Maintenance and Service Manual a a” 32000 sr Powershift & % Transmission i | ee : R MODEL 4 SPEED LONG DROP a MPONENTS CLARICHURTE> | 1198.246 SM R324 (Rov. 1250)TABLE OF CONTENTS HOW THE UMITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Silhouette. 6.0... .c eee cesses Fig. A R32000 Transmission Case and Front Caver Group ......... Fig. B Rleverse and ard and Forward and 2nd Clutch Group ........ Fig. C Low, 4th and Output Group. cote tees ereeee Figs D Control Valve Assembly... ..ceccccsceeeeeeeeeeene Axle Disconnect and Mechanical Parking Broke. ..... Assembly instruction illustration... DISASSEMBLY OF TRANSMISSION. ........, beterreneee TF CLEANING AND INSPECTION 2-22 - 12 REASSEMBLY OF TRANSMISSION. .......00.02.0000ceeeeseeree 1B) SERVICING MACHINE AFTER TRANSMISSION GVERHAUL...,.... 27 SPECIFICATION AND SERVICE DATA........ ce. 28 LUBRICATION <2 e cee e teeter veeeereueeee 2B TROUBLE SHOOTING GUIDE... - . wo 29 CLUTCH AND GEAR ARRANGEMENT . ween SHIELDED BEARING INSTALLATION 2.20.0 00220...000 TYPICAL FOUR SPEED POWER FLOW. . coe 36 EXTERNAL PLUMBING DIAGRAM... 0.00.0 ....00cceeeee ss 87-38-39, CONTROL COVER GASKET IDENTIFICATION - oo... seee AOedt NOTE: Mettié Dimensions Shown in Brackets [|TRANSMISSION ASSEMBLY ‘The transmission and hydraulic torque portion of the power train enacts an important sale in transmitting engine pawer to the driving wheels. In order to properly maintain and service these units it is important to first understand their function and how they operate. The transmission and tarque converter function together and opyrate through a common hydraulic system It is necessery to consider both units in the study of their function and operation. To supplement the text below, and for reference use therewith, the following illustrations ace provided: Basic Design Sihoustte Transmission Case and Front Cover Group Reverse ond Grd, Forward end Zod Cluteh Group Low, th and Output Group Control Valve Assemtsly ‘Acie Disconnect and Mechanical Parking Brake Assembly Instruction Clute and Gear arrangement Shielded Beoriag tnstellation Four Speed Power Flow Extemal Plumbing The HR, and MHR Model Transmissions are of three basic designs, The R Model contisis of a separate torque converter, mounted to the engine with the powershift sans: mission remotely mounted and connected to the torque converter with » drive shaft, ‘The HR Model consists of a torque converter and powershified transmission in one package mounted directly to the engi The MHR version is @ mid-mount torque converter and transmission assembly connected to the engine by means of a drive shaft. (Seo Fig. A for basic design silhouette.) The shift contrel valve assembly may be mounted directly on the side of the converter housing or front Yransmission caver, or remole mounted and cannected te the wansmission by means af flexible hoses. Tho function of the control valve assembly is to di ct ail under pressure to the desired dicectional and speed dlutch, A provision is made on cerlain models to neutralize the Iransmission when the brakes are applied, ‘This is accomplished through use of a brake actuated shutoff valve. The speed and direction clutch assem: blies ere maunied inside the transmission case and are connected ta the output shaft of the converler either by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power flow through the gear train lo provide the desired speed range and direction. ‘An axle disconnect is optional and is located on the output shaft, The drive to the front or r onnected or connected by manual shifting.HOW THE UNITS OPERATE ‘With the engine running, the converter charging pump draws oil from the transmission sump thraygh the removable oil suetion screen and directs it through the pressure regulating valve and cil filter, The pressure regulating valve maintains pressure #0 the transmission cantral cover for actuating the diree- ion end speed clutches, This reqwices small portion of the total volume af oil vied In the system. The remaining walume of oil is directed through the torque converter circuit to the oil cooler and returns to the transinission for positive lubrication, This regulator valve consists af a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in « dosed position. When @ ‘specific pressure is achieved, the valve spool warks against the spring until a port is exposed along the side of the bore. This sequence of events pravides the proper system pressure, After ent a ing the converter housing the oil Is directed through the stator support to the converter blade ity and exits In the passage berwoen the tvrbine shalt and converter support. The oil then flows aut of the converter fo the oil cooler. After leaving the cooler, the oil is directed to a fitting an the transmission. Thon through 2 series of tubes and passages Ivbricates the transmission bearings end clutches, The oil then ‘aravity drains ts the transmission sump. ‘The hydraulic torque converter consists besically of three elements end their related parts to multiply engine torque, The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque convarier and is the primary com- ponent which starts the oil flowing to the other components which results in torque multiplication, This el: cement can be compared to 2 contrifugal pump in that it picks up fluid at Hs center and discharges at its ovter diameter: The torque converter turbine Is mounted oppasite the impeller and is connected 12 the output shaft of the torque converter. This clement receives fluid at its outer diameter and discharges at its canter. Fluid directed by the impeller out into the particulae design of blading in the turbine and reaction member i the means by Which the hydraulic torque converter mvt ies torque. The reaction mamber of the torque converter is located between and at the center or inner diameters of the impeller and turbine elements. Its function is to take the fluid whieh is exhausting from the inner portion of the turbine and change its direction to allow corract antry for impe reulation Into olement, The torque converter will multiply engine tocque to its designed maximum multiplication ratio when the out- pot shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing In spe aultiplication is ineceasing. the forque The shift control valvo atsombly consists of a valve body with selector valve spools, A detent ball and spring In the selector spoal provides one position far each speed range. A detent ball and spring in the dir spool provides three potitions, one each for forward, noutval and reverse, With the engine running and the i nal contro! lewer oeutral position, ell pressure from the regulat- ing valve is blocked at the control valve, and the transmission is in neviral. Movement of the forward and reverse spool will direct oll, under pressure to either the forward or reverse direction clutch as desired,CLARK When aither directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selacter spool. The same procedure is used in the speed selector. The draviteally actuated piston. The piston is “oil # jvestion oF speed clutch assombly consists of 2 drum wi hy" by the use of sealing rings. A steel dise with external