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    32000 R and HR 3, 6, & 8 LD

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    20 views156 pages

    R and HR 3, 6, & 8 LD

    Uploaded by

    HERNAN

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Maintenance/Service Manual LM Cefol dele) eae UCL) R & HR MODEL Peek Oc ona LONG DROP SPICER OFF-HIGHWAY COMPONENTS ‘TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the rear wheels off the NOTE: If the transmission has 4 wheel drive, disconnect both ‘ground or disconnect the driveline to avoid damage to the trans- front and rear drivelines. Because of the design of the hydraulic ‘mission during towing. system, the engine cannot be started by pushing or towing. (©Copyright Spicer Of-Highway Products Division 1987 Unpublished material «All ghts reserved « Limited distbuton No part ofthe work may be reproduced in any form under any means without direct written permission of Spicer Of-Highway Products Division FORWARD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF-HIGHWAY COMPONENTS DIVISION product. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated with be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only Spicer Off-Highway Components Division-approved parts as listed in the applicable parts manual should be used. Use of ‘willsit” or non- approved parts may endanger proper operation and performance of the equipment. Spicer Off-Highway Components Divison does not warrant repair or replacement parts, nor failures resulting form the use of parts which are not supplied by or approved by Spicer Off-Highway Components Division. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts. TABLE OF CONTENTS HOW THE UNITS OPERATE. ‘SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Silhouette Converter Group... Converter and Transmission Case Group.... Reverse and 3rd and Forward and 2nd Clutch Group......nersnmFig. D Low (1st Clutch) and Output Group. Fig. E Regulating Valve, Charging Pump and Filter Group. Fig. F Control Valve Assembly. ‘Axle Disconnect and Mechanical Parking Brake... ‘Assembly Instruction Illustration HR32000 3 Speed Typical Cross Section DISASSEMBLY OF TRANSMISSION... REASSEMBLY OF TRANSMISSION. .......000000000 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL. 56 SPECIFICATIONS AND SERVICE DATA.. LUBRICATION... TROUBLE SHOOTING GUIDE.........-.. a oe 5B 16 SCREW RING GEAR INSTALLATION. TYPICAL THREE SPEED POWER FLOW... HR EXTERNAL PLUMBING DIAGRAW... CLEANING AND INSPECTION... SPEED SENSOR BUSHING INSTALLATION... 82 SCREW RING GEAR INSTALLATION.... R-MODEL SECTION. 6 &8 SPEED SECTION....... 8 SPEED SECTION. a DRIVE PLATE INSTALLATION. 98 ELECTRIC CONTROLS... 100 NOTE: Metric Dimensions Shown in Brackets} TRANSMISSION ASSEMBLY The transmission and hydraulic torque portion of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to first understand their funetion and how they operate. The transmission and torque converter function together and operate through a common hydraulic system, IW is necessary to consider both units in the study of their function and operation. To supplement the text below, and for reference use therewith, the following illustrations are provided: Basic Design Sithouette Converter Group Converter and Transmission Case Group Reverse and 31d, Forward and 2nd Clutch Group Low (Ist) Clutch and Output Group Regulating Valve, Charging Pump and Filter Group Control Valve Assembly ‘Axle Disconnect and Mechanical Parking Brake ‘Assembly Instruction Ring Gear Installation Clutch and Gear Arrangement ‘Three Speed Power Flow Extemal Plumbing The R, HR, and MHR Model Transmissions are of three bi designs. The R Model consists of a separate torque converter, mounted to the engine with the powershift trans- mission remotely mounted and connected to the torque converter with a drive shaft. The HR Model consists of a torque converter and powershifted transmission in one package mounted directly to the engine. The MHR version is @ mid-mount torque converter end transmission assembly connected to the engine by means of # drive shaft. (See Fig. A for basic design silhouette.) The shift control valve assembly may be mounted directly on the side of the converter housing or front transmission cover, or remote mounted and connected to the transmission by means of flexible hoses. The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutch. A provision is made on certain models to neutralize the transmission when the brakes are applied. This is accomplished through use of a brake actuated shutoff valve. The speed and direction clutch assem: blies are mounted inside the transmission case and are connected to the output shaft of the converter either by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power flow through the r train to provide the desired speed range and direction. ‘An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can be disconnected or connected by manval shifting, HOW THE UNITS