ana SPICER Service Manual Powershift Transmission 24000 Series HR 4-Speed Long Drop TSM-0009 April 2000Maintenance & Service manual HR24000 4 Speed LD FOREWORD “This manual has been prepared to provide the customer and the maintenance personne! with information and instructions on the maintenance and repair of the Spicer Off Highway Powor Shift Transmission. Extreme care has been exercised in the design” solection of materials and manufacturing fof these units. The slight outlay in personal aitention and cost required to provide regular ‘and proper lubrication, inspection al stated intervals, and such adjustments as may be Indicated willbe reimbursed many times in low cost operation and trouble free servic. In order to become familar with the various parts of the transmission, its principal of ‘operation, trouble shooting and adjustments, it fs urged that the mechanic study the Instructions in this manual carefully and uso it as a reference when performing ‘maintenance and repair operations. Whenever repair or replacement of component parts is required’ only Spicer Off-Highway approved parts as listed in the applicable parts manual should be used. Use of “wi non-approved parts may endanger proper operation and performance of the equipment. Spicer Off-Highway doos not warrant ropair or replacement parts, nor falures resulting from the use thereof, which are not supplied by or approved Spicer Off-Highway. IMPORTANT: Always furnish the Distributor with the transmission serial and ‘model number when ordering parts. TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing. NOTE: If the transmission has 4 wheel drive, disconnect both front and rear drivelines. Because of the design of the hydraulic system, the engine cannot be ‘started by pushing or towing ‘©Copyright Dana Spicer OFF Highway Products Division Unpublished Material — Al rights reserved Limited Distribution No part of this work may be reproduced in any form Under any means without direct written permission of Dana Spicer Off-Highway Products Division Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD ‘TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basie Design FA Convanter and Transmission Case Group... Fg 8 Convener Group . . Fio.c Four Speed Cluteh and Gear Group : Fig. Cluteh Group : Fig. E Control Vaive Assembly FoF Charging Pump and Regulating Valve Group, Fig. External Plumbing and Pressure Check Points Fig. H Assembly Istrictions| Fit HR28000 Typicel Cross Section Fig J DISASSEMBLY OF TRANSMISSION 1 REASSEMBLY OF TRANSMISSION 2 CLEANING AND INSPECTION 69 ‘SERVICING MACHINE AFTER TRANSMISSION OVERHAUL 60 ‘TOWING Of PUSH STARTING « SPECIFICATIONS AND SERVICE DATA, ... 6 LUBRICATION we 6 TROUBLE SHOOTING GUIDE 2 CLUTCH AND GEAR ARRANGEMENT. 6 POWER FLOW. 64 ELECTRIC SOLENOID CONTROL o7 CONTROL WARING DIAGRAM . 68 DRIVE PLATE INSTALLATION 69 ‘TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 70 NOTE: Metric Dimensions Shown in Brackets [ }. Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD HOW THE UNITS OPERATE “Tho Fansmission and hydraulic torque portion ofthe powertrain enacts an impertant rele in ransmiting engine power othe civing heels. In order to properly mainiain and sence these uri tis important to fist understand ther function and how they operate, ‘The transmission and torque converter uncon together and operate tough a common hydraulic system. ts necessary to consider both unis inthe study ofthe funtion and operation. ‘To supplement the text below, ane for rterence use therewith, he folowing isrations are proved: SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Fig. A Converter and Transmission Case Group. Fa 8 Convener Grown Fig. Four Speed Clutch and Gaar Group Fig. D Cluteh Group Fa. € Control Valve Assembly FoF Charging Pump and Regulating Valve Group, Fo Extoinal Plumbing and Pressure Check Points Fo Assembly Instructions Fo! 1HR24000 Typical Coss Section Fad “The R, HR, and MHR. Model Transmissions are of tree nase dasions, “Tho R Modal consists ofa separate txque conver” mound othe engine wih fe powershi rans mission remota mounted and connected to the torque convertor with a dive shat, “Tho HR Model consists ofa torque converior and powershflod tansmision in one package mound directo tho engin. “The MER version ia mid:mount argue converter and ransmission assembly connected tothe engine by means ofa dive sha (Gee Fig. A forbasie design sthouetie) ‘The shift convo valve assembly may be mounted drecty on the side ofthe converter housing o ont ansmission cover or remote ‘mounted and connected fo the transmission by means of flexible hoses. The function of the conrol vave assambly is to direct il under pressure othe desired arectonal and speed ctch_ A prevson is made on certain models o nutralze the tansmission when ‘he brakes are applied. This is accomplished through use of @ brake actuated shut valve. The space and direction dutch assom- ‘los are mounted inside the transmission case and arecannectd to the output shat af the convetr ether by crect goaring or dive haf The purpose ofthe spood or drectonal cuiches iso rect the power ow treugh the gear tran fo provide the desired spood ange and direction ‘Anavie cisconnoc optional andi ocala onthe outpul sha, The drive tothe ont or ear ate canbe alseonnectod or connected ‘by manual shitting Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD With the engine running, the converter charging pump éraws ol fom the transmission sump trough the removable ol sucbon screen ‘and rete through the ol iter and the pressure regulating valve, ‘The pressure rutting vaive maintans pressure to the vansmisson control Cover Tor actuating the drection and speed cutches, “his requires a smal portion ofthe otal volume of i used inthe systom. The remaining volume of ol is dracted through the torque converter creat to the ol cooler and retums othe tansmision for postive luricaton, Ths regulator valve consists of a hardened ‘valve spool operating in a closely ited bore. The valve spol spring loaded to hold the valve ina closed postion. When a specie ‘Pressure s achioved, the valve spool works against the spring unl a por is exposed along the side ofthe bore, This sequence of {events provides the proper system pressure. [Atorentoring the converter housing the cl is crectd through the stator support tothe converter bade cay and oxi inthe passage between the tubine sha and convertor supper, The ol en flows ou of the converte othe ol eaoer. er teaving the cooler, the ol dracted fo 2 lurcating fing on the transmission and trough a series of tubes and passages Mricates the transmission bearings and ciches. The ol then gravy drain to the transmission sump. “The hycrauc torque converter consists basicaly of trae elemants and thie rated parts to mally engine torque, The engine ower tarsmited from the engine feel othe impeller element rough the inpeler cover This elements the pump portion of ‘he hyéraulic torque convertr and isthe primary component which stars the ol owing te the other components which resis in torque mtipicaton. This