18000 3 & 6 Speed Long Drop 0118 SPICER OFF-HIGHWAY COMPONENTS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 slight oullay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cast operation and trouble tree service. In order to become familiar with the various parts of the product, its principle of operation, trouble shosting 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 af “will-fi” or non-approved parts may endanger proper operation and performance ot the equipment. Clark. Hurth Components des not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by oF approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Dasign a ae Fig. A Canvertar Group a foes Fig Convener and Tranemisaion Case Group. Fig. C 42 Speod Clutch and Gece Group Fig, D ‘Clutch Group. fetes FE ‘Cantal Valve Asserity Fig. F Posing Brake Group Ui teeteeeeeeeee Fl eternal Plumbing Diagram Fig Assembly Instructions. fig! Rear View (Speed Sensor). cerereee Fie DISASSEMBLY OF TRANSMISSION. : sed CLUTCH DISASSEMBLY foes - 13 (CLEANING AID INSPECTION cry REASSEMBLY OF TRANSMISSION cesses OF SERVICING MACHINE AFTER TRANSMISSION OVERHAUL... ..... : 40 TOWING OR PUSH STARTING. - 40 SPECIFICATIONS AND SERVICE DATA. - vee At LUBRICATION fo tteeieet teenies ” TROUBLE SHOOTING GUIDE. . a POWER FLOW 13 Speed - . 4a PRESSURE CHECK POINTS. vette tates teres a CLUTCH AND GEAR ARRANGEMENT cy TRANSMISSION TO ENGINE INSTALLATION PROCEDURE, o.oo. .cesceeeceve ee 46 DRIVE PLATE INSTALLATION... 00.00 cess ce 5 RMODEL SECTION... a 53 6-SPEED SECTION - : voces 8 NOTE: Matic Dimansions Shawn in Brackets |HOW THE UNITS OPERATE The trantmission and hydraulic torque portion of the power ts engine power to the driving wheels. In order to properly maintain ond service these units it is important to first understand their function and how they operate, enacts an important role in tranemitting The tranwmission and torque converter function together and operele through common hydraulic sys Is necessary to consider both units in the study af thei function and operation, To supplement the text below, and for reference use therewith, the following illuste Basie Design ‘Convert Group ‘Convertor and Transmission Case Group “Thiss Speed Clutch and Gear Group Gurch Group ‘Control Valve Assambily Parking Brake Grown External Plumbing Disgrarn ‘Assembly Instuetions Rear View ‘Thwoe Speed Long Drop Power Flow Prossure Check Points Clutch and Gear Arrangement Transmission 1m Engine instalation Procedure ‘The HA Model consists of a torque converter and powershitted transmission in one package mounted directly to the engine. Tho R Modal consists of » soparate torque converter, mounted to the engine with the powershift transmission tamotely mounted and connected to the torque canverter with a drive shaft. ‘Tho shift control valve assembly is mounted directly an the side of the converter housing or front input cover. The function of the control valve assembly is to direct oil under pressure lo the desired directional and speed clutch. A provision is made-on certain models te neutralize the transmission when the brakes are applied, This Is aecomplish fed through use of a brake actuated chutolf valve, The speed and direction clutch assemblies. are mourried inside-the transmission ease and are connected to the output shaft of the converter by direct gaaring. The purpose 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 disconnoet is optional and is located on the: output shat: The drive to the front or rear axle can be discon nectad or connected by manual shiftingWith the engine running, the converter charging pump draws oil from the transmission sump through the n screen and directs it through the pressure regulating valve and cil filter. removable oil su The preseure regulating valve maintains pressure to the transmission control cover for actuating the dire sion ond speed clutches. This requires a small portion of the total volume of oll used in the sysiem. The 14 volume of oil ie directed through the torque converter circuit to the ell cooler and returns to in for positive lubrication. This regulator valve contists of 4 hardened valve spool operating in a closely fitted bore. The valve «pool it spring loaded to hold the valve in a closed position. When a specific prosture is achioved, the valve spool works agsinst the spring until a po aide of the bore, This sequence ef ovents provides the proper sysiom pressure. i: exposed slong the After entering the converter housing the oll Ie directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support. Tho ell thon flows out of ‘he converter to the oil cacler. After leaving the cooler, the sil is diresied to 2 lubricating fitting en the transasission and through a series of tubes end passages lubricates the transmission bearings and clutches. ‘The oil then gravity drains to the transmission sump. ‘The hydraulic torque converter consists basicelly of the torque. The engine power is transmitied from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter end is the pri penent which starts the il flowing to the other components which results in torque mul ‘ement can ke comparad fo 2 eentrifugal pump in that it picks up fluid at its center and discharges at its outer diameter. lemenis and thoir related parts to multiply engine ary come ication. This el- The torque converter turbine is mounted opposite the impeller and is connected te the ovtpul shaft of the torque convertor, This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and resction member is the means by which the hydraulic torque eonverter multiplies torqu ‘The reaction rember of the torque converter is located between and at the canter or inner diameters of the impeller and turbine elements. lis function i3 16 take the fluid which is exhausting from the ianer portion of the turbine and change revlation into the impeller element. direction to allow correct entry for ree The torque converter will multiply engine torque to its designed maximum multiplication ratio when the ot put shafl is af zero RPM. Therefore, we can say that as the ouiput shalt is decreasing in speed the torque multiplication i increasing. Tho shift control valve assembly consists of a valve body with selector valve spools. A detent ball end