OPERATE With the engine running, the converter charging pump draws cil from the transmission sump through the removable oil suction screen and direets it through the pressure regulating valve and cil filter. The pressure regulating valve maintains pressure to the transmission control cover for actuating the d tion and speed clutches. remaining volume of oil the transmission for posith in a closely fitted bor ‘This requires a small portion of the total volume of oil used in the system. The a por directed through the torque converter circuit to the oil cooler and returns to lubrication. This regulator valve consists of @ hardened valve spool operating The valve spool is spring loaded to hold the valve in a closed position. When a specific pressure is achieved, the valve spool works against the spring until a port is exposed along the side of the bore, This sequence of events provides the proper system pressure. After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to a fitting on the transmis Then through @ series of tubes and passages lubricates the transmission bearings and clutches, The oil then gravity drains to the transmission sump. The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com- ponent which starts the oil flowing to the other components which results in torque multiplication. This el- ement can be compared to a centrifugal pump in that it picks up fluid at Its center and discharges at its outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the par ction member is the means by which the hydraulic torque converter multiplies torque. lar design of blading in the turbine and The reaction member of the torque converter is located between and at the center or inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. The torque converter will multiply engine torque to its designed maximum multiplication ratio when the out- put shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing. ‘The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring in the selector spool provides 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. With the engine running and the directional control lever in neutral position, cil pressure from the regulat- 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 either the forward or reverse clutch as deéired. 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 selector. The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hy- dravlically actuated piston. The piston is “oil tight” by the use of sealing rings. A steel dise with external splines is inserted into the drum and rests against the piston. Next, 2 friction dise with splines at the inner diameter is inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A Hub with O. . splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direc- tion as long as no pressure is present in that specific clutch. To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows il under pressure to flow from the control valve, through a tube, to a chosen clutch shaft. This shaft has a drilled passageway for oll under pressure to enter the shaft. Oil pressure sealing rings are located on the clutch shaft, These rings direct oil under pressure to a desired clutch. Pressure of the oil forces the piston and dises against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against dises with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows them to drive as a unit. There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston is released. R-32000 HR-32000 MHR-32000 FIG. A Figure B HR32000 CONVERTER GROUP Tem DESCRIPTION ary. 1 Bearing Support Screw 6 2 Bearing Support Screw Lockwasher... 6 3 Drive Gear Snap Ring ... 3 4 Pump Drive Gear Bearing 3 5 Pump Drive Bearing Support. 3 6 Pump Drive Gear 3 7 Turbine Shaft Gear. ‘ 1 8 Turbine Shaft Gear Snap Ring . 1 9 Charging Pump Drive Sleeve. 1 10 Pump Sleeve Snap Ring ... 1 11 Valve to Housing Gasket..........++ 1 12. Valve Body “O" Ring.........-+ 1 13. Valve Body “0” Ring 1 14 Charging Pump& Oil Filter Assembly... 1 16 Valve Body “O" Ring... 1 16 Turbine Shaft Bearing .. 1 17 Turbine Shaft Piston Ring z 1 18! Turbine SHAR soa ue os enaisa as em aaa 1 19 Stator Support ooo... eee eeeveeeees 1 20 Stator Support Screw Lockwasher 6 21. Stator Support Screw. 6 22. Piston Ring.. 1 23. Piston Ring Expander Spring 1 24 Impeller Hub Gear Snap Ring 1 25 Impeller Hub Gear 1 26 Oil Baffle Oil Seal............... 1 27 Oil Baffle Seal Ring . 1 28 Oil Baffle...... 1 29. Oil Baffle Retainer Ring............+ 1 ITem DESCRIPTION arty. 30 Hub to Impeller Screw. .. 31 Impeller Hub Screw Backing Ring.... 1 32 Impeller 1 33. Impeller Hub “O” Ring .. 1 34 Impeller Hub 1 35. Impeller Hub Bearing 1 36 Bearing Snap Ring 1 37. Reaction Member Spacer ........ 1 38 Reaction Member..............5 1 39 Reaction Member Snap Ring ..... 1 40 Turbine Hub........0.c.esceeeeeee 1 AV TUBIRE cr ocx ewiennas a2 1 42. Turbine Hub Backing Ring .......... 