ring 18 ‘Speed Sensor Bushing Plug 18 Speed Sensor bushing Shim 20 Speed Sensor Bushing 21. Bushing "0" Ring 22 Converter Housing 23 Reducing Bushing 24 Breather 25 Fler Plug 28 Not Used 27 Not Used 28 Tube Sleeve Safety Valve Seat Safety Valve Seat Retainer 31. Pressure Relief Valve Plunger 32. Pressure Relief Valve Spring ‘83, Washer 34 Washer Retaining Ring ‘35 Convartor Housing Sleeve Forward Shaft 36 Converter Housing Sleeve Lock 37. Converter Housing Sleeve Screw Lockwasher ‘98 Converter Housing Sleeve Screw 39. Converter Housing Sleeve Reverse & 2nd Shaft 40 Converter Housing Sleeve Lock 41, Converter Housing Sleeve Screw Lockwasher nverter Housing Sleeve Screw 43. “idler Gear Retainer Plate Screw 44 “idler Gear Retainer Plate 45. “idler Gear 48. “idler Goar Boaring Assombly 47 “idler Gear Shaft Retainer Plato Screw 48 “idler Gear Shaft Retainer Piato Scrow Lockwasher 19 “Idler Gear Shaft Retainer Pate ‘idler Gear Shaft Converter Housing Sleeve Screw Converter Housing Sleeve Screw Lockwasher Converter Housing Sleeve Lock Converter Housing Sleeve 4th Shaft Por Plug Port Plug “0° Ring Por Plug *O" Ring Por Plug Pon Plug Por Plug “O" Ring (Oil Lube Return Plug 2BSSISREBRsS "8 Spoed Transmission Only ‘ARLAs Ruired QTy Fess es rem S8LSRRBSLBSEY SRLERISS 100 101 102 103 104 105 408 107 108 109 10 m1 m2 13 14 15 NI NI NI NI NI NI DESCRIPTION ary il Lube Retun Plug ‘O" Ring Cap Plug Gasket Gap Plug Tube Sieve 0" Ring Tubo Sioov Tube Sieve 0" Ring ‘Tube Sleeve Plug Pug 3rd Speed Pressure Tube Converter Housing to Transmission Case Screw 1 Lockwasher Convertor Housing to Transmission Case Screw 1 Converter Housing to Transmission Caso Gaskot Converter Housing to Transmission Dowel Pin Lockup Sleeve Retainer Screw Lockup Sleeve Retainer Screw Washer Lockup Sleeve Retainer Lockup Sleave ‘Spoed Sensor Bushing Plug ‘Speed Sensor Bushing Shim A ‘Transmission Case to Converter Housing Scrow Washer ‘Transmission Case to Converter Housing Screw Flaar Cover to Case Dowel Feear Cover to Case Gasket Floar Cover Plug lear Cover Fooar Cover Screw Lockwasher Rlear Cover Screw Rear Cover Screw Lockwasher Rear Cover Screw Roar Cover Screw Lockwasher Rear Cover Screw Screen Assembly Scroon Assombly Plug Clutch Pressure & Lube Tube “0” Ring Clutch Pressure & Lube Transfer Tube Clutch Prossure & Lube Tubo “0” Ring lear Cover Plug Case to Rear Cover Stud Nut Gage to Rear Gover Stud Nut Washer Pressure Tube Sleeve "0" Ring Pressure Tube Sleeve Cage to Rear Cover Stud Drain Plug ‘et Speed Clutch Pressure Tube ‘1st Speed Shaft Rear Bearing Lube Tubo Oil Level Plug, Dipstick Hole Plug ‘Tube Sleeve ‘Tube Sleeve “0” Ring Suction Tube °0" Ring Bot Lockwasher Oi Bato Oil Baffle Sorew NA. Not Hlustratea36000 CLUTCH GEAR GROUP 3,4& 6 SPEED-SHORT DROPDESCRIPTION fearing i Be 5 | 2 2 2, ig? i s Haag Bun ik we ‘ Bipiece Pi saaeggysccccee e024 30053 eee teeTyys 2888599558835 3 z Uy ideeoaseealiunpaelinanas ese 2g HERS ERRELEE QTY iTeM DESCRIPTION QTY (TEM Piston Inner Seal Piston Outer Seal DESCRIPTION ITEM ARnNA CL ITCH & GEAR GROND 2 42 & SPFEN GHORT NRAD st Washer 3 ge gf Meesssegeiisisle 55? oy 3 : gg Bb EUS OE ga 3 " PES GEM Hn SUSUTTE ian ldnleey sr ebsoapes | ee BREBBSSS! SZRSRB36000 PRESSURE REGULATOR VALVE & CHARGING PUMP 15TEM 36000 PRESSURE REGULATOR VALVE & CHARGING PUMP DESCRIPTION ‘Thrust Plate & Bearing Assembly Pump Driven Shaft Assembly ‘Thrust Plate & Bearing Assembly Wave Spring Pump Shaft Seal Pump Drive Shaft Assembly Charging Pump Housing Pump Suction Adaptor “O" Ring Pump Suction Adaptor Fitting Charging Pump Suction Tube Coupling Charging Pump Suction Tube Retainer Charging Pump Suction Tube Gasket Charging Pump Suction Tube Sleeve Rear Cover Suction Flange Rear Cover Suction Flange *O” Ring Regulator Valve Pilot “O" Ring ‘Spring Retainer Snap Ring Valve Spring Retainer Cup Valve Spring - Outer Qty rem 20 8 SBReRBRBEBSBBNBRR BR DESCRIPTION Valve Spring - Inner Regulator Valve Spool Clutch Pressure Supply “O" Ring Valve to Converter Housing Screw Lockwasher Valve to Converter Housing Screw Regulator Valve Plug Regulator Valve Plug Pressure Regulator Valve Safety Valve Piston ‘Safety Valve Piston Spring Piston Spring Retainer ‘Spring Retainer Snap Ring Pump Shaft Oil Seal Valve Body to Pump Gasket Valve to Pump Screw Lockwasher Valve to Pump Screw Valve to Pump Screw Lockwasher Valve to Pump Screw ary@-* _ ELECTRIC CONTROL VALVE 2936000 ELECTRIC CONTROL VALVE ASSEMBLY rem DESCRIPTION seseses 36 SREELESSS Plug Plug “0° Ring Directional Spool Directional Spool Spring Diroctional Spool Control Valve to Converter Housing Gasket ‘Air Actuator Piston Housing Stop Plug Piston Housing Plug *O" Ring Piston "0" Rng Giyd Ring Piston Piston Housing 0" Ring Declutch Spo! Plug Decltch Spe0! Spring Control Valve Housing Range Spool Spring Range Spoo! ‘Spool Plug *O" Ring Spool Piug Range S00! Dectutch Spo0! Stop Control Valve to Converter Housing Screw Seal Plato Gasket Seal Plate Seal Plate Gasket Pipe Plug Pipe Plug "0" Ring ‘Spool Stop Fin ‘Accumulator Spring - Outer ‘Accumulator Spring - Middle ‘Accumulator Spring - Inner ‘Accumulator Spool Cover Pate Sorow Cover Plato Roll Pin Piug Control Cover to Control Valve Screw Lockwasher Control Cover to Control Valve Screw Piug Piug Wire Gip Atachment Pate Dust Cover Stud ary Tem DESCRIPTION 48 Not Used 47 Dust Cover 48 Dust Cover Stud Washer 49 Dust Cover Stud Nut 50 Nut 51. Coil to Nut“O" Ring 52 Solenoid Coit 63 Connector Clip 54 Coll to Cartridge °O" Ring 85 Solenoid Cartridge 56 "0" Ring 57 °O" Ring 58 °O" Ring 59 60 er 62 63 4 Housing Plug Housing Plug "0" Ring 66 Plug 67 Valve Stop *O" Ring 68 Valve Stop Regulator Spool Ball ogulator Spool Regulator Spring Valve Stop Regulator Spring Regulator Spoot Regulator Spool Ball Pipe Plug "0" Ring Pipe Plug Regulator Spoo! Roll Pin Regulator Spoo! Rot Pin Pipe Plug 1 Plug "0" Ring ‘Spool Stop Pin ‘Accumulator Spring - Outer ‘Accumulator Spring - Mido ‘Accumulator Spring - Inner ‘Accumulator Spoo! ‘Control Cover Plug Not Used On This Model Sssisarxanrs SSISREBS s e10 ‘Controi Cover to Contr Valve Screw ‘Control Cover to Converter Housing Screw ‘Control Cover to Convorter Housing Screw Control Cover to Control Valve Screw {65 Control Cover to Control Valve Screw LockwashorASSEMBLY INSTRUCTIONS ELASTIC STOP NUT TORQUE THREAD SZE] Bor em 20 750-200__| (208.4-271.4] Tier te | 200-280 (2712-988) Tite | 950-050 | (4088-4745) tyares2 | 400-450 | (6424-6104)[Al ead in charters fo ail seals, piston rings and O" rings must be ‘smooth and tree from burs. rokube belore assembly ll piston sing grooves and “0° rings, with Mutipurpose grease Grade 2. ‘Apply thin coat of Loctite 638 (color green) to outside damotor of ll, Cl seals, Boe puge and bores thay ae fo Be intaid ino, before ‘sembly, Uso extreme care note alow sealant fo come ino con- tact with seal ip materia ‘Apply thin coat of Loctite 270 (color red) to al th hoe studs threads which do not have preappled sealant. It grease required for postoning gasket ding assembly, use Mui purpose grease Grade 2 ‘Aor aaeembly of parts using Loctite, there must not be any fee or ‘excess material which might ntor the ol circuit. Only use Loctte ‘nero spociiod. Gonera! Bearing instalation Procedure a thermal assembly ad Is used, (expanding by hoaling 275°F = 25°F [1254 147] 8 chock must be made fir mating pars have reached tne same temperature wihin 