element can be compared o a centfugal pumpin that it picks up fui at Rs canter and discharges at its “Te torque converter turbine is mounted opposte the impeller and is connected tothe OUbuR stat ofthe torque converter. Ts lament receives Mita ts outa lamer and eischarges ats carter. Fd rected by the impller ou ino the particular design of blading in the turbine and eacton members the means by whch the hydraulic torque converte multiples torcue. “The reaction member ofthe torque converter is located batween and atthe canter or inner clameters ofthe impli and turine ements, ts function i 10 take the fluid which is exhausting from the inner potion ofthe turhine and change is drecon to alow comect ei for recirculation int the impeller element. “The torque converter wil mliply engine torque to its designed maximum multiplication rato whan the aulput shaft isa 22 RPM, ‘Thoreor, we can say that as the output shaft is decreasing in speed the torque mutipicaon i inceasing, ‘The shift contol valve assembly consists of a valve body with selector valve spools. A detent ball and spring inthe selector poo! ‘Provides one positon for each speed range. A detent ball and spring inthe drecton spool provides tree positions, one each for forward, neutral and reverse, \With the engine unring and the dreconal conta lever in neutal poston, ol pressure from the regulating vave is Blocked atthe contol valve, and the ransmicson isn neural, Movement of the forward end reverse spool wil rec i, under preesure to eithor the forward or reverse direction clutch as desired, When her drecional ch is selected tne opposite clutch is reeved of pressure and vents back trough the cirecon selector spool. The same procedure is used inthe spocd solar. ‘The direction or speed cluch assembly consists ofa crum wth intemal splines and a bore to receive hy raulaly actuated pston, “The piston isl fai” by the use of sealing ngs. A steel disc wih extemal spines is inserted into the drum and resis agains he piston, Nox friton die with splines atthe mer dametor is inserted. Dis ao atemated unt the required total is achiovod. A hhoawy backup plat is ton inserted and secured with 2 snap ring. A Hub with O.D. spines isinsortd into tho splines of ccs with {wath on ie inner diameter. The discs and nub ae tee to increase in speed or oat nthe opposte drec:ton as ong as no pressure Is presentin mat specie cute Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD To engage the cich, as previously sated, the contol valve is placed inthe desired positon. This allows o under pressure to fow from the contol valve, through a passageway. toa chason cich shaft This shaft has 2 dled passageway fr ol undor pressure to enter te shaft Oi pressure sealing ngs ar located on the cltch shaft, These ngs direct ol under pressure toa desred cltch Prossureof the cil forces the piston and cscs agains the heawy backup plat, The discs, with txth on the eutr lamater, clamping ‘againe diece with fect on tha inner diameter, enablos the hub and cluch shaft fo be locked fogebher and allows fm to dv ae @ ‘There are bleed balls or bleed orfloas, depending upon the model, in the dutch pston which alow quick escape foro when the Pressure tothe pistons rloased, FIGURE A Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD \Y iS Figure B Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD CONVERTER AND TRANSMISSION ‘ase GROUP Item DESCRIPTION ary. ITEM DESCRIPTION ary. 1 Pipe Plug. 2 38 Clutch Pressure Tube “O” Ring 1 2 Air Breather. 1 34 Tube Sleeve . 1 3 Pipe Plug 1 35 Clutch Pressure Tube “O” Ring 1 4 Pipe Plug. 2 36 Tube Sleeve ...... . 1 5 Converter Housing Sleeve 1 37 Clutch Prossure Tube “O" Ring 1 6 Clip 1 38 Transmission Case Assembly 1 7 Clip Screw Lockwasher 1 39 Tube Sleeve ... 1 8 Clip Screw. 1 40 Clutch Pressure Tube “0” Ring 1 8 Clip Screw. 1 41 Rear Cover to Transmission Case Gasket. 1 10 Clip Screw Lockwasher .. 1 42 Transmission Case to Rear Cover 11 Clip 1 Dowel Pin . 1 12 Converter Housing Sleeve 1 43 Rear Cover Pipe Plug. . 1 13 Pipe Plug 2 44 Rear Cover .... 1 14 Converter Housing to Transmission 45 Rear Cover to Case Screw. 20 Case Screw Lockwasher 7 46 Rear Cover to Case Screw Lockwasher... 20 15 Converter to Transmission 47 Transmission Case to Rear Cover Case Screw 7 Dowel Pin 1 16 Pipe Plug. 2 46 Pipe Plug... 1 17 Plug... 1 49 Pipe Plug 1 18 Hole Plug Gasket 1 50 Magnetic Drain Plug 2 19 Case Assembly Hole Plug 1 51 Oil Baffle... eee 1 20 Converter Housing 1 52 Tube Clip. . 2 21 Screen Assembly Gasket....... 1 53 Clip Screw Lockwasher 1 22 Screen Assembly 1 54 Clip Screw. : 1 23 Converter Housing to Transmission 55 Suction Line Assembly “O” Ring. . 1 Case Gasket perenne 1 56 Suction Tube Assembly 1 24 Converter Housing to Case Dowel Pin 1 57 Screw Lockwasher 2 25 Clutch Pressure Tube “O" Ring 1 58 Suction Line Screw ... 2 26 Lube Tube Sleeve. 1 59 Clutch Lube Tube 1 27 Tube Sleeve 1 60 3rd Speed Tube . 1 28 Clutch Pressure Tube “O” Ring 1 61 High Speed Clutch Pressure Tube . 1 29 Tube Sleeve sertetenes 1 62 Low Speed Clutch Pressure Tube. 1 30 Clutch Pressure Tube “O" Ring . 1 63 Dipstick Tube Assembly 1 31 Tube Sleeve 1 64 Dipstick.... 1 32 Clutch Pressure Tube “O” Ring . Date: Apr 2000HR24000 4 Speed LD Maintenance & Service manual Figure C Date: Apr 2000Maintenance & Service manual ITeM 24 25 26 27 28 29 31 32 33 35 36 37 38 39 HR24000 4 Speed LD ‘CONVERTER & PUMP DRIVE GROUP DESCRIPTION Bearing Support Screw & Lockwasher Idler Gear Bearing Loceting Ring, Idler Gear Bearing Retaining Ring Pump Drive Idler Gear Idler Stub Shaft Bearing Bearing Retaining Ring Beoring Locating Ring. : Bearing Support Screw & Lockwasher Bearing Locating Ring Pump Drive Bearing Suppor. Bearing Retaining Ring, Pump Drive Gear Boa Bearing Locating Ring. Pump Drive Gear Idler Gear Stub Shaft... ‘Stub Shaft Lock Ball Piston Ring Expander Spring Piston Ring. Stator Support Bearing Snap Ring, Piston Ring, Bearing Retaining Ring, Bearing Locating Washer . Turbine Shaft Bearing Turbine Shatt a Battle Ring nnenninnna Stator Support Screw . ‘Auxiliary Pump Drive Bearing Suppor. Bearing Retaining Ring Pump Drive Gear Bearing... Bearing Locating Ring Auxiliary Pump Drive Ge Pump Mounting Cover Gasket Pump Mounting Cover, ..... . Pump Mounting Cover Canscrew Lockwashe Pump Mounting Cover Capscrew, Idler Shaft Locka Idler Gear Bearing Thrust Plate Idler Gear Bearing Assembly Idler Gear ary. ITem 41 Reverse Idler Ge 42 Idler Gear Bearing Thrust Plate 43 Bearing Retaining Plate Not 44 Turbine Retaining Ring 45 Turbine to Hub Scrow, 46 Turbine Hub Ring 47 Turbine 48 Tuvine Hub 49 Impeller to Cover “O" Ring. 50 Impeller Cover 51 Turbine Hub Bearing 52 impeller Cover to Bearing Cap “0” Ring, 53 Turbine Hub Bearing Retaining Ring 54 Turbine Retaining ing 55 Impeller Cover Bearing Cap 56. Drive Plate Assembly, 87 Drive Plate 58 Drive Plate Backing Ring . 59 Drive Plate Mounting Nut 60 Drive Plate Mounting Stud Lockwasher 81 Impeller Cover Stuc. Impolies to Cover Screw Impeller to Cover Serew Lockwasner DESCRIPTION Retaining Ring Freewheel Outer Race Retainer Ring Freewheel Assembly Reaction Member to Hub Boaring Spacer... Impol Impeller to Hub Screw Impeller to Hub Scrow Lock Tab SSSIsReae 71 impeller. 