ET a Leet ad RUE ULE C8000 Torque Converter Rye) tee ane ee)TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the NOTE: If the transmission has 4 wheel drive, rear wheels off the ground or disconnect the disconnect both front and rear drivelines. driveline to avoid damage to the transmission Because of the design of the hydraulic system, during towing, the engine cannot be started by pushing or towing. ‘@copyight Spicer lait, 1981, 1992, 1980, 1904 Unpstisned materia - Al gnts reserved Lites Disrbuton No pact of ts work cy be eprodaced in any form under any means woul dct witien permission of Spicer Gane 59:906-005 PRINTED INUSA.FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the CLARK-HURTH COMPONENTS product. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The sfight outlay in personal attention and cost required to provide regular and proper lubrication, stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principab of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as @ reference when performing maintenance and repair operations. ‘Whenever repair or replacement of component parts is required, only Clark- Hurth Components-approved parts as listed in the applicable parts manual should be used. Use of “willfit” or non-approved parts may endanger proper operation and performance of the equipment. Clark- Hurth Components does not warrant repait or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.NOTESThe torque converter 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 itis important fo first understand their func tion and how they operate. The torque converter and transom To obtain maximum serviceability they 10 consider both units in the study of thei ion function together and operate through ye been designed and built as separate uni function and operation, common hydraulic system. 4 is necessary, however, To supplement the text herein, and for reference use therewith, the following illustrations are provideds Internal Oil Flow Torque Converter Torque Converter Assembly External Oil Flow—Cenverter and Transmission TORQUE CONVERTER ASSEMBLY The torque converter assembly is composed of: (1) Torque Converter, (2) Output Shaft for driving the trans mission, (3) Coupling and Flange to mount the converter charging pump to supply oil under pressure to operate transmission clutches and for converter cooling. The torque converter is composed of four members: the impeller which is the driving member, the turbine, which is the driven member, the reaction member which it splined on a fixed support, and the drive dise, which couples the converter to the engine. The impeller and drive disc members form the outer shell. The turbine runs within the outer shell and is connected to the output thaft. The oil i the only connection between the turbit and impeller members. The reection member is splined to the converter support which is fixed and does nat ro- tate in either direction. A gear is splined to the impeller hub and drives through gears rotating the hydraulic Pumps mounted on the converter housing cover. HOW THE UNITS OPERATE— With the engine running, the converter charging pump draws oil from the transmission sump and directs 't through oil fillers to the regulating valve located on top of the transmission. From the regulating valve it is then directed through the control cover on the transmission fo the converter and to the transmission clutches, The pressure regulating valve mounted on the top 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 a hardened valve spool operating in # closely fitted bore, The valve spool is backed up by a spring to held the valve spool against its seat until the oil pressure builds up to the specified pressure. The valve spool then moves towards the spring until » port is exposed slong the side of the bore. The oil can then flow through this port into a distrib vutor which directs the oil into the converter inlet port. Aftor entering the converter, the oil is directed through the stator support to the converter cavity and exits between the turbine shaft and converter support. The oil then passes through an ail distributor which directs, the oil ovt of the converter by way of a down stream regulator valve and then to the oil cooler. After leaving the cooler the ofl is directed through a hose to the lubricating oil inlet on the transmission, then through a ser tubes to the transmission, bearings, and clutches, The oil then returns to the transmission sump. A safety valve is built in the transmission control cover and will open to bypass oll only if an excessive press sure is built up due to a blocked passage. The rear compartment of the conve: {an overflow to the transmission sump. Unit also houses the converter output shaft. A flexible hose provides The three members of the torque converter are composed of a series of blades. The blades are curved such @ manner 2s to force the cil to circulate from the impeller to the turbine, through the reaction member again Into the impelier. ireviation causes the turbine to turn in the same direction as the impeller. Oil enters the inner side of the impelter and exits from the outer side inte the outer side of the turbine. Ht then exits from the inner side of the turbine and after passing through the reaction member, again enters the inner side of the im- peller. -1-Converter “Stall” is achieved whenever the turbine and turbine shaft are stationary and the engine ating at full power or wide open throttle. CAUTION: Do not maintain “Stall” for more than 30 seconds at Excessive heat will be generated and may cause converter or transmission seal dama In converters equipped with Lock-up clutches, a hydraulic clutch, similar to the transmission clutches is used to "lock" the engine mechanically to the output shaft. This is accomplished by hydeau! lockup clutch which in turn locks the impeller cover to the turbine hub. During lock-up the converter turns at T to 1 speed ratio. The down stream regulator valve on the converter consists of vi is backed up by is used to mainta body and regulator spool. The spool pring te hold the valva until converter oil presture builds up to specified pressure. The valve a given converter pressure to insure proper performance under all conditions. The control valve assembly on the transmission consists of a valve body with selector valve spools connected to the steering column by exterior linkage. A detent ball and spring in the selector spool provides four positions, ‘one position for each speed range. A detent ball and spring in the direction spool provides three positions, one ‘each for forward, neutral, and reverse. (On certain models, this valve also contains » shut-off valve spool