1 43 Turbine Hub Screw .........eeceeee B 44 Impeller to Cover “O” Ring....... 1 45. Impeller Cover 1 46 Impeller Cover Bearing 1 47 Bearing Cap to Impeller Cover “O” Ring 1 48 Bearing Washer ..........000ee000e 1 49 Bearing Snap Ring.......-.....000. 0 1 50 Impeller Cover Bearing Cap. 1 51 Impeller Cover Sleeve ..............01 52 Ring Gear Screw ........ 16 53 Plain Washer.............. - 16 54 Flywheel Ring Gear...... 1 55 Bearing Cap to Impeller Cover Screw... 10 56 Bearing Cap to Impeller Cover Screw Lockwasher. . 57 Impeller to Cover Screw ..........6. 24 58 Impellerto Cover Screw Lockwasher... 24 Figure HR32000 CONVERTER & TRANSMISSION CASE GROUP ITEM DESCRIPTION ary 1 Pipe Plug....2..2.222 ce 1 2 Converter Housing Assembly. 1 3 Converter Housing to Front Cover Screw Lockwasher 12 4 Converter Housing to Front Cover Screw. 12 5 Tube Sleeve. 1 6 Tube Sleeve. 1 7 Converter Housing Sleeve 1 8 Converter Housing Sleeve Lock. 1 9 Converter Housing Sleeve Screw Lockwasher 1 10 Converter Housing Sleeve Screw 1 11 Converter Housing Sleeve Screw. 1 12 Converter Housing Sleeve Screw Lockwasher. 1 13 Converter Housing Sleeve Lock 1 14 Converter Housing Sleeve 1 15 Breather 1 16 Street Ell 1 17 Breather Reducing Bushing, 1 18 Tube Sleeve... 3 19° Pipe Plug 1 20 Converter Housing to Transmission Housing Screw Lockwasher 4 21 Converter Housing to Transmission Housing Screw.......s.sccee+ 4 22 Converter Housing to Transmission Housing Lockwasher. 4 23 Converter Housing to Transmission Housing Screw. 24 Lube Tube Retaining Screw Lockwasher. 25 Lube Tube Retaining Screw. 28 Suction Tube “O" Ring RSESSEVSSYSRESKRESBBY 4 1 1 1 ‘Suction Tube Spacer Ring. 1 Suction Tube Assembly. 1 ‘Suction Tube Retainer Screw Lockwasher. 1 ‘Suction Tube Retainer Screw 1 Tube Clip Screw. 1 Tube Clip Screw Lockwasher 1 Tube Clip... 1 Reverse Tube Assembly 1 Reverse Tube “O" Ring 1 Lube Tube Retainer Screw. cose 1 Lube Tube Retainer Screw Lockwasher 1 Lube Tube Assembly. 1 Tube Clip Screw. 1 Tube Clip Screw Lockwasher: 1 Tube Clip. 1 3rd Speed Tube. 1 3rd Speed Tube “0” Ring. 1 Valve Oil Supply Tube. 1 ITEM DESCRIPTION 45. Clutch Pressure Tube “O” Ring 46 Tube Sleeve. 47 Low Speed Clutch Pressure Tube. . 48 Transmission Case to Converter Housing Screw Lockwasher. 49 Transmission Case to Converter Housing Screw. 50 Rear Cover Dowel Pin 51 Rear Cover 52 Rat Cover to Transmission Case Screw Lockwasher. : 83 Rear Cover to Transmission Case Screw. 54 Rear Cover Pipe Plug, 55 Rear Cover to Case Stud Nut 56 Rear Cover to Case Stud Lockwasher. 57 Clutch Pressure Tube "0" Ring, 58 Tube Sleeve. 59 Rear Cover to Transmission Case Gasket 60 Rear Cover to Case Stud 61 Magnetic Drain Plug, 62 Oil Level Plug 63 Oil Level Plug... 64 Transmission Case Assembly 65 Screen Assembly Gasket 65 Screen Assembly 67 Suction Tube. 68 Suction Tube Clip Washer 69 Suction Tube Clip. 70 Suction Line Screw. 71 Suction Line Washer 72 Suction Line “0” Ring 73 Suction Tube Clip Rivet, 74 Converter Housing to Transmission Case Gasket 75 Oil Battle 76 Converter Housing Adaptor Ring 774th Speed Pressure Tube “O" Ring 78 — Low Speed Pressure Tube “O" Ring. 79 Converter Housing to Transmission Case Gasket . 80 Converter Housing to Transmission Case Spacer (12 plate clutch pack only) 81 Front Cover Oil Seal 82 Converter Housing Front Cover. 83 Converter Housing Front Cover Gasket. 84 Hose Fitting 85 Hose Assembly 86 Hose Fitting ITEMS 81 THRU 86 FOR MHR ONLY. ary 10 ITEM DESCRIPTION 1. Reverse & 3rd Clutch Shaft Piston Ring 1A. Piston Ring Expander Springs 2. Front Bearing Retainer Ring .. 3. Reverse & 3rd Shaft Front Bearing End Pate 4 Reverso & 3rd Shaft Bearing End Plate Bal. 5 Reverse & 3rd Shaft Front Bearing 6 Front Bearing Retainer Ring 7 Clutch Driven Gear Bearing - Shield in 8 GutchDrven Ger Bering San 9 Clutch Driven Gear... 10 Clutch Hub Oil Baffle Ring 11 Spring Retainer Snap Ring. 12 Clutch Driven Gear Bearing Snap Ring - 18 Clutch Driven Gear Bearing 14 Spring Retainer Snap Ring 15 Song Retr Srp Rng Reta 16 Spring Retainer . 17 Piston Return Spring 18 Spring Retainer. 19 End Plate Retainer Ring 20 End Plato- Reverse Clutch SRRHFLSLSLSRERSLSBBSBRVBR R OR HR32000 REVERSE & 3RD & FORWARD & 2ND CLUTCH GROUP Clutch Outer Dise- Reverse Clutch Clutch Inner Dise - Reverse Clutch Clutch Piston Assembly - Reverse Clutch Clutch Piston Outer Seal Clutch Piston Inner Seal Reverse f 31d Clutch Drum CCutch Piston Inner Seal Clutch Piston Outor Seal... Clutch Piston -3ed Clutch Clutch innar Diso 3rd Clutch Clutch Outer Disc-3rd Clutch ... End Plate - rc Clutch End Plate Retainer Ring Spring Retainer Piston Return Spring Spring Retainer ‘Spring Retainer Snap Ring Retainer ... ‘Spring Retainer Snap Ring 3rd Gear Bearing . ‘3rd Gear Bearing Snap Rng ‘Clutch Hub Oi Baffie Ring 3rd Gear... ‘3rd Gear Bearing Spacer » ‘3rd Gear Bearing Snap Ring ‘3rd Gear Bearing - Shield Out Reverse & 3rd Shaft Rear Bearing arty ITEM 47 B®SSSVISRSRRVSYSVAAPANYSISSIBRAGRIBSRISALBRISSS DESCRIPTION Low Clutch Drive Gear Gear Retaining Ring 2nd Gear CClutch Hub Oil Baffle