72 impeller Hub “0” Ring 73 impelier Hub Gear 74 Impeller Hub Gear Bearing 75 Idler Shaft “0” Ring 76 Idler Shaft. 77 Ol Battie Retaining Ring 78 Oil Bate, 79 Oil Seal. 80 Oi! Bat Seal Ring, Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD Figure D Date: Apr 2000Paton Reture Spring Spacer Revere © 2nd Cush Oram & Pug Asser Paton Return Spring Speng Rasaner Spang Reaner Sap Fig. 1 Speed Stat Fear Bearing at Stat egg Retainer Ring Bewning Cop Gate. Maintenance & Service manual HR24000 4 Speed LD CLUTCH AND GEAR GROUP Tem DESCRIPTION ary. ITEM DESCRIPTION Forward Sha Plt Beng ; (05 Font Bearing Cop Spring Retainer Ring : {66 Beanng Cap Sr, Soring Retin ' {67 Front Bearma Cap “O° Rina ston Reta Sorng Beteve Washer z (08 Front Bearing Cup Patan Retum Sing Spacer 1 169 Front Bewing Cone Forward Cuteh Sha, Onan & Plog Aarety 1 70. Formatd Shalt Gear Paton Rog Expander Sang : 2 71 Gan Retain ing Forward Shak Paton Ring 2 72 Tet Saved Cutch Sha Prot Seana. Paton Ring Slewe Retain Rig 1 72. Fron Bearing Space Piston Ring Sleeve ' 74 1st Speed Shaft Rew Bearing Ferward Shalt Rear Bean : 18 Spee Goat Bearing Lesting Ring Revere © 2nd Shot Pron Reg 3 st Speed Gear Bearing Some Fromt Beanng Retuning Rng 1 1 Gear Mb Asem Front Searing Soap Bing 1 eatle Rig evr & 2nd Shak Front Basing 1 law Seeed Gear Bearing Locating Rig Fret Gearing Retain Rg. : aw Spec Geer Baering ‘hteh Driven Geer Basing Assam : ‘etevite Weber Reto Revere Chich Gea Hob Aaserohy 1 ‘Song Retains Soap Ring Spring Retaining Snap Rng 1 Bateite Wher Spacer Soning Retainer 1 148 Chteh Sha Onn & Bled Vv Aatey Paton Return Sor Selenite Washer 7 {tt Speed Stat Rear Beaty Spacer ‘eran fang Rete 2nd Caeh One Hn Retaining Fong, ‘ate Reg Reverse @ 2nd Shat Rear Besrng 2a cer he Hs rd Ah Shae Oram & Pug Asser Patan Reta Springs Guten Seeng Reroner Seong Retane Stop Ring 3rd Cath Dae Mob Reta Mingo Bate Reg ard in Sha Ree Bearing, 114 Caton Das Hat . (Outen Doven Gear Beaneg Spacer {8 Ger & Hub Aveo ‘ten Divan Gear Soares Fear Divo Gos Thrust Washer. That Werner tock Ba. Twat Weer Locating ng. Spring Rosier Snap Ring Sorng Retanet Piston Retom Seng 1h Shalt Paton rg Front ewig Retanig Ring. Front deanng Saap fing, 4 Gute Shaft Font Beara Front Oven Gear Thrust Wathar (Guton Dven Geet Bearing ont earn Cap Scew Loekwosher Font Bearing Gap Sem Range °° Ring Front Out Flange Bean Cap Pg ‘eat anaring Cop ‘earng Cap Sew Lociwasher ‘earing Cap Seren later Sra Fron osnng aver Snot Ror Beng der Shot Rear Bearing Leck Ba 100 fer Bron Loco Rina 101 Pump Onve Siew 103 ler Geer Soecee SSSSRESRSSSSLERELK SAL Te 107 ir Snot Bowing CaP 108 eer Shak Bearing Cop Screw Lockwather M10 Oupat Sat 191 Ohapet Gow Spacer, 112 Output Sat Gear Fear Baan Cone ew Bronng Con faa Bronng Cap "0° ing eae Bron Cop "0" Ring eae Brain Coo Seren Lackwesher en Searing Cap Sere eas Bowring Cap 1 Seat exe out Farge ange Washer ange Nu 125 fa Bacng Cap Ser 126 Par Boring Cop Sere Lochwaher An ‘As Ruled Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LDMaintenance & Service manual HR24000 4 Speed LD CLUTCH ASSEMBLY-1sT ITEM DESCRIPTION ary. rem 1 Backing Plate Retaining Ring... 1 5 2 Clutch Disc Backing Plate 1 6 3 Clutch Inner Disc. “10 7 4 Clutch Outer Disc 10 8 CLUTCH ASSEMBLY -FORWARD Tem DESCRIPTION ony, mem 1 Backing Plate Retaining Ring... 1 5 2 Clutch Disc Backing Plate 1 6 3 Clutch Inner Dise. 12 7 4 Clutch Outer Dise 12 8 CLUTCH ASSEMBLY 4TH 8 3RD Hem DESCRIPTION ary, rem 1 Backing Plate Retaining Ring... 1 8 2 Clutch Disc Backing Plate 1 10 3 Clutch Inner Dise. 6 " a Clutch Outer Dise 6 12 5 Clutch Piston - 4th 1 13 6 Clutch Piston Seal - Outer 1 14 7 Clutch Piston Seal - Inner 1 15 8 4th& 31d Clutch Drum Assembly. 1 CLUTCH ASSIEMBLY -REVERSE -2ND ITEM DESCRIPTION ary. mem 1 Backing Plate Retaining Ring... 1 9 2 Clutch Disc Backing Plate 1 10 3 Clutch Inner Dise. 12 " 4 Clutch Outer Dise 12 12 5 Clutch Piston - Reverse 1 13 6 Clutch Piston Seal - Outer 1 14 7 Clutch Piston Seal - Inner 1 15 8 Reverse & 2nd Clutch Drum Assembly DESCRIPTION Clutch Piston . Clutch Piston Seal - Outer Clutch Piston Seal - Inner 1st Clutch Drum Assembly DESCRIPTION Clutch Piston Clutch Piston Seal - Outer Cluteh Piston Seal - Inner Forward Clutch Drum Assembly. . DESCRIPTION Clutch Piston Seal - Inner Clutch Piston Seal - Outer Clutch Piston - 3rd Clutch Outer Dise Clutch Inner Disc... 2.5 Clutch Disc Backing Plate . Backing Plate Retaining Ring. DESCRIPTION Cluteh Piston Seal - Inner Clutch Piston Seal - Outer Clutch Piston - 2nd Clutch Outer Disc Clutch Inner Disc. Clutch Dise Backing Plate Backing Plate Retaining Ring, Date: Apr 2000 ary. ary, ary.Maintenance & Service manual HR24000 4 Speed LD Figure F Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD CONTROL VALVE ASSEMBLY iTeM DESCRIPTION Elbow : wee Forward Pressure Tube Assembly Elbow Valve Plug Forward & Reverse Shift Spool Spool Position Spring Forward & Reverse Shift Spoot Ground Wire Harness - Receptacle Mounting Scrow .... Receptacle & Wire Assembly. . Dust Cover Mounting Stud Lockwasher. Dust Cover Mounting Stud Nut Grommet. Dust Cover Dust Cover Seal Dust Cover Mounting Stud. Value Spool Stop. Control Vaive Housing . Pipe Plug vests Shuttle Valve to Electric Control Gasket Port Plug. Spool Stop High-Low Shuttle Spool Shuttle Spool Spring. . Shuttle Valve Body .... Pipe Plug. Valve Mounting Screw Lockwasher. ary. rem DESCRIPTION ary. 28 Valve Mounting Screw 28 Valve Mounting Screw Lockwasher..... 30 Valve Mounting Serew 31 Shuttle Valve Solenoid 32 Solenoid Coit 33 Shuttle Volve Solenoid "0" Ring 34 Shuttle Valve Solenoid "0" Ring. 35. Shuttle Valve Solenoid “0” Ring. 36 15t Speed Shift Spool, 37 Spring 38 Plug Stop . 39 Roll Pin 40 Spool Stop 41. Shift Spoo! 42 Spo! Position Spring 43 Bore Plug "0" Ring. 44 Valve Housing Sp0o! Bore Plug 45 Piston Housing Assembly. 45 Stop Plug 47 Pug “0” Ring 48 Piston “O" Ring 49. Giyd Ring 50 Piston 51 Piston Housing. 52 "0" Ring. . Note: toms §3 the 56 options. 6 various declutch Date: Apr 2000HR24000 4 Speed LD Maintenance & Service manual FIGURE G. Date: Apr 2000Maintenance & Service manual ITEM DESCRIPTION 1 Valve Stop Roll Pin . . 2. Valve Stop. 3° Spring 4 Ball, 5 Valve Stop “0” Ring 6 Valve Piston . 7 Valve Spring - inner 8 Valve Spring - Outer 9 Regulating Valve & Filter Adaptor Assembly, 10 Pump Mounting Stud Lockwasher 11 Pump Mounting Stud Nut. 12 Filter Assembly.......... 13 Valve to Pump Capscrew. 14 Valve to Pump Capscrew Lockwasher 15 Valve to Pump Capserew...... 16 Valve to Pump Screw Lockwasher .. 17 Valve to Pump Gasket 18 Thrust Plate & Bearing Assembly. 19 Pump Driven Shaft Assembly . . 20 Thrust Plate & Bearing Assembly. 21 Wave Spring HR24000 4 Speed LD CHARGING PUMP & VALVE ‘ASSEMBLY GROUP ary. Hy Hae os nay oer aceanmrerasiany Gp oe ITEM DESCRIPTION 22 Thrust Plate Seal : 23 Pump Drive Shaft Assembly 24 Pipe Plug 25 Pump Mounting Stud. .. 