spring in the colector spool provides ane position for each speed range. & detent ball and spring spool provides three positions, one each for forward, neutral and reverse, the direction With the engine running and the directionel central lever in neutral position, oil pressure from the regulst ing valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and reverse spool will direct oil, under pressure to cither the forward or reverse direction cluich as desired. When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector spool, The same procedure is used in the speed solector. The direction er speed clutch assembly consists of a drum with imornal splinos and 9 bore to receive o hy. dravlicslly setuated piston. The piston is “il tight” by the use of sealing rings. A steel dise with external splines is inserted inte the drum end rests ageinst the piston. Next, « friction dise with splines at the inner diameter is inaerted, Discs are alternated until the required tatsl is schieved. A heavy back-up plate is then inserted and secured with a snap ring. A Hubwith .0, splines is inserted into the splines of discs with toath on the ianer diameter. The dises and hub are fe is the opposite ditee tion as long a8 no pressure is present in that specTe engage the clutch, as previausly stated, the contral valve is place sil under pressure to flaw from the control valve, through e passogeway, to @ chosen clutch shaft, This shaft has a drilled passageway for oil under pressure to enter the shaft, Oil pressure sealing rings are located on ‘he clutch shaft, These rings diree! oil under pressure to e desired elutes, Pressure of the oil Forces the piston andl discs against the heavy back-up plete. The discs, with teeth on the outer diameter, clamping against discs with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows them to 1 desired position. This allows ‘There are bleed balls or bleed crifices, depending upon the model, in the clutch piston which allow quick escape for cil when the pressure to the piston is released. HR MODEL BASIC DESIGN Figure AITeM DESCRIPTION 1 Pump to Housing Gasket 2 "0" Ring 3 Charging Pump Assembly... 4 Purnp Mounting Screw Lockwsher 5 Pump Mounting Screw... 8 Pump Mowing Scrow os... 7 Pump Mounting Stud Lockweasher 8 Pump Mounting Stud Nut... 9 Fike Assembly 10. Bearing Support Sexeer 11 Bearing Locating Rig 12. Pump Drive Baring Support. 13. Bearing Retaining Ring 14 Pump Drive Ger Bearing 15 Bearing Locating Ring 16 Pump Drive Gear 17 Idler Case Besring Lecatirg Ring 18 Ider Gear Beoring Retaining Ring 18. Pump Drive ale Gear 20 Idler Stub Shatt Bering - 21 Beating Rotairing Ring... 22 Bearing Locating Ring 24 Idler Gaae Stub Shat 24 Stub Shaft Lock Ball 25 Battle Ring 25 Turbine Shaft & Disc Hu Assembly 2 Turbine Shot Bearing 28 Bearing Locating Wesher 29 Bearing Rtaining Ring... 30 Piston ing 31 Bearing Snap Fing 32 euction Member Supper 34 Piston ing Expander Spring 3 Piston Ring 3% Pump Mounting Stud 38 Pump Mourning Stud - 3 Gil Seal 38 GiiBbattle Assembly 39° Rovorge tater Snft.. 40 Reverse Idler Shalt “O Ring, 41 Blrverse ior Shaft Lock Ball 42 Suopor Screw Washer 43. Reaction Mesnber Support Screw HR18000 CONVERTER GROUP ary Be ee en eee eM DESCRIPTION ary 44° Bearing Retainer Thrust Plate 1 45 Ravrsa loler Gra Bearing Assembly... .....esecee T 49 Rovorse liter Gear cd 47° Bearing Retaining Theust Plate cd 48 Retaining Piste Nut... . i 45 Impeller Hub Gear Bearing 1 50 npelle Hub Gear 1 SI impeller Hub “0” Fung 1 52 Impeller - 1 153. Irnpeller to Hub Screw Lock T: a) BA mpeller to Hub Screw bo B 85 Reaction Member Spacer... 1 56 Freewheal Outar Race Snap Ring 1 ‘57 Reaction Member tered 58 Froevihiew! Assembly . 1 58 Freewheel Outer Race Snap Ring 1 ‘60 Reaction Member Ratainer Ring sted 81 Impeller t0 Cover Serow and Lockwasher 18 82 Turbine Retaining Ring 1 63 Turbine Hub 1 64 Turbine 1 65 Turbine Sacking Ring 1 85 Turbing Hub Guaring Locating Ring at 87 Turbine Hub Bearing 1 6B Besring Retsining Washer - 1 ‘82 impeiler to Covi "O" Ring ..eeeeceeeeee at 70 impeller Cover... 1 Th Turbine Retaining Ring 1 72 impesier Cover Bore Plug “O” Ring at 73 Bore Plug... 1 74 Bore Plug Retaining Ring 1 78 Drive Plate Assembly . ed 78 Orive Plate 2 72 Orive Plate Backing Ring... . ut 78 Divo Flota Mounting Screw f Lockwasker 10 78 Turbine Hub Scrom W 80 Bearing Support Screw & Lockwosher 2 1 Aunilary Purnp Drive Bearing Suppont vt 82 Bearing Retaining Ring 1 83 Pump Drive Gear Bearing 1 BS Bearing Locating Ping eee cess ee eeeee 85 Awsiliary Pump Drive Gear. . 1 85 Remote Fater Adaptor (Optionsid 1Figure C14, 15 16 7 18 1” 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 HR 18000 LONG DROP CONVERTER AND TRANSMISSION CASE GROUP: SEE PAGE 62 FOR R MODEL (REMOTE MOUNTED) CASE & FRONT COVER GROUP. DESCRIPTION Valve to Converter Housing Screw Valve te Converter Housing Serew Lockwasher — Conieol Valve Assembly on Contral Valve Gasket Detent Ball _ Detent Spring .. Fipe Plug Air Breather .. Converter Housing Pipe Plug... Pipe Plug... Converter Ho! Converter Housing ta Transmission Case Serew Lockwasher Converter Housing to Transmission Case Screve “ Pipe Plug ..... Pipe Plug Screen Assembly Gasket - Screen Assombly .... Housing to Case Gasket Pressure Tube “O Ring .. Tube Sleeve Pressure Tube “O" Ring Tube Sleeve _ — - Clutch Pressure “O” Ring Low Speed Clutch Pressure Tube Pipe Plug ...... Pipe Plug Transmission Case Assembly Tube Sleeve. Pressure Tube “O" Ring Rear Cover to Case Gasket Rear Caver to Case Dowel Pin Rear Cover ... Sleeve Rear Cover to Case Screw arr. .F ° 1 1 2 2 1 1 1 1 1 1 16 BN 20 rem 35 36 7 38 39 40 41 42 43 44 45 46 a7 48 49 50 51 52 53 54 55 56 57 DESCRIPTION ary. Rear Cover to Case Screw Lockwasher 20 Pipe Plug ... 1 Pipe Plug . 1 Pipe Plug .. cece 1 Magnetic Drain Plug . 1 Oil Baffle 1 Suction Tube Clip 1 Clip Retaining Screw. 1 Clip. Lockwasher 1 Suction Line “O” Ring . 1 Suction Tube Assembly 1 Suction Tube Retz Lockwasher ... Suction Tube Ret Clutch Lube Tube rd Speed Tube Pressure Tube “O" Ring Tube Sleeve Tube Sleeve Dowel Pin oss Grd Speed Pressure Plug “O" Ring - 3rd Speed Pressure Plug .... Dipstick Tube Assembly Dipstick ing Screw ining Screw . ee ‘Optional Remote Mounted Control Valve Parts 58 59 60 61 62 63 64 65 Remote Contral Valve Adaptor Plate cece seo Remote Control Velve Mounting Plate oon Betent Spring Detent Ball Control Valve to Mounting Plate Gosket . Control Valve Assembly Valve to Meunting Plate Screw, Lockwasher ese Walve to Mounting Plate Screw... 