internal splines and a bore to receive » hy- splines i inserted into the drum and resis a st the piston. Next, « frietion disc with splines at the inner dismeter Is inserted. Discs are alternaled until the required total is achieved. A heavy back-up plate is then inserted and secured with @ snap ring. A Hub with 0.0 splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direc: tion as lang a8 no pressure is present in that specific clutch To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows oil under pressure ta flow from the control valve, threvgh @ tbe, 10 2 chosen clutch shaft, This shaft has a drilled passageway for oil under presture to snter the shaft, Qil pressure sealing rings are Ineated on the clutch shaft. These rings direct oil under pressure to a dosirad clutch, Prossure of the ll forces the piston and discs against the heavy back-up plate, The discs, with teeth on the outer diameter, clamping against dises with teeth on the inner diameter, enables the hub and clutch shaft ta be locked together and allows them to drive as a unite There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston is released. R-32000 HR-32000 MHR-32000 FIG. AFigure BTem 2 3 4 5 6 8 2 10 ” 12 13 4 1 16 7 18 18 20 21 22 23 24 25 28 a7 2a 2 30 u Fa 3 3a 36 36 7 38 38 40 40 a a 43 a 45 46 a R32000 TRANSMISSION CASE AND FRONT COVER GROUP DESCRIPTION Finnge Nut Corer. PHO NU ese seceeeeeecececteceee ge Nut WaRHEE esse cscs ge “O Ring be Angut Hoge... we Jngut Flaage Oil Seat... Ingut Shot Front Bear Ingut hott Front Besring. 6... Input Shaft Frent Besring Retaining Ring Pipe Plug ceccsavsressareres Front Cover & Tube Assembly.» O° Rag... ard Speed Tube Assembly. Tube GlIp eee eeee Tube Clip Serew Lackwashar Tube Glip Sere oes Reverse Tube Assembly . Bresther - Front Cover Stew... Front Cover Stews Lock, Sleeve Lackserow Lockwasher Sleeve LACKEEIOW 5 re eeee = Input Shaft Input Shaft Rewr Bearing =o. Inout Shaft Gear Input Shaft Gear Retaining Ring =... Tune Steove re ‘Tuts Sleove Detent Spang... . Detent Spring... cee Valve to Converter Housing Serew- Valve ta Converter Housing Screw Lackwasher Convmol Valve Assumbly ..-..2. 2+. Conttel Valve Gasket Gover to Case Serow. Gover to Case Serow Lackwasher Front Cover Plug - Front Cover Plug Front Cover Plug Gasket... Cover fo Case Serem. 0-2... Gaver to Cage Serow Lackwasher Clutch Pressure Tube “O° Ring Tube SIGEVE sess cessyerersseeeeeeeee Low Speed Chen Pressure Tuba... ‘Cover to Cas Screw Lockwasher: 1 Retsining Fling « ITEM 48 49 50 5 52 53 Bt 55 58 5 38 58 60 a 62 a at 68 oe 87 ea ae iy n n n 4 1% 16 "7 1 8 80 a a2 83 Ba 85 86 ar 28 eg 80 8 92 98 96 95 DESCRIPTION Cover ta Case Screw. Roar Cover Bawel Pin. Roar Cover ta Transminsian Cone Gasket Rear Cover. i Rear Cover to Transmission Gast Sexew Fear Cover Pipe Fu oss. seers Riesr Cover to Case Stud Nut Riear Cover to Cane Stud Lockwasher. Cluck Pressure Tube "0" Ring Tube Sleeve . . ear Gover to Cane Stud Magnetic Benin Plug... .eeee+- i Level Plug - - il Level Plug. . . il Battie Screen Assembly. oe - Scan Assembly Gasket... 2... Tranamistion Case & Tube Assembly. Front Cover Gasket... Suction Tube Chip Washer . Svation Tube Clip ....- Suction Tubs Acsemblyy Progsura Tube “O™ Ring. 44th Spsed Prassure Tube. Tube Sleove Pressure Tube “O” Ring... Tube Sleave d4th Spaed Clutch Lube Tube ‘Oil Distoutar Retainer Ring 6... esses 44th Cluteh Frant Qi Distskutar, . : Locking Bll : ‘il Distributor Retainer Ring ‘Suction Line Screw ‘Suction Line Wahec. ‘Suction Line “O° Ring oss esese . Front Cever Dawal Pin... 0s . ‘Suction Tube Cli Rivet 2. Valve Plate to Caver Screw Lockwasher Valve Plate 10 Caver Screw... Valve Blase Plug. a ‘Valve Plate: Cover. . Control Val Mounting Pate es sscs Front Cover to Transmission Case Spacer Gasket Front Cove’ 19 Transmission Case Spacer Low Specd Prosauro Tube 0" Ring... Ath Soeed Pressure Tube “D” Ring ... Cover ta Transmision Geae Screw LectivasherR OR HR32000 REVERSE & 3RD & FORWARD & 2ND CLUTCH GROUP ITEM DESCRIPTION ary ITEM DESCRIPTION ary, Roverse & 3rd Clutch Shaft Piston Ring . Front Bearing Retamner Ring . Reverse & 3rd Shaft Front Bearing End Piste. Roverse & 3rd Shaft Bearing End Plate Ball, . 1 48 Low Cluten Drive Gear... 2 3 4 5 Reverse & 3rd Shak Front Bearing 6 ? 8 46 Gear Retwining Ring... es AT 2nd Gear : 4B Cluten Hub Ol Bala Ring - 49. 2nd Gear Retainer Ring. 80 2nd Gear Locating Ring Retainer, 81 2nd Gear Locating Ring Retainer Snap, 52. Spring Retainer Snap Ring 52 Spring Retoiner Snap Ring Retainer 54 Spring Retainer 55 Piston Return Sp 5H Spring Retsiner a 57 End Plate Retainer Ring .- BB End Plate - 2nd Clutciy . 89 Clutch Quter Dise - 2nd Clutch : 60 Cluteh inner Dise - 2nd Ciuteh. a 61. Cluteh Piston Assembly - 2nd Gluten 62 Cluteh Piston Guter Seal Ring 83 Cluich Piston Inner Seal Ring Front Bearing Retainer Ring . Clutch Driven Gear Bearing « Shield In Clutch Driven Gear Bearing Snap Ring ...... a 1 1 1 1 1 1 i 9 Clutch Drives Gear cece TV 10 Clute Hub Oil Baffle Ring cece TV 11 Clutch Driven Gear Bearing Snap Ring... 1 12. Clutch Driven Gear Bearing, . 1 13 Bearing Locating Ring. ......-.. 1 14 Spring Retainer Snap Ring... we 15 Spring Retainer Snap Ring Retainer ,.......<. 1 16 Piston Return Balleville Washer cee 7 17 End Plate Retainer Ring eee 18 End Plato = Reverse Clutch 1 1 Clutch Outer Disc» Reverse Clutch 2 20 Clutch Inner Oise + Reverse Clutch 2 84 Forward & 2nd Clutch Brum, 21 Clutch Piston Assembly - Reverse Clutch 1 @8 Clutch Piston Inner Seal Ring... .e. seco 22 Clutch Piston Outer Seal Ring cee 66 Clutch Piston Guter Seal Ring 1 1 1 1 1 6 6 1 1 1 i i 1 1 1 1 1 1 1 1 1 1 23 Clutch Piston lnner Seal Ring. - 67 Cluteh Piston Assembly - Forward Glutoh 24 Reverse & 3rd Clutch Drum: 68 Clutch Outer Dise - Forward Cluteh 35 Clutch Piston Inner Seal Ring. 691 Clutch Inner Disc Forvard Cluteh 26 Clutch Piston Outer Seal Ring 70 End Plate « Fonward Clutch 27 Cluteh Piston - 3rd Clute : Ti End Plate Retainar Ring .. 28 Cluteh inner Dise - 3rd Cluteh a 72 Piston Retum Belleville Washer... 29° Clutch Outar ise - 3rd Clutch a 73. Spring Retainer Snap Ring Retainer 30. End Plate - 3rd Clutch a 74 Spring Retainer Snap Ring 31. End Plate Retainer Ring a 32 Spring Retainer .... 33 Pistan Return Spring 34. Spring Retainer 35. Spring Retainer Snap Ring Retainer 36. Spring Retainer Snap Ring 37 rd Gear Bearing 38 3rd Geor Bearing Snap Ring. 28. Clutch Hub Oil Baffle Ring 40 8rd Gear. : 41 Jed Geot Bearing SIE cee 42. 3rd Gear Bearing Snap Ring . 43. 3rd Gear Bearing = Shield Out. . 48 Reverse & 3rd Shaft Rear Bearing. BB eee 75. Bearing Locating Ring - J Clutch Driven Gear Bearing - JT Clutch Driven Gear Bearing Snap Ring .. 7H Clutch Hub Gil Batlle Ring. .... 0... 78 Forward Clutch Driven Gear : 80 Clutch Driven Gear Beating Snap Ring B1 Clutch Driven Gear Bearing - Shield ln a 82 Front Bearing Retainer Ring 83 Front Bearing Locating Ring 84 Forward & 2nd Shaft Front Bearing. 85 Forward & 2nd Shaft Rearing Fd Plats Bl 86 Farward& 2nd Shaft Front Bearing End Plate, 87 Front Bearing Retainer Ring BB Forward & 2nd Shaft Piston Ring...R OR HR32000 LOW, 4TH & OUTPUT GROUP ITEM DESCRIPTION ary. Low Speed Cluteh Shalt Pilot Bearing 2nd Gear Bearing End Plate... 