26 Pump Drive Gear Oil Seat * 27 Pump Mounting Screw Lockwasher 28 Pump Mounting Screw .. 29 Safety Valve Spacer 30 Safety Valve Poppet. 31 Safety Valve Seat 32 Safety Valve Spring 33 Safety Valve Retainer. 34 Pump Assembly to Converter Housing Gasket 35 Pump Body 36 Valve Mounting Screw... .e.eesee 37 Valve Mounting Screw Lockwasher 38 High Clutch Pressure "0" Ring 39 Valve to Converter Housing Gasket . 40 Control Valve Assembly ‘41 Valve Mounting Screw Lockwasher 42 Valve Mounting Screw. Date: Apr 2000 wae aneMaintenance & Service manual HR24000 4 Speed LD ‘CONVERTER LOCKUP Pon OPTION packing Brake—Option srry Pane Ore 5 pene { ese Sek Font Hest Exenargsr Sterna Pump Dive & For x" Ute Pressura Crack Pont 1825 P51 [oet72 keel [2"68-C] at Corot Ou. Spot -U FRONT VIEW REAR VIEW Bram Pag oF oat ere Figure H Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD REMOTE FILTER OPTION cnc nt ren oe on overeat Pree snes gan ne sername Lose 9 ncn ioiienoras agree ‘Howe tine Opting Ramanan " SamererOukt OX Tongeraine ""Tsretcoeras onto tans wad ees ‘Sos cies welcome ese, PTT " ‘Wal marion soma Ral SAE owe We onginaseecenne ‘Sinatra pce "TERETE, pane sonra Saher {OS a Pkt pense t Troteutgamneceq espn os fan Sao aa EN a a pt mat ‘rsd yo gnge arena ge Slowsnaoaipsan pqenctrnc hte Sperone Figure H Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD Large Pup & ar ar] ‘eat cen MECHANICAL DISCONNECT MECHANICAL DISCONNECT ‘rront Shown ‘Wire SPEEDO Rear avaiable Rear Shown Figure! Date: Apr 2000Maintenance & Service manual HR24000 4 Speed LD Assemble ter aa tan se Sem uae einen Aladin chaare a sels. ton vo sos utes aoe tng a8 £0" ge ate act nd At bor ay ‘nSiem bora Inspect taser (A, st ma a ig ws Labret apt ng ore ar to's aurea onthe bam, ‘Ong wins bo coer sop in congo gaa bese Ds ase et tes. sna etn ln {2a on pope sos pore Ses rena sees, an wih ‘op ary con of Parte 2 curse ae CBM eta Sans and tre ase tio ea. ‘opty ag coat of Lace No 82 outer set pats, in {2 lg tveacs. ‘Aratayaseamol, sang Som Hoyt att rman. 20 id et pe we ps, Inert trig aoe Sane aes Aromat et == Smee Soe see Da tam 20 0 une asses ay Sen ig eng ae p sae bere eater gn Seen ee I Taye o screen aay I Dee ETE o 9) As gatos irae au se EE, Sore ieee note buen a Reemaining six springs of each clach to Rear me & exparcter Seca cer eae cht "crap vee CSI) A meunnaigce = Pease Raw pm = Cn rng stn a pn So cmee erases Samco aoe SESS wae A “Teron 200250 Lbs F1271.22088 Nm} ‘oxsog mumbo compte wie 215 ant te nat socury info sha neck ire pte tem tat of sco ‘ed fone aan ony acew By S182 59001 seen atzotiy: (Vw 8°) is romeve for any “eason 4 must be 1 Olean stator suppet mourn surtace ant "apace. The Lote tn te hls ‘Spped ne wth ever ry ino mt be femaved mth proper tp tng cana appa holes a Ces a And cared win sokent Ory nae als epecal ee thoroughly and so 9 now sre fr 2 nal 6 seca se supe sone. Tien feces Siero Ube ese Nn SerCaston views “a Secteaton Laces Grade s Q) "er Plea Seren Teac Grace 8 G2 wor |e | eet Ry [ee so [res a pee [pee ge Ce a8 | rari (is eae pao | ae {35-31 (ign sg oa he a L386. 61a {it sss)-|| sees Tp se} Cheat [rss ae | ft aoe | wa fenesvaaa, [wee | rca ena ff aes | asta) |e was ional [Tater pena io atta) | sos (pms aeg) | a0 [fer amgy Bb | wn erst | mr 0 Date: Apr 2000HR24000 4 Speed LD Maintenance & Service manual Figures Date: Apr 2000MAINTENANCE AND SERVICE ‘The instructions contained heroin cover the disassembly ‘and reassembly of the transmission in @ sequence that would normally be followed ater the unit has been jemoved from the machine and is to be completely ‘overhauled. It must also be understood that this is a basic 24000 4 speed long drop output transmission with many ‘options. The units are very similar to trouble shoot, disassemble, repair and reassemble. ‘CAUTION: Cleanliness is of extreme importance and an ‘absolute must in the repsir and overhaul ofthis unit. Before ‘attempting any repairs, the exterior of the unit must be ‘thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism. DISASSEMBLY Figure 1 Sida view of the HR24000 4 speed transmission with ‘lectric control valve and modulation, Figure 2 \ted to catch remaining oil in element. fr element. Itis recommendeda small pan be Figure 3 Remove pressure regulating valve and charging pump ‘screws, stud nuts and washers. Remove regulating valve and nae ‘assembly.Figure 11 Figure 14 Remove drive plate attaching cap screws. Some units will Remove turbine hub to turbine shaft retainer ring. have stud nuts and washers, Figure 12 Figure 15 Remove drive plate and backing ring, Remove impeller cover to impeller cap screws, Figure 13, Figure 16 Remove impeller cover bearing cap. Remove impeller cover and turbine as an assembly.Figure 17 Remove turbine hub to impeller cover bearing retainer ring, Figure 19 Remove impeller cover bearing. IMPELLER COVER AND TURBINE REASSEMBLY (See cleaning and inspection pai Figure 20, Install impeller cover beoring in cover with bearing loc: fing up. ing If the turbine or turbine hub was replaced or dis- ‘assombled. this procedure must be used for reassembly. TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS |. Clean hub mounting surface and tapped holes with sede: be tora tong cei tpges Tekan ‘and clean, 2. Install backing ring and special screws to approximately 06 inch [1.5] of seated position. With a calibrated torque ‘wrench, tighten screws 37 to 41 Ibs. ft. torque (50,2-55.6 Nm, NOTE: Assombly of turbine hub must be completed within a fifteen minute period from start of x inatallation. The screws are prepared with a coating which begins to harden after installation in the hub holes. If not tightened to proper torque within the fifteen minute period, insufficient screw clamping tension will result. The speci ‘to be used for one installation only. If the screw i for any reason it must be replaced. The compound left in the hub holes must be removed with the proper tap and cleaned with solvent. Ory hole thoroughly and u new serew for reinstallation,Install turbine hub to impeller cover bearing retainer ring. Remove turbine locating ring from turbine shaft. Remove reaction member #1 Figure 25 Remove reaction member. NOTE: Some unite will fixed reaction member and some units will have wheeling reaction member. The fixed is @ one piece and the freewheeling is an assembly. Remove 3s an assembly. Figure 27, Remove impeller and hub assembly.Figure 31 Remove oil ba ‘assembly. NOTE: Reverse, second, thitd and fourth Clutches will ramain in the converter housing, Figure 29 Figure 32 Pry oil baffle from housing. NOTE: A resistence will be Remove 3rd speed clutch disc hub snap ring, retainer outer noted because of the heavy oil sealing ring. fing and retainer Figure 30 Support converter housing with 9 chain hoist. Remove Figure 33, converter housing to transmission case bolts Remove dise hub retainer ring and disc hub.af Figure 34 Remove 2nd speed clutch disc hub snap ring, retainer outer Figure ring and retainer. Remove the low clutch and i bolts, Figure 35 Remove dise hub retainer ring and dise hub. Remove low clutch rea Figur Using an impact wrench