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    TRANSMISION CLARKOHT-5000

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    51 views62 pages

    Transmision Clarkoht-5000

    Uploaded by

    HERNAN

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Maintenance and Service Manual 5000 Series Powershift & Transmission 4 SPEED a PRODUCTS DIVISION ea SPICER OFF-HIGHWAY I SM 54 (Pay, S01 TOWING OR PUSH STARTING Before toming the vehicle. be: sure to Eft the rear wheels NOTE: II the transmission has 4 wheel drive, disconnect off the ground or disconnect tne driveline to avoid both tront and rear drivelines. Because of the design of damage to the transmission during towing, the hydraulic system, the engine eannot be started by Pushing or towing. © copyright DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION +998 Unpublished meter - piled reserved No part of the work may be reproduced in any form under ‘any neans-without direct writes perrissen of DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION, FORWARD This manual has been prepared ta provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION product. Extreme care has been exercised in the design, selection of materials and manu: facturing of these units. The slight outlay in parsonal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts af the product, its principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION approved parts as listed in the applicable parts manual should be used. Use of “will-fit” or non-appraved parts may endanger proper operation and performance of the equipment. DANA ‘SPICER OFF-HIGHWAY PRODUCTS DIVISION does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts. ‘TABLE OF CONTENTS: ASSEMBLY INSTRUCTIONS ....000000000cc0:cccecceecceesceesseeesee 8 HOW THE UNITS OPERATE 00.0.0... ec ccecceeccstcsteetereerereeeee @ SHAFT AND CLUTCH IDENTIFICATION ....06.c00ccsssstesstressrererne 6 SECTIONAL VIEWS AND PARTS IDENTIFICATION Front and Rear Views, Shaft identification... eee 6 Transmission Case and Internal Tubing ........060 ccc eee eeceeeeeeeeee 7 Control Cover Assembly. 8 Transmission Clutch and Gear Group Input, Reverse, Sed and ath Clutch Group eee ‘stand Ind Clutch GOUD eevee ceevsseserseecreenneesesersnerre External Oil Flow —Conwerter and Transmission .-..2cc0secseeeeeerse 18 DISASSEMBLY OF THE TRANSMISSION ©0000. ..60006cc ccs WT REASSEMBLY OF TRANSMISSION 000000 e cece BD SERVICING MACHINE AFTER TRANSMISSION OVERHAUL «0... ..000.0055 43 SPECIFICATION AND SERVICEDATA ......0cc0cseccseeceecssaeeeecene M4 LUBRICATION 0... cccccccecccesseeseecseesteesieeeeeenenen en ene MB TROUBLE SHOOTING GUIDE |. ==... 2-2. 45 PRESSURE AND OIL FLOW CHECK SPECIFICATIONS «=... 2.2.2.2... 45 TABLE OF TORQUE LIMITS «2.0... .2ssecceecceesseceueeeeeeeeerenerene 46 PRESSURE AND Ol FLOW CHECK PROCEDURE . . ceeeeeeeeee 46 CLUTCH TAPER BEARING INSTALLATION ....00..000000000002eeeeeees 9 MODULATION CLUTCH ASSEMBLY . MODULATOR VALVE AND PARTS IDENTIFICATION. NOTE: Metric Dimensions Shown in Brackets (J. NOTES NOTES NOTE: 1. Lubricate all piston rings an ‘OF rings at asseenbly. 2, Use Permatex and Crane ‘Sealer ony where specified, 9. Apply very light coat of Permatex No.2 1.0.0. of all ‘ll seals before assembly, 4. Apply light coat of Crane: ‘Sealer to all pipe plups. After ‘eseembly af parts, using Permatex or Grane Sealer, there must be no free or ‘excess materi thal could ‘enter the oil cireutt Torque nuts 180-178 Lbg. FL. (e03.4237.2 Nm) Two clutches trent side 10 inner bronze plates Bouter steel plates ‘Assemble alternately starting ‘with inner Bronze: plate. B springs and 8 pins, ends to rest against piston teeth and end plate teeth, Torque Clutch Support bolts 80-88 Lbs, Fr [1085-119,3 Nema Press slseve flush to Bt [8,40 mm] below shoulder. Torque bolts (except as shown} Ws 23-25 Lbs, Ft, [91.2539 Nem) ig BP Lbs, Fi, [50,2556 Nir] 1 97-63 Lbs. Fl. [77,2854 Nm) NOTE: No ists or shims Between ‘disconnect housing and case wine ‘Apply Pormatex batore pressing into place, ¥ optional steel stamped cower ig used, use locking bolts and belleville washers. Torgue bolts 137-20 Lbs, Fe. [23,1-27,1 Nem] Terque bolts in pan and covers 1720 