Maintenance and Service Manual , 32000 | Powershift E — Transmission I ™, | R & HR MODEL 4 SPEED LONG DROP is ewe SPICER OFF-HIGHWAY le PRODUCTS DIVISION SM RHRIZALD 12.94TOWING OR PUSH STARTING Before towing the vehicle, be sure to lif the rear wheels NOTE: If the transmission has 4 wheel drive, disconnect, off the ground or disconnect the driveline to avoid both front and rear drivelines. Because of the design of damage to the transmission during towing the hydraulic system, the engine cannot be started by pushing or towing. © Copyight DANA SPICER OFF HIGHWAY PRODUCTS DIVISION 1989 ‘inpuSlshed material "All nants reserved imied Bisviuien No part of the work may be reproduced in any form under ‘any means without direct writen permission of DANA SPICER OFF-HIGHWAY PRODUCTS DIV'SION.FORWARD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF-HIGHWAY COMPONENTS. DIVISION product. Extreme care has been exercised in the design, selection of materials and manufacturing cf 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 with 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 ‘Spicer Off-Highway Components Division-approved parts as listed in ‘the applicable parts manual should be used. Use of “will-fit” or non- approved parts may endanger proper operation and performance of the equipment. Spicer Off-Highway Components Divison does not warrant tepair or replacement parts, nor failures resulting form the use of parts which are not supplied by or approved by Spicer Off-Highway Components Division. IMPORTANT: Always furnish the Distributor with the serlaf and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Silhouette... Converter Group ......... Converter and Transmission Case Group .. . Reverse and 3rd and Forward and 2nd Clutch Group....... Fig. D Low, 4th and Output Group . cette cette Fig. E Regulating Valve, Charging Pump and Filter Group ........ Fig. F Control Valve Assembly ...... voce ceeeeeesee FIQ.G Axle Disconnect and Mechanical Parking Brake ........ Fig. H Assembly Instruction Illustration . . DISASSEMBLY OF TRANSMISSION ... CLEANING AND INSPECTION REASSEMBLY OF TRANSMISSION - seen ‘SERVICING MACHINE AFTER TRANSMISSION OVERHAUL, ‘SPECIFICATION AND SERVICE DATA ...... LUBRICATION 20... 00.00... 00eee eee TROUBLE SHOOTING GUIDE ... ceeeeees RING GEAR INSTALLATION (16 SCREW)......... TYPICAL FOUR SPEED POWER FLOW... EXTERNAL PLUMBING DIAGRAM RING GEAR INSTALLATION (32 SCREW) . R-MODEL SECTION CLUTCH AND GEAR ARRANGEMENT . SHIELDED BEARING INSTALLATION CONVERTER DRIVE PLATE INSTALLATION ..............- NOTE: Metric Dimensions Shown in Brackets | |. CLECCCECCECEECECECECECEEECECCCEECEECCECECCECCECOEELECCELOECLETRANSMISSION ASSEMBLY ‘The transmission and hydraulic torque por n of the power train enacts an important role in transmitting ‘engine power 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 torque converter function together and operate through a common hydraulic system. It is necessary to consider both units in the study of their function and operation. To supplement the below, and for reference use therewith, the following illustrations ace provided: Basic Design Sithouette Converter Group Converter and Transmission Case Group Reverse and rd, Forward and 2nd Clutch Group Low. 4th and Output Group Regulating Valve, Charging Pump and Filter Group Control Vaive Assembly ‘Axle Disconnect and Mechanical Parking Brake Assembly Instruction Ring Gear Installation Clutch and Gear Arrangement Shielded Bearing Installation Four Speed Power Flow External Plumbing The R, HR, and MHR Model Transmissions are of three basic designs. The R Model consists of a separate torque converter, mounted to the engine with the powershift tans- mission remotely mounted and connected to the torque converter with 2 drive shaft. The HR Model consists of a torque converter and powershifted transmissio 10 the engine. fone package mounted directly ‘The MHR version is @ mid-mount torque converter and transmission assembly connected to the engine by means of a drive shaft. (See Fig. A for basic design silhouette.) The shift control valve assembly may be mounted directly on the side of the converter housing or front transmission cover, or remote mounted and connected to the transmission by means of flexible hoses. The function of the control valve assembly is to direct cil under pressure to the desired directional and speed clutch. A provision is made on certain models 10 neutralize the transmission when the brakes are applied. ‘This is accomplished through use of a brake actuated shutoff valve. The speed and direction clutch assem- blies are mounted inside the transmission case and are connected to the output shaft of the converter either by direct gearing or drive shaft. The purpese of the speed or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction. ‘An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can be disconnected or connected by manval shifting,HOW THE UNITS OPERATE With the engine running, the converter charging pump draws oil from the transmission sump through the removable oil suction screen and directs it through the pressure regulating valve and oll filter. The pressure regu! ing valve maintains pressure 0 the transmission control cover for actuating the direc- tion and speed clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil is directed through the torque converter circuit to the cil cooler and returns to the transmission for positive lubrication, This regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in a closed position. When a specific pressure is achieved, the valve spool works against the spring until a port is exposed along the side of the bore. This sequence of events provides the proper system pressure. After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in the pastage between the turbine shaft and converter support. The cil then flows out of the converter to the cil cooler. After leaving the cooler, the oil is directed to 2 fitting on the transmi Then through a series of tubes and passages lubricates the transmi ‘gravity drains to the transmission sump. ion. A bearings and clutches. The oil then The hydraulic torque converter consists basically of three ments and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com- ponent which starts the oil flowing to the other components which results in torque multiplication. This outer The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter. This element receives fluid ot its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converier multiplies torque. The reaction member of the torque converter is located between and at the center or inner diameters of the impeller and turbine elements. Its function is to take the flui of the turbine and change which is exhausting from the inner portion direction to allow correct entry for recirculation into the impeller element. The torque converter will multiply engine torque to its designed maximum multiplication ratio when the ovt- put shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing. ists of a valve body with selector valve spools. A detent bail and spring in the selector spool provides one position for each speed range. A detent ball and spring in the direction spoal provides three positions, one each for forward, neviral end rever With the engine running and the directional control lever in neutral position, ofl pressure from the regulat: ing valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and direct cil, under pressure to cither the forward or reverse direction clutch as desired. CEECECCECCECCECOEECECCECELEECECEECECCECEECECCOECEECECELEECELEWhen either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction solactor spocl. The same procedure is used in the speed selector. The direction or speed clutch assembly consists of @ drum with internal splines and a bore to receive a hy- draulically actuated piston. The piston is “oil tight” by the use of sealing rings. A steel disc with external splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner lameter is inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A Hub with ©.D. splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate tion as long as no pressure is present in that specific clutch. the opposite direc- To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows oil under pressure to flow from the control valve, through s tube, fo @ chosen clutch shaft, This shaft has a drilled psssageway for oil under pressure to enter the shaft. Oil pressure sealing rings are located on the clutch shaft, These rings direct oil under pressure to a desired clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against discs with teeth on the inner diameter, enobles the hub and clutch shaft to be locked together and allows them to drive as a unit, There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston is released, F-32000 HR-32000 MHR-32000Figure B CLEECOCECOECECECCECCECCCELCECCCEECEECECECECCCECEEECCECELELELTem 1 oer], HM kN " 12 13 14 15 16 7 18 19 20 21 22 23 24 25 26 27 28 29 HR32000 CONVERTER GROUP DESCRIPTION Bearing Support Screw ...... 06.0005 Bearing Support Screw Lockwasher. Drive Gear Snap Ring ......... Pump Drive Gear Bearing ....... Pump Drive Bearing Support... Pump Drive Gear . Turbine Shaft Gear. cess Turbine Shaft Gear Snap Ring . Charging Pump Drive Sleeve... Pump Sleeve Snap Ring Valve to Housing Gasket...... Valve Body "0" Ring....... Valve Body "O" Ring............ Charging Pump & Oil Filter Assembly Valve Body “O" Ring...... Turbine Shaft Bearing ... Turbine Shaft Piston Ring. . Turbine Shaft... Stator Support .... Stator Support Screw Lockwasher.... Stator Support Screw. Piston Ring Piston Ring Expander Spring Impeller Hub Gear Snap Ring Impeller Hub Gear... 2s... Oil Baffle Oil Seal. Oil Baffle Seal Ring Oil Baffle... Oil Baffle Retainer Ring.... ary. ooo wae ITEM 30 3 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 4g 50 51 52 53 54 55 56 57 58 DESCRIPTION Hub to Impeller Screw. Impeller Hub Screw Backing Ring. . Impeller... 2. Impeller Hub “O" Ring Impeller Hub. . Impeller Hub Bearing, Bearing Snap Ring... Reaction Member Spacer Reaction Member. Reaction Member Snap Ring .. . Turbine Hub .. Turbine ...... Turbine Hub Backing Ring .......... Turbine Hub Screw Impeller to Cover Impeller Cover oo... eee e. Impeller Cover Bearing ....... Bearing Cap to Impeller Cover “O” Ring Bearing Washer ............. Bearing Snap Ring........... Impeller Cover Bearing Cap. ... Impeller Cover Sleeve Ring Gear Screw Plain Washer... ... Flywheel Ring Gear...... Bearing Cap to Impelier Cover Screw . .. Bearing Cap to Impeller Cover Screw Lockwasher-.. 2.6.0.0. 0055 Impeller to Cover Screw impellerto Cover Screw Lockwasher . .. ary. 12 10 24 24DVVV VD VDD VDD VDD DVD DVI DP VV DVD DDPIDVAI IVI IID VO Figure CITEM HR32000 CONVERTER & TRANSMISSION CASE GROUP DESCRIPTION ary. Pipe Plug... . 1 Convertar Housing Assembly 1 Converter Housing to Front Cover Screw Lockwasher 2 Converter Housing to Front Cover Sevew «00... 12 Tube Sineve Tube Sleeve Convener Housing Si Converter Housing Sleeve Lock Converter Housing Sleeve Serew Lockwasher Converter Housing Sleeve Screw: Converter Housing Sleeve Screw Converter Housing Slaeve Scrow Lockwasher Converter Housing Sleeve Lock Converter Housing Sleeve Breatner. . Straet Ell Brasther Reducing Bushing Tube Sleave ug. feces Convener Housing to Transmission Housing Screw Lockwasher...... aa Converter Housing to Transmission Housing SCrW. ees eesecee : Convener Housing to Transmission Housing Lookwasher. 