if available), ifnot flange retainer ar must be used to hold the companion flange from {urning, loosen output flange nut. Remove nut, washer, "0" Figure 39 ‘ing and flange, Remove idler shaft bearing cap.Figure 40 Remove tho rear output flange nut, washer, “O” ring and flange. @) Figure 41 Remove output shat rear bearing cap bolts. Remove bearing cap.Figure 52 Remove bearing spacer. Figure 53 Remove idler shaft assembly. Figure 54 Remove 1st speed clutch assembly. Figure 55 Remove idler shalt front bearing, Figure 66 Remove oil sump oil baffle Figure 87 Remove forward clutch drive gear retainer ring and driv eer. Seo Figure 57-AYS \ Figure 87-A Figure 60 Remove sealing ring sleeve. Figure 58 Figure 61 Romove forward clutch assembly, Remove forward clutch rear bearing, Figure 69 Figure 62 Remove sealing ring sleeve retainer ring, Remove output thatt front bearing cap bolts and washers. =Figuro 63 Figure 66 Remove bearing cap and shims Unelinch lock nut by straightening upeet metal in notch in idler shatt: Remove shaft nut. Figure 64 Remove output shaft front taper bearing cup. Figure 67 Repeat procedure in Figure 66 for reverse idler shatt. CONVERTER HOUSING DISASSEMBLY la Figure 65 ‘Spread reverse clutch front bearing locating ring. Pry elute Figure 68 ‘sssembly from housing, Remove bearing spacers.Remove reverse idler ‘and outer taper bearing, igure 72 Remove taper bearing and thrust plate, Remove shaft. Use 3t to Lose lock bal Figure 70 With the help of an ssistant, spread the 4th speed clutch front bearing locating ring and pry clutch from converter Figure 73 housing while the assistant removes the idler gear and s ‘outer taper bearing Repeat procedures in Figures 71 and 72 for idler shaft romoval. Figure 74 “sing a soft bar, drive revarse idler shat from taper bearing, Spread the turbine shaft bearing locating ring —13Figure 82 xillary pump drive gear support bolts. Remove Figure 83 Remove auxiliary pump drive gear. Figure 84 If stator suppor is to be replaced, remove support screws and tap support from housing, Seo Figure 333 for oll sealing ring sleeve removal ‘1st CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY al Figure 85 Remove front bearing, ~~ Figure 86 Remove bearing spacer. —15-Y % Figure 93 Remove piston return spring (Belleville washer) retainer 7 e- in the 1st olutch are different than washers in the forward and reverse clutch. 1st clutch washers have (4) four holes in thom (for identification only). Do not mix tat clutch washers with forward and reverse washers, =7- pues eS Figure 97 Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston. (See cl ing and inspection page.) 1st CLUTCH REASSEMBLY Figure 98. Install clutch piston outer seal ring. NOTE: Ring must be sized before installing in clutch drum. Sizing is best accomplished by rotating piston while holding @ round object against the new seal ring as shown. Rotate piston until seal ring is flush with outer diameter of piston,bs Figure 102 Install Belleville washers (piston return springs). See note in Figure 95. First washer with large diameter toward spacer. Alternate seven (7) washers. See Figure 105-8. Figure Clutch piston inner seal and size as explained in = Figure 103, Install piston return spring (Belleville washers) retainer ring Figure 100 ‘on clutch shatt. Position piston in 1st clutch drum as shown. Use caution 98, not to damage inner and outer piston sealing rings. | Figure 104 Using a sleeve with the proper inner diameter, drive the Figure 101 Belleville washer ring into position. NOTE: Be certain Position piston retum spring spacer over clutch shaft. retainer ring is in full position in ring groove. 18-Install one steot disc, Figure 105, F washer over retainer ring, Figure 108-4 Cross section of 1st clutch. Figure 106 Figure 107 Install one friction disc. NOTE: The friction discs in the low clutch has a higher co-efficient rating than the friction discs inthe other clutches, therefore the dises must not be mixed. ‘The low clutch friction disc has a yellow mark of nongoluble paint on the outer diameter for permanent identification, ‘Altern | and friction disos until the proper amount of discs are inst t disc next to the piston is steel. last disc installed is friction. Figure 108 Install clutch disc end plate. eE= Figure 109 etainer ring. -19-Figure 110 Install clutch gear inner bearing. NOTE: This bearing does not have shield in it Figure 111 Position bearing spacer on clutch shaft Figure 112 Install low clutch driven gear and hub into clutch drum. ‘align splines on clutch hub with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must bein full position with internal teeth of all friction dies. =a Figure 113, Install clutch gear outer besring. NOTE: Outerbesring hes 9 shield in it, this shield must be up. Figure 114 Position front bearing spacer on clutch shaft » 3 ig - Figure 115, Install front bearingREVERSE AND 2nd CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY (Reverse being disassembled) Figure 116, Remove clutch shaft oil sealing rings. Figure 117 ring retainer ring. Figure 118 Remove front bearing, = Figure 119 Remove elutch g ring retainer ring. Figure 120 Pry reverse gear from clutch aésembly far enough to use # ‘gear puller. ae Figure 121 Remove reverse gear and bearing spacer.os . w b Figure 122 Romove clutch end plate retainer ring, ‘6 Figure 123 Remove end plate. “ Figure 124 Remove inner and outer clutch discs. —2— Figure 125 Remove inner reverse gear taper bearing. Figure 126 Compress piston rotum springs (Belleville washers) Remove return spring retainer ring and ring retainer. Figure 127 Remove piston return springs. (Belleville washers.)¥ Figure 128, Figure 131 Remove piston spacer. Remove end plate Remove clutch piston. Figure 132 Remove inner and outer clutch discs. DISASSEMBLY OF 2nd SPEED CLUTCH > 4 , rs Sort ‘ Figure 133 Figure 130 Compress piston return spring retainer. Remove retainer Remove end plate ret er ring ring, —23—Figure 134 Figure 137 Remove spring retainer and return spring, Install clutch piston in clutch drum. Use caution as not to damage seal rings. Sa * Figure 135 Remove clutch piston. , . Figure 138 (See cleaning and inspection page.) Position piston retum spring and spring retainer on clutch shat 2nd CLUTCH REASSEMBLY ¥ ~ we Figure 136 Install clutch piston outer and inner seat rings. Size rings as Figure 139 explained in Figure 98. Compress spring and install retainer ring, —m—Figure 140 Figure 143, ‘end plate retainer ring, Install one steel disc, REVERSE CLUTCH REASSEMBLY ~ Install one fr steel and friction dises Lnti the proper amount of discs are installed. First disc next Figure 144 to the piston is steel, last disc installed is friction. Install clutch piston outer and inner seal rings. Size 26 ‘explained in Figure 98. = Figure 145 Install clutch piston in clutch drum. Use caution as not 10 damage seal rings. ihFigure 146 Install one stool di Figure 147 Install one friction disc. Alternate steel and friction dises nti the properamount of discs are instslled, First disc next to the piston is steel, last disc installed is friction, — Figure 148, Install clutch dise end plate, —26— Figure 150 tuen spacer over clutch shaft. Position piston Figure 181 Install Belleville washers. First washer with large diameter toward spacer. Alternate seven (7) washers. See Figure 152-0,Figure 149 Install clutch dise end plate. me fe Figure 150 Install end plate retainer ring. Figure 151 Install new piston ring expander springs per instructions on page 50. 