operated by an air or hydraulic cylinder located on the control cover. This valve is connected to the brake system by a hose line. When the wheel brakes are applied, air or hydraulic Fluid enters the vaive and overcomes a spring force. This forces the spool to shift over and block pressure from entering the directional lviches. In this manner 2 “neutral” is established without moving the control levers. With the engine running and the directional control lever in neutral position, oil pressure is blocked at the control valve, and the transmission fs in neutral. Movement of the forward and reverse spool will direct oil, under pressure, to either the forward or reverse direction cluich a8 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 a bore to receive a hydraulically actuated piston. A piston is inserted into the bore of the drum, The piston is “oil tight” by the use of sealing rings. A friction dise with internal teeth is inserted into the drum and rests against the piston. Next, a disc with splines at the outer diamoter is inserted. Discs are alternated until the required total is achieved. After inserting the last disc, a serios of springs and pins are assembled in such a manner that these springs rest on teeth of the piston. A heavy back-up plate is then inserted and secured by a snap ring. A hub with |, and 0.0. splines Is inserted into the splines of ith teeth on the inner diametor and a splined shaft extending through the clutch support. This hub is retained by snap ring. The discs and inner shaft aro free to incroase in spaed oF rotated in the opposite direction as long as no pressure is present in the direction or speed clutch. To engage the clutch, a8 previously stated, the control valve under pressure to flow from the control cover valve, through a tube in the transmission case, to a chosen clutch. ‘Once into the drum, oil is directed through a drilled hole into the-rear side of the piston bore. Pressure of the cil forces the piston and discs over against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against discs, with teeth on inner diameter, enables the clutch drum and drive shaft to be locked to- gether and allows them to turn as a ur There are bleed balls in the clutch drums whi is released. placed in the desired position. This allows oil allow quick escape for cil when the pressure to the piston ‘The transmission gear train consists of six shafts: (1) Input Shaft, (2) R and Third Shaft, (5) Second and Fourth Shaft, (6) Output Shaft. /orse Shaft, (3) Idler Shaft, (4) Fiest ‘A screen mounted in a frame is positioned on the bottom of the transmistion ease, to screen out any foreign material. This screen is covered by the sump pan. This pan is provided with magnets to catch any metallic par- tleles. Some transmissions may have an axle declutching unit as optional equipment, this unit consists of a split ‘output shaft with a sliding splined sleeve to engage or disengage the axle. This is accomplished by manually shifting a lever in the operator's compartment which is mechanically connected to the shift fork on the clutch: ing unit sliding sleeve. This unit, of course, is only used on the four wheel drive machine. On the front drive only or the rear wheel drive only, the output shaft is on one plece type and an output flange assembled only ‘on the required end.‘TABLE OF CONTENTS HOW THE UNITS OPERATE..... SECTIONAL VIEWS AND PARTS IDENTIFICATION Internal Oll Flow — Torque Converter Torque Converter Assembly External Oil Flow — Converter and Transmission: DISASSEMBLY OF THE TORQUE CONVERTER. CLEANING AND INSPECTION............ REASSEMBLY OF THE TORQUE CONVERTER......... ‘SERVICING MACHINE AFTER TORQUE CONVERTER OVERHAUL... PUMP PRIMING PROCEDURE. ......sssecsssessesene LUBRICATION. ‘TABLE OF TORQUE LIMITS ‘TROUBLE SHOOTING GUIDE. RING GEAR INSTALLATION PROCEDURE. PROPER OIL CHECKING & FILLING PROCEDURE. ASSEMBLY INSTRUCTIONS... DRIVE PLATE INSTALLATION INSTRUCTIONS. NOTE: Metric Dimensions Shown in Brackets {_].CONVERTER PRESSURE Ml OIL TO COOLER LUBE AND DRAIN = i — ey 4 GOK DRIVE LOCK-UP & MM CLUTCH PRESSURE STANDARD peco--------~-- Se he Lock- uP LocK- uP GOV. DRIVETem DESCRIPTION Oil Battle... Front Bearing Cp. Front Bearing Spacer ear Bearing Cone eer Bearing Cup Seanng Cap "0" Ring Bearing Cap Stud font Sing Sap Ot Tape enn Pipe Pg : Convert Housing... Donates Presurs Regus Vee Ascombly Bion Bo Pine Pg Reducing’ Busing ‘A Broather and Chack Vaive Assembly Pump Hole Cover Gratet Pump Hele Cover Cover Seraw Lockwasher Gover Serv. Tube. Not Bearing Cap 36 Lube Tube "" Ring 37 Lie Tube 38 Ube Tube “0 Ring 5B Gaping Cap "0" fing 49 Beton ting AL Aaeptorto Shai Screw. 42 Bearing Gus. 43 outing Beer Cover. 2 Coverte Housing "0" Ring. 45 Turbine Shaft Goor 8 Thane Shai... 47 Bearing Gone: 2889S UBYBRRERLVSSISARGS AS evenness 49° Pleton Ring 5 Boe Pun 51 5 Sor 1 Hsing Sere 53 ‘Snap Ring. . He Gthame Dive Gear $8 Bison fing Exner Soio. 58 Piston Ring. 5? Stator Support 58 GilOsubttor Sleeve. 58 fousnginaecton Seow and isc 60 Housing Inspection Cover. 81 DrinPkg 62 Housing Inspection Cover 83. Housing Inepacton Sevow and Lockwasher 64 Bauring Cane. 85 Lock Up Adaptor @ ee : # Eeeiie & Esse 70 Beaing Cap Stud Lackwasher. 71 Bowing Cap Stud Na 72 Parmariont Pump Hole Cover Seow 73. Parmanent Pump Hole Cover Screw Lackiesie 74 Pormanent Pump Hote Cover 75 Permanent Pump Hole Cover Gasket. AR As Requied ary Botan et Item DESCRIPTION seer ca svoaseenenn nanan 3 Cover to Housing Serew. os (Gover tp Housing Screw Lackwashar Bow! Bites nce ss Pump Drive Shat ump Shat From Boating Pur Biven Gear Innpele Hub Scrow Backing ing Iinpele Hu Screw Bate Gi Sea Pump Shait Bear Bering Rear Searing Washer “Outer Rese Best Washer - Inner Pump Adaptor “O” ing. Pump Ader Pump Drive siaeve Pump Gasket. ‘Gonverter Charging Pur Bump Mounting Stud Nut... ump Mounting Stud Lockwother Pump Mounting Stud. SRG NUt Sis Nat sian: ite Washer Shap Bearing Washer Snap Ring (Gt Hato Sorew Washer Iimpol: Fus impale: Hub Bearing Snap Ring Reaction Meme Specs Rol Pi Bescton Membar Sm Rng. Bing Goor fing Gear Stud ing Geo Backing Piste. fing Gear Belevile Washer fing Gear Stue Nut. Innpeder Cover Beating Cap “O" Ring Basten ing. Front Bean. Iinpeter to Cavar “0 Ring Piston Ring Outer... Lockdlp Piston "0" Ring Lock-Up Inner Disc. LeckUP Inne Dise Plate Snap Aing rng Lock Pate. Sevew Lock Pte Lock Pate Sew Turbine ard LockUp Hub. ‘Turbine Hu Serew Backing ing. Tartine Hub Screw Taine Cowal Bn ‘ub Srp ing {ack Up Backs LookUp Outer LoekUp Piston. Piston Ring = ino. lempetir Cover Bearing, Recaier Preto ing Expander Sing ‘Snap Ring Impeller Cover Boiting Cap. Impaler Cover Besting Copacrew Genet R AP UM Uew ERR RBEe ee eRe