9cisconnecy 6 | ‘ 9 A int af ap? “2 - ie 1 err eT A ie - m tr PARKING BRAKE PARKING BRAKE LESS SPEEDO GEAR WITH SPEEOD GEARR & HR 18000 THREE SPEED LONG DROP CLUTCH AND GEAR GROUP SEE PAGE 71 FOR 6 SPEED CLUTCH & GEAR GROUP ITEM DESCRIPTION SLSCRYRR ERE EBB ESS SRLBSISESSERE Roverse and 2nd Shalt Piston fing Piston Bing Expander Springs Front Bearing Retaining Ring Front Bearing Srap Firg Reverse and 2nd Shatt Front Bearing. Clutch Driver Goor Bering ‘Bearing Retaining Ring Clutch Driver Gear Spacer Rare Chrch a ae Hub Aseribty Bott Ring vo Bearing Retaining Ferg Clutch Drivon Gear Bresing - Spring fietarsr Snap Ring... Proton Rater Disc Spring Pack Poston Raturn Sering Spacer Reverse and 2rd Outch Poston Rann Spring Spring Retains eee eee ‘Spring Retainer Saep Ring Roverso ane Indl Cintch Shalt fear Bearing 2nd Clutch Ose Hub Srp Ring. Botte Bing Ind Clutch Disc Hid Bore Plug ...... Geos Retones Snap Fira Forward Shalt Gear Forward Chute... Piston Retun Seting Spacar Piston Raton ssc Spring Pack Spring Retainer Snape Ring Forwaed Catch Shaft Pit Svaring low Speed Clutch Shatt Front Bearing Front Beanog Spacer Low Speed Gear Bealing Low Speed Gat Seanng Locating Ring Low Spoed Geor Spacer Low Speed Grat and Hub Assombly.. Battie ing Low Spood Geor Beating Locating Ring Low Speed Geat Bearing : LowSpoed Gear Bearing Retaining Ris Spring Retainer Snap Ring... es Spring Retainer : Peron Reture Spring Low Speed Chteh - later Shaft and Geot Besring Raraining ng Bearing Locating Ring. 310 Clutch Dise Hu Bearing Besring Locating Ring Bovina Car Locating rg resin Caroar 3rd Speed Cts Disc Huis” Bale Ring Sra Speed Gluten Sra Piet Bearing Spring Reteines Snap Ring ‘Spring Fetaner ary ITEM DESCRIPTION Piston Ring Expander Spring - Sed Speed Clute... | Sed Speed Clues Shaft Front sang Locating Ring. Sra Sede Ciuc Shit Front Seating Sed Speed Chich Shalt Font Beary Rotaining Ring. tet Spend Chute Shatt Piston Ring... Pistonfiing Sieeve Retainer Ring Piston Ring Sieeve - Siaove Roll Pin. Forword Clutch State Rest esting om Speed Charh Shaft far Bearing oar Bearing Support Washer Rese Beering Retaming Ring low Speed Chach Shaft Piston Ring eae Besring Cap “O" Ring - Being Cap Stud ow Speed Chach Shaft fear Bearing Cap Boring Cap Stud Lockwashar Being Cap Stud Nut Bearing Cap Pian Breving Cap“O" Ring esr Bean Cap Studi Nut Rear Gearing Cap StudLockwashor - lar Shot Pear Bean Cap Rea Bearing Cap Stud Fear Bearing Cap "0" Reng et Shot ear Bearing Retziner Ring Ree Beating Suppor Washet llr Shatt ae Bearing Bearing Cap Stud Beoring Cap Stud Lockwastor Beoving Cap Stud Nut Flange Nut Flange Washer Flange "0" Reg QuspurFiaege Goxput Shek Fer Ba Bearing Cap Gasket sr Bearing Gan OW Se uiput Shalt Rear Beoning ‘Output Shalt Raa Basing Spacer Ouat Gear - Buiput Ges! Spacer urput Shae ‘Sut Sah Fee Bong ing Can Flange Washer Flange Nut 11101 thes 122 Various Optionshone ween a LOW CLUTCH GROUP DESCRIPTION cary. Backing Plate Snap Ring... cen V Cluich Dise Backing Plate wd Cluteh Inaer Dice a Clutch Outer Dise 8 FORWARD DESCRIPTION ary, Backing Plate Snap Ring enscnnees V Clutch Dise Backing Plate 1 Clutch Inner Dise 8 Clutch Outer Dis 8 ITEM eve DESCRIPTION arr. Clutch Pision se v ‘Qvier Clutch Piston Ring... 1 Inner Cluteh Piston Seal. . 1 Low Speed Clutch Shaft and Drum Assembly... 1 CLUTCH GROUP ITEM eo DESCRIFTION a Ovter Clutch Piston Ring - Inner Cluteh Piston Seal Forward Clutch Shaft and Drum Assembly. SRD CLUTCH GROUP DESCRIPTION ary. Backing Plate Snap Ring enceenes V Clutch Dise Backing Plate cos Clutch Inner Dise 6 Clutch Outer Disc . woe & EM 5 6 7 & DESCRIPTION Clutch Piston Assembly REVERSE AND 2ND CLUTCH GROUP DESCRIPTION cary, Backing Plate Snap Ring... can Chutth Dise Backing Plate... a Clutch Innor Dise on 8 Clutch Outer Dise .... en) Clutch Piston none ee 1 1 Outer Clutch Piston: Seal... 1 Innge Clutch Piston Seal oun 1 ed Speed Clutch Shaft and Orum Assembly.. 1 DESCRIPTION arr. ‘Outer Cluteh Piston 28h on ssnmes 2 Inner Clutch Piston Seal ws 2 Reverse and 2nd Speed Clutch Shaft and Drum Assembly 1 Clutch Clutch Inner Dise [POM noHYDRAULIC CONTROL VALVE OPTIONAL MODULATION VALVETe weueMeon— CONTROL VALVE ASSEMBLY DESCRIPTION cary. Hydraulic Actuator Assembly 0... a Piston Housing "O" Ring a Piston Balance Spring .. - a Spring Retainer Pin Piston Seal Piston - Glyd Ring - Speed Selector Spool esau . a Spool Plug vo Gil Seal - 7 Pipe Plug . Control Valve Housing Dotont Ball soenee Detent Spring wn Control Walve Gasket - Valve Spool Stop Neutral Switch Actuating Pin Neutral Switch . . Declutch Spool Stop - co il Seal ce Forward and Reverse Valve Spool co NOTE: Items 22 thru 24 are various declutch options. MODULATOR VALVE ASSEMBLY (Optional) DESCRIPTION: ary, Modulator Valve Housing — ‘Accumulator Spring {laner) Not Used an All Models Accumulator Spring (Outer) — . . Accumulator Valve Spool Stop Plug “O” Ring Spool Stop Plug Regulator Spring Regulator Spool ~ Modulator Valve to Converter Housing Gasket ... eres sencePARKING BRAKE GROUP rr. rem DESCRIPTION Backing Plate Assembly a1 Aeluating Lover ccs at ? Brake Shoe and Lining .. 2 4 Broke Flange... 