27 Figure 152 Intal piston rings on clutch shaft per instructions on page 60. (@ each on standard converter, 4 each with lock-up converter) REVERSE AND 2ND CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY (2nd clutch being disassembled) Figure 153 Remove end plate retainer ring. Figure 154 Remove end plate,Figure 157 Install front bearing retainer ring 4 Figure 158 te reassembly into front housing, 3rd AND 4th SPEED CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY (4th being disassembled) Figure 189 Remove clutch shatt oll sealing rings cluteh shaft oll sealing rings. Gresse rings to Figure 160 Romove front bearing retainer ring. —2— Figure 161 Remove front bearing. = Figure 162 Remove gear front thrust washer.~% & . Figure 163 Figure 166 Remove thrust washer lock bal Remove bearing specer My Figure 164 Figure 167 Ramove clutch gear and dine hub Remove inner bearing ig Figure 165, Figure 168 Remove clutch gear outer bearing. Remove gear rear thrust washer. —29-Remove thrust washer lock ball Y Figure 170 locating ring. a Remove thrust wa! & ‘ee Figure 171 Remove clutch dige end plate retainer ring ‘% Figure 172 Figure 173 Remove inner and outer clutch dises, a igure 174 ring. -n-& t Figure 175 Figure 178 Remove spring retainer and spring. Remove end plate. x Figure 176 Remove elutch piston Figura 179 Remove inner and outer clutch dises. DISASSEMBLY OF 3rd SPEED CLUTCH h. Nui Figure 177 Figure 180 Remove end plate retainer ring Remove return spring retainer ring. asure 181 Remove spring retainer and spring. Figure 184 Inatal clutch piston in clutch drum. Use caution 98 not to damoge seal fogs ~ ss ‘ » ‘ ~/ © Figure 182 Remove clutch piton (See cleaning and inspection page.) Figure 188 ekeRURNLY GH Sed GeRED CLUTCH Postion retum spring and spring retainer on clutch shat. ~~ \ i. SS = Figure 183 I clutch piston outer and inner st rings. Size as ed in Figure 98. —32—‘3 “a Figure 187 Figure 190 Inetall one staal dise. Install end plate retainer ing, REASSEMBLY OF 4th SPEED CLUTCH » ” Figure 188, Install one friction dise. Alternate steel and triction discs nti the proper amount of discs 4, First disc next Figur Install clutch piston outer and inner seal rings. Size a¢ 191 to the piston is friction. explained in Figure 98. y 2 Figure 192 Figure 189 stall clutch piston in clutch drum. Use caution a8 not to Install end plate, damage seal rings —33—Figure 193 Position return spring and spring retainer on clutch shaft, Figure 194 Compress return spring and install spring retainer ring Figure 196 Install one steel disc. Figure 196 Install one friction disc. Alternate steel and friction discs ‘until the proper amount of disos are installed. First disc next to the piston ig steel, last disc installed is friction. Figure 197 Install end plate. Figure 198 Install end plate retainer ring. —4—Figure 199 Install inner thrust washer locating ring. Install clutch gear inner bearing. Figure 200 Position tock ball in hole in shaft. Asmall amount of grease Figure 203, will hold ball in place. Install bearing spacer. Figure 201 Position inner thrust washer on shaft aligning notch in Figure 204 with lock bal Install outer bearing <=Figure 205 Figure 208 ‘and hub into clutch drum. Align Install clutch shaft front bearing. NOTE: Beoring outer ‘on clutch hub with internal teeth of friction discs. diameter locating ring groove must be up. Install clutch driven ges pli 4 ¥ Figure 206 Figure 209 Position lock ballin hole in shatt. Install bearing retainer. yy J Figure 207 Figure 210 Position outer thrust washer on shaft aligning notch in Install olutch chatt oll sealing rings. Grease rings to washer with lock bal facilitate reassembly into front housing. 6FORWARD CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY ~~ Sh Figure 211 Remove clutch disc end pi Figure 212 Remove end plate. ~ Figure 213 Remove inner and outer clutch discs. mgd Figure 214 Compress piston retum springs (Belleville washers). Remove retum spring retainer ring and ring retainer. rh 6 Figure 215 Remove piston return springs. (Belleville washers). ~*~ ngs Figure 216 Remove piston spacer. -37—$F Figure 217 Remove clutch piston. Remove clutch shaft oil sealing rings Figure 220 ‘and expander springs. Position piston return spring spacer ove clutch shaft. (See cleaning and inspection page.) FORWARD CLUTCH REASSEMBLY 7—~—=D> at J i toward spacer. Alternate seven (7) washers. See Figure Figure 218 2A Install clutch piston outer and inn explained in Figure 98. ~ : Figure 222 Install piston return spring retai jure 219 retainer ring on clutch shaft. Compress return springs and Install clutch piston in clutch drum. Use caution a6 not to install retainer ring. Be sure ring is in full position in damage seal ring —s8-~ Figure 222-0 Figure 225 Install clutch disc end plate. ge Figure 226 ing. Install new expender springs Hows sas and clutch shaft oil sealing rings. Install one steel disc. OUTPUT SHAFT DISASSEMBLY a Figure 224 Install one friction disc. Alternate steel and friction discs Lunti the proper amount of discs. 3d, Fist ise next Figure 227 10 the piston i steo!, i friction, Remove raar taper bearing. —39—OUTPUT SHAFT REASSEMBLY : 3 Figure 228 Figure 231 Remove output gear. Install output shaft front taper bearing, large diameter of taper down. Figure 229 Figure 232 Remove gear spacer. Position gear spacer on output shaft. Figure 230 Remove front taper bearing. Figure 233 Position output gear on shaft with long hub of gear up. 40 —Figure 234 waft rear taper bearing, large diameter of Figure 237 Remove small idler gear. NOTE: Some special ratio units will have only one Idler gear, Install output taper down, IDLER SHAFT DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 238, Romove large idler gear Romove idler shat b bearing up far enough to use @ bearing puller Figure 236 Figure 239 lemove gear spacer. a(See cleaning and inspection page.) J = IDLER SHAFT REASSEMBLY 1 Figure 243, ring, outer locating ring groove up. tighten nut 200 to 250 ft. Ibs. Install il Install bearing retainer ni torque [271,2 + 38,9 Nim}. shaft rear Figure 240 (See cleaning and inspection page.) Position gear spacer on shaft REASSEMBLY OF TRANSMISSION Pe lease eaer ane eee wan't Figure 244 eer) Seve: Laker aser oneber Gh Jong: hab oe ged Install forward clutch rear bearing with bearing locating fown. ring toward front of transmission case. - Figure 242 Figure 248, Position smal idler gear on shaft with ong hub of gear Align clutch cil sealing ring sleeve with notch in case. Tap down. sleeve into position, —42—Figure 246 Install sleeve retainer ring Figure 247 Position forward clutch