Ring 2nd Gear Retainer Ring 2nd Gear Retainer Ring Retainer - 2nd Gear Retainer Ring Retainer Snap Ring Spring Retainer Snap Ring Sosa Redo Soap Png Par Spring Retainer Fiston Return Spring . Spring Retainer End Plate Retainer Ring End Plate 2nd Clutch CClutch Outer Dise- 2nd Clutch Clutch Inner Disc-2nd Clutch (Clutch Piston Assembly -2nd Clutch. (Clutch Piston Outer Seal Clutch Piston Inner Seal Forward & 2nd Clutch Drum Clutch Piston Inner Seal (Clutch Piston Outer Seal CClutch Piston Assombly - Forward Clutch . (Clutch Outor Dise - Forward Clutch ‘Clutch Inner Disc Forward Clutch. End Plate Forward Clutch End Plate Retainer Ring Spring Retainer Snap Ring Spring Retainer Piston Retun Spring . Spring Retainer coe ‘Spring Retainer Snap Ring Retainer Spring Retainer Snap Ring Clutch Driven Gear Bearing... ‘Clutch Driven Geer Bearing Snap fing « ‘Clutch Hub Oil Baffle Ring Forward Cluteh Driven Gear Clutch Driven Gear Bearing Snap Ring .. Clutch Driven Gear Bearing -Shield In Front Bearing Retainer Ring. "3 Front Bearing Locating Ring Forward & 2nd Shaft Front Bearing Forward & 2nd Shaft Bearing End Plate Ball. Forward & 2nd Shaft Front Bearing End Pate Front Bearing Retainer Ring Forward & 2nd Shaft Piston Ring 924 Piston Ring Expander Springs aty Figure E R OR HR32000 LOW (1ST) CLUTCH & OUTPUT GROUP ITEM DESCRIPTION 1. Low Speed Clutch Shaft Pilot Bearing 2 2nd Gear Bearing End Plate 32nd Gear Bearing 44 Bearing Retaining Ring Retainer 5 Low Speed Gear Bearing Retainer Ring 6 Low Speed Gear Bearing Assembly 7 Low Speed Gear 8 Clutch Hub Oi Bate Ring. 9 Spring Retaining Ring Retainer . 10 Spring Retaining Ring 11 Piston Return Dise Springs 12. Piston to Piston Return Disc Springs Spacer. 13. End Plate Retainer Ring 14 End Prato 15 Clutch Inner Disc 16 Clutch Outer Dise 17 Clutch Piston 18 Clutch Piston Outer Seat 19 Clutch Piston Inner Seal 20 Low Speed Clutch Drum SSESSIBRKSRVSRBBVBRRGRY Low Speed Shaft Rear Bearing Bearing Lockball Rear Bearing Retainer Plate . Rear Bearing Retainer Plate Screw Fear Bearing Cap Gasket Fear Bearing Cap Rear Bearing Cap Screw Lockwasher Rear Beating Cap Screw Rear Bearing Cap Plug Rear Bearing Cap “0” Ring Clutch Shaft Piston Plug Low Speod Shaft Rear Bearing Locating Ring Bearing Cap Screw Lockwasher Bearing Cap Screw Bearing Cap Screw ... Bearing Cap Screw Lockwasher Idler Shaft Bearing Cap ....... Ider Shaft Bearing Cap Gasket . Idler Shaft Nut . Rear Bearing Locating Ring... Idler Shaft Rear Bearing Lockball... ary ITEM DESCRIPTION 42 Idler Shaft Rear Bearing... 43 Rear Bearing Cap Oil Sez 44 Rear Beering Cap Screw - 45 Rear Bearing Cap Screw Lockwasher 46 Rear Bearing Cap . 47 Rear Bearing Cap "0" Ring - 48 Rear Bearing Cap “0” Ring 49 Rear Bearing Cup. 50 Rear Bearing Cone 51 Output Shaft Gear 52 Output Shaft Gear Spacer . 53 Output Shaft 4 Front Bearing Cone 55 Front Bearing Cup . 56 Front Beating Cap "0" Ring 57 Bearing Cap Shim 88 Front Bearing Cap... 59 Front Bearing Cap Oil Seal. 60 Front Bearing Cap Screw... 61 Front Bearing Cap Screw Lockwasher 62 Bearing Retainer Ring. 63 Bearing Locating Ring . 64 Idler Shaft Front Bearing 65 Idler Shaft 66 Idler Shaft Gear Key 67 Idler Shaft Gear 68 Bore Plug (option) 69 Disconnect Assembly optional. . 70 OilSeal 71 Output Flange 72 Output Flange "0" Ring 73 Output Flange Washer. 74 Output Flange Nut 75 Speedo Drive Gear 76 Rest Beating Cap 77 Ree Bearing Cap Screw Lockwasher 78 Roar Bearing Cap Screw 79 Speedo Driven Gear. 80 Speedo Tube Nut 81 Rear Bearing Cap Screw 82 Rear Bearing Cap Screw Lockwasher ary. AR ITEM DESCRIPTION ary. 1 eooawraaron W 12 13 14 15 16 7 18 19 20 21 22 23 24 25 PRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP Charging Pump Drive Sleeve. . Pump Sleeve Snap Ring ...... Valve to Housing Gasket......... Valve Body “O” Ring.............05 Valve Body “0” Ring Pipe Plug........... Safety Valve Seat........ Safety Valve Spacer Safety Valve Plunger .. Safety Valve Spring... Valve Stop “O” Ring .. Valve Stop. .. : Valve Stop Roll Pin .... Valve Stop Roll Pin ....... Valve Stop. . Valve Stop “0” Ring . Valve Piston Valve Spring - Inner. Valve Spring - Outer .... Valve to Converter Housing Stud... . Valve Body to Pump Gasket .. Pump Body Snap Ring Thrust Plate & Bearing Assembly... Pump Driven Shaft Assembly... Charging Pump Housing .. ITEM DESCRIPTION 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 4 42 43 44 45 46 47 48 49 50 Valve to Housing Stud Lockwasher .. Valve to Housing Stud Nut......... Thrust Plate & Bearing Assembly Wave Spring. .. Pump Shaft Seal... Pump to Filter Adaptor Screw Lockwasher......... Pump to Filter Adaptor Screw. ...... Pump Drive Shaft Assembly ........ Pump Drive Shaft Oil Seal Pressure Regulator Valve........ Valve Body Roll Pin........ Valve Body “O” Ring....... Pump to Filter Gasket Filter Adaptor Filter Adaptor Plug. . By-Pass Filter Disc Spring........ By-Pass Filter Disc By-Pass Filter Disc Seat Filter Seat Retainer Ring Filter Housing “O” Ring. Oil Filter Element Assembly Oil Filter Element Spring........ Filter Housing.......... Pipe Plug. Optional Adaptor for Remote Filter ary. RRR RA s [ peciurci Naw} INCHING | _ Decwren i FORWARD & DECWUTCH REVERSE ONLY FORWARD. ON YAIVE ROTATED 90" (rey cer segura 2 nan te rane ‘CONTROL VALVE ASSEMBLY jamnectuten) Figure G CONTROL VALVE ASSEMBLY ITEM DESCRIPTION ary. ITEM DESCRIPTION ary. 1 Oil Seal.......... eae | 22 = Overshift Spacer (Not on allmodels).... 1 2 Oil Seal Retainer Ring..... 1 23 Oil Seal Retainer Washer ... acece F 3 Oil Seal Retainer Washer .........-. 1 24 Oil Seal Retainer Ring... 1 4 Forward & Reverse Valve Spool...... 1 25 Oil Seal. 1 5 Control Valve Gasket.............- 1 26 Piston Housing Assembly........... 17 6 Detent Spring........++ 1 27 Stop Plug . ¥ 7 ~~ Detent Spring...........+5 1 28 Plug Ring... 1 8 Detent Ball......... 22.00. 3 29 Piston “O" Ring .. 1 9 Neutral Switch ..... ee ae 30 Glyd Ring .. 1 10 Detent Ball 1 31° Piston .. seeeseeteeseeseeeeneee 1 11° Valve Housing Plug . ee ae | 32 Piston Housing 1 12. Valve Housing Plug “O” Ring........ 1 33 Oil Seal....... ale ws 4 13 Overshift Spacer(Not on all models).... 1 34 Band Seal .. 1 14 Control Valve Housing..... nena b 35 “O" Ring... 1 15 Detent Spring Plug. a Figures A-B-C & D are various declutch options. 16 Detent Spring Plug Washer. . x 44 Adaptor Screw .......... wees 4 17 Detent Spring... 1 45 Adaptor Screw Lockwasher. 4 18 Valve to Adaptor Housing Screw..... 9 AB! Vales, Adaptor ssiaisinnuse asec 1 19 Valve to Adaptor Housing Screw 47 Valve Adaptor Gasket ...........--. 1 POeh Wesel vir) 9 4a. Adaptor Screw sau B 20 Speed Selector Spool Plug.........- 1 oe 4 21° Speed Selector Spool .............+ 1 50 Valve Adaptor Plate.........+ 1 AXLE. DISCONNECT PARKING BRAKE (MECHANICAL Figure H ITEM DESCRIPTION 1 Disconnect Housing Capscrew. . 2 Disconnect Housing Capscrew Lockwasher . 3 Disconnect Housing... 4 Disconnect Housing Plug. 5 Shift Hub. 6 Shift Fork. 7 Shift Fork Lockscrew. 8 Disconnect Shaft... rrem DESCRIPTION 1) Lock Nut. 2 Washer... ceccscese 3. Operating Lever. 4 Backing Plate. 5 Cam Shaft 6 Strut Assembly... 7 Return Spring 8 Brake Shoe, Lining & Rivet. AXLE DISCONNECT ary 4 ITem 9 10 " 12 13 4 18 DESCRIPTION Detent Ball Detent Spring. Shift Rail Shift Rail Oil Seal........-. Bearing Retainer Ring Bearing... Bearing Retainer Ring PARKING BRAKE GROUP 10 X 3 BRAKE ary rem 9 10 " 2 13 14 15 16 DESCRIPTION Brake Flange Brake Drum Brake Drum Screw Lockwasher... Brake Drum Screw Brake Lining Rivet Kit. . Backing Plate Screw Backing Plate Screw Lockwashe ary Cie, i. I used wih 12 plate ‘modulation only View °a 1.94(94,0] 7 Figure | LX Inmpatier Hub and Turbing Hud Assembly with Backing Ring and Special Self Locking Servs. 1 Clean hub meuning surface and tapped holes with solvent. Dry thoroughly being certain tapped holes are dry & clean. 2 Intall backing ring and special sf locking Tighton serous 40 to 45 Los. Ft [54.3:6,0 Nem) Note: Assembly f hub must be compote within a ‘toon minuto geriod from start of screw installa tion, The spacial serow isto bo Used for one in Sstllation ony. fhe screw Is removed for any reason i must be replaced. The epoxy let inthe hub Roles must be removed wih the proper tap tnd cleaned wth salvat. Dry hele thoroughly and Ube & new screw for renstalation 2X Gear to be assembled with long hub length to this See A Three clutches 6-ouer ste plates. Banner fricton lates. Assemble alternately, starting wih outer Stoo plate. A\ 800 Elastic Stop Nut Toraue Chart AX Low cluteh.scuter sto! plats, 8.innor triton plates, Assombie stematey, staring with outer ‘Stel plat. AX S00 Elastic Stop Nut Torque Chart AX shim output shat bearings to produce 6 108 Lbs In 0.88-0.80 Nm preload AX Tagnten cil screen assy. 10 1015 Ls. 11382000 Nm), View "a" 2 Places Melaion ony Low Clutch Reem Springs ‘Concave sido of fat spring to be paoad AX Heat nose bushing to 2000 Fo (93%) before ass}. of bushing 1 cover 2X Bearing shield OUT on ad speed cute Boring shld Mon Fag 8 Rev, euten Must be lose intemal ft bears, No. “3” etched on bearing, A. 12pm tosuaen wo cera, ue stein, ‘dian ton pashan stay, aig wwe el pa Notes [A.- Use Permatex & Crane Sealer only where B. All loadin chamfors fot ol seal, piston rings & ‘0 rings must be smooth & free rom burs Inspect at ass'y. Lsbricate all paten ring grooves & "0" rings ‘with i Betore ass. . Appi very ight coat of Permatex No. 2 10 0.0. ofall of seals betore assy .. iter assembly of parts using Permatex ot ‘Crane soslor, there must not bo any too oF ‘excess material that could enter the of ccul. F. - Apply ight coat of Crane Sealer to all pipe plugs G.