1 " Brake Drum . a1 2 Brake Drum to Flange Screw s : 13, Lockwasher ..... Brake Drum to Flange Screw Figure G DESCRIPTION Return Spring Brake Shoe, See Item 3 Brake Lining ... Brake ing Rivet . Backing Plate Screw Backing Plate Screw Lockwasher .CHECK POINT“ CONVERTER OUT TEMPERATURE (SEE SPECIFICATION PAGE) CHECK POINT "C ‘CONVERTER QUT PRESSURE SPECIFICATION PAGE) 781.0, MIN HOSE 10 COOLER CHECK POINT “F” CGOLER ‘OUTLET PRESSURE. OUTLET TEMPERATURE CHECK POINTS “F" & GARE FOR INITIAL CIRCUIT CHECKING ONLY THESE FITTINGS SHOULD BE PRO- VIDED ON THE PROTOTYPE MACHINE 18000 PLUMBING DIAGRAM 3 SPEED LONG DROP EINE ze we. CHECK POINT 8” CONVERTER INLET PRESSURE OPTIONAL REMOTE | MOUNTED FILTER 1./18-12. THD'S FOR STANDARD SAE “O" RING FITTINGS UNLET & QUTLET) 18000 PLUMBING DIAGRAM 3 SPEED LONG DROP (WITH REMOTE FILTER! SEE PAGE §5 FOR R MODEL PLUMBING DIAGRAM Figure Hfen & tom ula 1 Outar act oe8 Ae Histon ses 1 1 bo my suppor an 1 ane when nemsing soit wok Aes bts Iipot sea as shown sop a ae so ob Scent 009 Sorat Oo ol tame nor ane (3) saat ce ar ascoreay Inort ane (1) ftir 8 ‘Akerman oa! see con cise (eal proper amount of discs fre ined Eat sac newt ‘bine paton ir sine fet cee Inada Yao ae ao Pe Lbs FL Br 43,9 Re torque “Tigress nut 209 ts 260 Lb [err 2 28,0 Mm] trum 1 gat pul sem ‘e be located #5" 930 fier oa ot vane ‘Spoeiat eaareg—Dat ‘arg tee Bower fa be heaind 200° to Sede ase aT? C) ana ‘Sesto met be tosssombly mba sith harp geo emt Press bate ta shower imszcrvanes rovang Press HO tn out doer only Tighten ol scree eeeeipe— Yio to ube Fe [vn6 ° 209 Ne See must be sized par ‘er amsomble one ha Tighten nut 200 fa 280 Us Pr 54990 rem Must te hawt nein ores tu ene 200 [s0.0) Da wan ire aatrbtce foc fab posinaned in Zasteat inner ae Entarged view o steer supper eter ng expander ate Sq Ta clubs (2 8 Sd ‘Exnander gag 0 be ‘© Out seal eines Sppeoe Tab bm sing honk inno Mites ace [pinto ae assert ‘Stan win autor eee ae Figure |seats, piste rings, and °O Wo aor bas peck st eckerbh " 2. LabEaHE a pon na arcoresana“O"rngs wil tolore ear gy vet a co of Parmar No.2 9 OD of ohsta Delos assem Ae sasrby of parts Ltt ce Paematag hare tment beahy to areas maar fa coud ort the crea 5 App 8 ight oaat & Aly aime coming ofgreaseGnrmoen spa Igoe acle oer to assy 7 fio 2 nal oo by Coming HIV.98 roe BeGSu atu Gomel Pol ain nes of gost Boating part No. mus! be "GUT Charon rust bo "IN twaring wat a No.3 sicheo fon the bare “Taan, Nut To. 200-250, Lts-FL RNK6 Nm] ane Stake ly Phe ree 1 Ona le bo fone tie Be Grave Spa lst 1a br el with ze pstons Only reduced ste pistons Only sand aac arzomtly. Blianer fcion dies, “Stor with ouRerstee! becting plate next 1a piston, then {1} ‘gute staal dies atorata Sinal ang fision discs url Torque eapscrews 20 b 95 Lba.-FL [sar aise him), Lochmine ovary (3) apscrans legether as ahaan, Tochaite aust 102 prteade above eapicrew head, eurvlerseenran icra catia Bone, saunas ina plate than [t} ‘dco cre male NNeation for Lubeacated sa Screw Threads Fn tas OMASE WRERD Ww | unr nw rte Pease) | aoe | 2 a Tees [ofiremowen ap on ree | [sia wa Toes aa tes) ee a | [rngaaa |p eta [|r [isan tea Tosa asa] [eres [| ea ane) rea 28 | foe 5S [ise ero) a er | [aoe aus [ [rare [ses | roe aay Lana ala neu [ie coe | base eel | [er] pe] [waa |] oe ae | | ao 30} b3ss. aa | Ter aw ae | fea as || no | tie [ese aah Figure |REAR VIEW Figure J Assemble speed sensor bushing in housing to specified dimension with Loctile 262 and stake 3 places 1.397 [35.48] * 1,383 [35.13] VIEW R Stake 3 places approx. equally spaced — orientation not critical VIEW WW Typical 3 PlacesMAINTENANCE AND SERVICE ‘The insiruetians: contained herein coyor tho disasoemby and reassembly of the tansmission in a sequence that would nor mally oe followed aftar the unit has baen removed fos the fmuchine and is to be completely overhauled. i must aia be Understood that this is a basic TBO0D taneenission vith many options. ME 18000 wangmiasions are veey simitar ta trouble: shoot, cEsassemble, repai, and resseamble. CAUTION: Cisanliness is of extreme importance and an ab- solute must in the ropair and ewverhaul af this Unit, Before at- tempting any repairs, the exterise af the unit must be-thoroughly cleaned! te prevent the possibility of dit and foreign matter entering the mechanism. NOTE: For RModel tramote mounted iaremiscion) front end removal, repair & installation see R-Madel section page 57 DISASSEMBLY y Figure 2 ter assambiy Loosen itis racommonded 2 small pan be used ta catch the ol loft in'the filter element, Remove filter slement Figure 4 Somove pressure regulating valve-and charging pump belts ‘and stud nutsFigure 5 Figure 8 Romave valve end pump assembly. Remove impeller cover bore plug retainer ring Figura 6 Romeve drive plate mounting screws and washers Figure 10 Figuee 7 Through bore plug hale. romove turbine retaining ring, See Remove Brive plate and backing ting Figore 10-8Figure 10-4, Figure 1 Remove impeller cover to impeller bolts Figure 12 Remave impeller cover. NOTETurbine may romain in over bearing and will;come off with impellarcovar Figure 13 Impeller cover and tuibine being remaved as an assemblyFREEWHEEL DISASSEMBLY So Figure 19 puller holes provisied, remove ail beffie, hown can be abrieated from Figure 16 Leitner the reaction member or the froowhas! a to he replacad romove the irant outer race t rom the reactian member. ly eannot be serviced. F the ba replaced as an assembly Figure 20 O11 batflo removed. Remeve rexetion momber spaces Remove impeller anc fhub assembly.Figure 21 Figure 24 Remove pump deve idlar gear retaining cing Using 4 soft hammer, tap pump. drive gear and bearing support from housing. Figure 22 Remove idler gear and bearing assembly Remove geer and hearing assembly from housing. Figure 23, Remove pump driva bearing supper screw and lack washer, Figure 26 Ramove sump scraen stsembly,Figure 27 Figure 30 Support cenvenar housing with » chain hoist, Remove remaining Bolt Remove contral valve bolts and lockwashars Figure 28 Figure 31 Remove control valve sesambly, Use caution arnot to lose Soparate converter housing trem Transmission case as: detent springs and balls sembly, NOTE: Revevse and 2nd cluich wall remain in converter housing, Figure 29 Figure 32 Remove all halts but one securing tangmission 19 con: Using spreading type snap ring pliers. spresd eers an the verter housing rovorse clutch front beating retaining ring,Figure 33 Holding snap fing open pey reverse ond 2nd clutch Figure 36 assembly from converter haveing Using = pointed bar or acredtiver, pry oil seal from nowning. Use eaution az not 10 damage housing bora Figure 34 if not used proceed to Figure 39. i evaitable, nats flange retainer DAF MUST be Used to hold the campanion Mange tx turning, loosen F.T.0: flange aut Figure 37 Remove P.T.Q. bearing outer snap ring ull i Fa. Remove P.T.0. shaft and bearing fers housing. Fat 6 spaedt ‘rangmassicn disassembly and reassembly soe 6 spat suction starting on page 63. Figure 38 Fomove fiosgy nut. washer, “O' ring and tangsUsing an impact verench (if available), mot aflange retainer Figure 39 Ste cae he