20°F [11°C] oF ambien, tobe ure the bouringe are positoned soll again! tle spective shoulders Low (1st) ten taper bearing adjustment (See Special Instruction) La shalt abi cap mut baton as shown on a ZA bettas S09 Nut Trae Char. Special urine shait bearing 314MG loading notches must be on same sige as retaling rng. Cast iron piston rings in outer piston ring location and Viton Fings at nner piston rng location. all speed versions, al clueh Bend lock tabs at assembly, aor ghtoring cap scrows 0 proper torque, Tabs must be bent against screw head fats ‘or around comers as shown below 6—oO ‘Clutch piston tum spring: ‘Concave side of fist Baevile spring must be assembled toward dutch piston. Allamate remaring springs. ‘Al dowel pine must be installed in transmission case betore assembly of mating parts Tighten of seroon assombly 10 15 Hibs. [19-20 Nem] all modes. Pack al sealing ring grooves with gre. Install sealing ings and center rings ln ring grooves. ‘Must be loos intra ft arings witha No, 8 etched on the bearing. (01 Pump Sleave and Coupling Assembly. Torque clamp bolt 7.5109 tbs [10 -12.N-m, Bearing shield must face OUT on Low & Sr clutch, Bearing shield must face IN on Forward & Reverse clutches. A Impater hub an turbine hub assembly with backing ring ard special salldockng screws. 1. Clean hub mounting surtace and tapped holes with so ‘vet. Dy thoroughly, belng cerialn tapped holes are ‘lean and dy. 2, Install backing ing and special selttocking screws Tighion sorows to 90-99 fHbs [7987 Nm fr turbine and 58.64 fb [79-87 Nm] for impr. Note: Assembly of hub must be completed within a fiteen ‘minute period rom start of sew intalaion. Tho special ‘serOW i foo used for one instalation ony the screw is. omoved for any reason, I must bo roplacod. The epoxy lett inthe hub holes must be removed with the proper ap and Cloned with solvent. Dry hole thoroughly and use a new Aemate assembly of cuch ates, staring wit Inner ‘ere or retain, Friction Pate on modulated ches and Outer Stel Pate on ronmoduated caches. AX Clutch Plates - aty ‘ace bots obo uted a thee loetons- Reus Speci Modulete standard Torue 12 toner 6 Inner - _ — ote Outer Puceeour| rorquerrias | mi | We Oer Sue “75 ae m7 190uer i oor ~ iar ad [aro 3.88 4 gee taht - - inner ad aS ater ower ier an “Biner 5 8ter 8 8iter Torque Speccabn for ubsated Grades ‘or Plated Screw Threads Grades GD NOM] ANE THREAD ‘COURSE THREAD ANE TIRES ‘COURSE THREAD Sze) er Nm Seem || ape tem orm 7300] 223-245 | [ooa- 86a] | 000-200 | (ers - 200) || _345-s47 | ar-aroy_| 202-910 | (aaa 20) 250, 128-141 | [174-101] | 119- t2a | 1953-168) 700-198 | (204-268) | 180-178 — | “Bt6= 2371 —| =a25| 61-100 [Mead ass) | e200 —_|fina- 1280) || aaa rat [70-104] | 1-127 VBHD- 72 S000] —e4-70 | eea-048) | sre | (79-054 || 90-00 —[1iaat-r942) 1085-03 [aars| 41-8 [5-010 | a7-at | (502-8557 || 59-08 T0s-772T tare0| 20-29 | fs3-a037 | 29-25 | ote-soa)_|[_97-a1 8-488 istas| 16-20 | feiz-27.) | ve-16 | Wea-216) || 20-92 (353-408) | Bs00[ ott 1193-149) | 8-70] oats | [8 13-1487 | 92FRONT COVER ‘OR CONVERTER HOUSING PASSAGE MUST BE LEFT OPEN FOR INTERNAL LUBE TUBE TRANSFER TO LOW CLUTCH. PASSAGE MUST BE BLOCKED FOR EXTERNAL LUBE TUBE TRANSFER TO LOW CLUTCH. TIGHTEN PLUG 7-40 LBFFT [9.54135 Nem} LOW CLUTCH LUBE TRANSFER INSTRUCTIONS 93SPEED SENSOR INSTALLATION Regulator Valve and Charge Pump Ass'y. Lift transmission using this hole (0) f iN] SILO @) 1 5 : Rear view 1.990 + .007 [95.3 + .18] 1.060 + .007 [26.9 + .18] SHIM TYPE BUSHING Assemble Speed Sensor Bushing with shims required to provide correct dimension. Clean thread on bushing and housing with Locktite cleaner. Use Locktite number 270 or number 262 on both bushing and housing. Tighten bushing to 45-50 LBF-FT [61-68Nm] torque. After curing of Locktite, Speed Sensor Bushing must be secured with 40 LBF-FT [54.2 Nm] torque.MAINTENANCE AND SERVICE ‘The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence that would rrormally 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 HR98000 3, 4 & 6 speed short ‘op transmission with many options. Assemblies may vary on ‘spectic models. The units are very similar to trouble shoot, disassemble, repair, and reassemble. ‘CAUTION: Cleanliness is of extreme importance and an absolute rust in the repair and overhaul of ths unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibilty of dit and foreign matter entering the mechanism, Drain as much oil as possible betore disassembly. ‘See Figure 393 for LHR (Converter Lock-up) Disassembly and Reassembly. ‘See Figure 509 for R-Madel (Remate Mounted Transmission) Front Cover. DISASSEMBLY Figure 1 Figure 2 Rlamove diive plate mounting plate capseraws, Figure 3 Figure 4 Remove impeller cover bearing cap and “O° ringFigure 5 Remove turbine shaft to turbine hub retainer ring. NOTE: Retainer ring is ticker than the turbine huib locating ring wove gal cee eas secre ses ee oat OF rier eter weien ns ot talbott Saar aes ymmended an oll pan be available when Figure 6 Remove impeller cover to impeller scrows. Figure 10 Remove reaction member to stator support retainer rng. Figure 7 Using pry slots provided, remove impeller cover and turbine.Figure 11 Remove reaction momber and spacer. Spacer is dowel Figure 14 pinned to reaction member and does not need to be taken lemove charging pump suction tube, tube adapter flange ‘apart uniass replacement is necessary. ‘and *O" ring t- Figure 15 mae [2] pana crabs pure Se pom wra r Figure 13 ‘An impeller removal too, like the one shown, can be fabri Figure 16 cated to facilitate the removal ofthe impeller and oil bal, Flemove pump hole covers and pump adapters.Figure 20 Figure 17 t Remove control valve assembly. Remove valve to housing fees eent ane mee A Figure 18 [17 Pomove contol cover assembly to converter housing + Figure 21 Te CODA: SOUR: Ramer 2 orSt Flemove stator support to converter housing screws. eS Figure 22 Figure 18 Tum support to align notch with pump drive gear and Remove seal plate and inner and outer gasket remove suppor. 104Figure 23, 4 Support converter housing with a chain hoist and strap. Figure 26 Remove converter housing to transmission case screws. ‘Guraad fie feteee atti ee Sie no We ring groove and pry the reverse and 2nd clutch assembly from housing. Figure 24 Separate the converter housing assembly from the trans- mmission case. NOTE: The Reverse and 2nd and 4th speed Figure 27 ‘Shih aa dd belontaved let is’ cunienter totaled tees Romove output shaft nut, washer and "0" ring. Remove out note in Figure 25). put flange. Figure 25 ‘Spread the 4th Clutch Front bearing snap ring out of the ring ‘groove. Pry 4th clutch assembly from converter housing. NOTE: On a3 speed transmission this willbe the 3rd speed Figure 28, clutch, on a6 speed transmission this willbe Fwd-Hi and 3rd Remove output shatt rear bearing cap stud nuts and Cluten: See figure 235 for 6 speed clutch, lockwashers, 105Remove flange spacer. Remove the Srd shaft bearing cap stud nuts and Figure 32 Remove the ard shatt bearing cap and “O° rings, Figure 33, Remove the low (1st) clutch shaft bearing cap stud nuts and lockwashers, Figure 34 Romove the low (1st) clutch shaft bearing cap and shims. Keep shims and cap together, it bearing cap, low (1st) clutch, front and rear bearings, transmission case or rear ‘cover ave not replaced, the same shims will be used at reassembly.Figure 35 