Maintenance and Service Manual C 320 Torque I F Sho Converter i SPICER OFF-HIGHWAY Sn PRODUCTS DIVISION :TOWING OF PUSH STARTING Before towing the vehicle, be sure ta lit the rear wheels NOTE: Ifthe transmission has 4 wheel drive, disconnect off the ground or disconnect the driveline te avoid both front and rear drivelines. Because of tho design of damage te the transmission during towing. the hydraulic gystem, the engine cannot be started by pushing or towing. © Copyright DAMA SPICER OFF-HIGHWAY PRODUCTS DIVISION 1959 Unpublaneg matey All gr reserves Ne parte the work may be repreduced in any form under ‘any eheane-withou direct writen permission of DANA SPICER GFF-HIGHWAY PRODUCTS DIVISIONFORWARD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION product. Extreme care has been exercised in the design, selection of materials and manu- facturing of these units. The slight outlay in personal attention and cost required to Provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its Principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference ‘when performing maintenance and repair operations, Whenever repair or replacement of component parts is required, only DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION approved parts as listed in the applicable parts manual should be used. Use af “will-it” or non-approved parts may endanger proper operation and performance of the equipment, DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION, IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.‘TABLE OF CONTENTS HOW THE UNITS QPERATE. crear TORQUE CONVERTER ASSEMBLY (CROSS SECTION). ce INTERNAL OIL FLOW.ecsssssscseesensees TORQUE CONVERTER ASSEMBLY ~ EXPLODED VIEW. 4 ASSEMBLY INSTRUCTIONS... 87 DISASSEMBLY OF TORQUE CONVERTER... B CLEANING AND INSPECTION........ 415 REASSEMBLY OF TORQUE CONVERTER, PRESSURE AND LUBRICATION SPECIFICATIONS............. 23 IRREGULARITIES IN PERFORMANCE... 24 CONVERTER TO ENGINE INSTALLATION. ......c.cc000:csseeen 28 RING GEAR INSTALLATION (16 SCREW)... 26-27 RING GEAR INSTALLATION (32 SCREW) ......-..0.c:0ceccee seer 2829 FLEX PLATE INSTALLATION... 92-98 ASSEMBLY OF LOCK-UP COVER. ......ocssscespesesoseeon NOT! letric Dimensions Shown in Brackets [‘HOW THE UNITS OPERATE ‘The torque converter portion of the pawer train enacts an important role in delivering engine power to the driving wheels, In order to propérly maintain and service these units it Iz important to first understand theie function and how they opera The torque converter and transmission funstion together and operate throvgh a commen hydraulic system. To obtain maximum serviceability they have been designed and built |W is necessary, howrove 19 consider both units in the study of their function and operation, 12 text herein, and for rof To supplement nce use therewith, the following illu lions are provided Torque Converter Assembly — Cross Section Internal Oil Flaw — Torque Converter Terque Converter Assembly — Exploded View Assembly Instructions The torque converter Is compoted of four members: The impeller which is the driving member, the drive twrbine, which fs the driven member and the reaction member. The reaction member ion or can be free wheeling, de- pending on the application. The impeller and drive dise form the outer shell. The turbine runs within the outer shell and is connected to the output shaft. The oil is the only connection between the turbine and impeller member. Three pump drive gears are bearing mounted in the converter housing and meshed with a gear on the impeller hub. Wiih the engine cunning the pump drive gears rotate ot engine speed. The pumps are externally mounted on the converter housing and are connected to the pump shafts by a pump drive sleeve, With the engine running, the converter charging pump draws oil from the transmission sump and directs it through oil filters ta the pressure regulating valve located on top of the converter. From the regulating valve it is then directed to the transmission clwiches and inte the converter. Tho pressure regulating velve remains closed until requiced pressure is delivered ta the transmis actvating the direction and speed elutches. This regulator valve cansists of a hardened valve speal ape in a clovely fitted bore. The valve spool is backed up by & spring to hold the valve spool against it ‘the oil pressure averrides the spring fores. The valve spos| moves toward the spring until a port is exposed in. the side of the bore. The oil can flow through this port inta a distributor which directs the oil through passage inte the converter, After entering the convert fo the converter eavity. the directed into the converter support through the impeller bearing and Three members. of the torque converter are compoted of a series of blades. ‘The blades are evrved in weh a manner as to force the sil to cirevlate from the impeller to the turbine, theaugh the reaction member and again inte the impeller. This circulation cavses the turbine 19 twrn in the came direction as the impeller. Oil enters the inser diameter of the impeller and exits from the outer diameter into the outer diameter of the turbine, then exits frem the inner diamater of the turkine and through the reaction member. The oll again enters the inner diameter of the impeller. The oil exits between the turbine shaft and reaction member support and through an oil distributor which directs the cil out of the converter, and to the oil cooler. After leaving the cooler the oil is directed to the luk cating oil inlet on the transmission and through a series of tubes to the iransmission bearings, and clutches. ‘The oil is internally returned 10 the