companion Tk femove low chich ta bone ep sol mus tnd washes, «aL ant Be dl 10 ld the comanin flange fom Rernve cao, Fr 6 epsed Foreman vcton et ge 7 Figure 43 flange nut, washer, “O° ring and flange. Ifa parking brake 1s used remove brake Grum. Ramave brake backing plaie bolts and washers. Remove backing plate essambly. Figure 41 Figure 44 Remove bearing cup. Remove output shaft bearing eap stud auts and woshor:Figure 48 has optional Using pry slots provided, pry cover from transmission vy qa {vom housing, Using a soft hummer tap on lew eluteh, idler and fia to peovant cower from binding Remave output shaft besring cap speedometer gear. Remow output shaft Figure 46 Figure 49 Remove low éluteh, idler shalt and outout shatt reor baring Rear cover removed lncating rings. Figure 50 Remove law clutch rear besring setainer ring, Remove war caver bolts and washers,Figure 51 Figure 54 Low clutch rear beering spacer and retainer sing Romave outgut shaft front flange nut, washer, “O° ring and flange. Figure 52 Figure 55 Remove low clutch rear bearing Figure 63 Figure 58 Remove idler gear and ‘eer bearing as an assembly. Remove 2nd elutch disc hub retainer ting, —10-Figure 59 ak Tops low clutch assennbly fram housing. H possible it i Figure 57 recommended someone help in this operation to prevent the lew clutch from dropping out of the ease, Remave dise hub. Figure 60 Using contracting type snap ring pliers as shown, contract Ord clutch bearing cartiae locating ring. Lock pliaes to hold fing contracted. Figure 58 Compress gare on 3rd elute frant bearing locating ving Fiemave ring from ring groove, tis notnecessary toremove fing fram clutch, it will come ous whan eluteh be cemoved gure Blak Figure 61 Fram front of transmission and using a soft bar tsp 3rd speed clutch assombly from housing. If clutch seems difficult to remove recheck front and reer snap rings being Figure BEA sure they ae claar of the fing groave, aneigure 65 sump oil bate: Figura 62 Remove bearing ceftier, bearing and 3rd speed clutch disc hubs Figure 66 Figure 63 Remove forward clutch shaft drive gear retainer ring. See Remove 2rd speed olt ml Figure 66-4 Figure 64 Remove output shaft and bearings as en assembly. Figure 66-2 -12-igure 67 Remove fonwend clutch shalt drive gear Figure 68 Tap forward luteh from rear bearing, Figure 69 Remove tonward clutch ast bly. Figure 70 Figure 71 If piston cing sleeve or forward clutch rear bearing is to be replaced, wp besring from rear af housing. CLUTCH DISASSEMBLY Low Clutch Figure 72 Remove low goar end hub, bearing spacer and low clutch froat bearing, =13-Figure 73 Remave low speed gear bearing, Figure 74 Remove low gear hearing locating ring Figure 75, Remove and plate retainer ring -14- Figure 76 Remove end plate. Figure 77 Turn cluteh aver, Remove inner and guter clutch discs. Do not mix low clutch friction dises with friction dises in other clutches, Figure 78 Remove cluich piston return spring. A slaave with a portion fomoved is recommended for removing the clutch peston return spring, washer, and retainer ring. Sleeve shown is = ‘eommon pipe, with a 1-1/2 x 1 [39:0x26,0mm| opening. The pipe is 8 x Se1/a x 2-3/6 [155,0x85.0x78. 0mm), Compress spring nezainerwash er. Through opaning remove spring retaings snap ring. Release tension on spring retainer,Figure 73 Remove spring retsinerand spring, Turn elutch aver and tap slutch shaft on 2 black af wood to remove clyich pistan. Figure 82 Position piston intow clutch dim assnown. Use caution as, LOW CLUTCH REASSEMBLY 1 to damage inner and outer piston sealing rings. Figure 80 Install luton piston outer seat ring, NOTE: Ring must be sized oefore ‘installing in cluten drum, ‘Sizing 13. best Figure 63 Sccomplithed by rotating piston while holding 8 round Position piston return spring, spring retainer. and snap ting ‘object ageinat the new seal ring as shawn. Rotate piston in clutch um, until See ring is flush with auter dlametar of piston, Figure 81 Figure 84 fing and size as described in ‘st Compress spring and retainer. Install ratainer snap ring. Install clutch piston inner 5 Figure 80. -15—igure BS Install clutch inner bearing locating Figure 88 Install cha h disc end plate Figure 86 Install one stow! disc, Figure 89 Install end plate retainer Figure 87 Install one friction diss. NOTE: The frletion discs in the low sluych has a higher co-efficient rating than the friction discs in the oiler clutches therefore the dises must nat be mixed. The low clutch friction dise-has.a yallow mark af nansaluble paint on the outer diamotor for permanent identification. Alternate stee! and friction dises until the prope anaust of ises are mstallod, First dise naxt to the piston is stec!. last Figure 90 Install low speed gear inner bearing dice installed is fietio ~16-Figure 91 Position low gear ‘ront bearing spacer and bearing on Install low speed gear basing spacer sluich shaft me ON Tap bearing into position Geos splines must be in full position wath in frictian discs, REVERSE AND 2nd CLUTCH DISASSEMBLY (Reverse being disassembled) Figure 93 Figure 96 Inctall low spaod geor outer boaring, Remove clutch shat piston rings ane exeonder springs. NOTE: Nowe piston rings and exoandar springs must be installed pst lastetions on 9608 BB. Tees iS Figure 97 Figure 100 Remove tront bearing ratainer ring Remove gear as shown Figure 38 Figure 101 Remeve front bearing Remove beating spocer QS, ng ae, 4 eS sf 4 Figure 99 Figure 102 Pry reverse qaartiom clutch assembly tar enough te usa a Remove inner bearing. ‘gear puller. -18-Figure 103 Remove end plate retainer ring. Figure 104 Hamove ead plate Figure 105 Remove clutch dises, Figure 106 Refer to prorerluse shown in Figure 78 for removing retum spring retainer ring. Femove-sing, pision return disc spxing peck find spacer. Turn clutch over and sop shaft on a biock of wood fo temove eutch piston, Repeat pracadurs tor 2nd clutch disassembly NOTE: 2rd clutch will have a pring for piston tum. Do Not mh piston reur cise spxing packs with any cotter soring packs, See note on powe BB. REVERSE AND 2ND CLUTCH REASSEMBLY {Reverse being assembled) Figure 107 Install inner and outerclutch piston seal rings, Size rings as ‘explained in Figure BO, Position piston in clutch drum, = Figure 108 Install