Figure 38 Flomove the low (1st) clutch pressure and lube transfer Remove the rear cover to case stud nuts, screws and tubes and "0" rings. lockwashers, Figure 38 Figure 39 Remove the rd cltch rear bearing lacating rng. (1 speed Fomove ol soreen assombly plug and seroen. ‘hive shatt on a3 oF 6 speed transmission Figure 40 Pry rear cover from case tapping on output shaft and clutch Figure 37 ‘shaft to prevent binding. NOTE: The use of aligning studs lomove the output shaft rear bearing locating ring, will facitate cover removal 107Figure 41 Figure 44 Flomove rear cover and gasket. Remove the 2nd clutch aise hub retainer snap ring, ring rtainar and dise hub retainer ring Figure 42 Figure 45 Romove the 4th clutch disc hub retaining ring. NOTE: On a Romove disc hub. 3 speed transmission this will be the Srd clutch disc hub. Figure 43 Figure 46 Remove disc hub, Remove output shaft rear bearing.Figure «7 Figure 50 Remove tho ow (59) co andthe ouput shat ogee. Remove ol bale screws wth ockwashers Figure 43 Figure 51 Rlomove the output shaft front bearing. Romove oil baffle. Figure 49 Romove tho 3rd spead clutch assombly (on a 4 speod transmission only.) On a3 and 6 epeed transmission this will Figure 52 be the 1st speed drive shaft lemove suction tube bolts and lockwashers. 109Figure 53 Remove suction tube and "O" ring Figure 54 \With the aid of an assistant, spread the forward clutch shaft tear beating retaining snap ring. Tap on forward shaft to 4 » Figure 55 t Remeve foward clutch assembly. Figure 56 Flomove turbine shaft ear bearing outer race. Figure 57 clutch shaft front taper bearing cup ‘and spacer (oll baffle). DISASSEMBLY AND REASSEMBLY OF SUB-ASSEMBLIES OUTPUT SHAFT DISASSEMBLY Figure 58 Remove front bearing inner race.Figure 59 Figure 62 Install output gear inner retaining ring. Figure 63 Position output gear on shaft with long hub of gar toward Figure 60 inner ring Romove output gear. Figure 81 Figure 64 If needed remove output ger inner retaining ring. Install outer retainer ring 10-11Figure 65 ace) Press or drive front bearing inner race on output shaft with ee ee ‘shoulder on race down (toward gear) 4TH CLUTCH DISASSEMBLY (rd Clutch on 3 Speed) (For the 6 speed transmission soe Fwe-Hi and 3ed Clutch Figure 235) Figure 65 Position outer race of bearing on inner race. Figure 69 7m Rlemove clutch shaft ol sealing rings. Figure 67 Figure 70, Position 4th clutch disc hub (31d clutch of 8 speed) on shaft. Remove front bearing snap ring, roeFigure 71 Remove front bearing, Figure 72 Remove clutch disc backing plate snap ring, Figure 73 Remove backing plate. Figure 74 lomove the inner and outar clutch discs. Figure 75 Compress piston retun wave spring retainer. Remove spring retainer snap ring from groove, Release spring pressure, Figure 76 lemove spring retainer snap ring and retainer. 10-19Figure 77 lomave piston roturn wave spring Figure 78 Remove wave spring thrust washer. GR Figure 7 Turn clutch over and tap shaft on a block of wood to remove clutch piston 10-14 REASSEMBLY (See cleaning and inspection page) Figure 80 ‘Make sure the piston bleed valve is clean and tree of foreign ‘materials. Install the piston inner seal ring. Install the piston ‘outer seal ring. Lock ring joint socurly. Grease ring to stablize in ring groove. Figure 81 Position piston in clutch drum. Use caution as not to Figure 82 Position the wave spring thrust washer, wave spring, spring retainer and spring retainer snap ring on clutch shaftFigure 83 Figure 8 Compress wave spring and instal spring retainer ring being Certain ring isin full postion in ring groove, Figure 94 Install 1st steel outer disc. (Teeth on the outer diameter) Figure 85 Install 16t fiction inner disc (tecth on tho inner diameter). Alternate stee! and friction diace unt the proper amount of Figure 08 discs are installed. First disc next to the piston is steel, last Press the clutch shalt front bearing on shaft with snap ring dis installed is friction. groove in bearing down as shown. 1045Figure 89 Inctall front boaring snap ring. Figure 90 Pack ring grooves with grease and install clutch shaft sealing rings. Center rings in grooves before assembly into housing 3RD SPEED CLUTCH DISASSEMBLY AND REASSEMBLY (4 Speed Transmission Only) DISASSEMBLY Figure 92 ‘Remove rear bearing snap ring. Figure 91 Remove clutch shaft sealing ring. Figure 94 Remove the 3rd speed goar outer bearing retaining ringFigure 95, Figure 98 ‘Ramave the ard speed gear inner beating. Figure 98 Figure 99 Remove backing plate snap ring Romave inner and outer clutch discs. Figure 97 Figure 100 Romove backing plato, Remove the 3rd gear inner bearing snap ting. 10.17Figure 101 Figure 104 Compress the piston retum wave spring retainer. Remove Remove wave spring spring retainer snap ring trom groove. Release spring prossure, Figure 105 Figure 102 Remove clutch piston return spring retainer. Remove snap ring. Figure 103 Figure 108 Romove wave spring retainer. Remove clutch piston. 10-18REASSEMBLY (See cleaning and inspection pag Figure 107 ‘Make sure piston bleed valve is clean and free of foreign ‘materials. Install clutch piston inner seal rng, Install clutch piston outer seal ring. Lock piston ring joint securely. Grease fing to stabilize in ring groove. Install piston in clutch drum. Use caution as not to damage sealing rings. Figure 108 Postion the piston return spring retainer, wave spring, wave ‘pring retainer and retainer snap ring on clutch shat. Figure 109 Compress wave spring and install spring retainer ring being ‘certain ring isin ful position in ring groove, 10.10 Figure 110 Install the 3rd gear Inner bearing snap ring. Figure 111 Install the 1st stool outer dsc. Install the 1st fiction inner disc. Altemate steel and fiction discs until the proper ‘amount of cscs are installed. First disc next tothe piston is stool, act dice installed is fretion. = Figure 112 Position clutch ise backing plate on discs.Figure 113, Install backing plate snap fing. Figure 114 Install 3rd epeed gear inner bearing, NOTE: This bearing ‘does not have an oil shield in it Figure 115 Position the 3rd speed gear into clutch drum. Align splines ‘on gear with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in ful postion wit internal teeth ofall rction dsc. Figure 116 Install Srd gear outer bearing. NOTE: Outer bearing has an oil shield init, this shield must be up. ® Figure 118 Install clutch shaft rear bearing. NOTE: Rng groove in bear- ing must be up as shown.Figure 119 Install bearing snap ring Figure 122 Remove the front bearing inner race retaining ring. Figure 120 Install clutch shaft ear ol sealing ring, Grease ring to stab lize in ring groove. FORWARD CLUTCH Figure 123 DISASSEMBLY AND REASSEMBLY Flemove front bearing Inner reoe. (Non-modulaied. For modulated clutches ‘see modulation section.) DISASSEMBLY Figure 121 Figure 124 Flomave forward clutch shaft ol sealing rings Flemove beaving spacer. 1021Figure 125 Figure 128 Flomove clutch gear and outer bearing Remove the inner and outer clutch discs. Figure 126 Figure 129, Remove clutch cise backing plate snap rng, Remove clutch gear inner bearing Figure 130 Compross tho piston rotum wave spring rotainor. Remove Figure 127 spring retainer snap ring from ring groove. Release spring Remove backing plate. pressure.Figure 131 Figure 194 Flomove wave spring retainer and retainer ring, Flemove clutch piston. Figure 192 Figure 135 Fomove wave spring. Romove rear bearing snap ring Figure 133 Figure 136 Rlomove wave spring thrust washer Rlomove rear bearing. 