ae eN A RSPRESSURE REGULATING VALVE m4 ary. DESCRIPTION 1 1 jaton Stop 2 1 ston Stop “O” Ring 3 1 0 Spring 4 1 Stop Roll Pin 5 4 to Housing Serew 6 4 Valve 10 Housing Screw Lockwasher 7 1 Pressure Top Pipe Plug a 1 Pressure Regulating Valve Body 9 1 Piston Stop Roll Pin 10 1 Pipe Plug u 1 Regulating Valve Piston 2 1 Piston Stop “O” Ring 13 1 Piston Stop “ 1 Gasket 15 1 Regulator SpringCHECK POINTS CLUTCH PRESSURE CONVERTER INLET CONVERTER OUTLET CONVERTER TEMPERATURE CONNECTION LUBE PRESSURE COOLER INLET PRESSURE COOLER OUTLET PRESSURE COOLER OUTLET TEMPERATURE TOmmooR> ‘oom ‘GRAVITY OMAN TO Tranuisson ONE ME High Pressure Low Pressure ean must nant Contos 0 mms Scion end Drain HOR CONVERTER TO TANGOOVERHAUL INSTRUCTIONS FOR TORQUE CONVERTER The following instructions will cover the disstvem- CAUTION: Cleanliness is of ‘extreme. importance bly ond reassembly of the torque converter in a se- and an oeseiute must in the repair and Grothe of oe thet would norma ater qho—this Unit Before atempting any repairs, the entericy ee ae ne peg clawed alter the GF unit must be thoroughly clcaned te. prevent the essibilily of dirt andl foreign matter entering the pletely overhauled. mechanism. ° DISASSEMBLY OF THE TORQUE CONVERTER Figure 4 Figure 1 Install two bolts in threaded holes in bearing cap. Turn bolts evenly and remove bearing cap. Figure 2 Figure 6 Remove impeller to impeller cover bolts. Remove impeller cover bearing cap bolts.Figure 7 Using 2 puller as shown in Figure 7, remove bearing retainer plate, impeller cover, and turbine from tur- bine shaft. CAUTION: Secure impeller cover with a to prevent assembly from dropping. Figure 8 Turbine and impeller cover removed. Black impeller cover on the outer diameter and drive turbine hub from impeller bearing, If lock-up is not vsed, omit Figure 9 through 15 and refer to Figure 16. Straighten tangs on belt lock and remove bolt, bolt lock and snep ring lock from lock-up cover. Figure 10 Remove backing plate retainer ring Figure 11 Remove backing plate. Figure 12 Remove inner and outer lock-up di Figure 13 Remove lock-up piston. Figure 14 Remove lock-up piston outer sealing ring and "0" ring.Figure 20 Remove output shaft bearing cap. Remove lock wire and adaptor boltt from adaptor. Install two bolts in theaded holes in adaptor. Turn m belts evenly and remove adapter. Figure 21 Using a split puller 9s shown remove output shaft and outer taper beating. Figuro 18 Lock output gears with a soft bar and remove output flange not. Remove flange wather, °O” ring and flange. Figure 22 Remove ovtput gear, washer and inner teper bearing from rear housing =10-7A Figure 26 Remove reaction member from stator support. If re- action member is tight, threaded holes are provided to pull same from stator support. Figure 23 Remove turbine shaft and bearing assembly from converter housing. Figure 27 Remove impeller and baffle assembly from converter housing. Figure 24 Remove three (3) oil baffle re from housing. 13 Figure 28 Remove pump drive gear retainer ring. Remove pump drive gear and oil baffle from impeller hub. Figure 25 Remove reaction member retainer ring. Figure 29 Remove pump driven gear retainer rings. =neFigure 30 Remove pump shaft rear bearing retainer ring and washer, Figure 31 Using a soft bar tap pump shat assemblies fram converter housing. Figure 32 Remove bolts from stator supports, Remove stator suppor. a Figure 34 IF inner turbine shaft bearing cup is to be replaced remove a8 shown in Figure 34. CLEANING AND INSPECTION CLEANING ‘Clean al pants thoroughly using solvent type cleaning fluid, i 's recommended that parts be immersed in cleaning fluid anc ‘moved up aod down slowly until all ofc lubricant and foreign ratorial is dissolved and parts are thoroughly cleaned. CAUTION: Care should be excrcisad to avois skin rashes, fre hazards and inhalation of vapois when using solvent type cleaners, Bearings Remove bearings from cleaning fluc and strike fat against a block of wood to cislodge solidified particles of lubricant, Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bear ings using moisture free compressed air, Be caret to direct ait stream actess bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate crying process. Housings Clean interior and oxterior of housings, bearing cape, ate, ‘thorough. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground ot polished surfaces. Parts should remain in solution long enough 1a be thoroughly cleaned and heated. This will id the evapore tion of the cleaning solution and rinse water. Pars cleaned in solution tanks must be thoroughly rinsed with elean water to remove all races of alkali, Cast parta may also be cleaned with steam cleaner. CAUTION: Care should be exercised 10 avoid inhalation of vapors and skin rashes when using alkali cleaners.All parts cleaned must be thoroughly dried immedistely by sing moistureree compressed air or soft, lintless absorbent wiping rags free of abrasive materials such as metal flings, contaminated oll ot lapping compound INSPECTION ‘The importance of careful and thorough inspection of al pans ‘cannot be overstressed. Replacement of all parts showing ingication of wear or stress will eliminate costly and avoldable {oilures ata later dete. Bearings Carefully inspect al rollers, coges and cups for wear, chipping ‘0F nicks to determine fimess of bearings for further use. Do not replace a bearing cone or cup Individually without replacing the ‘mating cup or cone at the same time. After inspection dip bear- ings in recommended type Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed Oil Seals, Gaskets, Ete. Replacement of spring fond ol sels, “O" rings, metal se rings, gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at ® future time, Further loss of lubricant through @ warn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully, partcularly when, being installed, Cutting, scratching, or curling under of lip of seal seriously impaié its efficiency. Apply a thin cost of Permatex No. 2 on the outer diameter ofthe ol seal to assure an. all tight tt into the retainer. When assembling new metal type ‘sealing rings, same should be lubricated with coat of chassis (grease to stabilize rings in thelr grooves for ease of essombly of ‘mating members. Lubricate all “O" rings and seals with recom ‘mended type Automatic Trangmission Fluid before assembly, Gears and Shafts HH magna-thex process is availablo, use process to check parts Examine teeth on all gears caretully for wear, pitting, chipping, nicks, cracks or scores, If gear tooth show spots where cose: ‘hardening is worn through or cracked, replace with new gear. ‘Smal nicks may be removed with suitable hone. Inspect shafts and quills