piston return spring spscer, return disc spring pack and resainer ring, See note on page 86. oeFigure 112 Figure 109 Ingtall and plate, Ingiall 1st eee! aie Figure 113 Figure 1910 Install end plate retainer ring Install one friction disc. Figure 111 Install next stae! dise. Alternate friction ond steel dises i the proper smount oi discs ave installa. First disc next to Figure 114 the piston is steel, last disc installed ts friction, Install inner clutch driven goar bearing =20—Figure 118 Figure 115 Install front bearing NOTE: Snap ring groove in front Install bearing spacer bearing must be up. Figure 116 Install clutch driven gear jate clutch drum. Align splinas an Install front bearing retainer ring clutch gear with internal teeth af friction discs. T#p ¢ insu discs, into positon, Do net fares this uperstian. Guar be in fall position with internal teeth of all fret Figure 120 Install new clutch shalt piston rings and expander spiings: par instmuctions on page #, NOTE: 2nd clutch use a return spring and nat a disc spring pack for piston return, Figure 117, Install euter Bean =2eFigure 121 Forward elute will disassemble and razssomble the same ex pe reverse clutch, install pew clyich shaft piston rings ond thee reverse clutch, Install ayy clutch shalt piston singe Figue 124 expander springs per instructions on page 85. Ramove reverse idler repsctews, Figure 122 ‘The Sed speed clutch jesarible anid tasssemnbile t 658 the low clutch except for tha fiction lass, See nate in Figuee: 87. Install neve clutch shaft piston rings and expan springs per instruetian on page 85. CONVERTER HOUSING DISASSEMBLY Figure 128 Remove reverse idler shaft frant capscrews Figure 123 Swaighnen lockplate tabs from reverse idler capscrews. NOTE: Some units wil have a kick nut tybe idle gear retertion, DDisacoembaly and roossembly of this type is cxpiainad in dail starting on page 47, Figure 221. For ReMode! front end, 302 Figure 126 , page 59, Figura 14, Romove roverse idler gaar and bearing aeceritly —22-Figure 127 Remove forward shaft pilat hesring, Figure 130 Recommended procedure for removing bearing, Figure 128: / Using spraader type snap ring pliers spread ears on the turbine shaft baaning snap ring. Tap turbine shalt from Figure 131 eonvarter housing. Hemove reaction member support capscraws, Figure 129, Remove cilaaling dng nd trite sha Bening eine Tap reeetion member support trom housing Figure 132 2Figure 133 Flemawe heating from suppart. Remove support oil sealing Hing end sealing ring wxpandar spring Figure 134 H reverse eluich piston ring sleeve isto he replaced, cemove 9 shown, CLEANING AND INSPECTION CLEANING Clean all paris thoraughly using solvent type cleaning laid. It is recommended that parts be urmersed in cleaning slate anal maved up and doven slowly until all old lubeicant ond loreign materiel is dissolved and parts are theroughly cleaned. CAUTION: Cure should bo gxorised to aveid skin rashes: fire hazards and inhalation of vapors when using Salvent type cleaners Boaringe Remove bearings from cleaning fluid and strike larger side af cone fiat against a block of wood to dislodge solidified particles af lubricant. Immerse again in elesning —24— fluid t0 flush.ovt porticles, Repest above operation until bearings are tharcughly lean. Ory baannas using moist unefeee compressed air. Be careful ta direct vie stream aerags bearing to avout spinning. Oo not spin bearings when drying. Bearings may be rotated slawly 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 tans with mild alkali=olations providing these parts do not have ground or polishes aurfaces. Parts should ramain in solution long enough to be thoroughly cleanad and heated, This will aid the evaporation of the cleaning solution and nse water. Parla cleaned in solution tanks must bo thoroughly rinsed with clean water to remove all traces of alkali, Cast parts may also be cleaned with steam cleaner. CAUTION: Care should be axercised toavoldiskin rashes and inhalation of vapors when using alkali cleaners. All parts cleanodt must be thoroughly driad immediately by using mosture-free compressed air or soll. lintless absorbent wiping rage free of abrasive materiale such as motal Flings, contaminated oll ar lapping compound. INSPECTION ‘The importance of eavoful and tharough inspection of all parte cannat be oversteassad. Replacement of all parts shawing indication ef wear or sirass weil eliminate costly and aveidable failures at a later date, Bearings Carefully inspect all roliess. cages and cuss tor wear chipping oF nicks to determine finess of bearings tor further use, Do not replace a pearing cone or cup indivice ally without repineing the mating cup-oF cone at the same time, After inspection, dia bewings in cleen light oil and \wrap in clean lintiegs cloth or paper to protect them until installed Oil Seals, Gaskets and Retaining Rings Replacement ot spring load ol seals, "Q" rings, met sealing rings, gaskets and snap rings ss more economical when unit is disessembled than premature overtaul 19 Teplace these parts at a future time: Further loss of lubricant through ¢ worn seal may result in failure of other more expansive parts of the assembly. Sealing members should be handied carefully, perticularly when being installed Costing, seratching. oreurling under of lip of seal seriously impairs its efficiency. Apply a thin coatat Permatex No, 2 on the outer diemeter of the oil seal toassure an oil tighttit into the retainers When assembling aew metal type sealing rings, same should be lubricated with coat of chassis fprease to stabilize eings in their grooves for esse of Sssemoly of mating members. Lubricate all "O" rings and saais with recommended type Automatic Transmission Fluid before assembly Gears and Shafts f magna-flux process i paris, Examine ‘eath on all available, ure process to. chack 98ars carefully for weae, pitting,chipping, nicks. crecks or scores. I gear teeth show spots wevere case hardening i weer through or cracked. replace wath new gear. Small nicks may be removed with suitable hone, Inspect shalts and quills to make certain they are nat spring, bent. or splines twisted, and that shafts are trus. Housing, Cavers, t housings. covers aad bearing caps to be certain ey are thoroughly