4 Converter Housing to Transmission Housing Screw. Lube Tabe Retaning Serow Lockwashs Lube Tube Rataining Screw Suction Tube “0” Ring Suction Tube Spacer Ring ‘Suction Tube Assembly... 2 Suction Tube Retainer Screw Lockiasher ‘Suction Tube Retainer Serew Tube Clip Serew. Tuve Tube Ravers Tube Assembly Reverse Tube "0" Ring. Lube Tube Retainer Screw . ves Lube Tubo Retwiner Screw Lockwasher Lube Tube Assembly Tube Clip Screw 3rd Speed Tube “O” Ring ‘Valve Oi) Supply Tube ... aa Prema Tae“ ing. Tube Sleeve... cee... Low Speed Clutch Pre ‘Transmission Case to Converter Housing Screw Lockwasher. o ‘Transmission Case to Converter Housing Screw . ITEM 50 51 82 53 3a 55 36 37 58 59 60 er @ 63 84 65 86 87 68 68 70 n n cay a 75 76 n 78 79 80 at az 83 cs 85, 86 87 88 29 90 a 92 93 94 95 96 7 98 DESCRIPTION Rear Cover Dowel Pin 2 Rear Cover. 1 Rear Gover to Transmission Case ‘Serew Lockwasher 13 Resr Gover to Transmission Case Screw. 13 Roar Cover Pipe Plug. Rear Cover to Case Stud Nut 2 Rear Cover to Case Stu Lockwasner . 2 Clutch Pressure Tube “O” Ring. 3 Tube Sleeve 1 Rear Cover to Transmission Case Gasket . 1 fear Cover to Case Stuc. 2 Magnetic Drain Plug, 1 Oi Level Plug 1 i Lavel Plug. 1 ‘Transmission Case Assembly 1 Screen Assembly Gasket 1 Screen Assembly ' Oil Distributor Retainer Ring. 1 4th Clutch Front Oil Distributor... bed 1 1 1 1 1 1 1 1 1 1 ' 1 2 1 1 Pressure Tuba “O” Ring .-... viene Ath Speed Pressure Tue eee eee cseaeee Tube Sloave Pressure Tue “O” Ring Tube Sleeve. : 4th Speed Clutch Lube Tube. Oil Distributor Retainer Ring {Locking Bal! Suction Tube. Suction Tube Clip Washer. ‘Suction Tube Suetion Screen ip. ‘Suction Line Screw Suction Line Washer... Suction Line “0” Ring Converter Housing to Transmis GaSe DOWEL PIM eevee essere eeeseeeee Suction Tube Clip Rivet... ss ccssccsercereeee Converter Housing to Transmission Case Gasket . ereernes ‘OW Battle. Converter Housing Adaptor Ring 4th Speed Pressure Tube “0” Bing Low Speed Pressure Tube "0" Ring... Converter Housing to Transmission ose Gosket peered Convertor Housing to Transmission Case Spscer Front Cover Oi! Seal ne Converter Housing Front Cover........ Converter Housing Frant Cover Gasket. Hose Fitting Hose Assembly. sees Hose Fitting 00. c ccc eceeeeeeFigure D CEECCECCEECCEECCCECECOECEOECOECECCECEECCECEECEECELECEELR OR HR32000 REVERSE & 3RD & FORWARD & 2ND CLUTCH GROUP ITEM DESCRIPTION ary 1 Reverse & 3rd Clutch Shaft Piston Ring 3 1A. Piston Ring Expander Springs ..... a 2 Front Bearing Retainer Ring . fecsteteee T 3° Rovoreo & 3rd Shaft Front Bearing End Plata ' 4 Reverse & 3rd Shaft Boaring End Pate Ball. ....2.-. 1 S Reverse & 3rd Shatt Front Bearing, 1 @ Front Bearing Retainer Ring... 1 7 Clutch Driven Gear Bearing Shield In 1 8 Clutch Driven Gear Bearing Snap Ring. 1 9° Cluteh Driven Gear... 1 10 Clutch Hub Ot Batfie Ring .....- 1 14 Spring Retainer Snap Ring... 1 12. Clutch Driven Goer Beating Snap Ring - 1 13 Clutch Driven Gear Bearing, : 1 14 Spring Retainer Snap Ring... 1 15 Spring Retainer Snap Ring Retainer 1 16 Spring Retainer .. 1 17 Piston Retum Spring ... 1 18 Spring Retainer 1 48 End Plato Retainer Ring . cece 1 20 End Plate -Reverse Clutch ad 21 Clutch Outer Disc -Reverse Clutch... 6 22 Clutch Inner Disc - Reverso Clutch... esses 6 23 Clutch Piston Assembly - Reverse Clutch 1 24 Clutch Piston Outer Seal 1 25 Clutch Piston Inner Seal... 1 28 Reverse & Std Clutch Drum... 2... 1 27 Clutch Piston Inner Seal 1 28 Clutch Piston Outer Seal ......-.- 1 29° Clutch Piston- 3rd Clutch... 1 30 Clutch inner Disc-3rd Clutch... 6 31 Clutch Outer Disc - 3rd Clutch -. 6 32 End Plate-3ed Clutch... 1 33 End Plate Retainer Ring 1 34 Spring Retainer... .s 0 1 35 Piston Return Spring 1 36 Spring Retainer... eel 37 Spring Retainer Snap ing Retainer... 1 38 Spring Retainer Snap Ring 1 39 31d Gear Bearing 1 40. 3rd Gear Bearing Snap Ring 1 41° Clutch Hub Oil Baffle Ring... 1 42 3rd Gear... : 1 43 3rd Gear Bearing Spacer .....- 1 44 3rd Goar Bearing Snap Ring... sees 1 45 3rd Gear Bearing -Shield Out... - 1 48 Rlovorse & 3rd Shaft Rear Bearing... 1 (Tem DESCRIPTION Low Clutch Drive Gear... Goa Retaining Ring 2nd Gear Clutch Hub Ot Bate Ring 2nd Goar Retainer Ring 2nd Gear Retainer Ring Retsiner 2nd Gear Retainer Ring Retainer Snap | Spring Retainer Snap Ring Sing Retane Sap ing Rete Spring Retainer Piston Return Spring se. ssc Spring Reta End Pite Retainer Ring EndPlate-2nd Clutch... Clutch Outer Dise - 2nd Clutch Clutch inner Disc 2nd Catch Clutch Piston Assembly - 2nd Clutch. Clutch Piston Outer Seal Clutch Fiston inner Seal... Forward & 2nd Clutch Drum. oo -so ‘Gatch Piston inne Seal Clutch Piston Outer Seal... Cite Piston Assembly - Forward Clutch ‘luton Outer Disc = Forward Clutch =... Clutch ner Dise- Forward Clutch - End Plate - Forward Clutch End Plto Retainer Ring - Spring Retainer Srap Ring Spring REINO ea ececeeseeeeeee Piston Retum Spring Soring Retainer Spring Retainer Snap Ring Retainer Spring Retainer Snap Ring Clutch Driven Gear Bearing Catch Driven Gear Bearing Snap Ring Clutch Hub O# Bato Ring... Forward Clutch Driven Goar Clutch Drivan Gear Bearing Snap Ring «2. ‘Gutch Driven Gear Bearing “Shield in Front Bearing Retalner Ring... Front Beering Locating Ring... Forward & 2nd Shat Front Being Forward & 2nd Sha Bearing End Plate Ball. Forward & 2nd Shaft Font Bearing End Plat. Front Bearing Retainer Ring... Forward & 2nd Sha Piston Fig =... 2A. Piston Ring Expander Springs 3 BSSSSVSRKSRISYSVSHMYNYSSSISRRGSASSSISHLS SSS SSFigure E CLECECCEELECECCECCECEECOECECOECCEECOECECECCEECECECECEECEEECCEER OR HR32000 LOW, 4TH & OUTPUT GROUP ITEM DESCRIPTION ary ITEM DESCRIPTION ary 1 Low Speed Clutch Shaft Pilot Bearing Output Shatt Gear... cece eects 2 2nd Gear Bearing End Plate Output Shatt Gear Spacer... 3 2nd Gear Beating... 2.2. Output Shaft 4 Bearing Retaining Fing Retainer Front Bearing Cone 5 Low Speed Gear Beating Ring Front Bearing Cup 6 Low Speed Gear Bearing Assembly Front Bearing Cap "0" Ring ooo 7 LowSpeed Gear... Besring Cap Shim... 8 Clutch hub Oil Bae Ring |... Front Bepring Cap. . 9 Spring Retainer Ring Retainer : Front Besring Cap Oil Seal 30 Spring Retaining Ring... 0.0121. Front Bearing Cap Screw 11 Piston Return Dise Springs Front Bearing Cap Screw Lockwasher 1 52 1 of 8 1 a 5 1 1 55 1 a 56 at 1 7 1 a 58 aR 1 59 1 a 60 1 Mt 6 4 5 62 4 12 Pistonto Dise Spring Spacer 1 63th Goar Piston Ring ...... 3 13 End Plate Retaining Ring : at 64 Ath Goor Front Bearing Snap Ring 1 M4 End PG eee eevee aor ft 65 Idler Shatt Front Boaring ........00ssiessvses 15 Clutch inner Dise 9 (66 th Gear Bearing Snap Ring at 16 Clutch Outer Dise 22 9 67 Ath Gear Bearing Sea 17 Clutch Piston 1 68 Ath Gear Spacor : 1 18 Glutch Piston Outer Seal Ring at 69 4th Gear. 1 19 Clutch Fiston Innor Seal Ring. 1 70. Ath Gear Bearing nod 20 Low Speed Clutch Drum... 1 71 Beating Snap Ring nol 21 Low Spead Shaft Rear Bearing eoeennenneeel 1 72 Spring Retainer 2 1 22 Bearing Lockball MM 73 Piston Return Spring 1 23 Rear Bearing Retainer Pate... : a 74 Spring Retainar 1 24 Rear Bearing Retainer Plate Screw at 75 OilBaffieRing . : 1 25 Rear Beating Cap Gasket 1 78 Backing Plate Snap Ring - 1 26 © RearBearingCap....... 1 77 Clutch Disc Becking Plate .- 1 a Rem Boning Cop Serow Lockwasher fe 78 Clutch Inner Disc 6 28 Rear Bearing Cap Screw BoD 6 79° Clutch Outer Dise 6 29 Rear Bearing Cap Plu 1 80 Clutch Piston 1 30 Rear Boating Cap "0" Ring... 1 81 Clutch Piston Outer Seal Ring... 1 31 Clutch Shaft Piston Ring... 1 82 Clutch Piston innor Seal Ring 1 ‘32 Low Speed Shaft Rear Besring Locating Ring... ..... 1 3 4th Gatch Dum Locating ing 1 33. Bearing Cap Screw Lockwasher f2 84 4th Cluteh Drum. 1 34 Bearing Cap Screw 2 85 Idler Shaft 1 35 Bearing Cap Screw Lockwasher 2 ‘86 Idler Shaft Gear Key. 1 36 Bearing Cap Screw 2 ‘87 Idler Shatt Gear 1 37 Idler Shaft Bearing Cap 1 88 Bore Plug . : 1 38 Idler Shaft Beating Cap Gasket a 1 89 Disconnect Assambly 1 39 tdler Shaft Nut .2- 2-2. ut 90 Oil Soal 1 40 Adler Shaft Washer : 1 91 Output Flange - 1 41 Rear Bearing Locating Ring 1 92 Output Flange "0" Ring 1 42 Idler Shaft Rear Bearing Lock Ball ot 93. Output Flange Washer... 1 43. Idler Shaft Rear Bearing... 1 94 Output ange Nut 1 44° Rear Bearing Cap Oil Seal 1 95 Speedo Drive Goat 1 45. Rear Bearing Capscrew . ee 4 96 Rear Beating Cap 1 46 Roar Bearing Capscrew Lockwasher 4 97 Reat Bearing Cap Lockwasher 3 47 Rear Bearing Cap 1 98 Rear Bearing Cap Screw 3 48 Rear Bearing Cap "0" Ring... 1 99 Speedo Driven Gear... 2.2. 1 49 Rear Bearing Cap "O” Ring |. 1 100 Speedo Tube Nut Ta 50 Rear Bearing Cup 1 101 Rear Bearing Cap Screw... cece ccesveveseee T 51 Rear Bearing Cone uM 102 Rear Bearing Cap Screw Lockwasher 8DVIVVAVIDDI PPI VID IAD VIVID DVD DV A IVI DV AAI AVA IIAADIAII IID, LYE BA eK, on ASTem DESCRIPTION ary. 1 oer oo roan " 12 13 14 15 16 17 18 19 20 at 22 23 24 25 PRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP Charging Pump Drive Sleeve. Pump Sleeve Snap Ring.......... Valve to Housing Gasket............ Valve Body "0" Ring... Valve Body “O" Ring....... 2c cee Pipe Plug... eee eee ec eceeeee Safety Valve Seat... Safety Valve Spacer Safety Valve Plunger . . Safety Valve Spring . . Valve Stop “0” Ring Valve Stop. Valve Stop Roll Pin Vaive Stop Roll Pin... 0.0... es. Valve Stop... cies v eee eee Valve Stop "O" Ring... - eee Valve Piston .... Valve Spring - Inner... Valve Spring - Outer Valve to Converter Housing Stud Valve Body to Pump Gasket . Pump Body Snap Ring. ... Thrust Plate & Bearing Assembly .. Pump Driven Shaft Assembly . .. Charging Pump Housing .... ITEM DESCRIPTION ary. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 a 42 43 44 45 46 47 48 49 5 Valve to Housing Stud Lockwasher . . Valve to Housing Stud Nut . Thrust Plate & Bearing Assembly... Wave Spring. Pump Shaft Seal....... Pump to Filter Adaptor Screw Lockwasher........... Pump to Filter Adaptor Screw,...... Pump Drive Shaft Assembly ........ Pump Drive Shaft Oil Seal. Pressure Regulator Valve. . Valve Body Roll Pin... ....... Valve Body “O" Ring.......... Pump to Filter Gasket Filter Adaptor Filter Adaptor Plug... By-Pass Filter Disc Spring. By-Pass Filter Disc By-Pass Filter Dise Seat .....,.... Filter Seat Retainer Ring............ Filter Housing “O” Ring..... 0.0006 Oil Filter Element Assembly ......... Oil Fitter Element Spring........... Filter Housing. . . - Pipe Plug... ee. ses e eevee eee Optional Adaptor for Remote Filter . NNN RR *DECUTCH INCHING | FORWARD ONtY Eola er sas lars 18 rd 29 na ne cscich ve ti ant ‘Sr tate hang weno ane Figure G COCCECOCCECCCELEECECECCEECOECECOECCCOECECECECEELECEECECEOCLEECONTROL VALVE ASSEMBLY ITEM DESCRIPTION ary, ITEM DESCRIPTION ary. 1 Oil Seal. 1 22 Overshift Spacer (Not on all models).... 1 2 Oil Seal Retainer Ring......-.2.... 1 23. Oil Seal Retainer Washer ........... 1 3 Oil Seal Retainer Washer ........... 1 24 Ol Seal Retainer Ring.............- 1 4 Forward & Reverse Valve Spool...... 1 25 Oil Seal... 1 5 Control Valve Gasket............... 1 26 Piston Housing Assembly ........... 1 6 _ Detent Spring 127 Stop PLUG eee eeeeveeteeeeeeees 1 7 Detent Spring...........0eeeceeee Tt 28 Plug “O” Ring 1 8 _ Detent Ball 3 29 Piston “O" Ring. 1 9 Neutral Switeh 2... sees 180 Giyd Ring... eee eee 1 10. Detent Ball . 1 BE Piston eee eeeeeeeeeeeeeee 1 11. Valve Housing Plug 1-32 Piston Housing....2..000ceseeeeee 1 12 Valve Housing Plug “ Ring........ 1 33° Oil Seal... eee eee eeee 7 13. QvershiftSpacer(Notonallmodels).... 1 34 Band Seal......cccesceeeeeveeeee 1 14 Control Valve Housing.............. 1 35 1 15. Detent Spring Plug.......