1023REASSEMBLY (See cleaning and inspection page) a Figure 140 Position piston in clutch drum. Use caution as not to Figure 137 ‘Gamage sealing rings, Install clutch shaft rear bearing, NOTE: Snap ring groove In bearing must be up as shown. Figure 138 Figure 141 Install er bearing snap sing, Position wave spring thrust washer on clutch piston. a Figure 139 ‘Mako suro piston bleed valve is clean and free of foreign ‘material. install clutch piston inner goal rng, install cutch piston outer seal rng, Lock piston ring joint socurely. Grease Figure 142 ring to stabilize in ring groove. Position wave spring on thrust washer. 10-24Figure 143 Figure 146 Position clutch disc backing plate on discs. Figure 144 ree Compress wave spring and instal spring retainer ring being igure Certain rng i in full position in ring groove. Install backing plate snap ring. Figure 145 Install one stool disc. Install one friction aise. Atemate et ‘and fition dises until proper amount of discs are installed. Figure 148 First gisc next to the piston is steel, last disc installed is Instat clutch gear inner bearing. NOTE: This bearing does fee rt cu roe a AFigure 152 Install front boaring retainer ring. Figure 149 Install clutch driven gear into clutch drum. Align splines on = clutch gear with intemal teeth of fncton dises. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of al friction discs. Install ‘luich gear outer bearing. NOTE: The outer bearing has an il shiold init, this shield must be down. A q Figure 153 Pack sealing ring grooves with grease. Install clutch shaft ‘soaling rings. Cantar rings in grooves. 4 REVERSE AND 2ND CLUTCH DISASSEMBLY AND REASSEMBLY Figure 150 3 and 4 Speed Transmission Poston bearing spacer en clutch shat. (For 6 speed see Figure 268) DISASSEMBLY (Reverse Being Disassembled) Figure 151 Figure 154 Install clutch shaft front bearing Remove clutch shaft sealing rings. 10.28Figure 155, Figure 158 Remove front bearing retainer ring. Pry clutch gear up tar enough to use a a gear puller. Figure 156 Figure 158 move front bearing Remove clutch gear and outer bearing. Figure 157 Figure 160 Remove front bearing spacer. Remove backing plate snap ring. 1027Figure 161 lemeve backing plate. Figure 162 Remove inner and outer clutch discs. Figure 163 Remove clutch gear inner bearing, Figure 164 ‘Compress the piston return wave spring retainer. Remove ‘spring retainer snap ring from groove. Rolease spring pressure. Remove snap ring. Figure 165 Remove wave spring retainer. Figure 168 Fomove wave spring. 1028Figure 167 Remove wave spring thrust washer. Figure 168 Remove clutch piston. Turn clutch over. 2ND CLUTCH DISASSEMBLY Figure 169 Remove backing piate snap ring. Figure 170 Remove backing plat. Figure 171 Remove inner and outer clutch discs, Figure 172 Compress the piston retum wave spring retainer. Remove spring retainer snap ring from groove. Release spring pressure, Remove snap ring, 10.29Figure 176 Ces Remove citch piston. Remove wave spring retainer. REASSEMBLY OF 2ND SPEED CLUTCH (See Cleaning and Inspection Page) Figure 174 Figure 177 Remove wave spring ‘Make sure piston bleed valve is clean and free of foreign materials. Install clutch piston inner seal ring. Install clutch piston outer seal ring. Lock piston ring joint securely Grease ring to stablize in ing groove. Si X Figure 178 Figure 175 Poston piston in ouch drum. Use caulon as not to Fomove wave sping thst washer damage sealing rng. son 3Figure 179 Figure 162 Position wave spring and thrust washer on clutch piston. Compress wave spring and install spring retainer ring being ‘certain ring isin full positon in ring groove. : Agus ie ee roi nl oo il ss as en cn nome oe espe at tee tren Te ean tea aia eek eae Figure 181 Figure 104 Position wave spring retainer on wave spring, Postion clutch dise backing plate on discs. 1091ee Figure 185 Install backing plate snap ring, Turn clutch over. Figure 188 Postion wave spring thrust washer on clutch piston. REASSEMBLY OF REVERSE CLUTCH Figure 186 Figure 188 ‘Make sure piston bleed valve is clean and free of foreign Position wave spring on thrust washor. ‘material. Install inner seal rng. Install piston outer seal ring Lock piston ring joint securely. Grease ring to stabilize in ring groove. Figure 187 Install piston in clutch drum. Use caution as not to damage Figure 190 sealing rings. ! 4 Position wave spring retainer on wave spring.Figure 131 Compress wave spring and instal spring retainer ring being certain ring isin ful postion in ring groove. Figure 192 Inctall one stoo! disc. Install one friction dise. Alterato steel and friction discs until proper amount of discs are installed. First disc nest to piston is steel, last disc installed is fiction. Figure 195 Insall cltch gear inner bearing. NOTE: This bearing does rot have an ol shield init a ieee Figure 196 Install olutch driven gear into clutch drum. Align splines on 3 clutch gear with intemal tth of friction discs. Tap gear into Figure 183 Postion elutch aise backing plate on discs, position. Oo not force this operation. Gear splines must be in full position with internal teeth of al tition discs, soFigure 197 Install clutch goar outer boaring. NOTE: Outer bearing has ‘shield in it, this shield must be down. aes A Figure 198 Postion front bearing spacer on clutch shaft. Figure 198, Install front bearing. NOTE: Snap ring groove in bearing ‘outer race must be down. AQ Figure 200 Install front bearing retaining ring. Figure 201 Pack sealing ring grooves with grease. Install clutch shaft sealing rings. Center rings in ring grooves, LOW (1st) CLUTCH. DISASSEMBLY & REASSEMBLY DISASSEMBLY Figure 202 lemove rear clutch shalt sealing rings,Figure 203, Figure 208 Pry rear bearing up far enough to use a bearing puller. peed gear and outer bearing Figure 204 Remove rear taper bearing. Figure 207 Figure 205 Figure 208 Remove bearing thrust washer. Fomove backing plate. 1095Figure 208 Figure 212 Remove inner and outer clutch discs. Compress the piston retum wave spring retainer. Remove spring retainer snap ring from groove. Release spring pressure. Remove snap ring, Figure 210 Figure 213 Rlomove st speed gear inner bearing. Remove wave spring retainer. Figure 211 Figure 214 Remove 1st speed gear spacer. Romove wave spi gear spac ing. 10.98REASSEMBLY (See Cleaning and Inspection Page) Figure 215 Figure 218 Remove wave spring retainer. Position Srd speed driven gear on clutch shaft with long hub ‘of gear up. (4 speed transmission only) Figure 219 Position front taper bearing on clutch shaft with small lameter of taper up. Press bearing into position, NOTE: It thermal assembly aid is used, (expansing by heating 275% H/-260F. [195%C+/-{149C] a check must bo mado after mating parts have reached the same tomporaturo within 205F [1120] ambient, to be sure tho bearings are positioned solidly against their respective shoulders before bearing agjustment can be made. [um clutch over. Figure 216, Remove clutch piston. Figure 220 Install clutch piston inner seal ring. instal clutch piston outer Figure 217 seal ring. Lock piston ring joint securely. Grease ring to Remove the 3rd speed drive gear and front bearing, (Driven stabilize in ring groove. Install piston in clutch drum. Use ‘gear on 4 speed transmission only) Caution as nat to damage sealing rings. 