2nd Gear Besring...... Bearing Retaining Ring Rets Low Speed Gear Besring Ring - Low Spoed Gear Bearing Assembly . Law Speed Gear... Clutch Hub Oi! Baffle Ring . Spring Retainer Ring Retainer - Spring Retaining Ring Bellaviile Washer : Piston ta Belleville Weshor Spacer « End Plate Retaining Ring. . End Plate. eee ee eee eeees . Cluteh Inner Dise Cluteh Outer Dise Clutch Piston, Clutch Piston Outer Seal Ring. Clutet Piston Inner Seal Ring. Low Speed Cluteh rim Low Speed Shatt Rear Besring Bearing Lockbell Fear Beating Retsiner Plate Fleer Beating Retainer Plate Screw... Fiear Bearing Cap Gosket, Rear Beering Cap .. : Rear Bearing Cap Scraw Lockwssher Rear Bearing Cap Screw: . Rear Beating Cap Plug. — Rear Beating Cap “0” Ring a Clutch Shafi Piston Ring... Low Speed Shaft Rear Bearing Locating Ang Boaring Cap Screw Lockwash Bearing Cap Screw. . Bearing Cap Screw Lockws Bearing Cap Screw........ - Idler Shaft Bearing Cap Idler Shaft Bearing Cap Gasket, . Idler Shaft Nut. Idler Shaft Washer Rear Bearing Locating Ring. Idler Shaft Rear Bearing Lock Ball... Isler Shatt Rear Boaring , Rear Bearing Cap Oil Seal Rear Bearing Capserow Rear Bearing Capserew Lockwasher. .... Rese Bearing Cap Rese Bearing Cap “O" Ring. Rear Bearing Cap “O" Ring. Rear Bearing Cup we Regr Bearing Cone... esses se Bee ee ee me ee ITEM DESCRIPTION 52 53 5a 55 56 57 58 59 60 6 62 6a 64 65 86 er 68 69 7 n 2 73 7 8 16 7 78 it 80 31 82 83 84 85 86 a? 88 9 30 a 92 93 3é 95 36 37 98 99 Output Shaft Gear. Ouipsst Shaft Gear Spacer Ourput Shaft Front Bearing Cone Frent Gearing Cup... Frant Beating Gan “0” Ring Bearing Cap Shim. Front Bearing Cap. Front Bearing Cap Oil Seal Front Bearing Cap Screw... Front Bearing Cap Screw Lockwashor , Ath Gear Piston Ring...-.. + Ath Gear Front Besring Snap Ring. Idler Shalt Front Bearing Ath Gear Bearing Snap Ring... Ath Gear Bearing : 4th Geer Spacer. 4th Gear... 4th Gear Bearing Bearing Snap Ring ‘Spring Retsines. Piston Return Spring Spring Retainer. . ‘Oil Bettie Ring. Backing Plate Snep Ring ‘Cluteh Dise Backing Plete ‘Clutch Inner Disc: ‘Clutch Outer Disc ‘Cluteh Piston. Givtch Piston Outer Seal Ring (Clutch Piston Inner Seal Ring Ath Gluten Geum Locating Ring, Sth Cluteh Brom - Idler Shaft idler Shett Geor Key. . idler Shott Gear Bore Plug Disconnect Assembly - Oil Seat . ‘Sutput Flenge . ‘Output Flange “O" Ring, ‘Output Flange Washer ‘Output Flenge Nur - ‘Spaedo Orive Gear - Rear Besting Cap Rear Bearing Cap Screw Lockwasher Rear Beating Cap Screw. Spaedo Driven Gear. . 190Spaedo Tube Nut - 101 Rear Bearing Cap Screw... 102 Rear Bearing Cap Screw Lockwashar. 5 Ae OO ee ee eeTe ral || _ a | Figure EITEM DESCRIPTION ary. 1 1 2 Oil Seal Retainer Ring... 1 3 Oil Seal Retainer Washer .......... 1 4 Forward & Reverse Valve Spool...... 1 5 Control Valve Gasket.........--22++ 1 6 Detent Spring...............0.00-5 1 7 Detent Spring. ...... sess eeeeeeeeee 1 8 Detent Ballo... eee eee eee 9 Neutral Switch... 2.2... e eee 1 10 Detent Ball 1 17 Valve Housing Plug 1 12. Valve Housing Plug “O" Ring........ 1 13° Overshift Spacer(Noton all models}... 1 14 Cantral Valve Housing. wd 15° Detent Spring Plug...e.sceeeeeeeee 1 16 Detent Spring Plug Washer, 1 17 Detent Spring ....ceee.sseeeeee eens 1 18 Valve to Adaptor Housing Screw... 9 19 Valve to Adaptor Housing Screw Lockwasher ceceeteeeees 9 20. Speed Selector Spool Plug...-...6.+ 1 21 Speed Selector Spool.......-..6605 1 CONTROL VALVE ASSEMBLY ITEM DESCRIPTION ary. 22 Overshift Spacer (Not on all models}. 1 23 Oil Seal Retainer Washer . 1 24 Oil Seal Retainer Ring.......... 1 25 Oil Seals... ieee cs eeeee eee 1 26 Piston Housing Assembly .......... 1 QT Stop PUG eee eescveeeeeseeeeeee 1 2B Plug "O" RING. ce civeeeeeeeeeeee 1 29 Piston “O" Ring.............-2 ee 1 ST 1 BD Piston vo ceeee reser eeeeeeeees 1 32. Piston Housing 1 33 Oil Seal... es eeee eee 1 $4 Band Seal... 1 35 O" Ring 1 Figures A-B-C & D are various declutch options. 44 Adaptor Screw... ccceeeeeeeeee 45 Adaptor Screw Lockwasher.......... 0 & 46 Valve AGADIGE. is civeeeeseeeveee 1 47 Valve Adaptor Gasket ........ seed 48 Adaptor Screw... 8 49 Adaptor to Plate Gasket ..........5 1 50 Valve Adaptor Plate... .eeeceee 1ITEM, AXLE DISCONNECT DESCRIPTION ary. Disconnect Housing Capserew 4 Disconnect Housing Capscrew Lockwasher Disconnect Housing ........ coe Disconnect Housing Plug Shift Hub ... Shift Fork Shift Fork Lockscrew eM, 8 9 10 n 12 13 14 18 DESCRIPTION Disconnect Shaft Detent Bal Detent Spring Shift Rail Shift Rail Oil Se: Bearing Retainer Ring .. Bearing .... Bearing Reiainer Ring ..... MECHANICAL PARKING BRAKE DESCRIPTION arr. Backing Plate Assembly... Actuating Lever . Brake Shoe and Lining Brake Flange Brake Drum Brake Drum to Flange Screw Lockwather ... Brake Drum to Flange Screw .. TEM DESCRIPTION Return Spring .. Brake Shoe (see item 3).. Brake Lining Backing Plate Screw Lockwashi‘Bearing |.D. chamlers ta polnt toward wap rings as shawn Figure Giy wey light cast af Permatex No. 2 4 2.D, Tail seals before ass'y Ax LX cas inve santa 00 ag ot Ba An Sadan rns wih side steel plate, ZX, 0 este 09 na tare orn ON eves tn amazin rm ae 22, cos cane 000 na Tos Oot |A.- Use Permatex & Crane Sealer only where spectied. B.- Al ead in chamiors for oll goats, piston sings: & ‘Oring mist Dw smacth & tree tram murs Inepeet at assy 6. - Lubricate a piston ring grooves & "O" vings with of Betore assy 1D, - Apply very light coat of Permatex No. 210 0.0, cf all oll seals belare assy Moves ‘Shim oulput shat bearings to praducs 6 t0 B Lbs 1 [068.0.90 Nm] preioac. Tighten oil serean ass'y. 10 to 18 Lbs. P A faea.oNm Dd worn ye AN Ms: be one ita i bess No fon bearing. etched (12 Pinte Medulation} Twa clutshas,12-auter stosl Blote2,12:nner friction plates. Assemble alternately, Staring with outer ste! plate Bearing shield in .- Anor assembly of parts usag Permatex oF Crane sealer, thors must net be any foe or fexcese material thet could enter the oil ereuit F. = Apoly ight cost of Crane Sealer to a poe pugs G.-Apply a tin coating of grease between seal lis on lip type seals orice to ase H.- Apply ight coat of Permatex No. 2 10 yu oie stud trends, NOTE: Metric dimensions shown in Brackets [| [Low Cuutch Return Springs. Concave side of firs ballavita washer 16 be placed against cule piston. Remaining four ‘washers to be stacked alternately reversed ae shown iow “8” PLASTIC STOP NUT TORAUE Tame oe “a, i =e a Forward & Reverge Cluich Rewn Springs ‘Coneave side of frst osilgvilo washer 10 Be laced against cluich piston. Remaining sx ‘washers ef each clutch ta be slack allemataly raversed as shawn, Now | Fine THREAD COARSE THREAD Foe THAD COnnae THREAD See | weer ae wet ra ae eh a |] ae [ire eeg || asa | me wea | vis. er poe am a 1m [oo oat iza saa) [a3 asf sa 5. (soe seat |[ seo | [mr eea | se s[ ime. mal t [avg aam [area | panes soy | as. ae | paan ana 3ies | te 20 12 w | [sa ai || ev se | Cone. aa) | ae 90d as 08) 200 |b 60 | [oe—vasi|f nu) tise ie) 91 piea Mat Figure GNOTESCLARK MAINTENANGE AND SERVICE The instructions contained herein caver the dis- assembly and reassembly ofthe transmission in a seque that would normally be followed after the unit has been removed