to make certin they are not sprung, bent, o splines ‘twisted, and that shatts are tue, Housing, Covers, ete. Inspect housings, covers and bearing caps to be certain they ‘are thoroughly cleaned and that mating surfaoss, basting bores, ttc, ere free from nicks or burrs. Check all perts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures, NOTE: If convertor housing is replaced, sae page 31 for ‘speed sonsor bushing installation, REASSEMBLY OF TORQUE CONVERTER Instructions given below on reassembly of components ‘are given in the sequence that must be followsd in rebuilding Figure 35, Install stator support. Figure 36 Install support self locking bolts and tighten 80 to 8 ft. tbs. torque 1108.5 - 119,3 Nel. Figure 37 ‘With pump driven gear in position, install shaft and bearing assembly through rear of case and into pump driven ea.Figure 39 Install pump driven gear to shaft retainer ring. Repeat procedure for all pump shefts and gears. Figure 40 1 thin cost of No. 2 Permatex to outer diameter seal and press into bore of oil baffle. Lip of seal Appl of oil must be upwerd. NOTE; Before installing oil baffle remove impeller hub bolts and install new impeller te hub “O” ring. Figure 41 Install oil baffle on impeller and hub assembly. Use caution as not to damage cil seal. Install pump drive gear and retainer ring. Figure 42 | baffle “O" ring. Lubricate “O” cing with Figure 43 Install new sealing ting expander spring and ing ring on support. Expander spring gap to be 180° from sealing ring hook jolat. a Figure 44 Install impeller and oil baffle assembly over stator support and into converter hou: not to damage oil baffle “O" ring. 19. Use caution as aFigure 46 Press roll pin in reaction member. Press spacer on. roll pin. Figure 47 Install reaction member on stator support and secure with retainer ring. Figure 48 Install oil baffle lockwashers and flat washers on baffle ‘bolts, Install bolts and washers in converter housing. Tighten evenly and socurel Figure 49 Using a soft bar install turbine shaft inner bearing cup. Figure 50 Install turbine shaft inner bearing on shaft. Figure 51 Install turbine shaft oil sealing ring. Block converte housing on pilot end and install turbine shaft assembly in converter housing. asPosition output shaft inner bearing, gear spacer and. ‘gear in converter housing rear cover. Figure 53 Press ovter bearing on output shaft. Turn rear cover, over and position output shaft in ovlput gear and spacer. Press output shaft into inner bearing. Figure 54 Apply a thin coat of Permatex No. 2 on the outer diameter of the output shaft oil seal. Press oil seal in bearing cap with lip of seal down, m6 Figure 55 Install new “O" ring on output shaft bearing cap Install bearing cap on output shaft. Install stud nuts and tighten securely. This is to insure Proper seating of taper bearings. fent bearing cap from moving whi ing shims. Check gap between bearing cap and rear cover with shims used as a feeler gauge. REMOVE sufficient shims to produce a .002" [0, 050 mm| tight condition. EXAMPLE: Gep is 010" (0, 254 mm; final shim pack thickness to .008" [0, 203 mm]Figure 56 Install shim pack, bearing cap, stud lockwashers and stud nuts. Tighten nuts to 64 to 70 fi. Ibs. torque [86,8 - 94,9 Nem). Figure 62 Using a soft bar, lock converter output gears. Install output flange, flange “O" ring, washer, and nut. Figure 59 Install converter housing te rear cover “O" ring. Tighten flange nut 250 to 300 ft. Ibs. torque 1339,0 - 406,7 Nm]. Figure 60 Install year cover and output shaft on converter hous: ing. Figure 64 If governor drive is used, install new cil seal (lip of seal up] in turbine shaft bearing eap. Instali turbine shaft outer bearing cup in bearing cap. Figure 61 Install roar cover bolts and lockwashers. Tighten bolts 41 to 45 ft, Ibs. torque (55,6 -61,0 Nim]. a17-Figure 65 Install bearing cap on turbine shaft. Install sted nuts and lighten securely. This is to insure proper seating of taper bearings. Figure 66 Loosen stud nuts, Tighten stud auts evenly Finger tight, ‘his will prevent bearing cap from moving while slec!- ing shims. Check gap between bearing cap and reer cover with shims used as a feeler gauge. ADD suffi shims to produce a .002" [0, 050 mm] laase condition. EXAMPLE: Gop is .010" (0, 254 mm]; Finel shim thick: ress to be .012" [0,304 mm}. Remove bearing cao, Figure 67 Ingiall adaptor on turbine shaft. NOTE: Adaptor will vary for lock-up, lock-up and governor drive, and ‘governor drive, Assembly and disassembly is the seme for ail. install bolts and tighten 26 to 29 ft. Ibs. torque [95,3-99,3 Num}. 10 ol Tan Install °O" rings on lube tube {see arrows). Using bearing cap as a guide for lube tube flange, install lube tube in rear housing, Figure 69 With bearing cap shims and new °O" ring (see arrow) In position install bearing eap. Figure 70 Install lockwashers and nuts. Tighten nuts 64 to 70 ft, Ibs, torque [86,8 - 94,9 Nim]. If lock-up is used refer to Figure 71 through 87, If non lock-up is used refer to Figures 88 through 94.Figure 72 Install lock-up piston outer sealing "O" ring and piston outer lock joint sealing ring. Figure 75 Install one (1) steel outer disc. dise against steel euler disc Install friction inner Figure 73 Install lock-up piston in impeller cover. -19- Install lock-up back against the last friction disc. plate with flat side of plateFigure Install impeller cover to turbine hub front bearing. Figure 77 Install backing plate retainer ring, with spl at lock plate position, Figure 81 lostall turbine hub dowels. Figure 78 Install retainer ring lock, bolt lock and bolt. Tighten bolt to 17 to 16 ft, Ibs. torque (16,3 -21,7 Nm]. Bend tangs of bolt lock over head of bolt Figure 82 Position impeller to impeller cover “O” ring. Figure 79. Install turbine and lock-up hub in impeller cover. Turn turbine slowly 10 allow lock-up hub to engage in inner lock-up discs. Do not force this operation. When ture ‘ bine is in full position in lock-up dises, turn assembly Figure 3 over and block turbine to prevent it from dropping Instail turbine and lock-up caver on turbine shaft. out of po: = 20-Figure 84 Align holes in impeller with holes in impeller cover. Install bolts and lockwashers. Tighten bolts evenly and securely, igure 88 Position new “O" ring (see arrow) on impeller cover bearing cap. Install bearing cop on impeller cover. See Figure 95 for torque. Figure 85 Figure 89 IF lock-up is not used install turbine assembly on tur- Figure 66 Install bearing plate retziner ring. Install impoller cover and bearing assembly an turbine hub. Drive bearing into position. Align holes in Install bearing plate oil sealing ring. pelier with impeller cover and install bolts and lock= washers. Tighten