- Apply thin coating of grease between seal lips on lip type seats prior to assy ‘Apply light Goat of Permatex No. 2 to all vu ‘oto sud teas. NOTE: The ction discsinthelow clutch has ‘higher co-tetont rating than the ition ‘ses in the other eluiches, therelora he ‘ses must not ba mie, Tha low euth in- nor dszean beldontied byan "x" stampea ‘none side afte nner teeth The low catch inner sie also has a strp of non-eolubie {ell paint sprayed on the outer edge of the ise, Viow “R part euch piston. emainng fou singe TW be each atrmay revere ss shown Forward & Revers Cuch Ret Springs Concave side of tat sing to bo placed {gahst clitch piston, Reming 3 spngs teas teh oe sched atenotely tevsrsed es shown. See not on page 77 vi s* Enlarged view of Piston Fing & Expander Note: Expander gap te be approx. 160° Irom ring ‘hook Joint fo aid rng assorbly. ELASTIC STOP NUT TORQUE THAD Sze wrt wa] NOTE: Merc cimensions shown 2 a0 208 | ise er ‘r breckets [ie 00-20 | “aria = s089) Tr 8 00-350. “Hosa = 745) (See 100-450 = 610 Toraue Speciation for Lupicates _ race § Plate Sern Treaes Grace 8 ey |e TED GOARSE THREAD TNE THREAD COARSE THREAD, See | oer ny | weer wy || wer hu a con se [esa rose | ae] pre aa || ae ser [rae win | star] eee mo | Lees otal [or es | f rz9- 5a) [so oe | fiaats toe] | 0. an | ions ti] asf ste- oto) [ars at | [soa seal se ec | [rer se] se or || oes Tal ze | fasa- sea) [asa | (aie. aga |f oar | soa ses | a9 ae | | an Ee ETE SE | Figure | Figure J MAINTENANCE AND SERVICE ‘The instructions contained herein cover the disassembly and shafts with and without disconnect assemblies may vary on reassembly of the transmission in a sequence that would nor- specific models. The units are very similar to trouble shoot, mally be followed after the unit has been removed from the disassemble, repair, and reassemble, Drain as much oil as machine and is to be completely overhauled. It must also be possible before disassembly. See page 70 for R-Model understood that this is a basic HR32000 3 speed long drop (remote mounted) transmission front cover section, See page transmission with mary options. Companion flanges and output 85 for 6 & 8 speed maintenance information. DISASSEMBLY grea Figure 3 io ; na Remove filter element housing and element. NOTE: Its recom- SiGe ee ot 9 spond HRG2000 lone cho tarsi’ ‘mended a small pan be used to catch remaining oil in element housing, Figure 2 Remove two valve to converter housing capscrews, Install two aligning studs as shown. Remove remaining capscrews. Figure 4 Remave contol valve and gasket. Remove charging pump to pressure regulating valve stud nuts Figure 5 Figure 8 Remove charging pump ad fier adaptor assembly, Remove pump adaptor bolts, adaptor and gasket. “i Figure 9 Remove impeller cover bearing cap bolts, NOTE: Some Figure 6 units will have drive plates instead of ring gear. Remove Remove pressure regulating valve assembly and “0” rings. drive plates. Figure 7 Figure 10 Remove pump drive sleeve and gasket. Remove bearing cap and “0” ring. Figure 20 Figure 17 Romove pump drive gear support bots. Remove impoller assembly. Figure 21 Figure 18 Romove pump drive goar and bearing assomblie. Remove stator support to housing bolts. Figure 22 ‘Support converter housing with a chain fall Remove converter Figure 19 housing to transmission housing bolts. NOTE: For converter Remove stator support. NOTE: Support must be turned to clear housing removal on the 8 speed transmission, see Figure pump drive gear 1 in the 8 speed section, page 93. Figure 23, Separate the converter housing from the transmission housing. Remove gasket. NOTE: Forward and 2nd clutch wil remain in converter housing Figure 26 Figure 24 Use a spreading type snap ring plirs to sproad the ears on for ward clutch front bearing retainer ring. Remove forward clutch with pry bar. Figure 25 Figure 28 Remove turbine shaft gear retainer ring, Remove bearing from turbine shatt Figure 29, Figure 32, Remove 2nd clutch disc hub retainer ring retainer. Remove aise hub, igure 30 Figure 33 Remove dise hub ring retainer. Remove bearing end plate Figure 34 Figure 31 Remove brake drum stud nuts (used only to hold drum in place Remove dise hub retainer ring after drive shaft was removed). Romove brake backing plate bolts. Figure 40 Remove backing plate and brake band assembly Figure 50 Remove rear cover bolts and washers, Figure 47 Remove rear bearing retainer plate bolts am a a Figure 51 Using pry slots provided, pry cover trom transmission housing tapping on ‘st spood clutch and idlor shaft to allow covor to bo romoved without shaft binding. NOTE: The use of alignment Remove retainer plate. studs will facilitate cover removal Figure 52 Figure 49 Remove 1st speed clutch double bearing cup, outer taper Remove bearing locating ring, bearing and spacer. Figure 53 CAUTION: Outer cone, double bearing cup, spacer and inner beering cone are replaced as a set. < Figure 64 Remove low clutch inner bearing cone. NOTE: To remove the Jinner cone bearing without damage, a special bearing puller must be made (see diagram Fig. 54-A) or the outer cage and rollers may be pulled from the bearing inner race and the inner race can be removed ater the low clutch assembly has been removed from the transmission. See caution in Figure 63. encom. SE Figure 54-4, ‘A timken bearing cup, No. 29520 