Lbs, Ft. [28,1-27,1 Nera] Torque Gluten Support Bolts 8088 Los, Ft, (1085-119,3 Nem) Four clutches rear side 10 innar bronze plats. Souter steel plates embie altemataly starting with innar bronze plate, B-springs and 6 pins, énds to rest against piston tooth and and plate teath. ‘Adjuet Taper Bearings 000-004 (000.4101 ren] end play by ‘selecting variable thickness ‘snap ring a assembly. Four ‘clutches: this side, ‘Press sleeve flush to Wed. [f.40 mm] below shoulder. jote location of chamfars on this spacer, “Adjust taper bearings .000-003 [1,000.0,078 raen] end play. ‘Must have: appre. UB 175 mm] gap between batfle and snap ring for baaring lubrication. “Torque bearing lack nuts 175:200 Lbs. Ft, (287,9274,1 Nem] CAUTION: Drive bearing in place before ‘ughtening losxnuts. ‘Shim Oviput Shalt Bearings to produce # to a Lbs. In. [0,680.90 Nm] in preload forque output shall mute 250-300 Loa. Ft (909,0-4087 Nom NOTE: Metric dimensions shown i brackets [] FOR MODULATION CLUTCH ASSEMBLY ‘SEE MODULATION SECTION The trantmission portion of the power train enacts an important role in delivering engine power to the driving wheels, In order to properly maintain and service these units it is important te first understand their function and how they operate, The transmission and torque eanverter funetion tagether and operate thragh » commen hy ‘obtain maximum serviceability they have been designed and built as separate units. It is necessa consider both units in the sivdy of thelr function and operation, To supplement the text below, and for references use therewith, the following illustrations are provided: lie system. Te ,, however, to Fig. A — Front and Rear View, Shaft Identification Fig F_— Input and Forward Drive Shaft Grou; Fig. B — Transmission Case and Internal Tubing Fig, G = Roverse Drive Shaft Group —"R" Fig. C — Central Cover Assembly Fig, H — 2nd and 4th Drive Shaft Group — "A" D — Gutput Shaft Group Fig, | — Ist and ed Drive Shaft Group — "8" Fig. E — Idler Shaft Group — Fig. J — External Oil Flow—Converter and Trans. mission, HOW THE UNITS OPERATE — With the engine running, the converter charging pump draws eil from the transmission symp and directs it through oil filters fo the regulating valve located on top ef the transmission. From the regulating valve it is than directed thraugh the control cover on the transmission to the converter and ta the transmission clutches, pressure regulating valve mounted on the rop of the transmission remains closed until required pressure is delivered to the transmission for actuating the direction and speed clutches. This regulator valve consists of & hardened valve spocl operating in a closely fitted bore. The waive spool is backed up by # apring to held the valve spel against iis tom until the ail pressure builds up to the specified pressure. Tho valve spool then moves toward the spring until poct Is expoted slong the tide of the bore. The ail can then fiow through this port into a di tribvtor which dicacis the oll inte the converter inlet port ‘After entering the converter, the oll ix diractad through the stator support to the converter cavity and exits between the turbine shalt and. conve The oll then passes through an ll dsiriovior whch direct tha oil cut of and then te the oi! cooler. After leaving the cooler the 6 ha hase fo the lubrieating ail inlet an the Hensenission, then through & series of tubes 10 the irevarmistion, bearings, end clutches. The oll then returns to the transmission sump. A safety valve is buill in the transmission control cover and will open to bypass oil only if an excessive pressure is Built up due to 2 blocked passage. The rear compartment of the converter unit also houses the converter output shaft, A flexible hose provides an overilow 10 the transmission sump. The thres members of the torque converter are composed of a series of blades, The blacles are curved in such a@ manner as to force the ail to circulate from the impeller to the turbine, through the reaction member again into the impeller. Thit circulation causes the turbine 10 turn inthe same direction #8 the Impolier, Oil enters the inner He's of the impeller and exits from the autor side into the ovier side