transmission sump.The converter lube and leakage oil is returned fo the transmission sump by a flexible hose installed in the lowes! pipe tap hole in the converter housing. This line must have a continuous drop te allow by gravity flow, leakage oil to return to the trammission sump. A safety valve it built in the pressure regulating valve and will open to bypass ail only if an excessive pressure is built up due to a blocked passage: With the engine operating at any speed and the turbine and output shafts stationary, the esnvarter is in 2 “stall” condition. Full power or wide open throttle “stalls far more than 30 seconds at 2 time will generate excessive heat and may cause converter or transmission seal domage. fis") Converters ney SI verfersC320 SERIES CONVERTER OIL FLOW DIAGRAM FROM FILTER a Ji aT fe | hess} of = TQ COOLER: it ceo Ib GRAVITY DRAIN TO (BBnicu pressure TRANSMISSION SUMP Clow pressure (icaavity & suction320 CONVERTER ITEM DESCRIPTION ary, 1 Wale Stop o.oo eee 2 Valve Stop "O" Ring =... 3 Valve Pi 4 Valve Spring - lange... seers & Valve Spring - Quter 00... . 6 7 8 3 Valve Stop Roll Pin Rogulator'Valvo to Housing Screw Lackwasher.- Regulator Valve to Housing Screw..........- Valve Sion Roll Pin Be 10 Valve Stop “O Ring VW VaNE SHOR oo. eceeeeteeeeeeeee . 42. Regulstor Valve Assembly, am 13 Valve Housing Pipe Plug 14 Volve Housing Pipe Plug 15. Sofety Value Seat 16 Sofety Valve Plunger 17 Sefety Valve Spring . 18 Regulating Valve to: Housing °O" Ring 18 Regulating Value to Housing Gasket 20 Pump Drive Gear Snap Ring. 6+ 21 Pump Drive Gear vos 22 Conveiter Housing Adaptor Ring 23 Breather Assembly. 24 Converter Housing. 25 Pump Drive Shaft Bearing. 26 Pump Drive Shaft Spact 27 Pump Drive Shaft Bearing. «ses .+1 28 Pump Onive Shaft Bearing Snap Ring 23° Pump Drive Shaft, 30. Pump Orive Shaft Snap Ring 31 Pump Ovive Shaft Washer 32 Pump Shaft Snap Ring 32° Charging Pump Sleeve... 34 Charging Pump Gasket... 38 Converter Charging Pump, 36 Pump Mounting Stu 37 Pump Mounting Stud Lockwasher 38 Pump Mounting Stud Nut 39° Quiput Shaft Nut ... 40° Output Shaft Washer 41 Qutput Shaft “0 Ring. 42° Output Flange 1g Retainer Oil Seal 19 Retainer Stuet Nut... 45 Bearing Retainer Stud Lockwashar 48 Bearing Retainer SUA... cece sesie 47 Bearing Retainer Screw. 48 Bearing Retainer Screw Lackwrasher 43° Bearing Retainer. 5O Bearing Retsiner "0" Ring 51 Gutput Shaft Near Bearing nx Hae ees 52 Qutput Shaft Bearing Snap Ring 53 Qutput Shaft. 36 See SSSS Mees ee EE eee ee he eee ITEM DESCRIPTION ary. 54 Ounput Shah Gear 2-8-2 eee 85 Output Sha Front Bearing... 7 56 Bearing Snap Ring...... 1 57 Converter Housing Pipe Piug .- 1 58 Oil Battle Seraw Loekwashor 3 59 Oil Batlle Screws 3 80 Converter Housing Pipe Plug 1 61 Converter Housing Pipe Plug... ......+. 4 62 Gear Snap Ring eee T 63. Turbine Shaft Goor, 1 84 Turbing Shaft Snap Ring 1 65 Turbine Shaft Bearing . 1 86 Turbine Shaft Piston Ring 1 67 Turbine Shaft 1 68 Stator Suppor & Sieve Assembly 1 69. Piston Ring Expander Spring 1 70 Stator Support Piston Ring 1 71 Impeller Hub Gear Snap Ring. 1 72 \mpeller Huts Gear . 1 78 Statar Support Serew ... cee 6 24 Stator Support Sarew Lockwasher 6 75 Turbine Mul Serew anaes 8 76 Turbine Hub Serew Wesher 3 27° Turbine 1 78 Turbine Hud teed 29 Reaction Member Snap Rina .- 1 80 Reaction Member. 2 1 81 Reaction Member Spacer... ; 1 82 Bearing Snap Ring. 1 83 Impeller Hub Bearing weed 84 Impollar Hub... ee so0 weed 85 Impeller Hub “O" Ring weed 86 Impoller. 1 87 Impeller Hub Serew Backing ei 88 Hub to Impeller Screw ssriges 2 12 89 Oil Baffle wo ceeeteetereeeeeeeee W 90 Oil Baffle “O" Ring -....- 1 91 Oil Baffle Oil Seal........ . 1 92. Impeller to Cover “O° fling. 93° Impeller Cover 2 rr | Q4 Impeller Cover Bearing ....... peneee 95 Bearing Cap to Impeller Cover "O" Ring. 1 96 Bearing Washer - 1 97 Bearing Snap Ring........eeeeeveeeeeeeeeee T 98 Impeller Cover Bearing Cap ........ecseceeee V 99° Impeller Cover Sleeve... : 1 100 Ring Gear Serow eisies10 101 Ring Gear Screw Plain Washer 16 102 Flrwhee! Ring Gear . 1 103. Bearing Cap th Impeller Cover Serew ......... 10 104. Bearing Cap tolmpaller Cover Screw Washer .... 10 105. Impeller to Cover Screw er 106. Impeller to Cover Screw Washer ea tas: 24ic & cL-320 ASSEMBLY INSTRUCTION WITH OFFSET OUTPUT GENERAL NOTES. 3001 Parmates 8 Crana adler sey where specified Fy ight coat of Permater No 20 Dt ak notes shown ‘Prmatox suds uses rear bear esp —5—one PLATE UIcH 30 9 85 tba ina? my Fora Turbine os ‘Terqua cap serous & tcamire wary. 2 capacrows toget aa show, forme rust nex prose above ipsa Pe [EB weet Pea ak of canbe ects Saudia oxverar ‘OFFSET DRIVE WITH LOCK-UP Une: sring wth at nner ince srouldar ant. Do tbe bear nih eal ‘lt goaves in nee Torque Sprcteaton tr ates Pte Renew Tends crate 8 POWER TAKE OFF LOCKUP Wirk TACH ORE Tevgue cap ses ten comers Neck abs up gant bo hex Hate se oan, = vse 8 may | weer in, ‘GOARGE THRE uae eM ese | ang zen) | Tra srw | va. anal nat El Bie saa a a1 33m “3 woe) pies a ag] eae | ber a) ealOVERHAUL INSTRUCTIONS FOR TORQUE CONVERTER The following instructions will cover the di CAUTION: Cleanliness is of extreme importance and an and reageembly jorque converter in 3 sequence that abgolute mustin ths rapairand avechaul ofthis unit, Batore wel tallewed after the unit is removed From attempting any repairs, the extarior of the unit must be a completely overhauled raughly leaned to prevent the possibility of dirt end foraign matter entering the mechanism, DISASSEMBLY OF THE TORQUE CONVERTER Figure 1 Remave impeller caver bearing cap bolts Remove beating cap and drain oil. This will till nat drain all of the olf but will