must be used with the above bearing puller Figure 55 Remove idler shaft assembly, NOTE: The 6 & 8 speed trans- mission will have two gears and a heavier front bearing. Figure 56 Remove 1st speed clutch drive goar retainer ring Figure 57 Remove drive gear Figure 58 Figure 61 Remove 1st speed clutch assembly. ‘Remove front output ange nut, washer, °O" ring and flange. See 6 & 8 Speed Section for Range Shift Output Shaft Removal. Figure 59 Figure 62 Remove ‘st speed front bearing, Remove output shaft front bearing cap bolts and washers, Figure 60 Remove reverse and 3rd clutch assembly. =e Figure 64 Figure 67 Remove output shaft rear bearing cap bolts and washers. Remove rear taper bearing, } Figure 65 Figure 68 Remove bearing cap and “0” rings, Remove output shaft, goar spacor and front taper bearing, Figure 66 Block output gear. Push or drive output shaft through taper Figure 69 baring and output gee. Remove output gear Figure 70 Remove front bearing =< Figure 71 If idler shaft, idler goar or rear bearing are to be replaced, remove bearing and gear. Turn shaft over and remove the front bearing retainer ring and bearing, 1ST SPEED CLUTCH (LOW) DISASSEMBLY AND REASSEMBLY ‘See 8 Speed Section for 4th Speed Clutch Repair DISASSEMBLY ‘See Note in Figure 83 Figure 72 Remove clutch assembly front bearing inner race. Figure 73 Remove taper bearing retainer ring reteiner. Figure 74 Remove bearing retainer ring. Figure 75 Remove 1st speed gear and outer taper bearing, =13. b Figure 78 Figure 79 Remove taper bearing spacer. Remove inner and outer clutch discs. a Figure 77 Figure 80 Remove clutch end plate retainer ring, Remove inner taper bearing. bi -— Figure 81 Remove piston retuin disc spring retainer ring retainer washer. Remove end plate ea ks 4 ‘springs to precisely match each part within this assembly. WE Failure to replace all piston return springs can result in \f unequal deflection within the spring pack. The result of, balance may adversoly affect overall life of springs. ‘spring packs are to be used as complete assemblies and care should be taken not to intermix the individual disc springs with dise springs in another clutch OQ or disc spring pack. 1ST SPEED CLUTCH REASSEMBLY Figure 82 Remove retum disc spring retainer ring. Figure 85 Install clutch piston outer seal ring. Figure 83 Remove piston return disc spring. NOTE: Disc springs in the low clutch are different than springs in the forward and reverse clutch. Do not mix low clutch springs with for- ‘ward and reverse springs (see note at top of pagel. Non modulated units will have return springs in forward & roverse clutches. eo isis Figure 84 Remove return spring t piston spacer. Turn clutch over and tap Figure 86 lutch shaft on a block of wood to remove clutch piston. Install clutch piston inner seal ring. Install paton into clutch drum, Use caution as not to damage seal rings. See cleaning and inspection page. =15— a Figure 87 Install piston spacer. Figure 68 ‘See NOTE in figure 83. Install dise springs. First spring with large diameter toward spacer, Alternate (5 five washers. See page 59, Figure C. Figure 89 Position return spring retainer ring on clutch shaft. Compress dise springs and install retainer ring. Figure 90 Position ring retainer over retainer ring. Figure 91 Install one steo! disc. Figure 92 Install one friction diso, NOTE: The fr clutch has @ higher coefficient rati ises in the other clutches, therefore the discs must not bbe mixed. The low clutch inner disc can be identified by an “X” stamped on one side of the inner teeth, The low clutch inner disc also has a strip of non-soluble yellow paint sprayed on the outer edge of the disc. Alternate steel ‘and friction dises until the proper amount of discs are installed, First dise next to the piston is stool, lat disc installed is fiction, Figure $3 Install clutch dise end plate, Figure 94 Install end plate retainer ring Figure 95 Install inner clutch gear taper beering, -17- J Figure 96 Position taper bearing spacer on shat. Figure 97 Install 1st goar into clutch drum. Align splines on Tet gear with internal teeth of friction discs. Tap goar into position. Do not force this operation. Gear splines must be in full position with internal teeth ofall fiction discs. = Figure 98 Install outer taper bearing. Figure 99 Install low clutch taper bearing retainer ring. Figure 102 NOTE: Retainer ring is selected at assembly for proper Position front bearing on clitch sat Inner race, NOTE: Bearing thickness. A snap ring kit is available, Select the thickest could be installed in transmission case befoce intaling clutch, of the three rings in the kit that can be fitted into the snap ring groove to assure a proper taper bearing tightness. Check ring as shown for tight ring to beating fit. REVERSE AND 3RD CLUTCH DISASSEMBY AND REASSEMBLY DISASSEMBLY (Reverse being disassembled) Figure 100 Position ring retainer over retainer ring. et Figure 103, Remove clutch shaft piston rings. NOTE: Some units will