1 q 10.97Figure 221 Figure 224 Install piston return wave spring retainer ‘Compress spring and instal retainer ring being sure rng is In fl positon in ring groove. Figure 222 Figure 225, Position wave spring in retainer. Install one stoo! dsc. Install one friction disc. Altemate stool and friction ises until the proper amount of discs are installed. First disc next to the piston is steel, last disc Installed is trtion, Figure 223 Figure 226 Position clutch spring retainer on spring, Position backing plate on clutch discs. 1098Figure 227 Figure 230 Install backing plate snap ring Install clutch gear into cluich drum. Align splines on clutch ‘gear with intemal teeth of friction discs. Tap gear into Position. Do not force this operation. Gear splines must be in full positon with internal teeth ofall friction discs. Figure 231 Install clutch gear outer bearing. NOTE: Outer bearing has Figure 228 ildin it, this shield must be up. Install 1st speed gear spacer. A Figure 229 Install 1st gear inner bearing. NOTE: This bearing does Figure 232 not have an oll shld in it Install wear bearing thrust washer A 10399Figure 239 Install clutch shaft rear taper bearing, large diameter of bearing down, NOTE: If thermal assembly ald Is used, (expanding by heating 275%F-/-25%F[135°C+/-14#]0 a check ‘must be made alter mating parts have reached the same temperature within 20°F{11#G] of ambient, to be sure the bearings are positioned solidly against their respective shoulders before bearing adjustments can ba made, Figure 234 “The two clutch shaft oil sealing rings will be installed after the low clutch taper bearings are adjusted, DISASSEMBLY AND REASSEMBLY ‘OF FORWARD HIGH AND 3RD SPEED CLUTCH (6 Speed Transmission Only) FORWARD HIGH CLUTCH BEING DISASSEMBLED ae Figure 265 Install clutch shaft front bearing. NOTE: ‘Outer bearing locating ring groove must be down, Figure 296 Remove front bearing retainer ring. Figure 237 Romove front bearing > Figure 238 Remove clutch gear outer bearing retainer ring. 10.40_s Figure 239 Figure 242 Remove clutch gear and outer bearing Remove clutch disc backing plate. Se Figure 243 Figure 240 Romove inner and outer clutch discs. Remove clutch gear inner bearing, Figure 244 ‘Compress piston return wave spring. Remove retuin spring Figure 241 retainer ring. Remove ring retainer, wave spring and spring Fomove backing plate retainer ring retainer, 1041mcs = 2 nae & Figure 248 Rlomove clutch piston Remove inner and outer clutch diss. DISASSEMBLY OF 3RD CLUTCH = 5 ~~ ES Figure 249 ure ees pn sek tee toa: Porn sin TTIn Ghieh Cay rel foreeond ikl les Geko ase He ee etre we eiare mers een ano cone Ree a % Figure 247 Figure 250 Fomove backing plate Remove clutch piston. 1042REASSEMBLY OF FORWARD HIGH (6 SPEED ONLY) AND 3RD SPEED CLUTCH ‘See cleaning and inspection page. REASSEMBLY OF 3RD CLUTCH 3 Figure 254 Postion piston in clutch drum. Use caution as not to ‘damage sealing rings. Figure 251 Make sure piston bleed valve is clean and free of foreign materials, — Figure 255 Position piston return spring retainer, wave spring and retainer ring washer in clutch drum. Compress return spring {and install spring retainer ring being certain ring isin ful Figure 252 a Position in ring groove. Install clutch piston inner seal ring. Figure 259 Install clutch piston outer piston ring. Lock piston ring joint Figure 256 securely. Grease ring to stabilize in ring groove. Install one stee! dis. 10.43= a Figure 257 Inetall one fetion cise. Aliornate stool and fiction discs unt the proper amount of dgos aro installed. First disc next to the pision is steel, last disc installed is fiction. =~ ~~ Figure 258, Install clutch dise backing plate. Figure 259 Install backing plate retainer ring, REASSEMBLY OF FORWARD HIGH CLUTCH (6 SPEED ONLY) Figure 260 peat procedures in Figures 251 thru 259, ag = Figure 261 Install clutch gear inner bearing. NOTE: This bearing does. ‘not have a shield in it. “Sy 1 ae Install clutch driven gear into clutch drum. Align splines on clutch gear with intomal testh of friction dises. Tap goar into postion. Do not force this operation. Gear splines must be In full postion with internal teeth ofall friction discs.le 8 & Figure 263 Install clutch gear outer bearing, NOTE: Outer bearing has 2 shield in it, this shield must be down. A Figure 264 Install outer bearing retainer ring. Figure 265 Install clutch shaft front bearing, NOTE: Outer bearing locating ring groove must be down. A Sy Figure 266 Intall bearing retainer ring. “Fy ‘ Pe Figure 267 Pack oll sealing sing grooves with grease. Install sealing rings and center rings in ring grooves, DISASSEMBLY AND REASSEMBLY ‘OF REVERSE AND 2ND CLUTCH (6 Speed Only) DISASSEMBLY REVERSE CLUTCH BEING DISASSEMBLED (For Modulation see figure 479.) Figure 268 Remove front clutch shatt cil sealing rings.+ 4% Figure 269 Figure 272 Romove front bearing retainer rng, amove inner taper bearing. Remove clutch disc backing plate rotainer ring, — > ~ Figure 270 Figure 273 Using a gear puller remove front bearing, clutch gear and move backing plato, ‘clutch gear outer taper bearing, ao Figure 271 Figure 274 Remove bearing spacer. Remove inner and outer clutch discs. 1046> ca Compress clutch piston retum spring. Remove spring retainer ring, washer, spring and spring retainer. Remove clutch piston, DISASSEMBLY OF 2ND CLUTCH —_3 Figure 27 Remove clutch disc backing plate retainer ring Figure 278 ‘Remave backing plate. Figure 279 Romave inner and autor clutch dies ~~. “ah Figure 260 Compress clutch piston retum spring, Remove spring retainer ring, washer, spring and spring retainer. 1047oan Figure 281 Remove clutch piston REASSEMBLY OF 2ND AND REVERSE CLUTCHES See cleaning and inspection page. 2ND CLUTCH BEING REASSEMBLED Figure 262 Make sure piston bleed valve is clean and free of foreign materials, Figure 283 Install clutch piston inner seal ring. 1049 Install clutch piston outer seal ring. Lock piston ring joint securely. Grease ring to stabilize in ring groove. Install piston in clutch drum. Use caution as not to damage sealing “ie \ Figure 285 Position piston retuin spring retainer, retum spring and retainer ring washer in clutch drum. Figure 286 Compress return spring and install spring retainer ring being Certain ring isin full position in ring groove.Figure 287 Install ono steo! dsc. Install one fiction dico. Alternate stool ‘and fiction discs unti the proper amount of discs are installed. Fist disc next to the piston Is steel, last disc installed is fretion. Figure 288, Install clutch disc backing plate. Install backing plato retainer fing, REASSEMBLY OF REVERSE CLUTCH For Modulation see Figure 494. Figure 288 Ropeat procedures in Figures 282 through 288, Figure 290 Install clutch gear inner taper bearing with large diameter of taper down. Figure 291 Position taper bearing spacer on clutch shat. 1 Figure 292 Install clutch driven gear into clutch drum. Align splines on Clutch gear with internal teeth of friction discs. Do not force this operation. Gear splines must be in full position with internal teeth ofall friction discs.4’ Figure 296 Figure 293 ack oil sealing ring grooves with grease. Install sealing Install clutch drive goar outer taper bearing on clutch shatt rings and center rings in ring grooves. With large diameter of taper vp. TURBINE SHAFT DISASSEMBLY AND REASSEMBLY a 7 | DISASSEMBLY Figure 294 Install clutch shaft front bearing. NOTE: Bearing outer ftainer rng groove must be down, A ™ Figure 297 —~.ge Remove turbine chef ol sealing rng as Figure 295 Install bearing retainer ring. NOTE: Retain that can be fied Into snap ring groove To aosure a Figure 208 3 taper bearing tight Femove the bearing snap ng,Figure 299 Remove bearing washer Figure 302 Figure 300 Pry bearing up far enough to press or pull bearing from turbine shat. Figure 303 REASSEMBLY Insta bearing snep ring See cleaning and inspection page Figure 201 Figure 304 Press bearing on turbine shaft with outer diameter ring Pack ol sealing sing groove with grease. Install sealing ring ‘groove up, ‘and center ring in groove. 