from the machine and is to be completely overhauled, It must also be understood that this is 2 basie 22000 trangmission with many options. Companion flanges end output shafts with and without disconnect assemblies may vary on specific models. The units are very similar to trouble shoot. disassemble, repair and re- assemble, CAUTION: Cleanliness is of exireme importance end am absolute must in the repair and overhsul of this unit, Before sttempting any repairs, the extatior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechenism. DISASSEMBLY Figure 1 Side view of teansmission Figure 2 Remave central valve bolts and washers, Remove control valve. Use coution as-not to lose detent springs-and balls Figure 3. Remove companion flange nut, washer and " Figure 4 Femove front cover plug.Figure & Remove bolts securing front covarto transmission housing. Figure & input shaft is to be removed. tap.on threaded end of shaft. ramove input shaft, gear and bearing. Figure & Remove from cover and forward and 2nd clutch. ‘spacer, (Used Figure 7 Use a sprending type snap ring pliers to-spread the aars an Figure 10 forward clutch front beetiag retainer ring, Remove forward Rear view of transmission luteh with pry bar.Figure 11 Figure 14 Remave output flange aut, washer and "0" sing. Remove low clutch rear baring cap. Figuee 12 Figure 15 Remove idler sheft bearing cap bolts, bearing cap, idler Cut and remove lock wire, Remove: low clutch shaft oil shaft nut and spacer. sealing ring Figure 13 Figure 16 Remove idler shatt rear beating locating ring. Remove 3 bolts and bearing retainer plate,Figure 17. Romove bearing Incating ring Remove low clutch double bearing cup, outer cane and spacer. Figure 18 Romove resr cover bolts, Using pry slots provided, pry cover from transmission housing tapping an low elute and idler shaft to allow cover to be removed without shaft binding, NOTE: The use of alignment studs wil facilitate caver removal, Figure 18 Rarove bearing lock-balls. CAUTION: Outer cone, double bearing cup, spacer and inner bearing cone are replaced a5 a set. Remove low clutch inner bearing cone. NOTE: To remove the inner cone bearing without damage, a special bearing puller must be made (ses diagram Fig. 22-8) or the outer age and rollers may be pulled trom the bearing inner race and the inner rice can be ramaved after the law clutch assembly has bean removed from tha transmission. Sae caution in Figure 21.ave ee rcent, CUnWITH Ui RUBBER WHEEL AFTER HOM, Figure 25 Figure 22-0, A timkin bearing cup, No. 29520 must be used with the above bearing puller. Figure 26 Figure 23 Remave 2d gear ring retainer snap ring. Fomove idler shaft end 4th speed cluten from housing. Figure 24 Figure 27 Remove low speed drive guar retainer ring and ative gear. Ramove 2nd gear retainer ring retainer.7 Figure 31 Figure 28 Remowe reer output shalt besring cap bolts and cap. Remave 2nd gear retsiowr Figure 32 Remewve front output flaage nat, washer, “O” ring end companion flange. Figure 20 Figure 33 Remewe low eluteh assembly. Remove output shatt front bearing cap bolts and cap.Figure 34 Block output gear. Push output shaft from rear through bearing and gear. CLUTCH DISASSEMBLY 0G NOT MIX BELLEVILLE SPRING WASHERS IN LOW CLUTCH WITH OTHER SPRING WASHERS (SEE NOTE IN FIGURE 43) NOTE: G0 NOT MIX THE FRICTION DISCS IN THE LOW CLUTCH WITH THE FRICTION DISCS OF ANY OF THE OTHER CLUTCHES, (SEE NOTE FOLLOWING FIGURE 88}, Figure 37 LOW CLUTCH DISASSEMBLY Remove low speed gear taper bearing ratainer ring. Figure 35. Remove low speed geer and outer taper bearing, Remove Remove cluteh shalt frant bearing race, low clutch taper bearing spacer.CLARK Figure 39 Remove clutch and plate retainer ring. Remove clutch and plate and inner snd outer clutch discs. Figure 40 Figure 41 Remove snap ring. ring retainer. Remave eluteh piston return Belleville washer retainer ring. A sleeve with » portion removed is recommended for removing the eluteh piston.return spring sellevilie washers andretainer ring, Sleeve shove is acommon pipe, with e 1- 1/21 [39,0 x26, Omm] opening. The pipe ts 6 x 3-1/4 x 2- ‘3/4 [156.0 x 88,0 x 78, Omm. Compreas Belleville west ‘Thraugh opening remove retainer fing, Relesee tension on washers. Remove spring retainer ring. Figure 43 Remove Batlville washers and spacer. Tum clutch over ane tap clutch shat on a block of wood ta remove clutch piston. NOTE: Belloville washers in the low clutch are different than washers in the forward and reverse clutch, Bo not mix low clutch washers with forward and reverse washers. ‘See page 33 for washer identification, FORWARD AND 2ND CLUTCH DISASSEMBLY (Forward being disassembled) Forward and 2nd clutch and reverse end Gnd clutch disassemble and reassamble the same except tarward and reverse clutchas use belleville washers or the piston return and the 2nd and 3rd cliches use @ spring for the piston returnFigure 44 Figure 47 Remove clutch shatt piston rings. Pry fromt bearing inner race from shaft. Caution: Do not damage bearing roller surface Figure 45 Figure 48 Remove front bearing retainer ring. Ramove frant bearing locating ting. Figure 46 Figure 49 Remove spacarand bearing. Caution: Do not lose lock ball. Pry gear up to accommadate gear puller.Figure 60 Figura 53 Remove clutch driven gear and guter bearing, Fomave inner and outer clutch discs Figure 51 Figure 54 Remove end plate retainer ring. Remove inner besring. Remove bearing locating ring. 10Figure 59 Figure 68 Remove clutch piston. Campress spring retainer washer, Through epeningramove spring ratsiner snap ring, Release tension on spring 4th CLUTCH DISASSEMBLY Figure 87 Figure 60 Remove snap ring and snap ring retainer. Wve clutch shaft piston rings and front bearing retainer Figure 58 L Remove Belleville washers. NOTE: Non-madulated Figure 61 clutches will have @ piston retum spring in forward & Pry bearing up to accommodate gear puller. Remove front reverse, bearing, ==Figure 63 Poy ath gear up io accommedete puller and remove. Figure 64 Remave inner bearing spscer and inner bearing, Dis- eazemble elutch discs and piston ae explained in previous Figure 65 Ii reat bearing and or gesr are to ba replaced remove gear and taper bearing from lutein drum, CLEANING AND INSPECTION ‘CLEANING Clean all parts thoroughly using solvent type cleaning ‘uid, tis recommended that parts be immersed in cleaning ‘iid and moved up and down slawly unt ail old iubrleent and foreign matarial is dissolved and paris are thoraugihly leaned CAUTION: Care should be exercised to avoid skin rashes, fire hazards end inhalation of vapors when using solvent type cleaners, Bearings Remove bearings from cleaning fluid and strike lat agpinst @ block af wood te dislodge solidified particlos of fubricam. Immerse again in cleaning fluid ta flush aut articles. Repeat ebove operstion until bearings are theroughly clean. Dry bearings using moistura-frae com- pressed air, Be careful to direct ale 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, ‘ate,, Thoraughly, Cast parts may be cleaned in hot solution tanks vith mild alkali solutions praviding these parts de not have ground of polished surlaces. Parts should remei solution long enough ta be thoroughly cleaned and heated. ‘This will sid the evaporation of the cleaning solution and nse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkeli, Cast parts mey also be cleaned with steam cleaner. 