have Telfon piston rings and expander springs. these Figure 101 rings are to be replaced with a new style ring and does Install clutch shat front bearing inner race with large diameter NOT use an expander spring. See page 79 for proper of race down. piston ring installation. —18— Figure 104 Figure 107 Remove front bearing retainer ring. Remove front bearing Figure 108 Figure 105 Pry front bearing inner race up far enough to use bearing Remove front bearing end plate. paler. Figure 106 Figure 109 Remove end plate lock ball Remove besring inner race. 19 wee. F WW Figure 110 Figure 113 Remove clutch driven gear outer bearing retainer ring. Remove end plato Figure 111 Figure 114 Remove clutch gear and outer bearing Remove inner and outer clutch dises. Figure 112 Figure 115, Remove clutch disc end plate retainer ing Remove inner bearing —20— Figure 119 Remove clutch piston, Figure 116 Compress piston return spring. Remove spring retainer ring. 3RD SPEED CLUTCH DISASSEMBLY Figure 117 Figure 120 19 washer. Remove 3:d speed clutch shaft bearing Remove retainer ring roti z. Figure 118. Remove piston return spring and retainers. NOTE: Modulated clutches will have piston return disc Figure 121 springs. (See note on page 15, Figure 83.) Romove 3rd speed goar and outer bearing, Hat Figure 122 Figure 125 Remove clutch gear outer and inner beating spacer. Remove clutch disc end plate retainer ring, Figure 123 Figure 126 Pry inner bearing up far enough to use @ bearing puller. Romove end plate, oll, Figure 124 Figure 127 Remove inner bearing. Remove inner and outer clutch —22- Figure 131 Figure 128 Romove clutch piston. Compress piston return spring. Remove return spring retainer - See cleaning and inspection page. 3RD SPEED CLUTCH REASSEMBLY <= Figure 132 Install clutch piston inner and outer seal rings. Install clutch piston in clutch drum, use caution as not to damage seal rings. Figure 12 Remove retainer ring retaining washer Figure 133 Figure 130 Position the inner return spring retainer, the return spring and, Remove retum spring retainers and spring. the outer spring retainer on clutch shaft. ~23~ Figure 134 Position return spring retainer ring retaining washer on clutch shat fe Figure 136 Compress return spring and install retainer ring being cortain ring is in full postion in retaining washer and ring groove. “ Figure 136 Install one stool disc. Figure 137 Install one frition dise. Alternate steel and thiction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed in friction, 5 wy Figure 138 Install clutch dise ond plate. Install end plate retainer ring Figure 143 Install clutch gear outer bearing. NOTE: Outer bearing has a Figure 140 shield in it, this shield must be up. Install clutch gear inner bearing. NOTE: The inner bearing does rot have @ bearing shield, Figure 144 Install rd speed clutch shatt rear bearing. NOTE: Bearing outer Figure 141 diameter locating ring must be down. Inotall clutch gear inner and outer bearing spacer REVERSE CLUTCH REASSEMBLY Figure 142 Install clutch gear into clutch drum. Align splines on clutch geer with internal teeth of friction discs. Tap gear into position. Do Figure 146 not force this operation, Gear splines must be in full position Install clutch piston inner and outer ol seal rings. Install clutch with intemal teeth of all friction discs. piston in clutch drum, use caution as not to damage geal rings, 26 Adi , Figure 148 Position the inner return spring retainer, the return spring and Figure 149 the outer spring retainer. NOTE: If reverse and forward inal cin ata clutches are modulated, assemble disc springs as shown in Figure A on page 59. = Figure 160 Figure 147 Install one friction dise. Alternate steel and friction discs until Position return spring retainer ring retaining washer on clutch the proper amount of discs are installed. First disc next to the shaft piston is steel, last disc installed is fiction. el | Figure 148 ‘Compress roturn spring and install retainer ring being certain Figure 151 ring isin full position in retaining washer and ring groove. Install clutch disc end plate. —26— ‘ Figure 155 Install clutch gear outer bearing. NOTE: Outer bearing has a shield in it, this shield must be down. \ 3 bs iehgied o Install utc goa nner bearing, NOTE: This Bearing doesnot have a shiold init. se Figure 158 Install clutch gear outer bearing retainer ring. Figure 152 Install end plate retainer ring Figure 154 Install clutch gear into clutch drum, Align splines on reverse ‘gear with internal teeth of friction discs. Do not force this Figure 157 ‘operation. Gear splines must be in full position with internal Install clutch shaft front bearing inner race with large diameter ‘tweth of al friction discs. of race down: -27- Figure 158 Position front bearing over bearing race. a Figure 159 Position end plate lock ballin clutch shaft. Figure 160 Install bearing end plate, aligning notch in plate with lock bal, = - ~ me ~

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