assembly into sleeve, use caution Figure 249 as not to damage oil sealing rings on clutch shatt. Install idler shaft front beoring. Figure 248 Position forward shaft hub of gear tows Figure 250 figure 248-A, Install 13t clutch essembly in case. —43—Figure 254 Install bearing cap capscrows and washers, tighten to specified torque. (See torque char). Figure 261 Install idler shaft assembly into front bearing fees Figure 252 Figure 255 install output shaft front bearing taper bearing cup with Position oil beffle in transmission sump. arge diameter of taper in. Figure 263 Coat outer diameter of oll seal with Permatex #2 and press sal in bearing cap with lip of seal in. Remove any excess Figure 256 sealant. Install new “O" ring on bearing cap. Install front Position output shaft assembly in front bearing bore, use bearing cap and shims. caution as not to damage front oll seal, —44Figure 260 Position a new gasket and "O'" ring on rear of housing. A light cost of chassis grease will hold the gasket in place. Ingtall two aligning studs in housing, this will fa alignment of rear cover to housing Figure 267 Install 1t clutch rear bearing spacer Figure 258 Install 1st clutch rear bearing. NOTE: Besring locating ring Figure 261 ‘9roove must be out. Position lock ballin idler rear bearing. Align lock ball in idler shaft rear bearing with notch in rear Figure 259 lace and secure with Install bearing retainer ring. bolts and washers, Remove aligning studs. dieFigure 263, ‘Tighten cover bolts to specified torque, (See torque chart) Figure 264 Position speedometer gear on output shaft. (Optional - not used on all models.) Figure 265 With rear taper bearing cup in rear bearing cap, apply a very light coat of Permatex #2 to the outer diameter of the rear ‘output oil seal, Press seal in bearing cap with lip of seal in. With new 0" ring in position, install be Figure 266 Inetall bolts and washers and tighten to specified torque. ey J Figure 267 From the front, tap the idler shaft to the rear until the bearing locating ring groove is exposed. Install locating ting. Figure 268 From the front, tap the 1st clutch to the rear until the rear bearing locating ring groove is exposed. Install locating ring.Figure 269 Position new”"O" ring and gasket on 1st clutch rear bearing cap. Figure 270 Install copscrews and washers, tighten to specified torque. Figure 271 Position new gasket on idler shaft bearing cap. Install bearing eat bolts and lockw torque chart) ers, tighten to specified OUTPUT SHAFT ROLLING TORQUE PROCEDURE (Bearing Preload) Figure 272 ‘Tap output shatt front and rear to seat taper bearings. Loosen front bearing cap bolts. Using an inch Ib. torque ‘wrench, determine the rolling torque of the output shaft and record. Tighten front bearing cap bolts to specified torque, Check rolling torque with bolts tight. Torque must be 6 to 8 Inch Ibs. [0,68 -0,90 Nm] more than when bearing cop bolts were loose. Add or omit shims on the front bearing cap to achieve the proper preload. ~a — Figure 273 Install output flange, new "0" ring, washer and nut Figure 274 Using a flange retainer to prevent output shaft from turning, tighten flange nut 200 to 250 tt Ibs. torque. [271.2 «338.9 Num} —47—Position support in converter housing aligning holes in ‘support with holes in housing. Tap support into position. STATOR SUPPORT SCREW ASSEMBLY: Install 6 special stator support screws. Tighten screws to 12-16 ibe. ft. (16,3-21,6 N.m] torque. NOTE: Assembly of stator support to converter housing ‘must be completed within a 15 minute period from start of serew installation. The special screw is to be used for one installation only. If the screw is removed for any reason it ‘must be replaced, The Loctite left in the holes must be removed with the proper tap and cleaned with solvent. Ory hole thoroughly ond use a new screw for reinstallation, Figure 282 Position new "O" rings and gasket on front of transmission housing. A light coat of chassis grease will hold “0” rings and gasket in place. (See cleaning and inspection page.) CONVERTER HOUSING REASSEMBLY See Figure 333 for oil sealing ring sleeve information. Figure 285 Position auxiliary pump drive gear, bearing and support in housing, Figure 283 Install new sealing ring expander spring and oll sealing ring ‘on support. Expander spring gap to be 180° from sealing ‘ing hook joint. Press support bearing into position. NOTE: Bearing part number must be up. Figure 286 Clean stator support mounting surtace and tapped holes Align holes in bearing support with holes in housing. Install with solvent. Ory thoroughly, being certain tapped holes ar support screws and washers. Tighten to specified torque. clean and dry. (See torque chart) —a—Figure 287 Position charging pump drive gear, bearing and support in housing. Install support screws and washers, tighten to specified torque. (See torque chart) Position pump dri ‘stub shaft. Install, ind bearing on idler gear 9 Figure 289 If bearing was removed, press turbine shaft bearing into position. NOTE: Bearing outer locating ring groove down. erring. Install new turbine 1d ears on turbine shaft bearing retainer ring located in pron. Tp turbine 1nd bearing 19 is in full Figure 290 ‘With new "0" ring on shaft. position reverse idler shaft in housing. Align groove in shaft with notch in housing. Install Jock bal Figure 291 Figure 292 Install shaft spacer.Figure 293 Figure 296 jaring on shaft with large diameter of Install shaft retainer nut. Tighten nut 200 to 250 ft. Ibs. bearing spacer on short torque [271,2 - 338,8 Nm} Figure 294 Position reverse idler gear on shaft with hub of gear up. Install outer taper bearing in gear with large diameter of Figure 297 taper up. Stake nut securely in shaft notch. Figure 298 Figure 295, With new"0" ring on shaft, position idler shatt in housing. Position outer spacer on shaft. Align groove in shaft with notch in housing. Install lock ball ps ‘ang t=Figure 302 Spread ears on clutch front bearing locating ring. Tap reverse and 2nd clutch assembly into convertor housing, Align the snap ring groove in the bearing with the ‘snap ring in the housing, being certain bearing snap ring is in full position in snap fing groove. Figure 299 ‘Tap shaft into position, use caution a6 not to lose lock bi Figure 303 Position idler gear on bearing with hub of gear up. ©) Figure 304 Spread ears on 4th clutch front bearing locating ring. NOTE: The idler gear and taper bearing cup assembly ond ‘the 4th clutch assembly must be installed in the conv: housing at the same time as the idler gear must be positioned between the clutch front bearing and the clutch Figure 301 drum, Install the idler outer taper bearing with small Install idler gear inner taper bearing on shaft with large diameter of taper down, Make sure locating ring is in full diameter of taper down. Position fon shaft, position in ring groove. 