12CAUTION: Care should be exercised to avoid inhalation of vapors and skin rashes when using stkali cleaners All parts cleanac must be tharoughly driad immadiathey by using moisture-tree compressed air or soft, lintless absoriem wiping rags tee of abrasive materials such as metal filings, comtaminsted ail ar lapping compound, INSPECTION ‘Ths importance of earelul and thorough Inspectian ofall ports cannot be oversiessed, Replacement of all parts showing indication of waar or stress will eliminate costly and avoidable failures at e later date, Bosrings Carefully inspect all rollers: cages and cups for wear, chipping of nicks to determine fitness of bearings for further use, Do not replace a bearing cone or cua individ vally without replacing the mating cup of cone at the same time, Aer inspection, dip bearings in Automatic Trem mission Fluid and wrap in clean lintless cloth or papar to protect them until installed, Oil Seals, Gaskets, Etc. Replacement of spring load oil seals, "0" rings, metal sealing rings, gaskets and snap rings is more economical when unit is disassembled than premature overhaul 16 replace thase parts ata future time. Further loss of lubricent through a worn seal may result in failure of other more expansive parts of the assembly. Sealing members should be handled carefully. particularly when being installed. Cutting, scretching, ar curling under of lip of seal seriously impairs its efficiency. Apply thin cost af Permatex No. 20n the outer diameter of the oil seal to assure an oil tight fit into the retainer. When assembling naw metal type seeling rings, sama should be lubricated with coat of chassis graase to stabilize rings in thelr grooves for ease of ‘assembly of mating members. Lubricate ell "0" rings and seals with recommended type Automatic Transmission Fivid bofare assombly Gears. and Shates Irmagna-flux process is available, use procoss to check paris, Examine teeth on all gears cafefully for wear, pitting, chipping, nicks, cracks or seares. If geet teeth show po! where ease hardening is worn through or eracked, replace ‘with new gear. Small nicks may be removed with suitable hase. laspact shafts and quills te make certain they are not sprung, bent, or splines twisted, and that shafts are tua. Housing. Covers, ste. Inspect housings, covars and bearing caps te be cortain they e¢6 thoroughly claan and that mating surfaces, bearing borne, etc, are free from nicks oF burrs. Check ell pars ccaratully for evidence of cracks or condition which would ‘cause subsequent oll leaks oF fasnas: CLARK FORWARD AND 2ND GLUTCH REASSEMBLY (Forward being assembled) Figure 66 Figure 67 Insert slutch piston in clutch drum. CAUTION: Oo not damage sealing rings. See note in Figure 58. Figure 68 Install 1st Gellaville waster large diameter of bevel down as shown. NOTE: Do net mix forward clutch Selievilio low clutch washers. See NOTE: Figure 43. ‘washers 3BFigure 72 Install one frietion digs. Alternate steel end friction discs Figure 69 Until the proper amount of dises aro installed, Firat dise next 0 the piston ig steel, last disc install ion. lstoll 2nd Belleville waster with large diameter of bevel to the pintor 1, test dian Inestalled ta fredien. up. Install belance of washers. quantity of (7) saven alternating bovel Figure 70 Figure 73 Install Belleville snap ring ratainer and snapring, Compress Install end plate. Belleville vrashers and snap ting retsiner, install snap ting in lower snap ring groove. Install inner bearing locating ring. See page 33, Figure A, Figure 71 Figure 74 Ingert one steel disc, lastall end plate retainer ring.Figure 75 Figure 78 Intl utc evan gear nner beerng, NOTE: The Innet pata fra being oe bearing des not haves besnng shel Figure 76 Install clutch driven gearinta clutch dram, Align splines on clutch gear with internal teeth of friction dises. Tap gear inta position, Donot force this operation, Gearsplines must tba in full position with internal tasth of all friction Figure 77 Install driven gear cuter bearing, NOTE: Bearing shield in, Sen page 36 Install front bearing and outer race, 15FORWARD & REVERSE NON-MODULATED CLUTCHES AND 2ND& 3RD CLUTCH PISTON RETURN SPRING REASSEMBLY Figure a1 Install lock ball and bearing spacer. Install new clutch piston innerand outerssaling ring, Insert piston inte clutch eum using caution 8s net 16 demnage seals. Position inner spring retainer, piston retum spring, outer spring retainer and retainer snap ring rotainer and snap ring. Compress spring and retainer and install snap ring. See page 33. Figure B Assemble cluten discs and end plate as previously explained, LOW CLUTCH REASSEMBLY Figure 82 Install bearing retainer ring, Figure 85 Install neve clutch piston inner and outer sealing ring. Insert piston into clutch drum using caution as not te damage seals. Install piston to Belleville washers spacer. See NOTE: In Figure.43. Install Belleville washers. First washer Figure 83 ‘with large diameter of washer toward spacer, Alternate (5) Install piston rings, five washers. Sea page 33, Figure ©. —16-Figure 86 Position piston retun spring belleville washer snep ring. Compress belleville washars and install snap ring, Figure 87 Install snap ing reteiner Figure 88 Jnstall low gear inner taper bearing, Install one steel disc Install one friction die. NOTE: The friction discs in the low clutch has a higher co-efficient rating then the fiction discs inthe other clutches, therefore the discs must not bo mixed, Tha low clutch inner disc can be identified by an “x” stampad on one sida of tha inner teath. The low clutch inner dice also has a strip ef nen-soluble yollow point sprayedon the outer edge ofthe disc. Alternate steal and fretion discs until the proper amaunt of discs ate stalled, First disc next to the piston is steel, last disc Installed Is fiction, Figure Install end plate and retainer ring. Figure 90 Install low clutch taper bearing spacer. NOTE: When installing the 3rd gaar in the 3rd speed clutch a bearing spacer is used between the inner and outer 3rd gear bearing also, Figure 91 Install low gear into-clutch drum. Align gplings am low gear with internal teeth of friction dice. Tap gear into position, Do not force this operstion. Geer splines must be in full pasition with intemal teath of all friction discs, —7—Figure 92 Install low gear outer taper bearing. Figure 83 Install low clutch taper beering ratainer ring. NOTE: Retainer ring is selected at assembly fer proper ‘thickness, A snap ring kitis avsilable, Select the thickest ‘of the three rings in the kit that can be fitted into the snap ting groove to sesure # proper taper bearing tightness. Check ring as shawn for tight ring to bearing fit. Figure 94 Inguall love speed gaar taper bearing retainer ring ratainer, diameter of race down. 4TH SPEED CLUTCH REASSEMBLY Figuee 96 Instail piston, and piston retum spring See page 33, Figura 1, Install inner and outer dises 48 explained in Fig. 66 shrough Fig. 74. Instalt 4th speed gear inner hearing. NOTE: Bearing