--.ceeee 1 Figures A-B-C & D are various declutch options. 16 Detent Spring Plug Washer.......... 1 44 Adaptor Screw... 1.6... eee eee 4 17 Detent Spring. ..-.0.ec0e00-- 1 48. Adaptor Screw Lockwasher.......... 4 18 Valve to Adaptor Housing Screw... 9 46. Valve Adaptor... eee eee 1 19 Valve to Adaptor Housing Screw 47 Valve Adaptor Gasket .............5 1 Lockwasher..--. 8 48 Adaptor Screw ooo. eeeeeeeeeeeee 5 20. Speed Selector Spool Plug 149 Adaptor to Plate Gasket... 1 21 Speed Selector Spool .............. 1 50 Valve Adaptor Plate... 0. see eee see 1CCECECCECELCECCEECEEECCCEECOECECCCEECEECECECECELEELLITEM ITEM AXLE DISCONNECT DESCRIPTION ary. Disconnect Housing Capscrew Disconnect Housing Capscrew Lockwasher ... Disconnect Housing Disconnect Housing Plug .. Shift Hub Shift Fork .. Shift Fork Lockscrew .... 10 W 12 13 “4 15 DESCRIPTION Disconnect Shaft ... Detent Ball Detent Spring . ‘Shift Rai Shift Rail Oil Seal Bearing Retainer Ring Bearing Bearing Retainer Ring MECHANICAL PARKING BRAKE DESCRIPTION Backing Plate Assembly, Actuating Lever ... Brake Shoe and Lining Brake Flange ... Brake Drum .. Brake Drum to Flange Screw Lockwasher Brake Drum to Flange Screw ... 10 W 12 13 DESCRIPTION Return Spring .. Brake Shoe (see item 3). Brake Lining .. Rivet Backing Plate Screw Backing Plate Screw LockwasherASSEMBLY INSTRUCTION ILLUSTRATION Beating LO. charters to point towara-sna rings as snown 1.33)94.0; T Figure! CEECECEOCECCLCECECOCOECCEECCEECECOECCECOCCECE CEL EECECOELE2S impator ub ane Turbine Hub Assembly wih Backing Ring and Speciai Soll Locwing Screws 1 Coan hub mounting surface ane lapped holes with solvent. Dry tharaughly being certain tappec holes are dry @ clean, 2. Install backing fing anc special sell locking Tighion soraws 40 1048 Los. Fr. (56.561.0 Nm] Note. Assomrbly of hud must be eamplate within @ toes minute perog fom star of serew install lion. Tae special serew so be Used fOr One Slallation énly. 8 tra screw is removed Tor any feason t must bo roplaced. Tro opony let > Gear to be assembled with long hub length to this se, AX Treo cluichos.Souter steo! plates.6:nner tiction plates,Assembie alternately staring wll outer Sioe! plate ‘See Elastic Stop Nut Torque Chart Low eluten.9 outer se! plates. 2-innst ricton ates Assemble aliemately, sarang wih over See pale & & A S08 Caste Stop Nut Torque Chart 2S shim output sratt bearings 10 produce 6 10 8 Las i nsab oN my eloas AX Tighen of sereen ase'y. 10 10 15 Lbs Ft 13.8200 Ne View "a" 2 Paces Soaulaien ony Low Cluch Return Sarin Concave side af ict bel 8 washer to be AX Hest nose ushing to 200" F* (85*C} betere ase'y, of bushing 0 cover 2. tog at OUT on pn eh ang Inv'on Fat 8 Rey. che meme it bearings, No.'3" etched AX (12 Plate Mod.taion Two clutches. Zour steet Plates, 12inner fricten plates. Aasemble alterately, Saving wih outer see! plete oles A Use Permatex & Crane Sealer only whece specified [Al ead in chamJa's for of seals, pisten rings & ‘0 nngs must be smooth & ree Irom Bue Inspect at aee'y Lubricate a piston ring grooves & “O" rings sith al belo ass'y Apply very igh oat of Permatex No.2 10 0D hall of seals betore 338, Atte assembly of parts sing Permatex ot Crane sealer, thace must not be any fee oF ‘excess maria that cauld enter the of excl, ‘Apely ight eoat of Crane Sealer toll apa loge Aprly 0 tin costing of gresse between seal lips On ip type seals por a assy. + Apply light at of Permatex No. 210 al thru ‘oe stud tweets. 8 NOTE: The ction cise in telow latch has 2 higher cowticient ating than the cian Giscs in the hee clutenes, teretore the ses must not Be mized Tha fw lute i her aise carbo erties by an" x" stampoe Sniene sido of he nner ieth. The ow cuter tor ese also hab a stip of ron-soluble yellow pat sprayed on the outer edge of thease view placed againet clutch piston. Remaining four laasnets (9 be stacked aternarely reversed as shown Forard & Revorse Clutch Return Springs Concave da offre! bellevila washer ho be placed agains eluch piston. Remaining ix ‘washers of cach clutch fo be stacked ahematety reversed a shown, vw: Enlarged view of Piston Ring & Expander Note Expandor gap t0 bo approx. 180° fom ang ogi wt fo.a4s ting axsemly ELASTIC STOP NUT TORQUE. nae mai nore: ae amerins oen [wee [ase | gen cases @ ae Steren met aw 9 Figure 1DVIVPDDV PDI DV VDDD DIDI IDI ADA VAI AVA DI AYV AVIA VIII I YD NOTESMAINTENANCE AND SERVICE ‘The instructions contained horoin cover the disassembly ancl feassembly of the transmission in 8 sequence thet would orally be followed after the unit has been removed fram the machine and is to be completely overhauled. It must also be Understood that this is a basic 32000 tranemission with many ‘options, Companion flanges and output shafts with and without disconnect assemblies may vary on specific models. The units are very similar to trouble shoot, disassemble, repair, and reassemble. CAUTION: Cleanliness is of extreme importance and an absolute must in the tepair and overhaul of this unit. Before atternnting any repaits, the exterior of the unit must be ‘thoroughly cleaned to pravent the possibilty of dirt and foreign ‘matter entering the mechanism. See page 62 for RModel (remote mounted) transmission ‘ront cover section. DISASSEMBLY Figure 1 Sideview of transmission, Figure 2 Remave filter housing and filter element. NOTE: Some ‘nits will have @ double pump—proceed to figure 3. Figure 3 Remove charging pump to regulating valve stud nuts, Remove pump and filter adapter, or double pump assembiy Figure 4 Remove pressure regulating valve assembly.Figure 5 Remove pump drive sleeves. Figure 6 Romove two valve to converter housing capscrews, Install two atigning studs as shown. Remove remaining cap- screws. Remove control valve. Use caution as not to lose detent springs and balls. Figure 7 Remove modulator valve. Figure 8 Remove modulator valve adapter plete and alignment studs, Figure 9 Remove impeller cover bearing cap bolts. Figure 10 Romave impeller cover bearing cap. COEOCCECECOECECECEECECECEECCCCECOECELCEECCCOEEECOCECE EECFigure 11 Figure 14 Remove impeller cover bolts. Remove impeller cover bearing snap ring and spacer. ‘Separate impeller cover and turbine. Figure 15 Remove reaction member retainer ring. Figure 13 Figure 16 Remova impeller cover ond turbine es an sesembly. Remove reaction member and spacer.Figuro 17 Remove converter housing to engine housing spacer ring. Figure 18 Remove oil batfie retainer ring. Figure 19 Using pry slots in converter housing, pry oil balfle and impeller trom housing. NOTE: Impeller, oil baifie and impeller hub gear are remaved as an assembly. 4 Figure 20 Remove impetter assembly. Figure 21 Remove control valve adaptor screws, remove adaptor. Figure 22 Remove stator support te housing bolts COCECCECCECCECECCECECECECEECECCCECCECECCCECELCECCECEOECEC ELFigure 23 Figure 26 Remove stator support. NOTE: Support must be tured to Remave pump drive gear bearing support boits. clear pump drive gear. Figure 24 Figue 27 Remove converter housing to transmission housing bolts, Move center gear toward the rear of converter housing. Remove pump drive gear on the right. Figure 25 Support convorter housing with chain fall and separate Figure 28 from transmission housing, Remove pump drive gear on the lef.Figure 29 Remove center pump drive gear, Figure 30 Use a spreading type snap ring pliers to spread the ears on forward clutch front bearing retainer ring. Remove fonword Clutch with pry bor. NOTE: If clutch shaft front piston ring sloeves ae to be replaced see page 63. Figure 31 Remove converter to transmission housing spacer. (Used with 12 plate modulated clutches only Figure 32 Rear view of transmission, Figure 33, Remove output flange aut, washer and “O" ring. Figure 34 Remove idler shaft bearing cap bolts, bearing cap, idler shaft nut and spacer. COCCEECELOECCECCECEECOCCCECECECECCEOCCECECECCECECCECCEECELECLFigure 38 Figure 38 Remove 3 bolts and boating retainer plate Figure 39 Remove bearing locating ring. Figure 36 F bearing cap, Figure 40 Remove rear cover bolts. Using pry slots provided, pry cover from transmission housing tapping on low clutch and re 37 idler shaft to allow cover to be removed without shaft Cut and remove lock wire. Remove low clutch shaft ail binding. NOTE: The use of alignment studs will facilitate sealing ring, cover removalFigure 41 Remove bearing lock-balls. Figure 42 Remove low clutch double bearing cup, outer cone and spacer. Figs CAUTION: Outer cone, double bearing cup, spacer and inner beating cone ara replaced as a set. Figure 44 Remove low clutch inner bearing cone. NOTE: To Remove the inner cone bearing without damage, a special bearing puller must be made {see diagram Fig. 44-A) or the outer ‘cage and rollers may be pulled from the bearing inner race and the inner race can be removed after the low clutch essembly has been removed from the transmission. See caution in Figure 43, bse 125764 ‘CUT WiTH 1” RUBBER WBR.CENT. WHEEL AFTER HO) "OTRING ba Figure 44-0 ‘A timken bearing cup, No. 29520 must be used with the above bearing puller, Figure 45 Remove idler shaft and 4th speed clutch from housing. COOECECOCECECOCOECECOCECECECCEECECECCECOECCCECECOCEOCEECEELE ECFigure 49 Remove low speed drive gear retainer ring and drive gear. Remove 2nd gear cetainer ring retainer. Figure 47 Remove roverse and 3rd clutch assembly. Figure 48 Figure 61 Remove 2nd gear ring retainer snap ring, Remove 2nd gear, and 2nd gear bearing ond plate.Figure 52 Remove low clutch assembly. te | Figure 53 Remove rear output shaft bearing cap bolts end cap. Figure 54 Remove front output flange nut, washer, “O" ring and companion flange. —10- Figure 55 Fomove output shaft front bearing cap belts end cap. Figure 56 Block output gear. Push output shaft from rear though bearing and goar. A Figure 57 Remove impeller hub gear retainer ring, —COEECECECOCCCECEELCCCCECECECCECECCCEECECECELCEECECCELCECEFigure 58 Figure 61 Remove impeller hub gear. Remove impeller hub, “0” ring and impeller hub screw backi ring. CLUTCH DISASSEMBLY NOTE: Each disc spring assembly is made up of selected ‘springs to precisely match each part within this assembly. Failure to replace all piston return springs can result in unequal deflection within the spring pack. The result of this imbalance may adversely affect overall life of springs, ‘The disc spring packs are to be used as complete ‘assemblias and care should be taken not 10 Intermix the individual disc springs with disc springs in ancther clutch ‘or dise spring pack. NOTE: DO NOT MIX THE FRICTION DISC IN THE LOW CLUTCH WITH THE FRICTION DISCS OF ANY OF THE OTHER CLUTCHES. SEE NOTE FOLLOWING FIGURE 115) Figure 89 Lift oil battle end oi! seal assembly from impeller. LOW CLUTCH DISASSEMBLY Figure 60 Figure 62 Remove impeller to hub bolts Remove low clutch shaft front basting race. =Figure 63 Figure 68 Remove low speed gear taper bearing retainer ring retainer. Remove clutch ond plate retainer ring. Remove clutch end plato and inner and auter cluteh vises. Figure 64 Figure 67 Remove low speed gear taper bearing retainer ring, Remove low gear inner taper bearing. te Figure 65 Remove low speed gear and outer taper bearing. Remove Figure 68 low clutch taper bearing spacer Remove snap ring, ring retainar. a12— CCCECCECEECCCECCEECCECEECECECECECECOECELCECCEECEEELECEECECCECEFigure 68 Remove clutch piston return dise spring retainer ring. A sleeve with a portion removed is recommended for removing the clutch piston return spring washers and retainer ting. Sleeve shown is a common pipe, with # 1-172 x 1 [39,0 x 25,0mml ‘opening. The pipe is 6 x 3-1/4 x 2-314 [156,0 x 86,0 x 78,0mm}. Comptess. disc spring washer, Through opening remove retainer ting, Release tension on washers. Remove spring Figure 71 Remove clutch shaft piston rings and expander springs. See page 61 for proper piston ring and expander ring instal Figure 70 Remove disc spring washers and spacer. Turn clutch over and top clutch shaft on ¢ block of wood to remove clutch piston. NOTE: Dise springs in the low clutch are different than springs in the forward and reverse clutch. Do net mix low ‘clutch springs with forward and reverse springs (see note after Figure 61). Non modulated units will have retun springs in forward and reverse clutches, FORWARD AND 2ND CLUTCH DISASEMBLY (Forward being disassembled) Forward and 2nd clutch and reverse and 3rd clutch disassemble and reassemble the same except forword and reverse clutches luse disc spring washers for the piston return and the 2nd and Figure 73 3rd clutches use a spring for the piston return, Remove spacer and bearing. Caution: Do not lose lack ball 1Figure 74. Pry front bearing inner race from shaft. Caution: Do not samage bearing roller surface. Figure 75 Remove front bearing locating ring, Figure 76 Pry gear up to accommodate gear puller. —14— Figure 77 Remove clutch driven gear and outar bearing. Figure 78 Remove end plate retainer ring, Figure 79 Remove end plate, CLOEECECCCEECECCECECCECECCOECEOCECCECCECCECCECOECEECECECOECOECEFigure 83 Compress spring retainer washer. Through opening remove spring retainer snap ring, Release tension on spring retainer, Figure 0 Remove inner and outer clutch dises ~~ ON “s Figure 84 Remove snap ring and snap ring reteiner. Figure 85 Remove isc spring washers. NOTE: Non-rnodulated clutches Figure 82 will have a piston return spring in torwaed and reverse. (See Remove bearing locating ring. note after Figure 61), ~15-Figure 86 Remove clutch piston. 4th CLUTCH DISASSEMBLY Figure 87 Remove clutch shaft piston rings and front bearing retainer ing, mh N Figure 88. Pry bearing up to accommodate gesr puller. Remove front bearing retainer ring and front bearing. Figure 89) Remove front bearing locating ring Pry 4th goar up to accommodate puller and remove. Figure 91 Romove inner boating spacer and inner bearing. Dis- assemble clutch discs and piston as explained in previous. section. —16— CCE OCOECECEOECECCOECECCECECECECECECEECOCCECECECECEECECCECECEEECELFigure 92 If roar bearing and or gear are to be replaced remove gear and taper bearing from clutch arurn. CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning {iuid. tis recommended that parts be immersed in cleaning fluid and moved up and down slowly until all olé lubricant and foreign material is dissolved and parts are thoroughly cleaned. CAUTION: Care should be exercisad to avoid skin rashes, fire hazards and inhelation of vapors when using solvent typo cleaners Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles, Repeat above operation until bearings are thoroughly cleen, Dry bearings using moisture-free com- pressed air. Be careful to direct air stream across beering to avoid spinning. Do not spin bearings when drying, Bearings may be rotated slowly by hand to facilitate drying process. Housings Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkati solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. Tris will aid the evaporation of the cleaning solution and finse water. Pars cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam clean a7 CAUTION: Care should be exercised to avoid inhalation of vapors and skin rashes when using atkali cleaners. All perts cleaned must be thoroughly dried immediatley by using moisture-trae compressed air or soft, lintless. absorbent wining rags free of abrasive materials such as matal filings, contaminated oil or lapping compound, IWSPECTION ‘The importance of caretul and thorough inspection of all Paris cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date, Bearings Carefully inspect all rollers; cages and cups tor wear, chipping or nicks to determine fhness of bearings for further use. Do not replace a bearing cone or cup individ- ually without replacing the mating cup or cane at the same time, After inspection, dip bearings in Automatic Trans mission Fiuid and wiap in clean lintless cloth or paper to protect them until installed. Oi Seals, Gaskets, Ete. Replacement of spring load oi seals, "0" rings. metal sealing rings. gaskets and snap tings ig more economical when unit is disassembled than premature overhaul 10 replace these parts at a future time, Furtheross of lubricant through a warn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handied carefully, particularly when being installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. Apply a thin coatof Permatex No. 20n the outer diameter of the oil seal to assure an oil tight fit into the retainer. When assembling new metal type sealing rings, same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members, Lubricate all "O" rings and seals with recommended type Automatic Transmi Fluid before assembly, Gears and Shafts If magna-flux process ie available, use process to check parts, Examine teeth on all gears carefully for weer. pitting, chipping, nicks, cracks or scores. ff gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they aro not sprung, bent, oF splines twisted, and that shafts ara true, Housing. Covers, ete. Inspect housings, covers and bearing caps to be certain they are thoroughly clean and thet mating surtaces, bearing ores, etc., are free from nicks or burrs. Check all parts carefully for evidence of cracks or condition which would cause subsequent ail leaks or failureFORWARD AND 2nd CLUTCH REASSEMBLY (Forward being assembled) — Figure 96 Install 2nd washor with large diameter of bevel up. Install balance of washers, quantity of (7) sever alternating bevel. Figure 93 Install new clutch piston inner and outer sealing ings, Figure 94 Install ise spring snap ring retainer ahd snap ring. Compress Insert clutch piston in clutch drum. CAUTION: Do not renee and’eoen cies vettrer instal snop ring n lower anep damage sealing rings. See note in Figure 85. fing groove. install inner bearing locating ring. (See page 43. Figure A ss Figure 95 Install 4st disc spring washer, large diameter of bevel down as shown, NOTE: Do not mix forward clutch disc spring washers, Figure 98 with other washers. (See note after Figure 611. Inaert one steel dise, —1a CCCECCECCECEECCECECCCECECCECECCECECCEECECECCEECECECEELCEECLELEFigure 99 Install one friction dise. Altemate steel and friction discs Until the proper amount of cises are installed, First dise next 10 the piston is steel, last disc installed is friction, Figure 100 Install end plate. Figure 101 Install end plate retainer ring. —19— Figure 102 Install cluten driven gear inner bearing, NOTE: The inner bearing does not have # bearing shiele. Figure 103 Install clutch driven gear into clutch drum. Align splines ‘on clutch gear with internal teeth of fiction dises, Tap gear into position, Do not force this operation. Gear splines must be in full position with internal teeth of al friction discs. Figure 104 Install riven gear outer bearing. NOTE: Bearing shield in. (See page 59).Figure 108 Instalt jock ball and bearing spacer. Figure 106 Figure 109 Install front bearing inner race. Install bearing retainer ring. ™ \ Figure 110 Install piston rings and expander springs as explained on page 6 Figure 107 Install front bearing and outer race, —20— COEEQCECECECECEEECCEECECECCCECECCECCECECECCCECEECECELFORWARD & REVERSE NON-MODULATED CLUTCHES AND 2nd & 3rd CLUTCH PISTON RETURN SPRING REASSEMBLY Figure 111 Install new clutch piston inner and outer sealing ring. Insert piston into clutch drum using caution as not to damage seals. Position inner spring retainer, piston return spring, outer spring retainer and retainer scap riog retainer and snap ring. Compress spring and retainer and install snap ting, See page 43, Figure B. Assemble clutch disce and end plate as previously explainad, LOW CLUTCH REASSEMBLY Figure 112 Install new clutch piston inner and outer sealing sing, Insert piston into clutch crum using caution as not to damage seals. Install piston to dise spring washer spacer. Sea NOTE: After Figure 61. instal disc spring washers. First washer with large diameter of washer towerd spacer. Alternate (6) five washers. ‘See page 43, Figure C. Figure 13, Position piston return disc spring snap ring. Compress dise ‘spring and install snap ring, na Install snap ring retainer. Figure 115 Install low gear inner taper bearing. Install one steel disc. tion disc. NOTE: The Install one ft low clutch has a! be mixed. The fow clutch inner: “"X" stamped on one side of the inner teath. The ow clutch inner disc also has a strip of non-soluble yellow paint sprayed on the outer edge of the disc. Alternate steel! and frietion dises until the proper amount of discs are installed. First dise next to the piston is stool, last disc installed is frict 1Install end plate and retainer ring, Figure 117 Install low clutch taper bearing spacer, NOTE: When Figure 120 ingtalling the rd gear in the 3rd speed clutch a bearing Install low clutch taper bearing retainer ring spacaris usedbetween the innerand outer rd gear NOTE: Retainer ring is selected at assembly for proper aso thickness, A snap ring kit ia available. Select the thickest of the three rings in the kit that can be fitted into the snap fing groove to assure a proper taper bearing tightness. ‘Check ring as shown for tight ring to bearing fit, Figure 118. Install low gear into clutch drum. Align splines on low ‘gear with internal teeth of friction discs, Tap gear into es Position. Do not force this operation. Gear splines must be Figure 121 in full position with internal teath of all friction discs. Install low speed gear taper bearing retainer ring retainer. —22— CLCCCECCEECECECCECCCECOEECECEECECCECECELEECECEECECECECEECECEECECEEEEL™~ — ~~ eth ¢ Figure 122 Install tow clutch shaft front bearing inner race with large diameter of race down, 4th SPEED CLUTCH REASSEMBLY Figure 123 Install piston, and piston return spring. See Page 43, Figure D. Install inner and outer dises as explained in Fig. ‘93 through Fig. 101. Install 4th speed gear inner bearing. NOTE: Bearing Part Number must go down. See Figure 126, Figure 125 Install 4th speed gear outer bearing. NOTE: Bearing Part Number must go up. See Figure 126. It is recommended 0 rubber band be used tohold outer bearing rollers in position when installing bearing. Figure 126 Figure 124 Install bearing spacer between inner and outer 4th speed. goar bearings. Install 4th speed gear into clutch drum. Align splines on clutch gear with internal tooth of friction discs, Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of a friction discs. Figure 127 Install outer bearing locating ring, 23Figure 128 Install front bearing anc bearing retainer ring Figure 129 Install clutch shaft piston sings. TRANSMISSION REASSEMBLY Figure 130 View of output shaft as it would be positioned in transmission case. Note front cone bearing shouldered on shaft with large diameter of bearing in, and long hub of gear toward gear spacer. jure 131 Position output gear in transmission case with protrud= ing hub toward front of case. See Fig. 130. Inset output shalt, gear spacer and tsper bearing from front of case and through output gear. Install front taper bearing cup. Block output shaft and install rear taper bearing with large diameter in, Figure 132 Coat outer diameter of oll seat with Permatex No.2 and press seal in bearing cap with lip of seal in, Using new "O” rings install rear output bearing cap, oll seal and taper bearing cup on transmission case. Lube opening in bearing cap must be aligned with lube opening in case. Tighten bearing cap bolts to specified torque. (See torque chart.) 