catch most of it Figure 2 CAUTION: Convorter can net be complately drained of oil thru drain plugs. Ita recommended a container be used Figure 4 to catch oil, Use puller scraws in threaded holes in bearing Remove impeller cover besring to turbine hub retainer cop. ing.Figure 14, pump stud nuts. Figure 15 charging pump assembly. fe impeller andoil battle —10—Figure 26 Remave impeller hub to impeller belts Figure 23 Remave impoliar hub gedr retaining ring, Support outer edge of impeller cover, Using an appro- Figure 24 priate driver, drive turbine hub from impeller cover bearing Remave hub gear. Using an impact wrench (if available) remove: output flange na. Hf impact wrench ig not avilable a flange Figure 25 retainer bar must be used to hold flange from turning while Remove oil battle and seal from impeller hub, removing flange nut. 12Figure 32 Ourput shaft, gear and bearing pressed from bearing Figo Using a spreading type snap ring plier, spread ears : ar output shaft beating snap ring. Press bearing * Remove flange nut, washer, "0" ring and flange from outpst es by bearing retainer while apreading snap ring Figure 33 Remove reaction member support bolts, Remove support and turbine shalt assembly, NOTE: if converterhousing has bore plug in the rear centor line, remove plug, Remove turbine shaft gear retainer ring, Remove suppor and wall remain in rear of housing. This is apecial ratio gearand is larger than the support bore. Figure 30 Remove output shaft hearing retainer bolts, stud nuts and washers. turbine shaft assembly. Turbine shaft ge Figura 34 Figure 34 From front of housing drive output shaft assembly from Remove turbine shaft gear retainor ring and ggar, Soe converter housing note above —13—Figure 365 Remove turbine shaft bearing retainer ring from Figure 38 Remove support cil sealing ring: some models wil have an expander spring also. Figura 36 Remove turbine shaft and bearing fram suppor Figure 39 Remove prossure regulating valve to housing sarews and ockwashers. Figure 37 Remove turbine shaft oll sealing sing 1a Figure 40 Remove pressure regulating valve, safety valve plunger and spring,of Samm a Figure 41 it pressure regulating valve is to be disassembled compress valve spring stop, Taprall pin from valve housing, CAUTION: Spring stop is under spring pressure. Romova spring stop. inner and outer spring and valve piston, CLEANING AND INSPECTION CLEANING Clean all parts thorowghly using solvent type clean- ing fluid. 11 is recommended that parts be immersed eleening fluid and moved up arid dawn slowly until all ald lubricant and foraign material is dissolved and parts ere thoroughly cleaned CAUTION: Care should be exercised to avoid skin rashes, fire hazards and inhalation ef vapors whon using solvent type cleaners. Bearings Remove bearings from cleaning fluid end stctke of cone flat against a black of wood to dis- larger si lodge solidified particles of lubricant. Immarso again in cleaning fivid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed aie. Be care Ful to direer air stream across bearing 19 avoid ning. Do net spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process Freewhee! Assembly Clean the complete freewheel! assembly the same as cleaning bearings. NOTE: Do not disassemble free- 1eel assembly. If freewhesl arembly is damaged must be replaced with a complote assembly. Attor closning and drying freewheel assembly dip camiplete assembly in automatic transmission fluid an Housings Clean interior and exterior of housings, bearing caps, tc., thoroughly. Cast parts may be cleaned in het solu- tion tanks with mild elkali solutions providing these paris do net have graund or polished surfaces, Parts should remain in solution long enough to be tharough- ly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water, Parts cleaned in solution tanks must be thoroughly rinsed with clean water to removo all tracos of alkali. Cast parts may alzo be cleaned with steam cleaner. —15— CAUTION: Core shovld be exercized to aveid skin raahes and inhalation of vapors when using alkali cleaners. Thoroughly dry all parts deaned immediately by maisture-free comprsised air or soft, lintless ab- sorbent wiping rags free of abrasive materials such as. metal filings, contaminated oil or laping compound. INSPECTION The Importance of careful and therough inspection of all parte cannot be oversivessed. Replacement of al Parts shawing indication of wear or stress will elimi= aie costly and avoidable failures a a later da Bearings Carefully inspect all rollers, cages and cups for woar, chipping oF nicks t0 determine fitness of bearings for furthar use, De not replace @ bearing cone or cup individually without replacing the mating eup oF cone at the same time. After inspection, dip bearings in -cloan light oil and weap in clean lintless cloth or paper to protect them until installed. Oil Seals, Gaskets, Ere, Replacement of spring lasd oll saals, SO” ings, metal sealing rings, gaskets and snap rings is more cesnem- ‘eal when unit is disassembled then premature over- haut to replace these parts at a fulura time. Further loos of lubrieant through o worn seal may result in failure of other more expensive parts of the ascembly. Sealing members should be handled carofully, particularly wien being installed. Cuming, scratching, or curling vader of lip of seal seriously impairs its efficiency Apply 8 thin coat of Permatex No. 2 on the outer iameter of the ail seal 10 assure an oil tight fit into the roteiner. When assembling now metal type seal- ing rings, same should be lubricated with coot of hast grease te stabilize rings in their grooves for of assembly of mating members. Lubricate