of the turbine, It then exits from the inn side of the turbine and after passing through the reaction member, again enters the inner side of the impel Converter "Stall" is achieved whenever the turbine and Impeller shaft are stationary end the engine is oper ating at full power er wide epen throttle. CAUTION: Og net maintain “Stall” for mare than 30 seconds at a time. Excessive heal will be generated and may cause converter ar trenimission seal damage. In converters equipped with Lock-up clutches, a hydeaulie clutch, similar to the transmission cluiches is used lock" the engine mechenically to the output shaft. This i accomplished by hydraulic presivre actuating the kup elutch whieh in turn locks the impeller cover te the turbine hub. During lack-up the converter twens at 1 to 1 speed ratio. The down stream regulator valve on the converter eantists of a valve bady and regulator spool. The spaol is backed up by # spring to hold the valve until canverier oil pressure builds up to specified pressure. The valve is used to maintain # given converter pressure to insure proper performance under all conditions, The control valve assembly on the transmission consists of valve body with selector valve spools connected to the steering column by exterior linkage, A detent ball and spring in the selecior spool provides four positions, se position for each spted range detent ball and spring inthe direction spec! provides three positions, one ch'for forward, neutral, and reverse. Qn certain madsls, this valve olso contains @ shut-off valve speol operated by an air or hydraulic cylinder located on the control cover. This valve is connected to the brake system by 2 hate line. When the wheel brak are applied, air or hydraulic fluid enters the valve and overcomes a spring force. This forces the spoal to shi ‘ver and block pressure from entering the directional dutches. In this manner 3 “ncuieal” Is established without moving the conirol lever With the engine running and the directional control lever in neutral position, oll pressure Is blocked at the con- trol valve, and the transmission is in neviral, Movement of the forward and reverse spool will direct ail, under pres sure, te either the forward ar reverse direction cluteh as desired, and the opposite one is open to relieve pressure. The direction or speed clutch assembly consists of a drum with internal gear teeth and « bore to receiv bhydravially actuated piston, A picion is inverted ino the Bore of the drum. The piston is “all ih” by the wie sealing rings. A friction dise with internal teeth Is inzarted into the drum and rests against the piston. Next, a ith splines at the auter diameter is Insected. Discs are alternated unl the required total is achieved, After inserting the last disc, a series of springs and pins are assembled in such @ manner that these springs rest on leath of the piston. A heavy back-up plate is then inseried end secured by @ snap ring. A hub with LD. and O.D. splines erted into the splines of disce with teeth on the inner diameter and splined shaft extending throwgh the dlutch support. This hub is retained ky a snap ring. The dises and inner shaft are free ta inereaua in speed oF rotated in the opposite {8 long 28 no pressure is present in the direction or speed clutch, Yo engage the clutch, a3 previously stared, the cantral valve ix placed in the dazirad position, This allows oil ‘under pressure to flow from the control cover velve, through 2 tube in the transmission case, 1o a chosen clutch ‘Once inte tho drum, ol fe directed through » drilled hola into the rear side of the plrton bore, Preswre of the ‘ll foreas the piston and discs aver against the heavy hack-up plate, The dises, with teeth on the outer diameter, clamping against discs, with teeth on inner diameter, enables the Clutch Drurn Hub Gear... 0... eee TV 10 Quter Piston Ring Expander Spring ........... 0 24 Gear Snap Ring... 2.0... 6. eee eee TV 11 Clutch Piston Outer Seal . : 1 12 Clutch Piston Inner Seal eee T AR - As Required, 18 Inner Piston Ring Expander Spring .........6. 