24 COCECCECEECEECCECECECCECECECECECECECCCCEECECCECCCEECCEOECELFigure 133 Install front beating cap and shims. Tighten bolts to specified torqua. Tap cutgut shalt front and rear to seat taper bearings. Loosen front bearing cep bolts, Figure 136 Instalt low clutch front bearing, Figure 134 Using an inch Ib. torque wrench, determine the rolling torque of the output shaft and record, Tighten front bearing cap bolts to specified torque. Check rolling torque with bolts tight, Torque must be 6 to 8 inch Ibe. [0,68 - 0.90 N.m] more than when bearing cap bolts were loase. Add or ‘omit shims on the front bearing cap to achieve the proper preload. Figure 137 Instalt low chitch assembly from rear of transmission cose, Instalt output shart front companion flange, flange “O" ring, washer and flange nut. Block output gear. See elastic stop nut Install 2nd speed bearing end plate and 2nd speed gear on torque chart low clutch shat. =25—Figure 139, Figure 142 Install 2nd speed gear retoiner ring. Install reverse and 3rd clutch assembly from the frontef the transmission Figure 140 Figure 143 Install 2nd speed goar rotainar ring retainer. Install low speed drive goar and retainer ring, Figure 141 Figure 144 Install 2nd gear ring retainer snap ring. Instalt idler shaft and 4th speed clutch assembly. —26— COEOCCECECECCECCOEECCOECELECCECCECCECCECECECECCEECECECECECEECEOCEL145 Figure 148 Fig Install low clutoh inner taper bearing, NOTE: Heat bearing Install outer taper bearing. NOTE: Heat bearing in hot oil in hot oil bath prior to installation, bath prior to installation. Figu Figure 149 Inte bearing spacer Install retainer pte, inner Giamster chamir toward ° be og. Figura 150 Figure 147 Install bolts and block gears. Torque bolts to specifications ‘stall bearing cup, and lack wire together. —27—Figure 151 Figure 154 Install low clutch shaft sealing ring, Tap cover in place and secure with bolts and lockwashors torque cover bolts to specifications Figure 182 Install idler shaft spacer and nut. See elastic stop nut torque: Figure 156 chart. ‘Tap low clutch and idler shaft 1 rear of transmission to allow for rear bearing snap ring clezrance. Install snap ‘ing, Figure 153 Install alignment studs and new gasket. Place lock balls in low shaft and idler shaft, Alight coat of grease will held lock balls in place. Position shatts so lock balls align with Figure 158. notches in rear cover. Install new “O" ring and gasket on low shaft bearing cap, 28 COECCOECECCCECCECECCECCECCCCCECECCCECCECECECECECECEOECLELFigure 157, Install beanng cap with bolts and lackwashers, Torque to specifications, Figure 168 ‘natell idler shaft roar bearing locating ring, Use naw gasket and install idler shaft bearing cap and cap bolts and lockwashers. Torque bolts to specifications. Figure 180 Install new “O" ring. Install washer and flange nut, Block output shaft. See olastic stop nut torque chart IMPELLER REASSEMBLY Figure 161 Clean impeller hub mounting surface and tapped holes with solvent. Dry thoroughly being certain tapped holes are dry and clean, Install new “O" ring on impeller hub, Position impeller hub serew backing ring, Figure 162 Align holes in impeller hub with holes in impeller and backing —29—Figure 163 Install (12) impeller hub apecial screws to approximately .06 inch [1.5) of seated position. With a calibrated torque. wranch, tighten screws to 40-45 Lbs, Ft. [64,3-61,0 N.m.] ‘torque. NOTE: Assembly of impeller to impeller hub must be completed within a fifteen minute period from start of ‘serew installation. The screws are propared with coating which begins to harden after installation in the impeller hub holes. If not tightened to proper torque within the fifteen ‘minute period, insufficient screw clamping 1 result. The special screw is to be used for one i only. If the scraw is removed for any reason replaced. ‘The compound Ieft in the hub holes must be removed with the proper tap and cleaned with salvent, Dry hole thoroughly and use a now screw for reinstallation. Figure 164 Apply a light coat of Patmatex No. 2 on the outer diameter of the oil baffle seal. Press seal in oil baffle with lip of seal down. —30— Figure 165 Install a new oil baffle seal ring. Figure 166 Install oil baffle on impelter assembly. Figure 167 Install impeller hub gear. COCCCCOCCOECCCCCECECECECECECECCCOECECECCECCECCCECCECECCOECECEEELEFigure 168 Secure impeller hub gear with retainer ring, Figure 169 Install new turbine shaft piston ring. DRIVE GEAR RETAINER RING TURBINE SHAFT NOTE: LONG HUB OF DRIVE GEAR TOWARD. RETAINER RING Figure 170 Tap turbine shaft and bearing assembly into converter housing from front. At the reat of the converter housing install turbine shaft gear and retainer ring as shown, Figure 171 Support converter housing with chain fall. Spread forward ‘lutch front bearing retainer ring and tap forward and 2nd clutch assembly into transmission case assembly. Be certain snap ring is in full position in ring groove, Figure 173 Install left pump drive gear. anFigure 174 Figure 17 Install right pump drive gear. Install transmission case gasket and "O" ning seals. Figure 175 Figure 178 Align holes in pump drive gear bearing supports with holes Install housing spacer, gasket and "0" ring seals. NOTE: im converter housing. Install bolts and washers end tighten Housing spacer is used with 12 plate clutch modulation to speficified torque. only. Figure 179 Install alignment studs and position corwerter housing on Figure 176 studs. NOTE: Turn output shaft to align clutch dise hub in Install 2nd speed clutch pilot bearing. clutch ang final assembly. —32— -CCECECEECCCCECECECCCCECECECCECECCEECECCCEECECOCECOEECEEEELEFigure 180 Instell converter housing to transmission housing bolts and tighten to secified torque. NOTE: Bolts are not to be used to Pull converter housing to transmission housing, Figure 181 {Install new sealing ring expander spring and oil sealing ring om support, NOTE: Expander spring gap to be 180° from sealing ring hook joint. Positian support an turbine shaft tum support to clear pump drive gear. Align suppart holes with converter housing, Install stator support bolts and tighten to specified torque. Figure 183 Grease stator support piston ring, cil baifle cil saal and seal ring to facilitate reassembly. Instalt impeller and oit baffle assembly in converter housing, Figure 184 Position ail baffle in housing, Secure with oil baffe retainer fing, baing sure ring is in full position in ring groove. Figure 185 Install reaction member spacer with tang facing out. Install roaction member. —3-Figure 186 Figure 187 Position turbine in impeller cover. ~S Figure 188 Install spacer and turbine to impelter cover bearing snap ring, Figure 189 Position new impeller to impelter cover “0” sing on Impoller, Install turbine and impeller cover. Figure 190 Instoll impeller cover bolts and torque to specifications. Figure 191 Install new “0” ring seal in impeller cover bearing cap, 34 -CLEECCCECCECCECCECECCECECCECCECCECCECCECOCEECCEEELECLFigure 192 Figure 195 Install bearing cap and bolts, torque to specifications. Install gasket and modulator value Figure 193 Figure 198 Install gasket and 90° adapter. Install and tighten internat Position new gasket. Position detent spring and balls screws, Install bolts and torque to specifications. Instalt control valve, Figure 194 Figure 197 Install alignment studs and new modulator valve adapter Install contral_ valve balts and lockwashers, remove plate gasket, Install medulator va aligning studs. tighten bolts to specified torque. 36Figure 198 Install pump driva sleeves, Figure 199 Install pressure regulating valve assembly. Figure 200 Install pump and filter adapter. Install pump to regulating valve stud nuts, NOTE: Some units wilf have a double pump and not @ filter adaptor. Figure 201 Install now oil filter element. Install filter housing, Torque pump to regulating valve stud nuts to specifications, Torque filtar housing 20 to 26 ft Ibs. [27,2-33,0 N.m} Figure 203 Install converter housing te engine housing spacer cing, —36— ~-CCEECCCECCECECCECCECCECECCEECECCCCECECCECCCEEECELCLSERVICING MACHINE AFTER TRANSMISSION OVERHAUL n, torque converter, and its allied hydraulic system are important links in the drive line between the engine and the wheels. The proper oper- ation of either unit depends greatly on the condition and operation of the other; therefore, whenever repair ‘or overhaul of one unit is performed, the balance of the sysiom must be considered before the job can be considered completed. After the overhauled or repairad transmission has been installed in the machine, the oil cooler, and con- necting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a de- ‘ree of judgment must be exercised as to the method employed. ‘The following are considered the minimum steps to be taken: 1. Drain entire system thoroughly. 2. Disconnect and cle feasible, hydraulic lit machina for cleaning. hydraulic lines. Where 5 should be removed from 3. Replace oil filter elements, cle cases thoroughly. ing out filter The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil end I foreign material has been rection of normal oil flow will not n the cooler. if neces- sary, cooler assembly should be removed from machine for cleaning, using oil, compressed air and steam cleaner for that purpose. DO NOT vse flushing compounds for cleaning purposes, 5. On remote mounted torque converters remove drain plug from torque converter and inspect Interior of converter housing, goars, etc. if presence of considerable foreign material is noted, it will be necessary that converter be re- moved, disassembled and cleaned thoroughly. It is realized this entails exira labor; however, such labor is a miner cost campared to cost of difficulties which can result from presence of such foreign material in the system. 6. Reassemble all components and ure only type oil recommended in lubrication section. Fill transmission through filler opening until fluid comes up to LOW mark on transmission dipstick. NOTE: If the dipstick is not accessible oil levei check plugs are provided. Remove LOWER check plug, fill until ofl runs from LOWER oil hole. Replace filler and level plog. Run engine two minutes at 500-600 RPM to prime torque converter and hydraulic Ii check level of fluid in transmi running at idle (500-600 RPA). Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install oil level plug or dipstick. Recheck with hot il (180-200" F.) [82, 2-93, 3° Cl. Bring oll level 10 FULL mark on dipstick or runs freely from UPPER oil level plug. 7. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary. TORQUE IN (LBS.—FT.) BOLTS, CAPSCREWS, STUDS AND NUTS Grade 5 Identificotion, 3 Radial Dashes 120° Apart on Head of Bolt Grade 8 Mentification, 6 Radial Dashes 60° Apart on Head of Bolt WUBRICATED OR PLATED Grade 5 Grade 8 "| ag wetitinn | rattan | 5000 64-70 [86,8-94.9) 90-99 [122,0-134,2] 80-86 (108.-119,3] —37—SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION AND TORQUE CONVERTER CONVERTER OUT Converter ute ol erp, 380° 200" OL FILTRATION Full ow ol Ber salty Dy pt, as strane ereen PRESSURE (823°-a33¢e1 In sun ot tater of tranaisson case ‘Tranamiagon 9 NEUTRAL, CLUTCH PRESSURE 240-300 110548. 