bolls evenly and securely. -n-Figure 97 install bearing retainer plate. Figure 95 Install self locking bearing cap bolts in bearing cay and lighten 52 to $7 #t. Ibs. torque [70,5 - 77,3 Num Figure 92. Install bearing plate retainer ring. Figure 96 Install pump drive-sleeve and pump on converter housing rear cover. Figure 93 Install new sealing ring expander spring and cil soal- ing ring on bearing plate. Expander spring gop 10 be 180° from sealing ring hook joint. Install lockwashers and stud nuts, Tighten securely. Position new “O" ring on impeller cover bearing cap. Install bearing cap on impeller cover. =2-SERVICING MACHINE AFTER TORQUE CONVERTER OVERHAUL The transmission, torque converter, and its allied hydraulic system ks in the drive line Is. The proper ;pends greatly on the condition and operation of the other; therefore, whenever repair for overhaul of one unit is performed, the balance of the system must be considered before the jab can be considered completed. After the overhauled of repaired transmission has been installed in the machine, the cil cooler, and con- necting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a de- gree of judgment must be exercised as to the method ‘employed. The following are considered the minimum steps 10 be take Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning. 3. Replace oil filter elements, cleaning out filter «cases thoroughly. 4. The oll cooler must be thoroughly cleaned, The cooler should be “back flushed” with oil and compressed ait until all foreign material has beon, 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, using oil, compressed sir and stam 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 hovsing, gears, ete. Ht presence of considerable foreign material is noted, it will be necessary that converter be re- moved, disassembled and cleaned thoroughly. Wis reslized this entails extra labor: however, such labor is a minor cost compared to cost of ficulties which can result from presence of such foreign material in the system. Reassemble all components and use transmission through filler opening until fluid comes up to LOW mark on tranimission dipstick. NOTE: If the dipstick is not accessible ol level check plugs are provided. Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug. Run engine two minutes at 500.600 RPM to prime torque converter and hydraulic lines. Re- check level of fluid in transmission with engine running at idle (500-600 RPM). ‘Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install oil level plug or dipstick, ‘Recheck with hot oil {180-200" F.) (82, 2.93, 3° Cl. Bring oil level to FULL mark on dipstick or runs freely from UPPER cil level plug, 7. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary. CONVERTER CHARGE PUMP REPLACEMENT AND PRIMING PROCEDURE 1. The cause for pump failure must be found and corrected before » replacement pump is installed. Check all of the hoses, tubes, “0” rings, adaptors and split flanges. 2 3. After all cheoks have 4. See filling instructions in paragraph 6 above, 5 the pump. 6. I the pressure does not come up, check the oil I Replace any collapsed or damaged hoses, damaged split flange "0" rings, tube “O" rings and adaptors. jen made and corrections completed install the pump. ‘Start the engine, Run the engine at low idle for two minutes, watch the clutch prassure gage and listen for cavitation of el and bleed off air from system as follows 7. To bleed off the airfrom the system, loosen the proseure gags ine at the pressure regulating valve orloasen the pressure hose atthe oil filter or pressure regulating valve. Crank the engine over until the ai is dieplaced with oil, DO NOT START ‘THE ENGINE, 8 If bleeding the lines dos ‘not correct the problem it may becom: 1essary to prime the pump. Disconnect the suction hose or pressure hose, whichever is higher, and fill the port with transmission oil, reconnect the hose and tighten. 9. Start the engine and check pressure. 10. Recheck oi ‘with hot oll (180-200°F} with engin idle. Add oi! as necessory to bring oil level to ull mark =2SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION AND TORQUE CONVERTER COMRTER OUT Converter alti np. 180°» 200" (1 FLTAATION Ful tow ok tr etey pes, le ion sreen PRESSURE (was sa9"9) UUTEN PRESSURE 300.220 pi (1281.1 ~ time settee [ez3"- 953°C) engine ne (00 0600 APM at aul within ps [248 UP elt srnbre inatyone sh one Sp fo Pe opt peroing messin 195 pi(2783 HPs minum pseu w|2000 RM, w NOTE: Never use sonics tras while making cuuree re dutch preveore checks. Unto. hadog Bake vemahc wear compenation aod mo item Srrored echtching in forward andlor course urtummen nag aka sare ma uo, ‘rl nt gv + rue reeding SUK En Dae cdo ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS. LUBRICATION THe oF on caracire "Psa a Wns cones Prevaling Abn Temoeratre WREST v FEeee aa nance coor Ra Ee ae crease ca CHECK PERIOD Check oil isl DAILY with engine running 11 500-500 BPH and oil af 190" ve 200" F fbn,3- 98.3" 6)" eel PUL NORMAL ® . 1 SA DRAIN PERIOD angen. 4 -Oer ni Fh wo ew cate aon (eo. 98.9" ¢ "ng" ante NOTE: ie cecommended set fia loments bbe chonged ster 5D and 100 hour of ep sation oh ew and rebuilt or repeired write o ranamiain and ramore sume Serman.""Chan xeon thoroughly, tnd aplace, vsing sew gaskats | oo (8) Denia oll thar, sameve and send atl Sra an mmmermed| pT ‘neal new element, “a ehcmedige geste iter Orne Oe MOF (eta senior wow nak sue Scarrarananta Ne 16) Run engine at 500.600 RPM to prime ‘Setcincawons“becent Osewaternees mon s00, converter end Fines. — - imeorane, nan Aiea eee eg (=) Recheck level with engine running a “oemnies mumsnet GESTURE ne amnowee Ss eoreneanion., See egs mmmo Serato level fe LOW mark When il tompers vane tore Te hot (160-200" F) [622.935 C] rte an ate ake final at ere chek, BRING OW. teva TO FUL man” ‘Normal drain periods and filter change intervals are for average environmental and duty-cycle conditions, Severe or sustained high operating temperatures er very dusty atmospheric conditions will cause acceler= ated deterioration and contamination, For extreme conditions judgment must be used to determine the required change intervals. =26—TORQUE IN (FT.