10851DISASSEMBLY AND REASSEMBLY OF IMPELLER AND OIL BAFFLE DISASSEMBLY Figure 308 Remove impeller to hub screws. Figure 305 Romove impeller hub gear snap ring Figure 309 Romove screw backing ring. Romove impollor from hub. Remove hub to impeller “O" ting. REASSEMBLY See cleaning and inspection page. Clean hub mounting surface and tapped holes with Figure 306 solvent. Dry thoroughly, being certain tapped holes are clean Romove impollor hub goat. and dry Figure 310 If removed, install impollor hub bearing in hub Install hub Figure 307 bearing snap ring. Position a new hub to impeller “Oring on Rlomove oi battle, oll seal and baffle seal ring. hub. 1082‘elie a Figure 311 ‘Align holes in impelor with impollor hub. Position impellor on hub using caution as not to disrupt “O* ring Figure 312 Install backing ring, Figure 313 Install special self locking screws. Tighten screws 58-64 ft. lbs. (79-87 N.mj. NOTE: Assembly of hub must be completed within a fifteen minute period from start of screw installation. The special screw is to be used for one installation only. i the screw is removed for any reason it ‘must be replaced. The epoxy let in the hub holes must be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use a new screw for reinstallation, Figure 314 ‘Apply alight coat of Loctite 638 to the outer diameter ofthe ‘il baffle oll seal, Press oll seal in cil baffle with lip of seal own. a Figure 315 Position oil baffle on impeller, use caution as not to damage ‘il seal. Install new ol baffle sealing rng. Figure 316 Position hub gear on impeller hub. Install gear to hub snap ring. 1053DISASSEMBLY AND REASSEMBLY OF TURBINE AND IMPELLER COVER DISASSEMBLY Figure 320 ‘Straighten turbine hub bot lock tabs. Remove turbine to hub bots. Femove turbine hub. REASSEMBLY See cleaning and inspection page Figure 317 Block impeller cover as shown, Remove turbine hub to front bearing snap ring. Te ar ‘Align holes in turbine with holes in turbine hub. Position lock tabs and install turbine hub bolts, Tighten bolts to speciied torque. (See torque char). Bend a comer of the lock tab ‘over a flat of the bot heads. NOTE; On unite with converter lock-up, special turbine to hub installation ‘must be used. See Lock-up section. Figure 318 Remove bearing spacer Figure 922 Figure 319 CConter impelier cover over turbine and hub. Install impeller ‘Tap turbine and hub trom impeller cover bearing, ‘cover beating in impeller cover and over turbine hub. 1056Figure 323 Position bearing washer on turbine hub. Figure 326 iain el ‘Tap turbine shaft and bearing from housing. NOTE: Before removing the pump drive gear assemblies it is recommended each gear be marked for its location for reassembly. Various gear retios dictate proper gear location at reassembly. Figure 324 Install turbine hub to bearing snap ring CONVERTER HOUSING DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 327 Remove pump drive gear bearing support screws and lockwashors. Figure 925 Figure 928 lomove turbine shat front boaring locating snap ring, Remove pump drive gears and bearing assemblies, 1055‘VALVE SEAT SELES RETAINER Figure 329 I¥unit has a lube prossure relief valvo, disassemble in order ‘shown for cleaning and inspection OIL SEALING RING SLEEVE REMOVAL (Remove sleeves only if they are to be replaced.) 1 - Remove clutch shaft front bearing locating ring. 2- Remove retainer plate screw, washer and plate. 3 - Using a suitable puller, remove sloove. CONVERTER HOUSING REASSEMBLY (See Cleaning and Inspection Page) OIL SEALING RING SLEEVE INSTALLATION ‘1-When installing a new sleeve it is recommended a 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, 2 - Position sleeve lock. 3 - Install capscrew and washer, tighten to specified torque. Position clutch shaft front bearing locating ring in ring groove. Figure 290 Pump drive gear installation. See note after figure 926. Install the right and left gear in the proper location. Insta the center charging pump dive gear. 1056 Figure 331 Tighten pump drive gear bearing support screws to specified torque, Figure 332 I¥unit has lube pressure relief valve and was disassomblod for cleaning or replacement, reassemble in order shown, Postion turbi into positon f Shaft and bearing in housing. Tap bearing ‘enough to install Bearing snap ring,Figure 334 Install bearing snap ing. Tap turbine shaft until snap ring shoulders in greove in housing. Figure 335 Spread reverse clutch front bearing locating ring and tap ravorse and 2nd clutch assembly inte converter housing. Be ‘certain locating ring is in full postion in ing groove. Figure 336, ‘Spread 4th speod clutch front boaring locating ring. NOTE: On a 6 speed transmission this will be the forward-hi and 3rd clutch, Tap clutch assembly into position being certain ring is in full position in ring groove. Figure 337 Install forward clutch shaft front bearing. TRANSMISSION REASSEMBLY See cleaning and inspection page. NOTE: If @ new transmission housing or converter housing is needed for reassembly sce assembly instruction page for speed sensor bushing installation. ‘See assembly instruction page for screw and nut torques. Figure 338 Position a new “O" ring on the suction tube and install tube in transmission case. Figure 339 Install suction tube to case screws and washers. Tighten to specified torque, 1087Figure 340 Figure 343 Position oil baffle in case. Install Srd speed clutch assembly (on 2 4 speed only). On a 3 and 6 speed this will be low clutch drive shaft Figure 341 aE: Inctal oil battle scrows and tighton to specified torque. igure ne With the locating ring in position in the low clutch front ‘bearing boro install the spacor (oil bale) and front bearing ‘cup. See figure 346, Spacer (oil baffle) : ring cup Locating ring: Figure 342 Position the forward clutch assembly into the rear bearing bore. Push clutch shaft rear bearing through bearing bore far enough to instal outer locating ring. Push clutch sssembly back in bearing bore untl locating ring shoulders in bearing bore. Figure 945 1058Figure 346 Figure 248 “The low clutch (1st) and the idler shaft (output) must bo The use of aligning studs will facilitate rear cover installed in the transmission case together. The help of an Installation. Tap cover into place. ‘assistant or by placing the transmission case on the front face may facitate this step. Be sure clutch and idler are in {ull position in case, Figure 350 Figure 347 Install cover to case screws and washers and tighten to Install output shatt rear bearing. NOTE: Snap ring groove specified torque. must be out. (To th Figure 348 Install