all Rings and seals with Automatic Transmission Fluid before assembly. Gears ond Shafts If magma-flux process is available, use process to check parts. Examine leeth on all gears carefully for wear, pitting, chipping, nicks, cracks or ecores. if gear teeth show spots where ease hardening is worn through or racked, replace with new gear. Small nicks may be: remeved with suitable hone. Inspect shatts and quills to make certain they are not sprung, bent, or splines twisted, and that shafis are truce Housing, Covers, ote. Inspost housings, avers and bearing capt to be certain they are thereughly cleaned and that mating surfoces, bearing bores, etc. are free fram nicks or burrs. Check all parts carefully for evidenes of cracks or conditions which would cause subsoquent oil leaks or failures,REASSEMBLY OF TORQUE CONVERTER NOTE: If converter housing was changed. see page 31 for ‘speed sensor bushing installation. oF a = Figure 42 If pressure requlating valve was disassembled, re assemble as follows: Install new "0" ring on valve spring stap (one on each end. only ene shown). Insert piston in housing, Install ner and outer valve springs. Install spring stop on spring. Depress spring stop and install spring stop roll pin Figuee 43 Position safety valve spring and plunger in converter housing. Figuee 44 Install new gasket an canvarter housing, and now “O" ring onvalve housing. Position valve.assemblyan converter housing. -16— Figure 45, Install valve screws and lockwashers. Tighten 23 to-25 las, torque [31,2-33,8 Nm) Figure 46 Apply a light coat of Permatex on the outer diameter of the output shaft ail seal, Press oil seal in bearing retainer from inside of ratainer as shown andto dimension shown. See assombly instruction shaat, page 6. Figure 47 Spread ears on the rear beering retainer ting in bearing rotwingr, Pross output rear bearing in bearing retainer. Be ‘certain snap ning is in full position in snapring groove. Press ‘output shaft into bearing retainer. Use eaution a8 nat te ‘damage oil seal, Position output gear on shaft. Press front ‘output bearing on shaft, NOTE: Use bearings with full inner race shoulder only. De not use bearing with seal or shield grooves on inner race. Install bearing ratainar ring.Figure 48 Install output flanga, “O” ring, washer and fienge nut Tighten nut 200 10 260 ft, ibs. torque [271.2-338,9 Nan) Install new “Q" ring on autput shaft bearing retainer Position output assembly on converter housing, Install lockwashers, eap serows and stud nuts. Tighten stud nuts 41 t0 45 ft hs, torque [55.6-61,0 N.m). Tighten ‘capscrews 37 to 41 tt tbs, torque [50.1-58.5 Nm \. Figure 50 Install new wil sealing ring, Expander spring no longer Used with new sealing rings Figure 61 If turbine shaft bearing was rmoved, press bearing on shalt. NOTE: Ball bearing loading notches must be away from shoulder of turbine shatt. Install naw turbine what oil sealing ring. Figure 52 Install turbine ehaft asgembly in reaction mamber suppart. Use etution as not ta damage turbine shaft oil sealing ring. 17 Figure 63 Install turbine shaft bearing rataining ring.Figure 54 Figure 57 Position turbine shaft qear on shart. Install Tap pump drive shaft assembly into housing until rear fing. See note in Figure 33 and reassemble a bering snap ring snoulders in bearing bare Wael \ L aa Figure 58 Figwe 88 instal suppor washers and crews. Torque screws 87 10 Postion pump shat ree’ Beating reaieing washer In a's. tre (772984 Nl newing Figure 56 Position puma drive shaft and bearing assembly into Figure 89 converter housing. Install ratainer washer snap ring,Figure 60 Install pu gear. Figure 61 Install deive gear rotainar sing. Figun Clean impeller hub maunting surtace and tapped holes with solvent. Dry thoroughly baing cantain tapped holas are dry and clean. install new "O" ring on impeller hu, Position impeliarhub screws backing ring, (NOTE: Backing ring used (on 13° convertars anly). 19 Figure 63 Align holes in impeller hub with holes in impeller, On 12" converters with 8 impellar hub screws, install serews and flat washers. Tighten 41 to 45 ft. Ibs. torque [55.6-61.0 N.m}. Lockwire in pairs to prevent loosening. Sav view R” on page 7. SEE FIGURE 64 FOR 13° CONVERTER WITH SPECIAL IMPELLER HUB SCREWS, r Figure 64 12" Converter with 12 special serews and backing ring. Install |12) impaller hub special screws to approximately 06 inch [1,5] of seated position. With calibrated torque wrench, tighten screws te 40-85 Lbs. Ft. [54.3-61.0 N.m] torque. NOTE: Assembly of impeller to impaller hub must be completed within a fifteen misute period from start of screw installation, The serawe are prepared with casting which beqins te hardan aftee installation in the iepeller hub holgs, If not tightened te proper torque within the fifteen minute peciod, inautlicient screw clamping tension weil result. The special ecrew is to be used far one installation only. IF the screw is remowad for any reason it must be replaced, The compound left in the hub holes must be removed with the proper tap and cleaned with salvant. Dry hole thoroughly and use a new screw for reinstallation.Figure 65 Figue 68 Install new oil baffle ofl seal as shown in assembly Support turbine and hub assembly at the turbine hub e nstiuctian sheat page 6 Position baffle and seal on ‘outer aage, Position impeller caver ovor turvine assembly, mpollor assembly use caution ax not to damage oil seal centaring bearing bare with turbine hub, Install impeller cover bearing Figure 68 Figure 69 Position impeller hub gear on hub. Install bearing spacer and retainer ring Figure. 