—LBS.) BOLTS, CAPSCREWS, STUDS AND NUTS Grode $ Identification, 3 Rodial Grode 8 Identification, & Redia! Doshes 120° Aport on Head of Bolt Doshes 60° Apert on Head of Bolt LUBRICATED OR PLATED ! Nominal Fine Thread ‘Thre Fine Thread Course Thread Sie] togeetan itm. | toquetbe rein | rortltne'tinm, | roSSe teh [asco | siriaares) | “eronoaisg) | taanaaine | aarnaze, (ars 16-20 [21,7-27.1) 12-16 (16.3-21.7] 28-32 [38,0-43,4] 28-20 [35,3-40.7) 2750 | asaa(ssaaaa) [2028912990] | “arei soaeney [aban eeraee 4375 41-45 |55.6-61.0) 37-41 [60.2-55.6) 58-64 |78.6-86,8) 62-57 [705-77.3) ‘5000 | 64-70 (06.8-98.9) 57-03 177,3-85.4) 90-99 |122,0-134.2) | 20-88 (108.5-112.3), 625 | ort00 1306198 | avo nnera2ay | ize [seraraT [Tess Peet zz | (exso | vasat raven) [3.198 (1532.160)) | a0-os ae o-aseal [TeB-1e fi6e 207 at PRESSURE AND OIL FLOW CHECK SPECIFICATIONS. ALL CHECKS MADE WITH HOT OIL (180- 200" F,) [82.2 - 93,3" C.] ‘A. Clutch Pressure at Transmission Control Cover See Specifications and Service Data, B. Transmission to Converter Line See External Oil Flow Diagram, ©. Convertor-Out Pressure See Pressure and Oil Flow Checks, D. Temperature Gauge Connection Soo Extemal Oil Flow Diagram, Lubricating Pressure 25 p.s.i (172.4 kPs] Maximum at High Free idle. Converter Return Line Sea External Oil Flow Diagram. Converter Pump Output See Pump Chatt. TROUBLE SHOOTING GUIDE The fallawing data is presented 28 an aid te locoting the source of difficully in s malfunctioning unit, it Is necestory to consider the forque converter charging pump, transmission, ail cooler and composting ell lines. 4 comninte system when running down the source of trouble since the proper eperation of any: unit therets depends greatly on the concition and operation of the others By studying the principles ef operation toperner with deta'in this section, st ody be possible to correc! any malfunction whith may. sezur r= the wysten TROUBLE SHOOTING PROCEDURE BASICALLY CONSISTS OF TWO CLASSIFICATIONS: MECHANICAL AND. fivDRAUUC, MECHANICAL CHECKS, Prior to checking any pat of the system from a hydraulic standpoint, the following mechanical checks should bbe made. 1. A check should be mede to be sure all conttoh lever connecting pointe. inkegs is properly connected and adjusted at all 2. Check shift levers anc! rods for binding or restrictions in travel thet would prevent full engagement, Shift Jevers by hand at tranimssion cao, if full engagement canner ie obtained, eilficlly may be in coniol cover and velve astombly. HYDRAULIC CHECKS, Before caecking on the torave converter, transrittion and allied hydraulic systems for pressures and rte Of oll How, is esuentil that tne following preliminary ence by ede ” J. Check il level in Iramumiasion. This should be cone with ail wemperatures of 180-700 F. (82,293.3°C | DO NOT AITEME THESE CHECKS WiTH COLD OIL. Yo bring the ol wompuatee te ie fpuctneee necossary fo either wark the machine or “wal” eut the converter. Where he former foeone ie senate yi Inner means should be emaloyed 4 fellows Engage shift levers in forward and high speed end apply brakes, Accelerate engine half to three-quarter throttle @ Hold sai] until desived converter outlet temperature is reached. CAUTION: FULL THROTTLE STALL SPEEDS FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER -35—PRESSURE AND Oll FLOW CHECKS Whenever improper performance is evident the following bas performed and recorded. It is also recommended th: pressure and oil flow checks should be ‘these checks be taken periodically as a preventative main- tenance measure. Doing so will permit possible detection of difficulties in advance of actual breakdown, thus permitting scheduling of repair operation. Likewise, repaic of minor difficulties can be made at considerably less ‘cost and dewn-time than when delayed until major and complete breakdowns occur. Analyzing the results of these checks by comparison with specifications and with each other will indicate in most cases the basic item or assembly in the system as the source of difficulty. Further checking of that assembly will permit isolation of the specific cause of trouble, (SEE PLUMBING AND CHECK POINT DIAGRAM) ‘OL PRESSURE AT CONVERTER OUT PORT. Install hydraulic pressure gauge at PRESSURE connection on Converter Regulstor Valve or ot CONVERTER OUT pressure tap. (All models do not have pressure regulating valves.) Check and record cil pressure at 2000 RPM and at maximum speed (engine at full throttle) (see instructions on Stalling Converter previously listed). ‘CONVERTER ‘MINIMUM CONVERTER MAXIMUM CONVERTER ‘MODEL ‘OUT PRESSURE ‘OUT PRESSURE 55 psi. (379.3 kPa} 70 psi. [482.6 kPa] 55 psi. (379.3 kPa] 70 pai. [482.6 kPa] 55 pis, (379.3 kPa] 70 pai, (482.6 kPa] $n converter charging pump and oil filters. Flow meter must be able to Disconnect hose between pump and filter at filter end and using suitable fittings connect to pressure port of tester Install hose between filter and tester, connecting same to reservoir port of tester. DO NOT USE TESTER LOAD VALVE AT ANY TIME DURING TEST. When taking flow reading, all readings should be taken lor-the first (lot) half of flow gauge. Whenever the needle shows on the right half of gauge, correct by switching to highor If @ flow meter is not available for checking converter pump output, proceed with manual transmission and converter ‘checks. If the converter shows leakage within specifications and clutch pressures {180 to 220 p.s.i)(1241.1 - 1516,8 kPa] ‘are all equal within 5 p.si. [34,5 kPa] refer to paragraph on Low Converter Charging Pump Output. PUMPS ARE RATED AT 2000 APM — Refer to Vehicle Manufacture Manual for specific pump output, NOMINAL PUMP RATINGS: ¢-5000 ¢-8000 €-16000 21GPM. 21 GPM 40 GPM. 31GPM. 31 GPM. 50 GPM. 40 GPM. 65 GPM. Pump output listed applies to a new pump in each ca ump output is more than 20% detow spe A.20% tolerance below this figure is permissible; hows tation the pump must be replaced or rebuilt. ~26—TRANSMISSION CLUTCH LEAKAGE Check clutch pressures at low engine idle with oil at operating temperatures 180 - 200° F. (62, 2-93, 3° C). Engine speed must remain constant during entire leakage check. Shift lever into forward 4 or 8 speeds. Record pressures, Shift lever in reverse and Ist. Record pressure. All pressure must be equal within 5 psi, [34.5 KPé If clutch pressure varies in any one clutch more then 5 psi, (34,5 KPel., repair clutch. If a flow meter is available install in line coming out of converter pump. See flow diagram for location of pressure on flow checks. Check pump volume at 2000 RPM and at low engine idle, Record readings. See pump volume specifications at 2000 RPM. Inatall flow meter in the line coming from transmission to converter. Check oil volume at 2000 RPM and at low idle in the following speed selections. Record readings. Forward —Low speed thru High Reverse — Low speed Subtract readings In each speed from pump volume reading to get transmission clutch leakage. Example: Pump Volume at idle 8 gal. Pump volume 8 Forward-Low speed thru High 6 gal. Forward —Low speed 6 Reverse—low speed 6 gal. Clutch leakage 2 If clutch leakage varies more than 1 gal. from one clutch to another, repair clutch. cage LEAKAGE IN TRANSMISSION CLUTCHES Leakage in Leakage in Leakage in 8000 series must not exceed 6 gal. mas Leakage in 16000 series must not exceed 7 gal. max. CONVERTER LUBE FLOW ynnect CONVERTER DRAIN BACK line at transmission with engine running at 2000 RPM and measure cil into a gallon container. Measure oil leakage for 15 seconds and multiply the volume of oll by four to get gallons per minute loakege. LEAKAGE IN CONVERTER Leakage in C270 series not to exceed 2 gel. max. Leakage in C5000 series not to exceed 3 gal. max. in CBO00 series not to exceed 5 gal. max. Leakage in C16000 series not to exceed 5 gal. max. LOW CLUTCH PRESSURE WITH NORMAL CLUTCH LEAKAGE CAUSE REMEDY 1. Low Oil Level. 