1 14 Snap Ring - selected at assembly variable thickness snap ting and tanged washer are used to assure proper taper bearing tightness ......... AR zo = mone > FIG 1 CHECK POINTS CIUTCH PRESSURE CONVERTER INLET CONVERTER OUTLET CONVERTER TEMPERATURE CONNECTION LUBE PRESSURE COOLER INLET PRESSURE COOLER OUTLET PRESSURE COOLER OUTLET TEMPERATURE AUTOMOTIVE DIVISION OVERHAUL OF TRANSMISSION ASSEMBLY CAUTION: Cleanliness is of extreme importanco and The instructions contained herein cover the disas- an absolute mst in the repair and overhaul of this sembly and reassembly of the wansmission in a sa- unit. Before attempting any repairs, the exterior of quence that would normally be followed after the unit the unit must be thoroughly cleaned to prevent the has been removed from the machine and is to be possibility of dirt and foreign metier entering the completely overhauled. mechanism, DISASSEMBLY OF THE TRANSMISSION Figure 4 Figure 2 Remove forward, reverse, Srd and Ath clutch cover Remeve sump pan and magnets, with 2 soft kar and remove ing, washer and flange. output flange nut, “O' CLUTCH DISASSEMBLY rates taper bearings in the input, reverse, Srd and 4th clutch drums. Fallow the same pracedure as explained in Figures 7 thry 13 t0 disassemble input, roverse, 3rd and 4th clutch, If raper caller bearings are used, mack seach part remaved fo match with the clutch support These parts must ke reassembled on the same support they were removed from. If taper bearings, cluich rupert or clutch drum ave 10 be replaced, reassemble ‘with new parts as explained on pages 49 and 50. If ball bearings are used follow procedure explained in the service manuel, NOTE: All clutches are ditassombled in a similar man- nner. Clutch shevin baing disassembled is 4th speed Figure 7 Depress end plate end remove retainer ring, Figure 9 Remove cluich dise hub retainer ring, Remove clutch disc hub. Remeve release spring ‘outer clutch disc. Figure 11 Figure 12 Figure 13 Remove clutch drum and bearing assembly, NOTE: If clutch drum hub gear, support bearings, or piston ring outer race, are to be replaced, use Figure 14 through 18; If replacersent is rot necessary disre- ard and continue on with Figure 19. Figure 14 Remove dutch drum hub gear retainer ring. (let and Ind clutch only.) Figure 15 Remeve clutch drum hub gear (Ist and 2nd clutch only). Figure 16 Remove drum support roller bearing retainer ring. Figure 19 Figure 17 Remove drum support ball bearing retainer ring. Press or drive roller and ball bearing from SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and hydraulic system are important links in the di between the angine and the whasis. The proper oper- ation of ‘unit depends greaily on the condition and operation of the other; therefore, whenever repair ‘or overhaul of one unit is performed, the balance of the system must be considered before the job con be considered completed, After the ovechouled or repaired transmission has been installed in the machine, the oil cooler, and eon- necting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and de- gree of judgment musi be exercised as io the method employed. ‘The following are considered the minimum steps to bbe taken: entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydravlic lines should be removed from machine for cleaning. 3. Replace oll filter elements, cleaning out fiher cases thoroughly. 4, The ail easier must be thoroughly cleaned. The cooler should be “back flushed” ith oil and compressed air unt all foreign material has been removed. Flushing in direction of normal oil flow will not adequately clean the cooler, If neces- sary, cooler assembly should be removed from machine for cleaning, vsing oil, compressed air and steam dleaner for thet purpose. DO NO vse flushing compounds for slezning purposes, 3 ‘On remote mounted torque conve drain plug from torque converter. and interior of converter housing. gears, ate. IF presence of consid noted, it will be n moved, disassemble It is realized this entails exira labor; however, such labor is a minor east compared to cost af difficulties which can result from presence of such foreign material in the system. Reessemble all components and use only type oil recommended in lubrication ection. Fill itansmission through filler opening wntil fluid comes vp to LOW mark on transmission