67 Figure 70. Install hub gear eetaining ting, Instell new oil baffle "O” ring. —20—Figura 80 on impeller cover. install bearing cap Tighten to spacifications Figure BY Figure 73, Position pump drive slaeves on pump drive shafts install impeller cover to impallar bolts. Tighten specifications Figure B2 ing plump st the same pump opening it was mm. Ingtall stud nuts ancl washers, tighten to 2Converter Out Pressure OL PRESSURE AND LUBRICATION SPECIFICATIONS, FOR C220 SERIES CONVERTERS Operating specifications: Converter outat of temperature 180° - 200" F. (32,3° 99.9" Cl Transmission in NEUTRAL. 25 P.S1. [1724 kPal minimum pressure at 2000 RPM engine peed AND a maximum of 70 PS. (482.6 {kPa} outlet pressure with angine operating at no4oad governed speed. Converter outlet prasssure equals the total pressure drop of the cnoler, coolar lines and beck pressure of the tranmamis: sion lubrication systems. Converter Lube Flow Loakage in Convertor TYPE OF on caraciry Heck reno DRAIN PERIOD Disconnect CONVERTER DAAIN BACK ine at transmission with engine running at 2000 RPM and measure oll into a gallon containes. Messure ol leskage for 15 seconds and multiply the walursa of cil by four to get gallons per minute leckage. LUBRICATION Laakage in C320 sorias not t0 exceed 2 gallons maximnun. RECOMMENDED LUBRICANTS FOR CLLSK POWER SHIFTED TRANBMISBION Set Lube Chart Consult Operators anual on seal raechine maul for system aipacty Targue Converter ransminsin and alld hydracte sya mutt be canadered at a hale fo Steemine apace Che. 200400 8°94 end sitet TBO" to 200" F [2.2 93,3" CL Mainatn os level fo FULL ark | DAIRY with engine sunning nary 500 hours, change sl filer slement, iad ool nyse at rust 90 300" (MOTH: Ie vetemmandd Yas fbr elanéss bee deanged shy 50) and 100 hover ‘shee oe mew and rebuilt or enpeced unite (shale tonsils and vemave au rman, "Cleon serean Thoroughly ‘eplace, eng new gasket (8) ain a ar, rene ane tar ‘er lamer. Clean fr shell sd Ingall new sleet, (6 ell ranemission to LOW mark « (a) Recheck level with engine runsing #t [500 500 RPM ed dil to bring [ved a LOW ark. Wine ol tepare fore be hot (190-200 F) [822.9935 C] ‘mabe final ail oval check BRING: OSL EVEL To FULL MARK. rat Prevating Ambient Temperature: 4 me cere aga Waa fa aronawen Cee required change intervals. —23—Moke all checks with converter outle! temperatu ROUBLE 1, Low canvertsr OUT pressure [Below 25 PS. 172.4 kP3) vw wingine ot 2000 APM — NOT LOAD) Governed Speed [See Converter Pressure Speeifietions) 2. Suetion line taking air. 3. High conwester QUT pressute (Above 70 PS. [483.5 kPa) with engine at 2000 APAA — NO LOAD) Governed Speex (See Converter Pressure Specifictions) y Converter. 6 Low clutch pressure. (Gee pressure speci tions) IRREGULARITIES IN PERFORMANCE C320 Series Converters PROBABLE CAUSE Worn oil sealing and "O" ings ‘Wern oil pump. Safety Valve stays open. Low oil level. ‘Suction line connections taking air Worn oil pump. Oil cooler ar oil lines restricted. Gil 120 heavy Cold oil, S90 item: No. 1 & 2 cooler or oi cooler lines restricted causing safety valve te stay open, Oil cooler teo small Worn ail pump. Converter deain line to transmission oF oil sump not installed properly. Worn coupling 9@are Worn ail pump Damaged bearing Worn drive gears, Transmission malfunc- tion. Worn ail pump. Regulator valve stuck open. re at least 180° - 200° F. [82.3° - 93.3% C.] REMEDY Trouble is internal and will require a eom- plete teardown of the converter. B, Replace, C. Clean and check valve spring and walve D, Fill te propor level. E, Check oil line connections and tighten securely. F. Replace, 6. Check oil cooler line and ail cooler for rictions. Clean or replace: Check oll weight. See oil recommends: tions. 1. Converter pressure in cold weather will Vary. AS Sonn as converter gets hot, pres sure shauld drop. J, Clean and check oil cooler and oil cooler 12s. Replace if necessary, K. Replace with larger cooler. L. Replace oil pump. #4. Install at lowett drain opening in conver- ter housing, Line must maintain constant gradual drop to oll sumpfor gravity drain. IN. Replace, 0. Replace. P. A complete teardown will be necessary to determine this. Replace if necessary. ©. Replace R. Close pressure line to transmission con- wal valve, If eluteh pressure returns te normal, trouble Is in transmission. S. Replace, 1. Clean and cheek valve for warn or dirly parts, replace if necessary.IRREGULARITIES IN PERFORMANCE (Conr'd.) C320 Series Converters TROUBLE PROBABLE CAUSE REMEDY 7. High clutch pressure. Regulator valve stuck U. See item T See pressure specifications) loved. . Lack of power. Improper engine func: ¥. Tune engine. tian. Enging stall speed below W, Tune engine, Cheek govern. low converter out press Xk. See item No. 1. ure, Air in the oi Y, See item No, 2. Improper sil. Z. See cil recommendations. 9. Ol in engine flywheel “O" ring berween impel- AA, Replacc. housing. ler cover and impeller damaged ‘Oil baffle "O" ring BB. Replace. damaged, ‘Oil baffle ofl seal CC. Replace. damaged, GENERAL INFORMATION. (Use Clark 1833614 0 Fitar ony, (Use Clark 2155012 Oil Fite: Element only. |Use mininum number of Pipe and Mose Fittings. ‘Gravity drain fram Converter Sump to Transmission must be off minimus length and have no ol ‘Caalee capacity for normal application, 20 per cent of net Engine Horsepower at Governad Speed. ‘Chock oil loved with engine idling and transmission in neutral ‘CHANGE OIL FILTER ELEMENT EVERY £00 HOURS. DRAIN AND REFILL SYSTEM EVERY 1000 HOURS. bends to trap ox or TRANSMISSION CLUTCH OIL PRESSURE P. ‘The 6320 Converter will be equipped with one of theae variations involving the cluteh regulating valve ‘Thay ace as follows |iniat cover for Convarter oil only with clutch preseure valve in ranemissina control rover. 