a new gasket and “O" ring on rear of transmission Figure 351 ‘case. A light coat of grease wil hold gasket in place. Instat output bearing outer race locating ring 10-59Figure 352 Position output lange spacer on shaft Figure 353 Coat outer diameter of oil seal with Loctite 638 and press seal in the output shaft bearing cap with Ip of seal in. Using ‘new "0" rings install rear output bearing cap on transmission aoa Figure 254 Install lockwashers and stud nuts, tighten to specified Figure 357 torque. Position new “O" rings on bearing cap. Install cap on studs,Figure 358 Install lckwasher and stud nuts, tighten to specification. Figure 359 Install oll sump screen assembly and plug. Tighten plug 10 to 15 LBF-FT. [19-20 Nem]. REFER TO PAGE 10-94 FOR LOW (1ST) CLUTCH TAPER BEARING ADJUSTMENT. NOTE: After low (1st) clutch taper bearing adjustment and bearing cap and shims are installed and torqued, return transmission to an upright position. Remove low clutch rear bearing cap and shims and proceed to Figure 360. Figure 360 Install now 0" sings on the clutch pressure and lubo transfer tubes, position tubes in rear cover. Pack ol sealing ring grooves with grease, install sealing rings and center ‘ings in ring grooves. 1061 Figure 961 Position pre-selected shim pack on studs. Figure 362 Inctal bearing cap, washers and stud nuts. Tighton to ‘specified torque. Figure 363 Position the 2nd speed clutch dige hub on the low (1st) Clutch shaft. Install dso hub retainer ring Instal retainer ring rtainar. Install ring retainer, retainer ring. See Figure 264,Low Clutch Shaft Ring retainer retaining ring Dise hub retalner ring Retainer ring retainer 2nd Clutch Dise Hub Figure 364 Figure 367 Position the 2nd and 3rd clutch pilot bearings on clutch ‘shafts, alight coat of grease wil hold bearings in postion. Figure 265 ‘The use of alignment studs will faciitata housing to housing Install turbine shaft rear bearing outer race. ‘assembly. Install alignment studs and position convortor housing on studs. NOTE: Turn output shaft to align clutch dige hub In olutch dis Figure 369 Figure 366 Install convertor housing to transmission housing bolts and Install a new transmission housing to converter housing tighten to specified torque. NOTE: Bolts are not to be ‘gasket and °O" rings on transmission housing. A light coat of used to pull front cover to transmission housing. ‘grease will hold gasket in poston. Tighten bolts to specified torque (see torque chart).Figure 370 Pack oil sealing ring groove on stator support with grease. Inctall sealing ring. Install impeller hub bearing inner race ‘on siator support. Position support on turbine shaft, turn ‘support to clear pump drive gear. Align support holes with ‘converter housing. Figure 371 Install stator support screws and tighten to specified torque. For Lock-up s00 lockup section starting with Figure 393, Figure 372 Position impeller and cll bafle assembly In converter housing. Figure 373 Install oil bale retaining ring. Figure 374 With the reaction member spacer and dowel pin in place, position reaction member on stator support. Figure 375 Install reaction member to support snap ring 10-63Figure 382 Tighten crive plate screws per instructions. CONTROL VALVE INSTALLATION The use of alignment studs will facilitate valve installation. Figure 383 Position control valve to converter housing gasket and Control valve assembly on alignment studs, Figure 284 Install he two control valve to converter housing screws. 1065 Figure 985 Position one seal plate gasket, seal plate and outer seal plate gasket on studs against control valve. Figure 388 Position control valve cover assembly on studs. Figure 387 Install control valve cover screws, use caution as to install ‘screws in the proper location. Tighten screws to specified torque.Figure 368, Figure 391 Position solenoid protection cover and instal stud nut Install regulator to converter housing screws and washers and stud nuts. lookwashers. Tighten to specified torque. Figure 989 Tighten stud nuts to specified torque. Figure 392 Inetall charging pump suction tube, “O" ring, adapter fiting, ‘adapter flange and flange screws and lockwashers. Tighten sorews to specified torque. Figure 390 Install @ new °O" ring on the pressure regulator valve housing. Position regulator valve and charging pump on converter housing 1066HR36000 CONVERTER SECTION LOCK-UP. DISASSEMBLY AND REASSEMBLY PROCEDURE. CONVERTER LOCK-UP PERMITS DIRECT ENGINE DRIVE FOR HIGH SPEED TRAVEL CYCLES. This lock-up section must be used in conjunction with the HR36000 transmission maintenance and Service section of this manual for complete isassembly and reassembly. MAINTENANCE AND SERVICE, ‘The instructions contained herein cover the disassembly and, CAUTION: Cleanliness is of extreme importance and an reassembly of tho lock-up portion ofthe torque converter ‘absolute must in the repair and overhaul of this unt. Before ina sequence that would normally be folowed after the unit ‘attempting any repairs, the extorior of tho unit must be has been removed from the machine and is to be completely thoroughly cleaned to prevent the possibilty of dit and foreign ‘overhauled, NOTE: Some units will have drive gears and some ‘matter entering the mechanism. Units will have flex plato drive, Dieassembly and roassembiy willbe the same. DISASSEMBLY Figure 393 Figure 395 Remove impeller cover bearing cap bolts. Flomove front bearing retainer, retaining ring, Figure 396 Figure 398 Flemove bearing retainer ol sealing ring and expander lomove bearing cap and “O" ring. spring, 1067Figure 397 Remove bearing retainer. Figure 398 move impelir covar to impeller bots. Using pry slots provided, pry impoller cover and lock-up ‘assembly from impaller. CAUTION: When impeller cover is far enough trom impelier, use a hook and hoist in one of the bolt holes to prevent assembly from falling, Figure 400 Remove impeller cover to impeller “O” ring. IMPELLER COVER AND LOCK-UP DISASSEMBLY AND REASSEMBLY DISASSEMBLY : bE ‘| Figure 401 ‘Support impeller cover on blocks as shown. Tap turbine hub {rom impeller cover beating. Figure 402 lemove turbine and lock-up hub from impeller cover.i Straighten comers of turbine hub capscrew lockplate. Remove turbine hub capscrews and lockplates. NOTE: A change has been made on the turbine to turbine lock-up hub retention. See assembly instruction page for proper rei Figure 404 Separate lock-up hub from turbine. Figure 405 Remove lock-up backing plate to impeller cover self locking capscrews, Lee Remove backing plates. NOTE: Some lock-ups will have ‘one friction dise as shown in Figure 407 and some wil have two frictions discs soparated by a steol disc as, ‘shown in Figure 408. Figure 407 Flomove one friction disc. (1 plate lock-up), Figure 408 Remove two friction discs and one inner steel disc. (2 plate lock-up).Figure 412 Flemove lock-up piston inner piston ring from impeller cover. Figure 409 Romove lock-up drive dc. Figure 413 Flomove impeller cover bearing, See cleaning and inspection se as transmission maintenance and service manual and our ‘complete transmission disassembly and reassembly Remove lock-up piston. “3 Yy ly REASSEMBLY OF THE LOCK-UP, IMPELLER COVER AND TURBINE Figure 414 FRamove lock-up piston outer piston ring and ring expander Install @ new lock-up piston inner piston ring. Be sure ring spring, NOTE: Not al