1. Fill 10 proper level. 2. Broken spring in transmission regulator valve. 2, Replace spring. 3. Clutch pressure regulator valve spool stuck in 3. Clean valve spool and sleeve. open position. 4, Faulty charging pump. 4, See paragraph on charging pump output. LOW CLUTCH PRESSURE WITH EXCESSIVE CLUTCH LEAKAGE 1, Broken or worn clutch piston sealing rings. % 2. Clutch drum bleed valve ball stuck in open 2. Clean bleed valve thoroughly. position. 3. Broken oF worn sealing rings on clutch support. 3. Replace sealing rings. 4. Low converter charging pump output. 4. See paragraph on charging pump output. ~a7—LOW CONVERTER CHARGING PUMP OUTPUT CAUSE REMEDY Low cil level. 1. Fill 10 proper level. Sump screen plugged. 2. Clean screen and sump. Air leaks at pump intake hose and connections. 3. Tighten all connections or raplace hose if ‘or collapsed hose. necessary. Defective oil pump. 4. Replace pump. LOW FLOW THROUGH COOLER WITH LOW CONVERTER IN PRESSURE Defective safety by-pass valve ‘pring. 1. Replace spring. Converter by-pass valve partially open. 2. Check for worn by-pass ball seat, Excessive converter internal leakage. See para- 3. Remove, disassemble, and rebuild convertor ‘graph on converter lube flow. assembly, replacing all worn or damaged parts, 4. See paragraph on Clutch leakage. LOW FLOW THROUGH COOLER WITH HIGH CONVERTER OUT PRESSURE Plugged cil cooler. Indicated if transmissi 1. Back flush and clean oil cooler. lube pressure is low. Restricted cooter return lin Lube ail ports in transmission plugged. cated if transmission lube pressure is 2. Clean out lines. 8. Check lube lines for restrictions. ‘OVERHEATING Worn oil sealing rings. See paragraph E, 1. Remove, lrassemble, and rebuild convert. ‘or assombly, Worn oil pump. 2. Replace. Low oil level. 3. Fill to proper level. Pump suction line taking ai. 4. Check oil line connections and tighten secur- ely. NOISY CONVERTER Worn coupling gears. 1. Replace. Worn ell pump. 2, Replace. Worn or damaged be 3. A complete disessembly will be necessary to determine what bearing is faulty. LACK OF POWER Low engine RPM at converter stall 1, Tune engine check governor, ‘See “Over-heating” and make same checks. 2, Make corrections as explained in “Over-Heat- ing. —28-& CL-8000 TORQUE CONVERTERS: FLYWHEEL RING GEAR INSTALLATION PROCEDURE © FLYWHEEL TORQUE TO 45 LBFFT (61,0 Nm} C & CL-8000 249087 229769 2.094 [53.18] H Backing Ring is to be replaced order Part No. 230694 Backing Plate. ‘The 802551 Kit Includes: 1 249087 Ring Gear 24 735050 Stud 36 228987 Bellevile Wosher 24 229769 Stud Nut 1 802562 Instruction Sheet 1 Remove all burs fom Rhee! Mounting Foon and Pit 4 Intl remaining studs. Tighten 33 10 98 WER HA - ove, dean with solvent. 48.8 Nal torene ‘The engine Fyhet and Housing must conform to stendord 5 ist Backing Pate 290594, S.AE.No. 1” SAE. 0027 toloranca specticevons tot Plot Bores,Eecentcties end Mounting Face devations. Check © Lubvicate Stud Threads, Btevile Washers and Nuts with fngine crankatatt “End Play", must be the same valve SAE MOGt Dotore and aftr the torque converter Is mounted to the engi 7 IntalBetevile Wathors and Baste Stop Nuts e8 shown 48 washers, each stud for © & CLO and HR & 2 Insta tro (3 Stu 235060 equally spaced. Tighten 3310 Un 34000 ¢ washer, each stud for C & C8000) Tighten SSIbH TAB - 485 Newt of torque fuss ina cise cross pater to 25 BER [94 Nel. Then {ihten nuts in interment of BP (6.7 Nenlin aes cons {3 Instat Ring Gear 249087 by taping taht in lace. pattern to 35 loft (47.5 Non for © & CLSCOO and HR & {ipR 94000 and 46 te 61,0 Neal for C & CL-EO0D torque. -29-PROPER OIL CHECKING & FILLING PROCEDURE Refer to transmission maintenance manual or lubrication chart, Use only specified transmission fluid. Fill torque converter and transmission through filler opening until fluid comes vp to LOW mark on transmission dipstick. NOTE: If the dipstick is not acces- sible oil level check plugs are provided. (See below). Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug. Run engine two minutes at 500-600 RPM to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine running at idle (500-600 RPM). Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install oil level plug or dipstick. Recheck with hot oil (180-200 degrees). Bring oil level to FULL mark on dipstick or runs freely from UPPER oil level plug. FULL OIL LEVELVIEW “'S" (Output Drive Gear Sensor) Inspect Dim. “W' Stake 3 places approx. ‘equally spaced. Schl ‘SPEED SENSOR BUSHING INSTALLATION assembly, from gear tooth. Atter curing of Loctite, ‘speed sensor bushing ‘must be secure with 40 Fr, Lb. (54.2 N-m} torque. VIEW “T” Inspect at assembly. Dim. * REAR VIEW OF CONVERTER (Pump Drive Gear Sensor) ‘Assemble Speed Sensor Bushing in housing to specified dimension ““U" or “W" with Loctite 262 and stake (3) three places. See Pump Drive and Output Gear Charts for dimensions. PUMP DRIVE RATIO. DRIVE GEAR | DRIVEN GEAR | SPEED SENSOR BUSHI RATIO | NO.OF TEETH | NO. OF TEETH | DEPTH “U” PER VIEW 1.250 82 0 1.060 ¢ 007 [26.9 17] 1.057, 35 Ed 1.060 4.007 [26.9% 17] saerase | o7(@5°PA) | 35 (25° PA) 1,390.4 007 [35.9 .17] 946 7 358 1.390 + 007 [35.3 +.17] 800 40 Ed 1.390 + .007 [95.38.17] OUTPUT GEAR RATIO TURBINE SHAFT ‘OUTPUT RATIO | & GEAR ASS'Y GEAR SPEED SENSOR BUSHING NO.OF TEETH | NO.OF TEETH | DEPTH “W" PER VIEW “S" 1.323, a1 a 1.080.007 [26.9+.17] 1118 34 38 1,060 x .007 [26.917] 1.000 36 36 1.380 +.007 [35.317] 895 38. «4 1,990 +007 [35.3+.17] 246 39 33 1.990 007 [35.317]ASSEMBLY INSTRUCTIONS ‘C-8000 CONVERTER TIMPELLER HUB AND TURBINE HUB ASSEMOLY WITH BACKING FING AND SPECIAL SELF LOCKING SCREWS (GENERAL ASSEMBLY INSTRUCTIONS: clean mip mavring autace ard cagond tls fs ake. Ory iy beng sara topes nee se Sy ora Sa a InravEagany fag aad apstn sven fo obit 6 ch 0.) ‘Scxaa pasiah ith cabiaes trays wera ighien por Fab tena Sto 64 ta leuo( 76" 268 Ran ane ute fb scteus Suto ee hay [238 aCe im Na: Rana or ‘SErow masaion The acnave se propared wih a Song wen Seti heen tay station nie ht hole Boers Gacrna rica