180 to, 220 P-S., [124 kPa) pressure range. (See note). 2. Pressure regulator valve on Converter with 8 240 to 280 P.S.J. [1664.8 - 1990.5 kPa] pressure range. (See Notel 3. Pressure regulator valve on Converter with & 180 to 220 P.S.1 (1241.1 - 1516.8 kPa) pressure range. (See Notel NOTE: fll pressure cust be equal within § PIS. [34.5 kPal If clutch pressure wees in any One clutch more than 5 PSL (SL BKPA) repair clutch, All pressures rmust be taken with two elutches engaged 18816 SCREW RING GEAR INSTALLATION PROCEDURE (Non-Asbestos Ring Gearl Flomous all burs rom fiywheel mounting face and piiat bores. Clean the torque conver ting gear fywhoel mounting surface ‘and the ring ggar screw tepped holes with solvent. Dry tharoughly, being certain ring gear screw holes are dry and clean. Check engine flywheel and housing oF housing adaptor for conformance ta standard §.A.E. No. 3 — SAE J827 and J1053 tolerance specifications for plot bores siza, pilot bores eccentrcities and mounting face deviations, Measure and record engine crankshaft ane play. Install torque converter ring gear as shown, NOTE: Assembly of the ring gear must be completed within a fifteen minute period from start of sorew installation. The screws ore prepered with an epoxy ‘ating which begins to harden after italation inthe fyusheal mounting holes. H rat ‘ightaned to proper torque within the titeen minute period insuficion screw elaaping version wil rasuit Install backing ring and sixtean (16) special screws to aporosimately .08 inch [1,6 mm of seated position. itis permissible to ust 2 power wrench for this installation phase. With a calibrated torque weench tighten screws 30 te 33 pounds feet of torque [40,7 44,7 Nan To obtain maximum atfectivaness of the special screw’s locking festure, 2 minimum time period siter screw installation of ‘waive (121 hours is suggested before engine start up ‘The special scrmw is tn be ued for ONE instalation only. the screws is reaved for any reason it MUST BE REPLACED. recommended that the epoxy lett in the flywheel hale be removed wit the proper tap end clesned with solvent. Dry hole thoroughly and use a NEW scraw for reinetalistin, Asaemble torque converter to engine flywheel by sliding converter into: position by hand betore fastening housing attachment ‘screws. This may require more then one trial to match the drive gear testh. Pulling the converter ini pasition with housing ‘attachenent bolts is not recommended. ‘Measure engine crankshaft end play after asoambly of torque converter. This walue must be within one thousandth (DD! bof an nen [0,0254men} ot end play recorded in Paragraph #2) before assembly of torque converter. 02163 — 15 INCH 158.1116 SCREW RING GEAR KIT S0z3S2 — 15 INCH [38,3] 16 SCREW RING GEAR KIT 1 45765 Torque Conver Flog Goa 1240705 Torque Converter Ring Gast 16238288 ing Gaur Sr 15 Inch (381 18788288 lng Gear Scr 1.5 Inch (58.1 1 802184 nstatnon inaction Sheet 1248767 Bocking lng 1 ROQTEX ——ntataon Inetuevan Sheet ‘243757 Backing Rw Not bochided in:802163 Ring Gear Ki, Mut be Ordered Senaeately. CONVERTER INSTALLATION ‘Check end play on engine crankshat 4 recone! (End play to be as specched by engine manufactures ‘The uae of guide pine in the engine fiywhoe! housing will facitore converter instllstion, ‘Assombietorque convertar to angine flywheel ay lid ng eomverarinto position by hard bears Fast ning housin ‘This may require mare then one trial camatch the drive gear ‘goth, Pulling the converter into pasitin with houting attachment boltsis ‘not recommended tachment screws, Measure engino crankshaft sad play after arvembly of torque eanverer. This value must be within ane thousandth (1001) of an inch [0.0254 mmm of end piay recocced (im Paragraph #1) bafara assembly of torque converter. —26—BACKING RING ENGINE FLYWHEEL TORQUE CONVERTER RING GEAR RING GEAR SCREW RING GEAR SCREW Baer, ENGINE FLYWHEEL SEE PAGE 28 FOR INSTALLATION PROCEDURE AND BOLTTORQUE. BACKING RING 23767 2a2 screw StaBLe Drive ConNecTION NON-ASBESTOS CONVERTER DRIVE RING GEAR INSTALLATION PROCEDURE Remove a brs rom tywheet mounting tice and pit bores. Glean the torque converter fing gear fywheel mcunting surlace nd the ring gear Eetew appes holes with solvent. Dry thoroughly being cain ring gear eefew Roles are ay and clean Check engine tlywhes! and nausing or housing Sdaptor tor conformance ta standard SAE No 3 - SAE 927 and 1039 tolerance specifications for plot bores size pict bores eccentricties and mounting fare deviations. Measure ard record engine crankchatt end play Install torque converter ring gear as shown, NOTE: Assembly of the ring gear must be completed within a fiteen minute period from start of screw installation, The screw: are prepared wih an opoxy eating whieh begins 10 Made afer installation in the fiywhorl reounting holes W nck tightened to proper torque within the fitcon minute period insufficiam screw ciameing tension will result Install backing ring and thiety two (82) special screws fo approaimately 06 inch [1.5 mim] of seated position. Wis permissitie 10 Use a power wranch Sor this installation phase, Wh a calibrated torque wrench tighten screws 23 1a 25 pounds feet of torque (1.2-93.6 Nm) To obtain maxienum effectiveness of the special screw's locking featured, a minimum sime period aher sorow instalanian of twelve (12) hours s sugpesied belore engine star-up ‘The special eerew is to be std for ONE installation only Ifthe eerew ie removed for any reascn is MUST BE FEPLACED kis recommended that the epnry left in the fywheel hole be remcwed wit the proper tap and cleaned with saivent. Dry hole thoroughly and use 3 NEW screer for ee: installation. Assemble torque converter tn engine Syuhsel by sling converter into position by hand belore lastening housing attachment screws This may requre more than ane trial to maich the drve gear teeth. Pulling the conwerter into postion with Nousing, sttachmert bolts is not recommended Messure engine crankshat end play aller asserrbly of torque corwerter. This. value must be within one thousansth(.001) ef an inch [0.0254 ror of end play recorded (in Paragraph #2) beloce assembly of torque converte. 