2068 KPal With parking Operating seecifestors: ‘jake se: See note ol temperance 130° 200°F 25 PSI.11728 bral wnrrum pressure at 2000 122° 03.3°C1 engine a ee HOD to 00 REM, RPM engine sooed AND a rani of 70 PSA shit ta ection and soved dutch: AN ce 48290 Pal outlet prose wi engice operating at eaure mst bo eauat within ® pt [345 Aa, wloae governed Spe08 latch arse vais anyone can more tan 5 courons Forward and Reverse Manual e [34.5 kPa repo uch ‘Seeed Selection — Vana NOTE: Never use sevice brakes while making ccuuteu Tyee Mutple dnc, mydrmulcaly setuid, sping ease clutch pressure checks. Units hevingbrak ne utara west compensation sd a0 austen. all ‘nated declutching in forward andor rvorve wll lutenes ol cole ane Mice CLUTCH INNER bISC Frcton CLUTCH CUTER DISC St not give # rue reading, [ALWAYS USE PARKING BRAKE WHEN MAK NG CLUTCH PRESSURE CHECKS. LUBRICATION RECOMMENDED LUBRICANTS FOR CLARK HURTH COMPONENTS POWER SHIFTED TRANSMISSION AND TORQUE CONVERTERS Prevailing Ambient Temperate TYPEOF OL Ser Labe Crt, CAPACITY. Gongs Coors Marlon appabi machine ‘ Taman coe ‘eters capeay Tawa conven fk ee erate “rareason ana shes erie ar most by Stace fess eae Ensdeed oe eo dea caret 2 tect sreucane 9 CHECK PERIOD Chek oe! DALY vith eng ring a | neta Reece aa ate 2008 Flea Rem ne 8 Sag oa eptcoosse 95,3 Cl, Maintain Tee! to FUL. Mek : » "T Bava 832230 fn Posie er Fen DRAIN PERIOD —Fuery TOOD hours ean an ol sytem 2 NORWAL* Every 500 hows, change oi fter element Ringe” BIB no ae anton eon ‘aliows Orain with oll at 150" Wo 200" F 85.8 “Range # Sim Cater « 33°C. * cota ade Chaat ado Om NOTE Seite neato tn es go TRUEST aneeT Tow aobhoes OS arene, leh check evs wth engine raming 3¢ itn 500800 newt one ad oo ng fer {LOW mark Whan of temperaturs het 190:300° FI fa22 °C) ak fl Oi ovat chek BRING OIL LEVEL TO Putman NOTE: leis recommarded that filter ‘ements be changod afor 50nd 100 nove | [= (@) rnin vanamiston ond remove sump streen. Clean screen thorough tnd Faplace, using new geskots 12) rin oi titers, remove and decors ‘her slomente: Clean liter shall and neta now olomente, (2) fil wancmission to LOW mark (2) Run engine at 500 600 RPM to prime ‘convertor and fines ‘*Normal drain periods and filter change intervals are for average environmental and duty-cycle conditions, Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination. For extreme conditions judgment must be used to determine the required change intervals. —38— CCCCECECCECCEECECECCCECECECECCEECECOECCOCCEECECEECECECECEECEECETROUBLE SHOOTING GUIDE R and HR Model, 32000 Transmi The following data is presented as an ald 10 locating the source of difficulty in a malfunctioning unit. It is necessary to consider the torque converter charging pump, transmission, oil cooler, and connecting ines 45 « complete system when running down the source of trouble sines the proper operation of any unit th in depends greatly on the condition and operations of For The ion the others. By studying the principles of operation together with data in this section, it may be possible to correct any malfunction which may occur in the systern. TROUBLE SHOOTING PROCEDURE BASICALLY CON. SISTS OF TWO CLASSIFICATIONS: MECHANICAL AND HYDRAULIC MECHANICAL CHECKS Prior to checking any part of the system from a hydraulic standpoint, the following mechanical checks should be made: 1. A check should be made to be sure all control lever linkage is properly connected and adjusted at all connecting points. 2. Check shift levers and rads for binding or restrie- tiont in travel that would prevent Full engagemant. Shift levers by hand at control vaive, if full engage- ment cannot be obtained, difficulty may be in control cover and valve assembly. HYDRAULIC CHECKS Before checking on the forque converter, transmi sion, and allied hydraulic system for pressures and rate of oil flow, it is essential thet the following pre~ liminary checks be made: Check oil level in transmission. This shouid be done ‘with oi temperatures of 180 to 200° F. [82,2-93,3°C]. DO NOT ATTEMPT THESE CHECKS WITH ‘COLD Ol To bring the ail temperature to this specification it is necessary to either Wark the machine or "sail! out the converter. Where the former means in impractical, the larfer means should be employed as follows: Engage shift levers in forward and high speed and apply brakes. Accelerate engine half to throe-quarter throtle. Hold staf! until desired converter outlet temperature is reached. CAUTION: FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER, LOW CLUTCH PRESSURE Cause Romedy 1. Low oil level 1. Fill 10 proper level 2. Clutch pressure regulating valve spool stuck open. 2. Clean vaive spool and housing. 3. Faulty charging pump. 3. Replace pump. 4, Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings. 5. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly. LOW CONVERTER CHARGING PUMP OUTPUT 1. Low oil level 1. Fill 10 proper level 2. Suction screen plugged. 2. Clean suction screen, 3. Air leaks a1 pump intake hose and connections or 3. Tighten all connections or replace hose if necessary. collapsed hose, (8-22000 only} 4A. Defective oil pump. 4. Replace pump. ‘OVERHEATING 1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter assem- by, 2. Warn oil pump. 2. Replace. 3. Low oil level 3. Fill to proper tevel. 4. Pump suction line taking air. 42-32000 only) 4. Check oil line connections and tighten securely. NOISY CONVERTER 1. Worn coupling gears. 1. Replace. 2. Replace 3. A complete disassembly will be necessary to deter- mine what bearing is faulty. LACK OF POWER 2. Worn oil pump. 3. Worn or damaged bearings. 1. Low engine RPM at converter stall 2. See “Overheating” and make same checks. 1, Tune engine check governor. 2. Make corrections at explained in “Overheat ~39—THEORY OF OPERATION TRANSMISSION MODULATOR VALVE OPERATIONAL DESCRIPTION dividual modulator valve auletor spool is the same as that applying the clutch piston. Supply flow to the clutch and modulator is limited by a flow limit ice. From this limited flow the regulator spool drains flow {0 the vent port. The regulator spool restricts flow through the vent port to build clutch pressure at a pre- determined rate, Once the vent flow is shut off, only minimal flow passes through the flow limiting orifice to make up for normal spool and clutch leakages. Pressure on either side of the orifice is virtually ident- ical and full regulated system pressure is applied at the clutch piston. When forward direction is selected the oil under pressure enters the port on the “A” side of the reguletor spool. This passes through the dampening orifice. The pressure force on the spool area shifts the spool to the right exposing the vent port. The time required to shift the regulator spool over to expose the vent port shows up as a pressure spike at the beginning of the pressure versus time chart. The movement of the regulator spool is eppoted by the regulator and accumulator springs. This provides ‘an initial low pressure head of approximately 20 psi [137,9 Kpa] on the “AY side of the spool. This 20 pti [137.9 Kpa} is represented as a horizontal line on the pressure versus time chart immediately follow- ing the spike. Oil flows through the regulator spoo! orifice due to a pressure imbalance. Pressure at side A" is constantly 10 psi {68,9 Kpa] higher than side “B” az a result of the added force of the side "8" spring. The 10 psi [48,9 Kpa] supply through the regulater spool orifice gives a controlled flow rate. This con- trolled flow establishes the time it takes to fill the accumulated cavi As the accumulator cavity is filled, the accumulator spool is forced against the accumulator springs. As the springs compress their force increases causing the hydraulic pressure in the accumulator cavity and “BY side of the regulator spool to increase. Pressure on the “A” side of the regulator spool increases with the opposing force on the “B” side. This causes the rising slope in the clutch pressure versus time chart. ‘The rate of this rise is controlled by the accumulator spring force. Once the accumulator spool is stroked to its limit, pressure on “A” and “BY side of the regulator spool is balanced since no flow passes through the regulator spool orifice. The regulator spool spring pushes the regulator spool to the left shutting off the vent flow. The cluich and modulator pressure rapidly rise to the system regulated clutch supply pressure setting. This is the vertical line on the cluich pressure versus time chart. The entire modulator sequence of events occurs in less than two seconds, The steady rise of cluich pressure increases the clutch driving torque which results in a smooth clutch application. When forward direction is selected the reverse clutch and modulator are vented through the control valve to the transmission sump. The reverse accumulator cavity is vented beck through the regulator spool orifice. To hasten the reset timo of the accumulator, immediately prepering the transmission for a directional shift, full system regulated clutch supply pressure from the forwerd control valve is directed to the spring cavity of the reverse accumulator. When reverse direction is selected the reverse clutch and modulator function through the same sequence of ‘events as the forward clutch and modulator. This seme sequence of events also applies 10 the lock-up modulators. COCECEECECCCCECOECEECCECCOCEOCCECOECTCCECEECECECCECOECECECCL32000 SERIES MODULATION MODULATED FORWARD COREA ERRESIRET otare heck FORT ' HODULATION Fonwano (}- FROM SUPPLY ° REGULATOR: mg) Js i SIE 6 SPRING ° 6 si0€ 8 ° fr nequtaron sroot once Low uv Oo 8 ORIFICE SIDE A | ampenine oouLareo o Saree need etUrenenccsunt Oo ° shee roa OS ca) 10 FORWARO mare SYSTEM REGULATED CLUTCH PRESSURE MODULATED. PRESSURE ‘This pressure spike is ime required for spools to react. ‘The spike pressure is used to quickly fil the clutch presaure eupply MODULATED passages with cil, [Time Base. r agoumutator | --, Se6gt8 e}- it ACCUMULATOR } ‘SPRINGS, q B O of o ACCUMULATOR ° cave FROM SUPPLY TF FORWARD oO MODULATOR ‘vy. oO e ° Of Reverse VENT PORT MODULATOR: Oo O ) ° PRESSURE PORT To FORWARD ° cuure REGULATOR SPOOLS aaCONVERTER HOUSING TO TRANSMISSION CASE SPACER USED ONLY WITH 12 PLATE CLUTCH PACK ASSEMBLY. MODULATED VALVE ASSEMBLY ITEM DESCRIPTION ary. ana akwn = Accumulator Valve Stop Plug Accumulator Valve Stop Plug Accumulator Spring - Outer. Accumulator Spring - Inner Accumulator Valve Pin. Accumulator Valve Plug...... 000 : Modulator Valve Housing - = RNRNNNN 4a Tem DESCRIPTION ary. 9 Regulator Spool 10 Regulator Spring, : : 11 Regulator Spool Stop Plug "O” Ring. 12 Regulator Spool Plug........ 13 Modulator Valve to Plate Gasket 14 Housing Spacer Gasket. 16 Housing Spacer SRNNN (CC COECECCEECCOECCOECCECCECCECCOCEECECCECCCECCELCECCECEECCCECEECCECEFIG.A it REV.