52Figure 306 Position pilot bearings on 2nd and 3d clutch shafts, alight coat of grease will hold pilot bearings in place. —s3— Figure 308 ‘The use of two aligning studs will facilitate converter housing to the transmission housing. Install converter housing assembly to transmission assembly Using extreme caution ae to align the clutch pilots into the clutch dise hubs. As the clutch pilots enter the dise hubs turn the turbine shaft and output shaft back and forth. This will help align all of the clutch inner dises with the disc hubs. DO NOT FORCE THIS OPERATION. When all the clutches are properly aligned, the converter housing will be tight against the transmission housing. Install two housing 10 housing capscrews and lockwashers. Remove aligning studs. Install remaining capscrews and lockwashers. Tighten capsorews to specified torque. (See torque chart.) the oi batfle oil seal. Press seal in baffle with lip of seal toward impeller hub bearing, Position new oil battles ring on oil baffle. Position oil baffle in housing and install retaining ring. Be sure ring isin full position in ring groove. . Figure 310 Install impelior and hub assembly using caution as not to damage the oll bate oll saal. NOTE: Use extreme caution ‘not to cut, break or unhook the oll sealing ring on the suppor.FREEWHEEL REASSEMBLY NOTE: The freewheel assembly cannot be serviced. if the freewheel is damaged it must be replaced as an assembly. Figure 311 Position impeller hub beating spacer on stator support. Figure 314 Install outer race and sprag assembly in reaction member. NOTE: Undercut shoulder of race must go toward the rear of the reaction member. “« Figure 312 Z, a: \E For fixed reaction member, install reaction member with a thick side of blades out For freewheo! reaction member see Figure 314. Figure 316, Ingtall outer race to reaction member retainer ring, =e Yi Fo Figure 316 Figure 313, ton member retainer ring. Proceed to Figure 4MUST FREEWHEEL IN ‘CLOCKWISE ENGINE ROTATION Figure 317 Figure 320 jon member to impeller hub ges Install turbine hub to turbine shatt retainer ring Suppor. neal rection Figure 321 Install impeller cover to impeller screws and lockwashers. Figure 318. Tightan to specifind torque, (See torque chart) Install turbine locating ring on turbine shatt —\ Figure 319, With a new impeller cover to impeller "0" ring in place, Figure 322 install turbine and impeller cover assembly on turbine shatt. Position a new"0" ring over impeller cover bearing,Figure 324 ‘See special section on page 69 for drive plate installation. Figure 325 With @ new gasket in place, install the charging pump assembly on mounting studs. Install washers. nuts and ‘capscrews. Tighten to specified torque. (See torque chart.) Figure 326 Install new oll iter cartridge. NOTE: It is recommended ler cartridge be changed after 50 and 100 hours 19 on new and rebuilt or repaired units. aligning studs be used. Position new modulator valve to housing gasket on housing. Install valve assembly. Figure 328 Position a new modulator to control valve gasket and install ‘control valve assembly. —56—Figure 329 Position new shuttle valve gasket on control valve. install shuttle valve agcembly on control valve. Figure 330 Connect the pressure line from the shuttle valve to the contral valve. Connect the wires from the control valve to the shuttle valve solenoid. Figure 331 Install control valve to housing serews and lockwashers. NOTE: Use Loctite #262 on upper right hand screw. Tighten screws to specified torque. (See torque chart) —s7— ae Figure 332 Ifthe auxiliary pump drive is not ured, position anew gasket ‘and cover on opening. Install bolts and washers and tighten to specified torque. (See torque chart.) aS OIL SEALING RING SLEEVE REMOVAL NOTE: The following photos are not of the HR Converter Housing, but the sleeve removal procedure is identical. Figure 333, Remove clutch front bearing retaining ring, Figure 334 I gealing ring sle« Romove front jetainer screw and washer. Remove sleeve lock.Figure 336 Using a sleeve puller like the one shown, remove sleeve. Figure 336 Sleeve being removed. NOTE: When installing # new sleeve it is recommended a press or a driver be used to damage to the sleeve and be sure the notch in the is aligned with sleeve lock notch.CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid. itis recommended that parts be immersed in cleaning juid and moved up and down slowly unti all old lubricant and foreign material is dissolved and parts are thoroughly cleaned. CAUTION: Care should be exercised to avoid skin rashes, fire hazards and inhalation of vapors when using solvent type cleaners. Bearings Remove bearings from cleaning fluid and strike side of cone flat against a block of wood to dislodge solidified particles of lubricant, Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture free compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying, Bearings may be rotated slowly by hand to facilitate drying process. interior and exterior of housings, bearing caps, ‘tc, thoroughly. Cast parts may be cleaned in hot solution .anks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. Tris will aid the evaporation of the cleaning solution and rinse water, Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of, alkali, Cast parts may also be cleaned with steam cleaner. CAUTION: Care shouldbe exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners. {All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft, lintless absorbont wiping rags free of abrasive materials such as ‘metal filings, contaminated oil or lapping compound. INSPECTION ‘The importance of careful and thorough inspection ofall parts cannot be overstressed. Replacement of all parts ‘showing indication of wear or stress will eliminate costly and avoidable failures at a later date, Bearings Carefully ingpect all rollers, cages and cups for wear, chipping of nicks to determine fitness of bearings for further use, Do not replace @ bearing cone or cup individ- ually without replacing the mating cup or cone at the same ime. After inspection, dip bearings in clean light oil and ‘wrap in clean lintless cloth or paper to protect them until install Oil Seals, Gaskets and Retaining Rings Replacement of spring load oil seals, “O" rings, metal sealing rings, gaskets and snap rings is more economics when unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of lubricant through a wom seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed, Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. Apply athin coat of Permatex No. 2 on ‘the outer diameter ofthe oil seal to assure an oil tightfit into, the retainer. When assembling now metal type sealing rings, same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members. Lubricate all “O” rings and seals with recommended type Automatic Transmission Fluid before assembly. Gears and Shafts if magne-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hhone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are true. Housing, Covers, etc. Inspect housings, covers and bearing caps to be certain they are thoroughly cleaned and that mating surfaces, bearing bores, etc., are free from nicks or burrs. Check parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures. —s9—