cleaned and that mating surfeces, bearing bores, etc, are free Irom nicks or burrs. Check oll paris earatully for evidence of cracks or condition which would c&us# Subsequent oil leaks or Failures, For convortar housing with locknut type idiar shaft, see Page 48 Figuee 228 REASSEMBLY (Converter Housing) Figure 137 i}, ": . Position support in genverter Aousing aligning holes of Suppor! willy housing Figure 195 Inatall reverse clutch pistan ring sleeve in housing Figure 138 Tap support into: position Figure 136 Install new sealing ring expanderspring and oil sealing ring on support. Expander apring qap to be 180° from sealing Figure 139 ring hook jaint. Press support bearing into position. NOTE: Tighten support holts 23 to 25 ft Ibs, torque [31,2 - 2.9 Bearing part number must be up. Nm -25—Press turbine shaft bearing into position. Install bearing washer and retainer sing Inetall new turbine chaft orl sealing sing. Figura 141 Spread airs on turbine shalt beat ing located in reaction member support. Tap turbina shalt into pesitien Figure 142 Pross idler gear bearing or shaft. Install shaft and bearing in idler goa. Postion eparer on shut, press basting on aha nia gear. NOTE: See Figure 228 for lock out type idir shaft retantion Figure 143, Position reverse idlor and bearing assembly into converter housing. NOTE: Lang hut of gear out, Figure 14 Install reverse idler shaft capscrews and lockweshers, Tighten 58 to 84 ft, bs, torque [78,6 - 46.8 Mm.) ~26- Install bearing retainer plate, lock plate and idler gear copscrews, Tighten capscrews 58 ln 64 ft. Ibs. torque [78.6 - 86,8 N.m.]. Bend lockplate tabs over capscrews heads te prevent loosening,TRANSMISSION REASSEMBLY Figure 146 resard clutch shalt rear bearing into bearing bore with 19 ring taward front af housing, forward slutch shatt piston ring sleeve vith groove in housing. Tap sleeve inte position and seeure with sleeve retainer ring. Figure 149 Fosition fenward shaft gear on shaft g Figure 147 Position jonvard clutch assembly into transmission Figure 180 housing, Use caution as nat to damage (arward shaft piston Install gear reteiner ring, See Figure 160-4, tings, Figure 148 Top clutch axgerbly inte gestion, Figure 150-8 —27-igure 151 If 3rd speed clutch «aar bearing carrier was disassembled press beating inst lacating ing. Se 3rd speed ch into bearing and scare mth retainer ring Position dist hus and beoting carrier on 3rd seecd clutsh, Figure 152 Align splines on disc hut with i inclutch, Do not farce this operat be in full position with internal teeth of all f Itoeth af friction discs Diss hub splines must ns Figure 153 Position the 3rd clutch trant basring locating ring on clutch ‘assembly, Ring will be installed in hausing ring groove lever lon the text Figure 154 Using contacting type snep ring pliers as shown, lack pliers © hold ring contracted. Tap rd speed clutch assembly and beating carrigr ime housings until sry rinse pu in housing is aligned with snap ring. Remove pliers being sure snap ring is in full position in snap ting groove, Figure 155 Position sump oil baie in housing, Soe page 79 for € spead ut pur installtion, Figure 156 Install output shaft and bearing assembly in housing.ihe From front of housing install 3rd speed elutch front b retainer ring. NOTE: Be certain ring isin full position From front of housing install 2nd speed clutch disc hub en low clutch shat Figure 160, Install dise hub eetainer ring Figure 158, Figure 161 From rear of housing position low speed clutch in bearing stall front output flange, naw “O" ring, washar and nut bore, Tap eluteh in place, Tighten 200 49 260 4, lbs. torque (271.2 » 338.0 Nn] -29-fo Sonvemenr (errr St) be Vom Figure 162 Figure 165 diet shaft and bearing assembly in end of ich, NOTE: He pecial low ratic is incorporated, the ‘shalt will have Two gears on Hl. (UNL shawn is & standard rate) Love shalt oil sealing sing sizing tont, Figure 166 install new oil sealing ring on low clutch shaft Figure 163 -d botars installing low shaft Pasitian low cluich reer bearing an shalt, with snap ring bs ‘@ sizing, tool can 52 made from jpraove put Figure 164, Figure 167 Tap bearing into position lnstall low shaft rase bearing spacer — a0Figure 168, Install Bearing retainer ring Figure 169 Position new gasket aod “Oring on rear of transmiasio hrouginig. A thin coat of chassis greese wil hold the gasket ‘OF ring in placa, Install rear caver Note two aligning studs to facilitats caver to housing assembly. Tap cover in place aligning shalt hearings with tearing bores, Remove studs and install caver bolts and lockwoshers Figure 170 Tighten rear cower bolts 47 to 41 Ins. torque [50,2 - 85.6 Nm) -31— Figure 171 Install jaw, idler and ougput shaft rear bearing loceting cing. Figure 172, Apply a light coat of Permatex No. 2 to the outer diametar of upto seal. Pres roward baaring side of bearing cap. Po! Gn bearing cep. NOTE: Some units will have = gasket only Between the esp and cover £ Z Figura 173 Instol loakiwsahaes and stud nuts, Tiphter 91 te 102 th, tbs, torque (123.4 = 135.6 Nm.Figure 174 Install autput flange, "O” ving, wehar and flange nut. Black lange to prevent turning. Tighten flange aut 200 to 250% Ibs. torque [271.2 - 338.0 N.m Figura 175 Position new" Q" ring an ilershatt bearing cap. Install brain fa Dh CHECK POINTS A & D SHOULD BE MONITORED By _ GAUGES LOCATED IN OPERATORS COMPARTVENT. CHECK POINT "A" CLUTCH PRESSURE Ws NPT CLUTCH PRESSURE 180 TO 220 PSI [1281 - 1516 kPa}, _— FWD. (CONSTRUCTION HOLE ONLY} TRANSMISSION FWD CLUTCH PRESSURE PORT (i NPTF) SRO [8 NPR) 2ND TRANSMISSION REV. CLUTCH PRESSURE PORT [i NETF) THESE PORTS ARE PROVIDED FOR INSTALLATION OF BACK-UP WARNING LIGHT PRESSURE SWITCH OR HORN 1st (LOW) DRAIN aaaSUMP SCREEN CHECK POINT "H" LUBE PRESSURE i PTF 1525 P51 [108 - 172 kPa] a BO00 APM & 140° - BO0° F (Be, 2-85.3* C] AF CONVERTER OUTLET. TO LUBE FROR COOLER HOSE LINE OPERATING REQUIREMENTS 1. PRESSURE LINES AMBIENT TO 250° F [121* C] FOR CONTINUOUS: OPERATION. MUST WITHSTAND 300 PS. [2068 KPa] (CONTINUOUS OPERATION WITH 600 PS: [$197 KPa SURGE PRESSURE. REF SAE 100R! HYDRAULIC HOSE 2 Olt SPECIFICATIONS ‘SEE CLARK DWG NO. 236647 FOR CLARK RECOM. MENDATIONS FOR USE IN TORQUE CONVERTERS 8 POWER SHIFT TRANSMISSIONS 3. ALL HOSE LINES USED MUST CONFORM TO SAE SPEC NO. SAE J1019 TESTS & PROCEDURES FOR HIGH-TEMPERATURE TRANSMISSION Ol HOSE, LUBRICATING OW. HOSE & HOSE ASSEMBLIES. 