Pant Number must go dow, Sea Figure 99. pp Figura 97 Install bearing spacer between inner and outer 4th speed eer bearings. Install 4th speed gear into clutch drum, Align splines an clutch geer with internal teeth af friction discs. Tap gear inte position. Bornnt force this operation, Gearsplines mus bbe in full position with internal teeth of all friction discs. —18=Figure 98 Install 4th speed goar outer bearing. NOTE: Searing Part Number must go up. See Figure 99. It is recommended a rubber band be used to hold outer bearing rollers in position when installing bearing, Figure 100 Install outer bearing locating ring. —13- ote: Figure 101 Install front bearing and besring retainer ring. Figure 102, Install clutch shaft piston rings. TRANSMISSION REASSEMBLY Figure 103, View of output shaft as it would be positioned in trans mmission case. Nota front cane esting shoulderad on sha! with large diameter of Bearing in, and lang hub of gear toward gaar spacer.Figure 104 Position output geer in transmission case with protruding hub toward front of case. See Fig. 103, Insert output shat, gear spacer end taper besring fram front of case and through ovlgut geer, install frant taper bearing cup. Block ‘output sheft and instsll rear taper bearing with larga ‘diameter in, Figure 105 Gast outer diameter of oi! seal with press sesl in bearing cap with ip of asal in, Using new "0 tings install rear autput bearing cap, oll seal and taper besting cup on transmission case. Lube opening in bearing cap must be aligned with lube opening in case. Tighten beating cap bolts to specified torque. (See torque chart}. Figure 106, Install front bearing cep and shims. Tighten bolts to specified torque. Tap output shaft front end raar to seat taper bearings. Loosen front tearing cap bal Figure 107 Using an inch th. torque wrench, detamine the calling ‘torque of the output shatt and record. Tighten front bearing ‘cap bolts to specified torque, Chack rolling torque with bolts tight. Torque must be: 6 to 8 inch tbs, [0.68-0.,90 Nm} more than when bearing eap bolts were loose. Add or omit shims on thé frost bearing cap ta achieve the proper preload. Figure 108 Install output shaft front sompsnion flange, flange “O" sing, washer and flange nut. Block output gasr. Tighten nut to specified torque. [See elastic stap nut torque chat.) ~2—Figura 108 Figure 112 Install low eluteh front bearing, Install 2nd speed gear retsiner ring Figure 110 Figura 113. Inetall lovr clutch agcembly from rege of transmission case, Install 2nd speed gear ratainer ring retainer. Install 2nd speed bearing and plate and 2nd spead.gear on Figure 114 ow cluten abaft. Install 2ad gear ving retainer snap ing.Figure 115 Figure 118 Install reverse and 3rd clutch assembly from the front of the Install low cluteh inner taper bearing. NOT in hot oil bath prior to installation, Figure 116 Figure 119 Install low speed drive gear and retsiner ring Install Bearing spacer igure 117 Figure 120 Install idler ghett and 4th speed clutch assembly. Install bearing cup. 2Figure 121 Install outer taper bearing. NOTE: Heat bearing in hat oi bath prior to installation Figure 125 Inetall idler shoft spacer and nut, Torque nut to specified torque (Sre elastic stop nut torque chart.) Install retainer plate, inner diameter chamfer tavrard bearing. Figure 126 . Install alignment studs and new gasket. Place lock balls in Figure 123, low shaft and idler shaft. ighttcoat of grease will hold lock Install bolts and black qears. Torque belts to specifications balls in place. Position shefts eo lock balls elign with and look vite togathar. notches in rear cover 2Tsp cover in place and secure with bolts end lockwashers torque cover bolts te specifications. Install bearing cap with bolts and leckwashers. Torque te specifications, Figure 128 Ton low clutch and idler shalt to rear of transmission te allow for reer bearing snap ring clearance, Install snep ring. Figure 431 Install idler shatt rear bearing vesting ring, Figure 132 if install idler shatt beoting cop and cap ers. Torque bolts to specifiastions. Use mew gasket Inatall naw “O" ring and goskot on law shaft bearing agp. bolts and lockwa roCLARK Figure 136 Support converter housing with chain fal. Spread foward clutch front beating retainer ing and tap facwand and 2nd ‘lutch assembly into transmission case assembly. Be ‘zertaia snp ting is in full position in ring groove, Figuee 133 Install new "0" ring. Install washer and flange aut, Block aurpat shaft and torque mut to specified torqus. (Ses elastic stop: nut torque chert) RIVE GEAR een RING + INPUT SHAFT NOTE: LONG HUB OF ORIVE GEAR TOWARD. RETAINER RING Figure 134 Input shaft, rear beating, drive gear and snap sing. Figure 137 Install Bad speed clutch pilot bearing. Figure 136 Figure 138 Install input shaft ince front bearing, Inetell transmission ease gasket and "0" ring seals. —25—Figure 139 Install housing spacer, gaeket and “CO” ring seals. NOTE: Housing spacer is used with 12 plate clutch modulation only. Figure 140 Supper frontcovar with 2 chain fall. Install slignment studs in ‘transmission case. Position front caver asembly on aligning studs, Turn outputtlange teualiga eluteh dise huts in clutch, Oo not force this operation. With front cover in Position againet the transmission case install cover to case bolts, Tightan to specified torque Figure 141 Install front cover plug, Figure 142 Intell companiaes flange, flange “O" sing, washer anc nut Torque rut to specitieg tarqua, (See elastic stop nut torque hartt Figure 143 Locate detent balls and springs in control valve. Positian ‘sew gasket, Secure valve with bolts and washers, Tighten 10 specified toraue. NOTE: See pages 40 and 41 for proper control cover 26 =CLARK SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and hydraulie system ere important llnks in the drive line between the engine and the wheels. The proper eper- ation of either unit depends greatly on the condition andl operation of the other; therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the jab can be considered completed, Alter the overhauled o¢ repaired transmission has been installed in the machine, the oil cooles, and con- necting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a de- gree of judgment must be exercised as to the method employed. ‘The following ave considered the minimum steps to be taken: 1. Drsin ent system tharaughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning. 3. Replace cil filter elements, cleaning out filter eaves thoroughly. 4 removed. Flushing in direction of normal el flow will not adequately clean the eaolee. neces sory, coeler assembly should be removed from machine for cleaning. using cil, compr and steam cleaner for that purpose. use flushing compounds for ‘slesning purposer, 5. 