& FWD. apo ——————— 063 - 064 —_——=— 11600 - 1.628) MODULATED FWD. & REV. CLUTCHES 2nd & 3rd & NON- FIG.6 MODULATED FORWARD & REVERSE CLUTCHES FIG.C OL oases 11.219 1.245) LOW (1st) CLUTCH FIG.D (4 SPEED ONLY) 4TH 4316 SCREW RING GEAR INSTALLATION PROCEDURE (Non-Asbestos Ring Gear) Remove afi burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting suttace ‘and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain cing gear screw holes are dry and clean, Check engine flywheel and housing oF housing adaptor for conformance ta standard SAE, No. 3 — SAE J927 and 1033 ‘tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine crankshaft ed 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 screw installation. The screws ate prepared with an epoxy ‘coating which begins to harden after installation in the flywheel mounting holes. If not tightened to proper torque within the fifteen minute period insutficient screw clamping tension will result Install backing ring ond sixteen (161 special sctews to approximately 06 inch |1 5 mm| of seated position Its permissible to use ‘2 power wrench for this installation phase. With a calibrated torque wrench tighten screws 30 to 33 pounds feet of torque I40,7 - 447 Nan To obtain maximum effectiveness of the special screw's locking featute, a minimum time period after screw installation of twelve (12) hours is suggested before engine startup, The special screw 1s to be used for ONE installation oniy. Ifthe screw is removed for any reason t MUST BE REPLACED. itis Tecommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent, Diy hole thoroughly and use 2 NEW screw for reinstallation, Assemble torgue converter to engine flywiee! by sliding convaiter into position by hand before fastening housing attachment screws, This may require more than one trial to match the rlrive gear teeth. Pulling the converter ito position with housing attachment bolts is rot recommenced. Measure engine crankshatt end play alter assembly of torque converter. This value must be within one thousandth (0611 of an inch [0,0254mml of end play recorded lin Paragraph #2) belore assembly of toraue converter 202559 — 1.5 INCH (38.1) 16 SCREW RING GEAR KIT 802554 — 15 INCH 198,11 16 SCREW RING GEAR KIT 1289381 Torque Convertor Biss Gear 1249341 Torque Converter Ring Gear Y6 730288 Bing Geer Serew 1.5 Inch (38.1) 16 236288 ng Gear Seve 15 tnt (38.11 1 802855 Instadauan inseacton Sheet 243767 Backing fing 1 BUZS5 ——Instalation Inston Sheet 242987 Backing Ang not cud im BOZEGE ing Geir Kat Mus} bi Otter Separatly Dimensions are in inches Dimensions in? | are mm. ‘SEE PAGE 45 FOR INSTALLATION ILLUSTRATIONS ‘SEE PAGE 50 FOR 32 BOLT INSTALLATION ~44— CCECECCECECECECECECCECCECCCCCCECECCCCECEELECCEECECEOEELBACKING RING ENGINE FLYWHEEL TORQUE CONVERTER RING GEAR RING GEAR SCREW RING GEAR SCREW (98) 296288 1.500 [38,1] ENGINE FLYWHEEL SEE PAGE 44 FOR INSTALLATION PROCEDURE AND BOLT TORQUE TORQUE CONVERTER RING GEAR 249341 — 45TURBINE HUB SCREW IMPELLER HUB SCREW IMPELLER HUB & TURBINE HU8 ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS. 1. CLEAN HUB MOUNTING SURFACE AND TAPPED HOLES WITH SOLVENT. ORY THOROUGHLY BEING CERTAIN TAPPED HOLES ARE DRY ANO CLEAN, 2. INSTALL BACKING RING AND SPECIAL SCREWS 70 APPROXIMATELY .O8 INCH {1,5} OF SEATEO POSITION. WITH A CALIBRATED TORQUE WRENCH, TIGHTEN SCREWS 40 10 45 LBS, FT. TORQUE [84.3-61.0 Nem). NOTE: ASSEMBLY OF IMPELLER OR TURBINE HUB MUST BE COMPLETED WITHIN [A FIFTEEN WINUTE PERIOD FROM START OF SCREW INSTALLATION. THE SCREWS ANE PREPARED. WITH A COATING WHICH BEGINS TO HARDEN AFTER INSTALLATION IN THE HUB HOLES. IF NOT TIGHTENED TO PROPER TORQUE WITHIN THE FIFTEEN MINUTE PERIOD. INSUFFICIENT SCREW CLAMPING TENSION WILL RESULT. THE SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION ‘ONLY. IF THE SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED. ‘THE COMPOUND LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER TAP AND LEANED WITH SOLVENT, DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION. —46— CCCEECEEECCELECCCEECEECEEECCECECEEEECECEEECEECCELCELKEY 157 (Low ———— 2D ———— jap 6 4TH (HI) 4 SPEED TRANSMISSION aCooler ‘ultel pressure Cooler Outlet temperature Filter ype "A": Use replacement element 215502 Pod "AQ", DO NOT SUBSTITUTE ‘Cooler Ports “A and "J" are permanent requirements ‘and thes installation 18 required in this area, Modulated forward clutch check port Port "'’” Converter outlet temperature Port "R” Converter outlet pressure Port “'T” Checkpoint transmission forward clutch pressure Checkpoint transmission reverse ciutch pressure “RY, and "DD" Used for field trouble shooting PLUMBING DIAGRAM FOR HR 32000 'W/12 PLATE MODULATION AND AUXILIARY LUBE —48— CEEEECECECECCECEECELEECCECECEECCECECEECECCECCECEECEECECOECEECLEEFROM CONVERTER INSTALL GAUGE IN THIS LINE FOR CONVERTER “OUT” PRESSURE" ‘CLUTCH PRESSURE ‘CHECK POINT? OWL LEVEL, FROM COOLER TO ‘CHECK POINT ‘TRANSMISSION LUBE DISTRIBUTOR CHARGING PUMP OIL SUCTION SCREEN ‘TWPE "A" FILTER, USE REPLACEMENT ELEMENT 215502 INSTALL GAUGE IN THIS: Do NaT SuBsTiTuTE LINE FOR CONVERTER “QUT” PRESSURE" ‘CLUTCH PRESSURE CHECK POINT** lL LEVEL FROM COOLER TO CHECK POINT ‘TRANSMISSION LUBE DISTRIBUTOR NOTE: ALL TYPE "A" FILTERS USE CLARK FILTER REPLACEMENT CHARGING PUM o1L ELEMENT PaRT NO. 215502 SUCTION SCREEN 00 NOT SUBSTITUTE. 32000 SERIES PLUMBING DIAGRAM (WITH REMOTE FILTER) “CONVERTER OUT 25 MIN..70 MAX. PSI. [172-482 kPa] TRANSMISSION IN NEUTRAL, PRESSURE OIL TEMPERATURE 180-200" F. [82,2-93,3" C.}. ENGINE AT 2000 RPM “*CLUTCH PRESSURE 240-280 PSI [1654-1830kPa] — WITH PARKING BRAKE SET (SEE NOTE), OIL TEMPERATURE 180-200" F. [82,2-93,3° C.], ENGINE AT IDLE [400 to 600 APM), SHIFT THRU DIRECTION AND SPEED CLUTCHES. ALL CLUTCH PRESSURE MUST BE EQUAL WITHIN 5 PSI. [34 kPa]. IF CLUTCH PRESSURE VARIES IN ANY ONE CLUTCH MORE THAN 5 PSI, [34 kPa] REPAIR CLUTCH. NOTE: NEVER USE SERVICE BRAKES WHILE MAKING CLUTCH PRESSURE CHECKS. UNITS HAVING BRAKE ACTUATED DECLUTCHING IN FORWARD AND/OR REVERSE WILL NOT GIVE A TRUE READING, ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS. 4932 SCREW RING GEAR INSTALLATION PROCEDURE (Non-Asbestos Ring Gear) 1. Remove all burrs trom flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface and tre ring gear screw tapped holes with solvent, Dry thoroughly, being certain ring gear screw holes ace dy and clean. 2. Check engine flywheel and housing or housing adaptor for contormanca to standacd S.A.E. No.9 — SAE J927 and J1033, tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine crankshatt end play. Install torque converter ring geat as shawn. NOTE: Assembly of the ring gear must be completed within a fifteen minute period from start of screw installation. The screws are prepared with an epoxy Coating which bagins to harden after installation in the flywheel mounting holes. If not tightened 10 proper torque within the fifteen minute period insufficient screw clamping tension will result 4. Install backing ring and thirty-two (22) spacial serews te approximately .06 inch |1,5 rmm| of seated position. It is permissible to use a power wrench for this installation phase. With & calibrated torque wrench tighten screws 23 to 25 pounds feet of torque 131.2 - 338 Nut To obtain maximum effectiveness of the special scrow’s locking feature, a minimum time periad ater screw installation of twelve (12) hours is suggested before engine start-up. ‘The special screw is to be used for ONE installation only. If the screw 's removed for any reason it MUST BE REPLACED. Itis recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent, Dry hole thoroughly and use a NEW screw for re:nstallation. 5. Assemble torque converter 0 engine flywheel by siding converter into position by hand before fastening housing attachment screws, This may tequite more than one tial to match the dive gear teeth. Puling the converter into position with housing etachment bolts is not recommended. 6, Measure engine crankshaft end play atter assembly of torque convarter. This value must be within one thousandth (001) of en inch [0,0254ram! of end play recorded fin Paragraph #2) before assembly of torque converter. 202544 — 1.5 INCH [38.1132 SCREW RING GEAR KIT 802547 — 25 INCH [535] 32 SCREW RING GEAR KIT 1249265 Toss Convorter Ring Goat 1248255 Torque Converter Ring Geat 32 243970 ‘Ring Guar Serew 15 inch 138.11 32 237153—_Rng Gear Screw 26 Inch 1635) 1 802560 Instalation instruction Sheet 1882550 _Instalaton Instruction Sheet 1175 INGH [44,4132 SCREW RING GEAR KIT 802548 3.0 INCH 176.21 32 SCREW RING GEAR KIT 1289265 Torque Convert Ring Gear 1289265 Torue Converter Ring Gear 2 244903——Ring Gar Serew 1.78 inch [43,43 32236938 Ring Goat Serow 30 neh 17628 1 $02860 _Instalaton instruction Shest 1 802550 Installation Instruction Sheet 802545 — 2.0 INCH 180.8) 32 SCREW BING GEAR KIT 202549 _ M832 SCREW RING GEAR KIT 1289265 Torque Converter Ring Goar 1248265 Torque Convenes Ring Geat 32240318 Ring Guar Screw 29 Inch [5081 24200007 Ring Gear Serew IMB « 1251 1202860 Installation instruction Sheet 1 -BDDEEN —_InealatenInsbuction Sheet 2236837 Backing Ring Not Incuced in Ring Gear Kt. Must be Ciceted Separately NOTE: The initial installation dkive gear mounting kit includes a converter air breather. This breather is used on € & CL 270/C & CL 320 converters only and is not required for the HA & LHF 2B000/HR & LHR 37000 applications. SEE PAGE 51 FOR INSTALLATION ILLUSTRATIONS, —s0 — CECECCCECCCECCOECOECECCECCECECEELECECCEECECECECECECECCECEECOELELBACKING RING ENGINE FLYWHEEL TORQUE CONVERTER RING GEAR, RING GEAR SCREW ENGINE FLYWHEEL RING GEAR SCREW (32i 243970 1.500 138,11 (321 244903 1.750 f44/4| (32) 240318 2.000 {50,81 (32! 237153 2.500 1635] SEE PAGE 50 (32) 26998 3.000 176,21 ik FOR INSTALLATION hs C (32) 4200087 (M8 x 1.25) ml PROCEDURE AND BOLT TORQUE \ Ray BACKING RING 236937 TORQUE CONVERTER RING GEAR 249265 oeDPV VDD ADD VDD PVD DDD DDD DDD DDD DVD DDD DD DD ID DDD R-MODEL SECTION32000 FRONT COVER GROUP ITEM DESCRIPTION arty 1 Flange NutCotter .......... ceed 2 Flange Nut .......... 1 3) Flange Nut Washer 0. 1 4 Range “O" Ring ........... eee 1 5 Input Flange... 2... eects Tt 6 Input Flange Oil Seal 1 7 Input Shaft Front Bearing Retaining Ring ...... 1 8 Input Shaft Front Bearing .. .1 9 Input Shaft Front Bearing Retaining Ring ...... 1 10 Pipe Plug .... : ot 11 Front Cover & Tube Assembly at 12 “O" Ring cece .2 13 3rd Speed Tube Assembly .......-....2..-. 1 14° Tube Clip . -2 15 Tube Clip Screw Lockwasher ....... 6.0.6.5 2 18 Tube Clip Screw 20 eeee ee 2 17 Reverse Tube Assembly 0.2... eee 1 18 Breather 19 Front Cover Sleeve 20 Front Cover Sleeve Lock 21 Sleeve Lockscrew Lockwasher .... 22 Sleeve Lockscrew 22.2... eee ceees 2 TEM SBERRBRAESBBENRRRB g —53— DESCRIPTION arty Input Shaft 1 Input Shaft Rear Bearing ..... 1 Input Shaft Gear ....... 0.00... 1 Input Shaft Gear Retaining Ring ............ 1 Tube Sleeve... eee 1 Tube Sleeve 1 Detent Spring .......... 1 Detent Spring . a1 Valve to Converter Housing Screw........... 9 Valve to Converter Housing Screw Lockwasher 9 Control Valve Assembly 1 Control Valve Gasket... .2..eccceeeeecee dT Detent Ball . _ pester eeeteeseeee T Detent Ball. .... 2.2.2.2... 1 Pipe Plug... 0.0 e veer ee 1 Cover to Case Screw . bee Cover to Case Screw Lockwasher ........... 4 Front Cover Plug ad Front Cover Plug Gasket 0.00.2... eee Cover to Case Screw 4 Cover to Case Screw Lockwasher . 432000 ASSEMBLY INSTRUCTION ILLUSTRATION Beating LD. cnamiers to poirt toward snap rings as shown, ‘Spacer used wit 12 plate modulation only. COECEECCECECOECCCEECCCECECECECCECECECECCECECECEEOECEECELCEEELEZ\ sey coy gn conto pert No. 219 0 of all of seals before ass'y Goar to be assembled with long hub length to this sige. AX tn te te see poop nen plates. Assemble alternate, Starting with outor stool pate, ZA se teste Sc Nu Tee Cr ZA tm en tee pes 9 te tan Plates. Assemble aliermately, stating with outer Stoel la Notes specified 8. - All iead in chamters for ol seals, piston tings & "9" rings must be smooth & Tree from burrs Ingpect al ase'y .