02649 . 1.5 INCH [38,1] 32 SCREW RING GEAR KIT 2652 - 2.5 INCH [65-5] 32 SCREW RING GEAR KIT 1 248473 SDC Torque Cormerter Ring Ge 1 209473 SOG Torque Converter Ring Gear 52 249570 Ring Gear Soraw 1 5 Inch [38. SB BITISI Ring Gear Screw 25 Incn [63.5] 1 -BOQESS—netallaton Incruction Shee 1) 802655 instalation instruction Sheet 02080 - 1.75 INCH [44.4] 32 SCREW RING GEAR KIT 02659 - 2.0 INCH [78.2] 22 SCREW BING GEAR KIT 1 B4R473 SD Toque Converter Ring Gear 1 249479. SDC Terque Carnwerter Ring Gear 52 244903 Ring Gear Serow 1 75 Inch (44,4) 92 296K Ang Gear Screw 3.0 Inch [76-21 1802685 Insdllaten Instruction Sheet 1 BOESS —nslelaion Instruction Sheet BO2851 20 INCH [50,8] 32 SCREW RING GEAR KIT (802654 . M32 SCREW RING GEAR KIT 1 BARAT SDE Torque Canwerter Ring Gear 1 248473 SDC Torque Converter Fing Gear 32 BACSIA Ring Gew Screw 2.0 inch (50,8) 824200007 Fling Gear Screw [MB x 125) 1 BOZ655 Installation Instruction Sheet 1 802855 Insiallation situction Shewt 28807 Backing Ping Net Included in Ring Gear Ka. Must be-Ordeved Separately NOTE: The ints instalation dive gear mounting kit includes a converter air breather. This Breathe is used on C & CL 2700 & CL.320 conwertirs.only and is nol requied for the HFt 8 LHF 28000/H & LHR 2000 applications. SEE PAGE 29 FOR INSTALLATION ILLUSTRATIONSBACKING RING ENGINE FLYWHEEL RING GEAR SCREW ENGINE FLYWHEEL RING GEAR SCREW. 182) 243970 1.500 [38,1) (82) 244903 1.750 [444] $32) 240318 2.000 (50,8) (82) 237153 2-500 (63,5) (32) 236938 3.000 [76,2] (32) 4200097 [M8 x 1,25] SEE PAGE 28 FOR INSTALLATION PROCEDURE AND BOLT TORQUE Ky CASING RING TORQUE CONVERTER RING GEAR reSERVICING MACHINE AFTER TORQUE CONVERTER OVERHAUL The wansmission, torque converter, and its allied hydraulic system ere important links in the drive line between the engine and the wheels. The proper o ation of spends greatly on the condition ‘ther; therefore, whenever repair is performed, the balance of the system must be considered before the job can be considered completed, After the overhauled or repaired wansmission has ben installed in the machine, the oil cooler, end con necting hydraulic system must be thoroughly cleaned ‘This can be accomplished in several manners and a de. saree of judgment must be exorcisad a to the method employed. The following are considered the minimum steps to be taken: 1. Drain entire system thoraughly. 2. Disconnect and clean all hydraulic lines, Where feasible, hydraulic lines should be removed from machine for cleaning 3. Replace oil filler elements, cleaning out cates thoroughly. 4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil and compressed air until all foreign material hes been will not adequately clean the cooler. If neces- sary, cooler assembly should be removed from machine for cleaning, using sil, compressed sir and steam elesner for that purpose. DO NOT use flushing compounds for cleaning purposes. 5. On remote mounted torque converters remove drain plug from torque converter and inspect jer housing, gears, ete. IF ‘of considersble foreign material is ‘will be necessary thet converter be ee moved, disassembled and cleaned thorowahly. IW is realized this entoils extra labor, however, such labor ie a minor cost compared to ott of difficulties which can result from presence of such foreign meteriel in the system 6 Recsemble all components and use only type ell recommended in lubrication sectl twansmission through opening until fluid coms Up to LOW mark on transmission dipstick, NOTE: If the dipstick is no! accessible cil level check plugs are provided Remove LOWER check plug, fill until all runs from LOWER il hole. Replace filler ond level plug. Run engine two minutes at 500-600 RPA 10 prime torque converter and hydrauile lines. Re heck level of fluid in transmission with engine Funming et idle (S00-00 RPM) Add quantity necessary ta bring fluid level te LOW ‘on dipstick or runs freely frer LOWER oil level chock plug hole. In level plug or dipstick. Recheck with hot oil (180-200" F.) [B2, 2.99, °C) Bring ol! level 19 FULL mark on dipstick or runs freely from UPPER oil level plug. 7. Recheck all drain plugs, lines, connections, ete., for leaks and tighten where necessary. CONVERTER CHARGE PUMP REPLACEMENT AND PRIMING PROCEDURE The couse for pump failure must be found and corrected before a replacement pump is installed, Check all of the hoses, tubes, “O" rings, adaptors and split flanges, 2. Replace any collapsed or damaged hoses, damaged split flange "0" rings, tube “0! rings and adaptors. 3. Alter ail chacks have bean made and corrections cempletad install the pump. 4, See filling instructions in paragraph & above. 5, Stam the engine, Run the engine at low idle for two minutes, weteh the eluten pressure goye and lists the pump, for eavitation of 6. If the pressure does not come up, check the oil level and bleed off air from system as follows 7, To bieed off the airfromthe ayetem, Jozen the presaure gage lina at the pressure ragulsting val ‘orloagen the pressure hose at the oil filter or pressure regulating valve. Crank the engine over urtil the airis displaced with oil, DO NOT START THE ENGINE. Bf bleeding the lines does not comact the problem it may become necessary ta prime the pump, Disconnect the suction hose ar pressure hose, whichever is higher, and fill the port with transmission oil, reconnect the hose and tighten. 