7 On remote mounted torque cenverters romeve drain plug from torque converter and Inspect Interior ef converter housing, gears, etc IF presence of considerable foreign materiel is noted, it be necessary that converter be re- moved, disassembled and cleaned thoroughly. Ir Is realized this entails oxwa labor; however, such labor Is.» minor cost compared to cost of difficulties which can result from presence of such foreign material in the system. Rosssemble ali components and use only type oil recommended in lubrication sectior Fill transmission through filler opening until fluid comes up to LOW mark on transmission dipstick, NOTE: If the dipstick is not accessible oil level check plugs are provided. Remove LOWER check plug, fill until oil runs. from LOWER cil hole. Replace filler and level plug. Run engine two minutes st 500-600 RPM to prime torque converter and hydraulic lines. Re- check level of flvid in transmission with engine running at idle (500-600 RPMI. Add quantity necessary to bring fluid level fo LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install’ oil level plug or dipstick. ‘Recheck with hot ll (180-200" F.) [82, 2.93, 3° C], Bring cll level te FULL mark on dipstick or runs freely from UPPER oil level plug, Recheck all drain. plugs, lines, connections, ete., for leaks and tighten where necessary. TORQUE IN {LBS.—FT.) ‘BOLTS, CAPSCREWS, STUDS AND NUTS Grade 5 identification, 3 Rodial Dashes 120° Apart on Head of Balt LUBRICATED OR PLATED Grode 8 Identification, 6 Radial Dathes 60° Apart on Head of Balt Grade 5 Grade 8 [ Nomina Fine Thread ‘Course Thread Fine Thread Course Thread — | Bree | Torque tbe, PuiM.m. | Tosque Ube FeJem, | Torquo Ube. Fi./Mm. | Torqaw Ube, Fe/ALm. 3t2e | 1620 (907-271) v2.46 [16a217) | 28-32 [980-4941 aiso | 2020 /95.9a88) | 25-75 (51.2.3) 37-41 (602-556) 4176] 41-45 (55.681 0) | 37-41 (502 55.6) 5-64 (78.6-86.8) 52.57 (90.5-77.3) 5000 | Ga-70 (86.8-84.9] 57-63 (77,2-864] 0-08 (122,0-1382] | 80-88 [108.5-110.9) g26 | 9t-100 jizaarseq) | e790 (i11.21220) | 126-14) (079.5091,2) | 115427 (18 re‘CONVERTER OUT PRESSURE SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION AND TORQUE CONVERTER Converter outlet oll amp. 180" «20 F on riurRATION wer 835 o Teanemieaion in NEUTRAL, [Opresong specineann 28 PSI, [1724 KPs; minenum presmae sf 2000 RPM angi speed AND w Msn of FO PS ED. HP] cult gatas mh eine Soeeating wt ose powmed specs Seed Seaciion — Maran! Muze chica Myatt souateg, sprang reaoied autowsno wea compansaion ind ne vate. A cheng oil eaated ans Nees PATCH PRESUME ‘ELUNE INNER O82 frenion CUUTEH DUTEN OC Sime LUBRICATION TYEE OF OM See Lube Char caracry be Toraue hoaae . CHECK: PERIOD: . 900.600 RM wed oil at 180" to 08° 9 | aamat « | BRAIN PERIGO NOTE: Ie rocemmanded far itr tomer bbe changed ster 30 and 100 hours of sp: ration om sew and rab oe eptined writ Drain wananiashon end mest. sump terwan.” Cheon tern thoroughly, nd replace, vong new grate. (1 Drain at filers, remove and siscrd {ilar loan Clam filer salle and Install new elements (2) Rafat mansission to LOW mark (AD Res aging at 500-200 RPAN te pris wo running at “Sentymmmmtenee ‘5-000 BOM and ad oll ty bing Tavel fe LOW mark. When al eve i bot 86.200" 7} [02.2.933° C] sake Fal of evel cack, BRING Ol TEVEL To FUML MARK, Fall Neola ate Epa san ermine In sump ot beciom af eenamsion ome 280 280 al 884.8 18805 Fa] — Wich pakeng brake se owe note. of teneeratue 120" » 2007 F M22" » 833" C. engine atic [60 ta 800 FPR hit ma Gectian anc pees chaches. Alt cuseh pracore must be ecu wich © pe F,6 MP AF ‘ute preure varia inary ene teh Par AA al reper cluten NOTE. Hover use sence. brakes file rthing ‘euten presture ‘checks Unita hing. brah Seveved eclstching i Rarwed njor rover ‘wl nat ge 8 tue rang, “ALWAYS USE PARKING BRAKE WHEN MAKING ‘CLUTCH PRESUME CHECK sommes ease nausea mmr rovning Amaia Tarmpmracre ipediaaa an ener what cecaeibeae at Galkag Servs tae arrmmes es srmanca i ‘Normal drain periods and fier change intervals are fer a) Severe of sustained high operating ated deteriaration and contamination required change intervals. 26 rage environmental and duty-cyele conditions. temperatures or very. dusty stmospheric conditions, wil cvse scealer F extreme conditions judgment must be used to determine theTROUBLE SHOOTING GUIDE R and HR Mod: The fallowing data is presented as an aid t0 locating he soures of difficulty in a malfunctioning unit. it is ecestary to consider the foraue convertor charging pump, transmission, oil cooler, and connecting: lines fo @ complete system when running dawa the source of trouble tinge the proper operation of any snit thw in depends greatly on ihe canditian and operation: af For The 32000 Transmission the sihers. By studying the principles of operation rogerher with data in this section, it may be posible to carvaet any malfunction which may eccur ia the sytem, TROUBLE SHOOTING PROCEDURE BASICALLY CON- SISTS OF TWO CLASSIFICATIONS: MECHANICAL AND HYDRAULIC. MECHANICAL CHECKS Pia te checking any part of the system from a hydraulic stondpaint, the follawing rsechanical ehacks should be made: 1. A check should be made te be sure all control lever linkage i properly connected and adjusted at ail connecting. points 2, Check shift lavers and rods for binging ar restris- tions in travel that would prevent full engegement, Shift levers by hand a1 control valve, if full enga ment cannot be obtained, difficulty mey be in control ‘cover and valve assembly HYDRAULIC CHECKS Before checking on the torque converter, teantenis- sion, and allied hydraulle systern far pressures and rate of ail flow, it iz erential that the fellawing ppre- liminary checks be made: Check oil level in transmission, This should be dane with ail temperatures of 180 to 200" F. (82,2-73,9° DO NOT ATTEMPT THESE CHECKS WITH COLO CI To bring the oil temperature to this sped is necessary te wither week the machine er the convartae, Where the formar mauns is impractical, she larier means should be employed as follows! Engage shift levers in forward and high speed and apply brakes. Accelerate engine half 12 three quarter Heottie Hold stall until desired converler outlet temperature: ix reached. CAUTION: FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER LOW CLUTCH PRESSURE Cause 1. Low ail level, ‘Clute peeesu requlating valve epeel stuck pen. Remedy Fill te propor lovel Clean valve spool and housing. 3. Feuly charging pum Replace pump. 4. Broken or warn clutch shaft ar piston sealing rings Replace sealing rings Clutch piston bleod valve stude open. Clean bleed valves thoroughly LOW CONVERTER CHARGING FUMP OUTPUT 1. Low oll level 1. Fill to proper lew 2. Suction screen plugged 2. Clean suction sereen 3. Air leake at pump intake home and connections or 3. Tighten all connections or replace hose if necessary. collapsed hose, (32008 oniy) 4. Defective sil pump. 4. Replace pump. OVERHEATING 1. Worn i sealing rine 1. Remove, disastemble, and rebuild converter asbams bly. 2. Ween oil pump, 2. Replace, 3 Lowe oil level 3. Fill to proper bevel 4. Pump suction line taking alr. (R:32000 only) 4. Check oil line connections and tighten securely. NOISY CONVERTER 1. Worn coupling gears 1. Replece. 2. Worn ell pump. 2. Replace, 3. Worn or damaged bearings 3, & complete disassembly will be macessary to dat tine what bearing ls Faulhy. LACK OF POWER 1. Lew ongine RPAL at converter ats 1. Tune engine check gavernor. 