- Lubricate all piston ring grooves & “O" rings with oil betore ass'y. . - Apply very ight coat of Permatex No. 2 0 0.0. of all oll seals batore ase'y ZA soarnre eset nesoing Bearing si out ZX tes sonr moa megs ne 9 ee AR are ssa nse es gggmeviotaten seanszeny Beating shield in E. - Alter assembly of parts using Permatex or ‘Crane sealer, there must nat bo any tree oF ‘excess material that could enter the all ecu Apply light coat of Crane Salar to all ppe plugs. G. -Apply a thin coating of grease betwen seal lips on lip type soais prior to ass'y. H. - Apply ight coat of Parmatex No. 2 ta all thru ‘nolo etd threads, NOTE: Metric cimensions shown in brackets [| View "a" 2 Places Low Gun Retum Springs. ELASTIC STOP NUT TORQUE Se 8 we as Tews a 5 sonar Erg Sn a Perna Staats [- moos ae Von's S| ee ee teeta |p Fev te uh Aon Sng Ec tocar ee Ses Son oe Cente no meen soe are Sera mre Tongue Speteton to aorctes Grade 5 @) Sr Puted Sue Tease Groae 0) FRE THES Coane THREAD PE THREAD SRR TRS Ra |, lL | at se ovo [as aS] ee wo Pn ea | ae [nat | sar |r am | fase. ma] | sree | [ 77a: esa |] ao. a [Goat ae aT teas ase | fas tsse- nt Tara tae seg [Pacer pase et ee ett one on wif isa oa| ep sa oe | ten eet ts we | tans ae moat tart] “wow tea ae [ae | we et ef pee ee sof tes ear] ee | tee Poe | tae at ee 55MAINTENANCE AND SERVICE The instructions contained herein cover the dis- assembly and reassembly of the transmission ina sequence that would normally be followed after the unit has been removed from the machine and is to be completely ‘overhauled. It must also be understood that this is a basic 32000 transmission with many options, Companion flanges and output shafts with end without disconnect assemblies may vary on specific models. The units are very Imilar 10 trouble shoot, femble, repair and re- assemble. CAUTION: Cleanliness is of extreme importance and an absolute must in the repair and overhaul of this unit Betore attempting any repairs. the exterior of the unit must bbe thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism. DISASSEMBLY Figure 1 Remove control valve bolts and washers. Remove control valve. Use caution as not to lose detent springs and balls. Figure 2 Remove companion flange nut, washer and “0 ring. Figure 3 Remove Font cover plug Figure 4 Remove botts securing frant cover to transmission housing. CLEECECCECEOCCCECCCECECOECCECECECECEECCECECCEECECECECCEEEECLEEINSTALL INPUT SHAFT OIL SEAL IN FRONT COVER AS SHOWN ON PAGE 72. DRIVE GEAR RETAINER RING INPUT SHAFT NOTE: LONG HUB OF DRIVE GEAR TOWARD RETAINER RING Figure 5 Remove front cover and forward and 2nd clutch. Figure 8 Input shaft, rear bearing, drive gear and snap ting. Figure 6 Figue 9 Use a spreading type snap ring pliers to spread the ears on for- ‘ward clutch front bearing retainer ring. Remove forward cluich Install input shaft into front bearing. with pry bar. Figure 7 Figure 10 If input shaft is to be removed, tap on threaded end of shaft, ‘Support converter housing with chain fall. Spread forward remove input shaft, gear and bearing. Clutch front bearing retainer ring and tap forward and 2nd clutch assembly into ransmission case assembly, Be certain snap ring ‘See cleaning and inspection page. is in full position in ring groove. —57-Figure 71 Figure 14 test nt see hatch it boring, tora cos Poston Het cover sembly on ling studs, Tun autpt flange 10 align etch ce hu in catch. Do ‘rot force this operation, With font cove in poston against the anemiston cese instal cover 10 case bolts Tighten 1 pected tou Figure 12 Install tensmission case gasket and “0 ring seals. Figure 15 Install front cover plug. Figure 13 Figure 16 Install housing spacer, gasket ing seals. NOTE: Hous Install companion flange, flange “0” ring, washer and nut. Tor- ing spacer is used with 12 plate clutch modulation only. que nut to specified torque. (See elastic stop nut torque chart). CCEECECECECCECEECECECCECECECECOECECECLCEECECECCCECECECCEEECEEELFigure 17 Locate detent balis and springs in contral valve. Position new gasket. Secure valve with bolts and washers. Tighten to specified torque. weaanis se, seams ree fest race SHIELDED SEARING INSTALLATION NOTE: The disc spring packs are to be used as complete assemblies and cara should be taken not to intermix the individual dise springs with disc springs in another clutch or disc spring pack. Each disc spring assembly is made up of selected springs to precisely match each part within this assembly. Failure to replace all piston return springs can resut in unequal deflection within the spring pack. The result of this imbalance may adversely affect overall of springs. Service replacement assemblies are banded ‘together and must be replaced as assembly. beanin shen lst TACE OU seaming sie32000 - C270/C320 EXTERNAL PLUMBING DIAGRAM i enary cheek pint“ Filer Assembly (90 Sia a Te ee (Chock point “F" Cooler outlet pressure ‘Check point *B" (Cooler outer tomporatuce, ‘Cuch pressure tne from Rag. Vane 19 ‘concenar ain leation. ‘Select west connection ‘or gaviy arama ans, (Greck point -D' Gorveror ol temperature Beane herent Surin ting tom transmission sum pur. ray drain—must have ‘Gheck point "C* cormerter ‘Outer pressure. Convener alto toma. 10" 200°, ‘onus spo om fee seoaarc) omer to Yana sin, JFanemission nora parting speceatone: Notes 2581 [20 sal mney Het line operating requirement, posure af 2000 REM engine. 1, Pressure Lines—Suiabie or operston rom Asie dimensions shown peo and 9 maximum of 70 PS! ambien to 250° ('21"°0)conmuous operating es ere {HB30 NP al cute posse (omperarure Must witsand 900 PS e008 Pal wah engine operaing at grmunan rssr wih G P! P| Mote: Do not devi ize, noloed governed epe6d intrmitont surget Ret SAE. Spee. Ne Soviets any le 8h LBITJO0RT Hyglaulie Hose Spestiation 2, Suction Line—B be proeces ‘rom colapse Dy nlrmevan sel wre Rel SAE. Spee. No, Brrscor yoraute Hose Speciation FILTER ASSEMBLY CHART ‘Sulla fr operton tom abies Yo 250% f21."C}, Continuous operating tempera. Spinone ‘8 Grovty Orin Line—Suiable for operation [Ferns] recipe NE | “aasarsy Nos Eon ‘rom arbiont fo 250° [21°C] contro * a S602 207055 | aerony operaing temperature, Rel SAE. Spee Ne JSIZI00R sage Can Sing Eomont Hygraue Hose Spectiation Zsa 248787 4. Hose Lines used trust contr to SAE 5 Dual Can 258 | cuntlerent_|_ 248622 ‘Spec. No. JTOT Test Procogure for High ‘amp. Tansmisson OF Hose, 5. Seo Lubrication Spectications COEECCCECCCOECECOCECECECECCEECCECECECECCELECECECEECECELOECELEPROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS NOTE: NOT ALL TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS Fill the oil sealing ring grooves with a good grade of grease, this will help stabilize the teflon ring and expander spring in the ring ‘r00ve for installation, Position the expander spring in the inner groove of the new piston ring, with the expander spring gap 180° from the hook joint gap ‘of the piston ring. Catefully position the piston ring and expander spring on the clutch shaft in the inner most ring groove. Hook the piston piston ring joint. Repeat steps 1, 2 and 3 for the remaining ring or rings making cortain all hook joints are fastened securely. Apply 2 heavy coat of grease to the outer diamotor of the rings and clutch shaft. Center the piston ring's in the ring groove. ‘Boforo installing the clutch assembly in the front cover oF converter housing itis recommended a piston ring sleeve PIN's 241309, 237576 or 234266 be used to center all of the piston rings in their respective ring grooves, Use extreme caution to not damage piston rings when installing the clutch shaft in the front trasnmission cover or converter housing, USED FOR POSITIONING PISTON RING PISTON RING OF PISTON RINGS SLEEVE 234265 OF 297578 BEARING lr 41 241308, OF Le = J ‘cLUTCH SHAFT ‘CLUTCH SHAFT Oger BEARING PISTON RINGS PISTON RINGS\ Ba sure that lead in chamfer and intersection of lead in chamfer to piston fing bore Is free of bums. and nicks. 248424 Piston Ring 248425 SPRING GAP AND RING GAP ARE 180° APART 614.060 + .007 [26.9 .17} Stake 3 places approx. equally spaced. © After curing of Loctite, spead sensor bushing must be secure with 40 1.3904 .007 [35.34.17] Assemble Speed Sensor Bushing in housing to specified REAR VIEW dimension with Loctite 262 and stake (3) three places. SPEED SENSOR BUSHING INSTALLATION —62— Ft, Lb, [54.2 Nem} torquo. CC CCECECEECELECECCECECCEECCCECECCECECEEECECCCCECECEELLELEEEOIL SEALING RING SLEEVE REMOVAL NOTE: The following photos are not of the HR Converter Housing but the slaave removal procedure is identical Figure 4 Figuro 1 Remove clutch front bearing locating ring. Figure 5 Sleeve being removed. See cleaning and inspection page. NOTE: When installing 3 new sleeve itis recommended a press (a driver be used to prevent damage to the sleeve and be eure the notch in the sleeve is aligned with slaeva lock notch. tnstall Figure 2 sleeve lock and capscrew. Tighten screw to specified torque, Remove oil sealing ring sleeve retainer screw. See torque chart! Figure 3 Remove screw and sleeve lack. ~~32000 TRANSMISSION CONVERTER DRIVE PLATE INSTALLATION "A" dimension (Bolt Circle diame'er) and ceder Drive Plate Kit listed below. ALIGNMENT HOLES. (9 DRIVE PLATE AND WELD NUT ASSEMBLY INTERMEDIATE. DRIVE PLATES BACKING FING “R Dimension (Bott Circle Diameter! 13.125" (338,375 mvmnl Diameter Kit No, 802335 13,60" (342,900 mm] Diameter kit No, 802833 17.00" (431,800 men] Diameter kit No, 802454 Each kit will include the following parts: 4) Intermediate Drive Plates 1. Drive Plate and Weld Nut Assembly. 1 Backing Ring. 10 Screw and Lockwasher Assembly. 1 Instruction Shoot. TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES — SEE ILLUSTRATION ABOVE Position chive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plate and backing ring with holes in impeller cover. NOTE: Two dimples 180° apan in backing ting must be out (taward engine fiywhoel). Install capscrews and washors. Tighten 23 to 26 ft. Ibs. torque [31,2 - 33,8 Nm. SEE PAGE 65 FOR TRANSMISSION TO ENGINE INSTALLATION PROCEDURE CCEOCEEEECECCECEECCEECELECEECECECECCELCCECEEECECECECELECEEELTRANSMISSION TO ENGINE INSTALLATION PROCEDURE | Remove all burrs from flywheel mounting face and ‘nose pilot bore. Clean drive plate surface with solvent, 2. Check engine flywheel and housing for conformance to standard S.AE #3 - SAE. J-927 tolerance ‘specifications for pilot bore size, pilot bore runout and mounting face fistness. Measure and record engine ‘crankshaft end play. 3. Install two 3.60 [88,90 mm] long transmission to flywheel housing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align drive plate mounting screw hole with the flywheel housing access hole. 4. Install a 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. 5. Locate transmission on flywheel housing aligning drive plate to flywheel and transmission to flywheel housing, Install transmission to fiywheel housing screws. Tighten screws to specified torque. Remove trans- mission to 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. Snug screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access, hole. A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate sctews, Rotate the engine flywheel and install the remaining seven (7) flywheel to drive plate attaching screws, Snug screws but do not tighten. After oll eight (8) screws are installed torque each one 25 to 30 ft. Ibs. torque [33,9 - 40,6 Num.], This will re- quite torquing each screw and totating the engine ‘iywheel until the full amount of eight (8 screws have been tightened. 8. Measure engine crankshaft end play after tans: mission has been completely installed on engine ‘flywheel. This value must be within .001 (0,025 mm} of the end play recorded in step No. 2. Ky l q |DDVDVDVD DDD DD DD DDD DDI VDDD DVD DVDV IV VDD DAVIDA III II DD NOTES.aA SPICER OFF-HIGHWAY SR PRODUCTS DIVISION Statesville, North Carolina Brugge, Belgium se.nsay28 PRINTED IN USA, Price on Request