mora {aon wl age gnc er ob ed ‘Sne Intnl on tha screws removed for ny ramaon must Setoplaced. the stmpourd ok Inthe os lee Maa be roroved sith the proper tap ana. ‘slvent: Dry howe thorough nd uae Snow sete fr ro Toga pt ots 88 tbe ox (oes 8105 nin) Lock.uP Torque cover bets Is Boor be Ft a Was? res hing Must be loose iofemal beara No S otoned an oeanng, E Assemtle snap ning with! Fapedge cn ing Expander Piston ring expander instalation fi | S| view oF RING JOINT Holes nus be ee ota & burs Loup etch / "Strtnge inner plates : 1 stoe outer plate Coat wan type A" od Dror to assamely Cork gant aren specie Stamped cage’ beng oni expan ‘open Fira aston ring ant expander instalation ed ry Porat studs used. fn tear Dearing cap, Torque outout shat ‘Mur 280-906 tae FY [390° #087 Nom 1 not assem ost gears In any combination except tase listed bao "A wrong cQmbrnaion may mesh but wil rot ran propery we PrN] no RATIO veemm_| oureur | tein 13 7 zea [= view oF 18 2a [aires [a ING JOT Te ae seer [ae 205 [wre |e 306 sa [apes a ~32~TAPERED OEARING INFORMATION: ‘GENERAL insure coming of Doan 8 relat par Seatrgboarng cap witout vsng Sins CaUTISN insta a Sap meting ees whan sealing boar sehr nce eed int rs by should bo rotated & housing rappaa each tome bag ap is assembled lo laste proper aighinant hie bears NOTE: Figs, aden, age pon singe 8 bow Should be assenbiog afer zheng prevent damage lo The vatious pars Sssombied stir chimming & bearings 1 OUTPUT SHAFT BEARINGS:— move bearing cap soos ar sea ated eft heck gap between cap & houtng win Shims used-as Tooker REMOVE suffcint shims to ‘5 002 tight [conditon EXAMPLE'“Gap = 018, nal shit thichnees to Be 008, ‘TURBINE SHAFT BEARINGS:OFFSET & STRAIGHT THAU ORIVE. Remove Deming cap stews sr sexing bowing cay 38 noted above tik gap between ap & Rousing nth Shame Ysed a5 a tole gage ADD auticent sime'te peduce 2.002 loose env EXAMPLE™ Sep st, fat shim ‘ness to be 02 7, wo rano_| one cean | reetH | omve cean | Teens 1350 [_ ae = 268s a fosr_ [pes 35 200867 3 Bavest | —atares [Sree pa] saree [seee Pa [sepa F a8 = ao | as © ane? = ONEAAOD GENERAL ASSEMBLY INSTRUCTIONS: -NOTE: 2:6 PATO 25° PRESSE ANGLE GEARS IDENTIFIED BY GACOVE LOCK-UP & Gov. DRIVE 1 Assemble to parts it as Ie locaton ot charging Inepect at assembiy Use Bermarek & Crane Seal only where Apply very ight coat ot Permatex NO. 2 fo ‘aot seals pos to assem ‘ler assombiy of paris van Permatex o: C: ings must. be smooth & Mee fem Gots ‘brats all ston rings & "0" ings at assembly a Bi Seater More must be mo ies or exeets tratral > hgbeglonet he 3 reat ings mearced "x have a whe ‘entiation math on he 6D ‘Benoies high Temperate mater tn coat aPiroace swash Seal ee prer's sisenby, Gov, ORIVE Torque capserows & lookwie ‘ogether a8 shown, icone Imus! no protrude above Capscrow head —33— bearng exp asC & CL8000 Series Converter Drive Plate INSTALLATION INSTRUCTIONS Proper Identification by Bolt Circle Diameter ‘Measure the “A” dimension (Bolt Circle diameter) and order Drive Plate Kit listed below. “At Dimension (Balt Circle Diameter) 18.00" [981,000 mm] ciameter it No. 802587-10enm 16.00" 406,400 mn} diameter Kit No. €02858-10mm 16.00" [406.400 mm) clametor Kot No. 802500-711820 18.875" (428,525 mm] ciamotor *¥ GUN. 202809-7/16:20, 17,00" [431,800 mn} diameter Rit No. 802888-10mm 17.09" [431,800 mm] diameter ‘No. 802862.7118-20 Each kit wi Include tha folowing pars: ' intormecite Drive Pitas 1 Dave Plata Assembly 1 Backing Pate 14 Drive Pate Mounting Capscrews Inatraction Shoot “#1 pe. Drive Plate Mounting Spacers Included In Kit No, 802608, ‘OnE PLATE AMD "A: Dimension (Bot Circle Diameter) 16.00" (406,400 mm cierster (RtNo, 802504 W/O Nuts Each kt wl nclude the folowing parts: 6 Intormeciate Drive Plates 1 Backing Pate 14 Deve Plate Mounting Capscrows Instucton Sheet NOTE: Assombly of toxplatos must be oompiatod ‘within a 15 minuto period rom star of scraw instalation. ithe screw is removed for any reason ‘must be replaced. Tho adhesive let inthe tapped holes must be removed wih the propee tap and ‘Cleaned win solvent. Dry the hole thoroughly and Use anew sorew or ranataliaon, Position drive 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 186° apart in becking ring must be out foward engine flywheel) Instat capscrews, Tighten capscrews 52-57 ftibs torque [70.4 - 77.1 Nm. ‘See page 35 for TORQUE CONVERTER TO ENGINE INSTALLATION PROCEDURETRANSMISSION TO ENGINE INSTALLATION PROCEDURE Remove all burrs from flywheel mounting face and ose pilot bore. Clean drive plate surface with solvent, Dry thouroughiy. Check engine flywheel and housing for conformance to standard SAE. #1 - S.AE J927 and J-1033 tolerance spacticetions for pilot bore size, pilot bore runout and mounting face flatness. Measure and record engine crankshaft end play. {Install two 9.50 [28,90 mm] long converter to flywheel housing guide studs in the engine flywheel housing 8 shown. Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole. {install a 4.00 {101,60 mm] long drive plate locating stud in a drive plate nut, Align the locating stud in the ‘drive plate with the flywheel drive plate mounting screw hole positioned in Step No. 3. Locate converter on flywheel housing aligning drive plate to flywheel and converter to flywheel housing. Install converter to flywheel housing screws. Tighten screws 10 specified torque. Remove converter to engine guide studs. Install remaining screws and tighten to specified torque. Remove drive plate locating stud, Install drive plate attaching screw. Snug screw but do ot tighten. Some engine fywheel housings have a hole located on the flywheel housing circumference in line with the drive plate sctew access hole. A screwdriver or pry bar used to hold the drive plate against the flywheel! will facilitate installation of the drive plate screws. Rotate the engine flywheel and install the remaining seven (7) flywheel to drive plate attaching screws, Snug screws but do not tighten, After all eight (8) screws are installed, tighten each capscrew to the following torque- 7/18 capscrew 58- 64 ft Ibs torque [78-86 N.m}:M-10 capsorews 48-55 ft lbs torque [65-75 N.m]. This will require rotating the engine flywheel until the full amount of eight (8) screws have been tightened. Measure engine crankshaft end play after converter has been completely installed on engine flywheel. This value must be within .001 [0,025 mm] of the end play recorded in Step No. 2. Plates To Be Installed |: With Concave Side Toward Engine Flywheel.NOTES‘Capabilay rstings, features and specifications vary depending upen the modo! type of service. Applications approvals must be obtained Lone ena eee al SPICER CLARK-HURTH OFF-HIGHWAY COMPONENTS DIVISION Dre eM eC tea)