2. Sea “Overhesting end make same checks 2. Make corrections os explained in “Gvecheating:™ —23-TRANSMISSION CLUTCH MODULATION ‘TRANSMISSION MODULATOR VALVE OPERATIONAL DESCRIPTION [Both dirgetional clutch assemblies are contolled by individual madulator valves, The pressure rise at side “A af the regulator spo! is the samme as thet applying the clutch pisten. Supply flow to te elutch and modulator is kmited bya flowrlimiting orifice. From this-limited flow the ragulater spoal dteins How to the vant port. The regulator spool restricts flow through the vent port to bbulld clutch pressure at @ peedatermined rate, Doe the vent flow fs shut off, aly minimal flaw passes through the Haw limiting jrifice to make Up for normal spool and clutch leskagas. Pressure on sitter sida af the onifies is virally idantcal and full regulstad system pressure Is epplled at the clutch piston, ‘When forward direction is selected the ofl under pressure onters the port on the “A side of the reguiator spool. This passes ‘through the quick release ball chock. The pressure fore on the spool area shifts the spool to the right exposing the wert part “The time required ta shift the regular spool over fo expase the: vent port shows up 8S & pressure apie at the beginning of the [pressure versus time: chart ‘The movement af the vagulatar spool is opposed by the ragulster and socumulator springs, This provides an intial low pressure hhead of appraximataly 20 ps! (137, Kpa] on the “A’ side of tha spool. This 20 psi 137.9 Kpal is represented as.a horizontal ne ‘on the pressure versus tins chart immadistety following the spike. Oil flows thrauah the ragulater spool orifice: due to a pressure Imbalance, Pressure ot ths side "A is constantly highar than side “B" a5 a result of the adcad force af the side “B” spring, ‘The prossure 0 SUPPLY OPC S08 4 QUICK RELEASE MonuLATED Oo BALL CHECK SLUICH pressunE. oO ° = EHeak bone Oo ce To FORWARD iter SYSTEM REGULATED CLUTCH PRESSURE MODULATED PRESSURE PRESSURE ‘This pressure spike i time required far spooks 10 ra Sate ‘Ths Soike pressuz6 is vBEd to Quickly fil the culch pressure SuDDy passages with al, 7 TIME BAsE—e} ACCUMULATOR SPRINGS ACCUMULATOR cavirTy FROM SUPPLY FORWARD. [= MODULATOR ~ ulema, ENT PORT QUICK RELEASE BALL CHECK PRESSURE PORT To FORWARD = CRUTCH BeguLarcr —31—CONVERTER HOUSING TO TRANSMISSION MODULATED VALVE ASSEMBLY ITEM DESCRIPTION ary. Item DESCRIPTION ory, 1 Accumulator Valve Stop Plug . 2 3 Regulator Spool . 2 2. Accumulstor Valve Stop Plug “O” Ring. 2 10 Regulator Spring. 2 3 Accumulater Spring - Qute 2 11 Regulator Spool Stop Plug "QO" Ring 2 4 Accumulator Spring - Inner -2 12 Regulator Spool Plu 2 8 Accumulator Valve Pin, 2 13 Modulator Valve to Plate Gasket . ot 6 Accumulator Valve .. 2 14 Housing Spacer Gasket 7 Plug cece 2 15 Housing Spacer @ Modulator Valve Housing .. 1 —32—FIG. A MODULATED FWD. & REV. CLUTCHES 2nd & 3rd & NON- FIG.B MODULATED FORWARD & REVERSE CLUTCHES \ 038 «049 [1.219 » 1.245] LOW (ist) CLUTCH FIG.D (4 SPEED ONLY) —a—32000 SERIES-4 SPEED CLUTCH & GEAR ARRANGEMENT CONVERTER CHARGE PUMP REPLACEMENT AND PRIMING PROCEDURI ‘The cause for pump failure must be found ancl comected before 4 relacement pump is installed, Check ail of the hoses, tubes, “D™ rings. adapters and split flanges Replace any collapsed or damaged hases, damaged split flange “0” rings, tube “O" rings and adeptors Alter all checks have been mada and corrections completed install the pump. See filling Instructions on page 27 Stat the engine. Run the engine at low idle for two minutes, watch the sluteh pressure gage and listan for cavitation of tha pume, H the pe sure does not came up, cherk the ail level and bleed off sir from system as follows, To bleed off the air from the system, loosen the pressure hase at the oil filter or pressure regulating valve, Crank the engine over until the THE ENGINE, 198 line at the pressure regulating valve or loosen the pressure is displaced with cil, OO NOT START W bleeding the lines docs not correct the problem it may become necossary te prime tha pump, Disconnéet the suction hose 1 pressure hose, whichever is highar, and fill the port with transmission ail, reconnast the hase and tighten, ‘Stort tha engine and check pressure Recheck oil level with hot ail (189-200°F) with engine at idle, Add oil as necessary to bring oil fevel to full mark —34—BEARING. SHIELD. DMUST FACEIN CLARK BEARING SHIELD “MUST FACE OUT FRONT BEARING SHIELD BEARING sme” MUST FACE OUT ————— BEARING SHIELD DAUST FACE IN SHIELDED BEARING INSTALLATION 35 —KEY —— 157 (Low) 4 SPEED TRANSMISSION a6 —32000 - C270/C320 EXTERNAL PLUMBING DIAGRAM Crack point “E" (Goat Fre preenurs Y cr (Fiar sazercty i208 char) Now Ene for pum must be breech fo a ot fee Lune tom pam to tar ana from far fo vege (Gheess port "3" ver it proscar Prue mg. ve ech pint 4° p-Ehach pseu ine Tonite Aral onsen and sagopa in ih onan art estion ‘Slt awa commie ‘or gray ran fo tars oo ‘Check point "3" | \ orto Be cecum unnmnes Soares sen act pstt comin pe mre me ciate ha occa, Sabana erase as See ne vee Seer had test maim Face tne cperaing regulerems, ee Me EE en acarucemon Eager Creve eect, wena eure Sere ace eae hr oe Sees ne ig a WeDo i yan a Songiercta ante Jera00Mi fees Hoss Speciation 2 Section Line be peau fore cola ty Fimrmoven sel ite. Aa S.AE. Spee. Brns004 Heraule Howe Spectator ER ASSEMBLY CHART ‘utabl for eburtion fom aon m2 {BSOeF [121150] Certinuoue operating temperate =r 3. Graity Dein Line—Suitte or mrs om Came Ne] Recaro; Ho foment from arian! io 250°F (N21 cornu 1 ‘opmming inmpacaiine Fal Si & Spee No. JSHTANORS A an Hyeratit Hoan Sip icon a amt eee 4, AIL Mowe Lines wey must snd 1s SAE. Sone. Nex 018 Test Prcechrw fr Mh ‘Temp. Tanamisson 01 Hew 5 Se Ltwication Speereatone, -a7-CLARK OIL CIRCUIT AND PLUMBING DIAGRAM FOR C-5000 OR C-8000 WITH R-32000 SERIES TRANSMISSION Port B Port A \ CR Port B Ct { x 3 . ey Suction ine mL obese a Port B. (Uppers ona 4 Drain tine” Pons Freie Pert To Fed | ‘Transmission Lube c ‘Auction Lina) 6 AB Port U - Glutéh Pressure AG E Pott AM - Converter Outlet Tempeature 4 Heat Port AN. Converter Outlet Presse Exchanger Note: Port AU Breather Heat aH Install Breather and Valve Aexembiy in highest Exchanger ! ‘converter Port as Bbresn Ln6) Mote: Por AS - Ganvertar Drain E - Ne Gravity Drain to Lransmission line must have uv ~ AK) ‘continuous slope from converter ta transmission, 38CLARK OIL CIRCUIT AND PLUMBING DIAGRAM FOR C-& CL. 270 AND RS2000 SERIES TRANSMISSION WITH MODULATION ‘AND AUXILIARY LUBE, PUMP _ a8 in ara fora Fora o pve READY in highaset comueronr poet me Conant reve snd Pee har om AE te peo chuch Pesoee Pema he ae Te Tet tee tian sn Cor From Port a ote: Po At Cortr Cutt Tempseatite Forts fo be ue ox Gormorn llat Tene Pew Pow Iwona: Por AN-Cemtrer Ques Prsature ral Each “Ouse Tomporatue Fore A Tale tube ee ak Pon gs Oh Sea Fooasi Presure Bor Pleguure Range So A fetta wha Se late S ee oma seca o | | Sanne nary emp Lehn Pan Por a” Port AF rs] co ae 6 wx constr wo) SOE ox tre sav ames we] | tee i Se eH en puns 8 NPA ete | ne BSL Naits| Men ree eee eer Sea ee are a my rm | el sr Hr eto gig Car sem at ee pe Wire su Sart sarang cep mtn = Susanne 7 IE ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PREBSURE CHECKS. 39 —90-9 32000 Control Valve (Vertical) With Modulation 40 —32000 Control Valve (90° Position} With Modulation a