units will have an expander ring under lock joint is securely fastened. Grease ring to stabilize in the piston ring Fing groove, 10-70Figure 415, Position lock-up piston outer ol sealing ring expander spring in ring groove. install ol sealing ring over expander spring being sure lock joints securely fastened. Expander spring {gep to be 180 from sealing ring hook joint. Grease ring to {aciiate assembly into impeller cover. NOTE: Not all units will have an expander spring under the piston ring. Position lock-up piston in impeller cover using caution as not to damage the inner an outer piston rings. eg Tae Figure 417 Position drive disc in impeller cover, aligning holes in drive ‘ise with holes in impeller cover Figure 418 Install lock-up disc (tition). NOTE: Some units will have two (2) lock-up dises (friction) and one steal disc, if you hhave a two (2) lock-up discs, Install one (1) friction ise (teeth on the Inner diameter of disc). Install steel disc (teeth on the outer diameter). Install second friction isc. The steel disc separates the two friction disc: Figure 419 ‘Some units will have only one (1) friction dise as shown in Figure 419 Install raion de. Figure 420 Position lock-up backing plato in impeller cover aligning holes in backing plate with holes in drive disc and impeller cover.\ eat) x Figure 424 Figure 421 Position turbine and lock-up hub in impeller cover assembly aligning lock-up hub teeth with drive disc (discs). Install turbine in cover. CAUTION: Do not foree this operation. ‘Tum impeller cover and turbine over. NOTE: Do not let turbine lock-up hub slip out of lock-up dise (discs). TRANSMISSION PORTION OF LOCK-UP ® Figure 423 Install capscrew backing ing. Install turbine to lock-up Figure 426 hub special capscrews, ‘After converter housing has been removed, check turbine NOTE: SEE SPECIAL CAPSCREW INSTALLATION shaft to transmission housing lock-up pressure sleeve. If PROCEDURE ON ASSEMBLY INSTRUCTION PAGE. slaeve is to be replaced, remove sleeve retainer capscrow. 1072Figure 427 Romove retainer and sleeve. Figure 428 Remove modulator lock-up valve supply line tube nut from rmadulator valve. Figure 429 Remove supply ine from pressure regulator valve fiting. 10-73 Figure 490 Remove lock-up supply line from modulator valve. Figure 431 Remove supply line from lockup inlet elbow on transmission housing, Figure 432 Remove modulator valve from transmission. turbine and impelier cover installation.Figure 433 Position a new impeller caver to impaliar“O" ring on impeller "3 ! nate {Align holes in impeller cover with holes in impeller. Carefully installimpelier cover and lock-up assembly on impeller. Use ‘extreme caution as not to disrupt or damage “O" ring Install, Cover to impeller capscrews and tighten to specified torque. By Figure 495, ‘Align holes in bearing retainer with dowel pins in end of the ‘turbine hub. Tap retainer into position, 10-74 Figure 436 Install new sealing ring expander spring and oll sealing ring ‘on impeller cover bearing retainer. Expander spring gap t0 'be 180® from sealing ring hook joint. Figure 437 Install bearing retainer retaining ring Figure 438 Position a new *O" ring on impeller cover bearing cap. NOTE: If flex plate drive is used, see flex plate tion page. Inst3 ”W Figure 439 Figure 442 Postion besring cap on impeller cover using caution as not Install valve to adapter capscrews and washers tighten to to damage “O' ring. Install solf locking capscrews, tighten specified torque. (See torque chart). ‘capscrews 62 to 67 It. lbs. torque [71-77 Nem}, Figure 443 Figure 440 Install lock-up supply line from valve to Init eltow on Postion modulator lock-up Valve adapter and new gasket on transmission housing transmission rar cover studs. Insta lockwashors and stud nuts Tighten to spect torque. (See torque chart. Figure 444 Figure 441 Install lock-up valve supply line from pressure regulator Position lock-up valve and new gasket on valve adapter. valve to modulator valve. 1075eae ITEM DESCRIPTION 1 Hub tolmpaller Serew 2. 2. Impeller to Hub Screw Backing Ring, 3. Impeler 4 Impaler Hub "0" Ring 5 Impeller Hub. 6 Impeller Hub Bearing. 7 Beating Snap Ring 8 Reaction Member Spacer Dowel Pia. ons... 10 Reaction. Member 11 Reaction Member Spi 12 Turbine Hub Screw... 13. Turbine Hub Screw Bac 14 Turbine. z 18 Impeller to Cover “O" Ring 16 Turbine and Lock-Up Hub 17 Lock-Up Backing Pate Screw. 18 Lock-Up Backing Plate. 18 Lock-Up Disc, 20° LockUp Clutch Piate (Not used on one plate lckup) arty BBSRRSERSBRENBRRBN YF 1076 EM DESCRIPTION ary LookUp Dise. 1 (Not used on one plate lock-up) (Outer Drive Dis Inner Piston Ring Lock Up Piston. (utor Piston ing Piston "0" Ring. Impeller Cover... Impeller Cover Scrow Impeller to Cover Screw Impeller Cover Bearing... Bearing Cap to Impeller Cover Turbine Hub Snap Ring. Dowel Pin... Bearing Retainer... Fiston Ring Expander Spring ieton Ring Bearing Snap Ring Impeller Cover Bearing Cap. Bearing Cap to Impeller Co ‘and Lockwasher. Hie woe eae36000 WHEEL GROUP rem WITH LOCK-UP DESCRIPTION Hub to Impeller Screw Impeller to Hub Screw Backing Ring Impeller Impeller Hub “O* Ring Impeller Hub Impeller Hub Bearing Bearing Snap Ring Roaction Member Spacer Dowol Pin Reaction Member Roaction Member Snap Ring ‘Turbine Hub Screw ‘Turbine hub Screw Backing Ring Turine Impelier to Cover *O" Ring “Turbine and Lock-Up Hub Lock-Up Backing Plato Screw Lock-Up Baoking Plate Lock-Up Disc: Lock-Up Clutch (Not used on one plate lock-up) 10.7 TEM 21 DESCRIPTION Lock Up Disc (Not used on one plate lock-up) Outer rive Dise Inner Piston Ring Lock Up Piston Outer Piston Ring Piston Fing Expander Spring Inpeler Gover Impeler Cover Screw Lockwasher Impeter to Cover Screw Iimpeler Gover Bearing Bearing Cap to Impeler Cove Turbine Hub Snap Ring Dowel Bearing Retainer Pieton Ring Expander Spin Paton Ring Bearing Snap Ring Impelet Cover Bearing Cap Boaring Cap to impolr Cover Seow and LockwasherMODULATION SECTION NOTE: Clutch retum disc spring packs are certified according to compression weight specifications and are pre-packed in quantities to repair one (1) specific clutch. The disc spring packs are to be used as complete assemblies and care should be taken not to intermix the individual disc springs with disc springs in another clutch or disc spring pack. Each disc spring assembly is made up of selected springs to precisely match each part within this assembly. Failure to replace all piston return springs can result in unequal deflection within the spring pack. The result of this imbalance may adversely affect overall ife of springs. 10-78FORWARD CLUTCH DISASSEMBLY AND REASSEMBLY (Modulation only) DISASSEMBLY Figure 449 Figure 448, Fomove clutch shaft oll sealing rings. Pe — Figure 450 Figure 447 Pry clutch gear and outer bearing from clutch shat. ‘Remeve front bearing inner race retalner ring. Figure 448 Figure 451 Pry inner race from clutch shat. Remove clutch gear inner bearing 1079Figure 452 Figure 455 Remove clutch disc end plate retainer ring. Compress piston retum disc springs and remove spring retaining ring. Figure 453 Figure 456 lomove end plate. Use caution as not to lose end plate ball Remove retaining ring, ring retainer and dlse springs. See land spring, (Modulated clutch only.) note after Modulation Section heading. >, Figure 454 Figure 457 Flomove inner and outer clutch diss. Remove clutch piston