9. Start the angi \d check pressure, 10. Recheck oll level with hat oil (180-200°F) with engine at idle. Add oil ax necessary to bring ail level to full markSPEED SENSOR INSTALLATION VIEW “T"" (Purip Drive Gear Sensor) Inspect at assembly. Dim. "U" from gear tooth. | OF CONVERTER __ REAR VI Stake 3 places approx. equally spaced Atter curing of Loctite, ‘speed sensor bushing must be secure with 40 FL. Lb, (54.2 Nem] torque. Inspect at assembly. Dim. “W" trom gear tooth Assemble Speed Sensor Bushing in housing to specified dimension “UU” or “W" with Loctite 262 and stake (3) three places. See Pump Orive and Gutput Gear Charts for dimensions. PUMP DRIVE RATIO DRIVE GEAR | DRIVEN GEAR | SPEED SENSOR BUSHING Ravio_| NO.OF TEETH | NO.OF TEETH | DEPTH “U" PER VIEW "T" __37 42 1,060: 007 [26.9 + .17] 41 3 1.060 2.007 (26.9:+.171 ‘OUTPUT GEAR RATIO. TURBINE SHAFT OUTPUT ] RATIO | & GEAR ASS'Y GEAR SPEED SENSOR BUSHING | NO.OF TEETH NO. OF TEETH | DEPTH 'W" PER VIEW "S” 1.338 21 28 1.060.007 [26.94.17] | 1.130 23 26 1.060.007 [26.917] 1.042 24 es 1.390-+ 007 [35.34.17] 960 | 88 24 1.380 «007 [95.3 » 17) 26 23 1.890.007 [85.3..17] oe28000/32000 SERIES TRANSMISSION AND C-270/C-320 CONVERTER DRIVE PLATE INSTALLATION INSTRUCTIONS Proper Identification by Bolt Circle Diameter. Measure the “A’ dimension (Bolt Circle diameter} and order Drive Plate Kit listed below. ‘A’Dimansion (Belt Circle Diameter} NOTE: Assembiy of lexplates must A" Direanalon (Bol Clide toram poaars me] Dlrerse Neceightad etn te mau 7A, Demaraon (Bot Gm ew pon tom sat cre ei Si os rm Camere Sent We srw trea rey a ees 13.50 1982:00 mm Darmter eeu a iat seaute Toe ieee Sremie baln betaine ru sa.s0 (up-a00 min Darter pimowehmemmes reat ase az ac0 17.00" [431,800 mm) Diameter cleaned with solvent. Dry the hele . fern boeass Seeapuyern esa cme te soe" 34800 nn Daetae wonraton joy ust ae Each isl inca he fotning por onl ete te otowng pars A erica Orv Pen 5 iamadate Drie Paes + One Pre and We! Wr Anse + ondary fing + Baca Rig {0 ar Pho Weber Cree 40 Drie Pini Houréog Semen 10 Orke Pi naar 10 bot Pins Wistar 1 insvueton shew 1 Instruction Sheet TO FACILITATE ASSEMBLY, ALIGN SWALL HOLES IN DRIVE PLATES-SEE ILLUSTRATION ABOVE. Postion dive plate and weld rut assembly on impeller cover with weld nuts tomard cover. Align intermediate drive plate and backing ring with holes i: impeller cove:. NOITE: Two dimples: 180 degrees: apart in backing ring must be out toward engine hy whee!) Install capscrews and washers, Tighten 33 t0 36 Ms. torque [45-49 Nm] SEE PAGE 33 FOR TRANSMISSION TO ENGINE INSTALLATION PROCEDURETRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1. Remove all burrs from flywheel mounting faos and nose pilot bore. Clean drive plate surface with salvent. ‘Check engine flywheel and housing for conformance to standard SAE #3 - SAE. J927 tolerance Spacifications for pilot bore siza, pilot bore nunout and mounting face flatness. Measure and record engine ‘crankshaft end play. 3. Install two 3.50 [88,90 mml long transmission to ‘flywheel housing guide studs in the engine flywheel hhousing 38 shown, Rotate the engine thwhee! to align a drive plate mounting serew hole with the flywheel housing access hale. 4. Install 2 4.00 [101,60 mm long drive plate locating ‘stud .3750-24 fine thread 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 transmission on flywheel housing aligning drive plate to flywheel and transmission to flywheel housing. Install transmission 10 fywiseel housing screws, Tighten screws to specified torque. Rlemave trans mission ta engine guide studs. Install remaining ‘screws and tighten to specified torque. 6. Remove drive plate locating stud 7. Install drive plate attaching screw and washer. Sug screw but do net tighten. Some engine flywheel housings have @ hole located on the flywheel housing circumference in line with the drive plate screw access hole. & screwdriver or pry bar used to hold the drive bloe agains the Arwhee! wil facta insaton ot plate scraws. Rotate the engine flywheel and ital the remaining seven tyne Wo Ge pate attaching screws, Snug screws but do not tighten. Alter all eight (8) screws are installed torque each ane 25 to 30 ft. ths. torque [93,9 - 40,65 N.m.. This will re Quire torquing each screw and rotating the engine flywheel unl the full smount of eight KB) screws have been tightened, 8. Meosure engine crankshaft end play after trans mission has been completely installed on engine flywheel. This value must be within .001 10,025 mm] of the end play recorded in step No. 2.DISASSEMBLY OF LOCK-UP COVER REASSEMBLY OF LOCK-UP COVER Figure 4 Figore 1 Postion new ol sealing ring an input hub. Grease rng lightly to Remove end plate to lock-up eover bots faciltate reassembly Figure 5 fon auter diameter of actuating piston and grease light. ston over input hub, use caution as not 1o damage ol vealing rings. Locate auter crive dise teeth with teeth on the outer diameter of the piston Install new oil seating rs Figure 2 Remove end plata and clutch disc Figure 6 Lubricate clutch diss lightly and position in cover, Align holes of Figure 3 end plate with hoies in diving dise snd lock-up cover Install Flemove piston and outer drive disc, bons and tighten 30 t0 35-Ibs.4. torque [40,7-27 4 Nem.ea. SPICER OFF-HIGHWAY SS Prooucrs pivision Statesville, North Carolina Morganton, North Carolina Plymouth, Minnesota Brugge, Belgium Price on Request 50-905-0076 PRINTED WVU SA