dipstick. NOTE: If the i e oil level check plugs are provided. Remave LOWER check plug, fill until off runs from LOWER oil hole. Replace filler and level plug. Run engine two. at 500-600 RPM to prime torque conve hydraulic lines. Re- check level of fluid in transmission with engine running at idle (500-600 RPM). ‘Add quantity necessary to bring fluid level ta LOW mark on dipstick or runt freely from LOWER cil level check plig hole. Install oll level plug or dipstick. ‘Recheck with hat oil 180-200" F.) (82, 2-93, 3° C]. Bring oil level to FULL mark on runs freely from UPPER cil level plug. stick or Recheck all drain plugs, lines, connections, elc., for leaks and FOUL iL LEVEL SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION ‘AND TORQUE CONVERTER ‘Career set ta, 180° 200" wax’ -aa a. “Tesi enn in NEUTRAL ‘Gpering sae ne ‘8 pe [3783 Kee insur geneon ot 29000 MM fine apm AND s-tasicnr of TD pat HARE AP tat prams WN angine Somling of noland esas opto snore Bares — Maina Spend Eeaetcr — Mares (om FIeTRATION (CLUTCH PRESEURE LUBRICATION “TYPE OF On San tube Chart CAPACITY — Consul Operniors Manual on appiable machine medel far iystem capacity. Toraue Converter, Transmitnon wre soba hydric ‘eyoum mutt be comudered a8 # whole 10 ‘determine apace CHECK PERIOD Check ail tes! DAILY with engine ewnting f82,2-58,3° Cy. Maintsin ol level te FULL met MORMAL® vary $00 hears, change oll iter sament. DRAIN FENOD very 1030 hour rain nd cb sper at ‘lowe: Drain with all ot 190° 40°200° [aa 93,2" cL NOTE: 1 x recommended hat ver seme nh be changed afer 50 aed 100 how oF ope ‘sation on new ond rebuilt or ropuined unite 6) Drain transmision and semave sump: ‘ein Cla trou tharcvahhy end plc, alng ee gushes. 8) Drain oll Fern, remove se inca {or somares Clann Fier hele an inal cow simone Rfid renaason to WOW sear, en ging BE 1500-400 WPM to prime Fl om fer sey you, iso sine coven Ie aurp st botom of reneiaeioe cam 10-220 ooh 1241.1 15188 KP] — With outing Dat age Aaa. Ee geetry 1827200" F 02-93" cy empiea ae fetes e20 Reon ‘Seu reton and wooed lets a ehh prem ‘most ne egal stin§ pA [ARE KP! alch pana See ctyomcics momma mat ar NOTE: Mewar une sendce brane hile mating lush qrenure checks Uedte having bens etavted deckaching ir farwenl wor noeete (wil not give tue raadeg ALWAYS SE PARKING BRAKE WHEN MAKING ‘CLUTCH PRESHURE CHECKS. i epi tetewennte et 4 Soe Segoe tern tarts =e, Seuss enim Fenestra a eres Semone Sauaraioeiees ‘+ Hanmalcesin parads and Aker charge Interval ae for average environmental and duny-cyele conditions, tats sc sans ees cles ae ated deterioration and contamination, required change. intervals. ric conditions ‘mon be weed v0 doterniva the TORQUE IN (FT—LBS.) BOLTS, CAPSCREWS, STUDS AND NUTS Grode § Identificotion, 3. Radiol Grade B identification, & Radial Deshes 120" Apart on Head of Bolt Dathes 60" Apart on Head of Balt LUBRICATED OR PLATED Fra need cane tarea | fea temg | cme tes] Torque Lbs. Ft./N.m, Torque Lbs, Ft./N.m. Torque Lbs. Fe./N.m. Torque Los. Fe./ Mm, piipzeia | anopossen | _vapasira) | eri nazial ezomparay | uasepesanay [tend passa zea9 (ab 3993) | 2825 ar2as9 | anal 602-856 41-45 (95,6-61.01 37-41 (80.2556) 58-64 (786-568) seranseal | eres panahay [ones aanasea] | eos [eentind) 31-100 [125.4-196,6) | _62-90(111.2-122.0) | 128-141 [1995-191.25 | 115-127 |156.0-1722) [Cleese [r2ecta1 (v7a.s-121.2y | 119-129 (183,2-168.11 | 190-198 [244,0-288,4) | 150175 (215,6-237.3) PRESSURE AND OIL FLOW CHECK SPECIFICATIONS. ALL CHECKS MADE WITH HOT OIL (180 - 200" F,) (82.2 -93,3° ¢.] A. Chitch Pressure at Transmission Control Cover See Specifications and Service Data. B. Transmission ta Converter Line Soe External Oil Flow Diagram. ©. Comerter-Out Pressure Soe Pressure and Gil Flow Checks. 1D. Temperature Gauge Connection Soe External Dil Flow Diagram. Lubricating Pressure 25 psi. [1724 kPa] Maximum at High Free bolo, Converter Ratuen Line Soe External Oil Flow Diagram. Converter Puma Output Sea Pump Chart TROUBLE SHOOTING GUIDE The following data is presented a4 an sd te loealing the source of difficulty in a malfunctianing unit. It Ix necessary to consider the torque

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