18000 SERIES-3 SPEED LONG DROP CLUTCH AND GEAR ARRANGEMENT = 45—2 eA TRANSMISSION TO ENGINE INSTALLATION PROCEDURE Remove all burrs from flywheel mounting face and nove pilot bore. Clean drive plate surface with solvent, ‘Check engine flywheel and housing for conform- anza te standard S.A.E. #3 -5,AE, J-927 tolerance specifications for pilot bore size, pilet bore runout and mounting fate flatness. Messure and record engine erankshatt end play. Install two 2.50 [63, 50mm] long transmission to flywheel housing vide studs in tho fy. wheel housi shown, Rotate the engine flyeheo! to align a drive hole with the flywheel! housing access hole. Install 2 4.00 (101, 60 mm] long drive plate locat ing stud .3750-24 fine thread In a drive plate nut. lfgn tho locating stud i the drive plate seth the flywheo! drive plata mounting screw hele ps Honad in step No. 3: Locate transmission on flywheel housing aligning drive plate to flywheel and tranemistion te fly- wheel housing. NOTE: Fig. 4 installation, align deive plato holes with flywheel studs Install trammission fo flywheel housing screws. Tighten screws to specified torque, Remove trans: mission to engine guide studs. Iastall remaining screws and tighton to specified torque, Romeve drive plate locating stud. Install drive plate attaching screw and washer. Snug screw but de nat tighten, NOTE: Fig. 4 stallation, install plate aiteching washers and nuts. Tighten each nut 28 to 30 ft, lbs, torque [38.0-40,6 Mimi, Some engine flywheel housings have a hole located on the flywheel havsing cir ‘with the drive plate screw access hole. A screwdriver or pry kar vsed to hold the plate against the Fiywheel will fecilitate in- fon of the drive plate screws, Rotate the en gine flywheel and install the remsining seven (7) Flywheel to drive plate attaching screws. Sug screws but da not tighten. After ail eight (8) screws are installed torque each one 25 to 30 fi. Ibs. torque [33,8-40,6 Nom, This will require torat serew and rotating the engine flywhee! amount of eight 1B} screws have been Meesure engine crankshaft end ploy afer transmis: sion has been completely installed on engine fly- wheel. This value must be within 01 [0,025mm] Gf the end play recorded in step No. 2 2 Does not apply te units having 3 Intermediate drive plots. See Fig. =46—909 1 - ker Gear Shatt 2 Shaft “O” Ring \ \ 8 ees 1 |S idler Gear Bearing Assembly 8 - Bearing Spacer 7 idler Shaft Lack Nut 2 Idler Gear DISASSEMBLY AND REASSEMBLY OF LOCK NUT TYPE IDLER SHAFT DISASSEMBLY Figure 221 Unolinch lack nut by etrightening upset matal in notch in idler shalt. Remowe idler shatt rut, aaFigure 226 Remove bearing spacer Figure 223 Remave idler gear and auter taper besring from idler shat. ‘ ‘he woe ? = Figure 227 Remove idlat shaft, use caution af not to lose: shaft lock Bll eter se page 23 tor further disassombly Figure 224 REASSEMBLY OF LOCKNUT TYPE Remove besring spacer IDLER SHAFT. ay Figure 228 Figura 225 With raw 0” ring on shatt, pasion idler shaft ant lock bell i Remove innor taper bering, corworter housing, Tap ¢haftinco position. Note lock balFigure 229 Figure 232 Install reverse ilar shalt spacer. Figure 230 Figure 233 {install inner taper bearing on shaft with large sliametar of tapar Install igtar gear outer taps beating with urge diameter of taper sown, up Figure 231 Figure 234 Position bewing spacer on shaft Position outer spacer on shatt.Figure 235 Install retainer nut and tighten rut 200 - 260 ft, Ibe. torque la71.2- $38.8 nl Ht the turbine of turbine hub was replacad or dis: assembled, this pracedure must be usad for reassembly, TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS 1. Clean hut mounting surfuee and tapped holes with ‘goivent. Dry thoroughly bing certain topped holes are dry end lean, 2. Install Backing sing and spectal screws to approximstaly 0B [1.61 of seated position, With @ calibrated torque wrench, tighten screws 37 ta 41 ths, ft torque (50.2 - 58,6 Nn| NOTE: Assembly of turbine hub must be complated ‘within » fifteen minute petiod Irom srt of screw instalation, Tha sarews are prepared with 8 costing which bagine to herdon after installs: ton thehub holes, I not tightened to proper torque within the en minute period, insufficient screw clamping result Thespecial screw is tp be used for one instal the screw is tomoved for sny reason rt must be replaced. Tha ‘compound [oft in the hub holes must Be rermoved with the pro- ft tap and-slaanad with salvert, Dry hole thoroughly and use a ews serew tor rainatalapon, Figure A Figure 238 Stake rut securely in shat notch, Figure B igure C18000 SERIES TRANSMISSION AND C2000 SERIES CONVERTER DRIVE PLATE KITS Proper Identification by Bolt Circle Diameter Measure the " dimension (Bolt Circle digmeter} and order Drive Plate: Kit listed below. Note four (4) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Two (2) kits ‘with three intermediate drive plates, ~ = ALIGNMENT HOLES. ro RTEAWEC ATE “AY Dimension (Bolt Cirele Diameter) “&* Dimension (Bolt Cirele Diameter) 111.38 (288,300 mm] Diameter Kit No, 802229 13.12" (333,375 mml Diameter 1312" ($39,375 mmm] Diameter kit Na, 802730 kit No, 802388 13.50" (942,900 mm! Dimeter 13:50" ($42,900 mm] Diameter Kit No. 802231 it No. 808332 17.00" (431.800 mm! Diameter Kit Na. 802358 Each Kit wall clude the following parts: 3 Imermodiote Drive Plates Esch Kit will include the following parts 2 ere 2 Intermediate Drive Plates 1W Screw andl Lockwesher Assembly 1 Drive Plate and Weld Nut Assembly 1 Instruction Sheet 1 Backing Ring, 10 Serew and Lockwasher Assembly, NOTE: Some div plates and backing rings will hav 1 Instruction Sheet. fourteen (141 mounting holes. Onty ten (10) meuiting elias will be used TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES — SEE ILLUSTRATION ABOVE Position drive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plote and backing ring with holes. impeller cover. NOTE: Two dimples 180° apart n Backing ring Mist be Out Froward engine tfywhael|. Install capecrewes andl washers, Tighten 23 to 25 lott tore (31,2. 33.8 NL Ser page 48 for transmission ta engine instalation procedut -s1